Operation, Parts PowerFill™ 3.5 Standard Series, Pro Series, and XL Pro Series 3A8110D For portable dispensing of water-based and oil-based non-flammable materials. Not approved for use in explosive atmospheres or hazardous (classified) locations. For professional use only. 125 psi (0.86 MPa, 8.6 bar) Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual before using the equipment. Be familiar with the controls and the proper usage of the equipment.
Contents Contents Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Configuration . . . . . .
Models Models Accessories Approval 110474 Certified to CAN/CSA C22.2 No. 68 Conforms to UL 1450 BackSaver Charger Programmable Fill Tube w/ Voltage Dosing Box Filler Description Part PowerFill 3.5 Standard Series PowerFill 3.5 Pro Series 26B417 26B418 120V 120V ✓ ✓ PowerFill 3.5 XL Pro Series 26B419 120V ✓ ✓ PowerFill 3.5 Standard Series PowerFill 3.5 Pro Series PowerFill 3.5 XL Pro Series PowerFill 3.5 Standard Series, UK PowerFill 3.
Important User Information Important User Information Thank You for Your Purchase! Before using your pump read this Owners Manual for complete instructions on proper use and safety warnings. Congratulations! You have purchased a high-quality pump made by Graco Inc. This pump is designed to provide superior performance with water-based and oil-based (mineral spirit-type) coatings. This user information is intended to help you understand the types of materials that can be used with your pump.
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
Warnings WARNING MOVING PARTS HAZARD Moving parts can pinch, cut or amputate fingers and other body parts. • Keep clear of moving parts. • Do not operate equipment with protective guards or covers removed. • Remove battery before cleaning, checking, or servicing equipment. BATTERY AND CHARGER COMPATIBILITY HAZARD • Only use DEWALT brand 18V Max or 20V Max batteries and battery chargers with this tool.
Component Identification Component Identification PowerFill 3.
Component Identification PowerFill 3.5 Pro and XL Pro Series A B C D E F G H 8 Power Head Dispense button Speed control Battery ProConnect cover 14 in. Hi-Rise fill tube (23 in.
Setup Setup Configuration 3. Using a 1/4 in. nut driver, remove the locking screw. Remove thumb screw. Using a 1/2 in. (or 13 mm) wrench, remove flanged bolt and spacer. 4. Flip ProConnect cover to rotate opposite way. Re-assemble flange bolt with spacer, locking screw, and thumb screw to secure. The PowerFill is capable of being set-up with the outlet on the left or right, depending on user preference. To change orientation, proceed with the following steps.
Setup Foot Bracket and Bucket Stabilizer Power Head 1. Attach sliding bracket to foot stand with provided thumb screw. 1. If necessary, pull piston upwards so slider will contact piston head. 2. Using a 1/2 in. (or 13 mm) wrench, assemble 5/16 - 18 flange bolts, assemble foot bracket in desired orientation and torque to 18 ft.-lbs. 2. Place slider on top of piston head. 3. Align piston head by slowly pressing piston downward with the Power Head until pins on Power Head rest atop the pump frame.
Setup 4. Attach Power Head by inserting pins into the holes on the pump. Power Head should automatically align with piston head once step 3 is complete. Standard Series Outlet Assembly 1. Assemble standard outlet to pump and using a 1/2 in. or 13 mm wrench, tighten flange head bolts. 2. Assemble ring to standard series outlet tab. NOTE: Ensure piston is properly inserted into the Power Head prior to operation. Should piston not align into the Power Head, manually pull the piston up and re-align. 5.
Setup Pro Series Outlet Assembly 1. Assemble Pro Series outlet to pump and using a 1/2 in. or 13 mm wrench, tighten flange head bolts. 2. Assemble Hi-Rise fill tube assembly by aligning scallop on tube with bolt located on the outlet fitting and insert it into the outlet assembly. Lubricate with water or grease if necessary. Rotate tube to secure. 12 3. Hand tighten wing bolt to hold tube in desired location.
Setup Box Filler 1. Ensure o-ring is in groove of box filling attachment. 2. Assemble box filling attachment, lanyard, and retaining clip. Connect assembly to outlet tube or standard outlet. 3A8110D 3. Align anti-rotation tab on box filler with cutout on outlet fitting and push the box filler on until the slot and groove are aligned. If difficult to push on, lubricate parts with water or grease. 4.
Setup Goose Neck Assembly (Optional Accessory) 1. Remove standard series outlet, if necessary, by loosening flange bolts. 2. Attach Pro Series outlet. 14 3. Align scallop on goose neck with bolt located on the outlet fitting and insert it into the outlet assembly. Lubricate with water or grease if necessary. Rotate tube to secure. 4. Hand tighten wing bolt to hold goose-neck in desired location.
Setup Battery Installation and Removal 2. To remove, press button on the back of the battery and pull battery from unit. Always start with a fully charged Battery. Do not splash or immerse Battery or charger in water. See Battery and charger information shipped with the pump. Replace and charge Battery only in a well-ventilated area and away from flammable or combustible materials. Remove and install Battery into the pump as follows: 1.
Start Up Start Up 1. Prior to dispensing, mix material as necessary. 2. Insert pump into bucket of material and adjust the bucket stabilizing bracket to desired height. 3. If desired, secure foot bracket to mounting surface to increase stability. 4. Apply Throat Seal Liquid (TSL) into pump throat. 5. Install battery on the Power Head, see Battery Installation and Removal, page 15. 6.
Operation Operation Pressure Relief Procedure 1. Remove battery from pump, see Battery Installation and Removal, page 15. 2. Slowly remove flange bolts shown below until pressure is relieved. To help prevent serious injury from pressurized fluid or splashed fluid, follow the Pressure Relief Procedure before pump is cleaned, and before equipment is serviced. In normal use, the PowerFill automatically relives pressure when the pump is switched off.
Operation Using the Pump 1. Insert battery into Power Head, see Battery Installation and Removal, page 15. 2. To operate pump, press and hold dispense button. Releasing the dispense button will stop the pump. 18 3. The variable speed control allows users to select the pump speed for precise dispensing, depending on application.
Pro-Series Operation Pro-Series Operation Programming the Pump 3. While the LED light is still blinking, press and release the repeat button to set the program for that volume of material and to exit programming mode. This must be completed within 10 seconds of releasing the dispense button or it will not save the program. 4. To pump the programmed volume, press and release the repeat button. If the button is held longer than two seconds, unit will revert back to programming mode. 5.
Pro-Series Operation Continuous Run Mode Continuous Run Mode is used for cleaning purposes to flush or recirculate water, or to transfer a large amount of material without having to hold the button down the entire time. 1. To make the unit continuously run, press and hold both buttons simultaneously for two seconds until the LED button begins to blink. 2. Release the buttons and the unit will continue to run until either button is pressed again, or when the battery runs out of power.
Cleaning Cleaning NOTE: Attach optional cleaning kit (P/N 18D167) and flush pump with water or compatible cleaning agent to remove any material or residue prior to removing any parts. NOTE: If inlet housing is stuck, use a screwdriver or rod for leverage to assist in unscrewing the housing. 3. 1. Lower the bucket stabilizer bracket. Remove Power Head, see Power Head Removal, page 25. Pump Disassembly 2. Remove filter by pinching tabs on filter and pulling.
Cleaning 4. Loosen thumb screws at top of pump and rotate pump cylinder 90 degrees. Slide pump cylinder off of piston. 5. Remove piston and clean in a bucket of water. Inspect seals for any damage and replace if damaged. 22 6. Clean out inside of pump housing and pump cylinder in bucket of water.
Cleaning Pump Re-assembly 1. 2. 3. Re-assemble inlet housing and filter. 4. Re-assemble Power Head, see Power Head Re-Assembly, page 26. 5. Apply Throat Seal Liquid (TSL) into pump throat. Carefully insert piston rod assembly into pump housing. Be careful not to damage the throat seal. Slide cylinder onto piston, rotate onto thumb screws. Hand tighten thumb screws.
Cleaning Cleaning Hi-Rise Filler Tube and Goose Neck Attachments 1. Remove box filler attachment from the Hi-Rise fill tube, if necessary. 2. Remove Hi-Rise fill tube or gooseneck from the pro outlet and insert orange cleaning ball into tube end and reassemble to the outlet port. 24 3. Put pump in bucket of water or cleaning solution and pump until the orange ball moves through the tube, cleaning the inside diameter.
Pro Connect Removal and Assembly Pro Connect Removal and Assembly Power Head Removal 1. 4. Remove locking screw and loosen thumb screw. Rotate cover open. 5. Grab Power Head by motor vents and pull the Power Head off the pump. Support Power Head with two hands, if necessary. Set speed control to Setting 1 and jog Power Head to position the piston and slider in the bottom dead center position. This step will make re-assembly easier. 2. Remove battery, see Battery Installation and Removal, page 15. 3.
Pro Connect Removal and Assembly Power Head Re-Assembly 1. If necessary, pull piston upwards so slider will contact piston head. 2. Place slider on top of piston head. 3. Align piston head by slowly pressing piston downward with the Power Head until pins on Power Head rest atop the pump frame. 4. Attach Power Head by inserting pins into the proper holes on the pump. Power Head should automatically align with piston head once step 3 is complete.
Troubleshooting Troubleshooting Problem Unit stops running 1. Remove battery before repairing pump. 2. Check all possible problems and causes before disassembling pump. Cause Battery is not fully seated. Re-insert battery, ensuring it is fully seated. Battery low on charge. Replace battery with fully charged one. Plugged outlet tube. Perform Pressure Relief Procedure, page 17, and clear all obstructions. Diagnostic lights blinks two times when dispensing button is pushed.
Troubleshooting Problem Equipment runs with intermittent flow Cause Solution Inlet filter is clogged. Remove filter and clean. Inlet valve is stuck open. Remove and clean inlet to allow for proper functionality Inlet is not installed or loose. Check inlet and ensure it is fully installed. Damaged inlet flapper valve. Remove inlet and check flapper valve for damage and replace if necessary. Faulty outlet flapper valve.
Troubleshooting Problem Cause Power Head feels loose or rocks on the pump Set screws located on the bottom of the Power Head may have become loose (see image below). 3A8110D Solution Tighten set screws carefully until the rocking has been removed (see image below).
Troubleshooting Testing the Switch Functionality Follow the steps below to test your switch functionality. To Open Unit - All Units 1. Remove battery, see Battery Installation and Removal, page 15. 2. Perform pressure relief procedure, see Pressure Relief Procedure, page 17. 3. Turn unit on its side and remove ten screws on clamshell. 4. Pull clamshell open and remove switch from slot in the clamshell. Pull switch free by disconnecting the connector on the end of the ribbon. 5.
Troubleshooting To Test Functionality - Standard Series 1. Using an Ohm meter, probe the ribbon lines 2 and 3 and press the dispense button. It should read ~0 ohms (Photo A). 2. If Ohm meter does not read ~0 ohms when pressing the dispense button, replace the switch. To Test Functionality - Pro Series 1. Using an Ohm meter, probe the ribbon lines 2 and 3 and press the dispense button. It should read ~0 ohms (Photo B). 2. Probe ribbon lines 1 and 4 and press the Repeat button.
Parts Parts PowerFill 3.5 Standard, Pro, and XL Pro Ref. Torque 1 3 in-lbs. (0.34 N•m) 2 5 in-lbs (0.56 N•m) 3 4 32 10 in-lbs (1.13 N•m) 20 in-lbs (2.26 N•m) Ref. Torque 5 6 7 8 24 in-lbs (2.71 N•m) 30 in-lbs (3.4 N•m) 40 in-lbs (4.5 N•m) 80 in-lbs (9 N•m) Ref. Torque 9 10 11 12 375 in-lbs (42 N•m) 140 in-lbs (16 N•m) 15 ft-lbs (20 N•m) 18 ft-lbs (24 N•m) Ref. Torque 13 14 34 ft-lbs(46 N•m) 100 in-lbs (11.
Parts PowerFill 3.5 Standard, Pro, and XL Pro Parts List Ref.
Parts Ref.
Technical Specifications Technical Specifications Max Working Pressure U.S. Metric 125 psi 0.86 MPa, 8.6bar PowerFill 3.5 Standard Dimensions, without outlet (with outlet) Length Width Height Weight 11.5 in. (11.5 in.) 6.2 in. (12 in.) 31.1 in. (31.1 in.) 15 lb. 29.2 cm (29.2 cm) 15.8 cm (30.5 cm) 79 cm (79 cm) 6.8 kg PowerFill 3.5 Pro Dimensions, without outlet (with outlet) Length Width Height Weight 11.5 in. (11.5 in.) 6.2 in. (14.7 in.) 31.1 in. (34.3 in.) 17 lb. 29.2 cm (29.2 cm) 15.8 cm (37.
Recycling and Disposal Recycling and Disposal End of Product Life At the end of the product’s useful life, dismantle and recycle it in a responsible manner. • • • Remove motors, batteries, circuit boards, and other electronic components. Recycle according to applicable regulations. • Do not dispose of electronic components with household or commercial waste. • Deliver remaining product to a recycling facility. Perform the Pressure Relief Procedure, page 17.
Graco Standard Warranty Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
Graco Information Graco Information For the latest information about Graco products, visit www.graco.com. For patent information, see www.graco.com/patents. TO PLACE AN ORDER, contact your Graco distributor or call 1-800-690-2894 to identify the nearest distributor.
Graco Information 3A8110D 39
All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. Original instructions. This manual contains English. MM3A8110 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA Copyright 2021, Graco Inc.
