Graco 311164M User Manual

Instructions - Parts

Xtreme Packages

High performance, high pressure spray packages for protective coatings. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 4 for model information and maximum working pressures.

311164M

r_x25dh1_x45dl1_311164_1f

II 2 G

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Sprayer Packages . . . . . . . . . . . . . . . . . . . . . . . . 4

Specialty Sprayer Packages . . . . . . . . . . . . . . . . 5

Configurable Cart Packages . . . . . . . . . . . . . . . . 5

Pump Packages . . . . . . . . . . . . . . . . . . . . . . . . . 6

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Component Identification - Cart Mount . . . . . . . . . 9

Component Identification - Wall Mount . . . . . . . . 10

System Components . . . . . . . . . . . . . . . . . . . . . 11

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 13

Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Prime/Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Circulating Zinc Fluids . . . . . . . . . . . . . . . . . . . . 16

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Preventive Maintenance Schedule . . . . . . . . . . 18

Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . 18

Corrosion Protection . . . . . . . . . . . . . . . . . . . . . 18

Cart Maintenance . . . . . . . . . . . . . . . . . . . . . . . 18

DataTrak Controls and Indicators . . . . . . . . . . . . 19

DataTrak Operation . . . . . . . . . . . . . . . . . . . . . . . . 20

Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Xtreme Lower Removal . . . . . . . . . . . . . . . . . . . . . 24

Disconnect and Reconnect Lower . . . . . . . . . . 24

Wall Mount Assembly . . . . . . . . . . . . . . . . . . . . . . 26

Hopper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 26

Airless Xtreme Sprayer Parts . . . . . . . . . . . . . . . . 28

Wall Mount Xtreme Package Parts . . . . . . . . . . . . 29

Parts - Airless Xtreme Sprayer Packages . . . . . . 30

Component Parts - All Airless Sprayer Packages 30

Common Parts . . . . . . . . . . . . . . . . . . . . . . . . . 35

Air-Assisted Xtreme Sprayer Parts . . . . . . . . . . . 37

Zinc Xtreme Sprayer Parts . . . . . . . . . . . . . . . . . . 38

Parts - Air-Assisted and Zinc Sprayer Packages 39

Dura-Flo Sprayer Parts . . . . . . . . . . . . . . . . . . . . . 40

Parts - Dura-Flo Sprayer Packages . . . . . . . . . . . 41

Cart Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Heavy Duty Cart, Model 287884 . . . . . . . . . . . . 42

Light Weight Cart, Model 287919 . . . . . . . . . . . 42

Pump Package Parts . . . . . . . . . . . . . . . . . . . . . . . 43

Pump Packages with L085C# Lowers (80:1 ratio) 44 Pump Packages with L115C# Lowers (35:1, 55:1

ratio) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Pump Packages with L145C# and L14AC1 Lowers

(31:1, 46:1, 90:1 ratio) . . . . . . . . . . . . . . . . . . . 46

Pump Packages with L180C# and L18AC1 Lowers

(24:1, 40:1, 70:1 ratio) . . . . . . . . . . . . . . . . . . . 47

Pump Packages with L220C# Lowers

(21:1, 30:1, 60:1 ratio) . . . . . . . . . . . . . . . . . . . 48

Pump Packages with L250C# Lowers (50:1 ratio) 49 Pump Packages with L290C# Lowers (16:1, 25:1,

45:1 ratio) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Mounting Hole Diagram . . . . . . . . . . . . . . . . . . . . . 54

Wall Mount Bracket . . . . . . . . . . . . . . . . . . . . . . 54

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Pump Package Performance Charts . . . . . . . . . . 57

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 60

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 60

2 311164M

Related Manuals

Component Manuals in U.S. English:

Manual Description

Related Manuals

311762

311238

311239

311486

3A0293

The Xtreme Packages manual is available in the following languages. See the following chart for specific languages and corresponding part numbers.

Manual Language

311164

312437

312438

312439

312440

312441

Xtreme Lower Instructions - Parts

NXT Air Motor Instructions - Parts

Integrated Air Control Modules for NXT Air Motors Instructions - Parts

DataTrak

Air Controls for Heavy and Light Duty Carts Instructions-Parts

™

Conversion Kit

English

Chinese

Dutch

Finnish

French

German

312442

312443

312444

312445

312446

312447

312448

312449

312450

Greek

Italian

Japanese

Korean

Portuguese

Russian

Spanish

Swedish

Turkish

311164M 3

Models

Sprayer Packages

Airless Sprayers, Wall Mount Packages, and Hopper Packages

Check your sprayer, wall mount, or hopper package’s identification plate (ID) for the 6-digit part number of your package. Use the following matrix to define the construction of your package, based on the six digits. For example, Sprayer Part Number X60D H 1 represents the Xtreme brand (X), pressure ratio (60 :1), de-icing motor (D), heavy duty cart (H), and complete package (gun and

hose included) with DataTrak Xtreme Sprayer Parts section starting on page 28. The digits in the matrix do

not correspond to the reference numbers in the Parts drawings and lists.

™

(1). To order replacement parts, see Airless

NOTE: All models have a maximum air input pressure of 100 psi (.7 MPa, 7 bar). Models with a 90:1 pressure ratio have a maximum air input pressure of 80 psi (0.55 MPa, 5.5 bar).

X60 D H 1

Second and

Third Digit Fourth Digit Fifth Digit Sixth Digit

First Digit

(Xtreme

brand)

Pressure Ratio

(xx:1)

Motor /

Exhaust Mount Option

D De-Icing H Heavy Duty 1

L Low Noise L Light Weight 2

W Wall Mount 3

Complete

Package DataTrak Hopper

✔✔

✔

✔ ✔ ✔

✔ ✔

Without

Integrated

Fluid Filter

4 311164M

Specialty Sprayer Packages

Models

Wall Mount Package 287978

Model 287978 is a 40:1 ratio unit that includes a low noise motor, DataTrak, external filter, and no gun or hose.

Air-Assisted Sprayers

All air-assisted sprayers include a de-icing motor, a heavy duty cart, G40 spray gun, and hose.

30:1 Pressure Ratio - 287975

40:1 Pressure Ratio - 287976

Zinc Sprayers

All zinc sprayers include a de-icing motor and a heavy duty cart. Models 287973 and 287974 also include Silver spray gun and hose.

25:1 Pressure Ratio - 287971

40:1 Pressure Ratio - 287972

25:1 Pressure Ratio - 287973

40:1 Pressure Ratio - 287974

Dura-Flo™ Sprayers

All Dura-Flo sprayers include a de-icing motor, a heavy duty cart, and Dura-Flo pump package. Only model 287980 includes a gun and hose.

23:1 Pressure Ratio - 287979

23:1 Pressure Ratio - 287980

32:1 Pressure Ratio - 287981

Configurable Cart Packages

NOTE: Configurable cart packages do not include lowers. Pair these packages with any Xtreme lower (145cc - 290cc) for a sprayer package.

All models include air controls, tie rods, coupling kit, and suction hose. Use the following matrix to define the construction of your cart package, based on the six digits. For example, cart package number XN3D H 2 represents the

™

Xtreme brand (X), motor (NXT3400), de-icing motor (D), heavy duty cart (H), and bare package with DataTrak

(2).

XN3 D H 2

Second and

First Digit

(Xtreme

brand)

Third Digit Fourth Digit Fifth Digit Sixth Digit

Motor Exhaust Mount Option DataTrak

NXT3400

NXT6500

D De-Icing H Heavy Duty

L Light Weight

✔

311164M 5

Models

Pump Packages

Check your pump package’s identification plate (ID) for the 6-digit part number of your pump package. For example, Pump Part Number P30M C 1 rep- resents the pump (P), pressure ratio (30 :1), low noise exhaust motor with

DataTrak

™

(M), carbon steel construction (C), and no built-in filter or air con-

trols (1). For

To order replacement parts, see Pump Package Parts section starting on page 43. The digits in the matrix do not correspond to the reference numbers

in the Parts drawings and lists.

NOTE: Models with 16:1 - 70:1 pressure ratios have a maximum air input pressure of 100 psi (.7 MPa, 7 bar). Models with a 90:1 pressure ratio have a maximum air input pressure of 80 psi (0.55 MPa,

5.5 bar).

P30 M C 1

Second and

First Digit

(pumps)

Third Digit Fourth Digit Fifth Digit Sixth Digit

Pressure Ratio

(xx:1) Exhaust Communication

D De-Icing none C Carbon Steel 1

E De-Icing DataTrak 2

L Low Noise none 3

M Low Noise DataTrak 4

Lower

Construction

Built-in

Filter

✔

✔✔

Air

Controls

✔

6 311164M

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. Refer back to these Warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

BATTERY HAZARD

Sparking can occur when changing batteries. The battery may cause an explosion if mishandled:

• You must use the battery type specified for use with the equipment.

• Only replace the battery in a non-hazardous location, away from flammable fluids or fumes.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

•Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

311164M 7

Warnings

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your Graco distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

8 311164M

Component Identification - Cart Mount

A Air Inlet, 3/4 npt(f) B Bleed Type Master Air Valve (required) C Air Pressure Relief Valve D Air Filter (hidden) E Air Pressure Gauge F Air Regulator Adjustment Knob GDataTrak

models)

J Fluid Drain/Purge Valve (required)

™

location (see page 19; not present on all

Light Duty Cart

K Fluid Filter L Grounding Wire (required) M Lower N Suction Hose and Tube P Fluid Outlet R Optional Fluid Outlet, for second gun S Packing Nut T De-Ice Control

Heavy Duty Cart

FIG. 1: Airless Sprayer

TI8408a

Hopper (288347) Option

r_x25dh1_x45dl1_311164_1f

311164M 9

Component Identification - Wall Mount

A Air Inlet, 3/4 npt(f) B Bleed Type Master Air Valve (required) C Air Pressure Relief Valve D Air Filter (hidden) E Air Pressure Gauge F Air Regulator Adjustment Knob GDataTrak

models) J Fluid Drain/Purge Valve (required) K Fluid Filter

™

location (see page 19; not present on all

L Grounding Wire (required) M Lower N Suction Hose and Tube P Fluid Outlet R Optional Fluid Outlet, for second gun S Packing Nut T De-Ice Control U Spray Gun VHose

FIG. 2: Wall Mount System

C,D

TI8413a

10 311164M

System Components

Component Identification - Wall Mount

* Bleed Type Master Air Valve (B)

Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.

• Be sure the valve is easily accessible from the pump and located downstream from the air regulator.

• Required in your system to relieve air trapped between it and the air motor when the valve is closed.

• Open to supply air to the motor.

• Close to shut off air to the motor, and bleed any

trapped air from the motor.

* Air Pressure Relief Valve (C)

Automatically opens to relieve air pressure if supplied pressure exceeds preset limit.

Air Regulator Adjustment (F)

Adjusts air pressure to the motor and fluid outlet pressure of pump. Locate it close to the pump. Read air pressure on gauge (E).

* Fluid Drain/Purge Valve (J)

Open valve to relieve pressure and when flushing or priming pump. Close valve when spraying.

De-Ice Control (T)

Turn knob (open) to reduce icing.

TI8160b

* Required system components.

Air Filter (D)

Removes harmful dirt from compressed air supply.

311164M 11

Grounding

The equipment must be grounded. Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit.

Table 1: Tools Required

• Grounding wires and clamps for pails

• Two 5 gal. (19 liter) metal pails

1. Connect the ground wire (244524) (L) to the ground stud on the air motor.

Setup

To avoid tip over, ensure cart is on a flat and level surface. Failure to do so could result in injury or equipment damage.

Table 2: Tools Required

• Two adjustable wrenches

• Non-sparking hammer or plastic mallet

• Torque wrench

1. Ground sprayer.

2. Check packing nut (S). Fill with Throat Seal Liquid (TSL). Torque to 25-30 ft-lb (34-41 N•m).

. 3

2. Connect the other end of the ground wire to a true earth ground.

3. Ground the object being sprayed, fluid supply container, and all other equipment in the work area. Follow your local code. Use only electrically conductive air and fluid hoses.

4. Ground all solvent pails. Use only metal pails, which are conductive, placed on a grounded surface. Do not place pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

TI1102-1

TI8250a

TI1102-2

TI8316a

3. Attach electrically conductive fluid hose to pump outlet and tighten.

4. Attach electrically conductive fluid hose (and air hose if using an AA gun) to gun and tighten.

5. Close bleed type master air valve (B). Connect air supply hose to 3/4 npt(f) air inlet (A).

6. Flush before using. See page 14.

7. Prime before using. See page 14.

12 311164M

Pressure Relief Procedure

1. Engage gun trigger lock.

Pressure Relief Procedure

4. Hold gun firmly against a grounded metal pail. Trigger the gun.

TI8252a

TI5049a

2. Close bleed type master air valve (B).

3. Disengage gun trigger lock.

NOTE: If using an AA gun, turn gun air regulator counter-clockwise to relieve pressure.

TI5048a

5. Engage gun trigger lock.

TI5049a

6. Drain fluid. To drain fluid, slowly open all fluid drain valves, including drain/purge valve (J), in system into a waste pail. If there is a return tube, open return line ball valve.

TI8417a

7. If you suspect the spray tip or hose is completely clogged, or that pressure has not been fully relieved after following the previous steps, very slowly loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually; then loosen completely. With tip removed, trigger gun into bucket.

Trigger Lock

Always engage gun trigger lock when you stop spraying to prevent gun from being triggered accidentally by hand or if dropped or bumped.

311164M 13

Prime/Flush

1. Follow Pressure Relief Procedure, page 13.

2. Remove tip and tip guard from gun.

3. Flushing only: If desired, remove built-in fluid filter

(present on some models). Reinstall filter cap after removing fluid filter.

4. Place suction tube in a compatible fluid (if priming) or solvent (if flushing).

Zinc sprayers only: Place return tube in a compatible fluid (if priming) or solvent (if flushing). Open return line valve.

5. Turn regulator adjustment knob (G) counterclockwise until it stops, and gauge (E) reads zero.

7. Prime or flush hose and gun:

a. Disengage gun trigger lock.

TI5048a

b. Trigger gun into grounded pail until a steady

stream comes from gun. If flushing, trigger gun

for 10-15 seconds.

TI8727a

NOTE: If using an AA gun, increase air pressure by turning gun regulator clockwise.

6. Open bleed type master air valve (B).

Zinc sprayers only: When clean solvent or fluid flows from return tube, close return line valve. Pump will stall.

14 311164M

c. Engage trigger lock.

8. If priming, equipment is now ready to spray; go to

Spray, page 16.

If flushing, proceed with step 9.

Prime/Flush

NOTE: The remaining steps are for flushing only.

CAUTION

Do not prime pump through drain/purge valve using two component materials. Mixed two-component materials will harden in valve and result in clogging.

9. Place drain tube in a grounded waste pail.

Open drain/purge valve (J) slightly by rotating counterclockwise.

TI8417a

10. Start the pump by rotating the air regulator adjustment knob (G) clockwise until pump begins to move.

11. When clean solvent flows from drain tube close drain/purge valve (J) by rotating clockwise. Pump will stall.

TI8417a

12. Follow Pressure Relief Procedure, page 13. Leave solvent in and store sprayer.

311164M 15

Spray

CAUTION

Do not allow pump to run dry. It will quickly accelerate to a high speed causing damage.

1. Prime. See Prime/Flush, page 14.

2. Follow Pressure Relief Procedure, page 13.

3. Install tip and tip guard on gun.

4. Open bleed type master air valve (B).

5. Turn regulator adjustment knob (G) until gauge (E) reads desired pressure. Turn clockwise to increase pressure, counterclockwise to decrease pressure.

7. Spray a test pattern. Read fluid manufacturer’s recommendations. Adjust as necessary. If using an AA gun, increase gun air pressure while testing spray pattern.

8. Zinc sprayers only: When not spraying, reduce air pressure to 30 psi (2.1 MPa, 21 bar). Open return line and close gun valve.

9. Flush when done spraying. See Prime/Flush, page

14.

10. Follow Pressure Relief Procedure, page 13.

Circulating Zinc Fluids

6. Disengage gun trigger lock.

TI5048a

16 311164M

1. When spraying zinc fluids, close return line valve. Circulation is not required when spraying.

2. To circulate fluid back to supply container while you are not spraying, open return line valve and lock gun trigger safety. Pump will continue to run.

3. Always relieve pressure before overnight shut- down, when changing spray tips, or when checking or servicing any part of system. During circulation, some fluid will be present in gun line and must be relieved.

Shutdown

5. Open bleed type master air valve (B). Turn regulator adjustment knob (G) counterclockwise to lowest possible fluid pressure.

CAUTION

Never leave water or water-base fluid in pump overnight. If you are pumping water-base fluid, flush with water first, then with a rust inhibitor, such as mineral spirits solvent (also called white spirit). Relieve pressure, but leave rust inhibitor in pump to protect parts from corrosion.

1. Follow Pressure Relief Procedure, page 13.

2. Remove tip and tip guard from gun.

3. Engage gun trigger lock.

TI5049a

4. Place siphon tube in grounded metal pail containing cleaning fluid.

6. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun until clean solvent dispenses.

TI8727a

7. Follow Pressure Relief Procedure, page 13.

311164M 17

Maintenance

Preventive Maintenance Schedule

The operating conditions of your particular system determine how often maintenance is required. Establish a preventive maintenance schedule by recording when and what kind of maintenance is needed, and then determine a regular schedule for checking your system.

Daily Maintenance

NOTE: For overnight shutdown, stop pump at bottom of its stroke to prevent fluid from drying on exposed displacement rod and damaging throat packings. Follow Pressure Relief Procedure, page 13.

1. Flush. See Prime/Flush, page 14.

Corrosion Protection

Always flush the pump before the fluid dries on the displacement rod. Never leave water or water-based fluid in the pump overnight. First, flush with water or a compatible solvent, then with mineral spirits solvent (also called white spirit). Relieve the pressure, but leave the mineral spirits solvent (also called white spirit) in the pump to protect the parts from corrosion.

Cart Maintenance

Periodically lubricate the axle between points A and B with lightweight oil. See F

Keep the cart clean by wiping up spills daily, using a compatible solvent.

. 4.

2. Relieve pressure. See Pressure Relief Procedure,

page 13.

3. Check packing nut (S, F replace TSL as necessary. Torque to 25-30 ft-lb (34-41 N•m).

4. Drain water from air filter.

5. Clean suction tube using a compatible solvent. It is recommended that you clean the outside of the sprayer using a cloth and compatible solvent.

6. Check hoses, tubes, and couplings. Tighten all fluid connections before each use.

7. Clean fluid line filter.

. 1). Adjust packings and

r_x25dh1_x45dh1_311164_38f

FIG. 4: Cart Assembly - Heavy Duty Model Shown

18 311164M

+ 42 hidden pages