Graco 334644A User Manual

Instructions-Parts

Xtreme® XL Air Motor

For use with high output reciprocating Graco pumps. For professional use only.

Important Safety Instructions:

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

Model No. 24X856
100 psi (0.7 MPa, 7 bar) Maximum
Working Pressure

334644A

EN

PROVEN QUALITY. LEADING TECHNOLOGY.

Contents

Related Manuals ................................................ 2

Warnings ........................................................... 3

Component Identification..................................... 6

General Information............................................ 7

Application................................................... 7

Reciprocating Signal Poppets....................... 7

External Pilot Lines...................................... 7

Manual Override Buttons.............................. 7

Low Pressure Operation............................... 7

Performance................................................ 7

Minimum Icing ............................................. 7

Bleed Air ..................................................... 7

Extended Capabilities................................... 7

Grounding.......................................................... 8

Accessories........................................................ 8

Bleed-type master air valve .......................... 8

Air Regulator ............................................... 8

Air Filter ...................................................... 8

Related Manuals

Run Motor Manually............................................ 8

Troubleshooting.................................................. 9

Ice In Air Motor............................................ 10

Repair................................................................ 11

Preventive Maintenance Schedule................ 11

Pressure Relief Procedure............................ 11

Repair Air Valve........................................... 12

Replace Pilot Valves.................................... 15

Repair Air Motor........................................... 15

Parts.................................................................. 18

Air Valve Parts............................................. 20

Kits and Accessories.................................... 21

Dimensions........................................................ 23

Mounting Hole Diagram................................ 23

Technical Specifications...................................... 24

Notes ............................................................... 25

Graco Standard Warranty.................................... 26

Manual Description

311762 Xtreme Lowers, Instructions-Parts
311825 Dura-Flo™ Lowers, Instructions-parts
334645 Xtreme XL Packages, Instructions-Parts

2

334644A

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.

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

• 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 from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the

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

• Do not alter or modify equipment. Alterations or modifications may void agency approvals
and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your 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.

Technical Data

Pressure Relief Proced ure

in all equipment manuals.

when equipment is not in use.

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.

• Pressurized equipment can start without warning. Before checking, moving, or servicing
equipment, follow the

334644A 3

Pressure Relief Procedure

and disconnect all power sources.

Warnings

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in
or solvent flowing through the equipment can cause static sparking. 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 sparking).

• Ground all e quipment in the work area. See

• Never spray or flush solvent at high pressure.

• 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.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering i nto pail. Do not use pail liners unless
they are anti-static or conductive.

•

Stop operation immediately

equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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 a mputation.

treatment.

if static sparking occurs or you feel a shock.Do not use

Grounding instructions

work area

canigniteorexplode.Paint

.

Get immediate surgical

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

• Engage trigger lock when not spraying.

• 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.

• Follow the
or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

Pressure Relief Proced ure

when you stop spraying and before cleaning, checking,

4

334644A

Warnings

WARNING

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment
includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.

334644A 5

Component Identification

Component Identification

Figure 1

Key:

A Directional Air Valve
B

Air inlet, 1 in npt (f)
CMuffler
D Pilot valve
E

Manifold
F Manual shuttle override button
G Ground screw

H

Static ground cable

J

Plug for optional solenoid

K

Optional reed switch mount
L External pilot lines
MDe-ice bleed air valve
N

Lift ring (800 lb (363 kg) maximum
P Pump drive rod

6 334644A

General Information

General Information

TheXtremeXLairmotorisairpilotedwithtwopoppet
valves operating a cup and plate main air shuttle
valve. Air exhausts around the cylinder, through
sound absorption materials, and out the rear bottom
of the shroud.

Application

This motor has 7% l arge r e ffec ti ve area, and is
intended to directly replace, the Graco Premier®
motor. TheXLwillacceptthesameM16x2.0
threaded tie rods , the same connecting rods, and the
same 3/8-16 mounting studs used with the Premier.
The XL motor is physically smaller than the Premier,
so it will fit anywhere the Premier is used. The 1 in.
air inlet is at a low front position instead of up on the
top so a different air hose may be required. There
are also threaded cart/shelf type mounting holes in
the base which match the ones used on the NXT®
motors. The XL motor fits the standard heavy duty
Xtreme cart so the larger Premier cart is no longer
necessary.

• Movethevalveoffcenterduetoiceordebris.

• Flush a pump if a poppet is plugged, stuck in the
open position, or the signal is leaking

See Run Motor Manually, page 8 .

Low Pressure Operation

This motor will run at 4–5 psi (20.6–27.5 kPa,

0.21–0.27 bar)

Performance

The air valve (A), manifold (E), and exhaust are
larger than the Premier air handling parts in order
to exhaust the 630 in
cylinder after a full stroke. This allows the fluid
pressure to come back faster as the piston is driven
from the other side. The near square pressure trace
that this generates makes for a small change-over
pulse, and full pressure output for running multiple
guns.

3

of compressed air from the

Minimum Icing

Reciprocating Signal Poppets

The poppets are identical to the ones used in the
Graco Merkur® motors and many air-operated double
diaphragm motors. Poppets are fully accessible and
caneasilybereplaced.

External Pilot Lines

The pilot lines (L) that run from the shuttle end ports
to the exhaust poppets are run externally in hydraulic
hose. This allows for cold weather operation without
running the air through the aluminum manifold, which
can sometimes get cold enough for ai rline moisture
to freeze and block the signals.

Manual Override Buttons

There are m anual override buttons (F) on each end
of the air va lve that allows the internal main shuttle
valve to be physicall y moved from one position to the
other. Run the motor manually to:

The oversizing of all the air handling parts described
in the General Information section mean that normal
air motor ice buildup has less effect on the pump
output.

Bleed Air

Use the de-ice bleed air valve (M) to run warm air
through the valve and exhaust for de-icing. This
is mainly helpful during warm weather, very high
humidity applications, or low pressure high cycle rate
applications.

Extended Capabilities

The XL motor will accept DataTrak™ counting, a
runaway stop solenoid, and the top mount linear
position transducer used with NXT motors.

334644A

7

Grounding

Grounding

The equipmen
of static sp
to ignite or
wire for the

Verify that
tightened
clamp (U) o
earth grou

tmustbegroundedtoreducetherisk

arking. Static sparking can cause fume s

explode. Grounding provides an esc ape

electric current.

the ground screw (GS) is attached and

securely to the air motor. Connect the

f the static ground cable (H) to a true

nd.

Air Regulator

Required in your system to adjust the air pressure to
the motor and flui d outlet pressure of pump. Locate
itclosetothemotor. Installagaugetoreadair
pressure.

Air Filter

Required in your system to remove harmful dirt and
moisture from compressed air supply. The minimum
recommended air filtration is 40 micron.

Run Motor Manually

Use the manual override buttons (F) on each end
oftheairvalvetophysicallymovetheinternalmain
shuttle valve from one position to the other. Run the
motor manually to:

• Movethevalveoffcenterduetoiceordebris.

• Flush a pump if a poppet is plugged, stuck in the
open position, or the signal is leaking

Figure 2

Acces

Blee

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

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

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

sories

d-type master air valve

1. Lower the air pressure to approximately 30–40
psi (2.1 kPa, 210 bar – 280 kPa, 2.8 bar) to
manually operation the buttons.

2. If a poppet is plugged:

a. Press the bu tton on the end w here the motor

stopped. This will cause the motor to run
another cycle.

b. Press the button again to finish flushing.

3. If a poppet is stuck in the open position or the
signal is leaking:

a. Press the button on the opposite end from

where the motor stopped and hold it in. This
willcausethemotortostroketotheother
end.

b. Release the button to allow the motor to

stroke back.

Note

For poppet issues, the motor can also be
manually operated by dis connecting the pilot
hose and controlling the pilot signal exhaust
with your finger.

8 334644A

Troubleshooting

Troubleshooting

Problem

Air motor will not run and there is
no obvious exhaust

Air motor doesn't run and large
volume of air blows through exhaust
outlet on either stroke.
Air exhausts from rear outlet
continuously when motor is stalled
against fluid valve on one stroke or
the other.
Motor stalled at bottom of stroke
with no exhaust at bottom pilot. No
exhaust at top pilot.

Motor stalled at bottom of stroke
with exhaust at bottom pilot. Some
exhaust at top pilot.
Motor stalled at top of stroke with
no exhaust at top pilot. No exhaust
at top pilot.

Motor stalled at top of stroke with
exhaust at top pilot. Some exhaust
at bottom pilot.

Cause Solution

Check air supply Supply air to motor inlet.
Pump is locked up. Disconnect or remove pump to

verify motor operation.
Icebrokelooseinmanifoldand
caught in air valve.

Main piston o-ring (10) has failed or
main valve. See below.

Shuttle valve cup (112) and plate
(105) failure.

Bottom pilot (15) is not exhausting.
Usually ice in the pilot or pilot
exhaust port.

Metered air hole in main valve
shuttle piston (102) is plugged .

Top pilot or fittings are leaking air
when not activ ated by motor piston.

top pilot (15) is not exhausting.
Usually ice in the pilot or pilot
exhaust port.

Metered air hole in main valve
shuttle piston (102) is plugged .

Bottom pilot or fittings are leaking
air when not activated by motor
piston.

Turn off and exhaust air. Push top

and bottom valve shift buttons (118)

back and forth until flush with base

of v al ve cap (107). Re sta rt motor.

Replace piston o-ring (10) See

page 10.

Replace shuttle valve cup (112)

and plate (105).

Disconnect pilot line (55) for that

pilot. If motor changes over, bottom

pilot is plugged. Replace pilot

valve(55) and/or thaw ice that is

blocking air signal.

Disconnect pilot line (55). If motor

still doesn't change over, shuttle

piston metering hole is plugged.

Clean or replace shuttle valve

piston assembly (102).

Tighten fittings leak or replace top

pilot valve (15).

Disconnect pilot line (55) for that

pilot. If motor change s over, top

pilot is plugged. Replace pilot

valve(55) and/or thaw ice that is

blocking air signal.

Disconnect pilot line (55). If motor

still doesn't change over, shuttle

piston metering hole is plugged.

Clean or replace shuttle valve

piston assembly (102)

Tighten fittings leak or replace

bottom pilot valve (15).

334644A 9

Troubleshooting

Problem

Air motor "bounces" at top change
over.
Air motor "bounces" at bottom
change over.
Air motor pauses at top change
over.
Air motor pauses at bottom change
over.
Motor run s slower and pump looses
fluid pressure on one stroke only.

Motor run s slower and pump looses
fluid pressure on both strokes
equally.

Leaking bottom pilot val ve or fitti ng.

Leaking top pilot valve or fitting.

Top pilot valve exhaust restricted
by dirt or ice.
Bottom pilot valve exhaust restricted
by dirt or ice.
Icehascollectedinairmanifold
passages, or valve.

Ice has collected where exhaust
expands from the shuttle valve plate
manifold (5) into the muffler (12)

Ice In Air Motor

When compressed air is exhausted, the sudden drop
in pressure causes the air temperature to drop below
the freezing point. This causes any water liqui d or
vaportoturntoice.

Higher air pressures pack high amounts of air and
water vap or in each cycle an d create more expansion
and ice. Higher cycle rates also build up the ice and
lower the motor temperature faster. It is important to
select the correct motor and pump size to run at a
lower pressure, and cycle slower.

Cause Solution

Thaw any ice in pilot valve, or
replace valve (15) if it is not ice.
Thaw any ice in pilot valve, or
replace valve (15) if it is not ice.
Swap pilot valve or clear exhaust
port.
Swap pilot valve or clear exhaust
port.
Thaw or remove ice. Lower
moisture content of compressed air.
Reduce load on motor. See below.
Open the bleed air valve (119)
on the main shuttle valve. This
will bleed some warm air through
anytime air is supplied to the motor.

To minimize ice build-up:

•

Lower the dew point of the compressed air.

refrigerated air dyer, coalescing filter, or desiccant
filter to lower the water vapor content of the air.

•

Raise the compressed air temperature.

going in helps the motor parts stay above freezing.
Compressed air, especially at these volumes, is
warm when compressed. Keep the air warm or
stay near the compressor to reduce icing.

• Use the bleed air to clear ice build up.

Use a

Warmer air

Warm humid climates can produce high levels of
icing because of the higher humidity levels. Low
ambient temperatures near freezing make it easier
for the motor parts to drop below freezing.

10 334644A

Repair

Repair

Preventive Maintenance Schedule

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

Pressure Relief Procedure

Follow the Pressure Relief Procedure
whenever you see this symbol.

3. Disengage the trigger lock.

4. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure.

5. Engage the trigger lock.

6. Open all fluid drain valves in the system, having a
waste container ready to catch drainage. Leave
drainvalve(s)openuntilyouarereadytospray
again.

7. If you suspect the spray tip or hose is c logged or
that pressure has not been fully relieved:

a. VERY SLOWLY loosen tip guard retaining

nut or hose end coupling to relieve pressure

gradually.
b. Loosen nut or coupling completely.
c. Clear hose or tip obstruction.

This equipment stays pressurized until pressure
is manually relieved. To help prevent serious
injury from pressurized fluid, such as skin injection,
splashing fluid and moving parts, follow the
Pressure Relief Procedure when you stop spraying
and before cleaning, checking, or servicing
equipment.

1. Engage trigger lock.

2. Close the bleed-type master air valve.

334644A

11

Repair

Repair Air Valve

Replace Complete Air Valve

Figure 3 Air Valve

Bleed Hole

1

1. Stop the pump at the middle of its stroke. Follow

Pressure Relief Procedure, page 11.

9. Reconnect the air line and pilot valve lines to
the motor.

Replace Seals or Rebuild Air Valve

See Kits and Accessories, page 21 , to order kits for
your pump.

Disassemble the Air Valve

1. Perform steps 1–5 from

Replace Complete Air Valve, page 12.

2. Usea2mmor5/64hexkeytoremovetwo
screws (109). Remove the valve plate (105).

3. Remove the two-piece cup assembly (112, 113,

123), and spring (111).

2. Disconnect the air line to the motor and the pilot
valve lines to the air valve (13).

3. If installed on air motor, remove reed s w itch kit
and solenoid from air valve (13).

4. Remove screws (23). Remove the air valve (13)
and gasket (27).

5. To repair the air valve, go to

Disassemble the Air Valve, page 12,step

1. To install a replaceme nt air valve, continue
with step 6.

6. Align the new air valve gasket (27) on the
manifold, then attach the air valve (13).

Note

Usegreasetoholdthegasket(27)in
place. Be sure the bleed air hole in the
gasket aligns with the bleed port in the
valve manifold.

7. Reattach the s olen oid bracket and the sole noi d.

8. Use screw to attach the reed switch assembly
to the new air valve. Be sure the sensor cables
are connected properly (see pump or package
manual).

Figure 4

4. Remove the snap ring (110) from each end. Use
the piston (102) to push the end caps (107, 117)
out of the ends. Remove end cap o-rings (106,

117).

5. Slide out the piston (102). Remove the u-cup
seals (108) from each end and the detent
assembly (103) and detent cam (104) from the
center.

12

334644A

Repair

Figure 5 Air Valve Assembly

Apply high quality lithium grease.

1

334644A 13

Repair

Reassemble the Air Valve

1. Lubricate detent cam (104) and install into
housing.

2. The piston (102) and u-cup seals (108) come
pre-assembled. Lubricate the u-cup seals (108)
on both ends of the piston (102) and install it in
the housing.

3. Lubricate and install the detent assembly (103)
into the piston, with the beveled center toward
the detent cam.

4. Lubricate and install new o-ring (106) on bottom
end cap (107). Lubricate and install new o-ring
(119) and runaway reset button (118) on top end
cap (117). Install the end caps (107, 117) into
the housing.

5. Install a snap ring (110) on each end to hold end
caps in place.

6. Install the spring (111).

7. Lubricate and install the cup o-ring (123) on the
cup body (113), then assemble the cup body to
the cup base (112c). Lubricate and install the
cup assembly. Align the small round magnet with
the air inlet.

8. Install the valve plate (105). Lightly tighten the
screws (109) to hold it in place .

14

334644A

Replace Pilot Valves

1. Stop the pump at the middle of its
stroke. Relieve the pressure. See

Pressure Relief Procedure, page 11.

2. Disconnect the air line to the motor.

3. Use a 10 m m soc ket wrench to remove the old
pilot valves (15) from the top and bottom covers.

4. Lubricate and install the new pilot valve s (15).
Torque to 95-105 in-lb (11-12 N•m).

Repair

4. Holdthetierodsandremovethetierodnuts
(TN).

Figure 6 Pilot Valves

Repair Air Motor

Air Motor Seal Kits are available. See

Kits and Accessories, page 21 for the correct kit for

your motor. Parts included in the kit are marked with
an asterisk (*). For best results, use all the parts in
the kit.

Disconnect the Air Motor

1. Flush the pump, if possible
(see package manual). Follow

Pressure Relief Procedure, page 11.

2. Disconnect the air and fluid hoses and the ground
wire

3. Hold the flats of the air motor piston rod with
a wrench. Use another wrench to loosen the
coupling nut (CN). Collect the coupling collars
and set aside.

5. Use a socket to remove the mounting screws
(MS).

6. Lift up on the air motor to remove it. The tie rods
will remain attached.

334644A 15

Repair

Disassemble the Air Motor

1. Disconnect pilot valve air lines (55) from the air
valve (13).

2. Remove four screws (24) and remove the
manifold (5) and two gaskets (22). Inspect foam
(42) for damage.

5. Remove the muffler (12) from around the
cylinder. Remove the cylinder (3).

6. Slide the piston assembly (4) straight up off the
bottom cover (1).

Note

The piston a nd rod are epoxied together
and only available as an assembly (4).
Do not attempt to take apart the piston
and rod assembly (4).

7. Remove the o-ring (10*) from around the piston
(4).

8. Use a flat head screw driver to remove the
retaining ring (11) from the bottom cover (1).

9. Remove the u-cup seals (8*, 9*), and o-ring (14*)
from the bottom cover (1).

3. Use a 15/16 in or 24 mm socket wrench to
remove the tie bolts (25).

4. Remove the top cover. Remove the o-ring (14*).

Note

Tobreakthecoverloose,placeapipeor
a long wrench handle through the lift ring
(17) and hit the pipe.

16 334644A

Repair

Reassemble the Air Motor

Note

The bearing (7) is pressed in the bottom
cover (1) and is only available with Bottom
End Cap Repair kit 24X559.

1. Lubricate and install the o-ring (14*) on the

bottom cover (1).

2. Lubricate and install new u-cup seal with flange

(9*), with the lips fac ing up, in the bottom cover
(1) from the bottom. The seal will snap into place.

7. Install the muffler (12) around the cylinder (3) and
inthegrooveonthebottomcover(1). Besure
the front opening is lined up with the flat on the
bottom cover (1).

8. Lubricate and install the o-ring (14*) on the top
cover (2).

9. Carefully place the top cover (2) on the cylinder
(3) and muffler (12). The flat vertical manifold
surfaces of the top and bot tom covers must align.
Be sure the muffler (12) is in the groove on both
the top and bottom covers.

Figure 7 U-cups

3. Lubricate and install the new u-cup seal (8)
over the top of the bearing with the lips facing
up. Install retaining clip (11). Snap in the new
bumper (19)

4. Lubricate the ins ide of the cylinder (3). Lower the
cylinder (3) onto the bottom cover (1).

5. Lubricate and install the o-ring (10*) around the
piston (4). It will fit loose.

6. Slide the piston assembly (4) down into the
cylinder (3). Be sure the o-ring (10*) stays in
place. Work it carefully into the groove.

334644A

10. Install the tie bolts (25) hand tight.

11. Tighten the tie bolts (25) halfway. Work in a
crisscross pattern. Then torque to 60 ft-lb (81
N•m).

12. Install two gaskets (22) on the top and bottom
caps with grease. Install the manifold (5). Torque
bolts to 95-105 i n-lb (10.7-11.9 N•m).

13. Reconnect the pilot valve air lines (55) to the air
valve (13).

17

Parts

Parts

Part No. 24X856

Apply lithium grease.

1

Torque to 95-105 in-lb (11-12 N•m).

2

Press to snap fit.

3

Apply medium thread locker.

4

Torque to 33+/- 3 ft -lbs. (44.7 +/- 4 N•m).

5

Torque to 60 +/- 2 ft-lbs. (81 +/- 2.7 N•m).

6

Piston rod (6) must move through bearing (7)

7

without force.

ps face up.

Li

8

Wiper faces down.

9

18 334644A

Parts

Ref.

1

★

2 24W584
3

★

4

★

5

★

7

8

★

9

★

10
11
12 24X560

13 24X562 VALVE, air, XL; see

14 109486
15 24A366

-15a 155685

-15b

-15c 154741

-15d 197650
16 16D001
17 15F931
18 NXT106

Part Description

24X559

24X561 KIT, cylinder 1
24X557 KIT, piston, motor 1
16Y968

---

---

---

---

★

---

★

---

★

COVER, bottom
COVER, top

MANIFOLD, exhaust, XL
BEARING, sleeve, 1.750

ID, 2.000 OD
PACKING, u-cup, 1.750
ID, 2.125 OD
SEAL, rod, wiper, 1.75"
rod
O-RING, piston

RING, retaining
COVER, muffler,

complete

Air Valve Parts, page 20

PACKING, o-ring
VALVE, pilot (includes

15a-15c)
PACKING, o-ring, middle

PACKING, u-cup, shaft
PACKING, o-ring, bottom
O-RING, buna, top
ADAPTER, lift ring
RING, lift, sst 1 9/16 thrd
BUMPER, piston (with

magnet)

Qty

Ref.

19

1
1

21 108014
22
23 110036

1

24 17B389

1

25 127582

1

26

1

27 24X565 GASKET, valve, 2 pack 1

1

28 555749 FITTING, adapter, 1/8

1

30

1

31

1

38 244524

2

-38a

2

39 111307

1

40 116343

1

42

1

51

1

52 104010

1

53 557832

1

55

1

Part Description

★

24A915 KIT, bumper, top and

bottom (with screws)
PACKING, o-ring

---

★

---

17C974 CAP, manifold, air, XL
C20987 PACKING, o-ring

▲

290079

17C776 GASKE T, muffler

▲

15F674

128090

GASKET, end cap
BOLT, M8 x 1.25 x 45 mm
SCREW, M8 x 1.25 x 85

mm
SCREW, 5/8–11 x 8.5 in

FITTING, swivel, 45°, 1npt
x1npsm

npt(m) x JIC (#4); 1/2 hex

CABLE, ground, wi th
clamp (includes 38a)
TAG, warning, grounding
(not shown)
WASHER, lock, external

SCREW, ground

LABEL, safety, motor
PACKING, o-ring
RING, retainer -187 basic

int
HOSE, coupled

Qty

1

1
2
4
4

6
1

2

2
1
1

1
1
1
1
2
2

2

▲

Replacement Warning labels, signs, tags, and
cards are available at no cost.

★

See Kits and Accessori es , page 21.

334644A 19

Parts

Air Valve Parts

Part No. 24X562

Apply high quality lithium grease.

1

Ref. Part Description Qty

101
102
103
104
105

106
107
108
109

110

111
112

---

---

★

---

★

---

★

---

★

★

104010

---

★

---

★

---

★

★

557832

---

★

---

★

★

See Kits and Accessories, page 21.

HOUSING, valve, air, XL 1
PISTON,valve,air,XL 1
PISTON, detent, small 1
CAM, detent, XL 1
PLATE, valve, air, xl,

lapped
PACKING, o-ring

CAP, valve, air, XL
PACKING, u-cup
SCREW, m3, thread

forming
RING, retainer -187 basic
int

SPRING, detent
BASE, cup, valve, air, xl,

lapped

1

2
2
2
2

2

1
1

Ref. Part Description Qty

113
114
115
117
118
119 16Y668 NEEDLE, valve, assembly 1
122 15K783 FITTING, elow, street,

123
124 555749
125
126
127

---

★

---

★

---

★

★

154741 PACKING, o-ring 2

---

★

★

295640

★

104130

---

★

---

★

CUP,valve,air,xl,zinc 1
ROLLER, detent, small 1
PIN, detent, small 1

BUTTON, reset 2

1/8–27 npt
O-RING

CONNECTOR, #4 JIC 1/8
PACKING, o-ring
PLUG, valve
RING, retaining

2

1
2
1
1
1

20 334644A

Parts

Kits and Accessories

Table 1 XL Air Motor Repair Kits

Part No.
NXT103

24X557

-- 15G478

--- Piston

- - - Shaft, Piston, Rod

24X558

--–

-- 155685

--–

-- 1547 41

-- 197650

--–

--–

- - – Seal, Rod

--–

--–

- - – Gasket, Muffler

Description
Lift Ring (17)

Piston/Rod
Assembly Repair
Kit

Bumper

Air Motor Soft Parts
Repair Kit

O-ring, Cylinder (2) (14)
Packing, O-ring,
middle
Packing, U-cup,
shaft
Packing, O-ring,
bottom

Oring, Buna, top (15d)
O-ring, piston (10)
Packing, U-cup (8)

Ring, Retaining (11)
Gasket, End Cap (2) (22)

Air Motor Parts
Ref.

(18)
(4)

(15a)

(15b)

(15c)

(9)

(42)

Part No.

24X559

--–

--–

--–

--– Seal,Rod

--–

--– Cover,Bottom

24X560

-- 15F674

--– Cover,Muffler

- - – Gasket, Muffler

24X561

--–

--–

--–

24A915

--–

--–

--–

Description
Bottom End Cap
Repair Kit

Bumper
Bearing, Sleeve (7)
Packing, U-cup (8)

Ring, Retaining (11)

Muffler Repair Kit

Label, warning (51)

Cylinder Repair Kit

O-ring (14)
Foam, Dampers
Cylinder, Motor (3)

Bumper Kit

Bumper, bottom
Bumper, top
Screw, top (3) (29)

Air Motor Parts
Ref.

(19)

(9)

(1)

(12)
(42)

(46)

(19)
(20)

334644A

21

Parts

Table 2 Air Valve Repair Kits

Kit No.

24X562

--- Valve,Air,XL

24X565

24X563

-- 104010

-- 154741

-- 295640

-- 104130

24X564

--- Base

---

-- 295640

--- Plate,valve

---

24X565

24X566

-- 104010

---

-- 557 832

-- 154741

- - - Button, Reset

-- 15K783

-- 555749 Connector, #4 JIC

Description
Repair, Complete
Valve Assembly

Kit, gasket, valve (2
pack) (27)

Repair. Valve
O-rings

O-ring (2) (106)
O-ring (2) (117)
O-ring (1) (123)
O-ring (1) (125)

Repair, Base/Cup
Assembly

Cup
O-ring (123)

Screw, M3 (2) (109)

Valve to Manifold
Gasket (2 Pack) (27)
CapwithPush
Button assembly

Packing, O-ring (106)
Cap, Valve,
Ring, Retaining (110)
Packing, O-ring (117)

Fitting, El bow,
Street, 1/8

Air Valve Parts
Ref.

(13)

(112)
(113)

(105)

(107)

(118)

(122)
(124)

Air Valve Parts

Kit No.
24X567

- - - Piston, detent

- - - Cam, Detent

---

- - - Roller, detent

- - - Pin, Detent

24X568

-- 104130

---

---

24X569

--- Piston,Valve

---

16Y668 Needle Valve

Table 3 Accessories

Part No.

256893
287839 Linear Sesnor, HLS motors

24X550

24X552

Description
Roller Assembly

Spring, Detent (111)

DataTrak Plug
Assembly

Packing, O-ring (125)
Plug, Valve (126)
Ring, Retaining (127)

Valve Piston
w/Seals Repair Kit

Packing U-Cup (108)

Description

Linear Sensor, potted, XM

Kit, Reed Switch and Solenoid,
DataTrak, XL bracket
Kit, Reed Switch, DataTrak, XL
bracket

Ref.

(103)
(104)

(114)
(115)

(102)

(119)

22

334644A

Dimensions

Dimensions

A

in. (mm)

14.25 (361.9) 16.66 (423.2) 21.75 (552.5) 17.9 (454.7) 2.63 (66.8) 7.38 (187.5)

B

in. (mm)

C

in. (mm)

D

in. (mm)

E

in. (mm)

F

in. (mm)

Mounting Hole Diagram

334644A 23

Technical Specifications

Technical Specifications

Xtreme XL Air Motor

US

Maximum Air Inlet Pressure 100 psi 0.7 MPa, 7 bar
Stroke Length (Nominal)
Motor Effective Area 132.7 in.
Motor Cylinder Inside Diameter 13 in. 330 mm
Minimum Filtiation Size 0.0016 in. 40 micron
Weight 104 lbs 47.2 kg
Air Inlet Size 1 in. npt (f)
Maximum Motor Speed

(Do not exceed maximum
recommended speed of fluid
pump, to prevent premature pump
wear.)

Sound Data

Sound Power
Measured at 70 psi (0.48 MPa, 4.8
bar), 20 cpm, per ISO-9614-2.

Sound Pressure
Tested 3.28 ft (1 m) from
equipment.

4.8 in. 122 mm

2

60 cpm

96 dBA

86.8 dBA

Metric

856 cm

2

24

334644A

Notes

Notes

334644A 25

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 exc
twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be
defective. This warranty applies only when the equipment is installed, operated and maintained in accordance
with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction,
damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper
maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco
be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures,
accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation,
operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized
Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace
free of charge any defective parts. The equipment will be returned to the original purchaser transportation
prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be
made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS
FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The
buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost
profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available.
Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT,
MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO.

manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of
their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of
these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco
supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold
hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices

and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be
drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en
Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou
en rapport, directement ou indirectement, avec les procédures concernées.

eption of any special, extended, or limited warranty published by Graco, Graco will, for a period of

These items sold, but not

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,
Phone:

612-623-6921

All written and visual data contained in this docum ent reflects the latest product information available at the time of publication.

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

contact your Graco Distributor or call to identify the nearest distributor.

or Toll Free:

Graco reserves the right to make changes at any time without notice.

Original Instructions. This manual contains English. MM 334644

Copyright 2015, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

1-800-328-0211

Graco Headquarters:

International Offices:

www.graco.com

Revision A, April 2015

Fax:

612-378-3505

Minneapolis

Belgium, China, Japan, Korea