Graco e-Xtreme Operation, Repair, And Parts

Operation,Repair,andParts

e e

e

- --Xtreme® Xtreme®

Xtreme®

Sprayer Sprayer

Sprayer

3A3164D

EN

Electric Electric

Electric

high high

high

pressure pressure

pressure

sprayer sprayer

sprayer

packages packages

packages

for for

for

application application

application

of of

of

protective protective

protective

coatings. coatings.

coatings.

For For

For

professional professional

professional

use use

use

only. only.

only.

Important Important

Important

Safety Safety

Safety

Instructions Instructions

Instructions
Readallwarningsandinstructionsinthismanualandinthee-Xtreme
Drivermanuals.Save Save

Save

all all

all

instructions. instructions.

instructions.

See page 3 for model information. See
Technical Speci󰘰cations for maximum
working pressure.

II 2 G c

Ex db IIA T2 Gb X

PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents

Contents

RelatedManuals................................................2

ModelInformation...............................................3

Warnings...........................................................4

ComponentIdenti󰘰cation.....................................7

Installation..........................................................8

PowerSupplyRequirements.........................8

ConnectthePowerSupply...........................8

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

InstallVentedOilCapBeforeUsing

Equipment......................................9

FlushBeforeUsingEquipment......................9

Setup.................................................................10

PressureReliefProcedure............................12

TriggerLock................................................12

Prime/Flush.................................................13

Spray.................................................................15

Shutdown...........................................................16

Maintenance......................................................16

PreventiveMaintenanceSchedule................16

ChangetheOil.............................................16

DailyMaintenance.......................................16

CheckOilLevel...........................................17

CorrosionProtection....................................17

Flushing......................................................17

CartMaintenance.........................................17

Troubleshooting..................................................18

ErrorCodeTroubleshooting..........................20

StandbyMode.............................................20

ErrorCodesTable........................................20

Repair................................................................22

XtremeLowerRemoval................................22

DisconnectandReconnectLower.................22

OutletCheckValves.....................................23

Parts..................................................................24

PartsDrawing..............................................24

OutletCheckValvesParts............................27

Dimensions........................................................29

TechnicalSpeci󰘰cations......................................32

GracoStandardWarranty....................................34

Related Related

Related

Manuals Manuals

Manuals

Part Part

Part

Description Description

Description

3A3165e-XtremeDriverInstallation

3A5124

e-XtremeDriverOperation,RepairandParts

311619PumpMountingKitManual

311762XtremeLowerManual

312145

XTRGunManual

2

3A3164D

ModelInformation

Model Model

Model

Information Information

Information

Package Package

Package

Filter Filter

Filter

Model Model

Model

Description Description

Description

Complete* Complete*

Complete*

(Hose (Hose

(Hose

and and

and

Gun) Gun)

Gun)

MaximumFluid

Tempterature:

160°F(71°C)

Bare Bare

Bare

(No (No

(No

Hose Hose

Hose

or ororGun) Gun)

Gun)

MaximumFluid

Temperature:

180°F(82°C)

Integrated Integrated

Integrated

Filter Filter

Filter

No No

No

Filter Filter

Filter

Lower Lower

Lower
Pump Pump

Pump

24Y901*e-XtremeEx45,Cart*

✔✔

24Y902

e-XtremeEx45,Cart

✔✔

24Y903*e-XtremeEx45,Cart

✔✔

24Y904

e-XtremeEx45,Cart

✔✔

24Y905*e-XtremeEx45,Cart

withHopper

✔✔

24Y906

e-XtremeEx45,Cart
withHopper

✔✔

24Y907*e-XtremeEx45,Cart

withHopper

✔✔

24Y908

e-XtremeEx45,Cart
withHopper

✔✔

24Y909*

e-XtremeEx45,WallMount

✔✔

24Y910e-XtremeEx45,WallMount

✔✔

24Y911*

e-XtremeEx45,WallMount

✔✔

24Y912e-XtremeEx45,WallMount

✔✔

145cc

24Z901*e-XtremeEx35,Cart

✔✔

24Z902

e-XtremeEx35,Cart

✔✔

24Z903*e-XtremeEx35,Cart

✔✔

24Z904

e-XtremeEx35,Cart

✔✔

24Z905*e-XtremeEx35,Cart

withHopper

✔✔

24Z906

e-XtremeEx35,Cart
withHopper

✔✔

24Z907*e-XtremeEx35,Cart

withHopper

✔✔

24Z908

e-XtremeEx35,Cart
withHopper

✔✔

24Z909*

e-XtremeEx35,WallMount

✔✔

24Z910e-XtremeEx35,WallMount

✔✔

24Z911*

e-XtremeEx35,WallMount

✔✔

24Z912e-XtremeEx35,WallMount

✔✔

180cc

Formaximumworkingpressure,seeTechnicalSpeci󰘰cations,page32.

*LowerFluidtemperatureduetoXTR5gun.

NOTE: NOTE:

NOTE:

Seethee-XtremeDriverInstallationmanualfordriverapprovalsinformation.

3A3164D 3

Warnings

Warnings Warnings

Warnings

Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.

WARNING WARNING

WARNING

FIRE FIRE

FIRE

AND AND

AND

EXPLOSION EXPLOSION

EXPLOSION

HAZARD HAZARD

HAZARD

Flammablefumes,suchassolventandpaintfumes,inwork work

work

area area

area

canigniteorexplode.Paint
orsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰reand
explosion:

•Useequipmentonlyinwellventilatedarea.

•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and

plasticdropcloths(potentialstaticsparking).

•Groundallequipmentintheworkarea.SeeGrounding Grounding

Grounding

instructions.

•Neversprayor󰘱ushsolventathighpressure.

•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.

•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable

fumesarepresent.

•Useonlygroundedhoses.

•Holdgun󰘰rmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunless

theyareantistaticorconductive.

•Stop Stop

Stop

operation operation

operation

immediately immediately

immediately

ifstaticsparkingoccursoryoufeelashock. ..Donotuse

equipmentuntilyouidentifyandcorrecttheproblem.

•Keepaworking󰘰reextinguisherintheworkarea.

Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
󰘱ammablevapors.Tohelpprevent󰘰reandexplosion.

•Cleanplasticpartsonlyinwellventilatedareas.

•Donotcleanwithadrycloth.

•Donotoperateelectrostaticgunsinequipmentworkarea.

SPECIAL SPECIAL

SPECIAL

CONDITIONS CONDITIONS

CONDITIONS

FOR FOR

FOR

SAFE SAFE

SAFE

USE USE

USE

•Topreventtheriskofelectrostaticsparking,theequipment’snon-metallicpartsshouldbe

cleanedonlywithadampcloth.

•Thealuminumhousingmaysparkuponimpactorcontactwithmovingparts,whichmay

cause󰘰reorexplosion.Takeprecautionstoavoidsuchimpactorcontact.

•All󰘱ameproofjointsarecriticaltotheintegrityofthedriverasapprovedforhazardous

locationsandarenotrepairableifdamaged.Damagedpartsmustbereplacedonlywith
genuineGracopartswithnosubstitutions.

4

3A3164D

Warnings

WARNING WARNING

WARNING

ELECTRIC ELECTRIC

ELECTRIC

SHOCK SHOCK

SHOCK

HAZARD HAZARD

HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcan
causeelectricshock.

•Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesandbefore

servicingorinstallingequipment.

•Connectonlytogroundedpowersource.

•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocalcodes

andregulations.

•Donotexposetorain.Storeindoors.

•Wait󰘰veminutesbeforeservicingafterpowerisremoved.

SKIN SKIN

SKIN

INJECTION INJECTION

INJECTION

HAZARD HAZARD

HAZARD

High-pressure󰘱uidfromgun,hoseleaks,orrupturedcomponentswillpierceskin.Thismay
looklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get

Get

immediate immediate

immediate

surgical surgical

surgical

treatment. treatment.

treatment.

•Donotspraywithouttipguardandtriggerguardinstalled.

•Engagetriggerlockwhennotspraying.

•Donotpointgunatanyoneoratanypartofthebody.

•Donotputyourhandoverthespraytip.

•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.

•FollowthePressure Pressure

Pressure

Relief Relief

Relief

Procedure Procedure

Procedure

whenyoustopsprayingandbeforecleaning,checking,

orservicingequipment.

•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.

•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.

MOVING MOVING

MOVING

PARTS PARTS

PARTS

HAZARD HAZARD

HAZARD

Movingpartscanpinch,cutoramputate󰘰ngersandotherbodyparts.

•Keepclearofmovingparts.

•Donotoperateequipmentwithprotectiveguardsorcoversremoved.

•Pressurizedequipmentcanstartwithoutwarning.Beforechecking,moving,orservicing

equipment,followthePressure Pressure

Pressure

Relief Relief

Relief

Procedure Procedure

Procedure

anddisconnectallpowersources.

BURN BURN

BURN

HAZARD HAZARD

HAZARD
Equipmentsurfacesand󰘱uidthatisheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:

•Donottouchhot󰘱uidorequipment.

3A3164D 5

Warnings

WARNING WARNING

WARNING

TOXIC TOXIC

TOXIC

FLUID FLUID

FLUID

OR OR

OR

FUMES FUMES

FUMES
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.

•ReadSafetyDataSheets(SDSs)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.

•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable

guidelines.

PERSONAL PERSONAL

PERSONAL

PROTECTIVE PROTECTIVE

PROTECTIVE

EQUIPMENT EQUIPMENT

EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisequipmentincludes
butisnotlimitedto:

•Protectiveeyewear,andhearingprotection.

•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent

manufacturer.

EQUIPMENT EQUIPMENT

EQUIPMENT

MISUSE MISUSE

MISUSE

HAZARD HAZARD

HAZARD

Misusecancausedeathorseriousinjury.

•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.

•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated

systemcomponent.SeeTechnical Technical

Technical

Data Data

Data

inallequipmentmanuals.

•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical

Technical

Data Data

Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestSafetyDataSheets(SDSs)fromdistributoror
retailer.

•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.

•TurnoffallequipmentandfollowthePressure Pressure

Pressure

Relief Relief

Relief

Procedure Procedure

Procedure

whenequipmentisnotinuse.

•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.

•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.

•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.

•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.

•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.

•Donotkinkoroverbendhosesorusehosestopullequipment.

•Keepchildrenandanimalsawayfromworkarea.

•Complywithallapplicablesafetyregulations.

6 3A3164D

ComponentIdentication

Component Component

Component

Identi󰘰cation Identi󰘰cation

Identi󰘰cation

Ref. Ref.

Ref.

Description Description

Description

AElectricDriver

BPumpLower

C

FluidDrain/PurgeValve

DPackingNut

E

PowerSwitch

F

FluidOutlet

GJunctionBoxCover

HPressureAdjustmentKnob

J

OutletCheckValve

L

StatusIndicatorLight(LED)

P

OilFillCap(vented)

S

JunctionBox

T

FilterCap(modelsequippedwithintegrated
󰘰lteronly)

NOTE: NOTE:

NOTE:

Seethee-XtremeDriverOperation/Repair

manualforwarninglabelinformation.

3A3164D

7

Installation

Installation Installation

Installation

Toreducetheriskofelectricshock,󰘰reand
explosion,allelectricalwiringmustbedonebya
quali󰘰edelectricianandcomplywithalllocalcodes
andregulations.

Power Power

Power

Supply Supply

Supply

Requirements Requirements

Requirements

SeeDriverInstallationmanualforinstructionsfor
powersupplyrequirements.

Connect Connect

Connect

the the

the

Power Power

Power

Supply Supply

Supply

SeeDriverInstallationmanualforinstructionsto
connectthepowersupply.

Grounding Grounding

Grounding

Thisequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundingprovidesanescapewireforthe
electriccurrent.

Sprayer: Sprayer:

Sprayer:

Systemisgroundedthroughthepower

cord.

Fluid Fluid

Fluid

hoses: hoses:

hoses:

Useonlyelectricallyconductivehoses
withamaximumof210ft.(64m)combinedhose
lengthtoensuregroundingcontinuity.Check
electricalresistanceofhoses.Iftotalresistance
togroundexceeds25megaohms,replacehose
immediately.

Spray Spray

Spray

gun: gun:

gun:

Groundthroughconnectiontoaproperly

grounded󰘱uidhoseandpump.

Fluid Fluid

Fluid

supply supply

supply

container: container:

container:

Followlocalcode.

Object Object

Object

being being

being

sprayed: sprayed:

sprayed:

Followlocalcode.

Solvent Solvent

Solvent

pails pails

pails

used used

used

when when

when

󰘱ushing: 󰘱ushing:

󰘱ushing:

Followlocal
code.Useonlyconductivemetalpails,placedon
agroundedsurface.Donotplacethepailona
non-conductivesurface,suchaspaperorcardboard,
whichinterruptsgroundingcontinuity.

To To

To

maintain maintain

maintain

grounding grounding

grounding

continuity continuity

continuity

when when

when

󰘱ushing 󰘱ushing

󰘱ushing

or or

or

relieving relieving

relieving

pressure: pressure:

pressure:

Holdthemetalpartofthespray
gun/dispensevalve󰘰rmlytothesideofagrounded
metalpail,thentriggerthegun/valve.

Tools Tools

Tools

Required: Required:

Required:

•Groundingwiresandclampsforpails(Gracopart

244524–notsupplied)

•Two5gallon(19liter)metalpails(Gracopart

101108–notsupplied)

1.Connectthegroundwire(Y)toagroundstudon

thebackofthemotor.

2.Groundtheobjectbeingsprayed,󰘱uidsupply

container,andallotherequipmentinthe
workarea.Followyourlocalcode.Useonly
electricallyconductiveairand󰘱uidhoses.

3.Groundallsolventpails.Useonlymetalpails,

whichareconductive,placedonagrounded
surface.Donotplacepailonanon-conductive
surface,suchaspaperorcardboard,which
interruptsgroundingcontinuity.

8 3A3164D

Installation

Install Install

Install

Vented Vented

Vented

Oil Oil

Oil

Cap Cap

Cap

Before Before

Before

Using Using

Using

Equipment Equipment

Equipment

Thedrivergearboxisshippedfromthefactory
pre-󰘰lledwithoil.Thetemporaryunventedcap(PX)
preventsoilleaksduringshipment.Thistemporary
capmustbereplacedwiththesuppliedventedoil
cap(P)beforeuse.

PX

P

ti31010a

Flush Flush

Flush

Before Before

Before

Using Using

Using

Equipment Equipment

Equipment

Thepump󰘱uidsectionwastestedwithlightweight
oil,whichisleftinthe󰘱uidpassagestoprotectparts.
Toavoidcontaminatingyour󰘱uidwithoil,󰘱ushthe
equipmentwithacompatiblesolventbeforeusing
theequipment.

SeePrime/Flush,page13.

3A3164D 9

Setup

Setup Setup

Setup

Toavoidtipover,makesurecartisona󰘱atand
levelsurface.Failuretodosocouldresultininjury.

1.Pullpressureadjustmentknob(H)outandturn
counterclockwiseuntilitstops.Pushtheknob
intolock.

2.Turnpowerswitch(E)OFF.Connectunitto
powersource.

OFF

3.Checkpackingnut(D).SeeXtremelowerpump
manual311762forpackingnuttorque.Fillwith
ThroatSealLiquid(TSL

TM

).

4.Attachelectricallyconductive󰘱uidhosetopump
loweroutletviaoutletcheckvalveandtighten.

NOTICE NOTICE

NOTICE

Attachingthehosedirectlytothelowerpump
canresultindamagetothesprayerduring
cavitation,orwhenthesprayerrunsoutof
material.Useanoutletcheckvalvebetween
thelowerpumpandhosetoavoiddamage.

NOTICE NOTICE

NOTICE

Theminimumhosesizeallowableis3/8in.
IDx50ft(10mmx15m).Smallerhoses
cancausehighpressurespikesandresultin
damagetothesprayer.

5.Attachhosetogunandtighten.

10 3A3164D

Setup

6.Attachmaterialsupplyinlethosetopumplower.

NOTE: NOTE:

NOTE:

Maximumsuggestedlengthis6ft(1.8
m),minimumsuggestedinnerdiameteris1in.
(2.5cm).

7.Checkoillevel.

NOTICE NOTICE

NOTICE

OnlyuseoilwithGracopartnumber16W645.
Anyotheroilmaynotlubricateproperlyand
cancausedamagetothedrivetrain.

8.Always󰘱ushandprimesprayerbeforeeachuse
(seePrime/Flush,page13).

3A3164D

11

Setup

Pressure Pressure

Pressure

Relief Relief

Relief

Procedure Procedure

Procedure

FollowthePressureReliefProcedure
wheneveryouseethissymbol.

Thisequipmentstayspressurizeduntilpressure
ismanuallyrelieved.Tohelppreventserious
injuryfrompressurized󰘱uid,suchasskininjection,
splashing󰘱uidandmovingparts,followthe
PressureReliefProcedurewhenyoustopspraying
andbeforecleaning,checking,orservicingthe
equipment.

1.Engageguntriggerlock.

2.Pullpressureadjustmentknob(H)outandturn
counterclockwiseuntilitstops.Pushtheknob
intolock.

3.Turnpowerswitch(E)OFF.

OFF

4.Disengageguntriggerlock.

5.Holdgun󰘰rmlyagainstagroundedmetalpail.
Triggerthegun.

6.Engageguntriggerlock.

7.Drain Drain

Drain

󰘱uid: 󰘱uid:

󰘱uid:

Placethedraintubeinagrounded
wastepail.Slowlyopen󰘱uiddrain/purgevalve
(C),anddrain󰘱uidintoawastepail.

8.Ifyoususpectthespraytiporhoseiscompletely
cloggedorthatpressurehasnotbeenfully
relieved:

a.VERYSLOWLYloosenthetipguard

retainingnutorhoseendcouplingtorelieve
pressuregradually.

b.Loosenthenutorhoseendcoupling

completely.

c.Withtipremoved,triggerthegunintothe

bucket.

Trigger Trigger

Trigger

Lock Lock

Lock

Alwaysengagethetriggerlockwhenyoustop
sprayingtopreventthegunfrombeingtriggered
accidentallybyhandorifdroppedorbumped.

12

3A3164D

Setup

Prime/Flush Prime/Flush

Prime/Flush

Toavoid󰘰reandexplosion,alwaysground
equipmentandwastecontainer.Toavoidstatic
sparkingandinjuryfromsplashing,always󰘱ushat
thelowestpossiblepressure.

1.PerformPressureReliefProcedure,page12.

2.Removetipandtipguardfromgun.

3.Placematerialsupplysuctionhoseinto
compatible󰘱uid(ifpriming)orsolvent(if󰘱ushing).

4.Closedrainvalve.

5.Turnpowerswitch(E)ON.

ON

6.Primeor󰘱ushhoseandgun:

a.Disengageguntriggerlock.

b.Triggergunintogroundedpail.Pullout

pressureadjustmentknob(H)andturn
clockwiseslowlytoincreasepressure,until
asteadystream󰘱owsfromgun.Pushknob
intolock.If󰘱ushing 󰘱ushing

󰘱ushing

,triggergununtilclean

solvent󰘱owsfromthegun.

c.Engagetriggerlock.

3A3164D 13

Setup

7.Ifpriming,equipmentisnowreadytospray
(proceedtoSpray,page15).If󰘱ushing,proceed
withstep8.

NOTE: NOTE:

NOTE:

Theremainingstepsarefor󰘱ushingonly.

NOTICE NOTICE

NOTICE

Donotprimepumpthroughdrain/purge
valveusingtwocomponentmaterials.Mixed
two-componentmaterialswillhardeninvalve
andresultinclogging.

8.PerformPressureReliefProcedure,page12.

9.Turnpowerswitch(E)ON.

10.Tostartpump,pulloutpressureadjustment
knob(H)andturnclockwiseslowlytoincrease
pressure,untilasteadystream󰘱owsfromdrain
valve.Pushknobintolock.

NOTE: NOTE:

NOTE:

Todeterminetheproperamountof
solventand󰘱ushingtime,removetheinlet
valvehousingtoverifyithasbeenfullycleaned,
especiallywhensprayinganewmaterialforthe
󰘰rsttime.

11.Waitforcleansolventto󰘱owfromdraintube.

12.Pullpressureadjustmentknob(H)outandturn
counterclockwiseuntilitstops.Pushtheknob
intolock.

13.Turnthepowerswitch(E)OFF.

14.Checkpumpandgun󰘰lters.

14

3A3164D

Spray

Spray Spray

Spray

NOTICE NOTICE

NOTICE

Donotallowpumptorundry.Itwillquickly
acceleratetoahighspeedcausingdamage.

1.PerformPrime/Flush,page13.

2.PerformPressureReliefProcedure,page12.

3.Installtipandtipguardontogun.Closethedrain
valve.

4.Turnpowerswitch(E)ON.

ON

5.Pulloutandturnpressureadjustmentknob
(H)untildesiredpressureisreached.Turn
clockwisetoincreasepressure,counterclockwise
todecreasepressure.Pushknobintolock.

6.Disengageguntriggerlock.

7.Sprayatestpattern.Read󰘱uidmanufacturer’s
recommendations.Adjustasnecessary.

NOTE: NOTE:

NOTE:

Whendeterminingthedesiredspray
pressure,alwaysincreasethespraypressure
untilthespraypatternfullydevelops.Thiswill
reducethepressuresurgewhenthepumpis
stalledandminimizeover-spray.

Dynamic Dynamic

Dynamic

Pump Pump

Pump

Outlet Outlet

Outlet

Pressure Pressure

Pressure

Ex35 Ex35

Ex35

Ex45 Ex45

Ex45

Pressure Pressure

Pressure

Adjust- Adjust-

Adjust-

ment ment

ment

Knob Knob

Knob

Setting Setting

Setting

PSI PSI

PSI

Bar Bar

Bar

MPa MPa

MPa

PSI PSI

PSI

Bar Bar

Bar

MPA MPA

MPA

132022.02.2040027.02.70

264044.04.4080054.05.40

396066.06.60120081.08.10

4128088.08.80160010810.8

5

160011011.0200013513.5

6192013213.2240016216.2

7

224015415.4280018918.9

8256017617.6320021621.6

9288019819.8360024324.3

10320022022.0400027027.0

8.Flushwhen󰘰nishedspraying.
PerformPrime/Flush,page13and

PressureReliefProcedure,page12.

3A3164D 15

Shutdown

Shutdown Shutdown

Shutdown

NOTICE NOTICE

NOTICE

Neverleavewaterorwater-based󰘱uidinpump
overnight.Ifwater-base󰘱uidhasbeenused,󰘱ush
withwater󰘰rst,thenwitharustinhibitor(suchas
mineralspirits).Relievepressure,butleaverust
inhibitorinpumptoprotectpartsfromcorrosion.

Toshutdown:

1.PerformPrime/Flush,page13.

2.PerformPressureReliefProcedure,page12.

Maintenance Maintenance

Maintenance

NOTICE NOTICE

NOTICE

Donotopen/removegearcover.Thegearside
isnotintendedtobeserviced.Openingthegear
covermayalterthefactorysetbearingpre-load
andmayreducetheproductlife.

Preventive Preventive

Preventive

Maintenance Maintenance

Maintenance

Schedule Schedule

Schedule

Theoperatingconditionsofyourparticularsystem
determinehowoftenmaintenanceisrequired.
Establishapreventivemaintenancescheduleby
recordingwhenandwhatkindofmaintenanceis
needed,andthendeterminearegularschedulefor
checkingyoursystem.

Change Change

Change

the the

the

Oil Oil

Oil

NOTE: NOTE:

NOTE:

Changetheoilafterabreak-inperiodof
200,000–300,000cycles.Afterthebreak-inperiod,
changetheoilonceayear.

1.Placeaminimum2quart(1.9liter)container

undertheoildrainport.Removetheoildrain
plug.Allowalloiltodrainfromthedriver.

2.Reinstalltheoildrainplug.Torqueto18–23ft-lb

(25–30N•m).

NOTICE NOTICE

NOTICE

Donotover-torque.Thedrainplugcan
becomestrippedanddamaged.

3.Opentheoil󰘰llcap(P)andaddGracoPartNo.

16W645silicone-freeISO220syntheticEPgear
oil.Checktheoillevelinthesightglass(K).Fill
untiltheoillevelisnearthehalfwaypointofthe
sightglass.Theoilcapacityisapproximately

1.0–1.2quarts(0.9–1.1liters).Do Do

Do

not not

not

over󰘰ll. over󰘰ll.

over󰘰ll.

NOTICE NOTICE

NOTICE

OnlyuseoilwithGracopartnumber16W645.
Anyotheroilmaynotlubricateproperlyand
cancausedamagetothedrivetrain.

4.Reinstalltheoil󰘰llcap(P).

Daily Daily

Daily

Maintenance Maintenance

Maintenance

NOTE: NOTE:

NOTE:

Forovernightshutdown,stoppumpatbottom
ofitsstroketoprevent󰘱uidfromdryingonexposed
displacementrodanddamagingthroatpackings.
PerformPressureReliefProcedure,page12.

1.PerformPrime/Flush,page13.

2.PerformPressureReliefProcedure,page12.

3.Checkpackingnut(D).Adjustpackingsand

replaceTSLasnecessary.Seelowerpump
manual311762forpackingnuttoque.

4.Checkhoses,tubes,andcouplings.tightenall

󰘱uidconnectionsbeforeeachuse.

16 3A3164D

Maintenance

Check Check

Check

Oil Oil

Oil

Level Level

Level

Checktheoillevelinthesightglass(K).Theoillevel
shouldbenearthehalfwaypointofthesightglass
whenthesprayerisnotrunning.Ifoilislow,open
the󰘰llcap(P)andaddGracoPartNo.16W645
silicone-freeISO220syntheticEPgearoil.

Theoilcapacityisapproximately1.0–1.2quarts
(0.9–1.1liters).Do Do

Do

not not

not

over󰘰ll. over󰘰ll.

over󰘰ll.

NOTE: NOTE:

NOTE:

Thedrivergearboxisshippedfromthe
factorypre-󰘰lledwithoil.Thetemporaryunvented
cap(PX)preventsoilleaksduringshipment.This
temporarycapmustbereplacedwiththesupplied
ventedoilcap(P)beforeuse.

NOTICE NOTICE

NOTICE

OnlyuseoilwithGracopartnumber16W645.Any
otheroilmayreducethelifeofthegears.

Corrosion Corrosion

Corrosion

Protection Protection

Protection

Always󰘱ushthepumpbefore󰘱uiddrieson
thedisplacementrod.Neverleavewateror
water-based󰘱uidinthepumpovernight.First,
󰘱ushwithwateroracompatiblesolvent,thenwith
arustinhibitor,suchasmineralspirits.Perform

PressureReliefProcedure,page12,butleaverust

inhibitorinpumptoprotectpartsfromcorrosion.

Flushing Flushing

Flushing

•Flushbeforechanging󰘱uids,before󰘱uidcancure
intheequipment,attheendoftheday,before
storing,andbeforerepairingequipment.

•Flushatthelowestpressurepossible.Check
connectorsforleaksandtightenasnecessary.

•Flushwitha󰘱uidthatiscompatiblewiththe󰘱uid
beingdispensedandtheequipmentwettedparts.

Cart Cart

Cart

Maintenance Maintenance

Maintenance

PeriodicallylubricatetheaxlebetweenpointsAand
Bwithlightweightoil(seebelow).

Keepthecartcleanbywipingupspillsdaily,usinga
compatiblesolvent.

3A3164D

17

Troubleshooting

Troubleshooting Troubleshooting

Troubleshooting

NOTE: NOTE:

NOTE:

Checkallpossibleremediesbefore

disassemblingpump.

NOTE: NOTE:

NOTE:

Thestatusindicator(L)onthedriverwillblink

ifanerrorisdetected.

Problem Problem

Problem

Cause Cause

Cause

Solution Solution

Solution

Exhausted󰘱uidsupplyRe󰘰llandprimethepump.

Clogged󰘱uidoutletline,gun*,
etc.;thehoseinnerdiameter
istoosmall

Clearthehose,outletcheckvalve,orgun;use
thehosewiththelargerinnerdiameter.

Pumpoutputlowon
bothstrokes

Wornpistonpacking

Replace.Seethepumplowermanual.

Improperlyinstalledintakeor
pistoncheckvalves

Checkandrepair.Seepumpthelowermanual.

Theintakevalveisclogged.

Cleantheintakevalve.

Nooutput

Exhausted󰘱uidsupplyRe󰘰llandprimethepump.

Exhausted󰘱uidsupplyRe󰘰llandprimethepump.

Clogged󰘱uidhoseorgun*Cleanthehoseorgun.

Fluiddriedonthepistonrod

Disassembleandcleanthepump(seethelower
manual).Inthefuture,stopthepumpatthe
bottomofthestroke.Keepthewet-cup󰘰lled
withcompatiblesolvent.

Pumpwillnotoperate

Driverpartsarewornor
damaged

Repairorreplacethedriver.Removethelower
fromthedriver.Ifthedriverwillnotcycleand
doesnotblinkanerrorcode,thentroubleshoot
thedriverorreplace.

Fluidisleakingfromthe
rupturedisk

Replacetherupturedisk;donotreplacewitha
pipeplug.

Theintakevalveisclogged.

Cleantheintakevalve.

NoPressureorFlow

Leakingdrainvalve

Closeorreplacethedrainvalve.

Overvoltage(over300V)SeepowersupplyrequirementsintheDriver

Installationmanual.

Driverdoesnotturnon

Nopowertothecontrolboard.

Verifythatthepowersupplyisconnected.
checkthejunctionboxconnections.

Outputlowondown
stroke

OpenorwornintakevalveClearorservicetheintakevalve.

OutputlowonupstrokeOpenorwornpistonvalve

packings

Clearthepistonvalve.Replacethepackings.

18 3A3164D

Troubleshooting

Problem Problem

Problem

Cause Cause

Cause

Solution Solution

Solution

Fluidsupplyisexhausted

Re󰘰llthe󰘱uidsupplyandprimethepump.

CloggedsuctionCleanthesuctiontube.

Openorwornpistonvalve
packings

Clearthepistonvalve.Replacethepackings.

OpenorwornintakevalveClearorservicetheintakevalve.

Cloggedgun,hose,outlet,
etc.

Clearthegun,hose,outlet,etc.

Erraticoraccelerated
pumpspeed

Openorwornoutletcheck
valve

Clearorservicetheoutletcheckvalve.

Cyclesorfailstohold
pressureatstall

Wornintakeorpistonvalveor
seals

Servicethepumplower(seeLowermanual

311762).

LoosesuctionlineTightensuctionlineconnections.Use

compatibleliquidthreadsealantorPTFEtape
onconnections.

Agitator/mixerisnot
submerged

Submergetheagitator/mixer.

Airbubblesin󰘱uid

Agitator/mixerRPMistoohighLowertheagitator/mixerRPM.

Incorrect󰘱uidpressureatgunSeethegunmanual.Readthe󰘱uid

manufacturer’srecommendations.

Fluidistoothinortoothick

Adjustthe󰘱uidviscosity.Readthe󰘱uid
manufacturer’srecommendations.

Poor󰘰nishorirregular
spraypattern

Dirty,worn,ordamagedspray
gun

Servicethespraygun(seespraygunmanual).

Overvoltage(greaterthan
300V)

Checkthepowersupply.

Driverdoesnotturn
overandLEDisoff

Nopowertothecontrolboard

ContactyourGracodistributororTechService
formoreinformation.

Driverdoesnotturn
overandLEDison

EncoderfaultCyclepower.

Recalibratetheencoderfollowingtheprocedure
listedinthee-XtremeDriverOperation/Repair
manual.
ContactyourGracodistributororTechService
formoreinformation.

Oilwasover-󰘰lledDrainandre󰘰lloilasstatedin

CheckOilLevel,page17.

Drainplugisnottightened
properly

Torqueto18–23ft-lb(25–30N•m).

Oilisleaking

Sealcartridgeo-ringmissing
ordamaged

Replacetheshaftbearingassembly.

*

To determine if the 󰘱uid hose or gun is obstructed, follow the Pressure Relief Procedure , page 12 . Disconnect
󰘱uid hose and place a container at pump 󰘱uid outlet to catch any 󰘱uid. Turn pressure adjustment knob just
enough to start the pump. If the pump starts, the obstruction is in the 󰘱uid hose or gun.

3A3164D 19

Troubleshooting

Error Error

Error

Code Code

Code

Troubleshooting Troubleshooting

Troubleshooting

Errorcodescantaketwoforms:

•Alarm: Alarm:

Alarm:

Alertsyoutothecauseofthealarmand

shutsdownthedriver.

•Deviation: Deviation:

Deviation:

Alertsyoutotheproblem,butthedriver
maycontinuetorunpastthesetlimitsuntilthe
systemabsolutelimitsarereached.

NOTE: NOTE:

NOTE:

Theblinkcodeisdisplayedusingthestatus
indicator(L)onthedriver.Theblinkcodegivenbelow
indicatesthesequence.Forexample,blinkcode2
indicatestwoblinks,apause,andthenrepeats.

NOTE: NOTE:

NOTE:

Toclearanerrorcode,󰘰rsttryturningthe
pressureadjustmentknob(H)counterclockwiseuntil
itstops.Ifthestatusindicator(L)doesnotstop
blinkingshortlyafterturningtheknobtozero,cycle
thepowerbyturningthepowerswitch(E)totheOFF
positionforatleast30secondsbeforeturningback
ON.

Standby Standby

Standby

Mode Mode

Mode

Whenslowblinkingisdisplayed,thedriverhas
enteredStandbyMode.Thedriverwillenterstandby
modewhenpoweredonandpressurizedwithaknob
settinggreaterthan7,andthepumphasnotmoved
anymaterialfor30minutes.

StandbyModewillbeexitedwhen:

•Materialstartstodispenseandcausesthepump
tomove,OR

•Thepressurecontrolknob(H)isadjusted,OR

•Thepowerswitch(E)iscycledOFFandON

Error Error

Error

Codes Codes

Codes

Table Table

Table

Blink Blink

Blink

Code Code

Code

Error Error

Error

Type Type

Type

Troubleshooting Troubleshooting

Troubleshooting

Steps Steps

Steps

1AlarmPump Pump

Pump

diving diving

diving

Thepumpisdivingrapidly.Apressureimbalancebetweentheupanddown
strokeofthepumpiscausingthepumptodivewithexcessivespeed.

•Pumpdivingmayoccurwhenthepumprunsoutofmaterialwhilespraying
athighpressure.

•Verifythatmaterialisbeingproperlyfedtothepump.

•Pressurefromthehosecould󰘱owbackintothepumponthedownstroke.

•Verifythatthecheckvalveisinstalledandisproperlyworking.

2AlarmVoltage Voltage

Voltage

Too Too

Too

Low Low

Low

•Verifythatlinevoltageiswithintherangespeci󰘰edin

TechnicalSpeci󰘰cations,page32.

•UsetherecommendedcordinPowerSupplyRequirements,page8.

•Cyclepowerandcheckstatusindicator(L)toseeiftheerrorisstillactive.

3AlarmVoltage Voltage

Voltage

Too Too

Too

High High

High

•Verifythatlinevoltageiswithintherangespeci󰘰edin

TechnicalSpeci󰘰cations,page32.

•Cyclepowerandcheckstatusindicator(L)toseeiftheerrorisstillactive.

4DeviationHigh High

High

Temperature Temperature

Temperature

Thetemperatureofthesystemisnearthemaximumoperationtemperature.The
performancehasbeenreducedtopreventthedriverfromcompletelyshutting
down.

•Reducepressure.

•Movetheunittoacoolerlocation.

20 3A3164D

Troubleshooting

Blink Blink

Blink

Code Code

Code

Error Error

Error

Type Type

Type

Troubleshooting Troubleshooting

Troubleshooting

Steps Steps

Steps

5

DeviationLow Low

Low

Temperature Temperature

Temperature

•Warmequipment.

6AlarmMotor Motor

Motor

Temperature Temperature

Temperature

Fault Fault

Fault

Motorisrunningtoohot.Allowunittocool.

•Reducepressure.

•Movetheunittoacoolerlocation.

7

AlarmBoard Board

Board

Temperature Temperature

Temperature

Fault Fault

Fault

Thecontrolboardisrunningtoohot.Allowtheunittocool.

•Reducepressure.

•Movetheunittoacoolerlocation.

8Alarm

Encoder Encoder

Encoder

Calibration Calibration

Calibration

Error Error

Error

•Cyclepowerandcheckstatusindicator(L)toseeiftheerrorisstillactive.

•Followthecalibrationprocedurelistedinthee-XtremeDriverOperation/Repair
manualtocalibratetheencoder(thiscodewillblinkifcalibrationisinprogress).

•ContactyourGracodistributororTechServiceformoreinformation.

9AlarmEncoder Encoder

Encoder

Error Error

Error

•Cyclepowerandcheckthestatusindicator(L)toseeiftheerrorisstillactive.

•Verifythattheinternalconnectionsareintact.

•ContactyourGracodistributororTechServiceformoreinformation.

10Alarm

Software Software

Software

Versions Versions

Versions

Do Do

Do

Not Not

Not

Match Match

Match

•Obtainsoftwareupdatetoken.SeeAccessories Accessories

Accessories

sectionfortokenpartnumber.

SeetheDriverOperation/Repairmanualfortokeninstallationinformation.

11Alarm

Circuit Circuit

Circuit

Board Board

Board

Communication Communication

Communication

Failure Failure

Failure

•Cyclepowerandcheckstatusindicator(L)toseeiftheerrorisstillactive.

•ContactyourGracodistributororTechServiceformoreinformation.

12Alarm

Internal Internal

Internal

Circuit Circuit

Circuit

Board Board

Board

Hardware Hardware

Hardware

Failure Failure

Failure

•Cyclepowerandcheckstatusindicator(L)toseeiftheerrorisstillactive.

•ContactyourGracodistributororTechServiceformoreinformation.

13,14Alarm

Internal Internal

Internal

Software Software

Software

Error Error

Error

•Cyclepowerandcheckstatusindicator(L)toseeiftheerrorisstillactive.

•ContactyourGracodistributororTechServiceformoreinformation.

SlowBlink

Deviation

SeeStandbyMode,page20.

3A3164D

21

Repair

Repair Repair

Repair

Toreducetheriskofinjuryduetoskin
injectionandsplashing,performthe

PressureReliefProcedure,page12before

performinganyrepairprocedure.

Xtreme Xtreme

Xtreme

Lower Lower

Lower

Removal Removal

Removal

Required Required

Required

Tools Tools

Tools

•Setofadjustablewrenches

•Torquewrenches

•Rubbermallet

•Threadlubricant

•Anti-seizelubricant

•Threadsealant

Disconnect Disconnect

Disconnect

and and

and

Reconnect Reconnect

Reconnect

Lower Lower

Lower

1.Flushthepump(seePrime/Flush,page13).
Stopthepumpatbottomofitsstroke.

2.PerformPressureReliefProcedure,page12.

3.Disconnecttheunitfromthepowersource.

4.Disconnectthe󰘱uidhose,thendisconnectthe
suctionhose.Holdthe󰘱uidinlet󰘰ttingwith
awrenchtokeepitfromlooseningwhileyou
disconnectthesuctionhose.

Donotliftthepumpbytheliftringwhenthe
weightexceeds360kg(800lb).Theliftring
couldfailandresultininjury.

Usecautionwhendisconnectingthelower;
theycanweighupto25kg(55lb).Take
appropriateprecautions.

5.Ifthedriverdoesnotrequireservice,leaveit
attachedtoitsmounting.

6.Removeclip(11)andslidecouplingcover(13)
uptoremovecoupling(12).

7.Useawrenchtoholdthetierod󰘱atstokeep
rods(8)fromturning.Unscrewnuts(10)and
removethelower(9).

8.RefertotheXtremeLowermanual(311762)to
servicethelower.

9.Reconnectthelowerbyfollowingthedisconnect
stepsinreverseorder.
NOTE: NOTE:

NOTE:

Torquethenuts(10)to50–60ft-lb(68–81

N•m).

22

3A3164D

Repair

Outlet Outlet

Outlet

Check Check

Check

Valves Valves

Valves

1.PerformPressureReliefProcedure,page12,and
disconnecttheunitfromthepowersourcebefore
removingorservicingtheoutletcheckvalve.

2.Whenreplacingtheoutletcheckvalve,reinstall
withtheproper󰘱owdirection.

Outlet Outlet

Outlet

Check Check

Check

Valve Valve

Valve

Repair Repair

Repair

1.Flushthepump(seePrime/Flush,page13).
Stopthepumpatthebottomofthestroke.

2.PerformPressureReliefProcedure,page12.

3.Disconnecttheunitfromthepowersource.

4.Placeawastecontainerbelowtheoutletcheck
valvetocatchanymaterial.

5.Usetwowrenchestoloosenthehose,then
disconnectthehosefromtheoutletcheckvalve
housing.

6.Useawrenchtoloosentheoutletcheckvalve,
thenremovetheoutletcheckvalvefromthe
pumplower.
NOTE: NOTE:

NOTE:

Thepressuredrainvalvemayremain
attachedtotheoutletcheckvalvehousingduring
repairifneeded.

7.Removetheoutletcheckvalvenutfromthevalve
housing.

8.Removeandcleanallinternaloutletcheckvalve
components.Inspectallcomponentsforwearor
damageandreplacecomponentsasneeded.

9.Reassemblepartsinthereverseorderthey
wereremoved;ballguides(3),springretainer,
compressorspring,andball.Useasmallblunt
tooltopushthatballinandverifythattheball
andspringmovefreely.

10.Replacetheo-ringandcoatwithgrease.

11.Torquetheoutletcheckvalvenutontothe
housingto75–80ft-lb(101–108N•m).
NOTE: NOTE:

NOTE:

Ifthepressuredrainvalvewasremoved
fortheoutletcheckvalverepair,reinstallatthis
point.

12.Reattachtheoutletcheckvalvetothepump
lowerandverifythe󰘱owindicationarrowis
pointingawayfromthepumpandthatthe
pressuredrainvalveoutletisfacingtheground.

13.Attachthedispensehosetotheoutletcheck
valve.

3A3164D 23

Parts

Parts Parts

Parts

Parts Parts

Parts

Drawing Drawing

Drawing

For information on Warning Labels, see Driver Operation/Repair manual.

Quick Start Guide 3A3067 (not shown) is available upon request.

†

Wall mount sprayers only.

24

3A3164D

Parts

Parts Parts

Parts

List List

List

Ref. Ref.

Ref.

Part Part

Part

Description Description

Description

Qty. Qty.

Qty.

255143(includes5,6)BRACKET,wallmount,painted(Models24Y909,24Y910,24Y911,24Y912,

24Z909,24Z910,24Z911,24Z912

1

1

24Y078
(includes14,20,21,22)

CART,heavyduty,painted(Models24Y901,24Y902,24Y903,24Y904,
24Y905,24Y906,24Y907,24Y908,24Z901,24Z902,24Z903,24Z904,
24Z905,24Z906,24Z907,24Z908)

1

4

24X901(includes2x31
Oiljugs,part16W645)

DRIVER,e-Xtreme1

5

100133

WASHER,lock,3/8

4

6100101

SCREW,cap,hexhd

4

7

15H392

ROD,adapterXtreme

1

8257150

ROD,tie,141/4long

3

L145CN(includes9a)LOWER,Xtreme,145,nf,xseal,disk(Models24Y903,24Y904,24Y907,

24Y908,24Y911,24Y912)

1

L145CL(includes9a)LOWER,Xtreme,145,w/󰘰lt,xseal(Models24Y901,24Y902,24Y905,

24Y906,24Y909,24Y910)

1

L180CN(includes9a)LOWER,Xtreme,180,nf,xseal,disk(Models24Z903,24Z904,24Z907,

24Z908,24Z911,24Z912)

1

9

L180CL(includes9a)LOWER,Xtreme,180,w/󰘰lt,xseal(Models24Z901,24Z902,24Z905,

24Z906,24Z909,24Z910)

1

9a258962

HOUSING,rupturedisc,assembly

1

10101712NUT,lock3

11244820

CLIP,hairpin(w/lanyard)

1

12244819

COUPLING,assembly,145-290Xtreme

1

13197340

COVER,coupler

1

14113361

CAP,tube,round(Models24Y901,24Y902,24Y903,24Y904,24Y905,
24Y906,24Y907,24Y908,24Z901,24Z902,24Z903,24Z904,24Z905,
24Z906,24Z907,24Z908)

2

17*

17L151

FITTING,elbow(Models24Y905,24Y906,24Y907,24Y908,24Z905,
24Z906,24Z907,24Z908)

1

20113362

WHEEL,semi-pneumatic(Models24Y901,24Y902,24Y903,24Y904,
24Y905,24Y906,24Y907,24Y908,24Z901,24Z902,24Z903,24Z904,
24Z905,24Z906,24Z907,24Z908)

2

21154628

WASHER(Models24Y901,24Y902,24Y903,24Y904,24Y905,24Y906,
24Y907,24Y908,24Z901,24Z902,24Z903,24Z904,24Z905,24Z906,
24Z907,24Z908)

2

22113436

RING,retaining(Models24Y901,24Y902,24Y903,24Y904,24Y905,
24Y906,24Y907,24Y908,24Z901,24Z902,24Z903,24Z904,24Z905,
24Z906,24Z907,24Z908)

2

24116746

FITTING,barbed,plated

1

25116750TUBE,nylon1

31‡16W645

KIT,oil(1quartBottle)

206994

FLUID,TSL8oz

1

206995(notincluded)FLUID,TSL1quart(notshown)

206996(notincluded)FLUID,TSL1gallon(notshown)

41

206997(notincluded)FLUID,TSL12quarts(notshown)

44aH42506

HOSE,cpld,4500psi,0.25ID,6ft(Models24Y901,24Y903,24Y905,
24Y907,24Y909,24Y911,24Z901,24Z903,24Z905,24Z907,24Z909,
24Z911)

1

44b164856

FITTING,nipple,reducing(Models24Y901,24Y903,24Y905,24Y907,
24Y909,24Y911,24Z901,24Z903,24Z905,24Z907,24Z909,24Z911)

1

3A3164D 25

Parts

Ref. Ref.

Ref.

Part Part

Part

Description Description

Description

Qty. Qty.

Qty.

44cH43850

HOSE,cpld,4500psi,0.375ID,50ft(Models24Y901,24Y903,24Y905,
24Y907,24Y909,24Y911,24Z901,24Z903,24Z905,24Z907,24Z909,
24Z911)

1

47XTR504

GUN,XTR5,1in.hnd,4fng,xhdrac(Models24Y901,24Y903,24Y905,
24Y907,24Y909,24Y911,24Z901,24Z903,24Z905,24Z907,24Z909,
24Z911)

1

25C189(1/2in.NPTfor
Integrated󰘰lterLowers)

VALVE,subassembly(Models24Y901,24Y902,24Y905,24Y906,24Y909,
24Y910,24Z901,24Z902,24Z905,24Z906,24Z909,24Z910)

1

55

127631(3/4in.NPTfor
No󰘰lterlowers)

VALVE,subassembly(Models24Y903,24Y904,.24Y907,24Y908,24Y911,
24Y912,24Z903,24Z904,24Z907,24Z908,24Z911,24Z912)

1

55a

245143VALVE,pressure,bleed1

5817A411LABEL,instructions1

64162505

FITTING,union,swivel

1

71*C19024FITTING,elbow,swivel(Models24Y905,24Y906,24Y907,24Y908,24Z905,

24Z906,24Z907,24Z908)

1

7424Z274

HOSE,suction,1in.nptx3ftL(Models24Y901,24Y902,24Y903,24Y904,
24Z901,24Z902,24Z903,24Z904)

1

81*

17D554

BRACKET,hopper,upper(Models24Y905,24Y906,24Y907,24Y908,
24Z905,24Z906,24Z907,24Z908)

1

82*17C474BRACKET,hopper(Models24Y905,24Y906,24Y907,24Y908,24Z905,

24Z906,24Z907,24Z908)

1

83*

112395

SCREW,cap,󰘱nghd(Models24Y905,24Y906,24Y907,24Y908,24Z905,
24Z906,24Z907,24Z908)

4

84*

16U537

COVER,complete(Models24Y905,24Y906,24Y907,24Y908,24Z905,
24Z906,24Z907,24Z908)

1

85*

17E114

HOPPER,weldment,Xtreme(Models24Y905,24Y906,24Y907,24Y908,
24Z905,24Z906,24Z907,24Z908)

1

86*

120307

FITTING,hoseadapter,male(Models24Y905,24Y906,24Y907,24Y908,
24Z905,24Z906,24Z907,24Z908)

1

87*

120308

FITTING,hoseadapter,female(Models24Y905,24Y906,24Y907,24Y908,
24Z905,24Z906,24Z907,24Z908)

1

87a*120781(PTFE

EncapsulatedViton)

GASKET,quickcoupler(Models24Y905,24Y906,24Y907,24Y908,24Z905,
24Z906,24Z907,24Z908)

1

87b*17C453(Buna-N6-pack)

(notincludedwith87)

GASKET,quickcoupler(6-PACK)(Models24Y905,24Y906,24Y907,
24Y908,24Z905,24Z906,24Z907,24Z908)(notshown)

1

88*

17L152

FITTING,swivel(Models24Y905,24Y906,24Y907,24Y908,24Z905,
24Z906,24Z907,24Z908)

1

89*

112958

NUT,hex,󰘱anged(Models24Y905,24Y906,24Y907,24Y908,24Z905,
24Z906,24Z907,24Z908)

4

101▲17J476

LABEL,warning(English/French/Spanish)

1

17K430

LABEL,warning,bag(Dutch/German/Swedish,Polish/Russian,
Italian/Turkish)

1

*

Included in Hopper Accessory Kit 25C188

▲

Additional Warning labels are available at no cost.

‡Thedrivergearboxisshippedfromthefactorypre-󰘰lledwithoil.Additionaloilmustbepurchasedseparately.

1

Torqueto145–155ft-lb(196–210N•m).

2

Applythreadlocker.

3

Torqueto56–60ft-lb68–81N•m).

4

Applylithiumgreaselubricant.

26 3A3164D

Parts

Outlet Outlet

Outlet

Check Check

Check

Valves Valves

Valves

Parts Parts

Parts

Outlet Outlet

Outlet

Check Check

Check

Valves Valves

Valves

Parts Parts

Parts

List: List:

List:

127631 127631

127631

(3/4 (3/4

(3/4

in. in.

in.

male male

male

npt npt

npt

inlet) inlet)

inlet)

25C189 25C189

25C189

(1/2 (1/2

(1/2

in. in.

in.

male male

male

npt npt

npt

inlet) inlet)

inlet)

Ref. Ref.

Ref.

Part Part

Part

Description Description

Description

Qty. Qty.

Qty.

1127882

NUT,seat(includes2*and4)for
187631version

1

25C190NUT,seat(includes2*and4)for

25C189version

1

2*

102595

PACKING,o-ring

1

3181492

GUIDE,ball

3

4102972BALL,metallic1

5

17A091

HOUSING,ball,check

1

6181535RETAINER,spring1

7

108361

SPRING,compressor

1

23245143VALVE,pressurebleed1

*

If the outlet check valve is disassembled, the o - ring (2) must be

replaced. The o - ring is designed to be crushed, and not reused.

Parts Parts

Parts

Speci󰘰cations: Speci󰘰cations:

Speci󰘰cations:

Ref. Ref.

Ref.

Instruction Instruction

Instruction

1

Torqueto101–108N•m(75–80ft-lb)

2

Applylubricant

Accessories: Accessories:

Accessories:

Part Part

Part

Description Description

Description

17B291

MIXER,jiffy,PS-1

24Z266

KIT,suctionset,1in.nptx6ftL

24Z274

KIT,suctionset,1in.nptx3ftL

24Z270

KIT,suction,drum,1in.nptx10ftL

17M677

SoftwareUpdateToken**

25C188

KIT,hopper(seePartsListforcontents)

**

See the Driver Operation/Repair manual for “ Software Software

Software

Token Token

Token

Update Update

Update

” procedure.

3A3164D

27

Parts

ATEX/Hazardous ATEX/Hazardous

ATEX/Hazardous

Location-Rated Location-Rated

Location-Rated

Power Power

Power

Cord Cord

Cord

Kits Kits

Kits

(1–gland (1–gland

(1–gland

cable cable

cable

shown) shown)

shown)

ATEX/Hazardous ATEX/Hazardous

ATEX/Hazardous

Location Location

Location

- --Rated Rated

Rated

Power Power

Power

Cords: Cords:

Cords:

A AA– ––Cord Cord

Cord

Grip Grip

Grip

B BB– ––Cable Cable

Cable

C CC– ––Cable Cable

Cable

Gland Gland

Gland

24Z267*

KIT,powercable,1gland,8M

111

24Z268*

KIT,powercable,1gland,15M

111

24Z269*

KIT,powercable,1gland,30M

111

24Z271

KIT,powercable,2gland,8M

—

12

24Z272

KIT,powercable,2gland,15M

—

12

24Z273

KIT,powercable,2gland,30M

—

12

*

Only one end has ATEX/Hazardous location cable gland. Power Supply must be outside of ATEX/Hazardous location for ratings to apply.

A: A:

A:

Cord Cord

Cord

Grip Grip

Grip

(ordinary (ordinary

(ordinary

location) location)

location)

PowerSupplymustbeoutsideofATEX/Hazardouslocationforratingstoapply.

B: B:

B:

Cable Cable

Cable

MOR® MOR®

MOR®

Polyrad® Polyrad®

Polyrad®

XT XT

XT

- --125 125

125

Armored Armored

Armored

and and

and

Sheathed Sheathed

Sheathed

Cable Cable

Cable

(125° (125°

(125°

C CCTemperature Temperature

Temperature

Rating) Rating)

Rating)

Manufacturer:GeneralCable
ManufacturerP/N:279220

UL UL

UL

1309 1309

1309

Type Type

Type

X110 X110

X110

(UL (UL

(UL

Listed Listed

Listed

File File

File

No. No.

No.

E85994) E85994)

E85994)

IEEE IEEE

IEEE

1580 1580

1580

Type Type

Type

P P

P

CSA CSA

CSA

C22.2 C22.2

C22.2

No. No.

No.

245 245

245

Type Type

Type

X110 X110

X110

IEC IEC

IEC

60092 60092

60092

– ––350 350

350

API API

API

- --RP14F*** RP14F***

RP14F***

***PermanufacturerGeneralCable,suitableforuseinClassI,Division1,andZone1HazardousLocations
wheninstalledinaccordancewithAPI-RP14F.Cableglandratingsmayhaveaneffectonoverallratings
andmustalsobeconsidered.

Forotherratings,listingsandinstallationinstructionsseemanufacturer’swebsite:http://www.generalcable.com/

C: C:

C:

Cable Cable

Cable

Gland Gland

Gland

– ––for for

for

driver, driver,

driver,

with with

with

ratings ratings

ratings

CROCLOCK CROCLOCK

CROCLOCK

®Cable Cable

Cable

Gland Gland

Gland

Manufacturer:PeppersCableGlands
ManufacturerP/N:CR-3B/NP/20/075NPT

Certi󰘰cate Certi󰘰cate

Certi󰘰cate

No. No.

No.

ABS: ABS:

ABS:

09–LD463991–PDA 09–LD463991–PDA

09–LD463991–PDA

(American (American

(American

Bureau Bureau

Bureau

of ofofShipping) Shipping)

Shipping)

CSA: CSA:

CSA:

1356011 1356011

1356011

•Ex Ex

Ex

d ddIIc IIc

IIc

/ //Ex Ex

Ex

e eeII IIIIClass Class

Class

I IIZone Zone

Zone

1 1

1

•Class Class

Class

I IIDivision Division

Division

2, 2,2,Groups Groups

Groups

A, A,

A,

B, B,

B,

C CCand and

and

D D

D

ATEX: ATEX:

ATEX:

BAS BAS

BAS

01ATEXT2271X 01ATEXT2271X

01ATEXT2271X

IECEx: IECEx:

IECEx:

SIR SIR

SIR

07.0099X 07.0099X

07.0099X

Foradditionalcerti󰘰cates/listingsandinstallationinstructions,seemanufacturer’swebsite:
http://peppersamerica.com/

28 3A3164D

Dimensions

Dimensions Dimensions

Dimensions

Wall Wall

Wall

Mount Mount

Mount

Systems Systems

Systems

3A3164D 29

Dimensions

Cart Cart

Cart

Systems Systems

Systems

30 3A3164D

Dimensions

Hopper Hopper

Hopper

Systems Systems

Systems

3A3164D 31

TechnicalSpecications

Technical Technical

Technical

Speci󰘰cations Speci󰘰cations

Speci󰘰cations

Ex35 Ex35

Ex35

e ee- --Xtreme Xtreme

Xtreme

Sprayers Sprayers

Sprayers

U.S. U.S.

U.S.

Metric Metric

Metric

Maximum󰘱uidworkingpressure

3500psi240bar,24.0MPa

Strokelength

4.75in.120mm
Maximumcontinuouscyclerate44cyclesperminute
TipSize

.023in.
Weight295lb135kg
Wettedparts

CarbonSteel,AlloySteel,304,440and17–PHGrades
ofStainlessSteel,ZincandNickelPlating,DuctileIron,

TungstenCarbide,PTFE;Leather,Aluminum
Operatingtemperaturerange23°to120°F-5°to50°C
Maximum󰘱uidtemperatureSeeModelsinformationinOperation/Repairmanual.
Inputvoltage

200–240VAC,singlephase,50/60Hz
Inputpower2.5kVA
MinimumRecommendedgeneratorsize5kW
Oilcapacity

1.0–1.2quarts0.9–1.1liters

Oilspeci󰘰cationGracopartnumber16W645silicone-freeISO

220syntheticEPgearoil
Inlet/OutletSizes
Fluidinletsize

1in.npt(m)[alsoincludes1in.nps(swivel)to

1in.npt(m)adapterelbow]

Fluidoutletsize

1/2npt(m)[alsoincludes1/2npt(f)to3/8npt(m)adapter]
HoseRequirements
MinimumpressureTheminimumhosepressureratingshouldbeequaltoor

greaterthanthemaximum󰘱uidworkingpressureofsprayer

Minimumlength

50ft.

15m
MinimumID3/8in.10mm
MaximumresistanceperISO80289,100ohms/ft

30,000ohms/m

SoundEmissions(perISO9614)forNormalOperation(Spraying@20cpm)
SoundPressureLpAAverage

70.2dBA

SoundPowerLwATotalPower

76.7dBA

SoundEmissions(perISO9614)forMaximumSpeed(Flushing@44cpm)
SoundPressureLpAAverage

77.4dBA

SoundPowerLwATotalPower

85.1dBA

32 3A3164D

TechnicalSpecications

Ex45 Ex45

Ex45

e ee- --Xtreme Xtreme

Xtreme

Sprayers Sprayers

Sprayers

U.S. U.S.

U.S.

Metric Metric

Metric

Maximum󰘱uidworkingpressure

4500psi310bar,31.0MPa

Strokelength

4.75in.120mm
Maximumcontinuouscyclerate44cyclesperminute
TipSize

.021in.
Weight295lb135kg
Wettedparts

CarbonSteel,AlloySteel,304,440and17–PHGrades
ofStainlessSteel,ZincandNickelPlating,DuctileIron,

TungstenCarbide,PTFE;Leather,Aluminum
Maximum󰘱uidtemperatureSeeModelsinformationinOperation/Repairmanual.
Operatingtemperaturerange23°to120°F-5°to50°C
Inputvoltage

200–240VAC,singlephase,50/60Hz
Inputpower2.5kVA
MinimumRecommendedgeneratorsize5kW
Oilcapacity

1.0–1.2quarts0.9–1.1liters

Oilspeci󰘰cationGracopartnumber16W645silicone-freeISO

220syntheticEPgearoil
Inlet/OutletSizes
Fluidinletsize

1in.npt(m)[alsoincludes1in.nps(swivel)to

1in.npt(m)adapterelbow]

Fluidoutletsize

1/2npt(m)[alsoincludes1/2npt(f)to3/8npt(m)adapter]
HoseRequirements
MinimumpressureTheminimumhosepressureratingshouldbeequaltoor

greaterthanthemaximum󰘱uidworkingpressureofsprayer

Minimumlength

50ft.

15m
MinimumID3/8in.10mm
MaximumresistanceperISO80289,100ohms/ft

30,000ohms/m

SoundEmissions(perISO9614)forNormalOperation(Spraying@20cpm)
SoundPressureLpAAverage

70.2dBA

SoundPowerLwATotalPower

76.7dBA

SoundEmissions(perISO9614)forMaximumSpeed(Flushing@44cpm)
SoundPressureLpAAverage

77.4dBA

SoundPowerLwATotalPower

85.1dBA

3A3164D 33

Graco Graco

Graco

Standard Standard

Standard

Warranty Warranty

Warranty

GracowarrantsallequipmentreferencedinthisdocumentwhichismanufacturedbyGracoandbearingits
nametobefreefromdefectsinmaterialandworkmanshiponthedateofsaletotheoriginalpurchaserfor
use.Withtheexceptionofanyspecial,extended,orlimitedwarrantypublishedbyGraco,Gracowill,fora
periodoftwelvemonthsfromthedateofsale,repairorreplaceanypartoftheequipmentdetermined
byGracotobedefective.Thiswarrantyappliesonlywhentheequipmentisinstalled,operatedand
maintainedinaccordancewithGraco’swrittenrecommendations.

Thiswarrantydoesnotcover,andGracoshallnotbeliableforgeneralwearandtear,oranymalfunction,
damageorwearcausedbyfaultyinstallation,misapplication,abrasion,corrosion,inadequateorimproper
maintenance,negligence,accident,tampering,orsubstitutionofnon-Gracocomponentparts.Norshall
Gracobeliableformalfunction,damageorwearcausedbytheincompatibilityofGracoequipment
withstructures,accessories,equipmentormaterialsnotsuppliedbyGraco,ortheimproperdesign,
manufacture,installation,operationormaintenanceofstructures,accessories,equipmentormaterials
notsuppliedbyGraco.

Thiswarrantyisconditionedupontheprepaidreturnoftheequipmentclaimedtobedefectivetoan
authorizedGracodistributorforveri󰘰cationoftheclaimeddefect.Iftheclaimeddefectisveri󰘰ed,Graco
willrepairorreplacefreeofchargeanydefectiveparts.Theequipmentwillbereturnedtotheoriginal
purchasertransportationprepaid.Ifinspectionoftheequipmentdoesnotdiscloseanydefectinmaterial
orworkmanship,repairswillbemadeatareasonablecharge,whichchargesmayincludethecostsof
parts,labor,andtransportation.

THISWARRANTYISEXCLUSIVE,ANDISINLIEUOFANYOTHERWARRANTIES,EXPRESSOR
IMPLIED,INCLUDINGBUTNOTLIMITEDTOWARRANTYOFMERCHANTABILITYORWARRANTY
OFFITNESSFORAPARTICULARPURPOSE.

Graco’ssoleobligationandbuyer’ssoleremedyforanybreachofwarrantyshallbeassetforthabove.
Thebuyeragreesthatnootherremedy(including,butnotlimitedto,incidentalorconsequentialdamages
forlostpro󰘰ts,lostsales,injurytopersonorproperty,oranyotherincidentalorconsequentialloss)shall
beavailable.Anyactionforbreachofwarrantymustbebroughtwithintwo(2)yearsofthedateofsale.

GRACO GRACO

GRACO

MAKES MAKES

MAKES

NO NO

NO

WARRANTY, WARRANTY,

WARRANTY,

AND AND

AND

DISCLAIMS DISCLAIMS

DISCLAIMS

ALL ALL

ALL

IMPLIED IMPLIED

IMPLIED

WARRANTIES WARRANTIES

WARRANTIES

OF OF

OF

MERCHANTABILITY MERCHANTABILITY

MERCHANTABILITY

AND AND

AND

FITNESS FITNESS

FITNESS

FOR FOR

FOR

A AAPARTICULAR PARTICULAR

PARTICULAR

PURPOSE, PURPOSE,

PURPOSE,

IN IN

IN

CONNECTION CONNECTION

CONNECTION

WITH WITH

WITH

ACCESSORIES, ACCESSORIES,

ACCESSORIES,

EQUIPMENT, EQUIPMENT,

EQUIPMENT,

MATERIALS MATERIALS

MATERIALS

OR OR

OR

COMPONENTS COMPONENTS

COMPONENTS

SOLD SOLD

SOLD

BUT BUT

BUT

NOT NOT

NOT

MANUFACTURED MANUFACTURED

MANUFACTURED

BY BY

BY

GRACO. GRACO.

GRACO.

Theseitemssold,butnotmanufacturedbyGraco(suchaselectricmotors,switches,hose,etc.),
aresubjecttothewarranty,ifany,oftheirmanufacturer.Gracowillprovidepurchaserwithreasonable
assistanceinmakinganyclaimforbreachofthesewarranties.

InnoeventwillGracobeliableforindirect,incidental,specialorconsequentialdamagesresultingfrom
Gracosupplyingequipmenthereunder,orthefurnishing,performance,oruseofanyproductsorother
goodssoldhereto,whetherduetoabreachofcontract,breachofwarranty,thenegligenceofGraco,or
otherwise.

FORGRACOCANADACUSTOMERS
ThePartiesacknowledgethattheyhaverequiredthatthepresentdocument,aswellasalldocuments,

noticesandlegalproceedingsenteredinto,givenorinstitutedpursuantheretoorrelatingdirectlyor
indirectlyhereto,bedrawnupinEnglish.Lespartiesreconnaissentavoirconvenuquelarédactiondu
présentedocumentseraenAnglais,ainsiquetousdocuments,avisetprocéduresjudiciairesexécutés,
donnésouintentés,àlasuitedeouenrapport,directementouindirectement,aveclesprocédures
concernées.

Graco Graco

Graco

Information Information

Information

ForthelatestinformationaboutGracoproducts,visitwww.graco.com.
Forpatentinformation,seewww.graco.com/patents.

To To

To

place place

place

an an

an

order, order,

order,

contactyourGracoDistributororcalltoidentifythenearestdistributor.

Phone: Phone:

Phone:

612-623-6921or or

or

Toll Toll

Toll

Free: Free:

Free:

1-800-328-0211Fax: Fax:

Fax:

612-378-3505

Allwrittenandvisualdatacontainedinthisdocumentre󰘱ectsthelatestproductinformationavailableatthetimeofpublication.

Gracoreservestherighttomakechangesatanytimewithoutnotice.

OriginalInstructions.ThismanualcontainsEnglish,MM3A3164

Graco Graco

Graco

Headquarters: Headquarters:

Headquarters:

Minneapolis

International International

International

Of󰘰ces: Of󰘰ces:

Of󰘰ces:

Belgium,China,Japan,Korea

GRACO GRACO

GRACO

INC. INC.

INC.

AND AND

AND

SUBSIDIARIES SUBSIDIARIES

SUBSIDIARIES

• ••P.O. P.O.

P.O.

BOX BOX

BOX

1441 1441

1441

• ••MINNEAPOLIS, MINNEAPOLIS,

MINNEAPOLIS,

MN MN

MN

55440-1441 55440-1441

55440-1441

• ••USA USA

USA

Copyright Copyright

Copyright

2016, 2016,

2016,

Graco Graco

Graco

Inc. Inc.

Inc.

All All

All

Graco Graco

Graco

manufacturing manufacturing

manufacturing

locations locations

locations

are are

are

registered registered

registered

to totoISO ISO

ISO

9001. 9001.

9001.

www.graco.com

RevisionD–March2017