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Xtreme Lower Instructions - Parts
NXT Air Motor Instructions - Parts
Integrated Air Control Modules for NXT Air Motors Instructions - Parts
DataTrak
Air Controls for Heavy and Light Duty Carts Instructions-Parts
™
Conversion Kit
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311164F3
Models
Models
Sprayer Packages
Airless Sprayers, Wall Mount Packages, and Hopper Packages
Check your sprayer, wall mount, or hopper package’s identification plate (ID) for
the 6-digit part number of your package. Use the following matrix to define the
construction of your package, based on the six digits. For example, Sprayer Part
Number X60D H 1 represents the Xtreme brand (X), pressure ratio (60 :1),
de-icing motor (D), heavy duty cart (H), and complete package (gun and hose
included) with DataTrak
Sprayer Parts section starting on page 28. The digits in the matrix do not corre-
spond to the reference numbers in the Parts drawings and lists.
™
(1). To order replacement parts, see Airless Xtreme
NOTE: All models have a maximum air input pressure of 100 psi (7
MPa, 70 bar). Models with a 90:1 pressure ratio have a maximum air
input
pressure of 80 psi (0.55 MPa, 5.5 bar).
ID
X60DH1
Second and
First
Digit
X
(Xtreme
brand)
Third DigitFourth DigitFifth DigitSixth Digit
Pressure Ratio
(xx:1)Motor / ExhaustMount Option
25
30
35
40
45
46
50
55
60
70
80
90
DDe-IcingHHeavy Duty1
LLow NoiseLLight Weight2
WWall Mount3
Complete
PackageDataTrakHopper
✔✔
✔
4
5
6
✔✔✔
✔✔
✔
4311164F
Specialty Sprayer Packages
Models
Wall Mount Package 287978
Model 287978 is a 40:1 ratio unit that includes a low
noise motor, DataTrak, external filter, and no gun or
hose.
Air-Assisted Sprayers
All air-assisted sprayers include a de-icing motor, a
heavy duty cart, DataTrak, G40 spray gun, and hose.
30:1 Pressure Ratio - 287975
40:1 Pressure Ratio - 287976
Zinc Sprayers
All zinc sprayers include a de-icing motor and a heavy
duty cart. Models 287973 and 287974 also include
DataTrak, Silver spray gun, and hose.
25:1 Pressure Ratio - 287971
40:1 Pressure Ratio - 287972
25:1 Pressure Ratio - 287973
40:1 Pressure Ratio - 287974
Dura-Flo™ Sprayers
All Dura-Flo sprayers include a de-icing motor, a heavy
duty cart, and Dura-Flo pump package. Only model
287980 includes a gun and hose.
23:1 Pressure Ratio - 287979
23:1 Pressure Ratio - 287980
32:1 Pressure Ratio - 287981
Configurable Cart Packages
NOTE: Configurable cart packages do not
include lowers. Pair these packages with any
Xtreme lower (145cc - 290cc) for a sprayer package.
All models include air controls, tie rods, coupling kit, and suction hose. Use the following matrix to define the construction of your cart package, based on the six digits. For example, cart package number XN3D H 2 represents the
™
Xtreme brand (X), motor (NXT3400), de-icing motor (D), heavy duty cart (H), and bare package with DataTrak
(2).
XN3DH2
Second and
First Digit
X
(Xtreme
brand)
N3
N6
Third DigitFourth DigitFifth DigitSixth Digit
MotorExhaustMount OptionDataTrak
NXT3400
NXT6500
DDe-IcingHHeavy Duty
LLight Weight
2
4
✔
311164F5
Models
Pump Packages
Check your pump package’s identification plate (ID) for the 6-digit part number
of your pump package. For example, Pump Part Number P30M C 1 repre-
sents the pump (P), pressure ratio (30 :1), low noise exhaust motor with Data-
™
Tr ak
(M), carbon steel construction (C), and no built-in filter or air controls (1).
For
To order replacement parts, see Pump Package Parts section starting on
page 43. The digits in the matrix do not correspond to the reference numbers in
the Parts drawings and lists.
ID
NOTE: Models with 16:1 - 70:1 pressure ratios have a maximum air
input pressure of 100 psi (7 MPa, 70 bar). Models with a 90:1 pressure ratio have a maximum air input pressure of 80 psi (0.55 MPa,
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. Refer
back to these Warnings. Additional, product-specific warnings may be found throughout the body of this manual
where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
•Use equipment only in well ventilated area.
•Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
•Keep work area free of debris, including solvent, rags and gasoline.
•Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
•Ground all equipment in the work area. See Grounding instructions.
•Use only grounded hoses.
•Hold gun firmly to side of grounded pail when triggering into pail.
•If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
•Keep a working fire extinguisher in the work area.
BATTERY HAZARD
Sparking can occur when changing batteries. The battery may cause an explosion if mishandled:
•You must use the battery type specified for use with the equipment.
•Only replace the battery in a non-hazardous location, away from flammable fluids or fumes.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
•Do not point gun at anyone or at any part of the body.
•Do not put your hand over the spray tip.
•Do not stop or deflect leaks with your hand, body, glove, or rag.
•Do not spray without tip guard and trigger guard installed.
•Engage trigger lock when not spraying.
•Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
311164F7
Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•Do not operate the unit when fatigued or under the influence of drugs or alcohol.
•Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
•Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS forms from distributor or retailer.
•Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco
replacement parts only.
•Do not alter or modify equipment.
•Use equipment only for its intended purpose. Call your Graco distributor for information.
•Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
•Do not kink or over bend hoses or use hoses to pull equipment.
•Keep children and animals away from work area.
•Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
•Keep clear of moving parts.
•Do not operate equipment with protective guards or covers removed.
•Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
•Read MSDS’s to know the specific hazards of the fluids you are using.
•Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
•Protective eyewear
•Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
•Hearing protection
8311164F
Component Identification - Cart Mount
Component Identification - Cart Mount
AAir Inlet, 3/4 npt(f)
BBleed Type Master Air Valve (required)
CAir Pressure Relief Valve
DAir Filter (hidden)
EAir Pressure Gauge
FAir Regulator Adjustment Knob
GDataTrak
models)
JFluid Drain/Purge Valve (required)
™
location (see page 19; not present on all
Light Duty Cart
KFluid Filter
LGrounding Wire (required)
MLower
NSuction Hose and Tube
PFluid Outlet
ROptional Fluid Outlet, for second gun
SPacking Nut
TDe-Ice Control
Heavy Duty Cart
F
A
C
D
G
E
B
L
F
S
A
M
R
P
FIG. 1: Airless Sprayer
T
B
E
C
D
K
J
N
TI8408a
Hopper (288347) Option
r_x25dh1_x45dl1_311164_1f
311164F9
Component Identification - Wall Mount
Component Identification - Wall Mount
AAir Inlet, 3/4 npt(f)
BBleed Type Master Air Valve (required)
CAir Pressure Relief Valve
DAir Filter (hidden)
EAir Pressure Gauge
FAir Regulator Adjustment Knob
GDataTrak
LGrounding Wire (required)
MLower
NSuction Hose and Tube
PFluid Outlet
ROptional Fluid Outlet, for second gun
SPacking Nut
TDe-Ice Control
USpray Gun
VHose
G
L
A
T
B
S
N
FIG. 2: Wall Mount System
F
E
C,D
K
J
R
P
U
V
TI8413a
10311164F
System Components
Component Identification - Wall Mount
* Bleed Type Master Air Valve (B)
Trapped air can cause the pump to cycle unexpectedly,
which could result in serious injury from splashing or
moving parts.
•Be sure the valve is easily accessible from the pump
and located downstream from the air regulator.
•Required in your system to relieve air trapped
between it and the air motor when the valve is
closed.
•Open to supply air to the motor.
•Close to shut off air to the motor, and bleed any
trapped air from the motor.
* Air Pressure Relief Valve (C)
Automatically opens to relieve air pressure if supplied
pressure exceeds preset limit.
Air Regulator Adjustment (F)
Adjusts air pressure to the motor and fluid outlet pressure of pump. Locate it close to the pump. Read air
pressure on gauge (E).
* Fluid Drain/Purge Valve (J)
Open valve to relieve pressure and when flushing or
priming pump. Close valve when spraying.
De-Ice Control (T)
Turn knob (open) to reduce icing.
TI8160b
* Required system components.
Air Filter (D)
Removes harmful dirt from compressed air supply.
311164F11
Grounding
Grounding
The equipment must be grounded. Grounding reduces
the risk of static and electric shock by providing an
escape wire for the electrical current due to static build
up or in the event of a short circuit.
Table 1: Tools Required
•Grounding wires and clamps for pails
•Two 5 gal. (19 liter) metal pails
1. Connect the ground wire (244524) (L) to the ground
stud on the air motor.
Setup
To avoid tip over, ensure cart is on a flat and level surface. Failure to do so could result in injury or equipment damage.
Table 2: Tools Required
•Two adjustable wrenches
•Non-sparking hammer or plastic mallet
•Torque wrench
1. Ground sprayer.
2. Check packing nut (S). Fill with Throat Seal Liquid
(TSL). Torque to 25-30 ft-lb (34-41 N•m).
S
L
F
IG. 3
2. Connect the other end of the ground wire to a true
earth ground.
3. Ground the object being sprayed, fluid supply container, and all other equipment in the work area. Follow your local code. Use only electrically conductive
air and fluid hoses.
4. Ground all solvent pails. Use only metal pails, which
are conductive, placed on a grounded surface. Do
not place pail on a nonconductive surface, such as
paper or cardboard, which interrupts grounding continuity.
TI1102-1
TI8250a
TI1102-2
TI8316a
3. Attach electrically conductive fluid hose to pump
outlet and tighten.
4. Attach electrically conductive fluid hose (and air
hose if using an AA gun) to gun and tighten.
5. Close bleed type master air valve (B). Connect air
supply hose to 3/4 npt(f) air inlet (A).
B
A
6. Flush before using. See page 14.
7. Prime before using. See page 14.
12311164F
Pressure Relief Procedure
1. Engage gun trigger lock.
Pressure Relief Procedure
4. Hold gun firmly against a grounded metal pail. Trigger the gun.
TI8252a
TI5049a
2. Close bleed type master air valve (B).
3. Disengage gun trigger lock.
NOTE: If using an AA gun, turn gun air regulator
counter-clockwise to relieve pressure.
TI5048a
5. Engage gun trigger lock.
B
TI5049a
6. Drain fluid. To drain fluid, slowly open all fluid drain
valves, including drain/purge valve (J), in system
into a waste pail. If there is a return tube, open
return line ball valve.
+
J
TI8417a
7. If you suspect the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the previous steps, very slowly loosen
the tip guard retaining nut or hose end coupling and
relieve pressure gradually; then loosen completely.
With tip removed, trigger gun into bucket.
Trigger Lock
Always engage gun trigger lock when you stop spraying
to prevent gun from being triggered accidentally by hand
or if dropped or bumped.
311164F13
Prime/Flush
Prime/Flush
1. Follow Pressure Relief Procedure, page 13.
2. Remove tip and tip guard from gun.
3. Flushing only: If desired, remove built-in fluid filter
(present on some models). Reinstall filter cap after
removing fluid filter.
4. Place suction tube in a compatible fluid (if priming)
or solvent (if flushing).
Zinc sprayers only: Place return tube in a compatible fluid (if priming) or solvent (if flushing). Open
return line valve.
5. Turn regulator adjustment knob (G) counterclockwise until it stops, and gauge (E) reads zero.
G
7. Prime or flush hose and gun:
a. Disengage gun trigger lock.
TI5048a
b. Trigger gun into grounded pail until a steady
stream comes from gun. If flushing, trigger gun
for 10-15 seconds.
TI8727a
NOTE: If using an AA gun, increase air pressure
by turning gun regulator clockwise.
-
E
6. Open bleed type master air valve (B).
B
Zinc sprayers only: When clean solvent or fluid flows
from return tube, close return line valve. Pump will
stall.
14311164F
c. Engage trigger lock.
8. If priming, equipment is now ready to spray; go to
Spray, page 16.
If flushing, proceed with step 9.
Prime/Flush
NOTE: The remaining steps are for flushing
only.
CAUTION
Do not prime pump through drain/purge valve using
two component materials. Mixed two-component
materials will harden in valve and result in clogging.
9. Place drain tube in a grounded waste pail.
Open drain/purge valve (J) slightly by rotating counterclockwise.
+
J
TI8417a
10. Start the pump by rotating the air regulator adjustment knob (G) clockwise until pump begins to move.
11. When clean solvent flows from drain tube close
drain/purge valve (J) by rotating clockwise. Pump
will stall.
-
J
TI8417a
12. Follow Pressure Relief Procedure, page 13. Leave
solvent in and store sprayer.
+
G
311164F15
Spray
Spray
CAUTION
Do not allow pump to run dry. It will quickly accelerate
to a high speed causing damage.
1. Prime. See Prime/Flush, page 14.
2. Follow Pressure Relief Procedure, page 13.
3. Install tip and tip guard on gun.
4. Open bleed type master air valve (B).
B
5. Turn regulator adjustment knob (G) until gauge (E)
reads desired pressure. Turn clockwise to increase
pressure, counterclockwise to decrease pressure.
G
+
-
7. Spray a test pattern. Read fluid manufacturer’s recommendations. Adjust as necessary. If using an AA
gun, increase gun air pressure while testing spray
pattern.
8. Zinc sprayers only: When not spraying, reduce air
pressure to 30 psi (2.1 MPa, 21 bar). Open return
line and close gun valve.
9. Flush when done spraying. See Prime/Flush, page
14.
10. Follow Pressure Relief Procedure, page 13.
Circulating Zinc Fluids
E
6. Disengage gun trigger lock.
TI5048a
16311164F
1. When spraying zinc fluids, close return line valve.
Circulation is not required when spraying.
2. To circulate fluid back to supply container while you
are not spraying, open return line valve and lock gun
trigger safety. Pump will continue to run.
3. Always relieve pressure before overnight shut-
down, when changing spray tips, or when checking
or servicing any part of system. During circulation,
some fluid will be present in gun line and must be
relieved.
Shutdown
Shutdown
5. Open bleed type master air valve (B). Turn regulator
adjustment knob (G) counterclockwise to lowest
possible fluid pressure.
CAUTION
Never leave water or water-base fluid in pump overnight. If you are pumping water-base fluid, flush with
water first, then with a rust inhibitor, such as mineral
spirits. Relieve pressure, but leave rust inhibitor in
pump to protect parts from corrosion.
1. Follow Pressure Relief Procedure, page 13.
2. Remove tip and tip guard from gun.
3. Engage gun trigger lock.
TI5049a
4. Place siphon tube in grounded metal pail containing
cleaning fluid.
G
B
-
6. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun until clean solvent dispenses.
TI8727a
7. Follow Pressure Relief Procedure, page 13.
311164F17
Maintenance
Maintenance
Preventive Maintenance
Schedule
The operating conditions of your particular system
determine how often maintenance is required. Establish
a preventive maintenance schedule by recording when
and what kind of maintenance is needed, and then
determine a regular schedule for checking your system.
Daily Maintenance
NOTE: For overnight shutdown, stop pump at
bottom of its stroke to prevent fluid from drying
on exposed displacement rod and damaging
throat packings. Follow Pressure Relief Procedure, page 13.
1. Flush. See Prime/Flush, page 14.
Corrosion Protection
Always flush the pump before the fluid dries on the displacement rod. Never leave water or water-based fluid in
the pump overnight. First, flush with water or a compatible solvent, then with mineral spirits. Relieve the pressure, but leave the mineral spirits in the pump to protect
the parts from corrosion.
Cart Maintenance
Periodically lubricate the axle between points A and B
with lightweight oil. See F
Keep the cart clean by wiping up spills daily, using a
compatible solvent.
IG. 4.
2. Relieve pressure. See Pressure Relief Procedure,
page 13.
3. Check packing nut (S, F
replace TSL as necessary. Torque to 25-30 ft-lb
(34-41 N•m).
4. Drain water from air filter.
5. Clean suction tube using a compatible solvent. It is
recommended that you clean the outside of the
sprayer using a cloth and compatible solvent.
6. Check hoses, tubes, and couplings. Tighten all fluid
connections before each use.
7. Clean fluid line filter.
IG. 1). Adjust packings and
B
A
r_x25dh1_x45dh1_311164_38f
FIG. 4: Cart Assembly - Heavy Duty Model Shown
18311164F
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