Instructions-Parts
Xtreme® XL Packages
High performance, high pressure spray packages for applying protective coatings. For professional use
only.
Important Safety Instructions
Read all warnings and instructions in this manual and in related
manuals. Save these instructions.
See Models on page 6 for maximum
working pressures.
334645B
EN
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
Related Manuals ................................................ 3
Warnings ........................................................... 4
Sprayer Packages.............................................. 7
Heavy Fluids Sprayer Packages ................... 8
Pump Packages ................................................. 8
Component Identification - Cart Mount................. 9
Component Identification - Wall Mount ................. 10
System Components........................................... 11
Grounding.......................................................... 11
Install Wall Mount Assembly................................ 12
Install Hopper Assembly......................................12
Setup................................................................. 13
Pressure Relief Procedure .................................. 14
Flush ................................................................. 15
Prime................................................................. 17
Spray................................................................. 19
Shutdown...........................................................19
Maintenance ...................................................... 20
Preventative Maintenance Schedule ............. 20
Daily Maintenance ....................................... 20
Corrosion Protection .................................... 20
Cart Maintenance.........................................20
Troubleshooting.................................................. 21
Remove Lower ................................................... 22
Disconnect and Reconnect Lower ................. 22
Parts.................................................................. 23
Dimensions........................................................ 34
Performance Charts............................................36
Technical Specifications...................................... 39
Graco Standard Warranty.................................... 40
2
334645B
Related Manuals
Manual Description
334644 Xtreme XL Air Motor, Instructions-Parts
Related Manuals
3A0293
311825 Dura-Flo™ Lowers, Instructions-parts
311762 Xtreme® Lowers, Instructions-Parts
311164
Air Controls, Instructions-Parts
NXT® Xtreme Packages, Instructions-
Parts
334645B 3
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
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 equipment in the work area. See
• Never spray or flush sol vent 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 into 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.
if static sparking occurs or you feel a shock.Do not use
Grounding instructions
work area
canigniteorexplode.Paint
.
4
334645B
Warnings
WARNING
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.
treatment.
• 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.
•Followthe
or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
Pressure Relief Procedure
when you stop spraying and before cleaning, checking,
Get immediate surgical
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
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 wo rk 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 e quipment 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 Procedure
in all equipment manuals.
Technical Data
when equipment is not in use.
334645B 5
Warnings
WARNING
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, movi ng, or servicing
equipment, follow the
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 MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved contai ners, and dispose of it according to applicable
guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Pressure Relief Procedure
and disconnect all power sources.
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.
6 334645B
Sprayer Packages
Sprayer Packages
Check your sprayer or wall mount package’s
identification plate (ID) on the side of the shelf
mounting bracket 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
3
represents the Xtreme XL brand (XL), pressure
ratio (45:1), on a heavy duty cart (H), and complete
package (gun, hose, and pump filter included) (3). To
order replacement parts, see Parts, page 23.
Note
All packages include 1 in. air controls consisting of inlet claw fittings, 40 micron filter/regulator,
relieving ball valve, and motor hose.
Approvals:
XL 45 H
II 2 G c 230°C (T2)
Maximum Air Working Pressure:
Never exceed the maximum air WPR listed on your model ID plate. This is the maximum set point on regulator
(G) which is read on gauge (E).
Pressure Ratio Maximum Air WPR Maximum Fluid WPR
XL 45
XL 70
XL 80
XL 95
XL 45 H
Third and
Second Digit
XL
*
Uses a Dura-Flo lower.
Fourth Digit
Pressure Ratio
(xx:1)
45*
70 W Wall Mount 2
803
95 4NANANA
Fifth Digit Sixth DigitFirst and
Mount Option
H
95 psi (0.65 MPa, 6.5 bar)
100psi(0.7MPa,7bar) 7100psi(48MPa,489bar)
88 psi (0.6 MPa, 6 bar) 7250 psi (50 MPa, 500 ba r)
76 psi (0.5 MPa, 5 bar) 7250 psi (50 MPa, 500 ba r)
With Hose
and Gun
Heavy Duty Cart
1
4500 psi (31 MPa, 310 ba r)
3
Hopper Filter
✔
✔✔
✔✔✔
334645B
7
Pump Packages
Heavy Fluids Sprayer Packages
Packages include a hopper, no fluid filter, 3/4 in outlet
check valve, 3/4 in x 50 ft. (15 m) hose, 1/2 in x 25 ft
(7.6 m) whip and XHF spray gun with 429 tip
24X593 - 70:1
24X594 - 80:1
Pump Packages
Check your pump package’s identification plate (ID),
attached to the black motor shroud, for the 6-digit part
number of your pump pac kage. For example, Pump
Part Number
pressure ratio (45:1), carbon steel construction (C),
and no built-in filter or air controls (2).
To order replacement parts, see Pump Package Parts.
PL 45 C 2
represents the pump (PL),
Note
Heavy-fluid materials vary and should be
tested with a qualified distributor. Material
should be pourable and self-leveling.
Pressure Ratio Maximum Air WPR Maximum Fluid WPR
PL 45
PL 70
PL 80
PL 95
PL 45
First and Second Digit
PL
Approvals:
95 psi (0.65 MPa, 6.5 bar)
100 psi (0.7 MPa, 7 bar) 7100 psi (48 MPa, 489 bar)
88 psi (0.6 MPa, 6 bar) 7250 psi (50 MP a, 500 bar)
76 psi (0.5 MPa, 5 bar) 7250 psi (50 MPa, 500 bar)
C2
Third and Fourth Digit
Pressure Ratio
(xx:1)
45
70 2 NA
80
95
II 2 G c 230°C (T2)
Fifth Digit Sixth Digit
Lower Construction Built-in Filter
C Carbon Steel
4500 psi (31 MPa, 310 bar)
✔
1
8 334645B
Component Identification
- Cart Mount
Component Identification - Cart Mount
Figure 1 Airless Sprayer
Key:
A
B
C Air Pressure Relief Valve
D
E
F Packing Nut
G
HAirMotor
J
K
Air Inlet, 1 in npt(f) on claw fitting
BleedTypeMasterAirValve(required)
Air Filter / Water S eparator
Air Pressure Gauge
Air Regulator Adjustment
Fluid Drain/Purge Valve (required)
Fluid Filter (if equipped)
L
MPump
N
P
R
S Spray Gun
T
U
WFluidHose
Grounding Wire (required)
SuctionHoseandTube(ifequipped)
Pump Fluid Outlet
Optional Fluid Outlet, for second spray gun
De-Ice Control (Bleed Air)
Hopper (if equipped)
334645B 9
Component Identification - Wall Mount
Component Identification
- Wall Mount
Figure 2 Airless Sprayer
Key:
A
B
C Air Pressure Relief Valve
D
E
F Packing Nut
G
HAirMotor
J
Air Inlet, 1 in npt(f) on claw fitting
Bleed Type Master Air Valve (required)
Air Filter / Water Spearator
Air Pressure Gauge
Air Regulator Adjustment
Fluid Drain/Purge Valve (required)
K
L
MPump
N
P
S Spray Gun
T
WFluidHose
Fluid Filter (if equipped)
Grounding Wire (required)
SuctionHoseandTube
Fluid Outlet
De-Ice Control (Bleed Air)
10 334645B
System Com ponents
System Components
Note
* Required system components.
leed Type Master Air Valve (B)
*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.
De-Ice Contol (T)
Turn bleed air knob (open) to reduce icing.
Grounding
The equipment must be grounded to reduce the risk
of static sparking. Static sparking can cause fumes
to ignite or explode. Grounding provides an escape
wire for the electric current.
Tools Required:
• Grounding wires and clamps for pails
• Two 5 gal. (19 liter) metal pails
1. Connect t
ground s
he ground wire (244524) (L) to the
tudontheairmotor.
— Open the valve to supply air to the motor.
— Close the valve to shut off air to the mo tor, 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 Filter (D)
Removes harmful dirt from compressed air supply. A
minimum 40 micron filter is used.
Air Regulator Adjustment (G)
Adjusts air pressure to the motor and fluid outlet
pressure of pump. Locate it close to the pump. Read
air pressure on gauge (E).
Figure 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.
* Fluid Drain/Purge Valve (J)
Open valve to relieve pressure and when flushing or
priming pump. Close valve when spraying.
334645B
11
Install Wall Mount Assembly
Install Wall Mount
Assembly
Note
Before mounting any pump assembly
to the wall always follow the
Pressure Relief Procedure, page 14.
1. Ensure the wall is strong enough to support the
weight of the pump assembly and accessories,
fluid, hoses, and stress caused during pump
operation.
2. Drill four 7/16 in. (11 mm) holes using
bracket as a template. Use any of the three
mounting hole groupings in the bracket. See
Dimensions, page 34.
3. Bolt bracket securely to wall using bolts
and washers designed to hold in the wall’s
construction.
4. Attach pump assembly to mounting bracket
(201).
5. Connect air and fluid hoses. Refer to
Setup, page 13.
Install Hopper Assembly
Note
If provided.
1. If necessary remove suction hose.
a. Disconnect suction hose (18).
b. Disconnect fitting (4) and quick disconnect
adapter (19) from the pump.
2. Attach bracket (30) to the cart (9) with nuts (16)
and screws (15).
3. Loosely attach bracket (29) to bracket (30) with
nuts (16) and screws (15).
4. Install elbow (4) and fitting (8) on the pump.
5. Install fitting (32) and fitting (5) on hopper (7).
6. Connect fitting (5) to fitting (8). Adj us t bracke t
(29) height to fit under the lip on the back of the
hopper (7). Tighten nuts (16).
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334645B
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