Graco Xtreme XL Packages 334645B Instructions-parts List Manual

Page 1
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.
Page 2
Contents
Related Manuals ................................................ 3
Warnings ........................................................... 4
Sprayer Packages.............................................. 7
Heavy Fluids Sprayer Packages ................... 8
Pump Packages ................................................. 8
Component Identication - Cart Mount................. 9
Component Identication - 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 Specications...................................... 39
Graco Standard Warranty.................................... 40
2
334645B
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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
NX Xtreme Packages, Instructions- Parts
334645B 3
Page 4
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-specic 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 owing 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 ush 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 ammable 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
Page 5
Warnings
WARNING
SKIN INJECTION HAZARD
High-pressure uid 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 uid 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 inuence of drugs or alcohol.
Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See
Use uids and solvents that are compatible with equipment wetted parts. See in all equipment manuals. Read fluid and solvent manufacturers 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 manufacturers replacement parts only.
Do not alter or modify equipment. Alterations or modications 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
Page 6
Warnings
WARNING
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate ngers 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 uids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
Read MSDSs to know the specic hazards of the uids you are using.
Store hazardous uid 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 uid and solvent manufacturer.
6 334645B
Page 7
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 dene 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 lter included) (3). To order replacement parts, see Parts, page 23.
Note
All packages include 1 in. air controls consisting of inlet claw ttings, 40 micron lter/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
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Page 8
Pump Packages
Heavy Fluids Sprayer Packages
Packages include a hopper, no uid lter, 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 lter 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
Page 9
Component Identification
- Cart Mount
Component Identication - 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 tting 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
Page 10
Component Identication - 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 tting 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
Page 11
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 lter 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, uid supply container, and all other equipment in the work area. Follow your local code. Use only electrically conductive air and uid 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
Page 12
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, uid, 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 tting (8) on the pump.
5. Install tting (32) and fitting (5) on hopper (7).
6. Connect tting (5) to tting (8). Adj us t bracke t (29) height to fit under the lip on the back of the hopper (7). Tighten nuts (16).
12
334645B
Page 13
Setup
Setup
To avoid tip over, ensure cart is on a at and level surface. Failure to do so could result in injury or equipment damage.
Tools Required:
Two adjustable wrenches
Non-sparking hammer or plastic mallet
Torque wrench
1. Ground sprayer. See G rounding, page 11.
2. Check packing nut (F). Fill with Throat Seal Liquid (TSL). Torque to 25-30 ft-lb (34-41 Nm).
3. Attach electrically conductive uid hose to pump outlet and tighten.
4. Attach electrically conductive uid hose (and air hose if using an AA gun) to gun and tighten. Check that all pressure co nnections are tight.
5. Close bleed type master air valve (B). Connect air supply hose to 1 in npt(f) ai r inlet (A).
6. Flush and prime before using. S ee
Flush, page 15,andPrime, page 17.
334645B 13
Page 14
Pressure Relief Procedure
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever you see this symbol.
This equipm is manuall injury fro splashing Pressure and befor equipmen
1. Engage gu
ent stays pressurized until pressure
y relieved. To help prevent serious
m pressurized uid, such as skin injection,
uid and moving parts, follow the Relief Procedure when you stop sp raying e cleaning, checking, or servicing
t.
n trigger lock.
4. Hold gun rmly against a grounded metal pail. Trigger the gun until pressure is relieved.
5. Engage trigger lock.
6. Drain uid. To drain ui d, slowly open all uid drain valves, including drain/purge valve (J), in system into a waste pail. If there is a return tube, open return line ball valve. Close v alve after uid is drained.
2. Close bleed type master air valv e (B).
3. Disengage gun trigger lock.
Note
If using an AA gun, turn gun a ir regulator counter-clockwise to relieve pressure.
Left: Xtreme Lower
7. If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved.
a. VERY SLOWLY loos en tip gua rd retaining
nut or hose end coupling to reli eve pressure
gradually. b. Loosen nut or coupling completely. c. Clear hose or tip obstruction.
Right: Dura-Flo Lower
14
334645B
Page 15
Flush
Flush
To avoid re and explosion, always ground equipment and waste container. To avoid static sparking and injury from splashing, always ush at lower possible pressure.
Flush the pump:
•Beforerstuse
When changing colors or uids
Before repairing equipment
Before uid dries or settles out in a dormant pump (check the pot life of catalyized uids)
5. Turn regulator adjustment knob (G) counterclockwise until it stops, and gauge (E) reads zero.
6. Open bleed type master valve (B).
At the end of the day
Before storing the pump
Flush at the lowest pressure possible. Flush with a uid that is compatible with the uid you are pumping and with the wetted parts in your syste m. Check with your fluid manufacturer or supplier for recommended flushing uids and ushing frequency.
1. Follow Pressure Relief P rocedure, page 14.
2. Remove tip and tip guard from gun.
3. If desired, remove uid lter. Reinstall lter cap after removing uid lter.
4. Place suction tube in a compatible solvent.
Note
Do not stretch hose tight’ let it hang to assist uid ow into the pump.
7. Flush hose and gun:
a. Disengage gun trigger lock. Hold the gun
against a grounded metal pail.
334645B 15
Page 16
Flush
b. Trigger gun, slowly open regulator
adjustment knob (G) until pump beings to cycle and a s teady stream comes from gun. Trigger gun for 10-15 seconds.
Note
If using an AA gun, increase air pressure by turning gun regulator clockwise.
c. After solvent is running clean, turn the
regulator adjustment knob (G) counter clockwise until it stops and the gauge reads zero. The pump will stop. Once the material stops owing, release the trigger and engage thetriggerlock. Stopthepumpwiththerod buried in the pump.
b. Start the pump by rotating the air regulator
adjustment knob (G) clockwise until pump begins to move.
c. When clean solvent flows from drain tube
close drain/purge valve (J) by rotating clockwise. Pump will stall.
d. Close the bleed type master air valve.
8. If ushing through drain/purge valve:
a. Place drain tube in a grounded waste pail.
Open drain/purge valve (J) slightly by rotating counterclockwise.
Left: Xtreme Lower
Right: Dura-Flo
Lower
Left: Xtreme Lower
Right: Dura-Flo
Lower
d. Stop the pump with the rod buried in the
pump.
e. Follow Pressure Relief Procedure, page 14.
Leave solvent in and store sprayer.
9. Remove uid lter and soak in solvent. Replace lter cap.
16 334645B
Page 17
Prime
Prime
1. Follow Press
2. Lock gun tri gun.
3. Place sucti sprayed.
Note
Do not stretch hose tight let it hang to assist uid ow into the pump.
4. Turn regulator adjustment knob (G) counterclockwise until it stops, and gauge (E) reads zero.
ure Relief Procedure, page 14.
gger. Remove tip and tip guard from
on tube in the material that will be
5. Open bleed type master valve (B).
6. Prime through drain valve if necessary.
Note
Usually 1K high viscosity materials.
NOTICE
Do not prime pump through drain/purge valve using two component materials. Mixed two-component materials will harden in valve and result in clogging.
a. Place drain tube in a grounded waste pail.
Open drain/purge valve (J) slightly by rotating counterclockwise.
334645B
Left: Xtreme Lower
Right: Dura-Flo
Lower
17
Page 18
Prime
b. Start the pump by rotating the air regulator
adjustment knob (G) clockwise until pump begins to move.
7. Prime hose and gun:
a. Disengage gun trigger lock. Hold the gun
against a grounded metal pail.
b. Trigger gun, slowly open regulator
adjustment knob (G) until pump beings to cycle and a steady stream comes from gun. Trigger gun for 10-15 seconds.
Note
If using an AA gun, increase air pressure by turning gun regulator clockwise.
c. Engage trigger lock.
8. The equipment i s now ready to spray; go to
Spray, page 19.
18 334645B
Page 19
Spray
Spray
NOTICE
Do not allow pump to run dry. It will quickly accelerate to a high speed causing damage.
1. Prime. See Prime, page 17.
2. Follow Pressure Relief P rocedure, page 14.
3. Install tip and tip guard on gun.
4. Open bleed type master air valve (B).
6. Disengage gun trigger lock.
7. Spray a test pattern. Read uid manufacturer’s
recommendations. Adjust pressure as necessary. If using an AA gun, increase gun air pressure while testing spray pattern.
8. Flush when done spraying. See Flush, page 15.
9. Follow Pressure Relief Procedure, page 14.
Shutdow
n
5. Turn regulator adjustment knob (G) until gauge (E) reads desired pressure. Turn clockwise to increase pressure, counterclockwise to decrease pressure.
NOTICE
leave water or water-base uid in pump over
Never
. If you are pumping water-base fluid, ush
night
aterrst,thenwitharustinhibitor,suchas
with w
al spirits. Relieve pressure, but leave rust
miner
itor in pump to protect parts from corrosion.
inhib
ow Pressure Relief Procedure, page 14.
Foll
Always flush the pump before the fluid dries on the displacement pump rod. See Flush, page 15.
334645B 19
Page 20
Maintenance
Maintenance
Preventative 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 over night shutdown, stop pump a t bottom of its stroke to prevent uid from drying on exposed displacement rod and damaging throat packings. Follow
Pressure Relief Procedure, 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, ush 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.
Keep the cart clean by wiping up spills daily, using a compatible solvent
1. Flush. See Flush, pag e 15.
2. Relieve pressure. See
Pressure Relief Procedure, page 14.
3. Check packing nut (S ). Adjust packings and replace TSL as necessary. Torque to 25-30 ft-lb (34-41 N•m).
4. Drain water from air lter.
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 uid connections before each use.
7. Cleanfluidlinefilter.
20 334645B
Page 21
Troubleshooting
Troubleshooting
1. Follow Pressure Relief P rocedure, page 14.
Problem Cause Solution
Does not operate.
Output low on both strokes.
Output low on upstroke. Open or worn piston val ve or
Erratic accelerated speed.
Runs sluggishly. Possible icing. Stop pump. Open De-Ice control. Cycles or fails to hold pressure at
stall.
Air bubbles in uid.
Poor nish or irregular spray pattern.
Valve closed or clogged.
Fluid hose or gun obstructed. Dried uid on displacement rod. Clean rod; always stop pump at
Air moto damage Air line restricted or air supply inadequate. Valves c losed or clogged. Fluid hose/gun obstructed; hose ID too small. Air motor icing.
Open or worn intake valve. Clear or service intake valve.Output low on down stroke. High viscosity uid.
packings. Fluid supply exhausted, clogged suction. High viscosity uid.
Open or worn piston valve or packings. Open or worn intake valve. Clear or service intake valve.
Worncheckvalvesorseals. Service lower. See
Loose suction line. Tighten. Use compatible liquid
Incorrect uid pressure at gun. See gun manual; read uid
Fluid is too thin or too thick.
r parts dirty, worn, or
d.
2. Check all possible causes and problems before disassembling pump.
3. See air motor manual for air motor specific troubleshooting
* To determine if fluid hose or gun is obs tructed,
follow Pressure Relief Procedure, page 14. Disconnect uid hose and place a container at pump uid outlet to catch any uid. Turn on air power just enough to start pump. If pump starts, the obstruction is in uid hose or gun.
Clear air line; increase air supply. Check that valves are open. Clean hose or gun.*
bottom of stroke; keep wet-cup filled with compatible solvent. Clean or repair air motor. See motor manual. Clear air line; increase air supply. Check that valves are open.
Clear hose or gun*; use hose with larger ID. Open De-Ice control.
Adjust intake spacers. Clear piston valve; replace
packings. Refill supply and prime pump. Clean suction tube. Reduce viscosity; adjust intake spacers. Clear piston valve; replace packings.
Remove Lower, page 22,and
Xtreme Lowers manual (311762).
thread sealant or PTFE tape on connections.
manufacturer’s recommendations. Adjust fluid viscosity; read fluid manufacturer’s recommendations.
334645B
21
Page 22
Remove Lower
Remove Lower
Required Tools
Set of adjustable wrenches
Torque wrench
Rubber mallet
Thread lubricant
Anti-seize lubricant 222955
Loctite® 2760™ or equivalent
Disconnect and Reconnect Lower
1. Flush pump; see Flush, page 15.Stop pump at bottom of its stroke. Follow
Pressure Relief Procedure, page 14.
2. Disconnect air hose.
3. Disconnect fluid hose (W). Hold fluid outlet fitting (P) with a wrench to keep it from loosening while you disconnect suction hose (N).
4. Note the relative position of lower’s uid outlet (P) to inlet (X) of motor for easier reassembly alignment. If motor does not require service, leave it attached to its mounting.
5. Hold the ats of the air motor piston rod with a wrench. Use another wrench to loosen the coupling nut (CN).
6. Remove the tie rod nuts (TN).
7. Remove lower. Refer to the Lower manual to service lower. To service motor, refer to separate motor manual.
8. Reconnect lower by following disconnect steps in reverse order.
Note
Torque nuts (308) to 50-60 ft-lb (68-81 N•m).
22
334645B
Page 23
Parts
Xtreme Sprayer Cart Packages
Parts
Apply grease to cart axles before assembling
1
wheels. For heavy uid packages 24X593 and 24X594
2
only. Apply anaerobic pipe sealant to all non-swiveling
3. pipe threads.
334645B 23
Page 24
Parts
Xtreme Packages Without A Hopper
Ref Part Description
PL95C2PUMP,
1
xtreme, xl, 220; Pump
Package Parts, page 32
PL95C1 PUMP,
xtreme, xl, 220; Pump
Package Parts, page 32
PL80C2PUMP,
xtreme, xl, 250; Pump
Package Parts, page 32
PL80C1 PUMP,
xtreme, xl, 250; Pump
Package Parts, page 32
PL70C2PUMP,
xtreme, xl, 290; Pump
Package Parts, page 32
PL70C1 PUMP,
xtreme, xl, 290; Pump
Package Parts, page 32
2 278770 HOSE,
coupled
4 116401 ADAPTER,
elbow
6 24W593 MODULE,
air controls; see manual 3A0293
9* 24Y078 CART, heavy
duty
10* 113362 WHEEL, semi-
pneumatic
11* 113436 RING,
retaining
12* 154628 WASHER 14* 113361 CAP, tube,
round
Sprayer Description and Quantity
No Hose and Gun With Hose and Gun
No Hopper
XL70H1 XL80H1 XL95H1 XL70H4 XL80H4 XL95H4 XL70H2 XL80H2 XL95H2
11
11
11
111111111
No Hopper, No filter
1
1
1
No Hopper
111111111
111111111
111111111
222222222
2222222
2222222
22
2
2
222222222
24
334645B
Page 25
Parts
Ref Part Description
15 112395 SCREW, cap,
flng hd
16 112958 NUT, hex,
flanged
18a 247301 HOSE; 1 in. x
6ft
18b 197682 TUBE, siphon 18c 181072 STRAINER 19 116402 ADAPTER,
qconnect
113498 VALVE, safety,
23
110 psi
120306 VALVE, safety,
85 psi
16M190 VALVE,safety,
95psi
25 XTR704 GUN, xtr7, 1"
hnd, 4 fng, xhdrac
26a H73850 HOSE; 3/8 x
50 ft
26b H72506 HOSE; 1/4 x 6
ft
26c 164856 NIPPLE, 3/8 x
1/4
Sprayer Description and Quantity
No Hose and Gun With Hose and Gun
No Hopper
XL70H1 XL80H1 XL95H1 XL70H4 XL80H4 XL95H4 XL70H2 XL80H2 XL95H2
No Hopper, No lter
No Hopper
444444444
444444444
111111111 111111111
111111111
111111111
111
111
111
111
111
*
Included in Cart Kit (9).
Includes Built-In Filter.
334645B 25
Page 26
Parts
Xtreme Packages With A Hopper
Part Description
Ref
1
PL95C2
PL80C2
PL70C2
PL70C1
PL80C1
2278770 4126939 5
128095
6 24W593
7
17E114
8
17C692 FITTING, cam/groove, 1.5m, 1-1/2 npt 24Y078 KIT, cart, heavy duty
9*
113362 WHEEL, semi-pneumatic
10*
113436
11*
154628
12*
113361
14* 15112395 16112958
113498
23
120306 16M190 XTR704
25
262854 H77550
26a
H73850
H75025 HOSE, coupled, 7250 psi, 1/2 in ID; 50
26b
H72506 16R883
26c
164856
---
29
---
30
31 15M987
PUMP, xtreme, xl, 220;
Pump Package Parts, page 32
PUMP, xtreme, xl, 250;
Pump Package Parts, page 32
PUMP, xtreme, xl, 290;
Pump Package Parts, page 32
PUMP, xtreme, xl, heavy duty;
Pump Package Parts, page 32
PUMP, xtreme, xl, heavy duty;
Pump Package Parts, page 32
HOSE, coupled FITTING, elbow, 9, fem ale, reducing FITTING, cam and groove; 1.5 npt(m) MODULE, air controls; see manual
3A0293 HOPPER
RING, retaining WASHER CAP, tube, round SCREW, cap, ng hd NUT, hex, anged VALVE, safety, 110 psi VALVE, safety, 85 psi VALVE, safety, 95psi GUN, xtr 7, 1" hnd, 4 fng, xhdrac GUN, XHF HOSE, coupled, 7250 psi, 3/4 in ID; 50
ft HOSE, coupled, 7250 psi, 3/8 in ID; 50 ft
ft HOSE, coupled, 7250 psi, 1/4 in ID; 6 ft
FITTING, nipple, reducing, 3/4 x 1/2 FITTING, nipple, 3/8 x 1/4 BRACKET, hopper BRACKET, hopper, upper FITTING, elbow, 60 deg
Sprayer Description and Quantity
With Hose and Gun
Hopper
24X593 24X594 XL70H3 XL80H3 XL95H3
1
1
1
1
1
11111 11111 11111
11111
11111 11111 11111 22222 22222 22222 22222 88888 88888 11
11
1
111
11
11
111
11
111
11
111 11111 11111 11111
26 334645B
Page 27
Parts
Part Description
Ref
---
32
FITTING, bushing, 1-1/2 41 16T480 VALVE, check 44 160032 45158491 4624P834
FITTING, nipple; 3/414 npt
FITTING, nipple; 1/214 npt
SWIVEL, straight, PTFE 47 171439 NIPPLE, pipe, reducing 48
17C453 GASKET, 2 in. (packet 6)
Includes Built-In Filter.
*
Included in Cart Kit 24Y078.
Sprayer Description and Quantity
With Hose and Gun
Hopper
24X593 24X594 XL70H3 XL80H3 XL95H3
11111 11 11 11 11 11 11111
Included in Hopper Kit 24X570.
Included in the Hose and Gun Kit 24X553.
334645B
27
Page 28
Parts
Dura-Flo Cart Packages
Apply grease to cart axles before assembling
1
wheels.
2. Apply anaerobic pipe sealant to all non-swiveling pipe threads.
28 334645B
Page 29
Dura-Flo Cart Package Parts
Parts
Part Description
Ref
1 PL45C1 PUMP, duraflo, xl, 430,
nf; Pump Package Parts,
page 32
2128093 3a 24X547
---
3b
5
15T271
128095
6 24W040
7
16U536
8
17C692 FITTING, cam/groove,
24Y078
9*
113362 WHEEL, semi-pneumatic
10*
113436
11*
154628
12*
113361
14* 15 112395 16 112958 17 238620 FILTER, paint 18 24T757 19 116402 ADAPTER, qconnect
---
20 23 114055 25 XTR504
26 24T755
29 17C474 BRACKET, hopper 30 17D554 BRACKET, hopper,
32 128094 48
17C453 GASKET, 2 in. (pack of
HOSE, coupled KIT, tting, nipple, 2 in.
npt x 2.5 in. PIPE, elbow female; 2 x
1.5 BUSHING,1.5x1npt reducer sst FITTING, cam and groove MODULE, air controls; see manual 3A0293 HOPPER, weldment
1.5m, 1-1/2npt CART, heavy duty
RING, retaining WASHER CAP, tube, round SCREW, cap, flng hd NUT, hex, anged
HOSE, w/siphon, xtreme
LABEL, identification VALVE, safety, 105 psi GUN, xtr5, 1" hnd, 4 fng,
xhdrac HOSE SET, xtreme, 5600 psi
upper FITTING, bushing, 1-1/2
6)
Quantity
No Hose and Gun With Hose and Gun
No Hopper
XL45H1
1111
1111
1111
1111
111
1111
1111 2222 2222 2222 2222 4448 4448 111 111 111 1111 1111
No Hopper,
No Filter
XL45H4
No Hopper With Hopper
XL45H2 XL45H3
1
1
1
11
11
1
1
1
1
*
Included in Cart Kit 24Y078.
334645B 29
Page 30
Parts
Wall Mount Packages
1. Apply stainless steel pipe sealant to all non-swiveling pipe threads.
30 334645B
Page 31
Wall Mount Package Parts
Part Description
Ref
201 24X181 202 24W593
203
PL45C1 PUMP, duraflo, xl, 430;
PL95C2
PL80C2
PL70C2
204 238620 FILTER, paint 205 197682 TUBE, suction 206 247302
116401 ADAPTER, elbow
207
120291
208 116402 ADAPTER, qconnect
---
210 211 206994 FLUID, tsl 8 oz bottle 214 187147 215 114967 216 195151 TUBE, intak e 217a 24X547 KIT, nipple, 2 in npt
---
217b 218 121239
219 112395 220 112958
128093
221
278770 113498
222
120306 16M190 114055
BRACKET, wall, xl MODULE, air controls, wall;
see manual 3A0293
Pump Package Parts, page 32
PUMP, xtreme, xl, 220;
Pump Package Parts, page 32
PUMP, xtreme, xl, 250;
Pump Package Parts, page 32
PUMP, xtreme, xl, 290;
Pump Package Parts, page 32
HOSE,suction,1innptx qconnect
PIPE, elbow female
LABEL, identication
STRAINER, inlet COUPLING, pipe, 1"
ELBOW, 1.5 x 2 np BUSHING,1.5x1npt
reducer sst SCREW, cap, flng hd
NUT, hex, anged HOSE, coupled HOSE, coupled VALVE, safety, 110 psi VALVE, safety, 85 psi VALVE, safety, 95 psi VALVE, safety, 105 psi
Parts
Quantity
XL45W1 XL70W1 XL80W1 XL95W1
1111
1111
1
1
1
1
1 1111
1111
111 1 1111 1111 1111 1111 1111 1111 1 1
1
4444 4444 1
111
1
1
1
1
Includes Built-In Filter.
334645B 31
Page 32
Parts
Pump Package Parts
Torque to 95105 ft-lb (129142 N•m).
1
Torque to 230–250 ft-lb (312–340 Nm).
2
32 334645B
Apply anaerobic pipe sealant.
3
Apply stainless steel pipe sealant to all
4
non-swiveling pipe threads.
Page 33
Pump Package Parts
Parts
Ref Part Description
101 24X856 MOTOR, air, 13 in.; includes
101a; see manual 334644
101a 102
103 15U606 NUT, lock, m16 x 2 104
105
106 244524 WIRE, ground assy with clamp 106a
107
108 171439 NIPPLE, pipe, rdcg 110
111
112
118 15K296 SPACER 120
15F674 LABEL, safety, motor (not shown)
184382 ROD, tie 17A048 ROD, tie, m16 x 2.0
100133 WASHER, lock, 3/8 120465 SPACER, mounting, threaded 112958 NUT, hex, anged 100101 SCREW, cap, hex hd
290079 TAG, warning, grounding (not
shown)
24W644 LOWER, durao, 3/4,
(18cm-cstl); see manual 311825
L22HC1 LOWER, xtreme, xl, 220; see
manual 311762
L22HC2LOWER, xtreme, xl, 220; see
manual 311762
L25HC1 LOWER, xtreme, xl, 250; see
manual 311762
L25HC2LOWER, xtreme, xl, 250; see
manual 311762
L29HC1 LOWER, xtreme, xl, 290; see
manual 311762
L29HC2LOWER, xtreme, xl, 290; see
manual 311762
184583 ADAPTER, rod 184582 ADAPTER, rod 184129 COLLAR, coupling 184130 COLLAR, coupling 184098 NUT, coupling 184096 NUT, coupling
172479 TAG, warning, lower (not shown)
Quantity
PL45C1 PL70C1 PL70C2 PL80C1 PL80C2 PL95C1 PL95C2
1111
1111111
111
3
333333
3333333
444444 4 4
444444 1111111
1111111
1
1
1
1
1
1
1
111
111111 1
222222 2
111111 1 1 1111111
HD
Includes Built-In Filter. Not for sale. Purchase individual parts as necessary. Replacement Warning labels, signs, tags, and cards are available at no cost.
334645B 33
Page 34
Dimensions
Dimensions
Sprayer Cart Packages
Mount A B C D E
Dura-Flo
Xtreme
40.75 in
(1035.05 mm)
40.75 in
(1035.05 mm)
28.5 in
(723.9 mm)
28.5 in
(723.9 mm)
26.25 in
(666.75 mm)
26.25 in
(666.75 mm)
46.25 in
(1174.75 mm)
51 in
(1295.4 mm)
Wall Mount and Pump Packages
25.75 in
(654.05 mm)
25.75 in
(654.05 mm)
Mount A B C D
Dura-Flo
Xtreme
34 334645B
30.75 in
(781.05 mm)
26.25 in
(666.75 mm)
49.25 in
(1250.95 mm)
43.5 in
(1104.9 mm)
22 in
(558.8 mm)
22 in
(558.8 mm)
23 in
(584.2 mm)
23 in
(584.2 mm)
Page 35
Wall Mount Bracket Mounting Hole Diagram
Dimensions
1
1/2 in (12.7 mm) diameter holes for mounting to stand
2
7/16 in (11 mm) diameter holes for mounting to wall
A
17.8 in (450.9 mm)
B
14.5 in (368.3 mm) C 5.4 in (136.5 mm) D
1.6in(41.4mm) E
9in(228.6mm)
F
12.4 in (314.3 mm) G 1 in (25.4 mm) H
5.3 in (133.4 mm) J
7.4 in (187.3 mm) K
2in(50.8mm)
334645B 35
Page 36
Performance Charts
0
1.0
9
18
26
35
44
53
60
6000
5000
4000
3000
2000
1000
300
250
200
150
2.0
3.0
4.0
5.0
6.0
7.0
100
50
Performance Charts
Calculate Fluid Outlet Pressure
To calculate uid outlet pressure (psi/MPa/bar) at a specific fluid ow (gpm/lpm) and operating air pressure (psi/MPa/bar), use the following instructions and pump data charts.
1. Locate desired ow along bottom of chart.
2. Follow vertical line up to intersection with selected uid outlet pressure curve. Follow left to scale to read uid outlet pressure.
45:1
Cycles Per Minute (cpm)
Fluid Pressure
psi (bar)
6000
(42.0, 420)
5000
(35.0, 350)
4000
(28.0, 280)
3000
(21.0, 210)
2000
(14.0, 140)
1000
(7.0, 70)
9
A
B
C
18
C
Calculate Pump Air Flow/Consump­tion
To calculate pump air flow/consumption (scfm or
3
m
/min) at a specic uid ow (gpm/lpm) and air pressure (psi/Mpa/bar), use the following instructions andpumpdatacharts.
1. Locate desired ow along bottom of chart.
2. Follow vertical line up to intersection with
selected uid outlet pressure curve. Follow right to scale to read air ow consumption.
Key: Air Pressure
A
100psi(0.7MPa,7bar)
B
70 psi (480 kPa, 4.8 bar)
C 40psi(280kPa,2.8bar)
26
B
A
35
44
53
60
300
(8.5)
250
(7.0)
200
(5.6)
150
(4.2)
100
(2.8)
50
(1.4)
Air Flow
scfm (m
3
/min)
0
36 334645B
1.0
(3.8)
2.0
(7.6)
3.0
(11.4)
4.0
(15.2)
Fluid Flow gpm (lp m )
5.0
(19.0)
6.0
(22.7)
7.0
(26.5)
Page 37
70:1
0
1.0
13
26
39
60
8000
7000
6000
5000
4000
3000
2000
1000
300
250
200
150
2.0
3.0
4.0
100
50
0
1.0
15
30
45
60
8000
7000
6000
5000
4000
3000
2000
1000
300
250
200
150
2.0
3.0
4.0
100
50
Fluid Pressure
psi (bar)
8000
(56.0, 560)
7000
(49.0, 490)
6000
(42.0, 420)
5000
(35.0, 350)
4000
(28.0, 280)
3000
(21.0, 210)
2000
(14.0, 140)
1000
(7.0, 70)
A
B
C
Cycles Per Minute (cpm)
13
26
B
C
Performance Charts
39
A
525260
300
(8.5)
250
(7.0)
200
(5.6)
150
(4.2)
100
(2.8)
50
(1.4)
Air Flow
scfm (m
3
/min)
80:1
Fluid P
psi (ba
ressure
r)
8000
(56.0, 560)
7000
(49.0, 490)
6000
(42.0, 420)
5000
(35.0, 350)
4000
(28.0, 280)
3000
(21.0, 210)
2000
(14.0, 140)
1000
(7.0, 70)
0
1.0
(3.8)
2.0
(7.6)
3.0
(11.4)
4.0
(15.2)
Fluid Flow gpm (lpm)
Cycles Per Minute (cpm)
15
A
B
C
C
0
1.0
(3.8)
30
2.0
(7.6)
B
45
3.0
(11.4)
A
60
4.0
(15.2)
300
(8.5)
250
(7.0)
200
(5.6)
150
(4.2)
100
(2.8)
50
(1.4)
Air Flo
scfm (m
w
3
/min)
Fluid Flow gpm (lpm)
334645B 37
Page 38
Performance Charts
0
1.0
17
34
51
60
8000
7000
6000
5000
4000
3000
2000
1000
300
250
200
150
2.0
3.0
100
50
Key: 95:1 Pumps Air Pressure
B
75 psi (517 kPa, 5.2 bar)
C 40psi(280kPa,2.8bar)
95:1
8000
(56.0, 560)
7000
(49.0, 490)
6000
(42.0, 420)
5000
(35.0, 350)
Fluid Pressure
psi (bar)
4000
(28.0, 280)
3000
(21.0, 210)
2000
(14.0, 140)
1000
(7.0, 70)
Cycles Per Minute (cpm)
17
B
C
C
34
51
60
300
(8.5)
250
(7.0)
200
(5.6)
B
150
(4.2)
100
(2.8)
50
(1.4)
Air Flow
scfm (m
3
/min)
0
1.0
(3.8)
2.0
(7.6)
3.0
(11.4)
Fluid Flow gpm (lp m )
38 334645B
Page 39
Technical Specifications
Xtreme XL Spray Packages
Technical Specications
U.S.
Maximum air inlet pressure to spraye r 150 psi 1 MPa, 10.3 bar Stroke length (nominal) Maximum pump speed
(Do not exceed maximum recommended speed of uid pump, to prevent premature pump wear)
Sound Data See Xtreme XL Motor manual for sound data. Air Inlet Size 1 in. npt(f) Wetted Parts
Fluid Inlet Size
All Xtreme Lower Pumps 1 1/4 npt(m) Dura-Flo Lower Pumps
Fluid Outlet Size
(Number of Outlets) Xtreme Lower Pumps With Built-In Filters (2) 1/2 in. npt(f) Xtreme Lower Pumps Without Filters (1) 1 in. npt(f) Dura-Flo Lower Pumps (1) 3/4 npt(m)
4.75 in. 60 cycles per minute
Carbon steel; ally steel; 304, 440 and 17–4 PH grades of stainless steel; zinc and nickel plating; ductile iron; tungsten carbide; PTFE; leather
2 in. npt(f)
Metric
Maximum Air Operating Pressure
XL45 100 psi 0.7 MPa, 7 bar XL70 100 psi 0.7 MPa, 7 bar XL80 88 psi 0.6 MPa, 6.1 bar XL95 76 psi 0.52 MPa, 5.2 bar
Maximum Fluid Working Pressure
XL45 4500 psi 31 MPa, 310 bar XL70 7100 psi 48.9 MPa, 489 bar XL80 7250 psi 50 MPa, 500 bar XL95 7250 psi 50 MPa, 500 bar
Weight
XL70, XL80, XL90 340 lbs. 154.2 kg XL45 341 lbs. 154.7 kg
334645B 39
Page 40
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 Gracos 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 verication of the claimed defect. If the claimed defect is veried, 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 document reects 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 c hanges at any time without notice.
Original Instructions. This manual contains Eng lish. MM 334645
International Offices:
Copyright 2015, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
1-800-328-0211
Graco Headquarters:
www.graco.com
Revision B, May 2015
Fax:
612-378-3505
Minneapolis
Belgium, China, Japan, Korea
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