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 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
Page 3

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
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-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
Page 5

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
Page 6

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
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 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
Page 8

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
Page 9

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
Page 10

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
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 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
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,
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).
12
334645B
Page 13

Setup
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.
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 N•m).
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.
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 fluid, such as skin injection,
fluid and moving parts, follow the
Relief Procedure when you stop sp raying
e cleaning, checking, or servicing
t.
n trigger lock.
4. Hold gun firmly against a grounded metal pail.
Trigger the gun until pressure is relieved.
5. Engage trigger lock.
6. Drain fluid. To drain flui d, 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. Close v alve after fluid
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 fire and explosion, always ground
equipment and waste container. To avoid static
sparking and injury from splashing, always flush at
lower possible pressure.
Flush the pump:
•Beforefirstuse
• When changing colors or fluids
• Before repairing equipment
• Before fluid dries or settles out in a dormant pump
(check the pot life of catalyized fluids)
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
fluid that is compatible with the fluid you are pumping
and with the wetted parts in your syste m. Check with
your fluid manufacturer or supplier for recommended
flushing fluids and flushing frequency.
1. Follow Pressure Relief P rocedure, page 14.
2. Remove tip and tip guard from gun.
3. If desired, remove fluid filter. Reinstall filter cap
after removing fluid filter.
4. Place suction tube in a compatible solvent.
Note
Do not stretch hose tight’ let it hang to
assist fluid flow 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 flowing, 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 flushing 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 fluid filter and soak in solvent. Replace
filter 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 fluid flow 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 fluid 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 fl uid in pump over
Never
. If you are pumping water-base fluid, flush
night
aterfirst,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 fluid 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, 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.
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 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. 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 fluid.
Poor finish or irregular spray
pattern.
Valve closed or clogged.
Fluid hose or gun obstructed.
Dried fluid 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 fluid.
packings.
Fluid supply exhausted, clogged
suction.
High viscosity fluid.
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 fluid pressure at gun. See gun manual; read fluid
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 fluid hose and place a container at
pump fluid outlet to catch any fluid. Turn on air
power just enough to start pump. If pump starts,
the obstruction is in fluid 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 fluid 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 flats 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 fluid 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 filter
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, 90º, 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, flng hd
NUT, hex, flanged
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; 3/4–14 npt
FITTING, nipple; 1/2–14 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, fitting, 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, flanged
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, identification
STRAINER, inlet
COUPLING, pipe, 1"
ELBOW, 1.5 x 2 np
BUSHING,1.5x1npt
reducer sst
SCREW, cap, flng hd
NUT, hex, flanged
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 95–105 ft-lb (129–142 N•m).
1
Torque to 230–250 ft-lb (312–340 N•m).
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, flanged
100101 SCREW, cap, hex hd
290079 TAG, warning, grounding (not
▲
shown)
24W644 LOWER, duraflo, 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
Performance Charts
Calculate Fluid Outlet Pressure
To calculate fluid outlet pressure (psi/MPa/bar) at
a specific fluid flow (gpm/lpm) and operating air
pressure (psi/MPa/bar), use the following instructions
and pump data charts.
1. Locate desired flow along bottom of chart.
2. Follow vertical line up to intersection with
selected fluid outlet pressure curve. Follow left to
scale to read fluid 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 specific fluid flow (gpm/lpm) and air
pressure (psi/Mpa/bar), use the following instructions
andpumpdatacharts.
1. Locate desired flow along bottom of chart.
2. Follow vertical line up to intersection with
selected fluid outlet pressure curve. Follow right
to scale to read air flow 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
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
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 Specifications
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 fluid 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 Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction,
damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper
maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco
be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures,
accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation,
operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized
Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace
free of charge any defective parts. The equipment will be returned to the original purchaser transportation
prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be
made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS
FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The
buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost
profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available.
Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT,
MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO.
manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of
their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of
these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco
supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold
hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices
and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be
drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en
Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou
en rapport, directement ou indirectement, avec les procédures concernées.
eption of any special, extended, or limited warranty published by Graco, Graco will, for a period of
These items sold, but not
Graco Information
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
To place an order,
Phone:
612-623-6921
All written and visual data contained in this document reflects the latest product information available at the time of publication.
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
contact your Graco Distributor or call to identify the nearest distributor.
or Toll Free:
Graco reserves the right to make 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