Graco XL 10000 Parts list manual

334644C
EN
Instructions - Parts
XL™10000 Air Motor
For use with high output reciprocating Graco pumps. For professional use only.
Model No. 24X856
100 psi (0.7 MPa, 7 bar) Maximum Working Pressure
Model No. 273088
100 psi (0.7 MPa, 7 bar) Maximum Working Pressure
(For use on XP-hf systems only)
Important Safety Instructions
Read all warnings and instructions in this manual and in related
manuals. Save all instructions.

2334644C
Contents
Related Manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Identification . . . . . . . . . . . . . . . . . . . . 6
General Information . . . . . . . . . . . . . . . . . . . . . . . . 7
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Reciprocating Signal Poppets . . . . . . . . . . . . . . . 7
External Pilot Lines . . . . . . . . . . . . . . . . . . . . . . . 7
Manual Override Buttons . . . . . . . . . . . . . . . . . . 7
Low Pressure Operation . . . . . . . . . . . . . . . . . . . 7
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Minimum Icing . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bleed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Extended Capabilities . . . . . . . . . . . . . . . . . . . . . 7
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 8
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bleed-type master air valve . . . . . . . . . . . . . . . . . 8
Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Run Motor Manually . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ice In Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . 11
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Preventive Maintenance Schedule . . . . . . . . . . 12
Pressure Relief Procedure . . . . . . . . . . . . . . . . 12
Repair Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . 13
Replace Pilot Valves . . . . . . . . . . . . . . . . . . . . . 16
Repair Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . 16
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air Valve Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Kits and Accessories . . . . . . . . . . . . . . . . . . . . . 22
Dimensions (Model No. 24X856) . . . . . . . . . . . . . . 24
Mounting Hole Diagram . . . . . . . . . . . . . . . . . . . 24
Dimensions (Model No. 273088) . . . . . . . . . . . . . . 25
Mounting Hole Diagram . . . . . . . . . . . . . . . . . . . 25
Technical Specifications . . . . . . . . . . . . . . . . . . . . 25
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 26
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 26
Related Manuals
Manual Description
311762 Xtreme Lowers, Instructions-Parts
311825 Dura-Flo™Lowers, Instructions-Parts
334645 Xtreme XL Packages, Instructions-Parts
3A4381 XP-hf Proportioner, Operation, Repair, Parts

Warnings
334644C 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-speci•c risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-speci•c
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
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 com-
ponent. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may voidagency approvals and create
safety hazards.
• Make sure all equipment 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.
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, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.

Warnings
4334644C
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent
•owing through the equipment can cause static sparking. To help prevent •re and explosion:
• Use equipment only in well ventilated area.
• Eliminateallignitionsources;suchas pilot lights,cigarettes,portableelectriclamps,andplasticdrop
cloths (potential static sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent 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.
•Stopoperationimmediatelyifstaticsparkingoccursoryoufeelashock.Donotuseequipmentuntil
you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
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. Get immediate surgical 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 de•ect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all •uid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.

Warnings
334644C 5
PERSONAL PROTECTIVE EQUIPMENT
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.

Component Identification
6334644C
Component Identification
Key:
A Directional Air Valve
B Air inlet, 1 in npt (f)
CMuffler
D Pilot valve
E Manifold
F Manual Shuttle Override Button
G Ground screw
H Static ground cable
J Plug for optional solenoid
K Optional reed switch mount
L External pilot lines
M De-ice bleed air valve
N Lift ring (800 lb, 363 kg) maximum
P Pump drive rod
FIG. 1

General Information
334644C 7
General Information
The XL 10000 air motor is air piloted with two poppet
valves operating a cup and plate main air shuttle valve.
Air exhausts around the cylinder, through sound absorp-
tion materials, and out the rear bottom of the shroud.
Application
This motor has 7% larger effective area, and is intended
to directly replace, the Graco Premier® motor. The XL
will acceptthesameM16x 2.0 threaded tie rods, the
same connecting rods, and the same 3/8-16 mounting
studs used with the Premier. The XL motor is physically
smaller than the Premier, so it will fit anywhere the Pre-
mier is used. The 1 in. air inlet is at a low front position
instead of up on the top so a different air hose may be
required. There are also threaded cart/shelf type mount-
ing holes in the base which match the ones used on the
NXT® motors. The XL motor fits the standard heavy
duty Xtreme cart so the larger Premier cart is no longer
necessary.
Reciprocating Signal Poppets
The poppets are identical to the ones used in the Graco
Merkur® motors and many air-operated double dia-
phragm motors. Poppets are fully accessible and can
easily be replaced.
External Pilot Lines
The pilot lines (L) that run from the shuttle end ports to
the exhaust poppets are run externally in hydraulic
hose. This allows for cold weather operation without
running the air through the aluminum manifold, which
can sometimes get cold enough for airline moisture to
freeze and block the signals.
Manual Override Buttons
There are manual override buttons (F) on each end of
the air valve that allows the internal main shuttle valve to
be physically moved from one position to the other. Run
the motor manually to:
• Move the valve off center due to ice or debris.
• Flush a pump if a poppet is plugged, stuck in the
open position, or the signal is leaking.
See Run Motor Manually on page 9.
Low Pressure Operation
This motor will run at 4–5 psi (20.6–27.5 kPa, 0.21–0.27
bar)
Performance
The air valve (A), manifold (E), and exhaust are larger
than the Premier air handling parts in order to exhaust
the 630 in3 of compressed air from the cylinder after a
full stroke. This allows the •uid pressure to come back
faster as the piston is driven from the other side. The
near square pressure trace that this generates makes
for a small change-over pulse, and full pressure output
for running multiple guns.
Minimum Icing
The oversizing of all the air handling parts described in
the General Information section mean that normal air
motor ice buildup has less effect on the pump output.
Bleed Air
Use the de-ice bleed air valve (M) to run warm air
through the valve and exhaust for de-icing. This is
mainly helpful during warm weather, very high humidity
applications, or low pressure high cycle rate applica-
tions.
Extended Capabilities
The XL motor will accept DataTrak™ counting, a run-
away stop solenoid, and the top mount linear position
transducer used with NXT motors.

Grounding
8334644C
Grounding
Verify that the ground screw (GS) is attached and tight-
ened securely to the air motor. Connect the clamp (U) of
the static ground cable (H) to a true earth ground.
Motor Lubrication
Graco does not require lubrication beyond the grease
installed at the factory or through regular maintenance.
With good quality compressed air and normal ambient
conditions, air motors will run millions of cycles without
additional lubrication.
However, if any of the following criteria apply to your
system, you will benefit from installing an air line lubrica-
tor in the air line before the air motor, or from occasion-
ally adding oil to an air filter cup.
• Air supply does not contain any oil.
• Air supply is very wet.
• Air supply is very dry.
• Air motor is run at low air pressure.
• Air motor is run in unusually hot or cold environ-
ments.
Accessories
Bleed-type master air valve
• Required in your system to relieve air trapped
between it and the air motor when the valve is
closed.
• Be sure the valve is easily accessible from the pump
and located downstream from the air regulator.
Air Regulator
Required in your system to adjust the air pressure to the
motor and •uid outlet pressure of pump. Locate it close
to the motor. Install a gauge to read air pressure.
Air Filter
Required in your system to remove harmful dirt and
moisture from compressed air supply. The minimum
recommended air •ltration is 40 micron.
Air Lubrication
237212 1” npt (f) accessory lubricator with a 16 oz.
bowl. See form 308169.
244841 Kit. Modular Lubricator. Use with XL Graco
spray packages with modular air controls. See form
3A0293.
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.
FIG. 2
Trapped air can cause the pump to cycle unexpect-
edly, which could result in serious injury from
splashing or moving parts.

Grounding
334644C 9
Run Motor Manually
Use the manual override buttons (F) on each end of the
air valve to physically move the internal main shuttle
valve from one position to the other. Run the motor man-
ually to:
• Move the valve off center due to ice or debris.
• Flush a pump if a poppet is plugged, stuck in the
open position, or the signal is leaking
1. Lower the air pressure to approximately 30–40 psi
(2.1 kPa, 210 bar – 280 kPa, 2.8 bar) to manually
operation the buttons.
2. If a poppet is plugged:
a. Press the button on the end where the motor
stopped. This will cause the motor to run
another cycle.
b. Press the button again to finish flushing.
3. If a poppet is stuck in the open position or the signal
is leaking:
a. Press the button on the opposite end from
where the motor stopped and hold it in. This will
cause the motor to stroke to the other end.
b. Release the button to allow the motor to stroke
back.
NOTE: For poppet issues, the motor can also be manu-
ally operated by disconnecting the pilot hose and con-
trolling the pilot signal exhaust with your •nger.

Troubleshooting
10 334644C
Troubleshooting
Problem Cause Solution
Air motor will not run and there is no
obvious exhaust Check air supply Supply air to motor inlet.
Pump is locked up. Disconnect or remove pump to verify
motor operation.
Ice broke loose in manifold and
caught in air valve. Turn off and exhaust air. Push top and bottom valve shift buttons (118)
back and forth until flush with base of
valve cap (107). Restart motor.
Air motor doesn't run and large vol-
ume of air blows through exhaust
outlet on either stroke.
Main piston o-ring (10) has failed or
main valve. See below. Replace piston o-ring (10) See page 10.
Air exhausts from rear outlet continu-
ously when motor is stalled against
•uid valve on one stroke or the other.
Shuttle valve cup (112) and plate
(105) failure. Replace shuttle valve cup (112) and plate (105).
Motor stalled at bottom of stroke with
no exhaust at bottom pilot. No
exhaust at top pilot.
Bottom pilot (15) is not exhausting.
Usually ice in the pilot or pilot
exhaust port.
Disconnect pilot line (55) for that
pilot. If motor changes over, bottom
pilot is plugged. Replace pilot
valve(55) and/or thaw ice that is
blocking air signal.
Metered air hole in main valve shuttle
piston (102) is plugged. Disconnect pilot line (55). If motor still doesn't change over, shuttle piston
metering hole is plugged. Clean or
replace shuttle valve piston assembly
(102).
Motor stalled at bottom of stroke with
exhaust at bottom pilot. Some
exhaust at top pilot.
Top pilot or •ttings are leaking air
when not activated by motor piston. Tighten •ttings leak or replace top pilot valve (15).
Motor stalled at top of stroke with no
exhaust at top pilot. No exhaust at
top pilot.
Top pilot (15) is not exhausting. Usu-
ally ice in the pilot or pilot exhaust
port.
Disconnect pilot line (55) for that
pilot. If motor changes over, top pilot
is plugged. Replace pilot valve(55)
and/or thaw ice that is blocking air
signal.
Metered air hole in main valve shuttle
piston (102) is plugged. Disconnect pilot line (55). If motor still doesn't change over, shuttle piston
metering hole is plugged. Clean or
replace shuttle valve piston assembly
(102)
Motor stalled at top of stroke with
exhaust at top pilot. Some exhaust at
bottom pilot.
Bottom pilot or •ttings are leaking air
when not activated by motor piston. Tighten •ttings leak or replace bot- tom pilot valve (15).
Air motor "bounces" at top change
over. Leaking bottom pilot valve or fitting. Thaw any ice in pilot valve, or replace valve (15) if it is not ice.
Air motor "bounces" at bottom
change over. Leaking top pilot valve or fitting. Thaw any ice in pilot valve, or replace valve (15) if it is not ice.

Troubleshooting
334644C 11
Ice In Air Motor
When compressed air is exhausted, the sudden drop in
pressure causes the air temperature to drop below the
freezing point. This causes any water liquid or vapor to
turn to ice.
Higher air pressures pack high amounts of air and water
vapor in each cycle and create more expansion and ice.
Higher cycle rates also build up the ice and lower the
motor temperature faster. It is important to select the
correct motor and pump size to run at a lower pressure,
and cycle slower.
Warm humid climates can produce high levels of icing
because of the higher humidity levels. Low ambient tem-
peratures near freezing make it easier for the motor
parts to drop below freezing.
To minimize ice build-up:
•Lower the dew point of the compressed air. Use a
refrigerated air dyer, coalescing •lter, or desiccant
•lter to lower the water vapor content of the air.
•Raise the compressed air temperature. Warmer
air going in helps the motor parts stay above freez-
ing. Compressed air, especially at these volumes, is
warm when compressed. Keep the air warm or stay
near the compressor to reduce icing.
• Use the bleed air to clear ice build up.
Air motor pauses at top change over. Top pilot valve exhaust restricted by
dirt or ice. Swap pilot valve or clear exhaust port.
Air motor pauses at bottom change
over. Bottom pilot valve exhaust restricted by dirt or ice. Swap pilot valve or clear exhaust port.
Motor runs slower and pump looses
•uid pressure on one stroke only. Ice has collected in air manifold pas- sages, or valve. Thaw or remove ice. Lower moisture content of compressed air. Reduce
load on motor. See below.
Motor runs slower and pump looses
•uid pressure on both strokes
equally.
Ice has collected where exhaust
expands from the shuttle valve plate
manifold (5) into the muf•er (12)
Open the bleed air valve (119) on the
main shuttle valve. This will bleed
some warm air through anytime air is
supplied to the motor.
Problem Cause Solution

Repair
12 334644C
Repair
Preventive Maintenance
Schedule
The operating conditions of your system determine how
often maintenance is required. Establish a preventative
maintenance schedule by recording when and what kind
of maintenance is needed, and then determine a regular
schedule for checking your system.
Pressure Relief Procedure
1. Engage trigger lock.
2. Close the bleed-type master air valve.
3. Disengage the trigger lock.
4. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure.
5. Engage the trigger lock.
6. Open all •uid drain valves in the system, having a
waste container ready to catch drainage. Leave
drain valve(s) open until you are ready to spray
again.
7. If you suspect the spray tip or hose is clogged or
that pressure has not been fully relieved:
a. VERY SLOWLY loosen tip guard retaining nut
or hose end coupling to relieve pressure gradu-
ally.
b. Loosen nut or coupling completely.
c. Clear hose or tip obstruction.
Follow the Pressure Relief Procedure
whenever you see this symbol
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury
from pressurized •uid, such as skin injection,
splashing •uid and moving parts, follow the
Pressure Relief Procedure when you stop spraying
and before cleaning, checking, or servicing
equipment.

Repair
334644C 13
Repair Air Valve
Replace Complete Air Valve
1. Stop the pump at the middle of its stroke. Follow
Pressure Relief Procedure, page 12.
2. Disconnect the air line to the motor and the pilot
valve lines to the air valve (13).
3. If installed on air motor, remove reed switch kit and
solenoid from air valve (13).
4. Remove screws (23). Remove the air valve (13) and
gasket (27).
5. To repair the air valve, go to Disassemble the Air
Valve, page 13, step 1. To install a replacement air
valve, continue with step 6.
6. Align the new air valve gasket (27) on the manifold,
then attach the air valve (13).
NOTE: Use grease to hold the gasket (27) in place. Be
sure the bleed air hole in the gasket aligns with the
bleed port in the valve manifold.
7. Reattach the solenoid bracket and the solenoid.
8. Use screw to attach the reed switch assembly to the
new air valve. Be sure the sensor cables are con-
nected properly (see pump or package manual).
9. Reconnect the air line and pilot valve lines to the
motor.
Replace Seals or Rebuild Air Valve
See Kits and Accessories, page 22, to order kits for
your pump.
Disassemble the Air Valve
1. Perform steps 1–5 from Replace Complete Air
Valve, page 13.
2. Use a 2mm or 5/64 hex key to remove two screws
(109). Remove the valve plate (105).
3. Remove the two-piece cup assembly (112, 113,
123), and spring (111).
4. Remove the snap ring (110) from each end. Use the
piston (102) to push the end caps (107, 117) out of
the ends. Remove end cap o-rings (106, 117).
5. Slide out the piston (102). Remove the u-cup seals
(108) from each end and the detent assembly (103)
and detent cam (104) from the center.
FIG. 3 Air Valve
FIG. 4

Repair
14 334644C
FIG. 5 Air Valve Assembly
Apply high quality lithium grease.
1

Repair
334644C 15
Reassemble the Air Valve
1. Lubricate detent cam (104) and install into housing.
2. The piston (102) and u-cup seals (108) come
pre-assembled. Lubricate the u-cup seals (108) on
both ends of the piston (102) and install it in the
housing.
3. Lubricate and install the detent assembly (103) into
the piston, with the beveled center toward the detent
cam.
4. Lubricate and install new o-ring (106) on bottom end
cap (107). Lubricate and install new o-ring (119)
and runaway reset button (118) on top end cap
(117). Install the end caps (107, 117) into the hous-
ing.
5. Install a snap ring (110) on each end to hold end
caps in place.
6. Install the spring (111).
7. Lubricate and install the cup o-ring (123) on the cup
body (113), then assemble the cup body to the cup
base (112c). Lubricate and install the cup assembly.
Align the small round magnet with the air inlet.
8. Install the valve plate (105). Lightly tighten the
screws (109) to hold it in place.

Repair
16 334644C
Replace Pilot Valves
1. Stop the pump at the middle of its stroke. Relieve
the pressure. See Pressure Relief Procedure,
page 12.
2. Disconnect the air line to the motor.
3. Use a 10 mm socket wrench to remove the old pilot
valves (15) from the top and bottom covers.
4. Lubricate and install the new pilot valves (15).
Torque to 95-105 in-lb (11-12 N•m).
Repair Air Motor
Refer to applicable system manual for alternate air
motor removal steps.
Air Motor Seal Kits are available. See Kits and Acces-
sories, page 22 for the correct kit for your motor. Parts
included in the kit are marked with an asterisk (*). For
best results, use all the parts in the kit.
Disconnect the Air Motor
1. Flush the pump, if possible (see package manual).
Follow Pressure Relief Procedure, page 12.
2. Disconnect the air and •uid hoses and the ground
wire.
3. Hold the •ats of the air motor piston rod with a
wrench. Use another wrench to loosen the coupling
nut (CN). Collect the coupling collars and set aside.
4. Hold the tie rods and remove the tie rod nuts (TN).
5. Use a socket to remove the mounting screws (MS).
6. Lift up on the air motor to remove it. The tie rods will
remain attached.
FIG. 6 Pilot Valves

Repair
334644C 17
Disassemble the Air Motor
1. Disconnect pilot valve air lines (55) from the air
valve (13).
2. Remove four screws (24) and remove the manifold
(5) and two gaskets (22). Inspect foam (42) for dam-
age.
3. Use a 15/16 in or 24 mm socket wrench to remove
the tie bolts (25).
4. Remove the top cover. Remove the o-ring (14*).
NOTE: To break the cover loose, place a pipe or a long
wrench handle through the lift ring (17) and hit the pipe.
5. Remove the muffler (12) from around the cylinder.
Remove the cylinder (3).
6. Slide the piston assembly (4) straight up off the bot-
tom cover (1).
NOTE: The piston and rod are epoxied together and
only available as an assembly (4). Do not attempt to
take apart the piston and rod assembly (4).
7. Remove the o-ring (10*) from around the piston (4).
8. Use a •at head screw driver to remove the retaining
ring (11) from the bottom cover (1).
9. Remove the u-cup seals (8*, 9*), and o-ring (14*)
from the bottom cover (1).

Repair
18 334644C
Reassemble the Air Motor
NOTE: The bearing (7) is pressed in the bottom cover
(1) and is only available with Bottom End Cap Repair kit
24X559.
1. Lubricate and install the o-ring (14*) on the bottom
cover (1).
2. Lubricate and install new u-cup seal with •ange (9*),
with the lips facing up, in the bottom cover (1) from
the bottom. The seal will snap into place.
3. Lubricate and install the new u-cup seal (8) over the
top of the bearing with the lips facing up. Install
retaining clip (11). Snap in the new bumper (19).
4. Lubricate the inside of the cylinder (3). Lower the
cylinder (3) onto the bottom cover (1).
5. Lubricate and install the o-ring (10*) around the pis-
ton (4). It will •t loose.
6. Slide the piston assembly (4) down into the cylinder
(3). Be sure the o-ring (10*) stays in place. Work it
carefully into the groove.
7. Install the muffler (12) around the cylinder (3) and in
the groove on the bottom cover(1). Be sure the front
opening is lined up with the •at on the bottom cover
(1).
8. Lubricate and install the o-ring (14*) on the top
cover (2).
9. Carefully place the top cover (2) on the cylinder (3)
and muffler (12). The •at vertical manifold surfaces
of the top and bottom covers must align. Be sure the
muffler (12) is in the groove on both the top and bot-
tom covers.
10. Install the tie bolts (25) hand tight.
11. Tighten the tie bolts (25) halfway. Work in a criss-
cross pattern. Then torque to 60 ft-lb (81 N•m).
12. Install two gaskets (22) on the top and bottom caps
with grease. Install the manifold (5). Torque bolts to
95-105 in-lb (10.7-11.9 N•m).
13. Reconnect the pilot valve air lines (55) to the air
valve (13).
FIG. 7 U-cups

Parts
334644C 19
Parts
Part No. 24X856 and 273088
Apply lithium grease.
Torque to 95-105 in-lb (11-12 N•m).
Press to snap fit.
Apply medium thread locker.
Torque to +/- 3 ft-lbs. (44.7 +/- 4 N•m).
1
4
3
2
5
8
7
9
6
Torque to 60 +/- 2 ft-lbs. (81 +/- 2.7 N•m)
Piston rod (6) must move through bearing (7)
without force.
Lips face up.
Wiper faces down.

Parts
20 334644C
Replacement Warning labels, signs, tags, and cards
are available at no cost.
See Kits and Accessories, page 22.
Ref Part Description Qty
124X559 COVER, bottom 1
17R815 COVER, bottom, motor, XP-hf
(For model 273088) 1
2 24W584 COVER, top 1
324X561 KIT, cylinder 1
424X557 KIT, piston, motor 1
24Z920 KIT, piston and rod
(For model 273088) 1
5 16Y968 MANIFOLD, exhaust, XL 1
7--- BEARING, sleeve, 1.750 ID,
2.000 OD 1
8--- PACKING, u-cup, 1.750 ID,
2.125 OD 1
9--- SEAL, rod, wiper, 1.75" rod 1
10--- O-RING, piston 1
11--- RING, retaining 1
12 24X560 COVER, muffler, complete 1
13 24X562 VALVE, air, XL; see Air Valve
Parts, page 21 1
14 109486 PACKING, o-ring 2
15 24A366 VALVE, pilot (includes
15a-15c) 2
-15a 155685 PACKING, o-ring, middle 1
-15b--- PACKING, u-cup, shaft 1
-15c 154741 PACKING, o-ring, bottom 1
-15d 197650 O-RING, buna, top 1
16 16D001 ADAPTER, lift ring 1
17 15F931 RING, lift, sst 1 9/16 thrd 1
18 NXT106 BUMPER, piston (with mag-
net) 1
Ref Part Description Qty
1924A915 KIT, bumper, top and bottom
(with screws) 1
21 108014 PACKING, o-ring 1
22--- GASKET, end cap 2
23 110036 BOLT, M8 x 1.25 x 45 mm 4
24 17B389 SCREW, M8 x 1.25 x 85 mm 4
25 127582 SCREW, 5/8–11 x 8.5 in 6
26 --- FITTING, swivel, 45°, 1npt x
1 npsm 1
27 24X565 GASKET, valve, 2 pack 1
28 555749 FITTING, adapter, 1/8 npt(m)
x JIC (#4); 1/2 hex 2
30 17C974 CAP, manifold, air, XL 2
31 C20987 PACKING, o-ring 1
38 244524 CABLE, ground, with clamp
(includes 38a) 1
-38a290079 TAG, warning, grounding (not
shown) 1
39 111307 WASHER, lock, external 1
40 116343 SCREW, ground 1
42 17C776 GASKET, muffler 1
5115F674 LABEL, safety, motor 1
52 104010 PACKING, o-ring 2
53 557832 RING, retainer -187basic int 2
55 128090 HOSE, coupled 2