Graco e-Xtreme Z25 Use and care manual

333208F
EN
Operation-Repair-Parts
Electric High Pressure
Airless Sprayer
Electric high pressure sprayer packages for application of protective coatings.
For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
For Model Information and maximum working pressure,
see page 2.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
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2 333208F
Contents
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Identification - Cart Mount . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connect Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install Vented Oil Cap Before Using Equipment . . . . . . 8
Flush Before Using Equipment . . . . . . . . . . . . . . . . . . . 8
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . . . 10
Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Prime/Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Preventative Maintenance Schedule . . . . . . . . . . . . . 13
Change the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cart Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Xtreme Lower Removal . . . . . . . . . . . . . . . . . . . . . . . 19
Disconnect and Reconnect Lower . . . . . . . . . . . . . . . 19
Outlet Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Parts List - Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Outlet Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Parts List - Outlet Check Valve . . . . . . . . . . . . . . . . . . 24
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 26
California Proposition 65 . . . . . . . . . . . . . . . . . . . . . . . . 27
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . 28
Model Information
*Lower fluid temperature due to XTR5 gun.
Related Manuals
Manuals are available at www.graco.com.
Model Description Maximum Working Pressure
Maximum Fluid
Temperature Approvals
24X450 Includes hose and gun 4500 psi (31 MPa, 310 bar) 160° F (71° C)*
24X451 No hose or gun 4500 psi (31 MPa, 310 bar) 180° F (82° C)
24Y452 Hopper Ready, includes hose and gun 4500 psi (31 MPa, 310 bar) 160° F (71° C)*
24W315 Includes hose and gun 2600 psi (18 MPa, 180 bar) 160° F (71° C)*
24W316 No hose or gun 2600 psi (18 MPa, 180 bar) 180° F (82° C)
24Y317 Hopper Ready, includes hose and gun 2600 psi (18 MPa, 180 bar) 160° F (71° C)*
25A829 High Temp Sprayer, no hose/gun 2600 psi (18 MPa, 180 bar) 390° F (200° C)
Manual in
English Description
311762 Xtreme Lower Manual
312145 XTR Gun Manual
333233 Electric Driver Manual
333267 Hopper Accessory Kit
3A4094 XHT High Temperature Gun

Warnings
333208F 3
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
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause
electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
• Do not expose to rain. Store indoors.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are antistatic or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.

Warnings
4 333208F
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut,
but it is a serious injury that can result in amputation. Get immediate surgical treatment.
•Do not 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.
•Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servic-
ing equipment.
•Tighten all fluid connections before operating the equipment.
•Check hoses and couplings daily. Replace worn or damaged parts immediately.
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.
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 compo-
nent. See Technical Specifications in all equipment manuals.
•Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equip-
ment 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 manufac-
turer’s replacement parts only.
•Do not alter or modify equipment. Alterations or modifications may void agency 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.
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 containers, and dispose of it according to applicable guidelines.
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. This 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.
WARNING

Component Identification - Cart Mount
333208F 5
Component Identification - Cart Mount
A Electric Driver
B Lower
C Fluid Drain/Purge Valve
D Packing Nut
E Power Switch
F Fluid Outlet
G Junction Box Cover
H Pressure Adjustment Knob
I Outlet Check Valve
L Red Indicator Light
P Oil Fill Cap (Vented)
S Junction Box
FIG. 1: Airless Sprayer
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D
A
C
F
E
G
H
IB
L
S
P

Installation
6 333208F
Installation
Power Supply
See Table 1 for power supply requirements. The system
requires a dedicated circuit protected with a circuit
breaker.
Select the minimum cord wire gauge based on length
according to the table below:
Connect Power
1. Cut power cord wires to the following lengths:
• Ground wire - 6.5 inches (16.5 cm)
• Power wires - 3.0 inches (7.6 cm)
• Add ferrules as necessary. See FIG. 2.
2. Bring cord to unit and remove two screws to
separate junction box cover (G) and power switch
(E) from remainder of sprayer. See FIG. 3.
3. With power switch (E) and junction box cover (G)
detached from machine, wires inside junction will
appear as below.
NOTE: Two wires will be installed in both terminals.
See FIG. 4:
• For Series A and B: terminals 1L1 and 3L2
• For Series C: terminals 1L1 and 5L3
NOTE: Press gasket against back sealing face of
junction box cover to ease installation of power
cord.
4. Insert power cord (from step 1) through cord grip
(C2) and into junction box (S).
NOTE: Power wires should be installed into
terminals. See FIG. 4:
• Series A and B: terminals 2T1 and 4T2
• Series C: terminals 2T1 and 6T3
Improper wiring may cause electric shock or other
serious injury. All electrical wiring must be done by a
qualified electrician and comply with all local codes
and regulations.
Table 1: Power Supply Specifications
Voltage Phase Hz Current
200-240 VAC 1 50/60 20 A
Length Gauge mm2
50 ft (15.24 m) 12 AWG 3.31
100 ft (30.48 m) 10 AWG 5.26
200 ft (60.96 m) 6 AWG 13.29
300 ft (91.44 m) 4 AWG 21.14
FIG. 2: Power Cord
GROUND
POWER
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FIG. 3: Power Switch
FIG. 4: Terminal Connections
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Installation
333208F 7
5. Attach ground wire to ground terminal inside
junction box (S).
NOTE: The power cord attaches to a separate
ground screw than the ground screw that is already
attached.
6. Place fan wires and other power wires into open
area on either side of disconnect block (J) as space
permits. Reinstall junction box cover. See FIG. 5.
7. Replace junction box screws and washers removed
in step 2 and tighten cord grip to securely hold
power cord in junction box (S). See FIG. 6.
NOTICE
If wires get pinched when the screws are tightened,
damage will occur. Make sure all wires are routed
correctly before installation.
FIG. 5: Grounding Wire
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J
FIG. 6: Junction Box Screws and Strain Relief
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S

Installation
8 333208F
Grounding
Sprayer: system is grounded through the power cord.
Fluid hoses: use only electrically conductive hoses with
a maximum of 210 ft. (64 m) combined hose length to
ensure grounding continuity. Check electrical resistance
of hoses. If total resistance to ground exceeds 25 mega
ohms, replace hose immediately.
Spray gun: ground through connection to a properly
grounded fluid hose and pump.
Fluid supply container: follow local code.
Object being sprayed: follow local code.
Solvent pails used when flushing: follow local code.
Use only conductive metal pails, placed on a grounded
surface. Do not place the pail on a non-conductive
surface, such as paper or cardboard, which interrupts
grounding continuity.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the spray
gun/dispense valve firmly to the side of a grounded
metal pail, then trigger the gun/valve.
Install Vented Oil Cap Before
Using Equipment
The driver gear-box is shipped from the factory prefilled
with oil. The temporary unvented cap (PX) prevents oil
leaks during shipment. This temporary cap must be
replaced with the vented oil cap (P), supplied with
equipment, before use.
Flush Before Using Equipment
The pump fluid section was tested with lightweight oil,
which is left in the fluid passages to protect parts. To
avoid contaminating your fluid with oil, flush the
equipment with a compatible solvent before using the
equipment.
See Prime/Flush procedure, page 11.
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.
FIG. 7: Unvented and Vented Oil Caps
PX
P
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K

Setup
333208F 9
Setup
1. Check packing nut (D). Fill with Throat Seal Liquid
(TSL). Torque to 25 ft-lb (34 N•m).
2. Attach electrically conductive fluid hose to pump
lower outlet via outlet check valve and tighten.
3. Attach hose to gun and tighten.
4. Attach material supply inlet hose to pump lower.
NOTE: Maximum suggested length is 6 ft (1.8 m),
minimum suggested inner diameter is 1 in. (2.5 cm).
5. Pull pressure adjustment knob (H) out and turn
counterclockwise until it stops. Push the knob in to
lock.
6. Turn power switch (E) OFF. Connect unit to power
source. See FIG. 3, page 6.
7. Always flush and prime sprayer before each use
(see page 11).
To avoid tip over, make sure cart is on a flat and level
surface. Failure to do so could result in injury or
equipment damage.
NOTICE
Attaching the hose directly to the lower pump can
result in damage to the sprayer during cavitation, or
when the sprayer runs out of material. Use an outlet
check valve between the lower pump and hose to
avoid damage.
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NOTICE
The minimum hose size allowable is 3/8 in. ID x 50 ft
(10 mm x 15 m). Smaller hoses can cause high
pressure spikes and result in damage to the sprayer.
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Pressure Relief Procedure
10 333208F
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Engage gun trigger lock.
2. Pull pressure adjustment knob (H) out and turn
counterclockwise until it stops. Push the knob in to
lock.
3. Turn power switch (E) off.
4. Disengage gun trigger lock.
5. Hold gun firmly against a grounded metal pail.
Trigger the gun.
6. Engage gun trigger lock.
7. Drain fluid: Slowly open fluid drain/purge valve (C),
and drain fluid into a waste pail.
8. If you suspect the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the previous steps, VERY SLOWLY
loosen the tip guard retaining nut or hose end
coupling and relieve pressure gradually; then loosen
completely. With tip removed, trigger gun into
bucket.
Trigger Lock
Always engage the trigger lock when you stop spraying
to prevent the gun from being triggered accidentally by
hand or if dropped or bumped.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.
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Prime/Flush
333208F 11
Prime/Flush
1. Perform Pressure Relief Procedure, page 10.
2. Remove tip and tip guard from gun.
3. Place material supply suction hose into compatible
fluid (if priming) or solvent (if flushing).
4. Pull pressure adjustment knob (H) out and turn
counterclockwise until it stops. Push the knob in to
lock.
5. Turn power switch (E) ON.
6. Prime or flush hose and gun:
a. Disengage gun trigger lock.
b. Trigger gun into grounded pail. Pull out
pressure adjustment knob (H) and turn
clockwise slowly to increase pressure, until a
steady stream flows from gun. Push knob in to
lock. If flushing, trigger gun for 10-15 seconds.
c. Engage trigger lock.
7. If priming, equipment is now ready to spray
(proceed to Spray, page 12). If flushing, proceed
with step 8.
NOTE: The remaining steps are for flushing only.
8. Place drain tube in a grounded waste pail.
9. Slightly rotate drain/purge valve handle (C)
counterclockwise to open.
10. To start pump, pull out pressure adjustment knob
(H) and turn clockwise until pump begins to move.
Push knob in to lock.
11. When clean solvent flows from drain tube, rotate
drain/purge valve handle (C) clockwise to close.
Pump will stall.
12. Perform Pressure Relief Procedure, page 10.
Leave solvent in and store sprayer.
To avoid injury from splashing, always flush at lowest
possible pressure.
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E
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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.
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C

Spray
12 333208F
Spray
1. Perform Prime procedure, page 11.
2. Perform Pressure Relief Procedure, page 10.
3. Install tip and tip guard onto gun.
4. Turn power switch (E) ON.
5. Pull out and turn pressure adjustment knob (H) until
desired pressure is reached. Turn clockwise to
increase pressure, counterclockwise to decrease
pressure. Push knob in to lock.
6. Disengage gun trigger lock.
7. Spray a test pattern. Read fluid manufacturer’s
recommendations. Adjust as necessary.
8. Flush when finished spraying. See Prime/Flush,
page 11.
9. Perform Pressure Relief Procedure, page 10.
Shutdown
To shutdown, perform Prime/Flush procedure, page 11.
Perform Pressure Relief Procedure, page 10.
NOTICE
Do not allow pump to run dry. It will quickly accelerate
to a high speed causing damage.
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NOTICE
Never leave water or water-based fluid in pump over
night. If water-base fluid has been used, flush with
water first, then with a rust inhibitor (such as mineral
spirits). Relieve pressure, but leave rust inhibitor in
pump to protect parts from corrosion.
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Maintenance
333208F 13
Maintenance
Preventative Maintenance
Schedule
The operating conditions of your particular 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.
Change the Oil
NOTE: Change the oil after a break-in period of 200,000
to 300,000 cycles. After the break-in period, change the
oil once per year.
1. Place a minimum 2 quart (1.9 liter) container under
the oil drain port. Remove the oil drain plug. Allow
all oil to drain from the driver.
2. Reinstall the oil drain plug. Torque to 18-23 ft-lb
(25-30 N•m).
3. Open the fill cap (P) and add Graco Part 16W645
ISO 220 silicone-free synthetic EP gear oil. Check
the oil level in the sight glass (K). (See FIG. 8.) Fill
until the oil level is near the halfway point of the
sight glass. The oil capacity is approximately 1.0 -
1.2 quarts (0.9 - 1.1 liters). Do not overfill.
4. Reinstall the fill cap. See FIG. 8.
Daily Maintenance
NOTE: For overnight shutdown, stop pump at bottom of
its stroke to prevent fluid from drying on exposed
displacement rod and damaging throat packings.
Perform Pressure Relief Procedure, page 10.
1. Perform Flush procedure, page 11.
2. Relieve pressure. See Pressure Relief Procedure,
page 10.
3. Check packing nut (D) See FIG. 1, page 5. Adjust
packings and replace TSL as necessary. Torque to
25 ft-lb (34 N•m).
4. Check hoses, tubes, and couplings. Tighten all fluid
connections before each use.
Check Oil Level
See FIG. 8. Check the oil level in sight glass (K). The oil
level should be near the halfway point of the sight glass
when the sprayer is not running. If oil is low, open fill cap
(P) and add Graco Part No. 16W645 ISO 220
silicone-free synthetic EP gear oil.
The oil capacity is approximately 1.0 - 1.2 quarts
(0.9 - 1.1 liters). Do not overfill.
NOTICE
Do not open/remove gear cover. The gear side is not
intended to be serviced. Opening the gear cover may
alter the factory set bearing pre-load and may reduce
the product life.
NOTICE
Only use oil with Graco part number 16W645. Any
other oil may not lubricate properly and can cause
damage to drive train.
FIG. 8: Sight Glass and Oil Fill Cap
NOTICE
Only use oil with Graco part number 16W645. Any
other oil may not lubricate properly and can cause
damage to drive train.
P
K

Maintenance
14 333208F
Corrosion Protection
Always flush the pump before 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 a rust inhibitor, such as
mineral spirits. Perform Pressure Relief Procedure
(page 10), but leave rust inhibitor in pump to protect
parts from corrosion.
Flushing
• Flush before changing fluids, before fluid can dry in
the equipment, at the end of the day, before storing,
and before repairing equipment.
• Flush at the lowest pressure possible. Check
connectors for leaks and tighten as necessary.
• Flush with a fluid that is compatible with the fluid
being dispensed and the equipment wetted parts.
Cart Maintenance
Periodically lubricate the axle between points A and B
with lightweight oil. See the following figure.
Keep the cart clean by wiping up spills daily, using a
compatible solvent.
FIG. 9: Cart
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A
B

Troubleshooting
333208F 15
Troubleshooting
NOTE: Check all possible remedies before
disassembling pump.
NOTE: The LED on the driver will blink if an error is
detected.
Problem Cause Solution
Pump output low on both
strokes
Inadequate power supply. See Power Supply, page 6.
Exhausted fluid supply. Refill and prime pump.
Clogged fluid outlet line, gun*, etc.;
hose inner diameter too small.
Clear hose, outlet check valve, or gun; use
hose with larger inner diameter.
Worn piston packing. Replace. See lower manual.
No output Improperly installed intake or piston
check valves.
Check and repair. See lower manual.
Exhausted fluid supply. Refill and prime pump.
Pump will not operate Inadequate power supply. See Power Supply, page 6.
Exhausted fluid supply. Refill and prime pump.
Clogged fluid hose or gun*. Clean hose or gun.
Fluid dried on piston rod. Disassemble and clean pump. See lower
manual. In future, stop pump at bottom of
stroke. Keep wet-cup filled with compatible
solvent.
Driver parts are worn or damaged. Repair or replace driver.
No pressure Fluid leaking from rupture disk. Replace rupture disk with new one; do not
replace with pipe plug.
Leaking drain valve. Close or replace.
Driver does not turn on
(fans may still run)
Over voltage (over 300 V) See Power Supply, page 6.
No power to control board. Verify power supply is connected.
Check junction box connections.
Output low on down stroke Open or worn intake valve. Clear or service intake valve.
Output low on upstroke Open or worn piston valve packings. Clear piston valve; replace packings.
Erratic or accelerated
pump speed
Fluid supply exhausted. Refill supply and prime pump.
Clogged suction. Clean suction tube.
Open or worn piston valve packings. Clear piston valve; replace packings.
Open or worn intake valve. Clear or service intake valve.
Clogged gun, hose, outlet, etc. Clear gun, hose, outlet, etc.
Open or worn outlet check valve Clear or service outlet check valve.
Cycles or fails to hold
pressure at stall
Worn intake or piston valves or seals. Service lower. See Xtreme Lower Removal,
page 19, and lower manual (311762).

Troubleshooting
16 333208F
Air bubbles in fluid Loosen suction line. Tighten suction line connections. Use
compatible liquid thread sealant or PTFE
tape on connections.
Agitator/mixer is not submerged. Submerge agitator/mixer.
Agitator/mixer RPM is too high. Lower RPM.
Poor finish or irregular
spray pattern
Incorrect fluid pressure at gun. See spray gun manual. Read fluid
manufacturer’s recommendations.
Fluid is too thin or too thick. Adjust fluid viscosity. Read fluid
manufacturer’s recommendations.
Dirty, worn, or damaged spray gun. Service spray gun. See spray gun manual.
Driver does not turn over
and LED is off
Over voltage (greater than 300 V) Check power supply
No power to control board Contact your Graco distributor or Tech
Service for more information.
Driver does not turn over
and LED is on
Encoder fault Cycle power.
Recalibrate the encoder following the
procedure listed in the Electric Driver Manual
(333233).
Contact your Graco distributor or Tech
Service for more information.
Oil is leaking Oil was over-filled Drain and refill as stated in Check Oil Level,
page 13.
Drain plug not tightened properly Torque to 18-23 ft-lb (25-30 N•m).
Seal cartridge o-ring missing or
damaged.
Replace shaft bearing assembly.
* To determine if fluid hose or gun is obstructed, follow Pressure Relief Procedure, page 10. Disconnect fluid hose
and place a container at pump fluid outlet to catch any fluid. Turn pressure adjustment knob just enough
to start pump. If pump starts, the obstruction is in fluid hose or gun.
Problem Cause Solution

Troubleshooting
333208F 17
Error Codes
Error codes can take two forms:
Alarm: alerts you to the alarm cause and shuts down
the pump.
Deviation: alerts you to the problem, but pump may
continue to run past the set limits until the system’s
absolute limits are reached.
NOTE: The blink code is displayed using the power
indicator (L) on the driver. The blink code given below
indicates the sequence. For example, blink code 2
indicates two blinks, a pause, then two more blinks, and
then repeats.
NOTE: To clear an error code, first try turning the
pressure adjustment knob (H) counterclockwise until it
stops. If the status indicator (L) does not stop blinking
shortly after turning the knob to zero, cycle the power by
turning the power switch (E) to OFF.
Power Saving Mode
When fast blinking is displayed, the sprayer has entered
Power Saving Mode mode. When the sprayer is on and
pressurized but the pump has not moved any material in
30 minutes, the sprayer will enter Power Saving Mode
and will only control up to 75% of the maximum pressure.
Power Saving Mode will be exited when:
• Material starts to dispense and causes the pump to
move, OR
• The pressure knob is adjusted, OR
• Power is cycled OFF and ON
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Blink Code Error Type Troubleshooting Steps
1 Alarm Voltage Too Low
• Verify that line voltage is within the range specified in Technical Data,
page 25.
• Use the recommended cord (see page 6 ).
• Cycle power and check status indicator to see if error is still active.
2 Alarm Voltage Too High
• Verify that line voltage is within the range specified in Technical Data,
page 26.
• Cycle power and check status indicator to see if error is still active.
• Verify that outlet check valve is installed on pump and functions properly.
NOTE: A faulty outlet check valve can result in excessive pump speed and
cause high voltage internally to the electric driver.
3 Deviation Low Temperature
• Warm equipment.
• Contact your Graco distributor or Tech Service for more information.

Troubleshooting
18 333208F
4 Deviation High Temperature
The temperature of the system is near the maximum operation temperature. The
performance has been reduced to prevent the sprayer from completely shutting
down.
• Check fan operation. Clean fan and driver housing. Verify fuses are intact in
junction box.
• Reduce pressure, duty cycle, or gun tip size.
• Move unit to a cooler location.
5 Alarm Motor Temperature Fault
Motor is running too hot. Allow unit to cool.
• Check fan operation. Clean fan and driver housing. Verify fuses are intact in
junction box.
• Reduce pressure, duty cycle, or gun tip size.
• Move unit to a cooler location.
6 Alarm Board Temperature Fault
The control board is running too hot. Allow unit to cool.
• Check fan operation. Clean fan and driver housing. Verify fuses are intact in
junction box.
• Reduce pressure, duty cycle, or gun tip size.
• Move unit to a cooler location.
7 Alarm Encoder Calibration Error
• Cycle power and check status indicator to see if error is still active.
• Calibrate the encoder (see driver manual).
• Contact your Graco distributor or Tech Service for more information.
8 Alarm Encoder Error
• Cycle power and check the status indicator to see if the error is still active.
• Verify that the encoder cable is connected securely.
• The encoder may need to be replaced.
• Contact your Graco distributor or Tech Service for more information.
9 Alarm Software Versions Do Not Match
• Obtain software update token and follow Software Update procedure
(contact your Graco distributor or Tech Service for more information).
10 Alarm Circuit Board Communication Failure
• Cycle power and check status indicator to see if error is still active.
• Contact your Graco distributor or Tech Service for more information.
11 Alarm Internal Circuit Board Hardware Failure
• Cycle power and check status indicator to see if error is still active.
• Contact your Graco distributor or Tech Service for more information.
12, 13 Alarm Internal Software Error
• Cycle power and check status indicator to see if error is still active.
• Contact your Graco distributor or Tech Service for more information.
Fast Flash Deviation See Power Saving Mode, page 17.
Blink Code Error Type Troubleshooting Steps

Repair
333208F 19
Repair
Xtreme Lower Removal
Required Tools
• Set of adjustable wrenches
• Torque wrench
• Rubber mallet
• Thread lubricant
• Anti-seize lubricant
• Thread sealant
Disconnect and Reconnect
Lower
1. Flush pump; see Prime/Flush, page 11. Stop pump
at bottom of its stroke.
2. Perform Pressure Relief Procedure, page 10.
3. Disconnect unit from power source.
4. Disconnect fluid hose. Disconnect suction hose.
Hold fluid inlet fitting with a wrench to keep it from
loosening while you disconnect suction hose.
5. If driver does not require service, leave it attached
to its mounting.
To prevent skin injection and splashing, never open a
camlock hose or applicator fitting while there is pres-
sure in the fluid line. Perform Pressure Relief Proce-
dure, page 10, before performing any repair
procedure.
The material and equipment may be hot. To avoid
burns, do not touch hot fluid or equipment. Wait until
equipment has cooled completely before performing
any repair procedure.
Do not lift the pump by the lift ring when the weight
exceeds 250 kg (550 lb). The lift ring could fail and
result in personal injury or damage to the equipment.
Use caution when disconnecting lower; they can
weigh up to 25 kg (55 lbs). Take appropriate
precautions.
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Repair
20 333208F
6. Remove clip (11) and slide coupling cover (13) up to
remove coupling (12).
7. Use a wrench to hold tie rod flats to keep rods (8) from
turning. Unscrew nuts (10) and remove lower (9).
8. Refer to Xtreme Lower manual (311762) to service
lower.
9. Reconnect lower by following disconnect steps in
reverse order.
NOTE: Torque nuts (10) to 50-60 ft-lb (68-81 N•m).
11
13
12
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10
8