Graco e-Xtreme Z60 User manual

3A6917A
EN
Instructions
e-Xtreme®Z60
High Pressure Airless Sprayers
Electric high pressure sprayer packages for application of protective coatings.
For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
See page 2 for Models information and Agency
approvals.
Important Safety Instructions
Read all warnings and instructions in this
manual and in your e-Xtreme Driver
manual before using the equipment.
Save all instructions.
WLD

23A6917A
Contents
Warnings ....................................3
Component Identification .......................6
Installation ...................................7
Power Supply ..............................7
Connect Power Supply ......................7
Grounding ................................7
Install Vented Oil Cap Before Using Equipment . . . 8
Flush Before Using Equipment ................8
Setup .......................................8
Pressure Relief Procedure ...................10
Trigger Lock ..............................11
Prime/Flush ..............................11
Spray ......................................13
Shutdown ..................................14
Maintenance ................................14
Preventative Maintenance Schedule ...........14
Daily Maintenance .........................14
Check Oil level ............................15
Corrosion Protection .......................15
Flushing .................................15
Cart Maintenance ..........................15
Troubleshooting .............................16
Error Code Troubleshooting .................18
Repair .....................................20
Xtreme Lower Removal .....................20
Disconnect the Lower ......................20
Reconnect the lower .......................20
Outlet Check Valves .......................21
Outlet Check Valve Repair ..................21
Parts ......................................22
Parts List ................................23
Cart Parts ...............................24
Outlet Check Valves Parts ...................25
Dimensions .................................26
Technical Specifications ......................27
Graco Standard Warranty .....................28
Related Manuals
Manuals are available at www.graco.com.
Component manuals in English:
Models
Part Description
3A6919 e-Xtreme Z60 Driver Manual
311762 Xtreme Lower Manual
312145 XTR Gun Manual
Model Description Approvals
25P245 e-Xtreme Z60, Heavy Duty Cart
25P246 e-Xtreme Z60, Light Weight Cart

Warnings
3A6917A 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 cord before servicing equipment.
• Connect only to grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on power and extension cords.
• Do not expose to rain. Store indoors.
• Wait five minutes after disconnecting power cord before servicing.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint 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 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.
•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
43A6917A
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
servicing 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.
• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
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.
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 Safety Data Sheets (SDSs) 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.
WARNING

Warnings
3A6917A 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.
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 Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request Safety Data Sheets (SDSs) 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
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 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.
WARNING

Component Identification
63A6917A
Component Identification
NOTE: See your e-Xtreme Driver manual for warning
label information.
WLD
(
*
6+$
/
'
7
&
)
-
%
3
8
Ref. Description
A Electric Driver
B Pump Lower
C Fluid Drain/Purge Valve
D Packing Nut
E Power Switch
F Fluid Outlet
G Junction Box Cover
H Pressure Adjustment Knob
J Outlet Check Valve
L Status Indicator Light (LED)
P Oil Fill Cap (vented)
S Junction Box
T Filter Cap (models with integrated filter only)
U Material Suction Hose
Ref. Description

Installation
3A6917A 7
Installation
Power Supply
See your driver manual for instructions for power supply
requirements.
Connect Power Supply
See your Driver manual for instructions to connect the
power supply.
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 the metal part of the spray
gun/dispense valve firmly to the side of a grounded
metal pail, then trigger the gun/valve.
Tools required
• Grounding wires and clamps for pails (Graco part
244524 - not supplied)
• Two 5 gallon (19 liter) metal pails (Graco part
101108 - not supplied)
1. Connect the ground wire (Y) to a ground stud on the
back of the motor.
2. 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.
3. Ground all solvent pails. Use only metal pails, which
are conductive, placed on a grounded surface. Do
not place pail on a non-conductive surface, such as
paper or cardboard, which interrupts grounding
continuity.
To reduce the risk of electric shock, and fire and
explosion, all electrical wiring must be done by a
qualified electrician and comply with all local codes
and regulations.
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.
WLD
<

Setup
83A6917A
Install Vented Oil Cap Before
Using Equipment
The driver gear box is shipped from the factory pre-filled
with oil. The temporary unvented cap (PX) prevents oil
leaks during shipment. This temporary cap must be
replaced with the vented oil cap (P) 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, page 11.
Setup
1. Pull pressure adjustment knob (H) out and turn
counterclockwise until it stops. Push the knob in to
lock.
2. Turn power switch (E) OFF. Connect unit to power
source.
3. Check packing nut (D). See your Xtreme lower
pump manual for packing nut torque. Fill with Throat
Seal Liquid (TSL™).
4. Attach electrically conductive fluid hose to the pump
lower outlet via the outlet check valve and tighten.
5. Attach the hose to the gun and tighten.
To avoid tipping over, make sure the cart is on a flat
and level surface. Failure to do so could result in
injury, such as crushing.
PX
P
ti36317a
H
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.
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.
WLD
OFF
E
WLD
76/

Setup
3A6917A 9
6. Attach the material suction hose (U) to the pump
lower.
NOTE: Maximum suggested length is 6 ft (1.8 m).
Minimum suggested inner diameter is 1 in (2.5 cm).
7. Check oil level.
8. Always flush and prime the sprayer before each use
(see Prime/Flush, page 11).
WLD
U
NOTICE
Only use oil with Graco part number 16W645. Any
other oil may not lubricate properly and can cause
damage to the drive train.
WLD
16W645

Setup
10 3A6917A
Pressure Relief Procedure
1. Engage the 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 the gun trigger lock.
5. Hold gun firmly against a grounded metal pail.
Trigger the gun.
6. Engage the gun trigger lock.
7. Drain fluid: Place the drain tube in a grounded
waste pail. 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:
a. VERY SLOWLY loosen the tip guard retaining
nut or hose end coupling to relieve pressure
gradually.
b. Loosen the nut or hose end coupling
completely.
c. With tip removed, trigger the gun into the
bucket.
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 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.
WLD
H
WLD
OFF
E
WLD
C

Setup
3A6917A 11
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.
Prime/Flush
1. Follow the Pressure Relief Procedure on page 10.
2. Remove the tip and tip guard from the gun.
3. Place material suction hose (U) into compatible fluid
(if priming) or solvent (if flushing).
4. Close the drain valve.
5. Turn power switch (E) ON.
6. Prime or flush the hose or gun:
a. Disengage the 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 until clean solvent
flows from the gun.
c. Engage the trigger lock.
To avoid fire and explosion, always ground equipment
and waste container. To avoid static sparking and
injury from splashing, always flush at the lowest
possible pressure.
WLD
WLD
U
WLD
WLD

Setup
12 3A6917A
7. If priming, equipment is now ready to spray
(proceed to Spray, page 15). If flushing, proceed
with step 8.
NOTE: The remaining steps are for flushing only.
8. Follow the Pressure Relief Procedure on page 10.
9. Turn power switch (E) ON. To start pump, pull out
pressure adjustment knob (H) and turn clockwise
slowly to increase pressure, until a steady stream
flows from drain valve. Push knob in to lock.
NOTE: To determine the proper amount of solvent
and flushing time, remove the inlet valve housing to
verify it has been fully cleaned, especially when
spraying a new material for the first time.
10. Wait for clean solvent to flow from drain tube.
11. Pull pressure adjustment knob (H) out and turn
counterclockwise until it stops. Push the knob in to
lock.
12. Turn power switch (E) OFF.
13. Check the pump and gun filters.
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.
WLD
H
WLD

Spray
3A6917A 13
Spray
1. Follow the Prime/Flush on page 11.
2. Follow the Pressure Relief Procedure on page 10.
3. Install tip and tip guard onto gun. Close the drain
valve.
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 the gun trigger lock.
7. Spray a test pattern. Read fluid manufacturer
recommendations and adjust as necessary.
NOTE: When determining the desired spray
pressure, always increase the spray pressure until
the spray pattern fully develops. This will reduce the
pressure surge when the pump is stalled and
minimize over-spray.
*The sprayer can stall at pressures higher than the
dynamic pressure. All components downstream of
the sprayer must be rated for the pressures listed in
Technical Specifications on page 27.
8. Flush when finished spraying. Follow the
Prime/Flush on page 11.
9. Follow the Pressure Relief Procedure on page 10.
NOTICE
Do not allow pump to run dry. It will quickly accelerate
to a high speed causing damage.
WLD
ON
E
WLD
H
Pressure
Adjustment Knob
Setting
Dynamic Pump Outlet
Pressure
psi Bar MPa
1 500 35 3.5
2 1000 69 6.9
3 1500 103 10.3
4 2000 138 13.8
5 2500 172 17.2
6 3000 207 20.7
7 3500 241 24.1
8 4000 276 27.6
9 4500 310 31.0
10 *5000 *345 *34.5

Shutdown
14 3A6917A
Shutdown
To shutdown:
1. Follow the Prime/Flush on page 11.
2. Follow the Pressure Relief Procedure on page 10.
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.
Change the Oil
NOTE: Change the oil after a break-in period of
200,000–300,000 cycles. After the break-in period,
change the oil once a 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 oil fill cap (P) and add Graco Part No.
16W645 silicone-free ISO 220 synthetic EP gear oil.
Check the oil level in the sight glass (K). 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 oil fill cap (P).
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. Follow
the Pressure Relief Procedure on page 10.
1. Follow the Prime/Flush on page 11.
2. Follow the Pressure Relief Procedure on page 10.
3. Check packing nut (D). Adjust packings and replace
TSL as necessary. See lower pump manual 311762
for packing nut toque.
4. Check hoses, tubes, and couplings. Tighten all fluid
connections before each use.
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.
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
Do not over-torque. The drain plug can become
stripped and damaged.
NOTICE
Only use oil with Graco part number 16W645. Any
other oil may not lubricate properly and can cause
damage to the drive train.
.
3

Maintenance
3A6917A 15
Check Oil level
Check the oil level in the 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 the fill cap
(P) and add Graco Part No. 16W645 silicone-free ISO
220 synthetic EP gear oil.
The oil capacity is approximately 1.0–1.2 quarts (0.9–
1.1 liters). Do not overfill.
NOTE: The driver gear box is shipped from the factory
pre-filled with oil. The temporary unvented cap (PX)
prevents oil leaks during shipment. This temporary cap
must be replaced with the supplied vented oil cap (P)
before use.
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. Follow the Pressure Relief Procedure
on page 10, but leave rust inhibitor in pump to protect
parts from corrosion.
Flushing
• Flush before changing fluids, before fluid can cure 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 below).
Keep the cart clean by wiping up spills daily, using a
compatible solvent.
NOTICE
Only use oil with Graco part number 16W645. Any
other oil may reduce the life of the gears.
3
.
PX
P
ti36317a
WLD
$
%

Troubleshooting
16 3A6917A
Troubleshooting
NOTE: Check all possible remedies before
disassembling the pump.
NOTE: The status indicator (L) on the driver will blink if
an error is detected.
Problem Cause Solution
Pump output low on both
strokes
Exhausted fluid supply Refill and prime the pump.
* Clogged fluid outlet line,
gun, etc. The hose inner
diameter is too small
Clear the hose, outlet check valve, or gun; use the hose
with the larger inner diameter.
Worn piston packing Replace the piston packing. See your pump lower manual.
No output Improperly installed intake
or piston check valves
Check and repair. See pump the lower manual.
The intake valve is clogged. Clean the intake valve.
Exhausted fluid supply Refill and prime the pump.
Pump will not operate Exhausted fluid supply Refill and prime the pump.
* Clogged fluid hose or gun Clean the hose or gun.
Fluid dried on the piston rod Disassemble and clean the pump (see the lower manual).
In the future, stop the pump at the bottom of the stroke.
Keep the wet-cup filled with compatible solvent.
Driver parts are worn or
damaged
Repair or replace the driver. Remove the lower from the
driver. If the driver will not cycle and does not blink an error
code, then troubleshoot the driver or replace.
No pressure or flow Fluid is leaking from the
rupture disk
Replace the rupture disk; do not replace with a pipe plug.
The intake valve is clogged Clean the intake valve.
Leaking drain valve Close or replace the drain valve.
Driver does not turn on Over voltage (over 300 V) See power supply requirements in your driver manual.
No power to the control
board
Verify that the power supply is connected. Check the
junction box connections.
Output low on the down
stroke
Open or worn intake valve Clear or service the intake valve.
Output low on the up
stroke
Open or worn piston valve
packings
Clear the piston valve. Replace the packings.
*To determine if the fluid hose or gun is obstructed, follow the Pressure Relief Procedure on 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 the pump. If the pump starts, the obstruction is in the fluid hose or gun.

Troubleshooting
3A6917A 17
Erratic or accelerated
pump speed
Fluid supply is exhausted Refill the fluid supply and prime the pump.
Clogged suction Clean the suction tube.
Open or worn piston valve
packings
Clear the piston valve. Replace the packings.
Open or worn intake valve Clear or service the intake valve.
Clogged gun, hose, outlet,
etc.
Clear the gun, hose, outlet, etc.
Open or worn outlet check
valve
Clear or service the outlet check valve.
Cycles or fails to hold
pressure at stall
Worn intake or piston valve
or seals
Service the pump lower (see your lower manual).
Air bubbles in fluid Loose suction line Tighten suction line connections. Use compatible liquid
thread sealant or PTFE tape on connections.
Agitator/mixer is not
submerged
Submerge the agitator/mixer.
Agitator/mixer RPM is too
high
Lower the agitator/mixer RPM.
Poor finish or irregular
spray pattern
Incorrect fluid pressure at
gun
See your gun manual. Read the fluid manufacturer’s
recommendations.
Fluid is too thin or too thick Adjust the fluid viscosity. Read the fluid manufacturer’s
recommendations.
Dirty, worn, or damaged
spray gun
Service the spray gun (see your spray gun manual).
Driver does not turn over
and LED is off
Over voltage (greater than
300 V)
Check the power supply.
No power to the 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 e-Xtreme Driver Operation/Repair
manual. Contact your Graco distributor or Tech Service for
more information.
Oil is leaking Oil was over filled Drain and refill oil as stated in Check Oil level, page 15.
Drain plug is not tightened
properly
Torque to 18-23 ft-lb (25-30 N•m).
Seal cartridge o-ring
missing or damage
Replace the shaft bearing assembly.
Problem Cause Solution

Troubleshooting
18 3A6917A
Error Code Troubleshooting
Error codes can take two forms:
• Alarm: Alerts you to the cause of the alarm and
shuts down the driver.
• Deviation: Alerts you to the problem, but the driver
may continue to run past the set limits until the
system absolute limits are reached.
NOTE: The blink code is displayed using the status
indicator (L) on the driver. The blink code given below
indicates the sequence. For example, blink code 2
indicates two blinks, a pause, 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 the OFF position for at
least 30 seconds before turning back ON.
Standby Mode
When slow blinking is displayed, the driver has entered
Standby Mode. The driver will enter standby mode when
powered on and pressurized with a knob setting greater
than 7, and the pump has not moved any material for 30
minutes.
Standby Mode will be exited when:
• Material starts to dispense and causes the pump to
move, OR
• The pressure control knob (H) is adjusted, OR
• The power switch (E) is cycled OFF and ON
Error Codes Table
Blink Code Error Type Troubleshooting Steps
1 Alarm Pump Diving
The pump is diving rapidly. A pressure imbalance between the up and down stroke
of the pump is causing the pump to dive with excessive speed.
• Pump diving may occur when the pump runs out of material while spraying at
high pressure.
• Verify that material is being properly fed to the pump.
• Pressure from the hose could flow back into the pump on the down stroke.
• Verify that the check valve is installed and is properly working.
2 Alarm Voltage Too Low
• Verify that line voltage is within the range specified in Technical
Specifications, page 27.
• Use the recommended cord in your driver manual.
• Cycle power and check status indicator (L) to see if the error is still active.
3 Alarm Voltage Too High
• Verify that line voltage is within the range specified in Technical
Specifications, page 27.
• Cycle power and check status indicator (L) to see if the error is still active.
4 Deviation High Temperature
The temperature of the system is near the maximum operation temperature. The
performance has been reduced to prevent the driver from completely shutting
down.
• Reduce pressure.
• Move the unit to a cooler location.

Troubleshooting
3A6917A 19
5 Deviation Low Temperature
Warm equipment.
6 Alarm Motor Temperature Fault
Motor is running too hot. Allow unit to cool.
• Reduce pressure.
• Move the unit to a cooler location.
7 Alarm Board Temperature Fault
The control board is running too hot. Allow the unit to cool.
• Reduce pressure.
• Move the unit to a cooler location.
8 Alarm Encoder Calibration Error
• Cycle power and check status indicator (L) to see if the error is still active.
• Follow the calibration procedure listed in the e-Xtreme Driver
Operation/Repair manual to calibrate the encoder (this code will blink if
calibration is in progress).
• Contact your Graco distributor or Tech Service for more information.
9 Alarm Encoder Error
• Cycle power and check the status indicator (L) to see if the error is still active.
• Verify that the internal connections are intact.
• Contact your Graco distributor or Tech Service for more information.
10 Alarm Software Versions Do Not Match
Obtain software update token. See Accessories section for token part number.
See the Driver Operation/Repair manual for token installation information.
11 Alarm Circuit Board Communication Failure
Cycle power and check status indicator (L) to see if the error is still active.
Contact your Graco distributor or Tech Service for more information.
12 Alarm Internal Circuit Board Hardware Failure
Cycle power and check status indicator (L) to see if the error is still active.
Contact your Graco distributor or Tech Service for more information.
13, 14 Alarm Internal Software Error
Cycle power and check status indicator (L) to see if the error is still active.
Contact your Graco distributor or Tech Service for more information.
Slow Blink Deviation See Standby Mode, page 18.
Blink Code Error Type Troubleshooting Steps

Repair
20 3A6917A
Repair
Xtreme Lower Removal
Required Tools
• Set of adjustable wrenches
• Torque wrenches
• Rubber mallet
• Thread lubricant
• Anti-seize lubricant
• Thread sealant
Disconnect the Lower
1. Flush the pump (see Prime/Flush, page 11).
2. Follow the Pressure Relief Procedure on page 10.
3. Disconnect the unit from the power source.
4. Disconnect the fluid hose, then disconnect the
material suction hose. Hold the fluid inlet fitting with
a wrench to keep it from loosening while you
disconnect the material suction hose.
5. If the driver does not require service, leave it
attached to the mounting.
6. Remove clip (11) and slide coupling cover (13) up to
remove coupling (12).
7. Use a wrench to hold the tie rod flats to keep rods
(8) from turning. Unscrew nuts (10) and remove the
lower (9).
8. Service the lower (refer to your Xtreme lower
manual).
Reconnect the lower
1. Use a wrench to hold the tie rod flats to keep rods
(8) from turning. Replace nuts (10) to the lower (9).
Torque nuts to 50-60 ft-lb (68-81 N•m).
2. Slide coupling cover (13) down over coupling (12) to
secure it. Reinstall clip (11).
3. Connect the material suction hose, then connect the
fluid hose. Hold the fluid inlet fitting with a wrench to
keep it from moving while connecting the material
suction hose.
Do not lift the pump by the lift ring when the weight
exceeds 360 kg (800 lb). The lift ring could fail and
result in injury.
Use caution when disconnecting the lower; it can
weigh up to 55 lb (25 kg). Take appropriate
precautions.
WL



WLD


