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.
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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.
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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.
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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.
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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).
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NOTICE
Only use oil with Graco part number 16W645. Any
other oil may not lubricate properly and can cause
damage to the drive train.
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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.
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