Graco e-Xtreme Use and care manual

Operation,Repair,andParts
e e
e- - -Xtreme® Xtreme® Xtreme®Sprayer Sprayer Sprayer
3A3164D
EN
Electric Electric
Electrichigh high highpressure pressure pressuresprayer sprayer sprayerpackages packages packagesfor for forapplication application applicationof of ofprotective protective protectivecoatings. coatings. coatings.
For For
Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanualandinthee-Xtreme
Drivermanuals.Save Save
Saveall all allinstructions. instructions. instructions.
See page 3 for model information. See
Technical Speci󰘰cations for maximum
working pressure.
II 2 G c
Ex db IIA T2 Gb X
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
RelatedManuals................................................2
ModelInformation...............................................3
Warnings...........................................................4
ComponentIdenti󰘰cation.....................................7
Installation..........................................................8
PowerSupplyRequirements.........................8
ConnectthePowerSupply...........................8
Grounding...................................................8
InstallVentedOilCapBeforeUsing
Equipment......................................9
FlushBeforeUsingEquipment......................9
Setup.................................................................10
PressureReliefProcedure............................12
TriggerLock................................................12
Prime/Flush.................................................13
Spray.................................................................15
Shutdown...........................................................16
Maintenance......................................................16
PreventiveMaintenanceSchedule................16
ChangetheOil.............................................16
DailyMaintenance.......................................16
CheckOilLevel...........................................17
CorrosionProtection....................................17
Flushing......................................................17
CartMaintenance.........................................17
Troubleshooting..................................................18
ErrorCodeTroubleshooting..........................20
StandbyMode.............................................20
ErrorCodesTable........................................20
Repair................................................................22
XtremeLowerRemoval................................22
DisconnectandReconnectLower.................22
OutletCheckValves.....................................23
Parts..................................................................24
PartsDrawing..............................................24
OutletCheckValvesParts............................27
Dimensions........................................................29
TechnicalSpeci󰘰cations......................................32
GracoStandardWarranty....................................34
Related Related
RelatedManuals Manuals Manuals
Part Part
PartDescription Description Description
3A3165e-XtremeDriverInstallation
3A5124e-XtremeDriverOperation,RepairandParts
311619PumpMountingKitManual
311762XtremeLowerManual
312145XTRGunManual
2
3A3164D

ModelInformation
Model Model
ModelInformation Information Information
Package Package
PackageFilter Filter Filter
Model Model
ModelDescription Description Description
Complete* Complete*
Complete*
(Hose (Hose
(Hoseand and andGun) Gun) Gun)
MaximumFluid
Tempterature:
160°F(71°C)
Bare Bare
Bare
(No (No
(NoHose Hose Hoseor or orGun) Gun) Gun)
MaximumFluid
Temperature:
180°F(82°C)
Integrated Integrated
Integrated
Filter Filter
Filter
No No
No
Filter Filter
Filter
Lower Lower
Lower
Pump Pump
Pump
24Y901*e-XtremeEx45,Cart*✔✔
24Y902e-XtremeEx45,Cart✔✔
24Y903*e-XtremeEx45,Cart✔✔
24Y904e-XtremeEx45,Cart✔✔
24Y905*e-XtremeEx45,Cart
withHopper✔✔
24Y906e-XtremeEx45,Cart
withHopper✔✔
24Y907*e-XtremeEx45,Cart
withHopper✔✔
24Y908e-XtremeEx45,Cart
withHopper✔✔
24Y909*e-XtremeEx45,WallMount✔✔
24Y910e-XtremeEx45,WallMount✔✔
24Y911*e-XtremeEx45,WallMount✔✔
24Y912e-XtremeEx45,WallMount✔✔
145cc
24Z901*e-XtremeEx35,Cart✔✔
24Z902e-XtremeEx35,Cart✔✔
24Z903*e-XtremeEx35,Cart✔✔
24Z904e-XtremeEx35,Cart✔✔
24Z905*e-XtremeEx35,Cart
withHopper✔✔
24Z906e-XtremeEx35,Cart
withHopper✔✔
24Z907*e-XtremeEx35,Cart
withHopper✔✔
24Z908e-XtremeEx35,Cart
withHopper✔✔
24Z909*e-XtremeEx35,WallMount✔✔
24Z910e-XtremeEx35,WallMount✔✔
24Z911*e-XtremeEx35,WallMount✔✔
24Z912e-XtremeEx35,WallMount✔✔
180cc
Formaximumworkingpressure,seeTechnicalSpeci󰘰cations,page32.
*LowerFluidtemperatureduetoXTR5gun.
NOTE: NOTE:
NOTE:Seethee-XtremeDriverInstallationmanualfordriverapprovalsinformation.
3A3164D 3

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING WARNING
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Paint
orsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰reand
explosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticsparking).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Neversprayor󰘱ushsolventathighpressure.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygroundedhoses.
•Holdgun󰘰rmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunless
theyareantistaticorconductive.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock. . .Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
󰘱ammablevapors.Tohelpprevent󰘰reandexplosion.
•Cleanplasticpartsonlyinwellventilatedareas.
•Donotcleanwithadrycloth.
•Donotoperateelectrostaticgunsinequipmentworkarea.
SPECIAL SPECIAL
SPECIALCONDITIONS CONDITIONS CONDITIONSFOR FOR FORSAFE SAFE SAFEUSE USE USE
•Topreventtheriskofelectrostaticsparking,theequipment’snon-metallicpartsshouldbe
cleanedonlywithadampcloth.
•Thealuminumhousingmaysparkuponimpactorcontactwithmovingparts,whichmay
cause󰘰reorexplosion.Takeprecautionstoavoidsuchimpactorcontact.
•All󰘱ameproofjointsarecriticaltotheintegrityofthedriverasapprovedforhazardous
locationsandarenotrepairableifdamaged.Damagedpartsmustbereplacedonlywith
genuineGracopartswithnosubstitutions.
4
3A3164D

Warnings
WARNING WARNING
WARNING
ELECTRIC ELECTRIC
ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcan
causeelectricshock.
•Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesandbefore
servicingorinstallingequipment.
•Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
•Donotexposetorain.Storeindoors.
•Wait󰘰veminutesbeforeservicingafterpowerisremoved.
SKIN SKIN
SKININJECTION INJECTION INJECTIONHAZARD HAZARD HAZARD
High-pressure󰘱uidfromgun,hoseleaks,orrupturedcomponentswillpierceskin.Thismay
looklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get
Getimmediate immediate immediatesurgical surgical surgical
treatment. treatment.
treatment.
•Donotspraywithouttipguardandtriggerguardinstalled.
•Engagetriggerlockwhennotspraying.
•Donotpointgunatanyoneoratanypartofthebody.
•Donotputyourhandoverthespraytip.
•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopsprayingandbeforecleaning,checking,
orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.
MOVING MOVING
MOVINGPARTS PARTS PARTSHAZARD HAZARD HAZARD
Movingpartscanpinch,cutoramputate󰘰ngersandotherbodyparts.
•Keepclearofmovingparts.
•Donotoperateequipmentwithprotectiveguardsorcoversremoved.
•Pressurizedequipmentcanstartwithoutwarning.Beforechecking,moving,orservicing
equipment,followthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedureanddisconnectallpowersources.
BURN BURN
BURNHAZARD HAZARD HAZARD
Equipmentsurfacesand󰘱uidthatisheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhot󰘱uidorequipment.
3A3164D 5

Warnings
WARNING WARNING
WARNING
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMES
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheets(SDSs)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisequipmentincludes
butisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestSafetyDataSheets(SDSs)fromdistributoror
retailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
6 3A3164D

ComponentIdentication
Component Component
ComponentIdenti󰘰cation Identi󰘰cation Identi󰘰cation
Ref. Ref.
Ref.Description Description
Description
AElectricDriver
BPumpLower
CFluidDrain/PurgeValve
DPackingNut
EPowerSwitch
FFluidOutlet
GJunctionBoxCover
HPressureAdjustmentKnob
JOutletCheckValve
LStatusIndicatorLight(LED)
POilFillCap(vented)
SJunctionBox
TFilterCap(modelsequippedwithintegrated
󰘰lteronly)
NOTE: NOTE:
NOTE:Seethee-XtremeDriverOperation/Repair
manualforwarninglabelinformation.
3A3164D
7

Installation
Installation Installation
Installation
Toreducetheriskofelectricshock,󰘰reand
explosion,allelectricalwiringmustbedonebya
quali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
Power Power
PowerSupply Supply SupplyRequirements Requirements Requirements
SeeDriverInstallationmanualforinstructionsfor
powersupplyrequirements.
Connect Connect
Connectthe the thePower Power PowerSupply Supply Supply
SeeDriverInstallationmanualforinstructionsto
connectthepowersupply.
Grounding Grounding
Grounding
Thisequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundingprovidesanescapewireforthe
electriccurrent.
Sprayer: Sprayer:
Sprayer:Systemisgroundedthroughthepower
cord.
Fluid Fluid
Fluidhoses: hoses: hoses:Useonlyelectricallyconductivehoses
withamaximumof210ft.(64m)combinedhose
lengthtoensuregroundingcontinuity.Check
electricalresistanceofhoses.Iftotalresistance
togroundexceeds25megaohms,replacehose
immediately.
Spray Spray
Spraygun: gun: gun:Groundthroughconnectiontoaproperly
grounded󰘱uidhoseandpump.
Fluid Fluid
Fluidsupply supply supplycontainer: container: container:Followlocalcode.
Object Object
Objectbeing being beingsprayed: sprayed: sprayed:Followlocalcode.
Solvent Solvent
Solventpails pails pailsused used usedwhen when when󰘱ushing: 󰘱ushing: 󰘱ushing:Followlocal
code.Useonlyconductivemetalpails,placedon
agroundedsurface.Donotplacethepailona
non-conductivesurface,suchaspaperorcardboard,
whichinterruptsgroundingcontinuity.
To To
Tomaintain maintain maintaingrounding grounding groundingcontinuity continuity continuitywhen when when󰘱ushing 󰘱ushing 󰘱ushingor or or
relieving relieving
relievingpressure: pressure: pressure:Holdthemetalpartofthespray
gun/dispensevalve󰘰rmlytothesideofagrounded
metalpail,thentriggerthegun/valve.
Tools Tools
ToolsRequired: Required: Required:
•Groundingwiresandclampsforpails(Gracopart
244524–notsupplied)
•Two5gallon(19liter)metalpails(Gracopart
101108–notsupplied)
1.Connectthegroundwire(Y)toagroundstudon
thebackofthemotor.
2.Groundtheobjectbeingsprayed,󰘱uidsupply
container,andallotherequipmentinthe
workarea.Followyourlocalcode.Useonly
electricallyconductiveairand󰘱uidhoses.
3.Groundallsolventpails.Useonlymetalpails,
whichareconductive,placedonagrounded
surface.Donotplacepailonanon-conductive
surface,suchaspaperorcardboard,which
interruptsgroundingcontinuity.
8 3A3164D

Installation
Install Install
InstallVented Vented VentedOil Oil OilCap Cap CapBefore Before BeforeUsing Using Using
Equipment Equipment
Equipment
Thedrivergearboxisshippedfromthefactory
pre-󰘰lledwithoil.Thetemporaryunventedcap(PX)
preventsoilleaksduringshipment.Thistemporary
capmustbereplacedwiththesuppliedventedoil
cap(P)beforeuse.
PX
P
ti31010a
Flush Flush
FlushBefore Before BeforeUsing Using UsingEquipment Equipment Equipment
Thepump󰘱uidsectionwastestedwithlightweight
oil,whichisleftinthe󰘱uidpassagestoprotectparts.
Toavoidcontaminatingyour󰘱uidwithoil,󰘱ushthe
equipmentwithacompatiblesolventbeforeusing
theequipment.
SeePrime/Flush,page13.
3A3164D 9

Setup
Setup Setup
Setup
Toavoidtipover,makesurecartisona󰘱atand
levelsurface.Failuretodosocouldresultininjury.
1.Pullpressureadjustmentknob(H)outandturn
counterclockwiseuntilitstops.Pushtheknob
intolock.
2.Turnpowerswitch(E)OFF.Connectunitto
powersource.
OFF
3.Checkpackingnut(D).SeeXtremelowerpump
manual311762forpackingnuttorque.Fillwith
ThroatSealLiquid(TSLTM).
4.Attachelectricallyconductive󰘱uidhosetopump
loweroutletviaoutletcheckvalveandtighten.
NOTICE NOTICE
NOTICE
Attachingthehosedirectlytothelowerpump
canresultindamagetothesprayerduring
cavitation,orwhenthesprayerrunsoutof
material.Useanoutletcheckvalvebetween
thelowerpumpandhosetoavoiddamage.
NOTICE NOTICE
NOTICE
Theminimumhosesizeallowableis3/8in.
IDx50ft(10mmx15m).Smallerhoses
cancausehighpressurespikesandresultin
damagetothesprayer.
5.Attachhosetogunandtighten.
10 3A3164D

Setup
6.Attachmaterialsupplyinlethosetopumplower.
NOTE: NOTE:
NOTE:Maximumsuggestedlengthis6ft(1.8
m),minimumsuggestedinnerdiameteris1in.
(2.5cm).
7.Checkoillevel.
NOTICE NOTICE
NOTICE
OnlyuseoilwithGracopartnumber16W645.
Anyotheroilmaynotlubricateproperlyand
cancausedamagetothedrivetrain.
8.Always󰘱ushandprimesprayerbeforeeachuse
(seePrime/Flush,page13).
3A3164D
11

Setup
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressure
ismanuallyrelieved.Tohelppreventserious
injuryfrompressurized󰘱uid,suchasskininjection,
splashing󰘱uidandmovingparts,followthe
PressureReliefProcedurewhenyoustopspraying
andbeforecleaning,checking,orservicingthe
equipment.
1.Engageguntriggerlock.
2.Pullpressureadjustmentknob(H)outandturn
counterclockwiseuntilitstops.Pushtheknob
intolock.
3.Turnpowerswitch(E)OFF.
OFF
4.Disengageguntriggerlock.
5.Holdgun󰘰rmlyagainstagroundedmetalpail.
Triggerthegun.
6.Engageguntriggerlock.
7.Drain Drain
Drain󰘱uid: 󰘱uid: 󰘱uid:Placethedraintubeinagrounded
wastepail.Slowlyopen󰘱uiddrain/purgevalve
(C),anddrain󰘱uidintoawastepail.
8.Ifyoususpectthespraytiporhoseiscompletely
cloggedorthatpressurehasnotbeenfully
relieved:
a.VERYSLOWLYloosenthetipguard
retainingnutorhoseendcouplingtorelieve
pressuregradually.
b.Loosenthenutorhoseendcoupling
completely.
c.Withtipremoved,triggerthegunintothe
bucket.
Trigger Trigger
TriggerLock Lock Lock
Alwaysengagethetriggerlockwhenyoustop
sprayingtopreventthegunfrombeingtriggered
accidentallybyhandorifdroppedorbumped.
12
3A3164D

Setup
Prime/Flush Prime/Flush
Prime/Flush
Toavoid󰘰reandexplosion,alwaysground
equipmentandwastecontainer.Toavoidstatic
sparkingandinjuryfromsplashing,always󰘱ushat
thelowestpossiblepressure.
1.PerformPressureReliefProcedure,page12.
2.Removetipandtipguardfromgun.
3.Placematerialsupplysuctionhoseinto
compatible󰘱uid(ifpriming)orsolvent(if󰘱ushing).
4.Closedrainvalve.
5.Turnpowerswitch(E)ON.
ON
6.Primeor󰘱ushhoseandgun:
a.Disengageguntriggerlock.
b.Triggergunintogroundedpail.Pullout
pressureadjustmentknob(H)andturn
clockwiseslowlytoincreasepressure,until
asteadystream󰘱owsfromgun.Pushknob
intolock.If󰘱ushing 󰘱ushing
󰘱ushing,triggergununtilclean
solvent󰘱owsfromthegun.
c.Engagetriggerlock.
3A3164D 13

Setup
7.Ifpriming,equipmentisnowreadytospray
(proceedtoSpray,page15).If󰘱ushing,proceed
withstep8.
NOTE: NOTE:
NOTE:Theremainingstepsarefor󰘱ushingonly.
NOTICE NOTICE
NOTICE
Donotprimepumpthroughdrain/purge
valveusingtwocomponentmaterials.Mixed
two-componentmaterialswillhardeninvalve
andresultinclogging.
8.PerformPressureReliefProcedure,page12.
9.Turnpowerswitch(E)ON.
10.Tostartpump,pulloutpressureadjustment
knob(H)andturnclockwiseslowlytoincrease
pressure,untilasteadystream󰘱owsfromdrain
valve.Pushknobintolock.
NOTE: NOTE:
NOTE:Todeterminetheproperamountof
solventand󰘱ushingtime,removetheinlet
valvehousingtoverifyithasbeenfullycleaned,
especiallywhensprayinganewmaterialforthe
󰘰rsttime.
11.Waitforcleansolventto󰘱owfromdraintube.
12.Pullpressureadjustmentknob(H)outandturn
counterclockwiseuntilitstops.Pushtheknob
intolock.
13.Turnthepowerswitch(E)OFF.
14.Checkpumpandgun󰘰lters.
14
3A3164D

Spray
Spray Spray
Spray
NOTICE NOTICE
NOTICE
Donotallowpumptorundry.Itwillquickly
acceleratetoahighspeedcausingdamage.
1.PerformPrime/Flush,page13.
2.PerformPressureReliefProcedure,page12.
3.Installtipandtipguardontogun.Closethedrain
valve.
4.Turnpowerswitch(E)ON.
ON
5.Pulloutandturnpressureadjustmentknob
(H)untildesiredpressureisreached.Turn
clockwisetoincreasepressure,counterclockwise
todecreasepressure.Pushknobintolock.
6.Disengageguntriggerlock.
7.Sprayatestpattern.Read󰘱uidmanufacturer’s
recommendations.Adjustasnecessary.
NOTE: NOTE:
NOTE:Whendeterminingthedesiredspray
pressure,alwaysincreasethespraypressure
untilthespraypatternfullydevelops.Thiswill
reducethepressuresurgewhenthepumpis
stalledandminimizeover-spray.
Dynamic Dynamic
DynamicPump Pump PumpOutlet Outlet OutletPressure Pressure Pressure
Ex35 Ex35
Ex35Ex45 Ex45
Ex45
Pressure Pressure
Pressure
Adjust- Adjust-
Adjust-
ment ment
mentKnob Knob Knob
Setting Setting
SettingPSI PSI
PSIBar Bar
BarMPa MPa MPaPSI PSI
PSIBar Bar
BarMPA MPA MPA
132022.02.2040027.02.70
264044.04.4080054.05.40
396066.06.60120081.08.10
4128088.08.80160010810.8
5160011011.0200013513.5
6192013213.2240016216.2
7224015415.4280018918.9
8256017617.6320021621.6
9288019819.8360024324.3
10320022022.0400027027.0
8.Flushwhen󰘰nishedspraying.
PerformPrime/Flush,page13and
PressureReliefProcedure,page12.
3A3164D 15

Shutdown
Shutdown Shutdown
Shutdown
NOTICE NOTICE
NOTICE
Neverleavewaterorwater-based󰘱uidinpump
overnight.Ifwater-base󰘱uidhasbeenused,󰘱ush
withwater󰘰rst,thenwitharustinhibitor(suchas
mineralspirits).Relievepressure,butleaverust
inhibitorinpumptoprotectpartsfromcorrosion.
Toshutdown:
1.PerformPrime/Flush,page13.
2.PerformPressureReliefProcedure,page12.
Maintenance Maintenance
Maintenance
NOTICE NOTICE
NOTICE
Donotopen/removegearcover.Thegearside
isnotintendedtobeserviced.Openingthegear
covermayalterthefactorysetbearingpre-load
andmayreducetheproductlife.
Preventive Preventive
PreventiveMaintenance Maintenance MaintenanceSchedule Schedule Schedule
Theoperatingconditionsofyourparticularsystem
determinehowoftenmaintenanceisrequired.
Establishapreventivemaintenancescheduleby
recordingwhenandwhatkindofmaintenanceis
needed,andthendeterminearegularschedulefor
checkingyoursystem.
Change Change
Changethe the theOil Oil Oil
NOTE: NOTE:
NOTE:Changetheoilafterabreak-inperiodof
200,000–300,000cycles.Afterthebreak-inperiod,
changetheoilonceayear.
1.Placeaminimum2quart(1.9liter)container
undertheoildrainport.Removetheoildrain
plug.Allowalloiltodrainfromthedriver.
2.Reinstalltheoildrainplug.Torqueto18–23ft-lb
(25–30N•m).
NOTICE NOTICE
NOTICE
Donotover-torque.Thedrainplugcan
becomestrippedanddamaged.
3.Opentheoil󰘰llcap(P)andaddGracoPartNo.
16W645silicone-freeISO220syntheticEPgear
oil.Checktheoillevelinthesightglass(K).Fill
untiltheoillevelisnearthehalfwaypointofthe
sightglass.Theoilcapacityisapproximately
1.0–1.2quarts(0.9–1.1liters).Do Do
Donot not notover󰘰ll. over󰘰ll. over󰘰ll.
NOTICE NOTICE
NOTICE
OnlyuseoilwithGracopartnumber16W645.
Anyotheroilmaynotlubricateproperlyand
cancausedamagetothedrivetrain.
4.Reinstalltheoil󰘰llcap(P).
Daily Daily
DailyMaintenance Maintenance Maintenance
NOTE: NOTE:
NOTE:Forovernightshutdown,stoppumpatbottom
ofitsstroketoprevent󰘱uidfromdryingonexposed
displacementrodanddamagingthroatpackings.
PerformPressureReliefProcedure,page12.
1.PerformPrime/Flush,page13.
2.PerformPressureReliefProcedure,page12.
3.Checkpackingnut(D).Adjustpackingsand
replaceTSLasnecessary.Seelowerpump
manual311762forpackingnuttoque.
4.Checkhoses,tubes,andcouplings.tightenall
󰘱uidconnectionsbeforeeachuse.
16 3A3164D

Maintenance
Check Check
CheckOil Oil OilLevel Level Level
Checktheoillevelinthesightglass(K).Theoillevel
shouldbenearthehalfwaypointofthesightglass
whenthesprayerisnotrunning.Ifoilislow,open
the󰘰llcap(P)andaddGracoPartNo.16W645
silicone-freeISO220syntheticEPgearoil.
Theoilcapacityisapproximately1.0–1.2quarts
(0.9–1.1liters).Do Do
Donot not notover󰘰ll. over󰘰ll. over󰘰ll.
NOTE: NOTE:
NOTE:Thedrivergearboxisshippedfromthe
factorypre-󰘰lledwithoil.Thetemporaryunvented
cap(PX)preventsoilleaksduringshipment.This
temporarycapmustbereplacedwiththesupplied
ventedoilcap(P)beforeuse.
NOTICE NOTICE
NOTICE
OnlyuseoilwithGracopartnumber16W645.Any
otheroilmayreducethelifeofthegears.
Corrosion Corrosion
CorrosionProtection Protection Protection
Always󰘱ushthepumpbefore󰘱uiddrieson
thedisplacementrod.Neverleavewateror
water-based󰘱uidinthepumpovernight.First,
󰘱ushwithwateroracompatiblesolvent,thenwith
arustinhibitor,suchasmineralspirits.Perform
PressureReliefProcedure,page12,butleaverust
inhibitorinpumptoprotectpartsfromcorrosion.
Flushing Flushing
Flushing
•Flushbeforechanging󰘱uids,before󰘱uidcancure
intheequipment,attheendoftheday,before
storing,andbeforerepairingequipment.
•Flushatthelowestpressurepossible.Check
connectorsforleaksandtightenasnecessary.
•Flushwitha󰘱uidthatiscompatiblewiththe󰘱uid
beingdispensedandtheequipmentwettedparts.
Cart Cart
CartMaintenance Maintenance Maintenance
PeriodicallylubricatetheaxlebetweenpointsAand
Bwithlightweightoil(seebelow).
Keepthecartcleanbywipingupspillsdaily,usinga
compatiblesolvent.
3A3164D
17

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
NOTE: NOTE:
NOTE:Checkallpossibleremediesbefore
disassemblingpump.
NOTE: NOTE:
NOTE:Thestatusindicator(L)onthedriverwillblink
ifanerrorisdetected.
Problem Problem
ProblemCause Cause
CauseSolution Solution Solution
Exhausted󰘱uidsupplyRe󰘰llandprimethepump.
Clogged󰘱uidoutletline,gun*,
etc.;thehoseinnerdiameter
istoosmall
Clearthehose,outletcheckvalve,orgun;use
thehosewiththelargerinnerdiameter.
Pumpoutputlowon
bothstrokes
WornpistonpackingReplace.Seethepumplowermanual.
Improperlyinstalledintakeor
pistoncheckvalves
Checkandrepair.Seepumpthelowermanual.
Theintakevalveisclogged.Cleantheintakevalve.
Nooutput
Exhausted󰘱uidsupplyRe󰘰llandprimethepump.
Exhausted󰘱uidsupplyRe󰘰llandprimethepump.
Clogged󰘱uidhoseorgun*Cleanthehoseorgun.
FluiddriedonthepistonrodDisassembleandcleanthepump(seethelower
manual).Inthefuture,stopthepumpatthe
bottomofthestroke.Keepthewet-cup󰘰lled
withcompatiblesolvent.
Pumpwillnotoperate
Driverpartsarewornor
damaged
Repairorreplacethedriver.Removethelower
fromthedriver.Ifthedriverwillnotcycleand
doesnotblinkanerrorcode,thentroubleshoot
thedriverorreplace.
Fluidisleakingfromthe
rupturedisk
Replacetherupturedisk;donotreplacewitha
pipeplug.
Theintakevalveisclogged.Cleantheintakevalve.
NoPressureorFlow
LeakingdrainvalveCloseorreplacethedrainvalve.
Overvoltage(over300V)SeepowersupplyrequirementsintheDriver
Installationmanual.
Driverdoesnotturnon
Nopowertothecontrolboard.Verifythatthepowersupplyisconnected.
checkthejunctionboxconnections.
Outputlowondown
stroke
OpenorwornintakevalveClearorservicetheintakevalve.
OutputlowonupstrokeOpenorwornpistonvalve
packings
Clearthepistonvalve.Replacethepackings.
18 3A3164D

Troubleshooting
Problem Problem
ProblemCause Cause
CauseSolution Solution Solution
FluidsupplyisexhaustedRe󰘰llthe󰘱uidsupplyandprimethepump.
CloggedsuctionCleanthesuctiontube.
Openorwornpistonvalve
packings
Clearthepistonvalve.Replacethepackings.
OpenorwornintakevalveClearorservicetheintakevalve.
Cloggedgun,hose,outlet,
etc.
Clearthegun,hose,outlet,etc.
Erraticoraccelerated
pumpspeed
Openorwornoutletcheck
valve
Clearorservicetheoutletcheckvalve.
Cyclesorfailstohold
pressureatstall
Wornintakeorpistonvalveor
seals
Servicethepumplower(seeLowermanual
311762).
LoosesuctionlineTightensuctionlineconnections.Use
compatibleliquidthreadsealantorPTFEtape
onconnections.
Agitator/mixerisnot
submerged
Submergetheagitator/mixer.
Airbubblesin󰘱uid
Agitator/mixerRPMistoohighLowertheagitator/mixerRPM.
Incorrect󰘱uidpressureatgunSeethegunmanual.Readthe󰘱uid
manufacturer’srecommendations.
FluidistoothinortoothickAdjustthe󰘱uidviscosity.Readthe󰘱uid
manufacturer’srecommendations.
Poor󰘰nishorirregular
spraypattern
Dirty,worn,ordamagedspray
gun
Servicethespraygun(seespraygunmanual).
Overvoltage(greaterthan
300V)
Checkthepowersupply.
Driverdoesnotturn
overandLEDisoff
NopowertothecontrolboardContactyourGracodistributororTechService
formoreinformation.
Driverdoesnotturn
overandLEDison
EncoderfaultCyclepower.
Recalibratetheencoderfollowingtheprocedure
listedinthee-XtremeDriverOperation/Repair
manual.
ContactyourGracodistributororTechService
formoreinformation.
Oilwasover-󰘰lledDrainandre󰘰lloilasstatedin
CheckOilLevel,page17.
Drainplugisnottightened
properly
Torqueto18–23ft-lb(25–30N•m).
Oilisleaking
Sealcartridgeo-ringmissing
ordamaged
Replacetheshaftbearingassembly.
* To determine if the 󰘱uid hose or gun is obstructed, follow the Pressure Relief Procedure , page 12 . Disconnect
󰘱uid hose and place a container at pump 󰘱uid outlet to catch any 󰘱uid. Turn pressure adjustment knob just
enough to start the pump. If the pump starts, the obstruction is in the 󰘱uid hose or gun.
3A3164D 19

Troubleshooting
Error Error
ErrorCode Code CodeTroubleshooting Troubleshooting Troubleshooting
Errorcodescantaketwoforms:
•Alarm: Alarm:
Alarm:Alertsyoutothecauseofthealarmand
shutsdownthedriver.
•Deviation: Deviation:
Deviation:Alertsyoutotheproblem,butthedriver
maycontinuetorunpastthesetlimitsuntilthe
systemabsolutelimitsarereached.
NOTE: NOTE:
NOTE:Theblinkcodeisdisplayedusingthestatus
indicator(L)onthedriver.Theblinkcodegivenbelow
indicatesthesequence.Forexample,blinkcode2
indicatestwoblinks,apause,andthenrepeats.
NOTE: NOTE:
NOTE:Toclearanerrorcode,󰘰rsttryturningthe
pressureadjustmentknob(H)counterclockwiseuntil
itstops.Ifthestatusindicator(L)doesnotstop
blinkingshortlyafterturningtheknobtozero,cycle
thepowerbyturningthepowerswitch(E)totheOFF
positionforatleast30secondsbeforeturningback
ON.
Standby Standby
StandbyMode Mode Mode
Whenslowblinkingisdisplayed,thedriverhas
enteredStandbyMode.Thedriverwillenterstandby
modewhenpoweredonandpressurizedwithaknob
settinggreaterthan7,andthepumphasnotmoved
anymaterialfor30minutes.
StandbyModewillbeexitedwhen:
•Materialstartstodispenseandcausesthepump
tomove,OR
•Thepressurecontrolknob(H)isadjusted,OR
•Thepowerswitch(E)iscycledOFFandON
Error Error
ErrorCodes Codes CodesTable Table Table
Blink Blink
BlinkCode Code CodeError Error
ErrorType Type TypeTroubleshooting Troubleshooting
TroubleshootingSteps Steps Steps
1AlarmPump Pump
Pumpdiving diving diving
Thepumpisdivingrapidly.Apressureimbalancebetweentheupanddown
strokeofthepumpiscausingthepumptodivewithexcessivespeed.
•Pumpdivingmayoccurwhenthepumprunsoutofmaterialwhilespraying
athighpressure.
•Verifythatmaterialisbeingproperlyfedtothepump.
•Pressurefromthehosecould󰘱owbackintothepumponthedownstroke.
•Verifythatthecheckvalveisinstalledandisproperlyworking.
2AlarmVoltage Voltage
VoltageToo Too TooLow Low Low
•Verifythatlinevoltageiswithintherangespeci󰘰edin
TechnicalSpeci󰘰cations,page32.
•UsetherecommendedcordinPowerSupplyRequirements,page8.
•Cyclepowerandcheckstatusindicator(L)toseeiftheerrorisstillactive.
3AlarmVoltage Voltage
VoltageToo Too TooHigh High High
•Verifythatlinevoltageiswithintherangespeci󰘰edin
TechnicalSpeci󰘰cations,page32.
•Cyclepowerandcheckstatusindicator(L)toseeiftheerrorisstillactive.
4DeviationHigh High
HighTemperature Temperature Temperature
Thetemperatureofthesystemisnearthemaximumoperationtemperature.The
performancehasbeenreducedtopreventthedriverfromcompletelyshutting
down.
•Reducepressure.
•Movetheunittoacoolerlocation.
20 3A3164D