Graco Xtreme XL Packages 334645B Operation manual

Instructions-Parts
Xtreme® XL Packages 334645B
EN
High performance, high pressure spray packages for applying protective coatings. For professional use
only.
Important Safety Instructions
Read all warnings and instructions in this manual and in related
manuals. Save these instructions.
See Models on page 6 for maximum
working pressures.
PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Related Manuals ................................................ 3
Warnings ........................................................... 4
Sprayer Packages .............................................. 7
Heavy Fluids Sprayer Packages ...................
Pump Packages .................................................
Component Identification - Cart Mount ................. 9
Component Identification - Wall Mount................. 10
System Components........................................... 11
Grounding.......................................................... 11
Install Wall Mount Assembly................................ 12
Install Hopper Assembly...................................... 12
Setup................................................................. 13
Pressure Relief Procedure .................................. 14
Flush ................................................................. 15
Prime................................................................. 17
Spray................................................................. 19
Shutdown........................................................... 19
Maintenance ...................................................... 20
Preventative Maintenance Schedule ............. 20
Daily Maintenance ....................................... 20
Corrosion Protection .................................... 20
Cart Maintenance......................................... 20
Troubleshooting.................................................. 21
Remove Lower................................................... 22
Disconnect and Reconnect Lower................. 22
Parts.................................................................. 23
Dimensions........................................................ 34
Performance Charts............................................ 36
Technical Specifications...................................... 39
Graco Standard Warranty.................................... 40
2334645B

Related Manuals
Related Manuals
Manual Description
334644 Xtreme XL Air Motor, Instructions-Parts
3A0293 Air Controls, Instructions-Parts
311 25 Dura-Flo™ Lowers, Instructions-parts
311762 Xtreme® Lowers, Instructions-Parts
311164 NXT® Xtreme Packages, Instructions-
Parts
334645B 3

Warnings
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
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in wor area canigniteorexplode.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.
4334645B

Warnings
WARNING
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.
•Followthe 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.
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 Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
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.
334645B 5

Warnings
WARNING
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.
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. 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.
6334645B

Sprayer Packages
Sprayer Packages
Check your sprayer or wall mount package’s
identification plate (ID) on the side of the shelf
mounting bracket for the 6 digit part number of
your package. Use the following matrix to define
the construction of your package, based on the six
digits. For example, Sprayer Part Number XL 45 H
3 represents the Xtreme XL brand ( XL ), pressure
ratio ( 45 :1), on a heavy duty cart ( H ), and complete
package (gun, hose, and pump filter included) ( 3 ). To
order replacement parts, see Parts, page 23.
Note
All packages include 1 in. air controls consisting of inlet claw fittings, 40 micron filter/regulator,
relieving ball valve, and motor hose.
Approvals:
II 2 G c 230°C (T2)
Maximum Air Wor ing Pressure:
Never exceed the maximum air WPR listed on your model ID plate. This is the maximum set point on regulator
(G) which is read on gauge (E).
Pressure Ratio Maximum Air WPR Maximum Fluid WPR
XL 45 95 psi (0.65 MPa, 6.5 bar) 4500 psi (31 MPa, 310 bar)
XL 70 100psi(0.7MPa,7bar) 7100psi(4 MPa,4 9bar)
XL 0 psi (0.6 MPa, 6 bar) 7250 psi (50 MPa, 500 bar)
XL 95 76 psi (0.5 MPa, 5 bar) 7250 psi (50 MPa, 500 bar)
XL 45 H 3
Third and
Fourth Digit Fifth Digit Sixth DigitFirst and Second Digit Pressure Ratio
(xx:1) Mount Option With Hose
and Gun Hopper Filter
45* HHeavy Duty Cart 1
✔
70 W Wall Mount 2
✔✔
03
✔✔✔
XL
95 4NANANA
* Uses a Dura-Flo lower.
334645B 7

Pump Packages
Heavy Fluids Sprayer Packages
Packages include a hopper, no fluid filter, 3/4 in outlet
check valve, 3/4 in x 50 ft. (15 m) hose, 1/2 in x 25 ft
(7.6 m) whip and XHF spray gun with 429 tip
24X593 - 70:1
24X594 - 80:1
Note
Heavy-fluid materials vary and should be
tested with a qualified distributor. Material
should be pourable and self-leveling.
Pump Packages
Check your pump package’s identification plate (ID),
attached to the black motor shroud, for the 6-digit part
number of your pump package. For example, Pump
Part Number PL 45 C 2 represents the pump ( PL ),
pressure ratio ( 45 :1), carbon steel construction ( C ),
and no built-in filter or air controls ( 2 ).
To order replacement parts, see Pump Package Parts.
Pressure Ratio Maximum Air WPR Maximum Fluid WPR
PL 45 95 psi (0.65 MPa, 6.5 bar) 4500 psi (31 MPa, 310 bar)
PL 70 100 psi (0.7 MPa, 7 bar) 7100 psi (4 MPa, 4 9 bar)
PL 0 psi (0.6 MPa, 6 bar) 7250 psi (50 MPa, 500 bar)
PL 95 76 psi (0.5 MPa, 5 bar) 7250 psi (50 MPa, 500 bar)
PL 45 C2
Third and Fourth Digit Fifth Digit Sixth Digit
First and Second Digit
Pressure Ratio
(xx:1) Lower Construction Built-in Filter
45 C Carbon Steel 1
✔
70 2 NA
0
PL
95
Approvals:
II 2 G c 230°C (T2)
334645B

Component Identification - Cart Mount
Component Identification
- Cart Mount
Figure 1 Airless Sprayer
Key:
AAir Inlet, 1 in npt(f) on claw fitting
BBleedTypeMasterAirValve(required)
C Air Pressure Relief Valve
DAir Filter / Water Separator
EAir Pressure Gauge
F Packing Nut
GAir Regulator Adjustment
HAirMotor
JFluid Drain/Purge Valve (required)
KFluid Filter (if equipped)
LGrounding Wire (required)
MPump
NSuctionHoseandTube(ifequipped)
PPump Fluid Outlet
ROptional Fluid Outlet, for second spray gun
S Spray Gun
TDe-Ice Control (Bleed Air)
UHopper (if equipped)
WFluidHose
334645B 9

Component Identification - Wall Mount
Component Identification
- Wall Mount
Figure 2 Airless Sprayer
Key:
AAir Inlet, 1 in npt(f) on claw fitting
BBleed Type Master Air Valve (required)
C Air Pressure Relief Valve
DAir Filter / Water Spearator
EAir Pressure Gauge
F Packing Nut
GAir Regulator Adjustment
HAirMotor
JFluid Drain/Purge Valve (required)
KFluid Filter (if equipped)
LGrounding Wire (required)
MPump
NSuctionHoseandTube
PFluid Outlet
S Spray Gun
TDe-Ice Control (Bleed Air)
WFluidHose
10 334645B

System Components
System Components
Note
* Required system components.
*B
leed Type Master Air Valve (B)
Trapped air can cause the pump to cycle
unexpectedly, which could result in serious injury
from splashing or moving parts.
• Be sure the valve is easily accessible from the
pump and located downstream from the air
regulator.
• Required in your system to relieve air trapped
between it and the air motor when the valve is
closed.
— Open the valve to supply air to the motor.
— Close the valve to shut off air to the motor, and
bleed any trapped air from the motor.
* Air Pressure Relief Valve (C)
Automatically opens to relieve air pressure if supplied
pressure exceeds preset limit.
* Air Filter ( )
Removes harmful dirt from compressed air supply. A
minimum 40 micron filter is used.
Air Regulator Adjustment (G)
Adjusts air pressure to the motor and fluid outlet
pressure of pump. Locate it close to the pump. Read
air pressure on gauge (E).
* Fluid rain/Purge Valve (J)
Open valve to relieve pressure and when flushing or
priming pump. Close valve when spraying.
e-Ice Contol (T)
Turn bleed air knob (open) to reduce icing.
Grounding
The equipment must be grounded to reduce the risk
of static sparking. Static sparking can cause fumes
to ignite or explode. Grounding provides an escape
wire for the electric current.
Tools Required:
• Grounding wires and clamps for pails
• Two 5 gal. (19 liter) metal pails
1. Connect the ground wire (244524) (L) to the
ground studontheairmotor.
Figure 3
2. Connect the other end of the ground wire to a
true earth ground.
3. 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.
4. Ground all solvent pails. Use only metal pails,
which are conductive, placed on a grounded
surface. Do not place pail on a nonconductive
surface, such as paper or cardboard, which
interrupts grounding continuity.
334645B 11

Install Wall Mount Assembly
Install Wall Mount
ssembly
Note
Before mounting any pump assembly
to the wall always follow the
Pressure Relief Procedure, page 14.
1. Ensure the wall is strong enough to support the
weight of the pump assembly and accessories,
fluid, hoses, and stress caused during pump
operation.
2. Drill four 7/16 in. (11 mm) holes using
bracket as a template. Use any of the three
mounting hole groupings in the bracket. See
Dimensions, page 34.
3. Bolt bracket securely to wall using bolts
and washers designed to hold in the wall’s
construction.
4. Attach pump assembly to mounting bracket
(201).
5. Connect air and fluid hoses. Refer to
Setup, page 13.
Install Hopper ssembly
Note
If provided.
1. If necessary remove suction hose.
a. Disconnect suction hose (1 ).
b. Disconnect fitting (4) and quick disconnect
adapter (19) from the pump.
2. Attach bracket (30) to the cart (9) with nuts (16)
and screws (15).
3. Loosely attach bracket (29) to bracket (30) with
nuts (16) and screws (15).
4. Install elbow (4) and fitting ( ) on the pump.
5. Install fitting (32) and fitting (5) on hopper (7).
6. Connect fitting (5) to fitting ( ). Adjust bracket
(29) height to fit under the lip on the back of the
hopper (7). Tighten nuts (16).
12 334645B

Setup
Setup
To avoid tip over, ensure cart is on a flat and level
surface. Failure to do so could result in injury or
equipment damage.
Tools Required:
• Two adjustable wrenches
• Non-sparking hammer or plastic mallet
• Torque wrench
1. Ground sprayer. See Grounding, page 11.
2. Check packing nut (F). Fill with Throat Seal
Liquid (TSL). Torque to 25-30 ft-lb (34-41 N•m).
3. Attach electrically conductive fluid hose to pump
outlet and tighten.
4. Attach electrically conductive fluid hose (and
air hose if using an AA gun) to gun and tighten.
Check that all pressure connections are tight.
5. Close bleed type master air valve (B). Connect
air supply hose to 1 in npt(f) air inlet (A).
6. Flush and prime before using. See
Flush, page 15,andPrime, page 17.
334645B 13

Pressure Relief Procedure
Pressure Relief Procedure
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
equipment.
1. Engage gun trigger lock.
2. Close bleed type master air valve (B).
3. Disengage gun trigger lock.
Note
If using an AA gun, turn gun air regulator
counter-clockwise to relieve pressure.
4. Hold gun firmly against a grounded metal pail.
Trigger the gun until pressure is relieved.
5. Engage trigger lock.
6. Drain fluid. To drain fluid, slowly open all fluid
drain valves, including drain/purge valve (J), in
system into a waste pail. If there is a return tube,
open return line ball valve. Close valve after fluid
is drained.
Left: Xtreme Lower Right: Dura-Flo Lower
7. If you suspect the spray tip or hose is clogged or
that pressure has not been fully relieved.
a. VERY SLOWLY loosen tip guard retaining
nut or hose end coupling to relieve pressure
gradually.
b. Loosen nut or coupling completely.
c. Clear hose or tip obstruction.
14 334645B

Flush
Flush
To avoid fire and explosion, always ground
equipment and waste container. To avoid static
sparking and injury from splashing, always flush at
lower possible pressure.
Flush the pump:
•Beforefirstuse
• When changing colors or fluids
• Before repairing equipment
• Before fluid dries or settles out in a dormant pump
(check the pot life of catalyized fluids)
• At the end of the day
• Before storing the pump
Flush at the lowest pressure possible. Flush with a
fluid that is compatible with the fluid you are pumping
and with the wetted parts in your system. Check with
your fluid manufacturer or supplier for recommended
flushing fluids and flushing frequency.
1. Follow Pressure Relief Procedure, page 14.
2. Remove tip and tip guard from gun.
3. If desired, remove fluid filter. Reinstall filter cap
after removing fluid filter.
4. Place suction tube in a compatible solvent.
Note
Do not stretch hose tight’ let it hang to
assist fluid flow into the pump.
5. Turn regulator adjustment knob (G)
counterclockwise until it stops, and gauge
(E) reads zero.
6. Open bleed type master valve (B).
7. Flush hose and gun:
a. Disengage gun trigger lock. Hold the gun
against a grounded metal pail.
334645B 15

Flush
b. Trigger gun, slowly open regulator
adjustment knob (G) until pump beings to
cycle and a steady stream comes from gun.
Trigger gun for 10-15 seconds.
Note
If using an AA gun, increase air
pressure by turning gun regulator
clockwise.
c. After solvent is running clean, turn the
regulator adjustment knob (G) counter
clockwise until it stops and the gauge reads
zero. The pump will stop. Once the material
stops flowing, release the trigger and engage
thetriggerlock.Stopthepumpwiththerod
buried in the pump.
d. Close the bleed type master air valve.
. If flushing through drain/purge valve:
a. Place drain tube in a grounded waste pail.
Open drain/purge valve (J) slightly by rotating
counterclockwise.
Left: Xtreme Lower Right: Dura-Flo
Lower
b. Start the pump by rotating the air regulator
adjustment knob (G) clockwise until pump
begins to move.
c. When clean solvent flows from drain tube
close drain/purge valve (J) by rotating
clockwise. Pump will stall.
Left: Xtreme Lower Right: Dura-Flo
Lower
d. Stop the pump with the rod buried in the
pump.
e. Follow Pressure Relief Procedure, page 14.
Leave solvent in and store sprayer.
9. Remove fluid filter and soak in solvent. Replace
filter cap.
16 334645B

Prime
Prime
1. Follow Pressure Relief Procedure, page 14.
2. Lock gun trigger. Remove tip and tip guard from
gun.
3. Place suction tube in the material that will be
sprayed.
Note
Do not stretch hose tight let it hang to
assist fluid flow into the pump.
4. Turn regulator adjustment knob (G)
counterclockwise until it stops, and gauge
(E) reads zero.
5. Open bleed type master valve (B).
6. Prime through drain valve if necessary.
Note
Usually 1K high viscosity materials.
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.
a. Place drain tube in a grounded waste pail.
Open drain/purge valve (J) slightly by rotating
counterclockwise.
Left: Xtreme Lower Right: Dura-Flo
Lower
334645B 17

Prime
b. Start the pump by rotating the air regulator
adjustment knob (G) clockwise until pump
begins to move.
7. Prime hose and gun:
a. Disengage gun trigger lock. Hold the gun
against a grounded metal pail.
b. Trigger gun, slowly open regulator
adjustment knob (G) until pump beings to
cycle and a steady stream comes from gun.
Trigger gun for 10-15 seconds.
Note
If using an AA gun, increase air
pressure by turning gun regulator
clockwise.
c. Engage trigger lock.
. The equipment is now ready to spray; go to
Spray, page 19.
1 334645B

Spray
Spray
NOTICE
Do not allow pump to run dry. It will quickly
accelerate to a high speed causing damage.
1. Prime. See Prime, page 17.
2. Follow Pressure Relief Procedure, page 14.
3. Install tip and tip guard on gun.
4. Open bleed type master air valve (B).
5. Turn regulator adjustment knob (G) until gauge
(E) reads desired pressure. Turn clockwise to
increase pressure, counterclockwise to decrease
pressure.
6. Disengage gun trigger lock.
7. Spray a test pattern. Read fluid manufacturer’s
recommendations. Adjust pressure as
necessary. If using an AA gun, increase gun air
pressure while testing spray pattern.
. Flush when done spraying. See Flush, page 15.
9. Follow Pressure Relief Procedure, page 14.
Shutdown
NOTICE
Never leave water or water-base fluid in pump over
night. If you are pumping water-base fluid, flush
with waterfirst,thenwitharustinhibitor,suchas
mineral spirits. Relieve pressure, but leave rust
inhibitor in pump to protect parts from corrosion.
Follow Pressure Relief Procedure, page 14.
Always flush the pump before the fluid dries on the
displacement pump rod. See Flush, page 15.
334645B 19

Maintenance
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.
aily Maintenance
Note
For over night shutdown, stop pump at
bottom of its stroke to prevent fluid from
drying on exposed displacement rod
and damaging throat packings. Follow
Pressure Relief Procedure, page 14.
1. Flush. See Flush, page 15.
2. Relieve pressure. See
Pressure Relief Procedure, page 14.
3. Check packing nut (S ). Adjust packings and
replace TSL as necessary. Torque to 25-30 ft-lb
(34-41 N•m).
4. Drain water from air filter.
5. Clean suction tube using a compatible solvent.
It is recommended that you clean the outside of
the sprayer using a cloth and compatible solvent.
6. Check hoses, tubes, and couplings. Tighten all
fluid connections before each use.
7. Cleanfluidlinefilter.
Corrosion Protection
Always flush the pump before the 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 mineral spirits.
Relieve the pressure, but leave the mineral spirits in
the pump to protect the parts from corrosion.
Cart Maintenance
Periodically lubricate the axle between points A and
B with lightweight oil.
Keep the cart clean by wiping up spills daily, using a
compatible solvent
20 334645B