Graco 333208A, Electric High Pressure Airless Sprayer Owner's Manual

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Graco 333208A, Electric High Pressure Airless Sprayer Owner's Manual | Manualzz

Operation-Repair-Parts

Electric High Pressure

Airless Sprayer

Electric high pressure sprayer packages for application of protective coatings.

For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

333208A

EN

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

For Model Information and maximum working pressure,

see page 2.

WLE

2

Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Component Identification - Cart Mount . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Connect Power . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fill With Oil Before Using Equipment . . . . . . . . . 8

Flush Before Using Equipment . . . . . . . . . . . . . . 8

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 10

Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Prime/Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Preventative Maintenance Schedule . . . . . . . . 13

Change the Oil . . . . . . . . . . . . . . . . . . . . . . . . . 13

Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . 13

Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . 13

Corrosion Protection . . . . . . . . . . . . . . . . . . . . . 13

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Cart Maintenance . . . . . . . . . . . . . . . . . . . . . . . 14

Model Information

Model Description Maximum Working Pressure

24X450 Includes hose and gun 4500 psi (31 MPa, 310 bar)

24X451 No hose or gun 4500 psi (31 MPa, 310 bar)

24W315 Includes hose and gun 2600 psi (18 MPa, 180 bar)

24W316 No hose or gun 2600 psi (18 MPa, 180 bar)

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Xtreme Lower Removal . . . . . . . . . . . . . . . . . . . 19

Disconnect and Reconnect Lower . . . . . . . . . . . 19

Outlet Check Valves . . . . . . . . . . . . . . . . . . . . . 20

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Parts List - Sprayer . . . . . . . . . . . . . . . . . . . . . . 23

Outlet Check Valve . . . . . . . . . . . . . . . . . . . . . . 24

Parts List - Outlet Check Valve . . . . . . . . . . . . . 24

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 26

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 26

Related Manuals

Manuals are available at www.graco.com.

Component manuals in English:

311762 Xtreme Lower Manual

312145 XTR Gun Manual

333233 Electric Driver Manual

333208A

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

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock .

Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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.

333208A 3

4

Warnings

WARNING

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.

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. This protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

333208A

Component Identification - Cart Mount

Component Identification - Cart Mount

A Electric Driver

B Lower

C Fluid Drain/Purge Valve

D Packing Nut

E Power Switch

F Fluid Outlet

G Junction Box Cover

H Pressure Adjustment Knob

I Outlet Check Valve

L Red Indicator Light

S Junction Box

S

H

A

G

D

L

E

C

B

WLE

I

F IG . 1: Airless Sprayer

F

333208A 5

6

Installation

Installation

Improper wiring may cause electric shock or other serious injury. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

Power Supply

See Table 1 for power supply requirements. The system requires a dedicated circuit protected with a circuit breaker.

Table 1: Power Supply Specifications

Voltage Phase Hz Current

200-240 VAC 1 50/60 20 A

Select the minimum cord wire gauge based on length according to the table below:

Length

50 ft (15.24 m)

100 ft (30.48 m)

200 ft (60.96 m)

300 ft (91.44 m)

Gauge

12 AWG

10 AWG

6 AWG

4 AWG mm

2

3.31

5.26

13.29

21.14

2.

Bring cord to unit and remove two screws to separate junction box cover (G) and power switch (E)

from remainder of sprayer. See F

IG

. 3.

2))

S

G

E

WLD

F IG . 3: Power Switch

3.

With power switch (E) and junction box cover (G) detached from machine, wires inside junction will appear as below.

NOTE: Two wires will be installed in both terminals

1L1 and 3L2. See F IG . 4.

NOTE: Press gasket against back sealing face of junction box cover to ease installation of power cord.

7

7

7

/

/

/

Connect Power

1.

Cut power cord wires to the following lengths:

• Ground wire - 6.5 inches (16.5 cm)

• Power wires - 3.0 inches (7.6 cm)

• Add ferrules as necessary. See F IG . 2.

WLE

C2

F IG . 4: Terminal Connections

4.

Insert power cord (from step 1) through cord grip

(C2) and into junction box (S).

5.

Attach power wires to terminals 2T1 and 4T2.

6.

Attach ground wire to ground terminal inside junction box (S). NOTE: The power cord attaches to a separate ground screw than the ground screw that is already attached.

LQ

POWER

F IG . 2: Power Cord

LQ

GROUND

WLD ti23132b

333208A

Installation

7.

Place fan wires and other power wires into open area on either side of disconnect block (J) as space

permits. Reinstall junction box cover. See F

IG

. 5.

NOTICE

If wires get pinched when the screws are tightened, damage will occur. Make sure all wires are routed correctly before installation.

G

E

J

WLD

F

IG

. 5: Grounding Wire

8.

Replace junction box screws and washers removed in step 2 and tighten cord grip to securely hold

power cord in junction box (S). See F

IG

. 6.

Grounding

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.

Sprayer: system is grounded through the power cord.

Fluid hoses: use only electrically conductive hoses with a maximum of 210 ft. (64 m) combined hose length to ensure grounding continuity. Check electrical resistance of hoses. If total resistance to ground exceeds 25 mega ohms, replace hose immediately.

Spray gun: ground through connection to a properly grounded fluid hose and pump.

Fluid supply container: follow local code.

Object being sprayed: follow local code.

Solvent pails used when flushing: follow local code.

Use only conductive metal pails, placed on a grounded surface. Do not place the pail on a non-conductive surface, such as paper or cardboard, which interrupts grounding continuity.

To maintain grounding continuity when flushing or relieving pressure: hold metal part of the spray gun/dispense valve firmly to the side of a grounded metal pail, then trigger the gun/valve.

S

WLE

F IG . 6: Junction Box Screws and Strain Relief

333208A 7

8

Installation

Fill With Oil Before Using

Equipment

Before using the equipment, open fill cap (P) and add

Graco Part No. 16W645 ISO 220 silicone-free synthetic gear oil. Check the oil level in the sight glass (K).

See F

IG

. 7

Fill until the oil level is near the halfway point of the sight glass. The oil capacity is approximately 1.5 quarts (1.4 liters). Do not overfill.

NOTE: Two 1 quart (0.95 liters) bottles of oil are supplied with equipment.

NOTICE

Only use oil 16W645. Any other oil will reduce the life of the gears.

Flush Before Using Equipment

The pump fluid section was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid contaminating your fluid with oil, flush the equipment with a compatible solvent before using the equipment.

See Prime/Flush

procedure, page 11.

P

F IG . 7: Sight Glass and Oil Fill Cap

K

333208A

Setup

Setup

To avoid tip over, make sure cart is on a flat and level surface. Failure to do so could result in injury or equipment damage.

1.

Check packing nut (D). Fill with Throat Seal Liquid

(TSL). Torque to 25 ft-lb (34 N•m).

D

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.

3.

Attach hose to gun and tighten.

4.

Attach material supply inlet hose to pump lower.

NOTE: Maximum suggested length is 6 ft (1.8 m), minimum suggested inner diameter is 1 in. (2.5 cm).

5.

Pull pressure adjustment knob (H) out and turn counterclockwise until it stops. Push the knob in to lock.

H

WLE

2.

Attach electrically conductive fluid hose to pump lower outlet via outlet check valve and tighten.

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. ti20171a_1

6.

Turn power switch (E) OFF. Connect unit to power

source. See F IG . 3, page 6.

7.

Always flush and prime sprayer before each use

(see page 11).

333208A 9

Pressure Relief Procedure

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

5.

Hold gun firmly against a grounded metal pail.

Trigger the gun.

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.

1.

Engage gun trigger lock.

ti8252a

6.

Engage gun trigger lock.

ti5049b

7.

Drain fluid: Slowly open fluid drain/purge valve (C), and drain fluid into a waste pail.

ti5049b

2.

Pull pressure adjustment knob (H) out and turn counterclockwise until it stops. Push the knob in to lock.

H

3.

Turn power switch (E) off.

ti20171a_1

2))

E

C

WLLD

8.

If you suspect the spray tip or hose is completely clogged, or that pressure has not been fully relieved after following the previous steps, VERY SLOWLY loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually; then loosen completely. With tip removed, trigger gun into bucket.

Trigger Lock

4.

Disengage gun trigger lock.

WLD

Always engage the trigger lock when you stop spraying to prevent the gun from being triggered accidentally by hand or if dropped or bumped.

ti5048b ti5049b

10 333208A

Prime/Flush

Prime/Flush

To avoid injury from splashing, always flush at lowest possible pressure.

1.

Perform

Pressure Relief Procedure , page 10.

2.

Remove tip and tip guard from gun.

3.

Place material supply suction hose into compatible fluid (if priming) or solvent (if flushing).

4.

Pull pressure adjustment knob (H) out and turn counterclockwise until it stops. Push the knob in to lock.

H

7.

If priming, equipment is now ready to spray (proceed to Spray

, page 12). If flushing, proceed with

step 8.

NOTE: The remaining steps are for flushing only.

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.

8.

Place drain tube in a grounded waste pail.

9.

Slightly rotate drain/purge valve handle (C) counterclockwise to open.

ti20171a_1

5.

Turn power switch (E) ON.

21

E

6.

Prime or flush hose and gun: a.

Disengage gun trigger lock.

WLE

C

WLLD

10. To start pump, pull out pressure adjustment knob

(H) and turn clockwise until pump begins to move.

Push knob in to lock.

H ti5048b b.

Trigger gun into grounded pail. Pull out pressure adjustment knob (H) and turn clockwise slowly to increase pressure, until a steady stream flows from gun. Push knob in to lock. If flushing , trigger gun for 10-15 seconds.

ti20171a_1

11. When clean solvent flows from drain tube, rotate drain/purge valve handle (C) clockwise to close.

Pump will stall.

c.

Engage trigger lock.

333208A ti8727a

C

WLD

12. Perform Pressure Relief Procedure , page 10.

Leave solvent in and store sprayer.

11

Spray

Spray

6.

Disengage gun trigger lock.

NOTICE

Do not allow pump to run dry. It will quickly accelerate to a high speed causing damage.

1.

Perform Prime

procedure, page 11.

2.

Perform Pressure Relief Procedure , page 10.

3.

Install tip and tip guard onto gun.

4.

Turn power switch (E) ON.

ti5048b

7.

Spray a test pattern. Read fluid manufacturer’s recommendations. Adjust as necessary.

21

E WLE

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.

H

+

_

8.

Flush when finished spraying. See Prime/Flush ,

page 11.

9.

Perform

Pressure Relief Procedure , page 10.

Shutdown

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.

ti20171a_1

To shutdown, perform Prime/Flush

procedure, page 11.

Perform

Pressure Relief Procedure , page 10.

12 333208A

Maintenance

Maintenance

Daily Maintenance

Preventative Maintenance

Schedule

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.

The operating conditions of your particular system determine how often maintenance is required. Establish a preventative maintenance schedule by recording when and what kind of maintenance is needed, and then determine a regular schedule for checking your system.

NOTE: For overnight shutdown, stop pump at bottom of its stroke to prevent fluid from drying on exposed displacement rod and damaging throat packings. Perform

Pressure Relief Procedure , page 10.

1.

Perform Flush

procedure, page 11.

2.

Relieve pressure. See

Pressure Relief Procedure

,

page 10.

3.

Check packing nut (D) See F IG . 1, page 5. Adjust packings and replace TSL as necessary. Torque to

25 ft-lb (34 N•m).

4.

Check hoses, tubes, and couplings. Tighten all fluid connections before each use.

Change the Oil

NOTE: Change the oil after a break-in period of 200,000 to 300,000 cycles. After the break-in period, change the oil once per year.

1.

Place a minimum 2 quart (1.9 liter) container under the oil drain port. Remove the oil drain plug. Allow all oil to drain from the driver.

2.

Reinstall the oil drain plug. Torque to 25-30 ft-lb

(34-40 N•m).

3.

Open the fill cap (P) and add Graco Part 16W645

ISO 220 silicone-free synthetic 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 1.5 quarts (1.4 liters). Do not overfill.

4.

Reinstall the fill cap. See F IG . 7, page 8.

Check Oil Level

See F IG . 7, page 8. Check the oil level in sight glass (K).

The oil level should be near the halfway point of the sight glass when the sprayer is not running. If oil is low, open fill cap (P) and add Graco Part No. 16W645 ISO

220 silicone-free synthetic gear oil.

The oil capacity is approximately 1.5 quarts (1.4 liters).

Do not overfill.

NOTE: Two 1 quart (0.95 liters) bottles of oil are supplied with equipment.

NOTICE

Only use oil 16W645. Any other oil may reduce the life of the gears.

Corrosion Protection

Always flush the pump before fluid dries on the displacement rod. Never leave water or water-based fluid in the pump overnight. First, flush with water or a compatible solvent, then with a rust inhibitor, such as mineral spirits.

Perform Pressure Relief Procedure (page 10), but

leave rust inhibitor in pump to protect parts from corrosion.

333208A 13

Maintenance

Flushing

• Flush before changing fluids, before fluid can dry in the equipment, at the end of the day, before storing, and before repairing equipment.

• Flush at the lowest pressure possible. Check connectors for leaks and tighten as necessary.

• Flush with a fluid that is compatible with the fluid being dispensed and the equipment wetted parts.

Cart Maintenance

Periodically lubricate the axle between points A and B with lightweight oil. See the following figure.

Keep the cart clean by wiping up spills daily, using a compatible solvent.

A

B

WLD

14 333208A

Troubleshooting

Troubleshooting

NOTE: Check all possible remedies before disassembling pump.

NOTE: The LED on the driver will blink if an error is detected.

Problem Cause Solution

Pump output low on both strokes

No output

Pump will not operate

No pressure

Driver does not turn on

(fans may still run)

Inadequate power supply.

Exhausted fluid supply.

Clogged fluid outlet line, gun*, etc.; hose inner diameter too small.

Worn piston packing.

Improperly installed intake or piston check valves.

Exhausted fluid supply.

Inadequate power supply.

Exhausted fluid supply.

Clogged fluid hose or gun*.

Fluid dried on piston rod.

Driver parts are worn or damaged.

Fluid leaking from rupture disk.

Leaking drain valve.

Over voltage (over 300 V)

No power to control board.

See Power Supply

, page 6.

Refill and prime pump.

Clear hose, outlet check valve, or gun; use hose with larger inner diameter.

Replace. See lower manual.

Check and repair. See lower manual.

Refill and prime pump.

See Power Supply

, page 6.

Refill and prime pump.

Clean hose or gun.

Disassemble and clean pump. See lower manual. In future, stop pump at bottom of stroke. Keep wet-cup filled with compatible solvent.

Repair or replace driver.

Replace rupture disk with new one; do not replace with pipe plug.

Close or replace.

See Power Supply

, page 6.

Verify power supply is connected.

Check junction box connections.

Output low on down stroke Open or worn intake valve.

Output low on upstroke Open or worn piston valve packings.

Erratic or accelerated pump speed

Fluid supply exhausted.

Clogged suction.

Open or worn piston valve packings.

Open or worn intake valve.

Cycles or fails to hold pressure at stall

Clear or service intake valve.

Clear piston valve; replace packings.

Refill supply and prime pump.

Clean suction tube.

Clear piston valve; replace packings.

Clear or service intake valve.

Clogged gun, hose, outlet, etc.

Open or worn outlet check valve

Clear gun, hose, outlet, etc.

Clear or service outlet check valve.

Worn intake or piston valves or seals. Service lower. See Xtreme Lower Removal ,

page 19, and Lowers manual (311762).

333208A 15

Troubleshooting

Problem Cause Solution

Air bubbles in fluid

Poor finish or irregular spray pattern

Driver does not turn over and LED is off

Loosen suction line.

Agitator/mixer is not submerged.

Agitator/mixer RPM is too high.

Incorrect fluid pressure at gun.

Fluid is too thin or too thick.

Dirty, worn, or damaged spray gun.

Over voltage (greater than 300 V)

No power to control board

Tighten suction line connections. Use compatible liquid thread sealant or PTFE tape on connections.

Submerge agitator/mixer.

Lower RPM.

See gun manual. Read fluid manufacturer’s recommendations.

Adjust fluid viscosity. Read fluid manufacturer’s recommendations.

Service spray gun. See spray gun manual.

Check power supply

Contact your Graco distributor or Tech Service for more information.

Cycle power. Driver does not turn over and LED is on

Encoder fault

Contact your Graco distributor or Tech Service for more information.

Oil is leaking Oil was over-filled

Drain plug not tightened properly

Seal cartridge o-ring missing or damaged.

Drain and refill as stated in Check Oil Level ,

page 13.

Torque to 25-30 ft-lb (34-40 N•m).

Replace shaft bearing assembly.

* To determine if fluid hose or gun is obstructed, follow Pressure Relief Procedure

, page 10. Disconnect fluid hose

and place a container at pump fluid outlet to catch any fluid. Turn pressure adjustment knob just enough to start pump. If pump starts, the obstruction is in fluid hose or gun.

16 333208A

Troubleshooting

Error Codes

Error codes can take two forms:

Alarm: alerts you to the alarm cause and shuts down the pump.

Deviation: alerts you to the problem, but pump may continue to run past the set limits until the system’s absolute limits are reached.

NOTE: The blink code is displayed using the power indicator (L) on the driver. The blink code given below indicates the sequence. For example, blink code 2 indicates two blinks, a pause, then two more blinks, and then repeats.

/

NOTE: To clear an error code, cycle power by turning the power switch (E) to the off position for at least 30 seconds before turning back on.

Power Saving Mode

When fast blinking is displayed, the sprayer has entered

Power Saving Mode mode. When the sprayer is on and pressurized but the pump has not moved any material in

30 minutes, the sprayer will enter Power Saving Mode and will only control up to 75% of the maximum pressure.

Power Saving Mode will be exited when:

• Material starts to dispense and causes the pump to move, OR

• The pressure knob is adjusted, OR

• Power is cycled OFF and ON

(

WLD

Blink Code

1

Error Type

Alarm

2

3

Alarm

Deviation

Troubleshooting Steps

Voltage Too Low

• Verify that line voltage is within the range specified in Technical Data ,

page 25.

Use the recommended cord (see page 6).

• Cycle power and check status indicator to see if error is still active.

Voltage Too High

• Verify that line voltage is within the range specified in Technical Data ,

page 25.

• Cycle power and check status indicator to see if error is still active.

• Verify that outlet check valve is installed on pump and functions properly.

NOTE: A faulty outlet check valve can result in excessive pump speed and cause high voltage internally to the electric driver.

Low Temperature

• Warm equipment to greater than -5° C.

• Contact your Graco distributor or Tech Service for more information.

333208A 17

Troubleshooting

Blink Code

4

Error Type

Deviation

5

6

7, 8

9

10

11

12, 13

Fast Flash

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Deviation

Troubleshooting Steps

High Temperature

The temperature of the system is near the maximum operation temperature. The performance has been reduced to prevent the sprayer from completely shutting down.

• Check fan operation. Clean fan and driver housing. Verify fuses are intact in junction box.

• Reduce pressure, duty cycle, or gun tip size.

• Move unit to a cooler location.

Motor Temperature Fault

Motor is running too hot. Allow unit to cool.

• Check fan operation. Clean fan and driver housing. Verify fuses are intact in junction box.

• Reduce pressure, duty cycle, or gun tip size.

• Move unit to a cooler location.

Board Temperature Fault

The control board is running too hot. Allow unit to cool.

• Check fan operation. Clean fan and driver housing. Verify fuses are intact in junction box.

• Reduce pressure, duty cycle, or gun tip size.

• Move unit to a cooler location.

Encoder Error

• Cycle power and check status indicator to see if error is still active.

• Calibrate the encoder (see Driver manual).

• Contact your Graco distributor or Tech Service for more information.

Software Versions Do Not Match

• Obtain software update token and follow Software Update procedure (contact your Graco distributor or Tech Service for more information).

Circuit Board Communication Failure

• Cycle power and check status indicator to see if error is still active.

• Contact your Graco distributor or Tech Service for more information.

Internal Circuit Board Hardware Failure

• Cycle power and check status indicator to see if error is still active.

• Contact your Graco distributor or Tech Service for more information.

Internal Software Error

• Cycle power and check status indicator to see if error is still active.

• Contact your Graco distributor or Tech Service for more information.

See Power Saving Mode

, page 17.

18 333208A

Repair

Repair

5.

If driver does not require service, leave it attached to its mounting.

To prevent skin injection and splashing, never open a camlock hose or applicator fitting while there is pressure in the fluid line. Perform Pressure Relief

Procedure

, page 10, before performing any repair

procedure.

Xtreme Lower Removal

Required Tools

• Set of adjustable wrenches

• Torque wrench

• Rubber mallet

• Thread lubricant

• Anti-seize lubricant

• Thread sealant

Disconnect and Reconnect

Lower

6.

Remove clip (11) and slide coupling cover (13) up to remove coupling (12).

11

13

12

7.

Use a wrench to hold tie rod flats to keep rods (8) from turning. Unscrew nuts (10) and remove lower (9).

1.

Flush pump; see Prime/Flush

, page 11. Stop pump

at bottom of its stroke.

2.

Perform Pressure Relief Procedure

, page 10.

3.

Disconnect unit from power source.

4.

Disconnect fluid hose. Disconnect suction hose.

Hold fluid inlet fitting with a wrench to keep it from loosening while you disconnect suction hose.

8

Do not lift the pump by the lift ring when the weight exceeds 250 kg (550 lb). The lift ring could fail and result in personal injury or damage to the equipment.

Use caution when disconnecting lower; they can weigh up to 25 kg (55 lbs). Take appropriate precautions.

333208A

10

9

WLE

8.

Refer to Xtreme Lower manual (311762) to service lower.

9.

Reconnect lower by following disconnect steps in reverse order.

NOTE: Torque nuts (10) to 50-60 ft-lb (68-81 N•m).

19

Repair

Outlet Check Valves

1.

Perform Pressure Relief Procedure , page 10, and

disconnect unit from power source before removing or servicing outlet check valve.

2.

When replacing outlet check valve, reinstall with proper flow direction.

Outlet Check Valve Repair

1.

Flush pump (see Prime/Flush

, page 11). Stop the

pump at the bottom of the stroke.

2.

Perform Pressure Relief Procedure , page 10.

3.

Disconnect unit from power source.

4.

Place a waste container below the outlet check valve to catch any material.

6.

Use a wrench to loosen the outlet check valve, then remove the outlet check valve from the pump lower.

NOTE: The pressure drain valve may remain attached to the outlet check valve housing during repair if needed.

7.

Remove the outlet check valve nut from the valve housing.

8.

Remove and clean all internal outlet check valve components. Inspect all components for wear or damage and replace components as needed.

9.

Reassemble parts in the reverse order they were removed; ball guides (3), spring retainer, compression spring, and ball. Use a small blunt tool to push the ball in and verify that the ball and spring move freely.

10. Replace the o-ring and coat with grease.

NOTICE

The o-ring is designed to be crushed and should not be reused. The o-ring must be replaced every time the outlet check valve housing is opened. If the o-ring is reused, damage to equipment could occur.

11. Torque the outlet check valve nut onto the housing to 75-80 ft-lb (101-108 N•m).

NOTE: If the pressure drain valve was removed for the outlet check valve repair, reinstall at this point.

12. Reattach the outlet check valve to the pump lower and verify the flow indication arrow is pointing away from the pump and that the pressure drain valve outlet is facing the ground.

WLD

5.

Use two wrenches to loosen the hose, then disconnect the hose from the outlet check valve housing.

WLD

13. Attach the dispense hose to the outlet check valve.

20

WLD

333208A

Notes

Notes

333208A 21

Parts

Parts

Sprayer

3

2

22

49

4

67

1

66

52

56

8

3

WLF

5

6

7 1 2

47

46

14 11

13

12

45

15

10

9

55

23

64

17

58

24

25

44

333208A

Parts

Parts List - Sprayer

Ref.

Part Description

6

7

4

5

8

9

1

2

3

262914 CART, painted, mortar, light wt

116406 WHEEL, semi pneu, light weight

113436 RING, retaining

24V016 DRIVER, non-hazardous location

100133 WASHER, lock, 3/8

100101 SCREW, cap, hex hd

15H392 ROD, adapter Xtreme

257150 ROD, tie, 14 1/4 long

LOWER, Xtreme, nf, Xseal, disk

L145C8 Models: 24X450, 24X451

L250C8 Models: 24W315, 24W316

101712 NUT, lock

244820 CLIP, hairpin (w/ lanyard)

244819 COUPLING, assembly, 145-290

10

11

12

13

14

15*

Xtreme

197340 COVER, coupler

16W767 PLUG, tubing

HOUSING, rupture, disc

127842 Models: 24X450, 24X451

17

258962 Models: 24W315, 24W316

116401 ADAPTER, elbow

23† 245143 VALVE, pressure bleed

24

25

44

116746 FITTING, barbed, plated

116750 TUBE, nylon

H43850 HOSE, Xtreme, 4500 PSI, .375ID,

45

50 ft (Models: 24X451, 24W316)

164856 FITTING, nipple, reducing

46

(Models: 24X451, 24W316)

H42506 HOSE, cpld, 4500 psi, .25 ID, 6 ft

(Models: 24X451, 24W316)

Qty.

4

1

1

4

3

1

1

2

2

1

1

3

1

1

1

2

1

1

1

1

1

1

57

58

64

65

49

52

55†

56

Ref.

Part

47

66

67

Description

XTR510 GUN, XTR5, 1 in. HND, 4fng,

XHD529, nf

(Models: 24X451, 24W316)

15H525 CAP, fill

17B507 COVER, junction box

VALVE, outlet check

17B509 GASKET, cover, junction box

TAG, oil

17A411 LABEL, instructions

162505 FITTING, union, swivel

15Y463 FITTING, bushing

(Models: 24X451, 24W316)

104572 WASHER, lock and spring

115264 SCREW, cap, socket head

† 127631 KIT, outlet check valve (includes 23, 55)

* Included in lower (9). See Xtreme lower manual for details.

Part Specifications:

Ref.

1

Instruction

Torque to 196-210 N•m (145-155 ft-lb)

2

Apply thread sealant

3

Torque to 68-81 N•m (50-60 ft-lb)

Qty.

1

2

2

1

1

1

1

1

1

1

1

333208A 23

Parts

Outlet Check Valve

23

7

5 2

2

WLD

$

$

6 3 4

1 1

Parts List - Outlet Check Valve

Ref.

Part

4

5

6

1

2*

3

7

23

Description

127882 NUT, seat (includes 4)

102595 PACKING, o-ring

181492 GUIDE, ball

102972 BALL, metallic

17A091 HOUSING, ball, check

181535 RETAINER, spring

108361 SPRING, compression

245143 VALVE, pressure bleed

Qty.

1

1

1

1

1

3

1

1

* If the outlet check valve is disassembled, the o-ring (2) must be replaced. The o-ring is designed to be crushed, and not reused.

Part Specifications:

Ref.

1

Instruction

Torque to 101-108 N•m (75-80 ft-lb)

2

Apply lubricant

Accessories:

Part Description

17B291 MIXER, jiffy, PS-1

24V083 HOPPER KIT

24V499 HOPPER BRACKET

245176 XTREME SIPHON TUBE KIT

24 333208A

Technical Data

Technical Data

Electric High Pressure Airless Sprayer

Models: 24X450, 24X451, 24W315, 24W316

US

Maximum fluid working pressure

(Models: 24X450, 24X451)

Maximum fluid working pressure

(Models 24W315, 24W316)

Stroke length

Maximum continuous cycle rate

(To prevent premature pump wear, do

NOT exceed maximum recommended speed of fluid pump)

Weight

Wetted Parts

4500 psi

2600 psi

4.75 in.

33 cycles per minute

Operating temperature range:

Input voltage:

Input current:

Sound pressure:

Oil capacity:

Oil specification:

Inlet/Outlet Sizes

Fluid inlet size

Fluid outlet size

Hose Requirements

Minimum pressure

Minimum length

Minimum ID

Maximum resistance per ISO 8028

230 lbs 104 kg

Carbon Steel, Alloy Steel, 304, 440 and 17-PH Grades of Stainless

Steel, Zinc and Nickel Plating, Ductile Iron, Tungsten Carbide, PTFE;

Leather, Aluminum

23° to 120° F -5° to 50° C

200-240 VAC, single phase, 50/60 Hz

20A maximum

74 dB at maximum cycle rate

1.5 quarts 1.4 liters

Graco part number 16W645 ISO 220 silicone-free synthetic gear oil

4500 psi

50 ft

3/8 in.

9100 Ω /ft

Metric

31 MPa, 310 bar

17.9 MPa, 179 bar

120 mm

1-1/4 npt(m)

3/8 npt(m)

31 MPa, 310 bar

15 m

10 mm

30,000 Ω /M

333208A 25

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by

Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT

LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE .

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy

(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT

MANUFACTURED BY GRACO . These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com

.

For patent information, see www.graco.com/patents .

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.

Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

Original instructions.

This manual contains English. MM 333208

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision A - August 2014

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