Instructions - Parts

XL™ 10000 Air Motor 334644C

EN

For use with high output reciprocating Graco pumps. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual and in related
manuals. Save all instructions.

Model No. 24X856

100 psi (0.7 MPa, 7 bar) Maximum Working Pressure

Model No. 273088

100 psi (0.7 MPa, 7 bar) Maximum Working Pressure
(For use on XP-hf systems only)
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Run Motor Manually . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Component Identification . . . . . . . . . . . . . . . . . . . . 6 Ice In Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Information . . . . . . . . . . . . . . . . . . . . . . . . 7 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Preventive Maintenance Schedule . . . . . . . . . . 12
Reciprocating Signal Poppets . . . . . . . . . . . . . . . 7 Pressure Relief Procedure . . . . . . . . . . . . . . . . 12
External Pilot Lines . . . . . . . . . . . . . . . . . . . . . . . 7 Repair Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . 13
Manual Override Buttons . . . . . . . . . . . . . . . . . . 7 Replace Pilot Valves . . . . . . . . . . . . . . . . . . . . . 16
Low Pressure Operation . . . . . . . . . . . . . . . . . . . 7 Repair Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . 16
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Minimum Icing . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Air Valve Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Bleed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Kits and Accessories . . . . . . . . . . . . . . . . . . . . . 22
Extended Capabilities . . . . . . . . . . . . . . . . . . . . . 7 Dimensions (Model No. 24X856) . . . . . . . . . . . . . . 24
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Mounting Hole Diagram . . . . . . . . . . . . . . . . . . . 24
Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 8 Dimensions (Model No. 273088) . . . . . . . . . . . . . . 25
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Mounting Hole Diagram . . . . . . . . . . . . . . . . . . . 25
Bleed-type master air valve . . . . . . . . . . . . . . . . . 8 Technical Specifications . . . . . . . . . . . . . . . . . . . . 25
Air Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 26
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 26

Related Manuals
Manual Description
311762 Xtreme Lowers, Instructions-Parts
311825 Dura-Flo™ Lowers, Instructions-Parts
334645 Xtreme XL Packages, Instructions-Parts
3A4381 XP-hf Proportioner, Operation, Repair, Parts

2 334644C
 Warnings

Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-speci• c risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-speci• c
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.

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 com-
ponent. 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 manu-
facturer’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.

334644C 3
Warnings

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent
• owing through the equipment can cause static sparking. To help prevent • re 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.
SKIN INJECTION HAZARD
High-pressure • uid 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 de• ect 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 • uid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.

4 334644C
 Warnings

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.

334644C 5
Component Identification

Component Identification

FIG. 1

Key:
A Directional Air Valve H Static ground cable
B Air inlet, 1 in npt (f) J Plug for optional solenoid
C Muffler K Optional reed switch mount
D Pilot valve L External pilot lines
E Manifold M De-ice bleed air valve
F Manual Shuttle Override Button N Lift ring (800 lb, 363 kg) maximum
G Ground screw P Pump drive rod

6 334644C
 General Information

General Information
The XL 10000 air motor is air piloted with two poppet • Move the valve off center due to ice or debris.
valves operating a cup and plate main air shuttle valve.
Air exhausts around the cylinder, through sound absorp- • Flush a pump if a poppet is plugged, stuck in the
tion materials, and out the rear bottom of the shroud. open position, or the signal is leaking.

See Run Motor Manually on page 9.

Application
This motor has 7% larger effective area, and is intended Low Pressure Operation
to directly replace, the Graco Premier® motor. The XL
will acceptthesameM16x 2.0 threaded tie rods, the This motor will run at 4–5 psi (20.6–27.5 kPa, 0.21–0.27
same connecting rods, and the same 3/8-16 mounting bar)
studs used with the Premier. The XL motor is physically
smaller than the Premier, so it will fit anywhere the Pre-
mier is used. The 1 in. air inlet is at a low front position Performance
instead of up on the top so a different air hose may be
required. There are also threaded cart/shelf type mount- The air valve (A), manifold (E), and exhaust are larger
ing holes in the base which match the ones used on the than the Premier air handling parts in order to exhaust
NXT® motors. The XL motor fits the standard heavy the 630 in3 of compressed air from the cylinder after a
duty Xtreme cart so the larger Premier cart is no longer full stroke. This allows the • uid pressure to come back
necessary. faster as the piston is driven from the other side. The
near square pressure trace that this generates makes
for a small change-over pulse, and full pressure output
Reciprocating Signal Poppets for running multiple guns.

The poppets are identical to the ones used in the Graco

Merkur® motors and many air-operated double dia- Minimum Icing
phragm motors. Poppets are fully accessible and can
easily be replaced. The oversizing of all the air handling parts described in
the General Information section mean that normal air
motor ice buildup has less effect on the pump output.
External Pilot Lines
The pilot lines (L) that run from the shuttle end ports to Bleed Air
the exhaust poppets are run externally in hydraulic
hose. This allows for cold weather operation without Use the de-ice bleed air valve (M) to run warm air
running the air through the aluminum manifold, which through the valve and exhaust for de-icing. This is
can sometimes get cold enough for airline moisture to mainly helpful during warm weather, very high humidity
freeze and block the signals. applications, or low pressure high cycle rate applica-
tions.

Manual Override Buttons

Extended Capabilities
There are manual override buttons (F) on each end of
the air valve that allows the internal main shuttle valve to The XL motor will accept DataTrak™ counting, a run-
be physically moved from one position to the other. Run away stop solenoid, and the top mount linear position
the motor manually to: transducer used with NXT motors.

334644C 7
Grounding

Grounding Accessories

Bleed-type master air valve

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. Trapped air can cause the pump to cycle unexpect-
edly, which could result in serious injury from
Verify that the ground screw (GS) is attached and tight- splashing or moving parts.
ened securely to the air motor. Connect the clamp (U) of
• Required in your system to relieve air trapped
the static ground cable (H) to a true earth ground.
between it and the air motor when the valve is
closed.
• Be sure the valve is easily accessible from the pump
and located downstream from the air regulator.

Air Regulator
Required in your system to adjust the air pressure to the
motor and • uid outlet pressure of pump. Locate it close
to the motor. Install a gauge to read air pressure.

Air Filter
FIG. 2
Required in your system to remove harmful dirt and
moisture from compressed air supply. The minimum
Motor Lubrication recommended air • ltration is 40 micron.

Graco does not require lubrication beyond the grease

installed at the factory or through regular maintenance.
Air Lubrication
With good quality compressed air and normal ambient 237212 1” npt (f) accessory lubricator with a 16 oz.
conditions, air motors will run millions of cycles without bowl. See form 308169.
additional lubrication.
244841 Kit. Modular Lubricator. Use with XL Graco
However, if any of the following criteria apply to your spray packages with modular air controls. See form
system, you will benefit from installing an air line lubrica- 3A0293.
tor in the air line before the air motor, or from occasion-
ally adding oil to an air filter cup.

• Air supply does not contain any oil.

• Air supply is very wet.
• Air supply is very dry.
• Air motor is run at low air pressure.
• Air motor is run in unusually hot or cold environ-
ments.

8 334644C
 Grounding

Run Motor Manually

Use the manual override buttons (F) on each end of the
air valve to physically move the internal main shuttle
valve from one position to the other. Run the motor man-
ually to:

• Move the valve off center due to ice or debris.

• Flush a pump if a poppet is plugged, stuck in the
open position, or the signal is leaking

1. Lower the air pressure to approximately 30–40 psi

(2.1 kPa, 210 bar – 280 kPa, 2.8 bar) to manually
operation the buttons.

2. If a poppet is plugged:

a. Press the button on the end where the motor

stopped. This will cause the motor to run
another cycle.

b. Press the button again to finish flushing.

3. If a poppet is stuck in the open position or the signal

is leaking:

a. Press the button on the opposite end from

where the motor stopped and hold it in. This will
cause the motor to stroke to the other end.

b. Release the button to allow the motor to stroke

back.

NOTE: For poppet issues, the motor can also be manu-

ally operated by disconnecting the pilot hose and con-
trolling the pilot signal exhaust with your • nger.

334644C 9
Troubleshooting

Troubleshooting

Problem Cause Solution

Air motor will not run and there is no Check air supply Supply air to motor inlet.
obvious exhaust Pump is locked up. Disconnect or remove pump to verify
motor operation.
Ice broke loose in manifold and Turn off and exhaust air. Push top
caught in air valve. and bottom valve shift buttons (118)
back and forth until flush with base of
valve cap (107). Restart motor.
Air motor doesn't run and large vol- Main piston o-ring (10) has failed or Replace piston o-ring (10) See page
ume of air blows through exhaust main valve. See below. 10.
outlet on either stroke.
Air exhausts from rear outlet continu- Shuttle valve cup (112) and plate Replace shuttle valve cup (112) and
ously when motor is stalled against (105) failure. plate (105).
• uid valve on one stroke or the other.
Motor stalled at bottom of stroke with Bottom pilot (15) is not exhausting. Disconnect pilot line (55) for that
no exhaust at bottom pilot. No Usually ice in the pilot or pilot pilot. If motor changes over, bottom
exhaust at top pilot. exhaust port. pilot is plugged. Replace pilot
valve(55) and/or thaw ice that is
blocking air signal.
Metered air hole in main valve shuttle Disconnect pilot line (55). If motor still
piston (102) is plugged. doesn't change over, shuttle piston
metering hole is plugged. Clean or
replace shuttle valve piston assembly
(102).
Motor stalled at bottom of stroke with Top pilot or • ttings are leaking air Tighten • ttings leak or replace top
exhaust at bottom pilot. Some when not activated by motor piston. pilot valve (15).
exhaust at top pilot.
Motor stalled at top of stroke with no Top pilot (15) is not exhausting. Usu- Disconnect pilot line (55) for that
exhaust at top pilot. No exhaust at ally ice in the pilot or pilot exhaust pilot. If motor changes over, top pilot
top pilot. port. is plugged. Replace pilot valve(55)
and/or thaw ice that is blocking air
signal.
Metered air hole in main valve shuttle Disconnect pilot line (55). If motor still
piston (102) is plugged. doesn't change over, shuttle piston
metering hole is plugged. Clean or
replace shuttle valve piston assembly
(102)
Motor stalled at top of stroke with Bottom pilot or • ttings are leaking air Tighten • ttings leak or replace bot-
exhaust at top pilot. Some exhaust at when not activated by motor piston. tom pilot valve (15).
bottom pilot.
Air motor "bounces" at top change Leaking bottom pilot valve or fitting. Thaw any ice in pilot valve, or replace
over. valve (15) if it is not ice.
Air motor "bounces" at bottom Leaking top pilot valve or fitting. Thaw any ice in pilot valve, or replace
change over. valve (15) if it is not ice.

10 334644C
 Troubleshooting

Problem Cause Solution

Air motor pauses at top change over. Top pilot valve exhaust restricted by Swap pilot valve or clear exhaust
dirt or ice. port.
Air motor pauses at bottom change Bottom pilot valve exhaust restricted Swap pilot valve or clear exhaust
over. by dirt or ice. port.
Motor runs slower and pump looses Ice has collected in air manifold pas- Thaw or remove ice. Lower moisture
• uid pressure on one stroke only. sages, or valve. content of compressed air. Reduce
load on motor. See below.
Motor runs slower and pump looses Ice has collected where exhaust Open the bleed air valve (119) on the
• uid pressure on both strokes expands from the shuttle valve plate main shuttle valve. This will bleed
equally. manifold (5) into the muf• er (12) some warm air through anytime air is
supplied to the motor.

Ice In Air Motor To minimize ice build-up:

When compressed air is exhausted, the sudden drop in • Lower the dew point of the compressed air. Use a
pressure causes the air temperature to drop below the refrigerated air dyer, coalescing • lter, or desiccant
freezing point. This causes any water liquid or vapor to • lter to lower the water vapor content of the air.
turn to ice. • Raise the compressed air temperature. Warmer
air going in helps the motor parts stay above freez-
Higher air pressures pack high amounts of air and water ing. Compressed air, especially at these volumes, is
vapor in each cycle and create more expansion and ice. warm when compressed. Keep the air warm or stay
Higher cycle rates also build up the ice and lower the near the compressor to reduce icing.
motor temperature faster. It is important to select the
• Use the bleed air to clear ice build up.
correct motor and pump size to run at a lower pressure,
and cycle slower.

Warm humid climates can produce high levels of icing

because of the higher humidity levels. Low ambient tem-
peratures near freezing make it easier for the motor
parts to drop below freezing.

334644C 11
Repair

Repair

Preventive Maintenance 1. Engage trigger lock.

Schedule 2. Close the bleed-type master air valve.

The operating conditions of your system determine how 3. Disengage the trigger lock.
often maintenance is required. Establish a preventative
maintenance schedule by recording when and what kind 4. Hold a metal part of the gun firmly to a grounded
of maintenance is needed, and then determine a regular metal pail. Trigger the gun to relieve pressure.
schedule for checking your system.
5. Engage the trigger lock.

Pressure Relief Procedure 6. Open all • uid drain valves in the system, having a
waste container ready to catch drainage. Leave
Follow the Pressure Relief Procedure drain valve(s) open until you are ready to spray
whenever you see this symbol again.

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 gradu-
ally.

b. Loosen nut or coupling completely.

This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury c. Clear hose or tip obstruction.
from pressurized • uid, such as skin injection,
splashing • uid and moving parts, follow the
Pressure Relief Procedure when you stop spraying
and before cleaning, checking, or servicing
equipment.

12 334644C
 Repair

Repair Air Valve Replace Seals or Rebuild Air Valve

See Kits and Accessories, page 22, to order kits for
your pump.
Replace Complete Air Valve
Disassemble the Air Valve
1. Perform steps 1–5 from Replace Complete Air
Valve, page 13.

2. Use a 2mm or 5/64 hex key to remove two screws

(109). Remove the valve plate (105).

3. Remove the two-piece cup assembly (112, 113,

123), and spring (111).

FIG. 3 Air Valve

1. Stop the pump at the middle of its stroke. Follow

Pressure Relief Procedure, page 12.

2. Disconnect the air line to the motor and the pilot

valve lines to the air valve (13).

3. If installed on air motor, remove reed switch kit and

solenoid from air valve (13).

4. Remove screws (23). Remove the air valve (13) and

gasket (27).

5. To repair the air valve, go to Disassemble the Air FIG. 4

Valve, page 13, step 1. To install a replacement air
valve, continue with step 6. 4. Remove the snap ring (110) from each end. Use the
piston (102) to push the end caps (107, 117) out of
6. Align the new air valve gasket (27) on the manifold,
the ends. Remove end cap o-rings (106, 117).
then attach the air valve (13).
5. Slide out the piston (102). Remove the u-cup seals
NOTE: Use grease to hold the gasket (27) in place. Be
(108) from each end and the detent assembly (103)
sure the bleed air hole in the gasket aligns with the
and detent cam (104) from the center.
bleed port in the valve manifold.

7. Reattach the solenoid bracket and the solenoid.

8. Use screw to attach the reed switch assembly to the

new air valve. Be sure the sensor cables are con-
nected properly (see pump or package manual).

9. Reconnect the air line and pilot valve lines to the

motor.

334644C 13
Repair

1 Apply high quality lithium grease.

FIG. 5 Air Valve Assembly

14 334644C
 Repair

Reassemble the Air Valve

1. Lubricate detent cam (104) and install into housing.

2. The piston (102) and u-cup seals (108) come

pre-assembled. Lubricate the u-cup seals (108) on
both ends of the piston (102) and install it in the
housing.

3. Lubricate and install the detent assembly (103) into

the piston, with the beveled center toward the detent
cam.

4. Lubricate and install new o-ring (106) on bottom end

cap (107). Lubricate and install new o-ring (119)
and runaway reset button (118) on top end cap
(117). Install the end caps (107, 117) into the hous-
ing.

5. Install a snap ring (110) on each end to hold end

caps in place.

6. Install the spring (111).

7. Lubricate and install the cup o-ring (123) on the cup

body (113), then assemble the cup body to the cup
base (112c). Lubricate and install the cup assembly.
Align the small round magnet with the air inlet.

8. Install the valve plate (105). Lightly tighten the

screws (109) to hold it in place.

334644C 15
Repair

Replace Pilot Valves 3. Hold the • ats of the air motor piston rod with a
wrench. Use another wrench to loosen the coupling
1. Stop the pump at the middle of its stroke. Relieve nut (CN). Collect the coupling collars and set aside.
the pressure. See Pressure Relief Procedure,
page 12.

2. Disconnect the air line to the motor.

3. Use a 10 mm socket wrench to remove the old pilot

valves (15) from the top and bottom covers.

4. Lubricate and install the new pilot valves (15).

Torque to 95-105 in-lb (11-12 N•m).

4. Hold the tie rods and remove the tie rod nuts (TN).

5. Use a socket to remove the mounting screws (MS).

FIG. 6 Pilot Valves

Repair Air Motor

Refer to applicable system manual for alternate air
motor removal steps.

Air Motor Seal Kits are available. See Kits and Acces-
sories, page 22 for the correct kit for your motor. Parts
included in the kit are marked with an asterisk (*). For
best results, use all the parts in the kit.

Disconnect the Air Motor

1. Flush the pump, if possible (see package manual).
Follow Pressure Relief Procedure, page 12.
6. Lift up on the air motor to remove it. The tie rods will
2. Disconnect the air and • uid hoses and the ground
remain attached.
wire.

16 334644C
 Repair

Disassemble the Air Motor 5. Remove the muffler (12) from around the cylinder.
Remove the cylinder (3).
1. Disconnect pilot valve air lines (55) from the air
valve (13). 6. Slide the piston assembly (4) straight up off the bot-
tom cover (1).

NOTE: The piston and rod are epoxied together and

only available as an assembly (4). Do not attempt to
take apart the piston and rod assembly (4).

7. Remove the o-ring (10*) from around the piston (4).

8. Use a • at head screw driver to remove the retaining

ring (11) from the bottom cover (1).

9. Remove the u-cup seals (8*, 9*), and o-ring (14*)

from the bottom cover (1).

2. Remove four screws (24) and remove the manifold

(5) and two gaskets (22). Inspect foam (42) for dam-
age.

3. Use a 15/16 in or 24 mm socket wrench to remove

the tie bolts (25).

4. Remove the top cover. Remove the o-ring (14*).

NOTE: To break the cover loose, place a pipe or a long

wrench handle through the lift ring (17) and hit the pipe.

334644C 17
Repair

Reassemble the Air Motor 7. Install the muffler (12) around the cylinder (3) and in
the groove on the bottom cover(1). Be sure the front
NOTE: The bearing (7) is pressed in the bottom cover opening is lined up with the • at on the bottom cover
(1) and is only available with Bottom End Cap Repair kit (1).
24X559.
8. Lubricate and install the o-ring (14*) on the top
1. Lubricate and install the o-ring (14*) on the bottom cover (2).
cover (1).
9. Carefully place the top cover (2) on the cylinder (3)
2. Lubricate and install new u-cup seal with • ange (9*), and muffler (12). The • at vertical manifold surfaces
with the lips facing up, in the bottom cover (1) from of the top and bottom covers must align. Be sure the
the bottom. The seal will snap into place. muffler (12) is in the groove on both the top and bot-
tom covers.

FIG. 7 U-cups

3. Lubricate and install the new u-cup seal (8) over the
top of the bearing with the lips facing up. Install 10. Install the tie bolts (25) hand tight.
retaining clip (11). Snap in the new bumper (19).
11. Tighten the tie bolts (25) halfway. Work in a criss-
4. Lubricate the inside of the cylinder (3). Lower the cross pattern. Then torque to 60 ft-lb (81 N•m).
cylinder (3) onto the bottom cover (1).
12. Install two gaskets (22) on the top and bottom caps
5. Lubricate and install the o-ring (10*) around the pis- with grease. Install the manifold (5). Torque bolts to
ton (4). It will • t loose. 95-105 in-lb (10.7-11.9 N•m).
6. Slide the piston assembly (4) down into the cylinder 13. Reconnect the pilot valve air lines (55) to the air
(3). Be sure the o-ring (10*) stays in place. Work it valve (13).
carefully into the groove.

18 334644C
 Parts

Parts
Part No. 24X856 and 273088

1 Apply lithium grease. 6 Torque to 60 +/- 2 ft-lbs. (81 +/- 2.7 N•m)
2 Torque to 95-105 in-lb (11-12 N•m). 7 Piston rod (6) must move through bearing (7)
3 without force.
Press to snap fit.
8 Lips face up.
4 Apply medium thread locker.
9 Wiper faces down.
5 Torque to +/- 3 ft-lbs. (44.7 +/- 4 N•m).

334644C 19
Parts

Ref Part Description Qty Ref Part Description Qty

1 24X559 COVER, bottom 1 19 24A915 KIT, bumper, top and bottom 1
17R815 COVER, bottom, motor, XP-hf 1 (with screws)
(For model 273088) 21 108014 PACKING, o-ring 1
2 24W584 COVER, top 1 22 --- GASKET, end cap 2
3 24X561 KIT, cylinder 1 23 110036 BOLT, M8 x 1.25 x 45 mm 4
4 24X557 KIT, piston, motor 1 24 17B389 SCREW, M8 x 1.25 x 85 mm 4
24Z920 KIT, piston and rod 1 25 127582 SCREW, 5/8–11 x 8.5 in 6
(For model 273088) 26 --- FITTING, swivel, 45°, 1npt x 1
5 16Y968 MANIFOLD, exhaust, XL 1 1 npsm
7 --- BEARING, sleeve, 1.750 ID, 1 27 24X565 GASKET, valve, 2 pack 1
2.000 OD 28 555749 FITTING, adapter, 1/8 npt(m) 2
8 --- PACKING, u-cup, 1.750 ID, 1 x JIC (#4); 1/2 hex
2.125 OD 30 17C974 CAP, manifold, air, XL 2
9 --- SEAL, rod, wiper, 1.75" rod 1 31 C20987 PACKING, o-ring 1
10 --- O-RING, piston 1 38 244524 CABLE, ground, with clamp 1
11 --- RING, retaining 1 (includes 38a)
12 24X560 COVER, muffler, complete 1 -38a 290079 TAG, warning, grounding (not 1
13 24X562 VALVE, air, XL; see Air Valve 1 shown)
Parts, page 21 39 111307 WASHER, lock, external 1
14 109486 PACKING, o-ring 2 40 116343 SCREW, ground 1
15 24A366 VALVE, pilot (includes 2 42 17C776 GASKET, muffler 1
15a-15c) 51 15F674 LABEL, safety, motor 1
-15a 155685 PACKING, o-ring, middle 1 52 104010 PACKING, o-ring 2
-15b --- PACKING, u-cup, shaft 1 53 557832 RING, retainer -187basic int 2
-15c 154741 PACKING, o-ring, bottom 1 55 128090 HOSE, coupled 2
-15d 197650 O-RING, buna, top 1
16 16D001 ADAPTER, lift ring 1
17 15F931 RING, lift, sst 1 9/16 thrd 1
18 NXT106 BUMPER, piston (with mag- 1
net)

 Replacement Warning labels, signs, tags, and cards

are available at no cost.
 See Kits and Accessories, page 22.

20 334644C
 Parts

Air Valve Parts

1 Apply high quality lithium grease.

 See Kits and Accessories, page 22.

Ref Part Description Qty

101 --- HOUSING, valve, air, XL 1 Ref Part Description Qty
102 --- PISTON, valve, air, XL 1 113 --- CUP, valve, air, xl, zinc 1
103 --- PISTON, detent, small 1 114 --- ROLLER, detent, small 1
104 --- CAM, detent, XL 1 115 --- PIN, detent, small 1
105 --- PLATE, valve, air, xl, 1 117 154741 PACKING, o-ring 2
lapped
118 --- BUTTON, reset 2
106 104010 PACKING, o-ring 2
119 16Y668 NEEDLE, valve, assembly 1
107 --- CAP, valve, air, XL 2
122 15K783 FITTING, elow, street, 2
108 --- PACKING, u-cup 2
1/8-27 npt
109 --- SCREW, m3, thread form- 2 123 295640 O-RING 1
ing
124 555749 CONNECTOR, #4 JIC 1/8 2
110 557832 RING, retainer -187basic 2
int 125 104130 PACKING, o-ring 1
111 --- SPRING, detent 1 126 --- PLUG, valve 1
112 --- BASE, cup, valve, air, xl, 1 127 --- RING, retaining 1
lapped

334644C 21
Parts

Kits and Accessories

Table 1 XL Air Motor Repair Kits
Air Motor Parts
Part No. Description Ref.
NXT103 Lift Ring (17)
24X557 Piston/Rod
Air Motor Parts
Assembly Repair Kit
Part No. Description Ref.
-- 15G478 Bumper (18)
24X559 Bottom End Cap
--- Piston (4)
Repair Kit
--- Shaft, Piston, Rod (4) --- Bumper (19)
24Z920 Piston/Rod --- Bearing, Sleeve (7)
Assembly Repair Kit
--- Packing, U-cup (8)
--- 15G478 Bumper (18)
--- Seal, Rod (9)
--- Piston (4)
--- Ring, Retaining (11)
--- Shaft, Piston, Rod (4)
--- Cover, Bottom (1)
24X558 Air Motor Soft Parts
Repair Kit 24X560 Muffler Repair Kit
--- O-ring, Cylinder (2) (14) -- 15F674 Label, warning (51)
-- 155685 Packing, O-ring, mid- (15a) --- Cover, Muffler (12)
dle --- Gasket, Muffler (42)
--- Packing, U-cup, shaft (15b) 24X561 Cylinder Repair Kit
-- 154741 Packing, O-ring, bot- (15c) --- O-ring (14)
tom --- Foam, Dampers (46)
-- 197650 O-ring, Buna, top (15d)
--- Cylinder, Motor (3)
--- O-ring, piston (10) 24A915 Bumper Kit
--- Packing, U-cup (8) --- Bumper, bottom (19)
--- Seal, Rod (9)
--- Bumper, top (20)
--- Ring, Retaining (11) --- Screw, top (3) (29)
--- Gasket, End Cap (2) (22)
--- Gasket, Muffler (42)

22 334644C
 Parts

Table 2 XL Air Motor Repair Kits

Air Motor Parts Air Motor Parts
Part No. Description Ref. Part No. Description Ref.
24X562 Repair, Complete 24X567 Roller Assembly
Valve Assembly --- Piston, Detent (103)
--- Valve, Air, XL (13) --- Cam, Detent (104)
24X565 Kit, gasket, valve (2 (27) --- Spring, Detent (111)
pack)
--- Roller, Detent (114)
24X563 Repair. Valve O-rings
--- Pin, Detent (115)
-- 104010 O-ring (2) (106)
24X568 DataTrak Plug
-- 154741 O-ring (2) (117)
Assembly
-- 295640 O-ring (1) (123) -- 104130 Packing, O-ring (125)
-- 104130 O-ring (1) (125) --- Plug, Valve (126)
24X564 Repair, Base/Cup --- Ring, Retaining (127)
Assembly
24X569 Valve Piston w/Seals
--- Base (112)
Repair Kit
--- Cup (113) --- Piston, Valve (102)
-- 295640 O-ring (123) --- Packing U-Cup (108)
--- Plate, valve (105) 16Y668 Needle Valve (119)
--- Screw, M3 (2) (109)
24X565 Valve to Manifold (27) Table 3 Accessories
Gasket (2 Pack) Part No. Description
24X566 Cap with Push But-
256893 Linear Sensor, potted, XM
ton assembly
287839 Linear Sesnor, HLS motors
-- 104010 Packing, O-ring (106)
24X550 Kit, Reed Switch and Solenoid,
--- Cap, Valve (107)
DataTrak, XL bracket
-- 557832 Ring, Retaining (110)
24X552 Kit, Reed Switch, DataTrak, XL
-- 154741 Packing, O-ring (117) bracket
--- Button, Reset (118)
-- 15K783 Fitting, Elbow, Street, (122)
1/8
-- 555749 Connector, #4 JIC (124)

334644C 23
Dimensions (Model No. 24X856)

Dimensions (Model No. 24X856)

A B C D E F
in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm)
14.25 (361.9) 16.66 (423.2) 21.75 (552.5) 17.9 (454.7) 2.63 (66.8) 7.38 (187.5)

Mounting Hole Diagram

24 334644C
 Dimensions (Model No. 273088)

Dimensions (Model No. 273088)

A B C D E F
in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm)
14.25 (361.9) 17.03 (432.5) 21.75 (552.5) 17.9 (454.7) 2.65 (67.3) 7.8 (198.1)

&

'

WLD

Mounting Hole Diagram

334644C 25
Technical Specifications
XL 10000 Air Motor
US Metric
Maximum Air Inlet Pressure 100 psi 0.7 MPa, 7 bar
Stroke Length (Nominal) 4.8 in. 122 mm
Motor Effective Area 132.7 in. 2 856 cm 2
Motor Cylinder Inside Diameter 13 in. 330 mm
Minimum Filtiation Size 0.0016 in. 40 micron
Weight 104 lbs 47.2 kg
Air Inlet Size 1 in. npt (f)
Maximum Motor Speed (Do not exceed maxi- 60 cpm
mum recommended speed of fluid pump, to
prevent premature pump wear.)
Sound Data
Sound Power 96 dBA
Measured at 70 psi (0.48 MPa, 4.8 bar), 20
cpm, per ISO-9614-2.
Sound Pressure 86.8 dBA
Tested 3.28 ft (1 m) from equipment.
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 veri• cation of
the claimed defect. If the claimed defect is veri• ed, 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 pro• ts, 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 dis-
tributor.
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 334644
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2015, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision C, June 2017