Graco XL 6500 Instructions Manual

Air motors

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Instructions

™

6500 and 3400 Air Motors

For use with high performance sealer and coating pumps. For professional use only.

Maximum Working Pressure:

100 psi (0.7 MPa, 7 bar)

Important Safety Instructions

Read all warnings and instructions in this manual

and in related manuals. Save all instructions.

See Page 5 for Model information.

3A5423K

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Summary of Contents for Graco XL 6500

Page 1 Instructions ™ 6500 and 3400 Air Motors 3A5423K For use with high performance sealer and coating pumps. For professional use only. Maximum Working Pressure: 100 psi (0.7 MPa, 7 bar) Important Safety Instructions Read all warnings and instructions in this manual and in related manuals.
Page 2 Performance ......7 XL 6500 ....... 24 Minimum Icing .
Page 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.
Page 4 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.
Page 5 Models Models Air Motor Part Matrix Check your motor’s identification plate (ID) for the 6-digit part number of your motor. Use the following matrix to define the construction of your motor, based on the six digits. For example, Motor Part X L 6 5 D 0 represents an XL motor (XL), 6500 cc per stroke (6 5), with standard exhaust (D) and no accessories (0).
Page 6 Component Identification Component Identification Key: Directional Air Valve Optional Reed Switch Mount Air inlet, 3/4 in. npsm union 1 in. npt valve External Pilot Lines Muffler (Static Free) De-Ice Bleed Air Valve Pilot Valve (qty. 2) Lift Ring (800 lb, 363 kg) Maximum Manifold Pump Drive Rod Manual Shuttle Override Button (qty.
Page 7 Reciprocating Signal Poppets Minimum Icing The poppet valves are similar to the ones used in the Graco Merkur® motors and many air-operated double diaphragm motors. Poppets are fully accessible and The oversizing of all the air handling parts described in can easily be replaced.
Page 8 NOTE: Adding oil to the air motor will result in some oil being present in the exhaust air. Motor Lubrication Graco does not require lubrication beyond the grease installed at the factory or through regular maintenance. With good quality compressed air and normal ambient conditions XL air motors will run millions of cycles without additional lubrication.
Page 9 Minimum Accessories Needed to Run Air Motor Minimum Accessories Run Motor Manually Needed to Run Air Motor Bleed-type Master Air Valve 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.
Page 10 NOTE: To find parts lists for the parts identified in the troubleshooting tables, see page numbers listed in the table below. Air Motor Model Parts List Page XL 3400 XL 6500 Problem Cause Solution Air motor will not run and there is no Check air supply Supply air to motor inlet.
Page 11 Troubleshooting Problem Cause Solution Motor stalled at top of stroke with no Top pilot valve (D) is not exhausting. Disconnect pilot line for that pilot. If exhaust at top pilot. Usually ice in the pilot or pilot motor changes over, top pilot is exhaust port.
Page 12 Troubleshooting Ice In Air Motor When compressed air is exhausted, the sudden drop in To minimize ice build-up: pressure causes the air temperature to drop below the • Lower the dew point of the compressed air. Use a freezing point. This causes any water liquid or vapor to refrigerated air dryer, coalescing filter, or desiccant turn to ice.
Page 13 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 4. Hold a metal part of the gun firmly to a grounded maintenance schedule by recording when and what metal pail.
Page 14 Repair Repair Air Valve 10. Use screw to attach the reed switch assembly to the new air valve, if needed. Be sure the sensor cables are connected properly (see pump or package manual). Replace Complete Air Valve 11. Reconnect the air line and pilot valve lines to the motor.
Page 15 Repair Repair Air Valve 24X567 24X568 17V347 24X569 * Apply high quality lithium grease. 3A5423K...
Page 16 Repair Replace Pilot Valves Reassemble the Air Valve 1. The piston (304) and u-cup seals (306) come pre-assembled. Lubricate the u-cup seals (306) on both ends of the piston (304) and install it in the housing. 1. Stop the pump at the middle of its stroke. Relieve 2.
Page 17 Repair Repair Air Motor 4. Use a flathead screwdriver to remove pump guard (PG) and coupling (CP). Refer to applicable system manual for alternate air motor removal steps. Air Motor Seal Kits are available. See Kits and Accessories, page 30 for the correct kit for your motor. Parts included in the kit are marked with an asterisk (*).
Page 18 Repair Disassemble the Air Motor 1. Follow steps 1 - 7 in Disconnect and Reconnect 8. Slide the piston assembly (10) straight up off the Lower, page 17. bottom cover (1). 2. Use a 6mm Allen wrench to remove two screws (43) NOTE: The piston and rod are epoxied together and and remove cover (44).
Page 19 Repair Reassemble the Air Motor NOTE: For additional parts information, see Parts 6. Slide the piston assembly (10) down into the beginning on page 24. cylinder (14). Be sure the o-ring (13) stays in place. Work it carefully into the groove. NOTE: The bearing (3) is pressed in the bottom cover 7.
Page 20 Repair Piston Seal Replacement Removal Replacement Refer to the illustration on the following page for the 1. Use grease to lubricate piston seal (6). instructions below. 2. Install piston seal (6) onto piston (10). 3. Install piston into cylinder (14). 4.
Page 21 Repair Piston Seal Replacement 3A5423K...
Page 22 Repair Replace the Linear Sensor (if present) 1. Stop the pump at the middle of its stroke. Follow the Pressure Relief Procedure, page 13. 2. Disconnect the air line to the motor. 3. Hold the adapter (39) with a wrench to keep it from turning, and unscrew the lift ring (40).
Page 23 Repair Remote DataTrak Connection Kits 24x550, 24x552, 19C374, and 19C375 NOTE: For installation instructions, see DataTrak Kits Installation and Parts manual. Series A Series B * Series A air valves are needed for kits 24X550 and 24X552. Series B air valves are needed for kits 19C374 and 19C375.
Page 24 Parts Parts XL 6500 XL65ROM Remote Exhaust † ‡ Torque evenly to 40 ft/lb (54 N•m). Torque to 120 in/lb (13.5 N•m). Apply lithium grease. Gasket seam aligns with exhaust hole. 3A5423K...
Page 25 Parts XL6500 Parts List Ref. Part Description Qty. Ref. Part Description Qty. 17M851 GASKET, poppet housing 17V316 COVER, bottom, motor, XL6500, 24Z347 HOUSING, poppet mach 17S929 ISOLATOR, poppet housing 17M826 SEAL, rod, wiper, 1.375 OD shaft 117026 SCREW, shcs m5 X 12 - - - - - BEARING, sleeve, 1.375 ID, 1.625 OD...
Page 26 Parts XL3400 Parts XL34ROM Remote Exhaust Torque evenly to 40 ft/lb (54 N•m). Torque to 120 in/lb (13.5 N•m). Apply lithium grease. Gasket seam aligns with exhaust hole. 3A5423K...
Page 27 Parts XL3400 Parts List Ref. Part Description Qty. Ref. Part Description Qty. 17S075 FOAM, temp barrier, poppet 17V315 COVER, bottom, motor, XL3400, 17M851 GASKET, poppet housing mach 24Z347 HOUSING, poppet 17M826 SEAL, rod, wiper, 1.375 OD shaft 17S929 ISOLATOR, poppet housing - - - - - BEARING, sleeve, 1.375 ID, 1.625 OD...
Page 28 Parts Air Valve Parts (17V344 - Standard Valve, 17V345 - Low Noise Valve) Apply high quality lithium grease. Blue thread sealant. 3A5423K...
Page 29 Parts Air Valve Parts List Ref. Part Description Qty. Ref. Part Description Qty. 317* 104010 PACKING, o-ring - - - - - HOUSING, air valve, XL, machined 318* 154741 PACKING, o-ring 115671 FITTING, connector, male 17S646 PIN, reset, XL air valve 24Z604 VALVE, needle, assembly 557832...
Page 30 Parts Kits and Accessories Table 1: XL Air Motor Repair Kits 6500: 17V316 Bottom Cover Repair Kit Air Motor Part Description 3400: 17V315 Parts Ref. - - - - - Bumper NXT103 Lift Ring (40) - - - - - Bearing, Sleeve 6500: 17V320 Piston/Rod Assembly Repair...
Page 31 Parts Table 2: XL Air Motor Repair Kits Part Description Air Motor Part Ref. 17V344 Repair, Complete Valve Assembly - - - - - Valve, Air, XL (30) 17R950 Gasket, Valve (29) 24X563 Repair, Valve O-rings 104010 O-ring (2) (317) 154741 O-ring (2) (318)
Page 32 Dimensions (Model XL6500) Dimensions (Model XL6500) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) Rod Full Up Rod Full Up Rod Full Down 14.65 (372) 17.75 (450) 18.20 (462) 17.54 (446) 3.10 (79) 8.0 (203) 3/4-16 UNF Mounting Hole Diagram 13.0 in.
Page 33 Dimensions (Model XL3400) Dimensions (Model XL3400) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) Rod Full Up Rod Full Up Rod Full Down 14.65 (372) 17.75 (451) 15.56 (395) 14.47 (367) 3.10 (79) 8.0 (203) 3/4-16 UNF Mounting Hole Diagram 9.75 in.
Page 34 Bumper to Bumper 4.90 in. 125 mm Maximum Cycle Rate 60 cycles/minute Remote Exhaust Models Outlet Connection 1-1/4 npsm(f) union Model XL 6500 Size Motor Effective Area Down Stroke 84.54 in. sq. 545 mm sq. Up Stroke 83.06 in. sq.
Page 35 Technical Specifications California Proposition 65 CALIFORNIA RESIDENTS WARNING: Cancer and reproductive harm – www.P65warnings.ca.gov. 3A5423K...
Page 36 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 manual is also suitable for:

Xl 3400