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Repair and Rebuild Kits for Graco Xtreme and XP Xtreme 290cc Lowers

28 Oct, 2025
erepaircenter

Repair Parts for Xtreme and XP Xtreme 290cc Lowers

When your Graco Xtreme or XP Xtreme 290cc Lower begins showing signs of wear—loss of pressure, throat leaks, or uneven spray—it’s time to rebuild. Understanding which repair parts and seal materials best fit your application is key to restoring performance and extending pump life. This in-depth guide from eRepairCenter.com explains every kit, component, and best practice for maintaining your sprayer lowers.

Overview of the Xtreme and XP Xtreme 290cc Lower

The Graco Xtreme and XP Xtreme sprayers are heavy-duty, high-output systems designed for professional contractors handling protective coatings, epoxies, polyurethanes, and other industrial materials. The heart of these sprayers is the 290cc lower pump, which pressurizes and transfers coating materials efficiently. Over time, abrasive coatings, solvents, and heat degrade seals and packings, making scheduled rebuilds essential.

To help users perform efficient, cost-effective maintenance, Graco offers dedicated repair kits designed around material compatibility and performance needs. These kits replace key wear components such as throat and piston packings, glands, o-rings, and valve balls.

Material Systems and Kit Types

Each 290cc lower can be rebuilt using one of three material systems, depending on your application:

  • PTFE (Teflon): Excellent for chemical resistance and high-temperature spraying.
  • UHMWPE / Leather: Best for abrasive or heavy coating applications requiring rugged durability.
  • UHMWPE / PTFE Hybrid: Combines chemical resistance and mechanical strength for versatility under 140°F (60°C).
AllPTFEUHMWPE / LeatherHybrid
Material System Best For Temp Range Seal Orientation Maintenance Notes Full Kit Ref Throat Kit Piston Kit
PTFE Chemical resistance; solvent-heavy coatings Up to ~200°F (93°C) Throat: down · Piston: up Lubricate packings during assembly 25D248 25D155 25D165
UHMWPE / Leather Abrasive/heavy coatings; long wear life Typical ambient to moderate Throat: up · Piston: up Soak leather 1 hr in oil; lubricate all parts 25D238 25D138 25D145
UHMWPE / PTFE Balanced chem resistance + durability Below 140°F (60°C) Throat: down · Piston: up Lubricate; ideal mixed-duty choice 25D262 25D179 25D193

Tip: If you’re addressing leaks at both ends or your service interval is overdue, a full kit (25D248 / 25D238 / 25D262) is often faster and more economical than buying throat and piston kits separately.

Detailed Breakdown of Xtreme / XP Xtreme 290cc Repair Kits

PTFE (Chemical-Resistant) Kits

25D155 – Throat Seal Repair Kit (PTFE)

  • Contents: 103a Male Gland, 103b Female Gland, (7) White PTFE V-Packings, 103f Wave Spring
  • Orientation: Throat packings face down.
  • Installation: Lubricate all packings to prevent tearing during compression.
  • Application: Ideal for solvent-based or chemically reactive coatings.

25D165 – Piston Seal Repair Kit (PTFE)

  • Contents: 104a Male Gland, 104b Female Gland, (5) White PTFE V-Packings
  • Orientation: Piston packings face up.
  • Installation: Lubricate before inserting the piston rod through the seals.
  • Application: Perfect for high-solvent, high-temperature coating systems.

Together, these kits align with the 25D248 Full Repair Kit—optimized for chemical resistance and higher temperatures up to 200°F (93°C).

UHMWPE / Leather (Abrasive-Duty) Kits

25D138 – Throat Seal Repair Kit (UHMWPE / Leather)

  • Contents: 103a Male Gland, 103b Female Gland, (3) Leather V-Packings, (4) Red UHMWPE V-Packings, 103f Wave Spring
  • Orientation: Throat packings face up.
  • Installation: Soak leather packings in oil for one hour and lubricate all components.
  • Application: Suited for abrasive materials—zinc primers, fireproofing coatings, and industrial enamels.

25D145 – Piston Seal Repair Kit (UHMWPE / Leather)

  • Contents: 104a Male Gland, 104b Female Gland, (2) Leather V-Packings, (3) Red UHMWPE V-Packings
  • Orientation: Piston packings face up.
  • Installation: Oil leather packings before assembly to improve sealing and flexibility.
  • Application: Recommended for extended-duty or high-abrasion operations.

Both kits match the 25D238 Full Repair Kit formulation—engineered for abrasive applications requiring toughness and long wear life.

UHMWPE / PTFE Hybrid (Chemical + Durability) Kits

25D179 – Throat Seal Repair Kit (UHMWPE / PTFE)

  • Contents: 103a Male Gland, 103b Female Gland, (3) White PTFE V-Packings, (4) Red UHMWPE V-Packings, 103f Wave Spring
  • Orientation: Throat packings face down.
  • Installation: Lubricate all seals during reassembly.
  • Application: For balanced chemical resistance and mechanical durability below 140°F (60°C).

25D193 – Piston Seal Repair Kit (UHMWPE / PTFE)

  • Contents: 104a Male Gland, 104b Female Gland, (2) White PTFE V-Packings, (3) Red UHMWPE V-Packings
  • Orientation: Piston packings face up.
  • Installation: Apply lubricant on each seal to avoid friction damage.
  • Application: Excellent all-around solution for moderate chemical exposure with long service life.

Together, these correspond to the 25D262 Full Repair Kit, combining chemical resistance and durability in one design.

Identifying Pump Series (A, B, or C)

The Xtreme / XP Xtreme 290cc Lowers are grouped into Series A, B, or C, determined by the circular grooves on the top filter cap. The O-rings differ by series and are not interchangeable:

  • Series A: Thick PTFE O-Rings (White)
  • Series B: Thin PTFE O-Rings (Blue & White)
  • Series C: Thin PTFE O-Rings (White)

If your pump is an older Series A, use the 24F975 Filter Cap Conversion Kit to improve sealing and ensure compatibility with newer filter systems.

Step-by-Step Rebuild Instructions

  1. Prepare Your Work Area: Relieve system pressure, clean surfaces, and gather tools.
  2. Disassemble the Lower: Remove the pump from the sprayer, separate the filter cap, strainers, and piston assembly.
  3. Replace Seals and Packings: Clean all surfaces and install new packings with correct orientation (throat down or up; piston up).
  4. Lubricate: Apply non-reactive lubricant to all O-rings and threads before tightening.
  5. Reassemble Using Torque Specs:
    • Top Cap: 190–210 ft-lb (258–285 N·m)
    • Inlet Fitting: 125 ft-lb (169 N·m)
    • Piston Rod: 135–150 ft-lb (183–203 N·m)
    • General Fasteners: 40–60 ft-lb (52–82 N·m)
  6. Test the Pump: Reattach to sprayer, prime system, and check for leaks or pressure loss.

When to Rebuild or Replace

  • Pressure loss or surging during operation
  • Visible leaks around the throat or piston
  • Paint bypass or solvent contamination
  • Increased effort to maintain spray pattern

If you observe multiple symptoms, consider a full rebuild with a complete repair kit instead of partial replacements to restore original performance.

Why Buy from eRepairCenter.com

  • All Major Kits In Stock: 25D138, 25D145, 25D155, 25D165, 25D179, 25D193 and full rebuild kits like 25D238, 25D248, and 25D262.
  • Aftermarket and OEM Options: Save with high-quality Bedford Precision alternatives that match OEM performance.
  • Expert Support: We help identify your pump series and correct repair kit.
  • Fast Shipping: Orders ship quickly from our Houston distribution center.

Frequently Asked Questions

Expand allCollapse all
When should I rebuild my 290cc lower?
Rebuild every 6–12 months under regular use, or sooner if you see pressure loss, leaks around the throat/piston, surging, or difficulty holding a consistent spray fan.
Which kit should I choose for chemical coatings?
Choose PTFE-based kits — throat 25D155 and piston 25D165 — or the full 25D248 for the best chemical and temperature resistance.
What’s best for abrasive, high-wear materials?
Use UHMWPE/Leather — throat 25D138 and piston 25D145 — or the full 25D238. Pre-oil leather packings and lubricate during assembly.
Can I use a hybrid option for mixed-duty jobs?
Yes, the UHMWPE/PTFE hybrid — throat 25D179, piston 25D193, or full 25D262 — balances chemical resistance and durability below 140°F (60°C).
Are Series A, B, and C O-rings interchangeable?
No. Match O-rings to your series using the filter cap grooves. Consider the 24F975 Filter Cap Conversion Kit for older Series A units to improve sealing.
Do Bedford Precision kits match OEM quality?
Yes. Bedford kits from eRepairCenter.com are engineered for precise fit and durability comparable to OEM, with strong value for fleet maintenance.

Final Thoughts

Rebuilding your Xtreme or XP Xtreme 290cc Lower restores pump efficiency, extends equipment life, and reduces downtime. Whether you choose PTFE for chemical resistance, UHMWPE/leather for abrasive coatings, or UHMWPE/PTFE for mixed-duty performance, the correct kit ensures smooth operation and professional results.

Find all your Graco Xtreme and XP Xtreme repair kits today at eRepairCenter.com — your trusted source for sprayer parts, repair kits, and expert guidance.