Graco 332245En E Users Manual 332245E Merkur High Pressure Sprayer, Instructions Parts, English
2015-04-02
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Instructions-Parts Repair Kits Accessory Kits See page 25 Merkur® High Pressure Sprayer 332245E EN For protective coating applications in hazardous or non-hazardous locations. For professional use only. See page 2 for model information, including maximum working pressures. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. ti21103a ll 2 G c T3 Related Manuals Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Merkur X48 Package . . . . . . . . . . . . . . . . . . . . . 3 Merkur X72 Package . . . . . . . . . . . . . . . . . . . . . 3 Bare Package . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 General Information . . . . . . . . . . . . . . . . . . . . . . 7 Prepare the Operator . . . . . . . . . . . . . . . . . . . . . 7 Prepare the Site . . . . . . . . . . . . . . . . . . . . . . . . . 7 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Air Lines Accessories . . . . . . . . . . . . . . . . . . . . . 7 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Pressure Relief Procedure . . . . . . . . . . . . . . . . . 9 Flush the Pump Before First Use . . . . . . . . . . . . 9 Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install the Spray Tip . . . . . . . . . . . . . . . . . . . . . 12 Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Preventive Maintenance Schedule . . . . . . . . . . 14 Tighten Threaded Connections . . . . . . . . . . . . . 14 Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 General Information . . . . . . . . . . . . . . . . . . . . . 16 Disconnect the Displacement Pump . . . . . . . . . 16 Reconnect the Displacement Pump . . . . . . . . . 17 Disconnect the Air Motor . . . . . . . . . . . . . . . . . . 18 Reconnect the Air Motor . . . . . . . . . . . . . . . . . . 18 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 System Packages . . . . . . . . . . . . . . . . . . . . . . . 20 Pump System Parts . . . . . . . . . . . . . . . . . . . . . 22 Cart Mount Kit 289694 . . . . . . . . . . . . . . . . . . . 23 Pump Only Control Panel Kits . . . . . . . . . . . . . 24 Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2 Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 26 Merkur X48 48:1 Ratio, 75 cc/cycle . . . . . . . . . . . . . . . . 26 Merkur X72 72:1 Ratio, 50 cc/cycle . . . . . . . . . . . . . . . . 27 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 30 Related Manuals Manual Description 312796 NXT™ Air Motor 312145 XTR™5 and XTR™7 Airless Spray Gun 332246 Merkur High Pressure Displacement Pump 407055 Air Control Panel Kit 407053 Merkur X48 Seal Repair Kit 407054 Merkur X72 Seal Repair Kit 307296 High Pressure Surge Tanks and Fluid Filters 308169 Air Filters and Lubricators 332245E Models Models Merkur X48 Package Gun Part Hoses Gun Fluid Tip Size Hose Gun 16U920 XTR504 0.019 ✔ Accessories Gun Fluid Whip Suction Fluid Hose Tube Filter ✔ Maximum Maximum Maximum Fluid Working Fluid Flow Drain Inlet Air Rate Pressure Valve Pressure Kit psi (MPa, bar) psi (MPa, bar) gpm (lpm) ✔ ✔ 100 4800 (33, 330) 1.2 (4.5) Merkur X72 Package Gun Part Gun Hoses Gun Fluid Tip Size Hose 16U918 XTR704 0.019 ✔ Accessories Gun Fluid Whip Suction Fluid Hose Tube Filter ✔ Maximum Maximum Maximum Fluid Working Fluid Flow Drain Inlet Air Rate Pressure Valve Pressure Kit psi (MPa, bar) psi (MPa, bar) gpm (lpm) ✔ ✔ 100 7200 (50, 500) 0.8 (3) Bare Package Bare packages do not include a gun or hose. Maximum Maximum Fluid Working Inlet Air Pressure Pressure psi (MPa, bar) psi (MPa, bar) Part Description Maximum Fluid Flow Rate gpm (lpm) 16V174 Merkur X72 100 7200 (50, 500) 0.8 (3) 16V175 Merkur X48 100 4800 (33, 330) 1.2 (4.5) Maximum Recommended Tip Size Model Merkur X72 Merkur X48 332245E Tip Size 0.021 0.025 3 Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable. WARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in 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 dispensing device, 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. • Engage trigger lock when not dispensing. • Do not point dispensing device at anyone or at any part of the body. • Do not put your hand over the fluid outlet. • Do not stop or deflect leaks with your hand, body, glove, or rag. • Follow the Pressure Relief Procedure when you stop dispensing 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 4 332245E 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. • Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment. 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 332245E 5 Installation Installation A F D B E C M R N P L G H J K ti21104a FIG. 1: Typical Installation Key: A B C D E F G H J 6 Air Shutoff Valve (optional accessory) Air Filter (optional accessory) Bleed Type Master Air Valve Pump Air Pressure Gauge Pump Air Pressure Regulator Cart Fluid Drain Valve Spray Gun Gun Fluid Supply Hose K L M N P R Whip Hose Pump Fluid Outlet Grounding Wire Wet-Cup Pump Fluid Inlet Suction Hose 332245E Installation General Information Components NOTE: Reference numbers and letters in parentheses in the text refer to the callouts in the figures. See FIG. 1. NOTE: Always use Genuine Graco Parts and Accessories, available from your Graco distributor. If you supply your own accessories, be sure they are adequately sized and pressure-rated for your system. • The red-handled bleed-type master air valve (C) is required in your system to relieve air trapped between it and the air motor when the valve is closed. Do not block access to the valve. FIG. 1 is only a guide for selecting and installing system components and accessories. Prepare the Operator All persons who operate the equipment must be trained in the operation of all system components as well as the proper handling of all fluids. All operators must thoroughly read all instruction manuals, tags, and labels before operating the equipment. Prepare the Site Ensure that you have an adequate compressed air supply. Bring a compressed air supply line from the air compressor to the pump location. Be sure all air hoses are properly sized and pressure-rated for your system. Use only electrically conductive hoses. The air hose should have a 3/8 npt(m) thread. For best performance, use 1/2 in. air line or larger. Keep the site clear of any obstacles or debris that could interfere with the operator's movement. Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts. • The pump air regulator (E) controls pump speed and outlet pressure by adjusting the air pressure to the pump. • The air relief valve (not shown) opens automatically to prevent overpressurization of the pump. • The airless spray gun (H) dispenses the fluid. The gun houses the spray tip (not shown), which is available in a wide range of sizes for different spray patterns and rates of flow. Refer to gun manual for tip installation. • The hose (J) provides the gun fluid supply. • The suction hose (R) with strainer allows the pump to draw fluid from a 5 gallon (19 liter) pail. • A optional fluid filter with a 60 mesh (250 micron) stainless steel element filters particles from fluid as it leaves the pump. • A fluid drain valve (G) relieves fluid pressure in the hose and gun. Have a grounded, metal pail available for use when flushing the system. Air Lines Accessories Install the following accessories in the order shown in FIG. 1, using adapters as necessary. 332245E • An air-line filter (B) removes harmful dirt and moisture from the compressed air supply. • A second bleed-type air shutoff valve (A) isolates the air line accessories for servicing. Locate upstream from all other air line accessories. 7 Installation Grounding Setup 1. If it is necessary to filter the material at the pump fluid outlet, install optional Fluid Outlet Filter Kit 16V583. See Accessories, page 25, for parts. The equipment and flush pail 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. a. Use a wrench to hold the pump fluid outlet fitting in place and a second wrench on the drain valve tee fitting. Remove drain valve tee fitting (G). 1. Pump: See FIG. 2. Verify that the ground screw (MS) is attached and tightened securely to the air motor. Connect the other end of the ground wire (M) to a true earth ground. b. Place fluid filter (401) in a vise. Apply thread sealant on threads and install fittings as shown. 401 M 1 MS ti12914a FIG. 2. Ground screw and wire G 1 2. Pump fluid hoses: use only electrically conductive fluid hoses. Check electrical resistance of hoses. If total resistance to ground exceeds 25 megohms, replace hose immediately. Genuine Graco hoses are conductive. FIG. 3: Optional Fluid Outlet Filter Kit 3. Air compressor: follow manufacturer's recommendations. 2. See FIG. 1. Attach end of fluid hose (J) to pump outlet (L), or filter, and tighten. 4. Spray gun: ground through connection to a properly grounded fluid hose and pump. 3. Attach other end of fluid hose (J) to reducing nipple and whip hose (K). Attach whip hose to gun and tighten. 5. Fluid supply container: follow your local code. 6. Object being sprayed: follow your local code. 7. Solvent pails used when flushing: follow your local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts the grounding continuity. ti21356a 1 If necessary, remove barbed fitting (13) from tee fitting (G) and install in fluid filter kit drain valve. 4. Close bleed type master air valve (C). Connect air supply hose to air inlet. C 8. To maintain grounding continuity when flushing or relieving pressure, hold a metal part of the spray gun firmly to the side of a grounded metal pail, then trigger the gun. ti21105a 5. Verify that suction hose fittings are tight. 6. Flush before using. See page 10. 7. Prime before using. See page 11. 8 332245E Operation Operation Pressure Relief Procedure Trigger Lock Follow the Pressure Relief Procedure whenever you see this symbol. This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment. See FIG. 4. Always engage gun trigger lock when you stop spraying to prevent gun from being triggered accidentally by hand or if dropped or bumped. Gun Trigger Safety Locked 1. Engage the trigger lock. TI5049a 2. See FIG. 1. Turn off the bleed-type master air valve (C). 3. Disengage the trigger lock. 4. Hold a metal part of the gun firmly to a grounded metal waste container. Trigger the gun to relieve fluid pressure. 5. Engage the trigger lock. Gun Trigger Safety Unlocked TI5048a FIG. 4. Trigger Lock 6. Open all fluid drain valves in the system, having a waste container ready to catch the drainage. Leave the drain valve(s) open until you are ready to spray again. Wet Cup 7. 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. Before starting, fill wet cup (N) 1/2 full with Graco Throat Seal Liquid (TSL) Part No. 206994, or compatible solvent. Flush the Pump Before First Use N The pump is tested with lightweight oil, which is left in to protect the pump parts. If the fluid you are using may be contaminated by the oil, flush it out with a compatible solvent. See Flush on page 10. FIG. 5. Wet Cup 332245E 9 Operation Flush 4. Turn regulator adjustment knob (E) counterclockwise until it stops, and gauge (D) reads zero. D Flush the pump: • Before first use • When changing colors or fluids • Before repairing equipment • Before fluid dries or settles out in a dormant pump (check the pot life of catalyzed fluids) • At the end of the day • Before storing the pump. E C ti21106a 5. Open bleed type master air valve (C). 6. Flush hose and gun: a. Disengage gun trigger lock. Flush at the lowest pressure possible. Flush with a fluid that is compatible with the fluid you are pumping and with the wetted parts in your system. Check with your fluid manufacturer or supplier for recommended flushing fluids and flushing frequency. TI5048a 1. Follow Pressure Relief Procedure, page 9. 2. See FIG. 1. Lock gun trigger. Remove tip guard and spray tip from gun (H). Refer to gun manual. 3. Place suction tube in a compatible solvent. b. Trigger gun slowly open regulator adjustment knob (E) until pump begins to cycle. Trigger gun into grounded pail until a steady stream comes from gun. Trigger gun for 10-15 seconds. NOTE: Do not stretch hose tight; let it hang to assist fluid flow into pump. TI8727a c. 10 Engage trigger lock. 332245E Operation Prime 7. Place drain tube in a grounded waste pail. Open drain/purge valve (S) slightly by rotating counterclockwise. 1. Follow Pressure Relief Procedure, page 9. 2. See FIG. 1. Lock gun trigger. Remove tip guard and spray tip from gun (H). Refer to gun manual. S 3. Place suction tube in a compatible fluid. ti21107a 8. Start the pump by rotating the air regulator adjustment knob (E) clockwise until pump begins to move. NOTE: Do not stretch hose tight; let it hang to assist fluid flow into pump. 4. Turn regulator adjustment knob (E) counterclockwise until it stops, and gauge (D) reads zero. E D ti21108a 9. When clean solvent flows from drain tube close drain/purge valve (S) by rotating clockwise. Pump will stall. C E ti21106a 5. Open bleed type master air valve (C). S ti21109a 10. Follow Pressure Relief Procedure, page 9. Leave solvent in and store sprayer. 332245E 11 Operation 6. Prime through drain valve: 7. Place drain tube in a grounded waste pail. Open drain/purge valve (S) slightly by rotating counterclockwise. b. Trigger gun slowly open regulator adjustment knob (E) until pump begins to cycle. Trigger gun into grounded pail until a steady stream comes from gun. TI8727a S ti21107a 8. Start the pump by rotating the air regulator adjustment knob (E) clockwise until pump begins to move. c. Engage trigger lock. 11. Equipment is now ready to spray; go to Spray, page 13. NOTICE Do not prime pump through drain valve using two component materials. Mixed two component materials will harden in valve and result in clogging. Install the Spray Tip E ti21108a 9. When clean material flows from drain tube close drain/purge valve (S) by rotating clockwise. Pump will stall. Follow Pressure Relief Procedure, page 9. Install the spray tip and tip guard as explained in your separate gun manual, supplied. The fluid output and pattern width depend on the size of the spray tip, the fluid viscosity, and the fluid pressure. Use the Spray Tip Selection Chart in your gun instruction manual as a guide for selecting an appropriate spray tip for your application. Maximum Tip Size S Larger tips can be used with less viscous material. ti21109a Model Merkur X72 10. Prime hose and gun: Merkur X48 Maximum Tip Size 0.021 0.025 a. Disengage gun trigger lock. TI5048a 12 332245E Operation Spray 6. Disengage gun trigger lock. TI5048a NOTICE Do not allow pump to run dry. It will quickly accelerate to a high speed causing damage. 7. Spray a test pattern. Read fluid manufacturer’s recommendations. 1. Prime. See Prime, page 11. 2. Follow Pressure Relief Procedure, page 9. 3. Install tip and tip guard on gun. 4. Open bleed type master air valve (C). 8. Flush when done spraying. See Flush, page 10. 9. Follow Pressure Relief Procedure, page 9. Shutdown C Follow Pressure Relief Procedure, page 9. ti21110a Always flush the pump before the fluid dries on the displacement rod. See Flush on page 10. 5. Turn regulator adjustment knob (E) until gauge (D) reads desired pressure. Turn clockwise to increase pressure, counterclockwise to decrease pressure. D E ti21111a 332245E 13 Maintenance Maintenance Preventive Maintenance Schedule The operating conditions of your particular system determine how often maintenance is required. Establish a preventive maintenance schedule by recording when and what kind of maintenance is needed, and then determine a regular schedule for checking your system. Replace lens covers on regulator gauge lenses when dirt makes gauges difficult to read. Tighten Threaded Connections Before each use, check all hoses for wear or damage. Replace as necessary. Check that all threaded connections are tight and leak-free. Wet Cup Fill the wet cup one-half full with Graco Throat Seal Liquid (TSL). Maintain level daily. 14 332245E Troubleshooting Troubleshooting NOTE: Check all possible problems and causes before disassembling the pump. Problem Pump fails to operate. Pump operates, but output is low on both strokes. Cause Solution Restricted line or inadequate air sup- Clear line or increase air supply. ply; closed or clogged valves. Check that the valves are open. Obstructed fluid hose or gun; fluid hose ID is too small. Open, clear*; use hose with larger ID. Fluid dried on the displacement rod. Clean; always stop the pump at the bottom of its stroke; keep the wet-cup 1/2 filled with Graco throat seal liquid (TSL). Dirty, worn, or damaged air motor parts. Clean or repair air motor. See air motor manual. Restricted line or inadequate air sup- Clear line or increase air supply. ply; closed or clogged valves. Check that the valves are open. Obstructed fluid hose or gun; fluid hose ID is too small. Open, clear*; use hose with larger ID. Worn packings in displacement pump. Replace packings. See displacement pump manual. Pump operates, but output is low on downstroke. Held open or worn ball check valves or piston packings. Clear valve; replace packings. See displacement pump manual. Erratic or accelerated pump speed. Exhausted fluid supply. Refill and prime. Held open or worn ball check valves or packings. Clear valve, replace packings; see displacement pump manual. Worn throat packings. Replace throat packings. See displacement pump manual. Fluid being pumped is visible in the TSL reservoir. * To determine if the fluid hose or gun is obstructed, relieve the pressure. Disconnect the fluid hose and place a container at the pump fluid outlet to catch any fluid. Turn on the air just enough to start the pump. It the pump starts when the air is turned on, the obstruction is in the hose or gun. 332245E 15 Repair Repair 5. Lower the coupling nut (106) enough to remove the coupling collars (107), and then remove the coupling nut (106). General Information 107 • Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawing. • Always use Genuine Graco Parts and Accessories, available from your Graco distributor. If you supply your own accessories, be sure they are adequately sized and pressure rated for your system. Disconnect the Displacement Pump 1. Stop the pump in the middle of the stroke. 2. Flush the pump, if possible. See Flush, page 10. Relieve the pressure. See Pressure Relief Procedure, page 9. 3. Disconnect the air and fluid hoses and the ground wire (109). 4. Move the spring guard (118) upwards or downwards. Hold the flats of the air motor piston rod with a wrench. Use another wrench to loosen the coupling nut (106). 106 ti21113a ti21114a 6. Use a hammer and brass rod to loosen the jam nut (105). Unscrew the jam nut as far as possible. 7. Unscrew the displacement pump by hand and place on work bench. ti21115a Threads are very sharp. To avoid cuts, use a rag to protect hands when hand turning or carrying the displacement pump. ti21112a 16 332245E Repair Reconnect the Displacement Pump 6. Screw the displacement pump into the adapter plate (103) until the cylinder top is flush with the top of the adapter plate. 1. Tilt the air motor onto its back, then hand turn the displacement pump into the adapter plate. Set the pump upright again. 2. Hold the air motor piston rod up with one hand. With your other hand, put the coupling nut (106) on the displacement rod. 3. Put the coupling collars (107) into the coupling nut (106) so large flanges point upward. 4. Place spring (118) over coupling nut (106). Hold spring down to connect the air motor rod and coupling nut (106). 107 103 106 ti12817a 5. Gently let the air motor piston rod drop onto the displacement rod. Hand tighten the coupling nut (106). 332245E Cylinder, not wet cup, should be flush with plate. FIG. 6. Align cylinder and adapter plate. 7. Align fluid outlet as shown and tighten the jam nut. 8. Hold the flats of the motor rod with a wrench. Use another wrench to tighten the coupling nut (106). Torque to 75-80 ft-lb (102-108 N•m). 17 Repair Disconnect the Air Motor Reconnect the Air Motor 1. Flush the pump, if possible. See Flush, page 10. Relieve the pressure. See Pressure Relief Procedure, page 9. 1. Screw the tie rods (104) into the bottom cover of the air motor. Torque to 50-55 ft-lb (68-75 N•m). 2. Disconnect the air hose, fluid hoses, and the ground wire (109). 3. Hold the flats of the air motor piston rod with a wrench. Use another wrench to loosen the coupling nut (106). 2. Align the tie rods (104) with the holes in the pump adapter (103). Carefully lower the air motor into place. 3. Attach the tie rod nuts (105) and torque to 50-60 ft-lb (68-81 N•m). 4. Tighten the mounting screws (209). 4. Use a 23 mm socket to remove the tie rod nuts (105). 5. Use a 13 mm socket to remove the top two mounting screws (209). 5. Hand tighten the coupling nut (106), then torque to 75-80 ft-lb (102-108 N•m). 6. Connect the air hose, fluid hose, and the ground wire. 6. Lift up on the air motor to remove it. The tie rods (104) and will remain attached. NOTE: Remove the two screws on the arms and tip back or remove the air control panel for easier removal of the air motor. 209 104 103 105 ti12819a 7. Use a socket on the flats of the tie rods (104) to remove them from the bottom cover of the air motor. NOTE: See air motor manual for service and parts information. 18 332245E Repair 332245E 19 Parts Parts System Packages 2 3 10 1 Apply stainless steel pipe sealant to all non-swiveling pipe threads. 15 1 23 12 17 19 16 13 18 9 11 14 4 5 6 7 8 ti21118a 20 332245E Parts System Packages Quantity System Packages Ref 1 Part --------- 2 3 4 5 6 16U947 16U948 277794 116401 116402 247301 7 8 9 197682 187147 H53825 H73825 10 11* 12* 13* 14* 15 16 XTR504 XTR704 15R874 245143 116746 116750 105332 15V204 17 ----- 18 164856 19 H52506 H72506 22 23 24 * 206994 --------- Description SYSTEM, pump, 48:1; see page 22 SYSTEM, pump, 72:1; see page 22 KIT, air control, X72 KIT, air control, X48 INSERT, control panel ADAPTER, elbow ADAPTER, quick connect HOSE, suction, 1 in. npt x quick connect TUBE, suction STRAINER, inlet HOSE, coupled; 5600 psi, 0.375 in. (9.5 mm) ID, 25 ft (7.6 m) HOSE, coupled; 7250 psi, 0.375 in. (9.5 mm) ID, 25 ft (7.6 m) GUN, XTR5 with RAC tip GUN, XTR7 with RAC tip FITTING, tee; 3/8 mxfxf VALVE, pressure, bleed FITTING, barbed, plated TUBE, nylon NUT, lock FITTING, elbow, 1/2 npt x 1/2 tube TUBE, nylon; 1/2 OD x 3/8 ID; 0.65 ft (0.2 m) FITTING, nipple, reducing; 3/8 x 1/4 nptm HOSE, coupled; 5600 psi, 0.25 (6 mm) ID, 6 ft (1.8 m) HOSE, coupled; 7250 psi, 0.25 (6 mm) ID, 6 ft (1.8 m) FLUID, TSL 8 oz bottle LABEL, identification COVER, lens, 12 sticker sheet; (not shown), order Kit 24A540 for 5 sheets 16U918, Merkur X72 72:1, 50cc 16U920, Merkur X48 48:1, 75cc Bare Packages 16V174, Merkur X72 72:1, 50cc 1 16V175, Merkur X48 48:1, 75cc 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Parts included in Drain Valve Kit 16U950 (purchase separately). 332245E 21 Parts Pump System Parts 1 Torque to 50-55 ft-lb (68-75 N•m). 2 Torque to 50-60 ft-lb (68-81 N•m). 3 Torque to 75-80 ft-lb (102-108 N•m). 4 101 Assemble pump (102) to top of within +/one thread. Torque jam nut of pump to 70-75 ft-lb (95-102 N•m). 108 1 104 107 3 106 109 110 103 2 105 4 ti21119a 102 22 332245E Parts Cart Mount Kit 289694 16V175, Merkur X48 Pump System 16V174, Merkur X72 Pump System Ref. 101 102 103 104 105 106 107 108 109 110 118 Part M18LN0 16U916 16U917 15T392 15M662 15U606 15T311 184128 111799 238909 289694 16U944 Description MOTOR, air, 7.5 in LOWER, assy, 50cc; 16V174 LOWER, assy, 75cc; 16V175 ADAPTER, pump lower ROD, tie NUT, lock, m16 x 2 NUT, coupler COLLAR, coupling SCREW, cap, hex hd WIRE, grounding assembly KIT, cart GUARD, spring Qty. 1 1 1 1 3 3 1 2 4 1 1 1 202 204 207 209 208 201 205 206 203 ti12634a Ref. 201 202 203 204 205 206 207 208 209 332245E Part --------15C871 ----119451 119452 115480 116630 111799 Description CART, frame HANDLE, cart CAP, leg SLEEVE, cart handle WHEEL, semi-pneumatic CAP, hub KNOB, t-handle SCREW, carriage SCREW, cap, M8 x 1.25 Qty . 1 1 2 2 2 2 2 2 4 23 Parts Pump Only Control Panel Kits 307 308 304 310 327 319 313 303 ti13468a 306 305 303 326 304 311 301 317 321 314 ti13567a ti13567b 16U948, X48 Air Control Kit 16U947, X72 Air Control Kit Ref. Part Description Qty. 301 114362 VALVE, ball 1 303 ----TUBE, 1/2 OD, cut to fit, 1.5 ft. order Tubing Kit 24D496 304 121212 ELBOW, swivel, 1/2T x 3/8 npt(m) 2 305 15T536 REGULATOR, air, 3/8 npt 1 306 ----ELBOW, swivel, 5/32 T x 1/4 npt 1 307 ----TUBE, black, cut to fit, 5 in. order Tubing Kit 24D496 308 ----SWIVEL, 90°, 5/32T x 1/8 npt(f) 1 310 15T500 GAUGE, pressure 1 311 113498 VALVE, safety 1 313 15T538 NUT, regulator 1 314 114381 SCREW, cap, button head 2 317 ----PANEL 1 318 ----LABEL, panel (not shown) 1 319 ----INSERT 1 320 105332 NUT, lock (not shown) 2 321 ----ELBOW, 1/2T x 1/2 npt 1 322 ----COVER, lens, 12 sticker sheet (not 1 shown), order Kit 24A540 for 5 sheets 326 ----FITTING, straight, 1/2T x 3/8 npt(m) 1 327 24P814 RING, grounding 1 24 332245E Repair Kits Repair Kits Sprayer Models Description Merkur X48 Merkur X72 Drain Valve Kit Includes tee fitting (11), bleed valve (12), barbed fitting (13), and nylon tube (14). 16U950 16U950 Displacement Pump Rebuild Kit See manual displacement pump manual. 16U925 16U924 XTR Gun Repair Kit See gun manual. 248837 248837 Accessories Fluid Outlet Filter, 16V583 Ref. 401 402 402 403 404 401 1 404 Part Description 155665 UNION, adapter 16W395 BUSHING, PIPE, 3/4-14(m) x 3/8-18(f) npt 237069 FILTER, paint, 7252 psi (50 MPa, 500 bar) 159239 NIPPLE, pipe, reducing, 1/2 x 3/8 npt Qty 1 1 1 1 403 Apply thread sealant to all pipe threads. Sprayer Models Description Merkur X48 Merkur X72 Air Filter Kit 1/2 npt(fbe) inlet and outlet, 20 micron filter. See air filter manual. 106149 106149 50 ft. Fluid Hose (5200 psi rated) H53850 Optional 50-foot hose, 3/8 in. ID, 5600 psi (38.6 MPa, 386 bar) maximum working pressure. 50 ft. Fluid Hose (7200 psi rated) Optional 50-foot hose, 3/8 in. ID, 7250psi (50 MPa, 500 bar) maximum working pressure. Whip Hose Replacement 6 ft (1.8 m) hose, 1/4 in. ID, 5600 psi (38.6 MPa, 386 bar) maximum working pressure. Whip Hose Replacement 6 ft (1.8 m) hose, 1/4 in. ID, 7250psi (50 MPa, 500 bar) maximum working pressure. 332245E H73850 H52506 H72506 25 Performance Charts Performance Charts Calculate Fluid Outlet Pressure Calculate Pump Air Flow/Consumption To calculate fluid outlet pressure (psi/MPa/bar) at a specific fluid flow (gpm/lpm) and operating air pressure (psi/MPa/bar), use the following instructions and pump data charts. To calculate pump air flow/consumption (scfm or m3/min) at a specific fluid flow (gpm/lpm) and air pressure (psi/MPa/bar), use the following instructions and pump data charts. 1. Locate desired flow along bottom of chart. 1. Locate desired flow along bottom of chart. 2. Follow vertical line up to intersection with selected fluid outlet pressure curve. Follow left to scale to read fluid outlet pressure. 2. Follow vertical line up to intersection with selected air flow/consumption curve. Follow right to scale to read air flow/consumption Merkur X48 48:1 Ratio, 75 cc/cycle Cycles per Minute Fluid Outlet Pressure psi (MPa, bar) 5000 (35, 350) 20 30 40 50 60 60 (1.7) A A 50 (1.4) 4000 (28, 280) B 3000 (21, 210) 30 (0.9) C C 2000 (14, 140) 40 (1.1) B 20 (0.6) 1000 (7, 70) 0 Air Flow scfm (m3/min) 10 6000 (42, 420) 10 (0.3) 0 0.2 (0.75) 0.4 (1.5) 0.6 (2.3) 0.8 (3.0) 1.0 (3.8) 1.2 (4.5) Fluid Flow gpm (lpm) tested in No. 10 weight oil Key: A B C 26 100 psi (0.69 MPa, 6.9 bar) 70 psi (0.48 MPa, 4.8 bar) 40 psi (0.28 MPa, 2.8 bar) Fluid Flow Air Flow 332245E Performance Charts Merkur X72 72:1 Ratio, 50 cc/cycle Cycles per Minute 7000 (48, 483) 30 61 45 A 100 (2.8) 6000 (42, 420) 5000 (35, 350) B 80 (2.3) A 4000 (28, 280) 60 (1.7) 3000 (21, 210) B C 2000 (14, 140) 40 (1.1) C 1000 (7, 70) 0 120 (3.4) 0 0.2 (0.75) 0.4 (1.5) 20 (0.6) 0.6 (2.3) Air Flow scfm (m3/min) Fluid Outlet Pressure psi (MPa, bar) 15 0.8 (3.0) Fluid Flow gpm (lpm) tested in No. 10 weight oil Key: A B C 100 psi (0.69 MPa, 6.9 bar) 70 psi (0.48 MPa, 4.8 bar) 40 psi (0.28 MPa, 2.8 bar) Fluid Flow Air Flow 332245E 27 Dimensions Dimensions 38.6 in. (980 mm) 18 in. (457 mm) 28 20.5 in. (521 mm) 332245E Technical Data Technical Data Merkur High Pressure Sprayers Maximum pump air inlet pressure Ambient air temperature range Maximum fluid temperature Sound data Weight Maximum fluid working pressure 16U920, 16V175 16U918, 16V174 Ratio 16U920, 16V175 16U918, 16V174 Wetted Parts Displacement pump Spray gun Fluid hoses Suction assembly 332245E US Metric 100 psi 0.7 MPa, 7 bar 35°–120°F 2°–49°C 160°F 71°C See Merkur Air Motor Technical Data 99 lb 45 kg 4800 psi 7200 psi 33 MPa, 330 bar 50 MPa, 500 bar 48:1 72:1 Stainless steel, plated carbon steel, tungsten carbide with 6% nickel, UHMWPE, PTFE See manual XTR guns technical data nylon carbon steel, aluminum, nylon 29 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. 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. For patent information, see www.graco.com/patents. Original instructions. This manual contains English. MM 332245 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA Copyright 2013, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. www.graco.com Revision E, September 2014
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File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.4 Linearized : Yes Page Mode : UseOutlines XMP Toolkit : 3.1-701 Producer : Acrobat Distiller 7.0.5 (Windows) Marked : True Copyright : 2013, Revision E September 2014 Job Ref : A225M, Z091932 Keywords : "MM 332245, 332245, 332245E, 332245EN-E, 332245EN, Merkur High Pressure Sprayer" Web Statement : 332245E - Merkur High Pressure Sprayer, Instructions-Parts, English Modify Date : 2014:10:22 08:51:53-05:00 Creator Tool : FrameMaker 11.0 Create Date : 2009:12:15 10:08:57Z Metadata Date : 2014:10:22 08:51:53-05:00 Format : application/pdf Description : Merkur High Pressure Sprayer, Instructions-Parts, English Title : 332245E - Merkur High Pressure Sprayer, Instructions-Parts, English Creator : Emily Bringle Subject : MM 332245, 332245, 332245E, 332245EN-E, 332245EN, Merkur High Pressure Sprayer Document ID : uuid:0cd48cf6-a51c-4e62-ae48-e2489ee001fc Instance ID : uuid:9e76c419-fe8a-4f69-a35c-c2d764d8b89d Page Count : 30 Language : en Author : Emily BringleEXIF Metadata provided by EXIF.tools