Graco 332245En E Users Manual 332245E Merkur High Pressure Sprayer, Instructions Parts, English

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332245E

EN

Instructions-Parts

Merkur®

High Pressure Sprayer

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

Repair Kits

Accessory Kits

See page 25

Related Manuals

2332245E

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

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 Fil-

ters

308169 Air Filters and Lubricators

Models

332245E 3

Models

Merkur X48 Package

Merkur X72 Package

Bare Package

Bare packages do not include a gun or hose.

Maximum Recommended Tip Size

Part

Gun Hoses Accessories

Maximum

Inlet Air

Pressure

psi (MPa, bar)

Maximum

Fluid Working

Pressure

psi (MPa, bar)

Maximum

Fluid Flow

Rate

gpm (lpm)

Gun Tip Size

Gun

Fluid

Hose

Gun

Fluid

Whip

Hose

Suction

Tube

Fluid

Filter

Drain

Valve

Kit

16U920 XTR504 0.019 ✔ ✔ ✔ ✔ 100 4800 (33, 330) 1.2 (4.5)

Part

Gun Hoses Accessories

Maximum

Inlet Air

Pressure

psi (MPa, bar)

Maximum

Fluid Working

Pressure

psi (MPa, bar)

Maximum

Fluid Flow

Rate

gpm (lpm)

Gun Tip Size

Gun

Fluid

Hose

Gun

Fluid

Whip

Hose

Suction

Tube

Fluid

Filter

Drain

Valve

Kit

16U918 XTR704 0.019 ✔ ✔ ✔ ✔ 100 7200 (50, 500) 0.8 (3)

Part

Description

Maximum

Inlet Air

Pressure

psi (MPa, bar)

Maximum

Fluid Working

Pressure

psi (MPa, bar)

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)

Model Tip Size

Merkur X72 0.021

Merkur X48 0.025

Warnings

4332245E

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-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

Warnings

332245E 5

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 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.

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

WARNING

Installation

6332245E

Installation

Key:

A Air Shutoff Valve (optional accessory)

B Air Filter (optional accessory)

C Bleed Type Master Air Valve

D Pump Air Pressure Gauge

E Pump Air Pressure Regulator

FCart

G Fluid Drain Valve

HSpray Gun

J Gun Fluid Supply Hose

K Whip Hose

L Pump Fluid Outlet

M Grounding Wire

NWet-Cup

P Pump Fluid Inlet

R Suction Hose

F

IG

. 1: Typical Installation

D

P

L

C

M

K

E

R

J

H

F

N

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G

B

A

Installation

332245E 7

General Information

NOTE: Reference numbers and letters in parentheses

in the text refer to the callouts in the figures.

NOTE: Always use Genuine Graco Parts and Accesso-

ries, available from your Graco distributor. If you supply

your own accessories, be sure they are adequately

sized and pressure-rated for your system.

F

IG

. 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 thor-

oughly 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 com-

pressor 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.

Have a grounded, metal pail available for use when

flushing the system.

Components

See F

IG

. 1.

• 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.

• 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 avail-

able in a wide range of sizes for different spray pat-

terns 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.

Air Lines Accessories

Install the following accessories in the order shown in

F

IG

. 1, using adapters as necessary.

• An air-line filter (B) removes harmful dirt and mois-

ture 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.

Trapped air can cause the pump to cycle

unexpectedly, which could result in serious injury

from splashing or moving parts.

Installation

8332245E

Grounding

1. Pump: See F

IG

. 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.

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.

3. Air compressor: follow manufacturer's recommen-

dations.

4. Spray gun: ground through connection to a properly

grounded fluid hose and pump.

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 card-

board, which interrupts the grounding continuity.

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.

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.

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).

b. Place fluid filter (401) in a vise. Apply thread

sealant on threads and install fittings as shown.

2. See F

IG

. 1. Attach end of fluid hose (J) to pump out-

let (L), or filter, and tighten.

3. Attach other end of fluid hose (J) to reducing nipple

and whip hose (K). Attach whip hose to gun and

tighten.

4. Close bleed type master air valve (C). Connect air

supply hose to air inlet.

5. Verify that suction hose fittings are tight.

6. Flush before using. See page 10.

7. Prime before using. See page 11.

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.

F

IG

. 2. Ground screw and wire

M

MS

ti12914a

F

IG

. 3: Optional Fluid Outlet Filter Kit

If necessary, remove barbed fitting (13) from tee fitting (G)

and install in fluid filter kit drain valve.

1

ti21356a

G

401

1

1

ti21105a

C

Operation

332245E 9

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever

you see this symbol.

1. Engage the trigger lock.

2. See F

IG

. 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.

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.

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 cou-

pling and relieve pressure gradually; then loosen

completely. With tip removed, trigger gun into

bucket.

Flush the Pump Before First Use

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.

Trigger Lock

See F

IG

. 4. Always engage gun trigger lock when you

stop spraying to prevent gun from being triggered acci-

dentally by hand or if dropped or bumped.

Wet Cup

Before starting, fill wet cup (N) 1/2 full with Graco Throat

Seal Liquid (TSL) Part No. 206994, or compatible sol-

vent.

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.

F

IG

. 4. Trigger Lock

F

IG

. 5. Wet Cup

TI5049a

TI5048a

Gun Trigger

Safety Locked

Gun Trigger

Safety Unlocked

N

Operation

10 332245E

Flush

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.

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.

1. Follow Pressure Relief Procedure, page 9.

2. See F

IG

. 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.

NOTE: Do not stretch hose tight; let it hang to assist

fluid flow into pump.

4. Turn regulator adjustment knob (E) counterclock-

wise until it stops, and gauge (D) reads zero.

5. Open bleed type master air valve (C).

6. Flush hose and gun:

a. Disengage gun trigger lock.

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.

c. Engage trigger lock.

E

D

ti21106a

C

TI5048a

TI8727a

Operation

332245E 11

7. Place drain tube in a grounded waste pail.

Open drain/purge valve (S) slightly by rotating coun-

terclockwise.

8. Start the pump by rotating the air regulator adjust-

ment knob (E) clockwise until pump begins to move.

9. When clean solvent flows from drain tube close

drain/purge valve (S) by rotating clockwise. Pump

will stall.

10. Follow Pressure Relief Procedure, page 9. Leave

solvent in and store sprayer.

Prime

1. Follow Pressure Relief Procedure, page 9.

2. See F

IG

. 1. Lock gun trigger. Remove tip guard and

spray tip from gun (H). Refer to gun manual.

3. Place suction tube in a compatible fluid.

NOTE: Do not stretch hose tight; let it hang to assist

fluid flow into pump.

4. Turn regulator adjustment knob (E) counterclock-

wise until it stops, and gauge (D) reads zero.

5. Open bleed type master air valve (C).

S

ti21107a

E

ti21108a

S

ti21109a

E

D

ti21106a

C

Operation

12 332245E

6. Prime through drain valve:

7. Place drain tube in a grounded waste pail.

Open drain/purge valve (S) slightly by rotating coun-

terclockwise.

8. Start the pump by rotating the air regulator adjust-

ment knob (E) clockwise until pump begins to move.

9. When clean material flows from drain tube close

drain/purge valve (S) by rotating clockwise. Pump

will stall.

10. Prime hose and gun:

a. Disengage gun trigger lock.

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.

c. Engage trigger lock.

11. Equipment is now ready to spray; go to Spray, page

13.

Install the Spray Tip

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 instruc-

tion manual as a guide for selecting an appropriate

spray tip for your application.

Maximum Tip Size

Larger tips can be used with less viscous material.

S

ti21107a

E

ti21108a

S

ti21109a

TI5048a

NOTICE

Do not prime pump through drain valve using two

component materials. Mixed two component materi-

als will harden in valve and result in clogging.

Model Maximum Tip Size

Merkur X72 0.021

Merkur X48 0.025

TI8727a

Operation

332245E 13

Spray

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).

5. Turn regulator adjustment knob (E) until gauge (D)

reads desired pressure. Turn clockwise to increase

pressure, counterclockwise to decrease pressure.

6. Disengage gun trigger lock.

7. Spray a test pattern. Read fluid manufacturer’s rec-

ommendations.

8. Flush when done spraying. See Flush, page 10.

9. Follow Pressure Relief Procedure, page 9.

Shutdown

Follow Pressure Relief Procedure, page 9.

Always flush the pump before the fluid dries on the dis-

placement rod. See Flush on page 10.

NOTICE

Do not allow pump to run dry. It will quickly accelerate

to a high speed causing damage.

C

ti21110a

E

D

ti21111a

TI5048a

Maintenance

14 332245E

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 connec-

tions are tight and leak-free.

Wet Cup

Fill the wet cup one-half full with Graco Throat Seal Liq-

uid (TSL). Maintain level daily.

Troubleshooting

332245E 15

Troubleshooting

NOTE: Check all possible problems and causes before

disassembling the pump.

* To determine if the fluid hose or gun is obstructed, relieve the pressure. Disconnect the fluid hose and place a con-

tainer 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.

Problem Cause Solution

Pump fails to operate. Restricted line or inadequate air sup-

ply; closed or clogged valves.

Clear line or increase air supply.

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.

Pump operates, but output is low on

both strokes.

Restricted line or inadequate air sup-

ply; closed or clogged valves.

Clear line or increase air supply.

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 displace-

ment 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.

Fluid being pumped is visible in the

TSL reservoir.

Worn throat packings. Replace throat packings. See dis-

placement pump manual.

Repair

16 332245E

Repair

General Information

• 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 Proce-

dure, 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).

5. Lower the coupling nut (106) enough to remove the

coupling collars (107), and then remove the cou-

pling nut (106).

6. Use a hammer and

brass rod to loosen the

jam nut (105). Unscrew

the jam nut as far as

possible.

7. Unscrew the displace-

ment pump by hand

and place on work

bench.

ti21112a

Threads are very sharp. To avoid cuts, use a rag to

protect hands when hand turning or carrying the dis-

placement pump.

ti21113a ti21114a

106

107

ti21115a

Repair

332245E 17

Reconnect the Displacement

Pump

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 cou-

pling nut (106).

Hold spring down

to connect the air

motor rod and coupling nut (106).

5. Gently let the air motor piston rod drop onto the dis-

placement rod. Hand tighten the coupling nut (106).

6. Screw the displacement pump into the adapter plate

(103) until the cylinder top is flush with the top of the

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).

ti12817a

107

106 F

IG

. 6. Align cylinder and adapter plate.

Cylinder, not

be flush with

plate.

wet cup, should

103

Repair

18 332245E

Disconnect the Air Motor

1. Flush the pump, if possible. See Flush, page 10.

Relieve the pressure. See Pressure Relief Proce-

dure, page 9.

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).

4. Use a 23 mm socket to remove the tie rod nuts

(105).

5. Use a 13 mm socket to remove the top two mount-

ing screws (209).

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.

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 infor-

mation.

Reconnect the Air Motor

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. 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).

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.

ti12819a

104

105

103

209

Repair

332245E 19

Parts

20 332245E

Parts

System Packages

Apply stainless steel pipe sealant to

all non-swiveling pipe threads.

1

17

16

3

2

10

19

18

9

11

14

4

5

6

7

8

1

12

13

15

ti21118a

23

Parts

332245E 21

System Packages

* Parts included in Drain Valve Kit 16U950 (purchase separately).

Ref Part Description

Quantity

System Packages Bare Packages

16U918,

Merkur X72

72:1, 50cc

16U920,

Merkur X48

48:1, 75cc

16V174,

Merkur X72

72:1, 50cc

16V175,

Merkur X48

48:1, 75cc

1 ----- SYSTEM, pump, 48:1;

see page 22 1 1

----- SYSTEM, pump, 72:1;

see page 22 1 1

216U947 KIT, air control, X72 1 1

16U948 KIT, air control, X48 1 1

3277794 INSERT, control panel 1 1 1 1

4116401 ADAPTER, elbow 1 1 1 1

5116402 ADAPTER, quick connect 1 1 1 1

6247301 HOSE, suction, 1 in. npt x quick

connect 1 1 1 1

7197682 TUBE, suction 1 1 1 1

8187147 STRAINER, inlet 1 1 1 1

9H53825 HOSE, coupled; 5600 psi, 0.375

in. (9.5 mm) ID, 25 ft (7.6 m) 1

H73825 HOSE, coupled; 7250 psi, 0.375

in. (9.5 mm) ID, 25 ft (7.6 m) 1

10 XTR504 GUN, XTR5 with RAC tip 1

XTR704 GUN, XTR7 with RAC tip 1

11* 15R874 FITTING, tee; 3/8 mxfxf 1 1 1 1

12* 245143 VALVE, pressure, bleed 1 1 1 1

13* 116746 FITTING, barbed, plated 1 1 1 1

14* 116750 TUBE, nylon 1 1 1 1

15 105332 NUT, lock 2 2 2 2

16 15V204 FITTING, elbow, 1/2 npt x 1/2

tube 1 1 1 1

17 ----- TUBE, nylon; 1/2 OD x 3/8 ID;

0.65 ft (0.2 m) 1 1 1 1

18 164856 FITTING, nipple, reducing; 3/8 x

1/4 nptm 1 1

19 H52506 HOSE, coupled; 5600 psi, 0.25

(6 mm) ID, 6 ft (1.8 m) 1

H72506 HOSE, coupled; 7250 psi, 0.25

(6 mm) ID, 6 ft (1.8 m) 1

22 206994 FLUID, TSL 8 oz bottle 1 1 1 1

23 ----- LABEL, identification 1 1 1 1

24 ----- COVER, lens, 12 sticker sheet;

(not shown), order Kit 24A540

for 5 sheets

1 1 1 1

Parts

22 332245E

Pump System Parts

101

102

110

ti21119a

Torque to 50-55 ft-lb (68-75 N•m).

1

Torque to 50-60 ft-lb (68-81 N•m).

2

Torque to 75-80 ft-lb (102-108 N•m).

3

Assemble pump (102) to top of within +/-

one thread. Torque jam nut of pump to

70-75 ft-lb (95-102 N•m).

4

105

104

103

106

107

108

109

1

2

3

4

Parts

332245E 23

16V175, Merkur X48 Pump System

16V174, Merkur X72 Pump System Cart Mount Kit 289694

Ref. Part Description Qty.

101 M18LN0 MOTOR, air, 7.5 in 1

102 16U916 LOWER, assy, 50cc; 16V174 1

16U917 LOWER, assy, 75cc; 16V175 1

103 15T392 ADAPTER, pump lower 1

104 15M662 ROD, tie 3

105 15U606 NUT, lock, m16 x 2 3

106 15T311 NUT, coupler 1

107 184128 COLLAR, coupling 2

108 111799 SCREW, cap, hex hd 4

109 238909 WIRE, grounding assembly 1

110 289694 KIT, cart 1

118 16U944 GUARD, spring 1

Ref. Part Description

Qty

.

201 ----- CART, frame 1

202 ----- HANDLE, cart 1

203 15C871 CAP, leg 2

204 ----- SLEEVE, cart handle 2

205 119451 WHEEL, semi-pneumatic 2

206 119452 CAP, hub 2

207 115480 KNOB, t-handle 2

208 116630 SCREW, carriage 2

209 111799 SCREW, cap, M8 x 1.25 4

201

202

203

204

205

206

207

208

209

ti12634a

Parts

24 332245E

Pump Only Control Panel Kits

16U948, X48 Air Control Kit

16U947, X72 Air Control Kit

ti13567a

301

303

314

317

326

311

305 304

310

313

306

307 308 304

ti13567b

327

319

321

303

ti13468a

Ref. Part Description Qty.

301 114362 VALVE, ball 1

303 ----- TUBE, 1/2 OD, cut to fit,

order Tubing Kit 24D496

1.5 ft.

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,

order Tubing Kit 24D496

5 in.

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

shown), order Kit 24A540 for 5

sheets

1

326 ----- FITTING, straight, 1/2T x 3/8 npt(m) 1

327 24P814 RING, grounding 1

Repair Kits

332245E 25

Repair Kits

Accessories

Fluid Outlet Filter, 16V583

Description

Sprayer Models

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

Apply thread sealant to all pipe threads.

1

404

403

401

402

Ref. Part Description Qty

401 155665 UNION, adapter 1

402 16W395 BUSHING, PIPE, 3/4-14(m) x

3/8-18(f) npt

1

403 237069 FILTER, paint, 7252 psi (50 MPa,

500 bar)

1

404 159239 NIPPLE, pipe, reducing, 1/2 x 3/8

npt

1

Description

Sprayer Models

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)

Optional 50-foot hose, 3/8 in. ID, 5600 psi (38.6 MPa, 386 bar) maximum

working pressure.

H53850

50 ft. Fluid Hose (7200 psi rated)

Optional 50-foot hose, 3/8 in. ID, 7250psi (50 MPa, 500 bar) maximum

working pressure.

H73850

Whip Hose

Replacement 6 ft (1.8 m) hose, 1/4 in. ID, 5600 psi (38.6 MPa, 386 bar)

maximum working pressure.

H52506

Whip Hose

Replacement 6 ft (1.8 m) hose, 1/4 in. ID, 7250psi (50 MPa, 500 bar)

maximum working pressure.

H72506

Performance Charts

26 332245E

Performance Charts

Calculate Fluid Outlet Pressure

To calculate fluid outlet pressure (psi/MPa/bar) at a spe-

cific fluid flow (gpm/lpm) and operating air pressure

(psi/MPa/bar), use the following instructions and pump

data charts.

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.

Calculate Pump Air Flow/Consumption

To calculate pump air flow/consumption (scfm or

m

3

/min) at a specific fluid flow (gpm/lpm) and air pres-

sure (psi/MPa/bar), use the following instructions and

pump data charts.

1. Locate desired flow along bottom of chart.

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

0

0

Fluid Flow gpm (lpm) tested in No. 10 weight oil

Fluid Outlet Pressure psi (MPa, bar)

Air Flow scfm (m

3

/min)

0.2

(0.75) 0.4 0.6 0.8 1.0

(1.5) (2.3) (3.0) (3.8) 1.2

(4.5)

10 20 30 40 50 60

1000

(7, 70)

3000

4000

5000

6000

(14, 140)

(21, 210)

(28, 280)

(35, 350)

(42, 420)

2000

10

20

30

40

50

60

(0.3)

(0.6)

(0.9)

(1.1)

(1.4)

(1.7)

A

B

C

A

B

C

Key:

A 100 psi (0.69 MPa, 6.9 bar)

B 70 psi (0.48 MPa, 4.8 bar)

C 40 psi (0.28 MPa, 2.8 bar)

Fluid Flow

Air Flow

Performance Charts

332245E 27

Merkur X72

72:1 Ratio, 50 cc/cycle

Cycles per Minute

0

0

Fluid Flow gpm (lpm) tested in No. 10 weight oil

Fluid Outlet Pressure psi (MPa, bar)

Air Flow scfm (m

3

/min)

0.2

(0.75) 0.4 0.6 0.8

(1.5) (2.3) (3.0)

15 30 45 61

1000

(7, 70)

3000

4000

5000

6000

(14, 140)

(21, 210)

(28, 280)

(35, 350)

(42, 420)

2000

20

40

60

(0.6)

(1.1)

(1.7)

80

(2.3)

100

(2.8)

120

(3.4)

7000

(48, 483)

A

B

C

A

B

C

Key:

A 100 psi (0.69 MPa, 6.9 bar)

B 70 psi (0.48 MPa, 4.8 bar)

C 40 psi (0.28 MPa, 2.8 bar)

Fluid Flow

Air Flow

Dimensions

28 332245E

Dimensions

38.6 in.

18 in.

20.5 in.

(457 mm)

(521 mm)

(980 mm)

Technical Data

332245E 29

Technical Data

Merkur High Pressure Sprayers

US Metric

Maximum pump air inlet pressure 100 psi 0.7 MPa, 7 bar

Ambient air temperature range 35°–120°F 2°–49°C

Maximum fluid temperature 160°F 71°C

Sound data See Merkur Air Motor Technical Data

Weight 99 lb 45 kg

Maximum fluid working pressure

16U920, 16V175 4800 psi 33 MPa, 330 bar

16U918, 16V174 7200 psi 50 MPa, 500 bar

Ratio

16U920, 16V175 48:1

16U918, 16V174 72:1

Wetted Parts

Displacement pump Stainless steel, plated carbon steel, tungsten carbide with

6% nickel, UHMWPE, PTFE

Spray gun See manual XTR guns technical data

Fluid hoses nylon

Suction assembly carbon steel, aluminum, nylon

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.

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

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.

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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