Graco 3A0732J Merkur Es Spray Packages Users Manual 3A0732J, Packages, Instructions/Parts Manual, English
2015-04-02
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Instructions/Parts Merkur® ES Spray Packages 3A0732J EN For low-volume fine finish spray applications. For professional use only. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. 15:1 Spray Packages 30:1 Spray Packages 100 psi (0.7 MPa, 7.0 bar) Maximum Air Inlet Pressure See page 3 for model information, including maximum fluid working pressure. ti15590a ti15589a II 2 G c T5 X Contents Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Prepare the Operator . . . . . . . . . . . . . . . . . . . . . 7 Prepare the Site . . . . . . . . . . . . . . . . . . . . . . . . . 7 Supplied Components . . . . . . . . . . . . . . . . . . . . . 7 Inline Fluid Filter Kits . . . . . . . . . . . . . . . . . . . . . . 7 Air Line Accessories . . . . . . . . . . . . . . . . . . . . . . 7 Wall Mount Packages . . . . . . . . . . . . . . . . . . . . . 8 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Flush Before Using Equipment . . . . . . . . . . . . . . 8 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Pressure Relief Procedure . . . . . . . . . . . . . . . . 10 Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . 10 Install the Spray Tip . . . . . . . . . . . . . . . . . . . . . 11 Adjust the Atomization . . . . . . . . . . . . . . . . . . . 11 Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . 12 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Tighten Threaded Connections . . . . . . . . . . . . . 13 Flush the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 General Information . . . . . . . . . . . . . . . . . . . . . . 15 To Remove Intake Valve Only . . . . . . . . . . . . . . 15 Disconnect the Displacement Pump . . . . . . . . . 15 Disassemble the Pump . . . . . . . . . . . . . . . . . . . 16 Reassemble the Pump . . . . . . . . . . . . . . . . . . . 16 Reconnect the Displacement Pump . . . . . . . . . 16 Repair Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . 18 Replace Pilot Valves . . . . . . . . . . . . . . . . . . . . . 20 Disconnect the Air Motor . . . . . . . . . . . . . . . . . . 21 Reconnect the Air Motor . . . . . . . . . . . . . . . . . . 21 Repair Air Motor . . . . . . . . . . . . . . . . . . . . . . . . 22 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Package Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Hose and Gun . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Displacement Pump Parts . . . . . . . . . . . . . . . . . 30 Air Motor Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Air Valve Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Air Control Parts . . . . . . . . . . . . . . . . . . . . . . . . 36 Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . . 38 Package Dimensions . . . . . . . . . . . . . . . . . . . . . . . 39 Package Weights . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Wall Bracket Mounting Hole Diagram . . . . . . . . . 40 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 42 15:1 Ratio Pumps . . . . . . . . . . . . . . . . . . . . . . . 42 30:1 Ratio Pumps . . . . . . . . . . . . . . . . . . . . . . . 43 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 44 Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 44 3A0732J Models Models Package 24F150 24F151 24F152 24F153 24F154 24F155 24F156 24F157 24F158 24F159 24N548* 24W281 24W283 24W285 24W287 * Series A A A A A A A A A A A A A A A Ratio Maximum Fluid Working Pressure psi (MPa, bar) Package Type Gun Mounting Material 15:1 15:1 30:1 30:1 30:1 30:1 30:1 30:1 15:1 15:1 30:1 15:1 15:1 30:1 30:1 1500 (10.3, 103) 1500 (10.3, 103) 3000 (20.7, 207) 3000 (20.7, 207) 3000 (20.7, 207) 3000 (20.7, 207) 3000 (20.7, 207) 3000 (20.7, 207) 1500 (10.3, 103) 1500 (10.3, 103) 3000 (20.7, 207) 1500 (10.3, 103) 1500 (10.3, 103) 3000 (20.7, 207) 3000 (20.7, 207) Air-assisted Air-assisted Air-assisted Air-assisted Airless Airless Air-assisted Air-assisted Air-assisted Air-assisted WB3000 Air-assisted Air-assisted Air-assisted Air-assisted G15 Carbide G15 Carbide G40 G40 Silver Plus Silver Plus G40 G40 G15 Carbide G15 Carbide ----G15 Carbide G15 Carbide G40 G40 Wall Stand Wall Stand Wall Stand Wall Stand Wall Stand ----Stand Stand Stand Stand Plated Steel Plated Steel Stainless Steel Stainless Steel Plated Steel Plated Steel Plated Steel Plated Steel Stainless Steel Stainless Steel Stainless Steel Plated Steel Stainless Steel Plated Steel Stainless Steel Part No. 24N548 is used as a supply pump in the WB3000 Waterborne Isolation System. It includes a pump bracket and items 7-19, 21, 23, and 28-42 on page 25. See manual 3A2497 for warnings and instructions for a waterborne system. 3A0732J 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, 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 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. • If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem. • Keep a working fire extinguisher in the work area. SPECIAL CONDITIONS FOR SAFE USE Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable vapors. To help prevent fire and explosion: • Clean plastic parts only in well ventilated area. • Do not clean with a dry cloth. • Do not operate electrostatic guns in equipment work area. 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. • Engage trigger lock when not spraying. • Do not point gun at anyone or at any part of the body. • Do not put your hand over the spray tip. • Do not stop or deflect leaks with your hand, body, glove, or rag. • Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment. • Tighten all fluid connections before operating the equipment. • Check hoses and couplings daily. Replace worn or damaged parts immediately. 4 3A0732J Warnings WARNING 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. • 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. PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This 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. 3A0732J 5 Warnings 6 3A0732J Installation Installation Prepare the Operator All persons who operate the equipment must be trained in the safe, efficient 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. A quick disconnect coupling is recommended. 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. • The 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 red hose (G) provides the gun air supply. • The blue hose (K) provides the gun fluid supply. • The suction kit with strainer (J) allows the pump to draw fluid from a 5 gallon (19 liter) pail. Inline Fluid Filter Kits Inline fluid filter kits are available as an accessory in stainless steel (24F271) or aluminum (24F272), to filter particles from fluid as it leaves the pump. Kits include a 60 mesh (250 micron) stainless steel element. Air Line Accessories Install the following accessories in the order shown in FIG. 2, using adapters as necessary. • An air-line filter (C) removes harmful dirt and moisture from the compressed air supply. • A second bleed-type air shutoff valve (B) isolates the air line accessories for servicing. Locate upstream from all other air line accessories. Supplied Components See FIG. 2 on page 9. • The red-handled bleed-type master air valve (D) is required in your system to relieve air trapped between it and the air motor and gun when the valve is closed. Do not block access to the valve. • The pump air regulator (F) controls pump speed and outlet pressure by adjusting the air pressure to the pump. • The air pressure relief valve (P) opens automatically to prevent overpressurization of the pump. • The gun air regulator (E) adjusts the air pressure to the air-assisted spray gun. 3A0732J 7 Installation Wall Mount Packages 1. Be sure the wall can support the weight of the pump, bracket, hoses and accessories, as well as the stress caused during operation. 2. Position the wall bracket at a convenient height. Do not stretch the suction hose tight; let it hang to assist fluid flow into the pump. For ease of operation and service, make sure the pump air inlet, fluid inlet, and fluid outlet ports are easily accessible. 3. Using the wall bracket as a template, drill mounting holes in the wall. Hole diameters and wall mounting dimensions are shown on page 40. 4. Attach the bracket to the wall. Use screws that are long enough to keep the pump from vibrating during operation. NOTE: Be sure the bracket is level. Grounding The equipment must be grounded. Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit. 1. Pump: See FIG. 1. Verify that the ground wire (26) is attached to the ground screw (23), and the screw is tightened securely to the adapter plate (10). Use any of the three threaded holes in the adapter plate. Connect the other end of the ground wire to a true earth ground. 2. Air and fluid hoses: Static electricity may build up when fluids flow through pumps, hoses, and sprayers. At least one hose must be electrically conductive, with a maximum of 500 ft. (150 m) combined hose length to ensure grounding continuity. Check electrical resistance of hoses. If total resistance to ground exceeds 25 megohms, replace hose immediately. 3. Air compressor: follow manufacturer's recommendations. 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 cardboard, 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. Flush Before Using Equipment The equipment was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid contaminating your fluid with oil, flush the equipment with a compatible solvent before using the equipment. See Prime the Pump, page 10. 10 26 23 ti16282a FIG. 1. Ground Wire 8 3A0732J Installation Setup 1. See FIG. 2. Attach one end of fluid hose (K) to pump outlet (or optional inline fluid filter outlet). 4. Attach remaining end of the air hose to air inlet at base of gun (H). 2. Attach other end of fluid hose to gun fluid inlet at base of gun (H). 5. Clip fluid and air hoses together with the supplied hose clips (qty. of 7). Space clips as needed. 3. Attach one end of the air hose (G) to gun air regulator (E). 6. Attach the fluid suction kit (J) to the pump inlet. B A E J D C F G P M L N H K Key: A B C D E F G H J K L M N P Main Air Supply Line Air Shutoff Valve Air Filter Bleed-type Master Air Valve (required) Gun Air Pressure Regulator Pump Air Pressure Regulator Gun Air Supply Line Spray Gun Fluid Suction Kit Gun Fluid Supply Line Pump Ground Wire (required) Mounting Bracket (used for wall mounting or stand) Pump Stand Air Pressure Relief Valve ti15591a FIG. 2. Typical Installation (Air-Assisted Stand Mount Package Shown) 3A0732J 9 Operation Operation Pressure Relief Procedure Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from skin injection, splashing or moving parts. Trigger Lock See FIG. 3. Always engage gun trigger lock when you stop spraying to prevent gun from being triggered accidentally by hand or if dropped or bumped. 1. Lock the gun trigger. 2. See FIG. 2. Turn off the bleed-type master air valve (D). Gun Trigger Locked 3. Unlock the gun trigger. 4. Hold a metal part of the gun firmly to a grounded metal waste container. Trigger the gun to relieve fluid pressure. tiI6581A 5. Lock the gun trigger. 6. If you suspect that pressure has not been fully relieved after following the steps above, check the following: Gun Trigger Unlocked a. The spray tip may be completely clogged. Very slowly loosen the air cap retaining ring to relieve pressure in the cavity between the ball/seat shutoff and the plugged tip. Clear the tip orifice. b. The gun fluid filter or the fluid hose may be completely clogged. Very slowly loosen the hose end coupling at the gun and relieve pressure gradually. Then loosen completely to clear the obstruction. c. 10 After following the steps above, if the spray tip or hose still seems completely clogged, 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 waste container. ti6582A FIG. 3. Trigger Lock Prime the Pump Have safety spring (9) in place during operation to reduce risk of pinching or loss of fingers. 1. See FIG. 3. Lock gun trigger. Remove tip guard and spray tip from gun. Refer to gun manual. 3A0732J Operation 2. See FIG. 2. Close gun air regulator (E) and pump air regulator (F) by turning knobs counterclockwise reducing pressure to zero. Close bleed-type air valve (D). Adjust the Atomization 3. Connect air line to bleed type air valve. 4. Check that all fittings throughout system are tightened securely. NOTE: Use this procedure with airless and air-assisted spray guns. 5. Position pail close to pump. Suction hose is 3 ft (0.9 m) long. Do not stretch hose tight; let it hang to assist fluid flow into pump. 1. Do not turn on atomizing air supply. Fluid pressure is controlled by the air pressure supplied to the pump (pump air regulator). Set fluid pressure at low starting pressure. For low viscosity fluids (less than 25 sec, #2 Zahn cup) with lower percent solids (typically less than 40%), start at 300 psi (2.1 MPa, 21 bar) at pump outlet. For fluids with higher viscosity or higher solids content, start at 600 psi (4.2 MPa, 42 bar). Refer to the following example. 6. Hold metal part of gun firmly to side of grounded metal pail, unlock trigger, and hold trigger open. 7. Open bleed-type air valve. Slowly turn pump air regulator clockwise, increasing pressure until pump starts. Example: 8. Cycle pump slowly until all air is pushed out and pump and hoses are fully primed. 9. Release gun trigger and lock trigger safety. Pump should stall against pressure. Pump Air Regulator Setting psi (MPa, bar) Pump Ratio 15:1 30:1 x x 20 (0.14, 1.4) 20 (0.14, 1.4) Approximate Fluid Pressure psig (MPa, bar) = = 300 (2.1, 21) 600 (4.2, 42) Install the Spray Tip 2. Hold gun perpendicular and approximately 12 inches (304 mm) from surface. 3. Move gun first, then pull gun trigger to spray onto test paper. Follow Pressure Relief Procedure, page 10. 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. NOTE: The maximum recommended spray tip size is .019 in. (0.483 mm). 4. Increase fluid pressure in 100 psi (0.7 MPa, 7 bar) increments, just to the point where a further increase in fluid pressure does not significantly improve fluid atomization. Refer to the following example. Example: Pump Air Regulator Increment psi (MPa, bar) Pump Ratio 15:1 30:1 x x 7 (.05, 0.5) 3.3 (0.02, 0.2) Incremental Fluid Pressure psi (MPa, bar) = = 100 (0.7, 7.0) 100 (0.7, 7.0) 5. If you are using an air-assisted spray gun, see Adjust the Spray Pattern on page 12. 3A0732J 11 Operation Adjust the Spray Pattern 3. See FIG. 4. For narrower pattern, turn pattern adjustment valve knob (AA) counterclockwise (out). If pattern is still not narrow enough, increase air pressure to gun slightly or use different size tip. NOTE: Use this procedure with air-assisted spray guns only. 1. See FIG. 4. Close off pattern adjustment air by turning knob (AA) clockwise (in) all the way. This sets gun for its widest pattern. OUT (narrower pattern) too little air correct amount of air FIG. 5. Spray Pattern Problems no air AA AA IN (wider pattern) TI0792A Shutdown Follow Pressure Relief Procedure, page 10. ti6559A FIG. 4. Pattern Air Knob Always flush the pump before the fluid dries on the displacement rod. See Flush the Pump on page 13. 2. See FIG. 5. Set atomizing air pressure at about 5 psi (0.35 bar, 35 kPa) when triggered. Check spray pattern, then slowly increase air pressure until tails are completely atomized and pulled into spray pattern. Do not exceed 100 psi (0.7 MPa, 7 bar) air pressure to gun. 12 3A0732J Maintenance Maintenance 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. Flush the Pump Read all Warnings. Follow all Grounding instructions. See page 8. 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 10. 2. Remove tip guard and spray tip from gun. Refer to separate gun manual. 3. Place suction tube in grounded metal pail containing cleaning fluid. 4. Set pump to lowest possible fluid pressure, and start pump. 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. 3A0732J 5. Hold a metal part of the gun firmly to a grounded metal pail. 6. Trigger gun. Flush system until clear solvent flows from gun. 7. Follow Pressure Relief Procedure, page 10. 8. Clean the tip guard, spray tip, and fluid filter element separately, then reinstall them. 9. Clean inside and outside of suction tube and suction hose. 13 Troubleshooting Troubleshooting NOTE: Check all possible problems and causes before disassembling the pump. Relieve the pressure before checking or servicing the equipment. Problem Air motor will not run. Cause Damaged air valve (214). Solution Replace or service air valve (214). See page 18. Damaged pilot valve (213). Replace pilot valves (213). See page 20. Air continuously exhausting around air motor piston rod. Damaged u-cups (207). Replace piston rod u-cups (207). See page 22. Air continuously exhausting from muffler. Damaged air valve plate (305) or cup (312). Replace or service air valve (214). See page 18. Air motor “bounces” at top of stroke. Damaged bottom pilot valve (213). Replace bottom pilot valve (213). See page 20. Air motor “bounces” at bottom of stroke. Damaged top pilot valve (213). Replace top pilot valve (213). See page 20. Icing inside motor. Air motor operating at high pressure or high cycle rate. Reduce pressure, cycle rate, or duty cycle of motor. Reduce dew point of compressed air in moisture coalescing filter. Pump fails to operate. Pump operates but does not prime. Pump operates, but output is low on both strokes. Restricted line or inadequate air supply; 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 (119). Clean; keep the packing nut wet-cup filled with Graco throat seal liquid (TSL). Held open or worn ball check valves or pis- Clear valve; replace packings. See page ton packings. 16. Worn suction hose o-ring (38). Replace suction hose o-ring (38). Restricted line or inadequate air supply; 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 page 16. Pump operates, but output is low on downstroke. Held open or worn ball check valves or pis- Clear valve; replace packings. See page ton packings. 16. 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 page 16. Fluid being pumped is visible in the packing nut wet-cup. Worn throat packings. Tighten packing nut. Bad spray pattern. Clean or repair spray gun or tip. Replace throat packings. See page 16. 14 See G15/G40 air-assisted gun manual or Silver Plus airless gun manual. 3A0732J Repair 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. To Remove Intake Valve Only The intake ball and seat may be cleaned or serviced without disconnecting the displacement pump. 1. Stop the pump. 2. Flush the pump, if possible (see page 13). Follow Pressure Relief Procedure, page 10. Disconnect the Displacement Pump 1. Stop the pump. 2. Flush the pump, if possible (see page 13). Follow Pressure Relief Procedure, page 10. 3. Disconnect the air hose, fluid hose, and suction hose. 4. See FIG. 6. Push the safety spring (9) down and hold to access the coupling pin (18). Push the retaining spring (19) up and push out the pin, using a screwdriver or punch. 5. Loosen the jam nut (13). 6. Unscrew the displacement pump by hand and place on work bench. 3. Disconnect the suction hose. 19 18 4. Remove the intake housing (110). See FIG. 7. 5. Clean or replace the ball guide (109), ball (116), seat (117), and o-ring (111). 6. Install the o-ring (111‡), seat (117), intake ball (116‡), and ball guide (109) in the intake housing (110). 7. Screw the intake housing (110) onto the cylinder (105). Torque to 70-80 ft-lb (95-108 N•m). 10 9 13 TI16261A FIG. 6. Safety Spring and Connecting Pin 3A0732J 15 Repair Disassemble the Pump NOTE: Pump Repair Kits are available. See page 31 to order the correct kit for your pump. Parts are marked with an ‡. 3. Install the male gland (114‡) in the cylinder (105). Install the throat packings in the following order with the lips facing down: blue UHMWPE (106‡), leather (113‡), UHMWPE, leather, UHMWPE. Install the female gland (112‡). 1. Follow the instructions under Disconnect the Displacement Pump, page 15. 4. Install the o-ring (104‡) on the packing nut (103). Loosely install the packing nut in the cylinder. 1. See FIG. 7. Loosen the packing nut (103), using a screwdriver and hammer. Remove the o-ring (104). 5. Liberally lubricate the piston packings and the top 2 in. (51 mm) of the displacement rod (119). 2. Unscrew the cylinder (105) from the intake housing (110). The rod and piston assembly will come with the cylinder. 6. Push the displacement rod (119) into the cylinder (105) from the bottom until the piston is completely in the cylinder and the rod protrudes from the packing nut (103). 3. Remove the ball guide (109), intake ball (116), seat (117), and o-ring (111) from the intake housing (110). 7. Grease the o-ring (107‡) and install it on the cylinder (105). 4. Drive the rod and piston assembly out the bottom of the cylinder. Remove the o-ring (107) from the cylinder. 8. Install the o-ring (111‡), seat (117), intake ball (116‡), and ball guide (109) in the intake housing (110). 5. Insert a plastic rod in the bottom of the cylinder and drive the throat packings and glands out the top. 9. Place the intake housing (110) in a vise. Screw the cylinder (105) into the intake housing. Torque to 70-80 ft-lb (95-108 N•m). 6. Put the rod (119) in a vise and unscrew the piston (124). Be careful not to drop the piston ball (120). Disassemble the piston packings from the piston. 10. Tighten the packing nut (103) 1/2 turn past handtight, or torque to 60-80 in-lb (6.7-9.0 N•m). 7. Clean and inspect all parts. Replace any damaged parts. 11. Ensure that the button plug (102‡) is in place on the packing nut (103). Reassemble the Pump NOTE: Soak the leather packings (113‡, 125‡) in hydraulic oil for one hour before installing them in the pump. 12. Follow the instructions under Reconnect the Displacement Pump, page 16. Reconnect the Displacement Pump 1. Install the piston wiper (123‡) on the piston (124), with the lips facing down. Install the female gland (122‡). Install the piston packings in the following order with the lips facing up: blue UHMWPE (126‡), leather (125‡), UHMWPE, leather, UHMWPE. Install the male gland (121‡). NOTICE The displacement pump can be damaged if the stroke is not centered when the pump is reconnected. Be sure to fully screw the displacement pump into the adapter plate (10). 2. Put the displacement rod (119) in a vise. Place the piston ball (120‡) in the cavity of the rod. Screw the piston assembly into the rod. Torque to 24-30 ft-lb (33-40 N•m). 1. Screw the displacement pump into the adapter plate (10) until it stops. Back off pump less than 1 turn, to align pump outlet as desired. 16 3A0732J Repair 2. Tighten the jam nut (13). Torque to 65-75 ft-lb (88-102 N•m). 4. Push the retaining spring (19) into place to cover the pin. 3. Align the hole in the displacement rod with the hole in the air motor rod. Use a screwdriver to push in the pin (18). 5. Fill throat packing nut wet-cup with TSL to prevent premature packing wear. ‡102 103 ‡104 ‡112 105 1 ‡106 ‡114 15 113‡ 1 107‡ 109❖ 116‡❖ 119 117❖ 111‡❖ ‡121 2 ‡126 ‡122 110 125‡ 2 1 ‡123 ‡120 124 1 Lips must face down. 2 Lips must face up. TI16131a FIG. 7. Displacement Pump 3A0732J 17 Repair Repair Air Valve 312◆ Replace Complete Air Valve 311◆ 305◆ 1. Stop the pump. Follow Pressure Relief Procedure, page 10. 2. Disconnect the air line to the motor. 3. See FIG. 14 on page 23. Remove four screws (211). Remove the air valve (214) and gasket (209*◆). 4. To repair the air valve, go to Disassemble the Air Valve, page 18. To install a replacement air valve, continue with step 5. 5. Align the new air valve gasket (209*◆) on the manifold, then attach the air valve (214). Torque screws (211) to 95-105 in-lb (11-12 N•m). 6. Reconnect the air line to the motor. 309†◆ ti16284a FIG. 8. Air Plate Removal 3. See FIG. 9. Remove the snap ring (310✠ ) from each end. Use the piston to push the end caps (307✠ ) out of the ends. Remove end cap o-rings (306†✠ ◆). 4. Remove the piston (302◆). Remove the u-cup seals (308†◆) from each end and the detent assembly (303◆) and detent cam (304◆) from the center. Replace Seals or Rebuild Air Valve NOTE: Air Valve Seal Kits are available. See page 35. Parts are marked with an †. Air Valve Repair Kits are available. See page 35. Parts are marked with an ◆. Air Valve End Cap Kits are available. See page 35. Parts are marked with an ✠ . Disassemble the Air Valve 1. Perform steps 1-3 under Replace Complete Air Valve, page 18. 2. See FIG. 8. Use a 2 mm or 5/64 hex key to remove two screws (309†◆). Remove the valve plate (305◆), cup (312◆), and spring (311◆). 18 3A0732J Repair ◆✠ 310 1 †✠ ◆306 ✠ 307 301 1 ◆304 1 ◆303 ◆311 1 ◆312 ◆305 1 †◆308 1 ◆302 †◆309 1 †◆308 ✠ 307 1 †✠ ◆306 ◆✠ 310 1 ti16213a Apply lubricant. FIG. 9. Air Valve Assembly 3A0732J 19 Repair Reassemble the Air Valve 1. See FIG. 9. Lubricate detent cam (304◆) and install into housing. 2. See FIG. 10. Lubricate the u-cups (308†◆) and install on the piston (302◆) with lips facing toward the center of the piston. 7. Install the spring (311◆). Lubricate and install the air valve cup (312◆), see FIG. 11. Align the small round magnet with the air inlet. 8. Install the valve plate (305◆). Tighten the screws (309†◆) to hold it in place. †◆308 Lips face down 312◆ ◆302 Magnet ti16283a FIG. 11. Air Valve Cup Installation Replace Pilot Valves †◆308 Lips face up ti12754a FIG. 10. Air Valve U-cup Installation 3. See FIG. 9. Lubricate both ends of the piston (302◆) and install it in the housing. 4. Lubricate and install the detent assembly (303◆) into the piston. 5. Lubricate new o-rings (306†✠ ◆) and install on the end caps (307✠ ). Install the end caps into the housing. 6. Install a snap ring (310◆✠ ) on each end to hold end caps in place. 20 1. Stop the pump. Follow Pressure Relief Procedure, page 10. 2. Disconnect the air line to the motor. 3. See FIG. 12. Push the safety spring (9) down and hold to access the pilot valve on the bottom cover. 4. See FIG. 14 on page 23. Use a 10 mm wrench to remove the old pilot valves (213) from the top and bottom covers. 5. Lubricate and install the new pilot valves (213). Torque to 95-105 in-lb (11-12 N•m). 3A0732J Repair Disconnect the Air Motor 19 18 1. Stop the pump. 2. Flush the pump, if possible (see page 13). Follow Pressure Relief Procedure, page 10. 3. Disconnect the air hose, fluid hose, and suction hose. 8 1 17 4. See FIG. 12. Push the safety spring (9) down and hold to access the coupling pin (18). Push the retaining spring (19) up and push out the pin, using a screwdriver or punch. 5. Remove the nuts (11) from the bottom of the tie rods (8). 6. Remove the pump lower (12). The adapter plate (10) will remain attached to the lower. 7. Remove the safety spring (9). 8. Loosen the nuts (17) at the top of the tie rods, then remove the tie rods. The mounting bracket (1) is loosened from the motor as the tie rods are removed. 9. Take the motor to a work bench. See Repair Air Motor on page 22. 10 9 11 TI16261A FIG. 12. Disconnect the Air Motor Reconnect the Air Motor 1. Replace the motor on the mounting bracket (1). 2. Screw the tie rods into the motor, with the top hex nuts (17) attached. Torque the tie rods to 5-10 ft-lb (7-13 N•m). NOTE: Always tighten the tie rods before tightening the top hex nuts (17). 3. Tighten the top hex nuts (17) to secure the mounting bracket (1). 4. Slide the pump with the adapter plate (10) attached onto the tie rods (8). Ensure that the safety spring (9) is in place and the pump outlet is oriented as desired. 5. Install the tie rod nuts (11). Torque to 100 in-lb (11 N•m). 6. Align the hole in the displacement rod with the hole in the air motor rod. Use a screwdriver to push in the pin (18). 7. Push the retaining spring (19) into place to cover the pin. 3A0732J 21 Repair Repair Air Motor Reassemble the Air Motor NOTE: Complete Air Motor Replacement Kits are available. Order 24G693 (2.5 in. motor) or 24G694 (3.5 in. motor). NOTE: Air Motor Seal Kits are available. See page 33 for the correct kit for your motor. Parts included in the kit are marked with an asterisk (*). For best results, use all the parts in the kit. Disassemble the Air Motor 1. See FIG. 14. Use a 10 mm socket wrench to remove four screws (211). Remove the air valve (214) and gasket (209*◆†). 2. Remove four screws (211) and remove the manifold (220) and two gaskets (208*). 3. Use a 10 mm socket wrench to remove the pilot valves (213) from the top and bottom cover. NOTE: For easier reassembly, start with the top cover (210) turned over on the workbench and assemble the air motor upside-down. 1. Lubricate and install the o-ring (202*) on the top cover (210). 2. Lubricate the inside of the cylinder (205). Lower the cylinder onto the top cover (210). 3. Install the shield (206) around the cylinder (205) and in the groove on the top cover (210). 4. See FIG. 13. Lubricate and install new u-cup seal (207*) in the bottom of the bearing in the bottom cover (201). The lips must face down. Lubricate and install new u-cup seal (207*) in the top of the bearing. Lips must face up Install retaining ring (217). *207 Lips face up 4. Use a 13 mm socket wrench to remove the tie bolts (212). 5. Remove the top cover (210). Remove the o-ring (202*). On 3.5 in. motors only, remove the plug (231) and o-ring (230*). 6. Remove the shield (206) and cylinder (205). 7. Remove the o-ring (204*) from the piston. *207 Lips face down. ti16285a FIG. 13. Air Motor U-cup Installation 8. Secure the piston (219) in a vise with soft jaws. Use a wrench on the flats of the rod (218) to remove the rod and bottom cover assembly (201) from the piston. 9. Remove the rod from the bottom cover assembly. 10. Remove retaining ring (217), u-cup seals (207*), and o-ring (202*) from the bottom cover. 22 3A0732J Repair 1 Apply lubricant. 231 213 1 204* 1 211 *230 1 214 210 211 220 219 202* 1 208* 1 *202 *217 *207 205 1 209*◆† 1 215 203 208* 201 206 *207 213 1 1 212 218 TI16130a FIG. 14. Air Motor Assembly 3A0732J 23 Repair 5. Lubricate and install the o-ring (202*) on the bottom cover (201). 6. Carefully push the threaded end of the rod (218) up through the bottom cover (201). 7. Apply 16G561 adhesive to the threads of the rod (218). Screw the piston (219) onto the rod. Place the piston in a vise with soft jaws and torque to 35-40 ft-lb (47-54 N•m). 8. Lubricate and install the o-ring (204*) on the piston (219). 9. See FIG. 15. Carefully place the bottom cover/piston assembly on the cylinder (205), sliding the piston (219) into the cylinder. The manifold surfaces of the top and bottom covers must align. Be sure the shield (206) is in the groove on both the top and bottom covers. 10. Install the tie bolts (212) hand tight. 11. Install two gaskets (208*) on the manifold (220). Install the manifold (220). Torque screws (211) to 95-105 in-lb (10.7-11.9 N•m). NOTE: The manifold is reversible for ease of placement of muffler or remote exhaust. 12. Align the air valve gasket (209*◆†) on the manifold, then attach the air valve (214). Torque screws (211) to 95-105 in-lb (11-12 N•m). 13. Tighten the tie bolts (212) halfway. Work in a crisscross pattern. Check that the shield (206) remains in the grooves on both covers. Continue tightening the bolts in pattern to 11-13 ft-lb (15-18 N•m). 14. On 3.5 in. motors only, lubricate the o-ring (230*). Install it and the plug (231) in the top cover (210). 15. Lubricate and install pilot valves (213) in top and bottom cover. Torque to 95-105 in-lb (11-12 N•m). 16. See Reconnect the Air Motor on page 21. 201 groove 206 groove 210 ti16281a FIG. 15. Align Shield in Grooves on Covers 24 3A0732J Parts Parts Package Parts NOTE: For hose and gun, see page 29. 20 Part of air motor (7) 22 21 7 Detail of Stand Kit (2) 1 (Ref) 1 4 9 17 26 4 5 8 43 10 16 6 2 23 11 13 19 18 43 3 12 TI16438a 15 37 38 42 TI16129a 3A0732J 25 Parts Package Parts 15:1 Ratio Pumps Ref. No. Description 1 2 3 4 5 BRACKET, wall KIT, stand; includes items 3, 4, 5, 6, and 43 below, and 418 on page 36 PLUG SCREW, cap, hex hd; 1/4-20 x 1.5 in. (38 mm) SPACER, tube 6 7 8 NUT, hex; 1/4-20 MOTOR, air; see page 32 KIT, rod, tie; includes rods and items 11 and 17 (3 of each) 9 SPRING, safety 10 ADAPTER, pump lower 11 NUT, lock 12 LOWER, pump; see page 30; also includes items 15, 18, and 19 13 NUT, jam 15‡ NIPPLE; 1/4 npsm x 1/4 npt; plated steel NIPPLE; 1/4 npsm x 1/4 npt; sst 16 KIT, suction hose, 5 gal. (19 l); 3/8 in. (10 mm) OD; includes items 37 (qty 1), 38, and 42 17 NUT, hex; 7/16-20 18‡ PIN, straight 19‡ SPRING, retaining 20 21 38 42 43 AIR CONTROL ASSEMBLY; see page 36 ELBOW, swivel; 1/4 npt(m) x 3/8 in. (10 mm) OD tube TUBE, polyurethane; 3/8 in. (10 mm) OD; 2 ft (0.61 m) SCREW, ground WIRE, grounding THROAT SEAL LIQUID; 4 oz (not shown) STRAINER, suction; 3/8 in. (10 mm) OD tube; pack of 3 O-RING; fluoroelastomer NUT, jam, suction WASHER, lock; 1/4; part of stand kit (2) 44* HOPPER, kit 22 23 26 28 37 Package 24F150 24F151 24W281 24F158 24F159 24W283 24H102 24H102 24F164 24H102 24F164 24H102 24F164 24H102 24F164 1 1 108175 100058 108175 100058 108175 100058 108175 100058 24H102 Qty --- --- --- --- 4 6 4 24G693 24G707 100015 24G693 24G707 100015 24G693 24G707 24G693 24G707 100015 24G693 24G707 100015 24G693 24G707 6 1 1 24H103 24H104 104541 24G701 24H103 24H104 104541 24G701 24H103 24H104 104541 24G701 24H103 24H104 104541 24G702 24H103 24H104 104541 24G702 24H103 24H104 104541 24G702 1 1 3 1 195150 162453 195150 162453 195150 162453 195150 195150 195150 24F148 166846 24F148 166846 24F148 166846 24F148 1 1 1 1 196762 Not sold separately. Order Tie Rod Kit, item 8. 196762 196762 196762 196762 196762 3 1 196750 196750 196750 196750 196750 196750 1 24H162 121141 24H163 121141 24H163 121141 24H162 121141 24H163 121141 24H163 121141 1 1 24H008 24H008 24H008 24H008 24H008 24H008 1 116343 238909 238049 24F160 116343 238909 238049 24F160 116343 238909 238049 116343 238909 238049 24F160 116343 238909 238049 24F160 116343 238909 238049 1 1 1 1 117559 15E813 117559 15E813 117559 15E813 117559 15E813 --- --17A493 --- --- 1 1 6 17A493 1 ‡ Included in Pump Lower Rebuild Kit. See page 31. * Not shown. See Merkur ES Hopper Kit manual 334011 for more information. 26 3A0732J Parts Package Parts 30:1 Ratio Pumps Ref. No. Description 1 2 Package 24F152 24F153 24W287 24F154 24F155 24F156 24F157 24W285 Qty 5 BRACKET, wall 24H102 24H102 24H102 24H102 24H102 24H102 24H102 24H102 KIT, stand; includes items 3, 4, 5, 6, and 24F164 24F164 24F164 24F164 24F164 43 below, and 418 on page 36 PLUG 108175 108175 108175 108175 108175 SCREW, cap, hex hd; 1/4-20 x 1.5 in. (38 100058 100058 100058 100058 100058 mm) SPACER, tube ----------- 6 7 8 NUT, hex; 1/4-20 MOTOR, air; see page 32 KIT, rod, tie; includes rods and items 11 and 17 (3 of each) 9 SPRING, safety 10 ADAPTER, pump lower 11 NUT, lock 12 LOWER, pump; see page 30; also includes items 15, 18, and 19 13 NUT, jam 15‡ NIPPLE; 1/4 npsm x 1/4 npt; plated steel NIPPLE; 1/4 npsm x 1/4 npt; sst 16 KIT, suction hose, 5 gal. (19 l); 3/8 in. (10 mm) OD; includes items 37 (qty 1), 38, and 42 17 NUT, hex; 7/16-20 18‡ PIN, straight 19‡ SPRING, retaining 100015 100015 100015 100015 100015 24G694 24G694 24G694 24G694 24G694 24G694 24G694 24G694 24G707 24G707 24G707 24G707 24G707 24G707 24G707 24G707 6 1 1 24H103 24H104 104541 24G702 24H103 24H104 104541 24G701 1 1 3 1 195150 195150 195150 195150 195150 195150 195150 195150 162453 162453 162453 162453 162453 166846 166846 166846 24F148 24F148 24F148 24F148 24F148 24F148 1 1 1 1 Not sold separately. Order Tie Rod Kit, item 8. 196762 196762 196762 196762 196762 196762 196762 196762 3 1 196750 196750 196750 196750 196750 196750 196750 196750 1 20 21 24H162 24H163 24H163 24H164 24H165 24H162 24H163 24H163 121141 121141 121141 121141 121141 121141 121141 121141 1 1 24H008 24H008 24H008 24H008 24H008 24H008 24H008 24H008 1 116343 238909 238049 24F160 1 1 1 1 3 4 22 23 26 28 37 38 42 43 AIR CONTROL ASSEMBLY; see page 36 ELBOW, swivel; 1/4 npt(m) x 3/8 in. (10 mm) OD tube TUBE, polyurethane; 3/8 in. (10 mm) OD; 2 ft (0.61 m) SCREW, ground WIRE, grounding THROAT SEAL LIQUID; 4 oz (not shown) STRAINER, suction; 3/8 in. (10 mm) OD tube; pack of 3 O-RING; fluoroelastomer NUT, jam, suction WASHER, lock; 1/4; part of stand kit (2) 24H103 24H104 104541 24G702 24H103 24H104 104541 24G702 24H103 24H104 104541 24G701 24H103 24H104 104541 24G701 116343 116343 116343 116343 116343 238909 238909 238909 238909 238909 238049 238049 238049 238049 238049 24F160 24F160 24F160 24F160 117559 117559 15E813 15E813 44* HOPPER, kit 24H103 24H104 104541 24G701 --- 24H103 24H104 104541 24G701 116343 116343 238909 238909 238049 238049 24F160 117559 117559 117559 117559 15E813 15E813 15E813 15E813 --17A493 --- --- 1 1 4 6 4 --- 1 1 6 17A493 1 ‡ Included in Pump Lower Rebuild Kit. See page 31. * Not shown. See Merkur ES Hopper Kit manual 334011 for more information. 3A0732J 27 Parts 28 3A0732J Parts Hose and Gun Air-Assisted Packages Airless Packages 30 30 37 29 32 36 36 32 33 TI16231a TI16230a Package Ref. No. Description 24F150 24F151 24W281 24F152 24F153 24W287 241811 29 HOSE, air, gun 241811 30 GUN, air-assisted, G15; see 3A0149 24C853 24F165 36★ Qty 241811 1 24C853 1 24C855 1 24F165 1 24F165 24F166 HOSE, fluid; 1/8 in. (3 mm) ID nylon; 1/4 npsm(f) sst couplings; 25 ft (7.6 m) long 33 24F158 24F159 24W283 235460 GUN, airless; see 311254 HOSE, fluid; 1/8 in. (3 mm) ID nylon; 1/4 npsm(f) plated steel couplings; 25 ft (7.6 m) long 24F156 24F157 24W285 241811 24C855 GUN, air-assisted, G40; see 3A0149 32 24F154 24F155 1 24F166 1 CLIP, hose; pack of 7 24H005 24H005 24H005 24H005 7 TIP; G15, G40 AAF412 AAF412 AAF412 AAF412 1 TIP; airless 163515 1 ★ Additional tip sizes are available. See manual 3A0149 for G15 and G40 AA Guns. See tip manual 306686 for Silver Plus Airless Guns. 3A0732J 29 Parts Displacement Pump Parts Part No. 24G701, Plated Steel Part No. 24G702, Stainless Steel ‡102 103 ‡104 ‡112 105 15, see page 26 ‡106 113‡ ‡114 107‡ 109❖ 116‡❖ 119 117❖ 111‡❖ ‡121 ‡126 110 125‡ ‡122 ‡123 ‡120 124 TI16131a 30 3A0732J Parts Displacement Pump Parts Part No. 24G701, Plated Steel Part No. 24G702, Stainless Steel Ref. Description 102‡ BUTTON, plug 103 NUT, packing; plated steel 24G701 24G702 --- --- 193047 NUT, packing; sst O-RING; buna-N; 1.262 in. (32.05 mm) OD 105 CYLINDER, pump --243176 106‡ V-PACKING, throat; 107‡ O-RING; PTFE; 1.254 in. (31.85 mm) OD V-Max™ UHMWPE --24G706 1 1 1 --- --- 3 --- --- 1 109❖ GUIDE, ball 15C011 110 VALVE, intake housing; plated steel 15B611 VALVE, intake housing; sst 111‡ ❖ 1 1 24H161 104‡ Qty 15C011 1 1 24H007 1 O-RING; PTFE; 0.941 in. (23.90 mm) OD --- --- 1 112‡ GLAND, female, throat; acetal --- --- 1 113‡ V-PACKING, throat; leather --- --- 2 114‡ GLAND, male, throat; acetal --- --- 1 116‡ ❖ BALL, intake; sst; 0.500 in. (13 mm) dia. 117❖ SEAT, carbide 105445 105445 1 15A968 15A968 1 KIT, rod, displacement; Chromex ; includes item 124, and items 18 and 19 on page 25 24G703 24G704 1 120‡ BALL, piston; sst; 0.3125 in. (7.94 mm) dia. 105444 105444 1 121‡ GLAND, male, piston; plated steel 119 ™ --- GLAND, male, piston; sst --- 122‡ GLAND, female, piston; plated steel 123‡ WIPER, piston 124 VALVE, piston; plated steel --- GLAND, female, piston; sst --- 126‡ V-PACKING, piston; --- 1 --- 1 1 Order item 119 V-PACKING, piston; leather V-Max™ UHMWPE 1 1 Order item 119 VALVE, piston; sst 125‡ 1 1 --- --- 2 --- --- 3 ‡ Included in Pump Lower Rebuild Kit. Order Kit 24H006 for Pump 24G701, or Kit 24G705 for Pump 24G702. ❖ Included in Intake Check Valve Kit 246429. 3A0732J 31 Parts Air Motor Parts Part No. 24G693, 2.5 in. (63.5 mm) Part No. 24G694, 3.5 in. (88.9 mm), shown 231 213 204* 211 *230 214 210 211 220 219 208* 202* *202 *217 *207 205 203 209*◆† 215 208* 201 206 *207 213 212 218 TI16130a 32 3A0732J Parts Air Motor Parts Part No. 24G693, 2.5 in. (63.5 mm) Part No. 24G694, 3.5 in. (88.9 mm), shown Ref. Description 201 KIT, cover, bottom; includes 202 (qty 1), 24G695 24G696 203, 207, 213 (qty 1), and 217 O-RING, cover Not sold separately. See Air Motor Seal Kit (below), Bottom Cover Kit (201, this table), or Top Cover Kit (210, this table) BEARING Not sold separately. See Bottom Cover Kit (201, this table) O-RING, piston Not sold separately. See Air Motor Seal Kit (below) or Piston Kit (219, this table) CYLINDER, motor 15M289 15M211 COVER, cylinder (includes English 15M302 15M212 warning label) SEAL, u-cup Not sold separately. See Air Motor Seal Kit (below) or Bottom Cover Kit (201, this table) GASKET, manifold Not sold separately. See Air Motor Seal Kit (below) or Manifold Assembly (220, this table) GASKET, air valve Not sold separately. See Air Motor Seal Kit, Valve Repair Kit 24A537, Valve Seal Kit 24A535 (below), or Manifold Assembly (220, this table) KIT, cover, top; includes 202 and 213 24H004 15X353 (qty 1 of each). 15X353 also includes 230 and 231. SCREW, M6 x 25 Not sold separately. See Manifold Assembly (220, this table) or Air Valve Replacement Kit (page 35) BOLT, tie, hex head 15M314 BOLT, tie, hex head 15M314 VALVE, pilot (pack of 2) 24A366 24A366 VALVE, air; includes items 209 and 211 24A351 24A351 (qty 4) MUFFLER 15M213 15M213 RING, retaining Not sold separately. See Air Motor Seal Kit (below) or Bottom Cover Kit (201, this table) ROD, air motor Not sold separately. See Motor Piston Kit (219, this table) KIT, piston, motor; includes 204 and 24G697 24G698 218, and 16G561 adhesive. MANIFOLD, assembly, includes 208, 24A579 24A579 209, and 211 (qty. 4) LABEL, warning (French and 15W719 15W719 Spanish) O-RING, top plug (24G694 only) Not sold separately. See Air Motor Seal Kit (below) PLUG, top cover (24G694 only) Not sold separately. See Top Cover Kit (210, this table) 202* 203 204* 205 206▲ 207* 208* 209*◆† 210 211 212 213 214 215 217* 218 219 220 229▲ 230* 231 24G693 24G694 Qty 1 2 1 1 1 1 2 2 1 1 8 2 3 1 1 1 1 1 1 1 1 1 1 ▲ Replacement Danger and Warning labels, tags, and cards are available at no cost. † Included in Air Valve Seal Kit 24A535. See page 35. ◆ Included in Air Valve Repair Kit 24A537. See page 35. 3A0732J * Included in Air Motor Seal Kit: 24G693 (2.5 in. Motor) 24G694 (3.5 in. Motor) 24G699 24G700 33 Parts Air Valve Parts ✠ 310 †✠ ◆306 ✠ 307 301 ◆304 ◆303 ◆311 ◆312 ◆305 †◆308 ◆302 †◆309 †◆308 ✠ 307 †✠ ◆306 ✠ 310 34 ti16213a 3A0732J Parts Air Valve Parts Complete Air Valve Replacement Kit 24A351 To replace the complete air valve, order Air Valve Replacement Kit 24A351. The kit includes items 301-312 below, and items 209 and 211 on page 33. Air Valve Repair Kits Air valve parts are not sold individually. The table below shows possible kit options for each part. Ref. Description 301 302◆ 303◆ 304◆ 305◆ 306†✠ ◆ 307✠ 308†◆ 309†◆ 310✠ 311◆ 312◆ HOUSING AIR VALVE PISTON DETENT PISTON ASSEMBLY DETENT CAM PLATE, air valve O-RING CAP U-CUP SCREW SNAP RING DETENT SPRING CUP Qty . 1 1 1 1 1 2 2 2 2 2 1 1 Air Valve Repair Kit 24A537 Air Valve Seal Kit 24A535 Air Valve End Cap Kit 24A360 ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ † Included in Air Valve Seal Kit 24A535. ◆ Included in Air Valve Repair Kit 24A537. ✠ Included in Air Valve End Cap Kit 24A360. Replacement screws (309) are available in a pack of 10. Order Kit 24A359. 3A0732J 35 Parts Air Control Parts Part No. 24H162, Air-Assisted, Wall Mount Part No. 24H163, Air-Assisted, Stand Mount 1 409 413 410 407 422 411 420 412 401 404 1 405 403 402 418 2 Part of 402 TI16132a 404 408 402 418 2 1 Connect tubing (406) between these two fittings. 2 Used on stand mount units only. Part No. 24H164, Airless, Wall Mount Part No. 24H165, Airless, Stand Mount 1 Connect tubing (406) between these two fittings. 1 409 2 Used on stand mount units only. 407 421 413 422 420 411 412 401 404 410 1 405 402 418 TI16229a 2 36 3A0732J Parts Air Control Parts Part No. 24H162, Air-Assisted, Wall Mount Part No. 24H163, Air-Assisted, Stand Mount Part No. 24H164, Airless, Wall Mount Part No. 24H165, Airless, Stand Mount Ref. Description 24H162 24H163 24H164 24H165 Qty 401 BRACKET, handle 24H105 24H105 24H105 24H105 1 402 REGULATOR, air 15T499 2 15T499 REGULATOR, air 15T499 403 TEE; 1/4 npt(m) 115219 115219 404 GAUGE, air pressure 108190 108190 GAUGE, air pressure 405 ELBOW, tube; 1/4 npt(f) x 3/8 in. (10 mm) OD tube 15T499 1 2 108190 108190 C38161 C38161 FITTING, tube; 1/4 npt(m) x 3/8 in. (10 mm) OD tube 1 1 1 120389 120389 1 406 TUBE, polyurethane; 3/8 in. (10 mm) OD tube; 2 ft (0.61 m) 24H008 24H008 24H008 24H008 1 407 VALVE, ball, air; 3/8 npt(fbe) 114362 114362 1 408 NIPPLE; 1/4 npsm x 1/4 npt 162453 162453 409 ELBOW, swivel; 3/8 npt(m) x 3/8 in. (10 mm) OD tube 16F151 16F151 410 ELBOW; 1/4 npt(f) x 1/8 npt(m) 121150 121150 411 VALVE, safety relief; 110 psi 113498 113498 412 ELBOW, swivel; 1/4 npt(m) x 3/8 in. (10 mm) OD tube 121141 121141 121141 413 NUT, regulator 115244 115244 418 ELBOW, street, 45°; 1/8 npt (mxf) NUT, regulator 114362 1 16F151 16F151 1 121150 121150 1 113498 113498 1 121141 1 2 115244 SCREW, cap, button-hd; 10-24 x 3/8 in. (10 mm) 421 PLUG, panel 422 RING, grounding 3A0732J 115244 113630 1 2 ELBOW, street, 45°; 1/8 npt (mxf) 420 114362 113630 1 114381 114381 2 16F547 16F547 1 24P812 24P812 24P812 24P812 1 114381 114381 37 Kits and Accessories Kits and Accessories Kit Description Part No. Airless to Air-Assisted Conversion Kit 24F161 Inline Fluid Filter, stainless steel 24F271 Inline Fluid Filter, aluminum 24F272 Standard Suction Hose, 5 gal. (19 l), 3/8 in. (10 mm) OD 24F148 Suction Hose, 5 gal. (19 l), 5/8 in. (16 mm) OD 24F149 Suction Tube, 1 gal. (3.8 l), 11/32 in. (9 mm) OD 24F147 Standard Push-on Strainer Kit 24F160 Screw-on Strainer Kit (for 24F149 5/8 in. Suction Hose Kit) 256426 Air Gauge Lens Cover Kit (sheet of 12 covers) 193199 Throat Seal Liquid (TSL); 4 oz (118 ml) 238049 Throat Seal Liquid (TSL); 8 oz (236 ml) 206994 Alternate U-Cup Pump Packing Kit (UHMWPE) 24H665 Hopper Kit 17A493 Hopper Screens (Pack of 5) 17B207 Hopper O-Ring Kit 17B208 Hopper Bungee Cord Kit 17C166 38 3A0732J Package Dimensions Package Dimensions A, inch (mm) Package B, inch (mm) C D inch (mm) inch (mm) 20.2 (513) Wall Mount Stand Mount 29.0 (737) 17.4 (442) 18.4 (467) Stand Mount with Hopper 29.0 (737) 17.4 (442) 26.5 (673) Front View Top View D B A C ti16288a ti16287a Package Weights Package Description Package Description 24F158 15:1 stainless steel, AA, wall lb kg 20 9 15:1 stainless steel, AA, stand 23 10 24F150 15:1 plated steel, AA, wall lb kg 20 9 24F151 15:1 plated steel, AA, stand 23 10 24F159 24F152 30:1 stainless steel, AA, wall 23 10 24F153 30:1 stainless steel, AA, stand 26 12 24F154 30:1 plated steel, airless, wall 22 10 24F155 30:1 plated steel, airless, stand 25 11 24W281 15:1 plated steel, AA, stand, hopper 32 15 32 15 15:1 stainless steel, AA, stand, 24W283 hopper 24W285 30:1 plated steel, AA, stand, hopper 35 16 24F156 30:1 plated steel, AA, wall 23 10 24F157 30:1 plated steel, AA, stand 26 12 3A0732J 24W287 30:1 stainless steel, AA, stand, hopper 35 16 39 Wall Bracket Mounting Hole Diagram Wall Bracket Mounting Hole Diagram 2 x 0.35 in. (9 mm) 2 x 0.281 (9/32) in. (7 mm). For wall mount only. 4.40 in. (112 mm) 2 x 0.62 in. (16 mm) 2 x 0.312 (5/16) in. (8 mm). For wall mount or to attach stand to bracket. 5.10 in. (130 mm) 2.69 in. (68 mm) 2 x 0.48 in. (12 mm) TI16289a 40 3A0732J Technical Data Technical Data Maximum fluid working pressure 15:1 Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 psi (10.3 MPa, 103 bar) 30:1 Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 psi (20.7 MPa, 207 bar) Maximum air inlet pressure . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7.0 bar) Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15:1 or 30:1 (see Models, page 3) Maximum fluid temperature. . . . . . . . . . . . . . . . . . . 160°F, 71°C Ambient air temperature range . . . . . . . . . . . . . . . . Package air inlet size . . . . . . . . . . . . . . . . . . . . . . . Package fluid outlet size . . . . . . . . . . . . . . . . . . . . . Maximum motor speed . . . . . . . . . . . . . . . . . . . . . . (Do not exceed maximum recommended speed of fluid pump, to prevent premature pump wear.) Maximum spray tip orifice size . . . . . . . . . . . . . . . . Sound data 24G693 Air Motor Sound power* . . . . . . . . . . . . . . . . . . . . . . . Sound pressure**. . . . . . . . . . . . . . . . . . . . . 24G694 Air Motor Sound power* . . . . . . . . . . . . . . . . . . . . . . . Sound pressure**. . . . . . . . . . . . . . . . . . . . . Wetted parts Plated steel pumps . . . . . . . . . . . . . . . . . . . . . . Stainless steel pumps . . . . . . . . . . . . . . . . . . . . Spray guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suction assembly . . . . . . . . . . . . . . . . . . . . . . . . 35-120°F, 2-49°C 3/8 npt(f) 1/4 npsm(m) 240 cycles per minute .019 in. (0.483 mm) 83.2 dBA 76.5 dBA 84.5 dBA 77.9 dBA Stainless steel, nickel plated carbon steel, tungsten carbide, ptfe, acetal, leather, ultra-high molecular weight polyethylene Stainless steel, tungsten carbide, ptfe, acetal, leather, ultra-high molecular weight polyethylene See manual 3A0149 (G15 and G40 AA guns) or 311254 (Silver Plus airless gun) Nylon, plated or stainless steel Stainless steel, nylon, acetal, fluoroelastomer, polyethylene * Sound power at 70 psi (0.48 MPa, 4.8 bar), 80 cpm. Sound power measured per ISO-9614-2. ** Sound pressure was tested 3.28 feet (1 m) from equipment. 3A0732J 41 Performance Charts Performance Charts 15:1 Ratio Pumps KEY A = 100 psi (0.7 MPa, 7 bar) B = 70 psi (0.5 MPa, 5 bar) C = 40 psi (0.3 MPa, 3 bar) = fluid flow = air flow Cycles per Minute Fluid Outlet Pressure psi (MPa, bar) 60 90 120 150 180 210 A 1200 (8, 80) 1000 (7, 70) 800 (5.5, 55) 600 (4, 40) B A B C 400 (3, 30) C 200 (1.4, 14) 240 10.5 (0.3) 9.0 (0.25) 7.5 (0.2) 6.0 (0.17) 4.5 (0.13) 3.0 (0.08) Air Flow scfm (m3/min) 30 1400 (10, 100) 1.5 (0.04) 0 0 42 0.10 0.15 0.20 0.25 0.30 0.35 0.05 (0.6) (0.75) (0.9) (1.1) (1.3) (0.2) (0.4) Fluid Flow gpm (lpm) tested in No. 10 weight oil 0.40 (1.5) 3A0732J Performance Charts 30:1 Ratio Pumps KEY A = 100 psi (0.7 MPa, 7 bar) B = 70 psi (0.5 MPa, 5 bar) C = 40 psi (0.3 MPa, 3 bar) = fluid flow = air flow Cycles per Minute 3000 (21, 210) 60 90 120 150 180 210 240 18.0 (0.5) A 15 (0.42) 2500 (17.5, 175) 2000 (14, 140) B 12.0 (0.34) A 1500 (10.5, 105) 9.0 (0.25) C 1000 (7, 70) B 6.0 (0.17) C 500 (3.5, 35) 3.0 (0.08) Air Flow scfm (m3/min) Fluid Outlet Pressure psi (MPa, bar) 30 0 0 0.05 (0.2) 0.10 (0.4) 0.15 (0.6) 0.20 (0.75) 0.25 (0.9) 0.30 (1.1) 0.35 (1.3) 0.40 (1.5) Fluid Flow gpm (lpm) tested in No. 10 weight oil 3A0732J 43 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. For patent information, see www.graco.com/patents. 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. Original instructions. This manual contains English. MM 3A0732 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA Copyright 2010, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. www.graco.com Revision G - July 2014
Source Exif Data:
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 : 2010, Rev. J, 08/2014 Job Ref : Z091251 Keywords : "MM 3A0732, 3A0732, 3A0732J, 3A0732EN-J, 3A0732EN, Merkur ES Spray Packages, For low-volume fine finish spray applications. 24F150, 24F151, 24F152, 24F153, 24F154, 24F155, 24F156, 24F157, 24F158, 24F159, 24N548, 24W281, 24W283, 24W285, 24W287" Web Statement : Merkur ES Spray Packages, Instructions/Parts Manual, 3A0732J, English Modify Date : 2014:09:04 13:08:47-05:00 Creator Tool : FrameMaker 9.0 Create Date : 2009:12:15 10:08:57Z Metadata Date : 2014:09:04 13:08:47-05:00 Format : application/pdf Description : Merkur ES Spray Packages, For low-volume fine finish spray applications. MM 3A0732 Title : 3A0732J, Merkur ES Spray Packages, Instructions/Parts Manual, English Creator : Michelle Oliveira Subject : MM 3A0732, 3A0732, 3A0732J, 3A0732EN-J, 3A0732EN, Merkur ES Spray Packages, For low-volume fine finish spray applications. 24F150, 24F151, 24F152, 24F153, 24F154, 24F155, 24F156, 24F157, 24F158, 24F159, 24N548, 24W281, 24W283, 24W285, 24W287 Document ID : uuid:6f468d51-9e7f-4bff-8548-21942eb0e8a2 Instance ID : uuid:8a963ce4-ce6f-48c5-8471-867a1d5245ef Page Count : 44 Author : Michelle OliveiraEXIF Metadata provided by EXIF.tools