3A0732E Merkur ES Spray Packages, Instructions/Parts Manual

3A0732E Merkur ES Spray Packages, Instructions/Parts Manual
Instructions/Parts
Merkur® ES
Spray Packages
3A0732E
ENG
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
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
3A0732E
Models
Models
Package
24F150
24F151
24F152
24F153
24F154
24F155
24F156
24F157
24F158
24F159
3A0732E
Series
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
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)
Air-assisted
Air-assisted
Air-assisted
Air-assisted
Airless
Airless
Air-assisted
Air-assisted
Air-assisted
Air-assisted
G15 Carbide
G15 Carbide
G40
G40
Silver Plus
Silver Plus
G40
G40
G15 Carbide
G15 Carbide
Wall
Stand
Wall
Stand
Wall
Stand
Wall
Stand
Wall
Stand
Plated Steel
Plated Steel
Stainless Steel
Stainless Steel
Plated Steel
Plated Steel
Plated Steel
Plated Steel
Stainless Steel
Stainless Steel
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.
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
3A0732E
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.
3A0732E
5
Warnings
6
3A0732E
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.
3A0732E
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
3A0732E
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)
3A0732E
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.
c.
10
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.
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.
3A0732E
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.
3A0732E
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
3A0732E
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.
3A0732E
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
Solution
Damaged air valve (214).
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.
See G15/G40 air-assisted gun manual or
Silver Plus airless gun manual.
Replace throat packings. See page 16.
14
3A0732E
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
3A0732E
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
3A0732E
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
3A0732E
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
3A0732E
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
3A0732E
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).
3A0732E
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.
3A0732E
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
3A0732E
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
3A0732E
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
3A0732E
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
3A0732E
25
Parts
Package Parts
Package
Ref.
No. Description
24F150 24F151 24F152 24F153 24F154 24F155 24F156 24F157 24F158 24F159 Qty
1
BRACKET, wall
24H102 24H102 24H102 24H102 24H102 24H102 24H102 24H102 24H102 24H102
2
KIT, stand; includes
items 3, 4, 5, 6, and 43
below, and 418 on page
36
24F164
24F164
24F164
24F164
24F164
1
3
PLUG
108175
108175
108175
108175
108175
4
4
SCREW, cap, hex hd;
1/4-20 x 1.5 in. (38 mm)
100058
100058
100058
100058
100058
6
5
SPACER, tube
---
---
---
---
---
4
100015
100015
100015
100015
1
6
NUT, hex; 1/4-20
100015
6
7
MOTOR, air; see page
32
24G693 24G693 24G694 24G694 24G694 24G694 24G694 24G694 24G693 24G693
1
8
KIT, rod, tie; includes
rods and items 11 and
17 (3 of each)
24G707 24G707 24G707 24G707 24G707 24G707 24G707 24G707 24G707 24G707
1
9
SPRING, safety
24H103 24H103 24H103 24H103 24H103 24H103 24H103 24H103 24H103 24H103
1
10
ADAPTER, pump lower 24H104 24H104 24H104 24H104 24H104 24H104 24H104 24H104 24H104 24H104
1
11
NUT, lock
104541 104541 104541 104541 104541 104541 104541 104541 104541 104541
3
12
LOWER, pump; see
page 30; also includes
items 15, 18, and 19
24G701 24G701 24G702 24G702 24G701 24G701 24G701 24G701 24G702 24G702
1
13
NUT, jam
195150 195150 195150 195150 195150 195150 195150 195150 195150 195150
1
15‡
NIPPLE; 1/4 npsm x 1/4 162453 162453
npt; plated steel
NIPPLE; 1/4 npsm x 1/4
npt; sst
16
162453 162453 162453 162453
166846 166846
1
166846 166846
1
KIT, suction hose, 5 gal. 24F148 24F148 24F148 24F148 24F148 24F148 24F148 24F148 24F148 24F148
(19 l); 3/8 in. (10 mm)
OD; includes items 37
(qty 1), 38, and 42
1
17
NUT, hex; 7/16-20
Not sold separately. Order Tie Rod Kit, item 8.
3
18‡
PIN, straight
196762 196762 196762 196762 196762 196762 196762 196762 196762 196762
1
19‡
SPRING, retaining
196750 196750 196750 196750 196750 196750 196750 196750 196750 196750
1
26
3A0732E
Parts
Ref.
No. Description
Package
24F150 24F151 24F152 24F153 24F154 24F155 24F156 24F157 24F158 24F159 Qty
20
AIR CONTROL ASSEM- 24H162 24H163 24H162 24H163 24H164 24H165 24H162 24H163 24H162 24H163
BLY; see page 36
1
21
ELBOW, swivel; 1/4
121141 121141 121141 121141 121141 121141 121141 121141 121141 121141
npt(m) x 3/8 in. (10 mm)
OD tube
1
22
TUBE, polyurethane;
24H008 24H008 24H008 24H008 24H008 24H008 24H008 24H008 24H008 24H008
3/8 in. (10 mm) OD; 2 ft
(0.61 m)
1
23
SCREW, ground
116343 116343 116343 116343 116343 116343 116343 116343 116343 116343
1
26
WIRE, grounding
238909 238909 238909 238909 238909 238909 238909 238909 238909 238909
1
28
THROAT SEAL LIQUID; 238049 238049 238049 238049 238049 238049 238049 238049 238049 238049
4 oz (not shown)
1
37
STRAINER, suction; 3/8 24F160 24F160 24F160 24F160 24F160 24F160 24F160 24F160 24F160 24F160
in. (10 mm) OD tube;
pack of 3
1
38
O-RING; fluoroelastomer
117559 117559 117559 117559 117559 117559 117559 117559 117559 117559
1
42
NUT, jam, suction
15E813 15E813 15E813 15E813 15E813 15E813 15E813 15E813 15E813 15E813
1
43
WASHER, lock; 1/4;
part of stand kit (2)
---
---
---
---
---
6
‡ Included in Pump Lower Rebuild Kit. See page 31.
3A0732E
27
Parts
28
3A0732E
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 24F152 24F153 24F154 24F155 24F156 24F157 24F158 24F159 Qty
29
HOSE, air, gun
241811 241811 241811 241811
30
GUN, air-assisted, G15; 24C853 24C853
see 3A0149
GUN, air-assisted, G40;
see 3A0149
32
1
24C853 24C853
1
24C855 24C855
1
GUN, airless; see
311254
235460 235460
1
HOSE, fluid; 1/8 in. (3 24F165 24F165
mm) ID nylon; 1/4
npsm(f) plated steel
couplings; 25 ft (7.6 m)
long
24F165 24F165 24F165 24F165
1
HOSE, fluid; 1/8 in. (3
mm) ID nylon; 1/4
npsm(f) sst couplings;
25 ft (7.6 m) long
33
24C855 24C855
241811 241811 241811 241811
CLIP, hose; pack of 7
36★ TIP; G15, G40
TIP; airless
24F166 24F166
24F166 24F166
1
24H005 24H005 24H005 24H005
24H005 24H005 24H005 24H005
7
AAF412 AAF412 AAF412 AAF412
1
AAF412 AAF412 AAF412 AAF412
163515 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.
3A0732E
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
3A0732E
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; V-Max
107‡
O-RING; PTFE; 1.254 in. (31.85 mm) OD
™
UHMWPE
1
1
24H161
104‡
Qty
--24G706
1
1
1
---
---
3
---
---
1
109❖
GUIDE, ball
15C011
110
VALVE, intake housing; plated steel
15B611
VALVE, intake housing; sst
15C011
24H007
1
111‡
❖
O-RING; PTFE; 0.941 in. (23.90 mm) OD
112‡
GLAND, female, throat; acetal
113‡
V-PACKING, throat; leather
114‡
GLAND, male, throat; acetal
---
116‡
❖
BALL, intake; sst; 0.500 in. (13 mm) dia.
105445
105445
117❖
SEAT, carbide
15A968
15A968
1
24G703
24G704
1
105444
105444
119
KIT, rod, displacement;
on page 25
Chromex™;
includes item 124, and items 18 and 19
120‡
BALL, piston; sst; 0.3125 in. (7.94 mm) dia.
121‡
GLAND, male, piston; plated steel
---
1
1
---
1
---
---
1
---
---
2
---
1
---
GLAND, male, piston; sst
GLAND, female, piston; plated steel
123‡
WIPER, piston
124
VALVE, piston; plated steel
---
GLAND, female, piston; sst
---
125‡
126‡
---
1
---
1
1
Order
item 119
V-PACKING, piston; leather
™
V-PACKING, piston; V-Max
UHMWPE
1
1
Order
item 119
VALVE, piston; sst
1
1
---
122‡
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.
3A0732E
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
3A0732E
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.
3A0732E
*
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
3A0732E
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.
3A0732E
35
Parts
Air Control Parts
Part No. 24H162, Air-Assisted, Wall Mount
Part No. 24H163, Air-Assisted, Stand Mount
1 409
413
407
410
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.
421
407
413
411
420
412
401
404
410
1 405
402 418
TI16229a
2
36
3A0732E
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
16F151
16F151
1
410
ELBOW; 1/4 npt(f) x 1/8 npt(m)
121150
121150
121150
121150
1
411
VALVE, safety relief; 110 psi
113498
113498
113498
113498
1
412
ELBOW, swivel; 1/4 npt(m) x 3/8 in. (10 mm) OD tube
121141
121141
121141
121141
1
413
NUT, regulator
115244
115244
NUT, regulator
418
114362
1
2
115244
ELBOW, street, 45°; 1/8 npt (mxf)
SCREW, cap, button-hd; 10-24 x 3/8 in. (10 mm)
421
PLUG, panel
3A0732E
115244
113630
114381
114381
1
2
ELBOW, street, 45°; 1/8 npt (mxf)
420
114362
113630
1
114381
114381
2
16F547
16F547
1
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
38
3A0732E
Package Dimensions
Package Dimensions
A, inch
(mm)
Package
B, inch
(mm)
C
D
inch (mm) inch (mm)
20.2 (513)
Wall Mount
29.0 (737)
Stand Mount
17.4 (442)
18.4 (467)
Front View
Top View
D
B
A
C
ti16288a
ti16287a
Package Weights
Package
Description
lb
kg
9
24F156
30:1 plated steel, AA, wall
23
10
23
10
24F157
30:1 plated steel, AA, stand
26
12
30:1 stainless steel, AA, wall
23
10
24F158
15:1 stainless steel, AA, wall
20
9
24F153
30:1 stainless steel, AA, stand
26
12
24F159
15:1 stainless steel, AA, stand
23
10
24F154
30:1 plated steel, airless, wall
22
10
24F155
30:1 plated steel, airless, stand
25
11
Package
Description
lb
kg
24F150
15:1 plated steel, AA, wall
20
24F151
15:1 plated steel, AA, stand
24F152
3A0732E
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
3A0732E
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.
3A0732E
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)
3A0732E
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
3A0732E
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.
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. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2010, Graco Inc. is registered to ISO 9001
www.graco.com
Revised 01/2011
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