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Instructions/Parts
Merkur
®
ES
Spray Packages
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.
3A0732C
ENG ti15590a ti15589a
II 2 G c T5
2
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
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
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 42
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 42
3A0732C
Models
Models
Maximum Fluid
Working Pressure psi (MPa, bar) Package Series Ratio
24F150
24F151
24F152
24F153
24F154
24F155
24F156
24F157
24F158
24F159
A
A
A
A
A
A
A
A
A
A
15:1 1500 (10.3, 103)
15:1 1500 (10.3, 103)
30:1 3000 (20.7, 207)
30:1 3000 (20.7, 207)
30:1 3000 (20.7, 207)
30:1 3000 (20.7, 207)
30:1 3000 (20.7, 207)
30:1 3000 (20.7, 207)
15:1 1500 (10.3, 103)
15:1 1500 (10.3, 103)
Package Type Gun
Air-assisted
Air-assisted
Air-assisted
Air-assisted
Airless
Airless
Air-assisted
Air-assisted
Air-assisted
Air-assisted
Mounting
G15 Carbide Wall
G15 Carbide Stand
G40
G40
Wall
Stand
Silver Plus
Silver Plus
G40
G40
Wall
Stand
Wall
Stand
G15 Carbide Wall
G15 Carbide Stand
Material
Plated Steel
Plated Steel
Stainless Steel
Stainless Steel
Plated Steel
Plated Steel
Plated Steel
Plated Steel
Stainless Steel
Stainless Steel
3A0732C 3
4
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.
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.
3A0732C
3A0732C
Warnings
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.
5
Warnings
6 3A0732C
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.
• 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.
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.
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
F IG . 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
• 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.
3A0732C 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.
. 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
10
26
23 ti16282a
F IG . 1. Ground Wire
8 3A0732C
Installation
Setup
1.
See F IG . 2. Attach one end of fluid hose (K) to pump
outlet (or optional inline fluid filter outlet).
2.
Attach other end of fluid hose to gun fluid inlet at base of gun (H).
3.
Attach one end of the air hose (G) to gun air regulator (E).
4.
Attach remaining end of the air hose to air 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.
6.
Attach the fluid suction kit (J) to the pump inlet.
B
J
A
G
E
D
C
F
P
M
L
N
H
K
Key:
A Main Air Supply Line
B Air Shutoff Valve
C Air Filter
D Bleed-type Master Air Valve (required)
E Gun Air Pressure Regulator
F Pump Air Pressure Regulator
G Gun Air Supply Line
H Spray Gun
J Fluid Suction Kit
K Gun Fluid Supply Line
L Pump Ground Wire (required)
M Mounting Bracket (used for wall mounting or stand)
N Pump Stand
P Air Pressure Relief Valve
F IG . 2. Typical Installation (Air-Assisted Stand Mount Package Shown)
3A0732C ti15591a
9
Operation
Operation
Pressure Relief Procedure Trigger Lock
Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from skin injection, splashing or moving parts.
See F IG . 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 F IG . 2. Turn off the bleed-type master air valve
(D).
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.
5.
Lock the gun trigger.
6.
If you suspect that pressure has not been fully relieved after following the steps above, check the following: 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.
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.
F IG . 3. Trigger Lock
Prime the Pump
tiI6581A ti6582A
Gun Trigger
Locked
Gun Trigger
Unlocked
Have safety spring (9) in place during operation to reduce risk of pinching or loss of fingers.
1.
See F IG . 3. Lock gun trigger. Remove tip guard and spray tip from gun. Refer to gun manual.
10 3A0732C
Operation
2.
. 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).
3.
Connect air line to bleed type air valve.
4.
Check that all fittings throughout system are tightened securely.
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.
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.
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.
Adjust the Atomization
NOTE: Use this procedure with airless and air-assisted spray guns.
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.
Example:
Pump
Ratio
15:1 x
30:1 x
Pump Air
Regulator Setting psi (MPa, bar)
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
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).
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.
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
Ratio
15:1 x
30:1 x
Pump Air Regulator
Increment psi (MPa, bar)
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.
3A0732C 11
Operation
Adjust the Spray Pattern
3.
See F
IG
. 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 F
IG
. 4. Close off pattern adjustment air by turning knob (AA) clockwise (in) all the way. This sets gun for its widest pattern.
AA
OUT (narrower pattern)
AA
IN (wider pattern) no air too little air correct amount of air
F IG . 5. Spray Pattern Problems
TI0792A
Shutdown
ti6559A
F IG . 4. Pattern Air Knob
2.
See F IG . 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.
Follow Pressure Relief Procedure, page 10.
Always flush the pump before the fluid dries on the dis-
placement rod. See Flush the Pump on page 13.
12 3A0732C
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.
Flush the pump:
• Before first use
• When changing colors or fluids
• Before repairing equipment
• Before fluid dries or settles out in a dormant pump
(check the pot life of catalyzed fluids)
• At the end of the day
• Before storing the pump.
Flush at the lowest pressure possible. Flush with a fluid that is compatible with the fluid you are pumping and with the wetted parts in your system. Check with your fluid manufacturer or supplier for recommended flushing fluids and flushing frequency.
1.
Follow Pressure Relief Procedure, page 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.
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.
3A0732C 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.
Air continuously exhausting around air motor piston rod.
Air continuously exhausting from muffler.
Air motor “bounces” at top of stroke.
Air motor “bounces” at bottom of stroke.
Icing inside motor.
Pump fails to operate.
Pump operates but does not prime.
Pump operates, but output is low on both strokes.
Pump operates, but output is low on downstroke.
Erratic or accelerated pump speed.
Fluid being pumped is visible in the packing nut wet-cup.
Bad spray pattern.
Cause
Damaged air valve (214).
Damaged pilot valve (213).
Damaged u-cups (207).
Damaged air valve plate (305) or cup
(312).
Damaged bottom pilot valve (213).
Damaged top pilot valve (213).
Solution
Replace or service air valve (214). See
Replace pilot valves (213). See page 20.
Replace piston rod u-cups (207). See
Replace or service air valve (214). See
Replace bottom pilot valve (213). See
Replace top pilot valve (213). See page
Reduce pressure, cycle rate, or duty cycle of motor.
Air motor operating at high pressure or high cycle rate.
Reduce dew point of compressed air in moisture coalescing filter.
Restricted line or inadequate air supply; closed or clogged valves.
Obstructed fluid hose or gun; fluid hose ID is too small.
Clear line or increase air supply. Check that the valves are open.
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 piston packings.
Worn suction hose o-ring (38).
Restricted line or inadequate air supply; closed or clogged valves.
Obstructed fluid hose or gun; fluid hose ID is too small.
Clear valve; replace packings. See page
Replace suction hose o-ring (38).
Clear line or increase air supply. Check that the valves are open.
Open, clear*; use hose with larger ID.
Worn packings in displacement pump.
Held open or worn ball check valves or piston packings.
Exhausted fluid supply.
Held open or worn ball check valves or packings.
Worn throat packings.
Replace packings. See page 16.
Clear valve; replace packings. See page
Refill and prime.
Clear valve, replace packings. See page
Tighten packing nut.
Clean or repair spray gun or tip.
Replace throat packings. See page 16.
See G15/G40 air-assisted gun manual or
Silver Plus airless gun manual.
14 3A0732C
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.
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.
. 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.
1.
Stop the pump.
2.
Flush the pump, if possible (see page 13). Follow
Pressure Relief Procedure, page 10.
3.
Disconnect the suction hose.
4.
Remove the intake housing (110). See F IG . 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).
19
18
10
13
F IG . 6. Safety Spring and Connecting Pin
9
TI16261A
3A0732C 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 ‡.
1.
Follow the instructions under Disconnect the Dis-
1.
See F IG . 7. Loosen the packing nut (103), using a
screwdriver and hammer. Remove the o-ring (104).
2.
Unscrew the cylinder (105) from the intake housing
(110). The rod and piston assembly will come with the cylinder.
3.
Remove the ball guide (109), intake ball (116), seat
(117), and o-ring (111) from the intake housing
(110).
4.
Drive the rod and piston assembly out the bottom of the cylinder. Remove the o-ring (107) from the cylinder.
5.
Insert a plastic rod in the bottom of the cylinder and drive the throat packings and glands out the top.
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.
7.
Clean and inspect all parts. Replace any damaged parts.
Reassemble the Pump
NOTE: Soak the leather packings (113‡, 125‡) in hydraulic oil for one hour before installing them in the 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‡).
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).
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‡).
4.
Install the o-ring (104‡) on the packing nut (103).
Loosely install the packing nut in the cylinder.
5.
Liberally lubricate the piston packings and the top 2 in. (51 mm) of the displacement rod (119).
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).
7.
Grease the o-ring (107‡) and install it on the cylinder (105).
8.
Install the o-ring (111‡), seat (117), intake ball
(116‡), and ball guide (109) in the intake housing
(110).
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).
10. Tighten the packing nut (103) 1/2 turn past handtight, or torque to 60-80 in-lb (6.7-9.0 N•m).
11. Ensure that the button plug (102‡) is in place on the packing nut (103).
12. Follow the instructions under Reconnect the Dis-
Reconnect the Displacement
Pump
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).
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 3A0732C
Repair
2.
Tighten the jam nut (13). Torque to 65-75 ft-lb
(88-102 N•m).
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).
4.
Push the retaining spring (19) into place to cover the pin.
5.
Fill throat packing nut wet-cup with TSL to prevent premature packing wear.
‡102
103
‡104
‡112
105
1
‡106
‡114
119
‡121
113‡
1
15
107‡
109 ❖
116‡
❖
117
❖
111‡
❖
110
2
1
‡126
‡122
‡123
‡120
124
125‡
2
1
2
Lips must face down.
Lips must face up.
TI16131a
F IG . 7. Displacement Pump
3A0732C 17
Repair
Repair Air Valve
312
◆
311
◆
Replace Complete Air Valve
1.
Stop the pump. Follow Pressure Relief Procedure, page 10.
2.
Disconnect the air line to the motor.
3.
. 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.
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
2.
See F
IG
. 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 ◆ ).
305 ◆
309†
◆
F IG . 8. Air Plate Removal ti16284a
3.
See F IG . 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.
18 3A0732C
Repair
◆✠
310
1
† ✠◆ 306
✠
307
1
◆
312
1 ◆ 304
1
◆ 311
◆ 303
301
◆ 305
1
† ◆ 308
1
◆ 302
†
◆
309
1
† ◆ 308
✠ 307
1
†
✠◆
306
◆✠ 310
1 Apply lubricant.
F IG . 9. Air Valve Assembly
3A0732C ti16213a
19
Repair
Reassemble the Air Valve
1.
See F
IG
. 9. Lubricate detent cam (304 ◆ ) and install into housing.
2.
. 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 ◆
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 ti16283a
Magnet
F IG . 11. Air Valve Cup Installation
†
◆
308
Lips face up
F IG . 10. Air Valve U-cup Installation ti12754a
3.
See F IG . 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.
Replace Pilot Valves
1.
Stop the pump. Follow Pressure Relief Procedure, page 10.
2.
Disconnect the air line to the motor.
3.
See F IG . 12. Push the safety spring (9) down and
hold to access the pilot valve on the bottom cover.
4.
See F IG . 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).
20 3A0732C
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.
4.
. 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
F IG . 12. Disconnect the Air Motor
Reconnect the Air Motor
1.
1
10
17
9 11
TI16261A
Replace the motor on the mounting bracket (1).
8
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.
3A0732C 21
Repair
Repair 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.
. 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.
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.
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.
Reassemble the Air Motor
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 F IG . 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
*207
Lips face up
Lips face down.
F IG . 13. Air Motor U-cup Installation ti16285a
22 3A0732C
1
Apply lubricant.
231
*230
1
213
1
210
219
202*
1
1
*202
*217
*207
1
205
1
203
206
*207
1
218
F IG . 14. Air Motor Assembly
3A0732C
Repair
204*
1
208*
220
211
214
211
209* ◆ †
215
208*
201
213
1
212
TI16130a
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 F
IG
. 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
F IG . 15. Align Shield in Grooves on Covers ti16281a
24 3A0732C
Parts
Parts
Package Parts
NOTE: For hose and gun, see page 29.
20
Part of air motor (7)
16
37
7
1
26
9
15
23
22
21
Detail of Stand Kit (2)
1 (Ref)
4
17
8
10
11
13
19
18
12
38
42
3
TI16129a
2
4
5
43
6
43
TI16438a
3A0732C 25
Parts
Package Parts
Ref.
No.
Description
Package
24F150 24F151 24F152 24F153 24F154 24F155 24F156 24F157 24F158 24F159 Qty
1 BRACKET, wall 24H102 24H102 24H102 24H102 24H102 24H102 24H102 24H102 24H102 24H102 1
2
3
4
KIT, stand; includes items 3, 4, 5, 6, and 43 below, and 418 on page
PLUG
SCREW, cap, hex hd;
1/4-20 x 1.5 in. (38 mm)
SPACER, tube
24F164
108175
100058
24F164
108175
100058
24F164
108175
100058
24F164
108175
100058
24F164 1
108175 4
100058 6
5 ----------4
6
7
NUT, hex; 1/4-20
MOTOR, air; see page
GC2095 GC2095 GC2095 GC2095 GC2095
24G693 24G693 24G694 24G694 24G694 24G694 24G694 24G694 24G693 24G693
6
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
9 SPRING, safety 24H103 24H103 24H103 24H103 24H103 24H103 24H103 24H103 24H103 24H103
10 ADAPTER, pump lower 24H104 24H104 24H104 24H104 24H104 24H104 24H104 24H104 24H104 24H104
1
1
1
11 NUT, lock
12 LOWER, pump; see
items 15, 18, and 19
104541 104541 104541 104541 104541 104541 104541 104541 104541 104541 3
24G701 24G701 24G702 24G702 24G701 24G701 24G701 24G701 24G702 24G702 1
13 NUT, jam
15 ‡ NIPPLE; 1/4 npsm x 1/4 npt; plated steel
195150 195150 195150 195150 195150 195150 195150 195150 195150 195150
162453 162453 162453 162453 162453 162453
NIPPLE; 1/4 npsm x 1/4 npt; sst
166846 166846 166846 166846 1
1
1
16 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
17 NUT, hex; 7/16-20
18 ‡ PIN, straight
19 ‡ SPRING, retaining
Not sold separately. Order Tie Rod Kit, item 8.
196762 196762 196762 196762 196762 196762 196762 196762 196762 196762
196750 196750 196750 196750 196750 196750 196750 196750 196750 196750
1
3
1
1
26 3A0732C
Parts
Package
Ref.
No.
Description 24F150 24F151 24F152 24F153 24F154 24F155 24F156 24F157 24F158 24F159
20 AIR CONTROL ASSEM24H162 24H163 24H162 24H163 24H164 24H165 24H162 24H163 24H162 24H163
21 ELBOW, swivel; 1/4 npt(m) x 3/8 in. (10 mm)
OD tube
121141 121141 121141 121141 121141 121141 121141 121141 121141 121141
22 TUBE, polyurethane;
3/8 in. (10 mm) OD; 2 ft
(0.61 m)
24H008 24H008 24H008 24H008 24H008 24H008 24H008 24H008 24H008 24H008
23 SCREW, ground
26 WIRE, grounding
116343 116343 116343 116343 116343 116343 116343 116343 116343 116343
238909 238909 238909 238909 238909 238909 238909 238909 238909 238909
28 THROAT SEAL LIQUID; 238049 238049 238049 238049 238049 238049 238049 238049 238049 238049
4 oz (not shown)
37 STRAINER, suction; 3/8 24F160 24F160 24F160 24F160 24F160 24F160 24F160 24F160 24F160 24F160 in. (10 mm) OD tube; pack of 3
117559 117559 117559 117559 117559 117559 117559 117559 117559 117559 38 O-RING; fluoroelastomer
42 NUT, jam, suction
43 WASHER, lock; 1/4; part of stand kit (2)
15E813 15E813 15E813 15E813 15E813 15E813 15E813 15E813 15E813 15E813
-----------
Qty
1
1
1
1
1
1
6
1
1
1
‡ Included in Pump Lower Rebuild Kit. See page 31.
3A0732C 27
Parts
28 3A0732C
Parts
Hose and Gun
Air-Assisted Packages
30
37
29
36
32
36
Airless Packages
30
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
24C855 24C855 GUN, air-assisted, G40; see 3A0149
GUN, airless; see
311254
32 HOSE, fluid; 1/8 in. (3 mm) ID nylon; 1/4 npsm(f) plated steel couplings; 25 ft (7.6 m) long
24F165 24F165
235460 235460
241811 241811 241811 241811
24C855 24C855
24F165 24F165 24F165 24F165
1
24C853 24C853 1
1
1
1
HOSE, fluid; 1/8 in. (3 mm) ID nylon; 1/4 npsm(f) sst couplings;
25 ft (7.6 m) long
24F166 24F166
33 CLIP, hose; pack of 7 24H005 24H005 24H005 24H005
36 ★ TIP; G15, G40 AAM413 AAM413 AAM413 AAM413
TIP; airless 163515 163515
24F166 24F166
24H005 24H005 24H005 24H005
AAM413 AAM413 AAM413 AAM413
1
7
1
1
★ Additional tip sizes are available. See manual 3A0149 for G15 and G40 AA Guns.
See tip manual 306686 for Silver Plus Airless Guns.
3A0732C 29
Parts
Displacement Pump Parts
Part No. 24G701, Plated Steel
Part No. 24G702, Stainless Steel
‡102
103
‡104
‡112
‡106
‡114
119
‡121
‡126
‡122
‡123
‡120
124
113‡
125‡
105
15, see page 26
107‡
109
❖
116‡ ❖
117 ❖
111‡ ❖
110
30
TI16131a
3A0732C
Parts
Displacement Pump Parts
Part No. 24G701, Plated Steel
Part No. 24G702, Stainless Steel
Ref.
Description
102‡ BUTTON, plug
103 NUT, packing; plated steel
NUT, packing; sst
104‡ O-RING; buna-N; 1.262 in. (32.05 mm) OD
105
106‡
CYLINDER, pump
V-PACKING, throat; V-Max
™
UHMWPE
107‡ O-RING; PTFE; 1.254 in. (31.85 mm) OD
109 ❖ GUIDE, ball
110 VALVE, intake housing; plated steel
VALVE, intake housing; sst
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.
117 ❖ SEAT, carbide
119
KIT, rod, displacement; 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
GLAND, male, piston; sst
122‡ GLAND, female, piston; plated steel
GLAND, female, piston; sst
123‡ WIPER, piston
124 VALVE, piston; plated steel
24G701 24G702 Qty
---
193047
---
---
243176
---
---
15C011
15B611
---
---
---
---
105445
105444
---
---
---
Order item 119
24H161
---
24G706
---
---
15C011
24H007
---
---
---
---
105445
15A968 15A968
24G703 24G704
105444
---
---
---
1
1
1
1
1
1
1
1
1
1
3
1
1
1
2
1
1
1
1
1
1
1
1
1
125‡
126‡
VALVE, piston; sst
V-PACKING, piston; leather
V-PACKING, piston; V-Max
™
UHMWPE
---
---
Order item 119
---
---
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.
3A0732C 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
*230
213
210
219
202*
205
*202
*217
*207
203
204*
208*
220
211
214
211
209* ◆ †
215
206
*207
218
201
213
208*
212
TI16130a
32 3A0732C
Parts
Air Motor Parts
Part No. 24G693, 2.5 in. (63.5 mm)
Part No. 24G694, 3.5 in. (88.9 mm), shown
Ref.
201
202*
203
204*
205
206
218
219
▲
207*
208*
209*
210
211
212
213
214
215
217*
◆ †
Description
KIT, cover, bottom; includes 202 (qty 1),
203, 207, 213 (qty 1), and 217
O-RING, cover
BEARING
O-RING, piston
CYLINDER, motor
COVER, cylinder (includes English warning label)
SEAL, u-cup
GASKET, manifold
GASKET, air valve
KIT, cover, top; includes 202 and 213
(qty 1 of each). 15X353 also includes
230 and 231.
SCREW, M6 x 25
BOLT, tie, hex head
BOLT, tie, hex head
VALVE, pilot (pack of 2)
VALVE, air; includes items 209 and 211
(qty 4)
MUFFLER
RING, retaining
24G693
24G695
Not sold separately. See Air Motor Seal Kit (below), Bottom Cover Kit
(201, this table), or Top Cover Kit (210, this table)
Not sold separately. See Bottom Cover Kit (201, this table)
Not sold separately. See Air Motor Seal Kit (below) or
Piston Kit (219, this table)
15M289
15M302
15M211
15M212
Not sold separately. See Air Motor Seal Kit (below) or
Bottom Cover Kit (201, this table)
Not sold separately. See Air Motor Seal Kit (below) or
Manifold Assembly (220, this table)
Not sold separately. See Air Motor Seal Kit, Valve Repair Kit 24A537,
Valve Seal Kit 24A535 (below), or Manifold Assembly (220, this table)
24H004 15X353
Not sold separately. See Manifold Assembly (220, this table) or
Air Valve Replacement Kit (page 35)
15M314
24A366
24A351
15M314
24A366
24A351
15M213
24G694
24G696
15M213
Not sold separately. See Air Motor Seal Kit (below) or
Bottom Cover Kit (201, this table)
Not sold separately. See Motor Piston Kit (219, this table)
24G697 24G698
220
229 ▲
230*
ROD, air motor
KIT, piston, motor; includes 204 and
218, and 16G561 adhesive.
MANIFOLD, assembly, includes 208,
209, and 211 (qty. 4)
LABEL, warning (French and
Spanish)
O-RING, top plug (24G694 only)
24A579
15W719
24A579
15W719
231 PLUG, top cover (24G694 only)
Not sold separately. See Air Motor
Seal Kit (below)
Not sold separately. See Top
Cover Kit (210, this table)
Qty
1
2
2
2
1
1
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
▲
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.
* Included in Air Motor Seal Kit:
24G693
(2.5 in. Motor)
24G694
(3.5 in. Motor)
24G699 24G700
3A0732C 33
Parts
Air Valve Parts
✠ 310
†
✠◆
306
✠ 307
◆
305
◆ 312
◆
311
◆
303
◆
304
301
†
◆
308
◆
302
†
◆
309
†
◆
308
✠ 307
† ✠◆ 306
✠ 310
34 ti16213a
3A0732C
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.
Air Valve
Repair Kit
24A537
Air Valve
Seal Kit
24A535 Ref.
Description Qty.
301
302
◆
303
◆
HOUSING
AIR VALVE PISTON
DETENT PISTON ASSEMBLY
304 ◆
305
◆
DETENT CAM
PLATE, air valve
306†
✠◆
O-RING
307 ✠ CAP
308†
◆
U-CUP
309†
◆
SCREW
310 ✠
311
◆
312
◆
SNAP RING
DETENT SPRING
CUP
1
1
1
1
1
2
2
2
2
2
1
1
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
† 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.
Air Valve
End Cap Kit
24A360
✔
✔
✔
3A0732C 35
Parts
Air Control Parts
Part No. 24H162, Air-Assisted, Wall Mount
Part No. 24H163, Air-Assisted, Stand Mount
1 409
407
420
413
410
411
412
401 1
405
Part of 402
408
1
Connect tubing (406) between these two fittings.
2
Used on stand mount units only.
402
418
2
403
402
404
418
2
404
Part No. 24H164, Airless, Wall Mount
Part No. 24H165, Airless, Stand Mount
1
409
407
421
420
TI16132a
1
Connect tubing (406) between these two fittings.
2
Used on stand mount units only.
413
411
412
36
401
410
1
405 402 418
2
404
TI16229a
3A0732C
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
401 BRACKET, handle
402 REGULATOR, air
REGULATOR, air
403 TEE; 1/4 npt(m)
404 GAUGE, air pressure
GAUGE, air pressure
405 ELBOW, tube; 1/4 npt(f) x 3/8 in. (10 mm) OD tube
FITTING, tube; 1/4 npt(m) x 3/8 in. (10 mm) OD tube
406 TUBE, polyurethane; 3/8 in. (10 mm) OD tube; 2 ft (0.61 m)
407 VALVE, ball, air; 3/8 npt(fbe)
408 NIPPLE; 1/4 npsm x 1/4 npt
409 ELBOW, swivel; 3/8 npt(m) x 3/8 in. (10 mm) OD tube
410 ELBOW; 1/4 npt(f) x 1/8 npt(m)
411 VALVE, safety relief; 110 psi
412 ELBOW, swivel; 1/4 npt(m) x 3/8 in. (10 mm) OD tube
413 NUT, regulator
NUT, regulator
418 ELBOW, street, 45°; 1/8 npt (mxf)
ELBOW, street, 45°; 1/8 npt (mxf)
420 SCREW, cap, button-hd; 10-24 x 3/8 in. (10 mm)
421 PLUG, panel
24H162 24H163 24H164 24H165 Qty
24H105 24H105 24H105 24H105
15T499 15T499
15T499 15T499
115219 115219
108190 108190
108190 108190
C38161 C38161
120389 120389
24H008 24H008 24H008 24H008
114362 114362 114362 114362
162453 162453
16F151 16F151 16F151 16F151
121150 121150 121150 121150
113498 113498 113498 113498
121141 121141 121141 121141
115244 115244
115244 115244
113630
113630
114381 114381 114381 114381
16F547 16F547
1
2
1
1
1
1
1
1
1
2
1
2
1
1
1
2
1
1
1
1
2
3A0732C 37
Kits and Accessories
Kits and Accessories
Kit Description
Airless to Air-Assisted Conversion Kit
Inline Fluid Filter, stainless steel
Inline Fluid Filter, aluminum
Standard Suction Hose, 5 gal. (19 l), 3/8 in. (10 mm) OD
Suction Hose, 5 gal. (19 l), 5/8 in. (16 mm) OD
Suction Tube, 1 gal. (3.8 l), 11/32 in. (9 mm) OD
Standard Push-on Strainer Kit
Screw-on Strainer Kit (for 24F149 5/8 in. Suction Hose Kit)
Air Gauge Lens Cover Kit (sheet of 12 covers)
Throat Seal Liquid (TSL); 4 oz (118 ml)
Throat Seal Liquid (TSL); 8 oz (236 ml)
Part No.
24F161
24F271
24F272
24F148
24F149
24F147
24F160
256426
193199
238049
206994
38 3A0732C
Package Dimensions
Package
Wall Mount
Stand Mount
A, inch
(mm)
29.0 (737)
B, inch
(mm)
20.2 (513)
C inch (mm)
D inch (mm)
17.4 (442) 18.4 (467)
Front View Top View
D
Package Dimensions
A
B
C ti16288a ti16287a
Package Weights
Package Description
24F150 15:1 plated steel, AA, wall
24F151
24F152
15:1 plated steel, AA, stand
30:1 stainless steel, AA, wall
24F153
24F154
24F155
30:1 stainless steel, AA, stand
30:1 plated steel, airless, wall
30:1 plated steel, airless, stand lb kg
20 9
23 10
23 10
26 12
22 10
25 11
Package Description
24F156
24F157
30:1 plated steel, AA, wall
30:1 plated steel, AA, stand
24F158
24F159
15:1 stainless steel, AA, wall
15:1 stainless steel, AA, stand lb kg
23 10
26 12
20 9
23 10
3A0732C 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 0.312 (5/16) in. (8 mm).
For wall mount or to attach stand to bracket.
5.10 in. (130 mm)
2 x 0.62 in.
(16 mm)
2.69 in.
(68 mm)
2 x 0.48 in.
(12 mm)
TI16289a
40 3A0732C
Technical Data
Technical Data
Maximum fluid working pressure
15:1 Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . .
30:1 Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1500 psi (10.3 MPa, 103 bar)
3000 psi (20.7 MPa, 207 bar)
Maximum air inlet pressure . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7.0 bar)
Maximum fluid temperature . . . . . . . . . . . . . . . . . . . 160°F, 71°C
Ambient air temperature range . . . . . . . . . . . . . . . . 35-120°F, 2-49°C
Package air inlet size. . . . . . . . . . . . . . . . . . . . . . . . 3/8 npt(f)
Package fluid outlet size . . . . . . . . . . . . . . . . . . . . . 1/4 npsm(m)
Maximum motor speed . . . . . . . . . . . . . . . . . . . . . .
(Do not exceed maximum recommended speed of fluid pump, to prevent premature pump wear.)
240 cycles per minute
Maximum spray tip orifice size . . . . . . . . . . . . . . . . .019 in. (0.483 mm)
Sound data
24G693 Air Motor
Sound power* . . . . . . . . . . . . . . . . . . . . . . .
Sound pressure**. . . . . . . . . . . . . . . . . . . . .
24G694 Air Motor
Sound power* . . . . . . . . . . . . . . . . . . . . . . .
Sound pressure**. . . . . . . . . . . . . . . . . . . . .
83.2 dBA
76.5 dBA
84.5 dBA
77.9 dBA
Wetted parts
Plated steel pumps . . . . . . . . . . . . . . . . . . . . . . Stainless steel, nickel plated carbon steel, tungsten carbide, ptfe, acetal, leather, ultra-high molecular weight polyethylene
Stainless steel pumps . . . . . . . . . . . . . . . . . . . . Stainless steel, tungsten carbide, ptfe, acetal, leather, ultra-high molecular weight polyethylene
Spray guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See manual 3A0149 (G15 and G40 AA guns) or
311254 (Silver Plus airless gun)
Fluid hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nylon, plated or stainless steel
Suction assembly . . . . . . . . . . . . . . . . . . . . . . . . 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.
3A0732C 41
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 11/2010
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