Graco 312797R - Merkur Non-Heated Spray Packages Instructions

Instructions/Parts

Merkur

®

Non-Heated

Spray Packages

312797R

EN

For high-performance finishing and coating applications in hazardous or non-hazardous locations. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

See the charts beginning on page 5 for model information, including maximum air inlet pressures and maximum fluid

working pressures.

Cart Mount Wall Mount

ti11881a ti11882a ll 2 G c T3

2

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Merkur 10:1 Packages

(G10Cxx and G10Wxx) . . . . . . . . . . . . . . . . 6


(G15Wxx, G15Cxx, and G15Txx) . . . . . . . . . 7


(G18Wxx and G18Cxx) . . . . . . . . . . . . . . . . 8


(G23Wxx and G23Cxx) . . . . . . . . . . . . . . . . 8


(G24Wxx and G24Cxx) . . . . . . . . . . . . . . . . 9


(G28Wxx and G28Cxx) . . . . . . . . . . . . . . . . 9


(G30Wxx, G30Cxx, and G30Txx) . . . . . . . . 10


(G36Wxx and G36Cxx) . . . . . . . . . . . . . . . 12


(G45Wxx and G45Cxx) . . . . . . . . . . . . . . . 13


(G48Wxx and G48Cxx) . . . . . . . . . . . . . . . 14

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

General Information . . . . . . . . . . . . . . . . . . . . . 16

Prepare the Operator . . . . . . . . . . . . . . . . . . . . 16

Prepare the Site . . . . . . . . . . . . . . . . . . . . . . . . 16

Wall Mount Packages . . . . . . . . . . . . . . . . . . . . 16

Cart Mount Packages . . . . . . . . . . . . . . . . . . . . 16

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 17

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Pressure Relief Procedure . . . . . . . . . . . . . . . . 18

Flush the Pump Before First Use . . . . . . . . . . . 19

Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . 19

Install the Spray Tip . . . . . . . . . . . . . . . . . . . . . 20

Adjust the Atomization . . . . . . . . . . . . . . . . . . . 20

Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . 21

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Preventive Maintenance Schedule . . . . . . . . . . 22

Tighten Threaded Connections . . . . . . . . . . . . . 22

Flush the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 22

Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

DataTrak Controls and Indicators . . . . . . . . . . . . 24

DataTrak Operation . . . . . . . . . . . . . . . . . . . . . . . . 25

Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Replace DataTrak Battery or Fuse . . . . . . . . . . 28

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Cart Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Wall Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Stand Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

G10xxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 33

G15xxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 34

G18xxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 35

G23xxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 36

G24xxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 37

G28xxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 38

G30xxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 39

G36xxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 40

G45xxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 41

G48xxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 42

Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Wall Mount Kit 24A578 . . . . . . . . . . . . . . . . . . . 43

Cart Mount Kit 289694 . . . . . . . . . . . . . . . . . . . . 43

Stand Mount Kit 24A577 . . . . . . . . . . . . . . . . . . 43

Pump and Gun Control Panel Kits . . . . . . . . . . . 44

Pump Only Control Panel Kits . . . . . . . . . . . . . . 45

DataTrak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Hopper Kit 256410 . . . . . . . . . . . . . . . . . . . . . . . 46

Air Control Mounting Kit 24E883,

Wall and Stand . . . . . . . . . . . . . . . . . . . . . . 46

5-Gallon Suction Hose Kits . . . . . . . . . . . . . . . . 46

55-Gallon Suction Hose Kits . . . . . . . . . . . . . . . 46

PTFE Suction Hose Kits . . . . . . . . . . . . . . . . . . 46

Drain Valve Kit 256425 . . . . . . . . . . . . . . . . . . . 46

Reinforced PTFE V-Packing Kits . . . . . . . . . . . . 46

Guns and Hoses . . . . . . . . . . . . . . . . . . . . . . . . 47

50-Foot Air/Fluid Hose Kit 24A955 . . . . . . . . . . 47

50-Foot Fluid Hose 24A413 . . . . . . . . . . . . . . . . 47

Wall Bracket Mounting Dimensions . . . . . . . . . . . 48

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Package Weights . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 50

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 50

312797R

Related Manuals

Related Manuals

Manual

312792

312794

312796

312798

313255

3A0149

312145

307273

Description

Merkur Displacement Pump

Merkur Pump Assembly

NXT ™ Air Motor

Merkur Electrostatic Packages

Merkur Heated Packages

AA Series Spray Gun (G15,

G40, and G40 with RAC)

XTR ™ 5 and XTR ™ 7 Airless

Spray Gun

Fluid Outlet Filter

.

DataTrak below.

™ includes agency approvals listed

# 53

Conforms to

FM std 3600 & 3610 for use in Class I Div 1

Group D

T3C Hazardous locations

0359

II 1 G

EEx ia IIA T3

Nemko 06ATEX1124

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. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• 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 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.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

312797R 3

4

Warnings

WARNING

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

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 forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your Graco 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 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 in this manual. Disconnect power or air supply.

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 MSDS’s 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, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

• Gloves

• Hearing protection

312797R

Models

Models

Check the identification plate (ID) for the 6-digit part number of your package. Use the following matrix and tables to define the components of your package. For example, package number G30C26 represents a Merkur package (G) , with a 30:1 ratio pump (30) , cart mounting (C) , and the components shown for (26)

in the table on page 10.

Wall Mount

ID

Cart and

Stand Mount

ID ti12326a

G

First Digit

G

(Merkur

Package)

30

Second and Third Digits

(Ratio)

24

28

30

36

10

15

18

23

45

48

10:1

15:1

18:1

23:1

24:1

28:1

30:1

36:1

45:1

48:1

C

C

T

W

Fourth Digit

(Mounting Type)

Cart

Stand

Wall ti12327a

26

Fifth and Sixth Digit

(Components Included)

See Tables, pages 6 to 14

312797R 5

6

Models

Merkur 10:1 Packages

(G10Cxx and G10Wxx)

Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar)

Maximum Fluid Working Pressure: 1000 psi (6.9 MPa, 69 bar)

Model

Wall

Mount

Cart

Mount

Pump

Assembly

G10W09 ----W10CAS

G10W01 G10C01 W10CAS

Gun

None

None

G10W03 G10C03 W10CAS

----G10C05 W10CAS

None

None

G10W05 G10C07 W10CAS G15 Carbide

G10W06 G10C08 W10CBS G15 Carbide

G10W07 G10C09 W10CAS G15 Carbide

G10W08 G10C10 W10CBS G15 Carbide

----G10C11 W10CAS G15 Carbide

----G10C13 W10CAS G15 Carbide

Air

Controls

(pump and gun)

Hoses

Gun

Fluid

Hose

Gun

Air

Hose

Accessories

Siphon

Kit

Fluid

Filter Hopper

✔

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DataTrak

Maximum

Fluid Flow

Rate gpm (lpm)

✔

✔

1.2 (4.5)

312797R

Models


(G15Wxx, G15Cxx, and G15Txx)

Maximum Inlet Air Pressure 100 psi (0.7 MPa, 7 bar)


Model

Wall

Mount

Cart

Mount

G15W09 -----

Stand

Mount

-----

Pump

Assembly

W15AAS

G15W01 G15C01 G15T01 W15AAS

G15W03 G15C03 ----W15AAS

Gun

None

None

None

----G15C05 W15AAS None

G15W05 G15C07 G15T03 W15AAS G15 Carbide

G15W06 G15C08 G15T04 W15AAS G15 Carbide

G15W07 G15C09 ----W15AAS G15 Carbide

G15W08 G15C10 ----W15AAS G15 Carbide

----G15C11 G15T05 W15AAS G15 Carbide

----G15C12 -----

----G15C13 -----

----G15C14 -----

G15W19 ---------

W15AAS G15 Carbide

W15AAS G15 Carbide

W15AAS G15 Carbide

W15BAS None

Air Controls Hoses Accessories

Pump

Only

Pump and

Gun

Gun

Fluid

Hose

Gun

Air

Hose

Siphon

Kit

Fluid

Filter Hopper

Data

Trak

Maximum

Fluid Flow

Rate gpm (lpm)

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*

*

*

*

0.40 (1.5)

G15W21 G15C21 -----

G15W23 G15C23 -----

W15BAS

W15BAS

----G15C25 G15T11 W15BAS

--------G15T12 W15BBS

None

None

None

None

G15W25 G15C27 G15T13 W15BAS G15 Carbide

G15W26 G15C28 G15T14 W15BBS G15 Carbide

G15W27 G15C29 -----

G15W28 G15C30 -----

W15BAS G15 Carbide

W15BBS G15 Carbide

----G15C31 G15T15 W15BAS G15 Carbide

----G15C33 ----W15BAS G15 Carbide

G15W51 G15C75 -----

G15W52 ---------

W15FAS

W15FBS

None

None

----G15C77 -----

----G15C78 -----

G15W53 G15C79 -----

G15W54 G15C80 -----

W15FAS

W15FBS

W15FAS

W15FBS

None

None

None

None

----G15C81 -----

G15W55 G15C83 -----

G15W56 G15C84 -----

W15FAS None

W15FAS G15 Carbide

W15FBS G15 Carbide

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0.8 (3.0)

2.4 (9.0)

* DataTrak with cycle counter only, no runaway solenoid.

312797R 7

8

Models


(G18Wxx and G18Cxx)



Model

Wall

Mount

Cart

Mount

G18W01 -----

Pump

Assembly Gun

W18EAS None

G18W03 -----

G18W04 -----

W18EAS None

W18EBS None

G18W05 G18C01 W18EAS None

G18W06 G18C02 W18EBS None

----G18C03 W18EAS None

G18W07 G18C05 W18EAS G40

G18W08 G18C06 W18EBS G40

G18W09 G18C07 W18EAS G40 RAC

G18W10 G18C08 W18EBS G40 RAC

Air Controls

Pump only

Pump and

Gun

Gun

Fluid

Hose

Hoses

Gun

Air

Hose

Accessories

Gun

Fluid

Whip

Hose

Siphon

Kit

Fluid

Filter

✔

✔

✔

✔

✔

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DataTrak

Maximum

Fluid Flow

Rate gpm (lpm)

✔

✔

✔

✔

2.0 (7.5)





Model

Wall

Mount

Cart

Mount

G23W01 -----

Pump

Assembly Gun

W23DAS None

G23W03 -----

G23W04 -----

W23DAS None

W23DBS None

----G23C01 W23DAS None

----G23C02 W23DBS None

G23W05 -----

G23W06 -----

W23DAS None

W23DBS None

G23W07 G23C03 W23DAS XTR5

G23W08 G23C04 W23DBS XTR5

----G23C05 W23DAS None

----G23C07 W23DAS

G23W09 G23C09 W23DAS

----G23C11 W23DAS

G23W10 G23C12 W23DBS

G40

G40

G40

G40

G23W11 G23C13 W23DAS G40 RAC

G23W12 G23C14 W23DBS G40 RAC

Air Controls Hoses

Pump only

Pump and

Gun

Gun

Fluid

Hose

Gun

Air

Hose

Siphon

Kit

Accessories

Fluid

Filter

Hopper

✔

✔

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DataTrak

Maximum

Fluid Flow

Rate gpm (lpm)

✔

✔

✔

✔

✔

✔

1.6 (6.0)

312797R





Model

Wall

Mount

Cart

Mount

G24W01 -----

G24W02 -----

Pump

Assembly Gun

W24FAS

W24FBS

G24W03 G24C01 W24FAS

G24W04 G24C02 W24FBS

None

None

G24W05 G24C03 W24FAS XTR5

G24W06 G24C04 W24FBS XTR5

G24W07 G24C09 W24FAS

G24W08 G24C10 W24FBS

G40

G40

G24W09 G24C11 W24FAS G40RAC

G24W10 G24C12 W24FBS G40RAC

Air Controls Hoses Options

Pump

Only

Pump and

Gun

Gun

Fluid

Hose

Gun

Air

Hose

Siphon

Kit

Fluid

Filter

DataTrak

Maximum

Fluid Flow

Rate gpm (lpm)

✔

✔

✔

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✔

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2.4 (9.0)





Model

Wall

Mount

Cart

Mount

G28W01 -----

Pump

Assembly Gun

W28EAS None

G28W02 ----W28EBS None

G28W03 G28C01 W28EAS None

G28W04 G28C02 W28EBS None

G28W05 G28C03 W28EAS XTR5

G28W06 G28C04 W28EBS XTR5

G28W11 G28C09 W28EAS G40

G28W12 G28C10 W28EBS G40

G28W13 G28C11 W28EAS G40RAC

G28W14 G28C12 W28EBS G40RAC


Pump

Only

Pump and

Gun

Gun

Fluid

Hose

Gun

Air

Hose

Siphon

Kit

Fluid

Filter DataTrak

Maximum

Fluid Flow

Rate gpm (lpm)

✔

✔

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✔

✔

✔

✔

✔

2.0 (7.5)

Models

312797R 9

Models


(G30Wxx, G30Cxx, and G30Txx)


Maximum Fluid Working Pressure: 3000 psi (20.7 MPa, 207 bar )

Model

Wall

Mount

Cart

Mount

Stand

Mount

Pump

Assembly Gun

G30W19 ----W30AAS

G30W01 G30C01 ----W30AAS None



----G30C07 ----W30AAS XTR5

----G30C08 ----W30ABS XTR5

G30W07 G30C09 ----W30AAS XTR5

G30W08 G30C10 ----W30ABS XTR5

----G30C11 ----W30AAS XTR5

----G30C13 ----W30AAS XTR5

----G30C15 ----W30AAS XTR5


-----

-----

-----

-----

G30T01

G30T02

W30AAS

W30ABS

None

None


G30W12 --------W30ABS None

G30W13 G30C21 G30T03 W30AAS G40

G30W14 G30C22 G30T04 W30ABS G40

----G30C23 G30T09 W30AAS G40

G30W15 G30C25 G30T05 W30AAS G40

G30W16 G30C26 G30T06 W30ABS G40

----G30C27 ----W30AAS G40

----G30C29 G30T07 W30AAS G40 RAC

----G30C30 G30T08 W30ABS G40 RAC

----G30C31 ----W30AAS G40 RAC

G30W17 G30C33 G30T11 W30AAS G40 RAC

G30W18 G30C34 G30T12 W30ABS G40 RAC

----G30C35 ----W30AAS G40 RAC

----G30C37 ----W30AAS XTR5

----G30C39 ----W30AAS G40

----G30C40 ----W30ABS G40

G30W51 ----W30CAS None

G30W53 -----

----G30C51

W30CAS

W30CAS

None

None

G30W55 G30C53

G30W56 G30C54

W30CAS None

W30CBS None


Pump

Pump and

Only Gun

Gun

Fluid

Hose

Gun

Air

Hose

Siphon

Kit

Fluid

Filter Hopper

Drain

Valve DataTrak

Maximum

Fluid Flow

Rate gpm (lpm)

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔ **

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

*

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

0.4 (1.5)

1.2 (4.5)

10 312797R

Models

Model

Wall

Mount

Cart

Mount

G30W57 -----

G30W58 -----

G30W59 G30C55

G30W60 G30C56

----G30C57

G30W71 -----

----G30C63

----G30C65

G30W73 G30C67

G30W74 G30C68

----G30C69

----G30C71

G30W75 G30C73

G30W76 G30C74

----G30C85

----G30C86

Stand

Mount

Pump

Assembly Gun

W30CAS

W30CBS

W30CAS

W30CBS

W30CAS

W30CAS

W30CAS

W30CAS

W30CAS

W30CBS

W30CAS

W30CBS

XTR5

XTR5

XTR5

XTR5

XTR5

None

None

G40

G40

G40

G40

W30CAS G40 RAC

W30CAS G40RAC

W30CBS G40RAC

W30CAS XTR5

XTR5


Pump

Pump and

Gun

Fluid

Only Gun Hose

Gun

Air

Hose

Siphon

Kit

Fluid

Filter Hopper

Drain

Valve DataTrak

Maximum

Fluid Flow

Rate gpm (lpm)

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔ **

✔

✔

✔

✔

✔

✔

✔

✔

✔ ✔ ** ✔

✔ ✔ ✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

1.2 (4.5)

* This package offers a short suction tube, rather than the standard suction hose.

** Fluid hose is 3/16 x 50 ft., rather than standard 3/16 x 25 ft.

312797R 11

Models





Model

Wall

Mount

Cart

Mount

G36W01 -----

G36W03 -----

Pump

Assembly

W36DAS

W36DAS

Gun

None

None

G36W04 ----W36DBS

G36W05 G36C01 W36DAS

None

None

G36W06 G36C02 W36DBS None

G36W07 G36C03 W36DAS XTR5RAC

G36W08 G36C04 W36DBS XTR5RAC

G36W13 G36C09 W36DAS G40

G36W14 G36C10 W36DBS G40

G36W15 G36C11 W36DAS G40RAC

G36W16 G36C12 W36DBS G40RAC

G36W17 G36C13 W36DAS G40

G36W18 G36C14 W36DBS G40

----G36C15 W36DAS XTR5RAC

----G36C16 W36DBS XTR5RAC


Pump

Only

Pump and

Gun

Gun

Fluid

Hose

Gun

Fluid

Whip

Hose

Gun

Air

Hose

Suction

Hose

Fluid

Filter

Drain

Valve DataTrak

Maximum

Fluid Flow

Rate gpm (lpm)

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

1.6 (6.0)

12 312797R

Models



Table A:



Model

Wall

Mount

Cart

Mount

G45W01 -----

G45W03 -----

Pump

Assembly

W45BAS

W45BAS

Gun

None

None

G45W04 ----W45BBS

----G45C01 W45BAS

None

None

G45W05 G45C03 W45BAS XTR5RAC

G45W06 G45C04 W45BBS XTR5RAC

----G45C05 W45BAS XTR5RAC

----G45C06 W45BBS XTR5RAC

G45W11 ----W45BAS

----G45C11 W45BAS

None

None


Pump

Only

Pump and

Gun

Gun

Fluid

Hose

Gun

Fluid

Whip

Hose

Gun

Air

Hose

Siphon

Kit

Fluid

Filter Hopper DataTrak

Maximum

Fluid Flow

Rate gpm (lpm)

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

0.8 (3.0)

Table B:



G45W13 G45C15 W45BAS

G45W14 G45C16 W45BBS

G40

G40

G45W15 G45C17 W45BAS G40 RAC

G45W16 G45C18 W45BBS G40 RAC

-----

Model

Wall

Mount

Cart

Mount

Pump

Assembly Gun

----G45C13 W45BAS

G45W17 G45C19

G45W18 G45C20

G45C21

W45BAS

W45BBS

W45BAS

G40

G40

G40

G40


Pump

Only

Pump and

Gun

Gun

Fluid

Hose

Gun

Fluid

Whip

Hose

Gun

Air

Hose

Siphon

Kit

Fluid

Filter Hopper

Drain

Valve DataTrak

Maximum

Fluid Flow

Rate gpm (lpm)

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔ ✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

0.8 (3.0)

312797R 13

Models



Table A:



Model

Wall

Mount

Cart

Mount

Pump

Assembly Gun

G48W01 W48CAS None

G48W03 G48C01 W48CAS None

G48W04 G48C02 W48CBS None

G48W05 G48C03

G48W06 G48C04

-----

-----

G48W11

G48C05

G48C06

-----

W48CAS

W48CBS

W48CAS

W48CBS

XTR5

RAC

XTR5

RAC

XTR5

RAC

XTR5

RAC

W48CAS None


Pump

Only

Pump and

Gun

Gun

Fluid

Hose

Gun

Fluid

Whip

Hose

Gun

Air

Hose

Siphon

Kit

Fluid

Filter Hopper

Drain

Valve DataTrak

Maximum

Fluid

Flow Rate gpm (lpm)

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

1.2 (4.5)

Table B:



Model

Wall

Mount

Cart

Mount

Pump

Assembly Gun

G48W07 G48C07 W48CAS G40

G48W08 G48C08 W48CBS G40

----G48C09 W48CAS G40

G48W13 G48C11 W48CAS G40

G48W14 G48C12 W48CBS G40

G48W15 G48C13

G48W16 G48C14

W48CAS

W48CBS

G40

RAC

G40

RAC

Air Controls

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

Hoses Accessories

Pump

Only

Pump and

Gun

Gun

Fluid

Hose

Gun

Fluid

Whip

Hose

Gun

Air

Hose

Siphon

Kit

Fluid

Filter Hopper

Drain

Valve DataTrak

Maximum

Fluid Flow

Rate gpm (lpm)

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔

✔ *

✔ *

✔

✔

✔

✔

✔ ✔

✔

1.2 (4.5)

✔ ✔ ✔ ✔ ✔ ✔

✔ ✔ ✔ ✔ ✔ ✔ ✔

14 312797R

Installation

Installation

Package configurations vary widely.

See pages 6-14 to determine the components included in your model. Items

designated as accessories are not included in the packages.

A Air Shutoff Valve (optional accessory)

B Air Filter (optional accessory)

C Gun Air Pressure Gauge

D Gun Air Pressure Regulator

E Bleed Type Master Air Valve

F DataTrak

™

G Pump Air Pressure Gauge

H Pump Air Pressure Regulator

J Solenoid Release Button (DataTrak equipped packages

only, not visible, see F IG . 8, page 25)

K Gun Swivel

L Air-Assisted Spray Gun

M Gun Fluid Supply Hose

N Gun Air Supply Hose

P Fluid Filter

R Pump Fluid Outlet

S Grounding Wire

T

Wet-Cup (not visible, see F

IG

. 4, page 19)

U Pump Fluid Inlet

V Suction Hose

W Fluid Drain Valve

A

B

D

C

E

G15 Spray Gun Shown with Supply Hose

L

N

P

R

W

K

M

V

F IG . 1. Typical Installation (Your package may not include all items shown.)

312797R

F

G

H

J

S

T

U ti12800a

15

Installation

General Information

NOTE: Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawing.

NOTE: Always use Genuine Graco Parts and Accessories, available from your Graco distributor. If you supply your own accessories, be sure they are adequately sized and pressure-rated for your system.

F IG . 1 is only a guide for selecting and installing system

components and accessories. Contact your Graco distributor for assistance in designing a system to suit your particular needs.

Prepare the Operator

All persons who operate the equipment must be trained in the operation of all system components as well as the proper handling of all fluids. All operators must thoroughly read all instruction manuals, tags, and labels before operating the equipment.

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 about 1.2-1.5 m (4-5 ft) above the floor. 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 10 mm

(0.4 in.) mounting holes in the wall. Wall mounting

dimensions are shown on page 48.

4. Attach the bracket to the wall. Use 3/8 in. (9 mm) screws that are long enough to keep the pump from vibrating during operation.

NOTE: Be sure the bracket is level.

Cart Mount Packages

In packages with M012xx and M018xx motors the muffler(s) are shipped loose. Ensure the muffler(s) are installed before first use.

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.

16 312797R

Installation

Components

See F IG . 1.

Components vary by package ordered .

See tables on pages 6 to 14. Your package may

include:

• The red-handled bleed-type master air valve (E) 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 (H) controls pump speed and outlet pressure by adjusting the air pressure to the pump.

• The air relief valve (not shown) opens automatically to prevent overpressurization of the pump.

• The gun air regulator (D) adjusts the air pressure to the air-assisted spray gun (L).

• The air-assisted or airless spray gun (L) 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 transparent hose (N, labeled “Air Hose Only”) provides the gun air supply.

• The blue hose (M) provides the gun fluid supply.

• The gun swivel (K) allows for freer gun movement and comes attached to the blue hose (AA packages). The airless gun has a built-in fluid swivel.

• The suction hose (V) with strainer allows the pump to draw fluid from a 5 gallon (19 liter) pail. A fluid hopper with screen also is available.

• A fluid filter (P) with a 60 mesh (250 micron) stainless steel element filters particles from fluid as it leaves the pump.

• A fluid drain valve (W) relieves fluid pressure in the hose and gun.

• DataTrak (F) provides pump diagnostics and material usage information. DataTrak equipped packages with M02xxx air motors do not have a runaway solenoid; all other DataTrak equipped packages do. See

page 24.

312797R

Air Line Accessories

Install the following accessories in the order shown in

F IG . 1, using adapters as necessary.

• An air-line filter (B) removes harmful dirt and moisture from the compressed air supply.

• A second bleed-type air shutoff valve (A) isolates the air line accessories for servicing. Locate upstream from all other air line accessories.

Grounding

1. Pump: See F IG . 2. Verify that the ground screw (GS)

is attached and tightened securely to the air motor.

Connect the other end of the ground wire (S) to a true earth ground.

S

GS ti12914a

F IG . 2. Ground screw and wire

2. Pump fluid hoses: use only electrically conductive fluid hoses Check electrical resistance of hoses. If total resistance to ground exceeds 25 megohms, replace hose immediately.

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.

17

Operation

Setup

1. See F IG . 1. Attach end of blue fluid hose (M) to

pump outlet (R) or filter (P) outlet.

2. Attach one end of the air hose (N) to gun air regulator (D).

3. Attach remaining end of the air hose (N) to air inlet at base of gun (L).

4. Attach gun swivel (K) to gun fluid inlet.

5. Attach other end of blue fluid hose (M) to gun swivel (K).

6. Clip fluid and air hoses together with the supplied hose clips (qty. of 7). Space clips as needed.

7. Apply lens cover to both regulator gauge lenses.

8. Verify that suction hose fittings are tight.

Operation

Pressure Relief Procedure

1. Engage the trigger lock.

2. See F IG . 1. Turn off the bleed-type master air valve

(D).

3. Disengage the trigger lock.

4. Hold a metal part of the gun firmly to a grounded metal waste container. Trigger the gun to relieve fluid pressure.

5. Engage the trigger lock.

6. Open all fluid drain valves in the system, having a waste container ready to catch the drainage. Leave the drain valve(s) open until you are ready to spray again.

7. If you suspect 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.

18 312797R

Operation

Flush the Pump Before First Use

The pump is tested with lightweight oil, which is left in to protect the pump parts. If the fluid you are using may be contaminated by the oil, flush it out with a compatible

solvent. See Flush the Pump on page 22.

Trigger Lock

Wet Cup

Before starting, fill wet cup (T) 1/3 full with Graco Throat

Seal Liquid (TSL) or compatible solvent.

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.

T

Gun Trigger

Safety Locked

Gun Trigger

Safety Unlocked

F IG . 3. Trigger Lock

TI6581A

TI6582A ti11927a

F IG . 4. Wet Cup

Prime the Pump

1. See F IG . 1. Lock gun trigger. Remove tip guard and

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

2. Close gun air regulator (D) and pump air regulator

(H) by turning knobs counterclockwise reducing pressure to zero. Close bleed-type air valve (E).

Also verify that all drain valves are closed.

3. Connect air line to bleed type air valve (D).

4. Check that all fittings throughout system are tightened securely.

5. Position pail close to pump. Suction hose is 4 ft

(1.2 m) long. Do not stretch hose tight; let it hang to assist fluid flow into pump.

6. Hold metal part of gun (L) firmly to side of grounded metal pail, unlock trigger, and hold trigger open.

7.

Units with runaway protection only: enable the prime/flush function by pushing the prime/flush button on the DataTrak.

312797R 19

Operation

8. Open bleed-type air valve (E). Slowly turn clockwise pump air regulator (H) increasing pressure until pump starts.

9. Cycle pump slowly until all air is pushed out and pump and hoses are fully primed.

10.

Units with runaway protection only: disable the prime/flush function by pushing the prime/flush button on the DataTrak.

11. Release gun trigger and lock trigger safety. Pump should stall against pressure.

Install the Spray Tip

Follow Pressure Relief Procedure , page 18. 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.

Adjust the Atomization

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)

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)

20 312797R

Operation

Adjust the Spray Pattern

Packages with Airless Guns

The spray tip orifice and spray angle determine pattern coverage and size. When you need more coverage, use a larger spray tip rather than increasing fluid pressure.

Align guard horizontally to spray a horizontal pattern.

Align guard vertically to spray a vertical pattern.

Packages with AA Guns

1. See F IG . 5. Close off pattern adjustment air by turn-

ing knob (AA) clockwise (in) all the way. This sets gun for its widest pattern.

OUT (narrower pattern)

AA

AA

3. See F IG . 5. 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. no air too little air correct amount of air

F IG . 6. Spray Pattern Problems

Shutdown

TI0792A

IN (wider pattern)

TI6559A

F IG . 5. Pattern Air Knob

2. See F IG . 6. 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 18.

Always flush the pump before the fluid dries on the displacement rod. See

Flush the Pump on page 22.

312797R 21

Maintenance

Maintenance

Preventive Maintenance

Schedule

The operating conditions of your particular system determine how often maintenance is required. Establish a preventive maintenance schedule by recording when and what kind of maintenance is needed, and then determine a regular schedule for checking your system.

Replace lens covers on regulator gauge lenses when dirt makes gauges difficult to read.

Tighten Threaded Connections

Before each use, check all hoses for wear or damage.

Replace as necessary. Check that all threaded connections are tight and leak-free.

Flush the Pump

Read all Warnings.

See page

17.

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 18.

2. Remove tip guard and spray tip from gun. Refer to separate gun manual.

3. Place siphon 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.

Units with runaway protection only: enable the prime/flush function by pushing the prime/flush button on the DataTrak.

7. Trigger gun. Flush system until clear solvent flows from gun.

8.

Units with runaway protection only: disable the prime/flush function by pushing the prime/flush button on the DataTrak.

9. Follow

Pressure Relief Procedure , page 18.

10. Clean the tip guard, spray tip, and fluid filter element separately, then reinstall them.

11. Clean inside and outside of suction tube.

Wet Cup

Fill the wet cup one-half full with Graco Throat Seal Liquid (TSL). Maintain level daily.

22 312797R

Troubleshooting

Troubleshooting

NOTE: Check all possible problems and causes before disassembling the pump.

Relieve the pressure before checking or servicing the equipment.

Problem

Pump fails to operate.

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 TSL reservoir.

Cause Solution

Restricted line or inadequate air supply; closed or clogged valves.

Dirty, worn, or damaged air motor parts.

DataTrak models only: Air valve cannot cycle because solenoid pin is extended.

Clear line or increase air supply. Check that the valves are open.

Obstructed fluid hose or gun; fluid hose ID is too small.

Open, clear*; use hose with larger ID.

Fluid dried on the displacement rod.

Clean; always stop the pump at the bottom of its stroke; keep the wet-cup 1/3 filled with

Graco throat seal liquid (TSL).

Clean or repair air motor. See manual

312796.

Enable runaway protection (See

DataTrak

Operation

,

Setup Mode , page 25). Bleed

Restricted line or inadequate air supply; closed or clogged valves.

Obstructed fluid hose or gun; fluid hose ID is too small.

Worn packings in displacement pump.

Held open or worn ball check valves or piston packings.

air from motor. Press on the DataTrak display to retract solenoid pin.

Clear line or increase air supply. Check that the valves are open.

Open, clear*; use hose with larger ID.

Replace packings. See manual 312792.

Exhausted fluid supply.

Held open or worn ball check valves or packings.

Worn throat packings.

Clear valve; replace packings. See manual

312792.

Refill and prime.

Clear valve, replace packings; see manual

312792.

Replace throat packings. See manual

312792.

* To determine if the fluid hose or gun is obstructed, relieve the pressure. Disconnect the fluid hose and place a container at the pump fluid outlet to catch any fluid. Turn on the air just enough to start the pump. It the pump starts when the air is turned on, the obstruction is in the hose or gun.

312797R 23

DataTrak Controls and Indicators

DataTrak Controls and Indicators

Key for F IG . 7

AA Runaway Limit, in cycles per minute (user settable;

00=OFF)

AB Lower Displacement (user settable)

AC Flow Rate Units (user settable to /min, gpm [US], gpm

[Imperial], oz/min [US], oz/min [Imperial], l/min, or cc/min)

AD LED (fault indicator when lit)

AE Display

PF Prime/Flush Key (Enables Prime/Flush mode. While in

Prime/Flush mode, runaway protection is disabled and the batch totalizer [BT] will not count.) LED will flash while in

Prime/Flush mode.

RK Reset Key (Resets faults. Press and hold for 3 seconds to clear the batch totalizer.) Push to toggle between flow rate and cycle rate. With runaway protection enabled, push to extend and retract the solenoid pin.

CF Cycle/Flow Rate

BT Batch Totalizer

GT Grand Totalizer

RT Runaway Toggle (enable/disable)

UT E1 Toggle

DT E2 Toggle

ST E5 Toggle

GT

AE, see details at right Run Mode

RK PF

AD TI11883a

AC

AB

RK

AA

CF

Setup Mode

BT ti8622b

RT

UT

DT

PF

ST ti8623b

F IG . 7. DataTrak Controls and Indicators

24 312797R

DataTrak Operation

DataTrak Operation

NOTE: The display (AE) will turn off after 1 minute to save battery life. Press any key to wake up the display.

NOTICE

To prevent damage to the soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

Setup Mode

1. See F IG . 7. Press and hold

Setup menu appears.

for 5 seconds until

2. To enter settings for runaway (if equipped), lower size, and flow rate units, and to enable runaway, E1,

E2, and E5 error options, press to change the value, then to save the value and move the cur-

sor to the next data field. See page 27 for a descrip-

tion of E1, E2, and E5 error codes.

NOTE: Graco recommends setting runaway (if equipped) to 60 . All DataTrak modules are shipped with runaway protection not enabled.

NOTE: When runaway, E1, E2, and E5 error options are enabled, a ✓ will appear on the setup screen. See F IG .

7.

3. Move the cursor to the E5 error enable option field, then press once more to exit Setup mode.

2. Runaway Screens 1 and 2: To reset the runaway solenoid, close the master air valve (E). Wait for air to completely bleed off the air motor.

3. Runaway Screens 3 and 4: After the air is bled off, push the solenoid release button (J) down to reset the air valve. The button will pop back up when the air valve is repressurized.

F IG . 8. Solenoid Release Button

J ti11902a

Run Mode

Runaway

NOTE: DataTrak is available with and without runaway protection. Packages with M02xxx air motors ship without a runaway solenoid. All other packages are equipped with a runaway solenoid.

1. See F IG . 7. If pump runaway occurs, the runaway solenoid will actuate, stopping the pump. The LED

(AD) will flash and the display (AE) will indicate a

runaway condition (see Table 1). The display will

cycle through six instruction screens.

4. Runaway Screens 5 and 6: Press to clear the diagnostic code and reset the runaway solenoid.

5. Open master air valve (E) to restart pump.

NOTE: To disable runaway monitoring, go to setup mode and set runaway value to 0 (zero) or toggle (RT) off (see . 7).

312797R 25


Prime/Flush

1. See F IG . 7. To enter Prime/Flush mode, press any key to wake up the display, then press . The

Prime/Flush symbol will appear in the display and the LED will flash .

2. While in Prime/Flush mode, runaway protection is disabled and the batch totalizer (BT) will not count.

The grand totalizer (GT) continues to count.

3. To exit Prime/Flush mode, press any key to wake up the display, then press . The Prime/Flush symbol will disappear from the display and the LED will stop flashing.

Counter/Totalizer

See F IG . 7. The last digit of the batch totalizer (BT) represents tenths of gallons or liters. To reset the totalizer, press any key to wake up the display, then press and hold for 3 seconds.

• If AC is set to gallons or ounces, BT and GT display gallons.

• If AC is set to liters or cc, BT and GT display liters.

• If AC is set to cycles, BT and GT display cycles.

Press to toggle between flow rate units and cycles.

A letter under the BT display indicates that both BT and

GT are displaying gallons (g) or liters (l). No letter means both BT and GT are displaying cycles.

Display

See F IG . 7. The display (AE) will turn off after 1 minute of inactivity in Run mode or 3 minutes in Setup mode.

Press any key to wake up the display.

NOTE: DataTrak will continue to count cycles when display is off.

NOTE: The display (AE) may turn off if a high-level static discharge is applied to the DataTrak. Press any key to wake up the display.

Diagnostics

DataTrak can diagnose several problems with the pump.

When the monitor detects a problem, the LED (AD, F IG .

7) will flash and a diagnostic code will appear on the dis-

play. See Table 1.

To acknowledge the diagnosis and return to the normal operating screen, press once to wake up the display, and once more to clear the diagnostic code screen

26 312797R

.

Symbol


Table 1: Diagnostic Codes

Runaway

(DataTrak only)

Diagnosis

Pump running faster than set runaway limit.

Cause

• Increased air pressure.

• Increased fluid output.

• Exhausted fluid supply.

312797R

E-1 Diving Up Leak during upstroke.

Worn piston valve or packings.

E-2 Diving Down Leak during downstroke.

Worn intake valve.

E-3 Low Battery Battery voltage too low to stop runaway.

Low battery. Replace battery;

see page 28.

E-4 Service

Component 1

(units with runaway protection only)

E-4 Disconnected

Solenoid

(units with runaway protection only)

E-5 Service

Component 2

Problem with stopping runaway. • Damaged solenoid.

• Damaged valve carriage.

• Runaway (RT, F

IG

. 7) protection may be enabled with pump that is not equipped with a runaway solenoid valve. Enter setup screen and disable runaway protection.

Solenoid is disconnected.

Solenoid is not engaging piston cup (112).

• Solenoid unplugged.

• Damaged solenoid wires.

• Bracket and solenoid not tight against air valve housing.

Problem with sensing valve movement.

• Sensors unplugged.

• Sensors mounted incorrectly.

• Damaged sensors.

• Damaged valve carriage.

E-6 Blown Fuse Fuse is blown. Replace fuse;

see page 28.

• Faulty solenoid or solenoid wiring.

• Extreme temperatures

(above 140°F [60°C]).

• Runaway (RT, F IG . 7) protection may be enabled with pump that is not equipped with a runaway solenoid valve. Enter setup screen and disable runaway protection.

27


Replace DataTrak Battery or Fuse

The battery and fuse must be replaced in a non-hazardous location.

Use only the following approved replacement batteries. Use of an unapproved battery will void Graco’s warranty and FM and Ex approvals.

• Ultralife lithium # U9VL

• Duracell alkaline # MN1604

• Energizer alkaline # 522

• Varta alkaline # 4922

Use only a Graco-approved replacement fuse. Order

Part 24C580.

Replace Battery

1. Unscrew cable from the back of the reed switch assembly. See F IG . 9.

2. Remove the cable from the two cable clips.

4. Remove two screws on back of module to access battery.

5. Disconnect the used battery and replace with an approved battery. See F IG . 11.

Replace Fuse

1. Remove the screw, metal strap, and plastic holder.

2. Pull the fuse away from the board.

3. Replace with a new fuse.

Solenoid Cable

Connection

Fuse

Sensor Cable

Connection ti11992a

F IG . 9. Disconnect DataTrak

3. Remove DataTrak module from bracket. See F IG .

10. Take module and attached cable to a non-hazardous location.

Battery

F IG . 11. DataTrak Battery and Fuse Location ti11994a

F IG . 10. Remove DataTrak ti11884a

28 312797R


312797R 29

Parts

Parts

Cart Mount

4

45

44

41

6 7

13

1

3a

2

48

30

5

21

17

15

20

19 ti12632a

312797R

3b

16

23

53

Wall Mount

3a

3b

16

1

2 49 23

6

41

5

13

7

4

44

45

23

48 54 ti12920a

Parts

312797R 31

Parts

Stand Mount

3a

3b

16 1 48

2

4 41

23

6

44

45

13

7

21

17

5

23

55

15

20

19 ti12919a

32 312797R

Parts

NOTE:

•

See page 43 for mounting kits for all packages.

•

See page 44 for repair parts and accessories.

Package

G10xxx

G15xxx

G18xxx

G23xxx

G24xxx

G28xxx

G30xxx

G36xxx

G45xxx

G48xxx

Parts List

Page

37

38

39

40

33

34

35

36

41

42

G10xxx Models

This list includes all possible parts for G10xxx packages. See page 6 to check whether a part is included in your

particular package.

Ref Part Description

6

7

1

2

W10CAS

W10CBS

24A585

Pump Assembly; see Manual 312794

M04LN0 x LW075A

M04LT0 x LW075A

PANEL, air control;

see page 44

3a 24A575 DATATRAK, assembly; see manual

313541

3b -----

4 256420

INSERT, panel (included with Part 2)

HOSE, suction (includes Part 5)

5 ----STRAINER (included with Part 4, or

see page 46 for packages of 10

)

8

24A587

-----

FILTER, fluid

FITTING, union, 3/8-18 npsm x

3/8-18 npt, (included with Part 6)

189018 SWIVEL, fluid hose (packages with gun)

9 241812 HOSE, fluid (packages with gun)

10 24C853 GUN, G15, carbide

11 AAM413 TIP (packages with gun)

12 AAMxxx TIP OPTION, (packages with gun)

13 512351 ADAPTER, outlet, 1/4 nptm x 3/8 nptf

14 256390 AIR HOSE, gun, (packages with gun)

15 256410 HOPPER (includes 17, 19, 20)

16 105332 NUT, lock, M5 x 0.08 (included with

Parts 2 and 49)

Qty

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Ref Part Description

17

18

-----

-----

TUBE, inlet, hopper (included with

Part 15)

CLIP, hose (packages with gun), see

page 46 for packages of 10

19 ----O-RING, hopper (included with

Part 15)

20 ----SCREEN, hopper (included with

Part 15)

21 24B299 ADAPTER, inlet, 3/4 nptf to 1/2 nptm, for suction hose

23 111799 SCREW, M8 x 16 (included with

Parts 49, 53, and 54)

Wall mount

Cart mount

48 238909 WIRE, grounding assembly

49 24E883 BRACKET, air control, wall mount only

(includes Parts 16 and 23)

53 See p. 43 CART MOUNTING KIT;

see page 43

(G10Cxx models only)

54

See p. 43 WALL MOUNTING KIT; see page 43

(G10Wxx models only)

Qty

1

7

1

1

1

1

1

1

1

6

4

----- Not sold separately.

NOTE: Replacement Warning labels, signs, tags, and cards are available at no cost.

312797R 33

Parts

G15xxx Models


particular package.

Ref. Part Description

1

2

W15AAS

W15BAS

W15BBS

W15FAS

W15FBS

24A585

Pump Assembly; see Manual 312794

M02LN0 x LW025A

M04LN0 x LW050A

M04LT0 x LW050A

M12LN0 x LW150A

M12LT0 x LW150A

PANEL, air controls (includes Part 3b)

M02xxx or M04xxx motor, pump and gun; see page

44

3a

24A583

24A581

M12xxx motor, pump only; see

page 45

M12xxx motor, pump and gun; see

page 44

DATATRAK, assembly; see manual

313541

M02xxx and M04xxx motor

M12xxx motor

3b

4

24A575

24A576

-----

256420

256422

256424


HOSE, suction (includes Part 5))

LW025A or LW050A displacement pump

LW150A displacement pump, cart mount

LW150A displacement pump, wall mount

STRAINER (included with Part 4) 5

----LW025A or LW050A displacement pump,

see page 46 for packages of

10

187190 LW150A displacement pump

6 24A587 FILTER, fluid

7 ----FITTING, union (included with Part 6)

8 189018 SWIVEL, fluid hose (packages with AA gun)

9 241812 HOSE, fluid (packages with gun)

10 24C853 GUN, G15 Carbide

11 AAM413 TIP (packages with AA gun)

12 AAMxxx TIP OPTION (packages with AA gun)

13

512351

121238

ADAPTER, outlet

LW025A or LW050A displacement pump,1/4 nptm x 3/8 nptf

LW150A displacement pump,

3/8 nptm x 3/4 nptf

14 256390 AIR HOSE, gun (all AA packages)

15 256410 HOPPER (includes 17, 19, 20, and 21)

Qty.

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1



Parts 2 and 49)

17 ----TUBE, inlet, hopper (included with Part

15)

18 ----CLIP, hose (all AA packages), see page

46 for packages of 10

19

20

21

-----

-----

-----

24B299

O-RING, hopper (included with Part 15)

SCREEN, hopper (included with Part

15)

ADAPTER, 3/4 in. to 1/2 in.

LW025A displacement pump with hopper (included with Part 15)

LW050A or LW075A displacement pump with suction hose

22 239069 HOSE, whip


Parts 49, 53, and 54)

Wall and stand mount

Cart mount

26 105335 SCREW (stand mount only)

37 166846 ADAPTER, for whip hose

48 238909 GROUNDING WIRE assembly

49 24E883 BRACKET, air control, wall and stand mount only (includes Parts 16 and 23)

53 289694 CART MOUNTING KIT;

see page 43


54 24A578 WALL MOUNTING KIT;

see page 43


55 24A577 STAND MOUNTING KIT;

see page 43

(G15Txx models only)

Qty.

2

1

7

1

1

1

1

1

1

1

1

1

6

4

1

1



34 312797R

Parts

G18xxx Models


particular package.

Ref. Part Description Qty.

1

2

W18EAS

W18EBS

Pump Assembly, see Manual 312794

M12LN0 x LW125A

M12LT0 x LW125A

PANEL, air controls (includes 3b)

24A583

24A581 pump only;

see page 45

pump and gun;

see page 44


313541

7

8

5

6

3b -----

4

256422

256424

187190

24A587

-----


HOSE, suction (includes Part 5) cart mount packages wall mount packages

STRAINER (included with Part 4)

FILTER, fluid

FITTING, union (included with Part 6)

189018 SWIVEL, fluid hose (packages with AA gun)

1

1

1

9

10

241812 HOSE, fluid (packages with gun) 1

GUN 1

24C855

24C857

G40

G40 with RAC tip

11 AAM413 TIP, (packages with gun)

12 AAMxxx TIP OPTION (packages with gun)

13 121237 ADAPTER, 3/8 nptm x

1/2 nptf

1

1

1

1

1

1

1

1

1




Parts 2 and 49)

18 ----CLIP, hose (all AA packages),


see



Parts 49, 53, and 54)

Wall mount

Cart mount






see page 43



see page 43


Qty.

1

2

7

1

1

1

1

1

6

4

1



312797R 35

Parts

G23xxx Models


particular package.


1

2

W23DAS

W23DBS


M12LN0 x LW100A

M23LT0 x LW100A


24A583

24A581 pump only;

see page 45

pump and gun;

see page 44


313541

7

8

5

6

3b -----

4

256421

256423

187146

24A587

-----




FILTER, fluid



1

1

1

9

10


GUN 1

XTR501

24C855

XTR 5

G40

24C857 G40 with RAC tip

11 AAM413 TIP (packages with G40 gun)

12 AAMxxx TIP OPTION (packages with G40 gun)

13 512351 ADAPTER, 1/4 nptm x 3/8 nptf


15 256410 HOPPER (includes Parts 17, 19, and

20)


Parts 2 and 49)

1

1

1

1

1

2

1

1

1

1

1

1


17

18

-----

-----


Part 15)

CLIP, hose (all AA packages), see


19 ----O-RING, hopper (included with Part

15)

20 ----SCREEN, hopper (included with Part

15)



Parts 49, 53, and 54)

Wall mount

Cart mount






see page 43



see page 43


Qty.

1

7

1

1

1

1

1

1

1

6

4

1



36 312797R

Parts

G24xxx Models


particular package.


1

2

W24FAS

W24FBS


M18LN0 x LW150A

M18LT0 x LW150A


24A583

24A581 pump only;

see page 45

pump and gun;

see page 44


313541

7

8

5

6

3b -----

4

256422

256424

187190

24A587

-----




FILTER, fluid



1

1

1

9

10


GUN 1

XTR501

24C855

XTR 5

G40


11 AAM413 TIP (Packages with G40 gun)

12 AAMxxx TIP OPTION (Packages with G40 gun)

13 121238 ADAPTER, 3/8 nptf x 3/4 nptm

1

1

1

1

1

1

1

1

1




Parts 2 and 49)



see



Parts 49, 53, and 54)

Wall mount

Cart mount






see page 43



see page 43


Qty.

1

2

7

1

1

1

1

1

6

4

1



312797R 37

Parts

G28xxx Models


particular package.


1

2

W28EAS

W28EBS


M18LN0 x LW125A

M18LT0 x LW125A


24A583

24A581 pump only;

see page 45

pump and gun;

see page 44


313541

7

8

5

6

3b -----

4

256422

256424

187190

24A587

-----




FILTER, fluid



1

1

1

9

10


GUN 1

XTR501

24C855

XTR 5

G40


11 AAM413 TIP (Packages with AA gun)

12 AAMxxx TIP OPTION (Packages with AA gun)

13 121237 ADAPTER, 3/8 nptm x 1/2 nptf

1

1

1

1

1

1

1

1

1


14 256390 AIR HOSE, gun (all AA packages


Parts 2 and 49)



see



Parts 49, 53, and 54)

Wall mount

Cart mount






see page 43



see page 43


Qty.

1

2

7

1

1

1

1

1

6

4

1



38 312797R

Parts

G30xxx Models


particular package.


1

2

3a

3b

4

5

W30AAS

W30ABS

W30CAS

W30CBS

24A586

24A585

24A583

24A581

24A575

24A576

-----

256420

24C581

256421

256423

-----


M04LN0 x LW025A

M04LT0 x LW025A

M12LN0 x LW075A

M12LT0 x LW075A


M04xxx motor, pump only, see

page 45


page 44

M12xxx motor, pump only; see

page 45


page 44

DATATRAK, assembly; see manual

313541

M04xxx motors

M12xxx motors



LW025A displacement pump

G30C37 Model

LW075A displacement pump, cart mount

LW075A displacement pump, wall mount


LW025A displacement pump, see


1

1

1

1

1

1

6

6a 24A587 FILTER, fluid, see Manual 307273

6b ----FITTING, union

8 189018 SWIVEL, fluid hose (packages with AA gun)

9

187146 LW075A displacement pump

24A587 FILTER, fluid, assembly (if included, uses parts 6a and 6b)

H52525

24B562

241812

HOSE, fluid (packages with gun)

G30W57–G30W60

G30C13, G30C57, G30C69

All other packages

1

1

10

XTR501

24C855

24C857

GUN 1

XTR 5

G40

G40 with RAC tip

11 AAM413 TIP (Packages with AA guns 1

12 AAMxxx TIP OPTION (Packages with AA guns)


3/8 nptf

1

1

1

1

1


14 256390 AIR HOSE, gun, 25 ft (7.6 m); used on most AA packages

256389 AIR HOSE, gun, 50 ft (15.2 m); Model

G30C69 only


20)


Parts 2 and 49)

17 ----TUBE, inlet, hopper (included with Part

15)

18 ----CLIP, hose (all AA packages), see

page 46 for packages of 10

19

20

-----

-----

O-RING, hopper (included with Part 15)

SCREEN, hopper (included with Part

15)

21 ----ADAPTER, 3/4 in. to 1/2 in.,

(LW025A only, included with Part 15)



Parts 49, 53, and 54)

Wall and stand mount

Cart mount

26 105335 SCREW (stand mount only)


41 256425 VALVE, drain, stainless steel (if equipped, includes Parts 44 and 45)

44 ----COUPLING, hose, drain (included with

Part 41)

45 ----HOSE, drain (included with Part 41)

48 238909 GROUNDING WIRE assembly

49 24E883 BRACKET, air control, wall and stand mount only (includes Parts 16 and 23)


see page 43



see page 43


55 24A577 STAND MOUNTING KIT;

see page 43

(G30Txx models only)

Qty.

1

1

1

2

1

7

1

1

1

1

1

1

1

1

1

1

6

4

1

1

1

1



312797R 39

Parts

G36xxx Models


particular package.


1

2

W36DAS

W36DBS


M18LN0 x LW100A

M18LT0 x LW100A


24A583

24A581 pump only;

see page 45

pump and gun;

see page 44


313541

7

8

5

6

3b ------

4

256421

256423

187146

24A587

------




FILTER, fluid



1

1

1

9

10

H42525

24A446


XTR 5 with RAC tip

1

G40 and G40 with RAC tip

GUN 1

XTR504

24C855

XTR 5 with RAC tip

G40



12 AAMxxx TIP OPTION (packages with G40 gun)


3/8 nptf

14 256390 AIR HOSE, gun, (all AA packages)


Parts 2 and 49)

1

1

1

1

2

1

1

1

1

1

1


18 ----CLIP, hose (all AA packages), see


22 239069 HOSE, whip (AA packages only)


Parts 49, 53, and 54)

Wall mount

Cart mount

37 166846 ADAPTER, for whip hose (AA packages only)

41 256425 VALVE, drain, stainless steel (includes

Parts 44 and 45)


Part 41)






see page 43



see page 43


Qty.

7

1

1

1

1

1

6

4

1

1

1

1



40 312797R

Parts

G45xxx Models


particular package.


1

2

W45BAS

W45BBS


M12LN0 x LW050A

M12LT0 x LW050A


24A583

24A581 pump only, 100 psi;

see page 45

pump and gun, 100 psi; see

page 44

24A582 pump and gun, 90 psi; see

page 44


313541

1

1

1

7

8

5

6

3b ------

4

256421

256423

187146

24A587

-----




FILTER, fluid



9

10

H42525

24A446


XTR 5 with RAC tip

1


GUN 1

XTR504

24C855

XTR 5 with RAC tip

G40



12

13

14

AAMxxx

512351

256390

TIP OPTION (packages with G40 gun)

ADAPTER, 1/4 nptm x 3/8 nptf

AIR HOSE, gun, (all AA packages)


20)


Parts 2 and 49)

1

1

1

1

1

2

1

1

1

1

1

1


17

18

-----

-----


Part 15)




15)

20 -----SCREEN, hopper (included with Part

15)



Parts 49, 53, and 54)

Wall mount

Cart mount


38 -----

39 -----

SWITCH, reed (included with Part 3a)

SCREW, switch (included with Part 3a)

40 -----

44 -----

CLAMP, hose (included with Part 3a)


Parts 44 and 45)

COUPLING, hose, drain (included with

Part 41)






see page 43



see page 43


Qty.

1

7

1

1

1

1

1

1

6

4

1

2

1

1

1

1

1

1



312797R 41

Parts

G48xxx Models


particular package.


7

8

1

2

W48CAS

W48CBS


M18LN0 x LW075A

M18LT0 x LW075A

PANEL, air controls (includes 3b, 16,

30, and 31) pump only, 100 psi;

see page 45

24A583

24A584 pump and gun, 85 psi; see

page 44


313541

5

6

3b -----

4 256423

INSERT, panel (Included with Part 2)


187146

24A587


FILTER, fluid

----FITTING, union (included with Part 6)


1

1

1

9

10

H52525

24A446


XTR 5 with RAC tip

1


GUN 1

XTR504

24C855

XTR 5 with RAC tip

G40



12

13

14

AAMxxx

512351

256390

TIP OPTION (packages with G40 gun)

ADAPTER, 1/4 nptm x 3/8 nptf

AIR HOSE, gun (all AA packages)


20)


Parts 2 and 49)

1

1

1

1

1

2

1

1

1

1

1

1


17

18

-----

-----


Part 15)




15)

20 ----SCREEN, hopper (included with Part

15)



Parts 49, 53, and 54)

Wall mount

Cart mount



Parts 44 and 45)


Part 41)






see page 43



see page 43


Qty.

1

7

1

1

1

1

1

1

1

6

4

1

1

1

1



42 312797R

Kits

Kits

Wall Mount Kit 24A578

101

102

Ref. Description

101 SCREW, cap, M8 x 1.25

102 PLATE, wall mount

Qty.

4

1

NOTE:

Air Control Mounting Kit 24E883 (see page 46)

also is required for wall mounting a package that has a control panel.

ti12633a

Cart Mount Kit 289694

204

208

202

Stand Mount Kit 24A577

302

304

207

209

301 ti12634a


201 -----

202 -----

CART, frame

HANDLE, cart

203 15C871 CAP, leg

204 ----SLEEVE, cart handle

205 119451 WHEEL, semi-pneumatic

206 119452 CAP, hub

207 115480 KNOB, t-handle

208 116630 SCREW, carriage

209 111799 SCREW, cap, M8 x 1.25

312797R

201

205

206

203

Qty.

2

2

2

2

4

2

2

1

1

303 ti12635a


301 ----FRAME

302 111799 SCREW, cap, M8 x 1.25

303 105521 PLUG, tubing

304 108063 GRIP, handle

Qty.

NOTE:

Air Control Mounting Kit 24E883 (see page 46)

also is required for stand mounting a package that has a control panel.

2

1

1

4

43

Kits

Pump and Gun Control Panel Kits

304 311 307 308

308

307

306

305

304

303

302

M12xxx and M18xxx air motors

Kits 24A581, 24A582, and 24A584

310

313

310

316

319

303

314

317

309

315

312

2

1

2

1

1

1

1

1

2

1

1

1

2

1

1

301 ti13565a ti13467a

321


Kit 24A585


301 114362 VALVE, ball

302 ----SWIVEL, tee

303 ----TUBE, 3/8 OD, cut to fit, order Tubing Kit 24D496

304 121141 ELBOW, swivel, 3/8T x 1/4 npt(m)

305 15T499 REGULATOR, air, pump, 1/4 npt

306 15T866 ELBOW, swivel, 5/32T x 1/8 npt

307 ----TUBE, black, cut to fit, order Tubing Kit 24D496

308 15T498 SWIVEL, 90°, 5/32T x 1/8 npt(f)

310 15T500 GAUGE, pressure

311 113498 VALVE, safety

312 162453 ADAPTER, 1/4 nps(m) x 1/4 npt

313 115244 NUT, regulator

314 114381 SCREW, cap, button head

315 15T499 REGULATOR, air, gun, 1/4 npt

316 115244 NUT, regulator

317 ----PANEL

318

319

320 105332 NUT, lock (not shown)

321 121141 ELBOW, 3/8T x 1/4 npt(m)

322

----LABEL, panel (not shown)

----INSERT

323

----COVER, lens, 12 sticker sheet (not shown), order Kit 24A540 for 5 sheets

----ELBOW, 1/4 npt(f) x 1/8 npt(m)

Qty.

1

1

1.3 ft.

3

1

2

4 in.

1

2

1

1

1

1

1

1

2

1

1

2

2

2

1

312797R

Kits

Pump Only Control Panel Kits

307 308

304 310

313

308

306

305

307

310

313

304

306

305 304

311

303

326

301

317

314 ti13567a

M07xxx, M12xxx, and M18xxx air motors

Kit 24A583

311

325

324

303

326

301

317

314 ti13566a


Kit 24A586

1

1

2

1

1

1

1

1

312797R 45

1

1

1

1

1

2

1

1

1

1

1

Kits

DataTrak

NOTE: See DataTrak manual, 313541, for all DataTrak related part numbers and kit information, including the reed switch and solenoid.

Hopper Kit 256410

Includes hopper (15), inlet tube (17), o-ring (19), screen (20), and fitting (21, 25cc pumps only).

Air Control Mounting Kit

24E883, Wall and Stand

Kit 24E883 includes bracket (49), two hex nuts (16), and two screws (23). Use either set of mounting holes.

16

49

23 ti13463b

5-Gallon Suction Hose Kits

Includes suction hose (4) and strainer (5).

Kit Packages

256420 10:1, 15:1, 30:1 -- M02xxx and

M04xxx air motors only

256421 23:1, 30:1 (M12xxx X L075xx),

36:1, 45:1, 48:1

256422 15:1 (M12xxx X L150xx), 18:1,

24:1, 28:1

256423 23:1, 30:1 (M12xxx X L075xx),

36:1, 45:1, 48:1

256424 15:1 (M12xxx X L150xx), 18:1,

24:1, 28:1

Wall/Cart

Both

Cart

Cart

Wall

Wall

256426 - Package of 10 strainers (5) for Kit 256420.

55-Gallon Suction Hose Kits

Includes suction hose, bung adapter, and strainer.

24A954 3/4 in. hose

24B598 - 1 in. hose

PTFE Suction Hose Kits

For pumping acid materials that are compatible with

PTFE. Includes suction hose, swivel, and strainer.

Kit Description Wall/Cart

24B337 3/4 in. hose, PTFE lined, with swivel Cart elbow

24B338 1 in. hose, PTFE lined, with swivel elbow

24B424 3/4 in. hose, PTFE lined, with straight swivel

Cart

Wall

24B425 1 in. hose, PTFE lined, with straight swivel

Wall

24J315 3/8 in. hose, 1/2 in. connection,

PTFE lined, with straight swivel

Wall or

Cart*

* Cart mount requires separate fitting, Part Number

114874.

Drain Valve Kit 256425

Includes drain valve (41), coupling (44), and hose

(45).

Reinforced PTFE V-Packing Kits

NOTE: See manual 312792 for information related to optional kits with reinforced PTFE seals for use with materials that cause chemical compatibility concerns with UHMWPE, such as acid catalyst materials.

46 312797R

Kits

Guns and Hoses

To find the correct parts for your model, locate the gun you have. The correct hoses and related parts are listed in the table below each gun.

XTR 5

10

8

22

37

9

10

14

G15 and G40

18

9 ti12636a


9 HOSE, fluid

241812 G10xxx-G30xxx; exceptions listed next in this table; 25 ft (7.6 m), 3300 psi (22.7 MPa, 227 bar) maximum working pressure

H52525 G30W57-G30W60, G48xxx; 25 ft

(7.6 m), 5600 psi (38.6 MPa, 386 bar) maximum working pressure

24B562 G30C13 and G30C57; 50 ft (15.2 m),

3300 psi (22.7 MPa, 227 bar) maximum working pressure

H42525 G36xxx-G45xxx; 25 ft (7.6 m); 4500 psi (30.1 MPa, 310 bar) maximum working pressure

10 XTR501 GUN, XTR

XTR504 GUN, XTR with RAC tip

Qty.

1

1

1 ti11993a

11

12

14

18

Ref. Part

8

9

10

22

37

Description

189018 SWIVEL, fluid hose

HOSE, fluid

241812 G10xxx-G30xxx, 25 ft (7.6 m), 3300 psi (22.7 MPa, 227 bar) maximum working pressure

24A446 G36xxx-G48xxx, 23 ft (7 m); 4100 psi (28.3 MPa, 283 bar) maximum working pressure

24C855 GUN, G40

24C857 GUN, G40 with RAC tip

24C853 GUN, G15

AAM413 TIP

AAMxxx TIP, option, see gun manual

256390 HOSE, air

----CLIP, hose; order Kit 24A588 for package of 10

239069 HOSE, whip (G36xxx-G48xxx packages only)

166846 ADAPTER, for whip hose

Qty.

1

1

1

1

1

1

7

1

1

1

1

312797R

50-Foot Air/Fluid Hose Kit

24A955

Optional 50-foot coupled fluid/air hose with 20 clips. Use with G10xxx-G30xxx models only (3300 psig maximum fluid working pressure).

50-Foot Fluid Hose 24A413

Optional 50-foot hose, 5600 psi (38.6 MPa, 386 bar) maximum working pressure.

47

Wall Bracket Mounting Dimensions

Wall Bracket Mounting Dimensions

11 in.

(279 mm)

4 in.

(102 mm)

Four 0.40 in. (10 mm) mounting holes ti12833a

Technical Data

Maximum fluid working pressure. . . . . . . . . . . . . . . .See

Models table on page 5.

Maximum pump air inlet pressure . . . . . . . . . . . . . . .100 psi (0.7 MPa, 7.0 bar)

Maximum gun air inlet pressure . . . . . . . . . . . . . . . .100 psi (0.7 MPa, 7.0 bar)

Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Models table on page 5.

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

Maximum fluid temperature. . . . . . . . . . . . . . . . . . . .160°F (71°C)

Sound data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Technical Data in air motor manual 312796.

Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Displacement pump: Stainless steel, tungsten carbide with 6% nickel, UHMWPE, PTFE

Spray gun: See Manual 3A0149 (AA guns) or

Manual 312145 (XTR guns).

Fluid hoses: nylon

Suction assembly: stainless steel, nylon

Fluid filter: See manual 307273.

Drain valve: stainless steel, nylon

48 312797R

Package Weights

Package Weights

Ratio, Motor,

Displacement Pump

Mounted

Pump*

Cart Mount

10:1, M04xxx, LW075A 68 (31)

15:1, M02xxx, LW025A 53 (24)

15:1, M04xxx, LW050A 66 (30)

15:1, M12xxx, LW150A 100 (45)

18:1, M12xxx, LW125A 100 (45)

23:1, M12xxx, LW100A 98 (45)

24:1, M18xxx, LW150A 102 (46)

28:1, M18xxx, LW125A 102 (46)

30:1, M04xxx, LW025A 60 (28)

30:1, M12xxx, LW075A 94 (43)

36:1, M18xxx, LW100A 100 (45)

45:1, M12xxx, LW050A 92 (42)

48:1, M18xxx, LW075A 97 (44)

Wall Mount

10:1, M04xxx, LW075A 42 (19)

15:1, M02xxx, LW025A 27 (12)

15:1, M04xxx, LW050A 40 (18)

15:1, M12xxx, LW150A 73 (33)

18:1, M12xxx, LW125A 72 (33)

23:1, M12xxx, LW100A 70 (32)

24:1, M18xxx, LW150A 76 (35)

28:1, M18xxx, LW125A 75 (34)

30:1, M04xxx, LW025A 34 (15)

30:1, M12xxx, LW075A 67 (30)

36:1, M18xxx, LW100A 73 (33)

45:1, M12xxx, LW050A 65 (29)

48:1, M18xxx, LW075A 70 (32)

Stand Mount

15:1, M02xxx, LW025A 29 (13)

30:1, M04xxx, LW025A 36 (16)

15:1, M04xxx, LW050A 42 (19)

Mounted pump*

+ siphon kit

30 (14)

37 (17)

43 (20)

69 (32)

54 (25)

67 (31)

103 (47)

104 (47)

101 (46)

-----

-----

61 (28)

98 (45)

-----

96 (43)

-----

43 (20)

28 (13)

41 (19)

-----

-----

-----

-----

-----

35 (16)

-----

-----

-----

-----

Weight in lb (kg)

Mounted pump

+ siphon kit

+ fluid filter

Mounted pump*

+ siphon kit or hopper

+ gun and hoses

Mounted pump*

+ siphon kit or hopper

+ gun and hoses

+ fluid filter

48 (22)

33 (15)

46 (21)

-----

-----

-----

-----

-----

40 (18)

-----

-----

-----

-----

76 (35)

62 (29)

75 (34)

-----

-----

-----

-----

-----

68 (31)

-----

-----

101 (46)

106 (48)

36 (16)

43 (20)

49 (22)

-----

-----

-----

81 (37)

81 (37)

78 (35)

84 (38)

83 (38)

-----

75 (34)

81 (37)

73 (33)

78 (35)

----

----

----

109 (49)

109 (49)

105 (48)

111 (50)

111 (50)

-----

104 (47)

108 (49)

101 (46)

105 (48)

-----

-----

-----

53 (24)

38 (17)

51 (23)

86 (39)

86 (39)

83 (38)

89 (40)

87 (39)

44 (20)

80 (36)

87 (39)

80 (36)

84 (38)

81 (37)

67 (31)

79 (36)

113 (51)

113 (51)

111 (50)

116 (53)

116 (53)

73 (34)

108 (49)

114 (52)

106 (48)

110 (50)

41 (19)

48 (22)

54 (25)

* Includes air controls.

----- This component configuration is not offered for these models.

312797R 49

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by

Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT

LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE .

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy

(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT

MANUFACTURED BY GRACO . These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com

.

For patent information, see www.graco.com/patents.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.

Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

Original instructions. This manual contains English. MM 312797

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2008, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision R - October 2012

Graco 312797R - Merkur Non-Heated Spray Packages Instructions

Instructions/Parts

Merkur

®

Non-Heated

Spray Packages

312797R

For high-performance finishing and coating applications in hazardous or non-hazardous locations. For professional use only.

Cart Mount Wall Mount

Contents

Related Manuals

Warnings

WARNING

WARNING

Models

G

24

28

30

36

10

15

18

23

45

48

C

T

W

Merkur 10:1 Packages

(G10Cxx and G10Wxx)

Merkur 15:1 Packages

(G15Wxx, G15Cxx, and G15Txx)

Merkur 18:1 Packages

(G18Wxx and G18Cxx)

Merkur 23:1 Packages

(G23Wxx and G23Cxx)

Merkur 24:1 Packages

(G24Wxx and G24Cxx)

Merkur 28:1 Packages

(G28Wxx and G28Cxx)

Merkur 30:1 Packages

(G30Wxx, G30Cxx, and G30Txx)

Merkur 36:1 Packages

(G36Wxx and G36Cxx)

Merkur 45:1 Packages

(G45Wxx and G45Cxx)

Table A:

Table B:

Merkur 48:1 Packages

(G48Wxx and G48Cxx)

Table A:

Table B:

Installation

General Information

Prepare the Operator

Wall Mount Packages

Cart Mount Packages

Prepare the Site

Components

Air Line Accessories

Grounding

Setup

Operation

Pressure Relief Procedure

Flush the Pump Before First Use

Trigger Lock

Wet Cup

Prime the Pump

Install the Spray Tip

Adjust the Atomization

Adjust the Spray Pattern

Packages with Airless Guns

Packages with AA Guns

Shutdown

Maintenance

Preventive Maintenance

Schedule

Tighten Threaded Connections

Flush the Pump