Graco 312799L User Manual

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Instructions/Parts

ti14530a ti15428b

Cart Mount

Wall Mount

™

Merkur

Bellows AA

and Airless

312799L

Spray Packages

Spray packages with a bellows seal for use with isocyanates, UV coatings and other moisture-sensitive materials. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See pages 9-14 for model information, including maximum air inlet pressures and maximum fluid working pressures.

II 2 G c IIB T3 (200°C)

Contents

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Important Two-Component Material Information . 7

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 7

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 7

Keep Components A and B Separate . . . . . . . . . 7

Moisture Sensitivity of Isocyanates . . . . . . . . . . . 7

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 7

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5:1 Packages

(G05Bxx) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

12:1 Packages

(G12Bxx) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

15:1 Packages

(G15Bxx) . . . . . . . . . . . . . . . . . . . . . . . . . . 10

23:1 Packages

(G23Bxx) . . . . . . . . . . . . . . . . . . . . . . . . . . 11

24:1 Packages

(G24Bxx) . . . . . . . . . . . . . . . . . . . . . . . . . . 12

25:1 Packages

(G25Bxx) . . . . . . . . . . . . . . . . . . . . . . . . . . 13

35:1 Packages

(G35Bxx) . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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

General Information . . . . . . . . . . . . . . . . . . . . . 15

Prepare the Operator . . . . . . . . . . . . . . . . . . . . 15

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

Mount the Pump . . . . . . . . . . . . . . . . . . . . . . . . 17

Supplied Components . . . . . . . . . . . . . . . . . . . . 17

Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 18

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Pressure Relief Procedure . . . . . . . . . . . . . . . . 19

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

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

Prime and Adjust the Pump . . . . . . . . . . . . . . . 20

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

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

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

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

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

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

DataTrak Controls and Indicators . . . . . . . . . . . . 23

DataTrak Operation . . . . . . . . . . . . . . . . . . . . . . . . 24

Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Replace DataTrak Battery or Fuse . . . . . . . . . . 27

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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

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

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

G05Bxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 32

G12Bxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 32

G15Bxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 33

G23Bxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 34

G24Bxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 35

G25Bxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 36

G35Bxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 37

Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Cart Mounting Kit . . . . . . . . . . . . . . . . . . . . . . . . 38

Cart Floor Mounting Kit . . . . . . . . . . . . . . . . . . . 38

Wall Mounting Kit . . . . . . . . . . . . . . . . . . . . . . . . 39

Mounting Hardware Kits . . . . . . . . . . . . . . . . . . 39

Air Control Mounting Kit-Wall . . . . . . . . . . . . . . 39

Air Control Mounting Kit-Cart . . . . . . . . . . . . . . 39

Pump and Gun Control Panel Kits . . . . . . . . . . . 40

Pump Only Control Panel Kits . . . . . . . . . . . . . . 41

DataTrak Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Suction Hose Kits . . . . . . . . . . . . . . . . . . . . . . . 42

Drain Valve Kit 256425 . . . . . . . . . . . . . . . . . . . 43

Overflow Chamber Kit 24E298 . . . . . . . . . . . . . 43

Reinforced PTFE V-Packing Kits and

PTFE Bellows Kits . . . . . . . . . . . . . . . . . . . . 43

Guns and Hoses . . . . . . . . . . . . . . . . . . . . . . . . 44

Mounting Plate Dimensions . . . . . . . . . . . . . . . . . 45

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 48

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 48

2 312799L

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Manual Description

312793 Merkur Bellows Displacement Pump 312795 Merkur Bellows Pump Assembly 312796

312798 Merkur Electrostatic Packages 3A0149 G15/G40 Spray Gun 312145

307273 Fluid Outlet Filter

™

NXT

Air Motor

™

XTR

5 and XTR™7 Airless Spray Gun

Related Manuals

312799L 3

Warnings

WARNINGWARNINGWARNING

WARNING

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.

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.

Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable vapors. To help prevent fire and explosion:

• Clean plastic parts only in a well ventilated area.

• Do not clean with a dry cloth.

• Do not operate electrostatic guns in equipment work area.

SPECIAL CONDITIONS FOR SAFE USE

Equipment must comply with the following conditions to avoid a hazardous condition which can cause fire or explosion.

• All label and marking material must be cleaned with a damp cloth (or equivalent).

• The electronic monitoring system is required to be grounded. See Grounding instructions.

4 312799L

Warnings

WARNINGWARNINGWARNING

WARNING

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 ser-

vicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses 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 compo-

nent. 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.

SUCTION HAZARD

Powerful suction could cause serious injury.

• Never place hands near the pump fluid inlet when pump is operating or pressurized.

312799L 5

Warnings

WARNINGWARNINGWARNING

WARNING

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

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.

6 312799L

Important Two-Component Material Information

Isocyanate Conditions

Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.

Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to isocyanates.

Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.

To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.

Material Self-ignition

Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.

Moisture Sensitivity of Isocyanates

Isocyanates (ISO) are catalysts used in two component coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.

NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

To prevent exposing ISO to moisture:

• Always use a sealed container with a desiccant

dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

• Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Never use solvent on one side if it has been contaminated from the other side.

• Always lubricate threaded parts with ISO pump oil or grease when reassembling.

Changing Materials

Keep Components A and B Separate

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate) and component B (resin) parts.

312799L 7

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

• Most materials use ISO on the A side, but some use ISO on the B side.

Models

ti15432a

DataTrak™ includes agency approvals listed below.

0359

II 1 G

Ex ia IIA T3 Ga

ITS13ATEX27862X

9902471

Class I, Div. 1,

Group D T3A

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 G15B54 represents a Merkur package (G), with a 15:1 ratio pump (15), bellows style (B), and the components shown for (54) in the table on page 10.

G15 B 54

First Digit

(Merkur

Package)

Second and Third Digits

(Ratio)

05 12 15 23 24 25 35

5:1 12:1 15:1 23:1 24:1 25:1 35:1

Fourth Digit

(Pump Style)

Fifth and Sixth Digit

(Components Included)

Bellows See Tables, pages 9 to 14

8 312799L

5:1 Packages (G05Bxx)

Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 500 psi (3.4 MPa, 34 bar)

Models

Model

Wall

Mount G05B01 G05B03 B05FA0 None G05B02 G05B04 B05FB0 None G05B05 G05B07 B05FA0 None G05B06 G05B08 B05FB0 None G05B09 G05B11 B05FA1 None G05B10 G05B12 B05FB1 None G05B13 G05B15 B05FA1 None G05B14 G05B16 B05FB1 None

Cart

Mount

Pump

Assembly Gun

Air Controls

Pump

Fluid

Pump

Only

and

Gun

Filter

Data Trak

✔✔

✔✔✔

✔

✔ ✔

✔✔

✔✔✔

✔

✔ ✔

12:1 Packages (G12Bxx)

Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 1200 psi (8.3 MPa, 83 bar)

Model

Wall

Mount G12B01 G12B03 B12DA0 None G12B02 G12B04 B12DB0 None G12B05 G12B07 B12DA0 None G12B06 G12B08 B12DB0 None G12B09 G12B11 B12DA1 None G12B10 G12B12 B12DB1 None G12B13 G12B15 B12DA1 None G12B14 G12B16 B12DB1 None

Cart

Mount

Pump

Assembly Gun

Air Controls

Pump

Fluid Filter

Data Trak

Pump

Only

and

Gun

✔✔

✔✔✔

✔

✔ ✔

✔✔

✔✔✔

✔

✔ ✔

Maximum

Fluid Flow

Rate

gpm (lpm)

2.4

(9.0)

Maximum

Fluid Flow

Rate

gpm (lpm)

1.6

(6.0)

Weight - lb/kg

Wall

Mount

78 (35.4) 107 (48.6) 79 (35.8) 108 (49.1) 73 (33.1) 102 (46.4) 74 (33.6) 103 (46.8) 78 (35.4) 107 (48.6) 79 (35.8) 108 (49.1) 73 (33.1) 102 (46.4 74 (33.6) 103 (46.8)

Weight - lb/kg

Wall

Mount

84 (38.1) 113 (51.4) 85 (38.6) 114 (51.8) 79 (35.8) 108 (49.1) 80 (36.3) 109 (49.5) 84 (38.1) 113 (51.4) 85 (38.6) 114 (51.8) 79 (35.8) 108 (49.1) 80 (36.3) 109 (49.5)

Cart

Mount

Cart

Mount

312799L 9

Models

15:1 Packages (G15Bxx)

Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 1500 psi (10.3 MPa, 103 bar)

Model

Wall

Mount G15B01 G15B05 B15BA0 G15B02 G15B06 B15BB0 G15B03 G15B07 B15BA0 G15B04 G15B08 B15BB0 G15B09 G15B13 B15BA0 G15B10 G15B14 B15BB0 G15B11 G15B15 B15BA0 G15B12 G15B16 B15BB0 G15B17 G15B21 B15BA1 G15B18 G15B22 B15BB1 G15B19 G15B23 B15BA1 G15B20 G15B24 B15BB1 G15B25 G15B29 B15BA1 G15B26 G15B30 B15BB1 G15B27 G15B31 B15BA1 G15B28 G15B32 B15BB1 G15B51 G15B55 B15FA0 G15B52 G15B56 B15FB0 G15B53 G15B57 B15FA0 G15B54 G15B58 B15FB0 G15B59 G15B63 B15FA0 G15B60 G15B64 B15FB0 G15B61 G15B65 B15FA0 G15B62 G15B66 B15FB0 G15B67 G15B71 B15FA1 G15B68 G15B72 B15FB1 G15B69 G15B73 B15FA1 G15B70 G15B74 B15FB1 G15B75 G15B79 B15FA1 G15B76 G15B80 B15FB1 G15B77 G15B81 B15FA1 G15B78 G15B82 B15FB1

Cart

Mount

Pump

Assembly

Air Controls

Pump

Only

and

Gun

✔

Hoses Accessories

Gun

Siphon

Gun

None

None G15 Carbide G15 Carbide

None 57 (25.9) 86 (39.1)

None G15 Carbide G15 Carbide

None

None G15 Carbide G15 Carbide

None 57 (25.9) 86 (39.1)

None G15 Carbide G15 Carbide

None

None G15 Carbide G15 Carbide

None 90 (40.8) 119 (54.1)

None G15 Carbide G15 Carbide

None

None G15 Carbide G15 Carbide

None 90 (40.8) 119 (54.1)

None G15 Carbide G15 Carbide

Fluid

Air

✔ ✔ ✔ ✔* ✔ ✔ ✔ ✔* ✔

✔ ✔ ✔

✔ ✔ ✔ ✔

✔ ✔ ✔ ✔* ✔ ✔ ✔ ✔* ✔

✔ ✔ ✔

✔ ✔ ✔ ✔

✔ ✔ ✔ ✔* ✔ ✔ ✔ ✔* ✔

✔ ✔ ✔

✔ ✔ ✔ ✔

✔ ✔ ✔ ✔* ✔ ✔ ✔ ✔* ✔

✔ ✔ ✔

✔ ✔ ✔ ✔

Kit

Fluid Filter

✔

✔✔

✔

✔✔

✔

✔✔

✔

✔✔

Data

Trak

✔

Maximum

Fluid Flow

Rate

gpm (lpm)

0.8

(3.0)

2.4

(9.0)

Weight - lb/kg

Wall

Mount

62 (28.1) 91 (41.4) 63 (28.6) 92 (41.8)

72 (32.7 101 (44.9)

73 (33.1) 102 (46.4)

58 (26.3) 87 (39.5) 67 (30.4) 96 (43.6) 68 (30.8) 97 (44.1) 62 (28.1) 91 (41.4) 63 (28.6) 92 (41.8) 72 (32.7) 101 (44.9) 73 (33.1) 102 (46.4)

58 (26.3) 87 (39.5) 67 (30.4) 96 (43.6) 68 (30.8) 97 (44.1) 95 (43.1) 124 (56.4)

96 (43.5) 125 (56.8) 105 (47.6) 134 (60.9) 106 (48.1) 135 (61.4)

91 (41.3) 120 (54.5) 100 (45.4) 129 (58.6) 101 (45.8) 130 (59.1)

95 (43.1) 124 (56.4)

96 (43.5) 125 (56.8) 105 (47.6) 134 (60.9) 106 (48.1) 135 (61.4)

91 (41.3) 120 (54.5) 100 (45.4) 129 (58.6) 101 (45.8) 130 (59.1)

Cart

Mount

* Fluid filter includes fluid drain valve.

10 312799L

23:1 Packages (G23Bxx)

Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 2300 psi (15.9 MPa, 159 bar)

Models

Model

Wall

Mount G23B01 G23B05 B23DA0 G23B02 G23B06 B23DB0 G23B03 G23B07 B23DA0 G23B04 G23B08 B23DB0 G23B09 G23B13 B23DA0 G23B10 G23B14 B23DB0 G23B11 G23B15 B23DA0 G23B12 G23B16 B23DB0 G23B17 G23B21 B23DA1 G23B18 G23B22 B23DB1 G23B19 G23B23 B23DA1 G23B20 G23B24 B23DB1 G23B25 G23B29 B23DA1 G23B26 G23B30 B23DB1 G23B27 G23B31 B23DA1 G23B28 G23B32 B23DB1

Cart

Mount

G23B35 B23DA0 G23B36 B23DB0

Pump

Assembly

Air Controls

Pump

Only

and

Gun

✔

Hoses Accessories

Gun

Siphon

Gun

Fluid

Air

None None

G40

G40 None 86 (39.0) 115 (52.3) None

G40

G40 None None

G40

G40 None 86 (39.0) 115 (52.3) None

G40

XTR

✔ ✔ ✔ ✔* ✔ ✔ ✔ ✔* ✔

✔ ✔ ✔

✔ ✔ ✔ ✔

✔ ✔ ✔ ✔* ✔ ✔ ✔ ✔* ✔

✔ ✔ ✔

✔ ✔ ✔ ✔ ✔✔✔* ✔✔✔* ✔

Kit

Fluid Filter

✔

✔✔

✔

✔✔

Data

Trak

✔

Maximum

Fluid Flow

Rate

gpm (lpm)

1.6

(6.0)

Weight - lb/kg

Wall

Mount

91 (41.3) 120 (54.5)

92 (41.7) 121 (55.0) 101 (45.8) 130 (59.1) 102 (46.3) 131 (59.5)

87 (39.5) 116 (52.7)

96 (43.5) 125 (56.8)

97 (44.0) 126 (57.3)

91 (41.3) 120 (54.5)

92 (41.7) 121 (55.0) 101 (45.8) 130 (59.1) 102 (46.3) 131 (59.5)

87 (39.5) 116 (52.7)

96 (43.5) 125 (56.8)

97 (44.0) 126 (57.3)

Cart

Mount

131 (59.5) 132 (60.0)

* Fluid filter includes fluid drain valve.

312799L 11

Models

24:1 Packages (G24Bxx)

Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 2400 psi (16.5 MPa, 165 bar)

Model

Wall

Mount G24B01 G24B05 B24FA0 G24B02 G24B06 B24FB0 G24B03 G24B07 B24FA0 G24B04 G24B08 B24FB0 G24B09 G24B13 B24FA0 G24B10 G24B14 B24FB0 G24B11 G24B15 B24FA0 G24B12 G24B16 B24FB0 G24B17 G24B21 B24FA1 G24B18 G24B22 B24FB1 G24B19 G24B23 B24FA1 G24B20 G24B24 B24FB1 G24B25 G24B29 B24FA1 G24B26 G24B30 B24FB1 G24B27 G24B31 B24FA1 G24B28 G24B32 B24FB1

Cart

Mount

G24B35 B24FA0 G24B36 B24FB0

Pump

Assembly

Air Controls

Pump

Only

and Gun

✔

Hoses Accessories

Gun

Siphon

Gun

Fluid

Air

None None

G40

G40 None 93 (42.2) 112 (50.9) None

G40

G40 None None

G40

G40 None 93 (42.2) 112 (50.9) None

G40

XTR

✔ ✔ ✔ ✔* ✔ ✔ ✔ ✔* ✔

✔ ✔ ✔

✔ ✔ ✔ ✔

✔ ✔ ✔ ✔* ✔ ✔ ✔ ✔* ✔

✔ ✔ ✔

✔ ✔ ✔ ✔ ✔✔✔* ✔✔✔* ✔

Kit

Fluid Filter

✔

✔✔

✔

✔✔

Data Trak

✔

Maximum

Fluid Flow

Rate

gpm (lpm)

2.4

(9.0)

Weight - lb/kg

Wall

Mount

98 (44.5) 127 (57.7)

99 (44.9) 128 (58.2) 108 (49.0) 137 (62.3) 109 (49.4) 138 (62.7)

94 (42.6) 113 (51.4) 103 (46.7) 132 (60.0) 104 (47.2) 133 (60.5)

98 (44.5) 127 (57.7)

99 (44.9) 128 (58.2) 108 (49.0) 137 (62.3) 109 (49.4) 138 (62.7)

94 (42.6) 113 (51.4) 103 (46.7) 132 (60.0) 104 (47.2) 133 (60.5)

Cart

Mount

132 (60.0) 133 (60.5)

* Fluid filter includes fluid drain valve.

12 312799L

25:1 Packages (G25Bxx)

Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 2500 psi (17.2 MPa, 172 bar)

Models

Model

Wall

Mount G25B01 G25B05 B25BA0 G25B02 G25B06 B25BB0 G25B03 G25B07 B25BA0 G25B04 G25B08 B25BB0 G25B09 G25B13 B25BA0 G25B10 G25B14 B25BB0 G25B11 G25B15 B25BA0 G25B12 G25B16 B25BB0 G25B17 G25B21 B25BA1 G25B18 G25B22 B25BB1 G25B19 G25B23 B25BA1 G25B20 G25B24 B25BB1 G25B25 G25B29 B25BA1 G25B26 G25B30 B25BB1 G25B27 G25B31 B25BA1 G25B28 G25B32 B25BB1

Cart

Mount

G25B33 B25BA0 G25B34 B25BB0

Pump

Assembly

Air Controls

Pump

Only

and

Gun

✔

Hoses Accessories

Gun

Siphon

Gun

Fluid

Air

None None

G40

G40 None 63 (28.6) 92 (41.8) None

G40

G40 None None

G40

G40 None 63 (28.6) 92 (41.8) None

G40

XTR

✔ ✔ ✔ ✔* ✔ ✔ ✔ ✔* ✔

✔ ✔ ✔

✔ ✔ ✔ ✔

✔ ✔ ✔ ✔* ✔ ✔ ✔ ✔* ✔

✔ ✔ ✔

✔ ✔ ✔ ✔ ✔✔✔* ✔✔✔* ✔

Kit

Fluid Filter

✔

✔✔

✔

✔✔

Data Trak

✔

Maximum

Fluid Flow

Rate

gpm (lpm)

0.8

(3.0)

Weight - lb/kg

Wall

Mount

68 (30.8) 97 (44.1) 69 (31.3) 98 (44.5) 78 (35.4) 107 (48.6) 79 (35.8) 108 (49.1)

64 (29.0) 93 (42.3) 73 (33.1) 102 (46.4) 74 (33.6) 103 (46.8) 68 (30.8) 97 (44.1) 69 (31.3) 98 (44.5) 78 (35.4) 107 (48.6) 79 (35.8) 108 (49.1)

64 (29.0) 93 (42.3) 73 (33.1) 102 (46.4) 74 (33.6) 103 (46.8)

Cart

Mount

107 (48.6) 108 (49.1)

* Fluid filter includes fluid drain valve.

312799L 13

Models

35:1 Packages (G35Bxx)

Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 3500 psi (24.1 MPa, 241 bar)

Model

Wall

Mount G35B01 G35B05 B35DA0 G35B02 G35B06 B35DB0 G35B03 G35B07 B35DA0 G35B04 G35B08 B35DB0 G35B09 G35B13 B35DA0 G35B10 G35B14 B35DB0 G35B11 G35B15 B35DA0 G35B12 G35B16 B35DB0 G35B17 G35B21 B35DA1 G35B18 G35B22 B35DB1 G35B19 G35B23 B35DA1 G35B20 G35B24 B35DB1 G35B25 G35B29 B35DA1 G35B26 G35B30 B35DB1 G35B27 G35B31 B35DA1 G35B28 G35B32 B35DB1

Cart

Mount

G35B35 B35DA0 G35B36 B35DB0

Pump

Assembly

Air Controls

Pump

Only

and

Gun

✔

Hoses Accessories

Gun

Fluid

Gun

Siphon

Gun

Fluid

Whip

None None

G40

✔ ✔ ✔ ✔ ✔*

G40

✔ ✔ ✔ ✔ ✔* ✔

None 89 (40.3) 118 (53.6) None

G40

✔ ✔ ✔ ✔

G40

✔ ✔ ✔ ✔ ✔

None None

G40

✔ ✔ ✔ ✔ ✔*

G40

✔ ✔ ✔ ✔ ✔* ✔

None 89 (40.3) 118 (53.6) None

G40

✔ ✔ ✔ ✔

G40

✔ ✔ ✔ ✔ ✔

XTR XTR

✔✔ ✔ ✔* ✔✔ ✔ ✔* ✔

Air

Kit

Fluid Filter

✔

✔✔

✔

✔✔

Data Trak

✔

Maximum

Fluid Flow

Rate

gpm (lpm)

1.6

(6.0)

Weight - lb/kg

Wall

Mount

94 (42.6) 123 (55.4)

95 (43.1) 124 (55.9) 104 (47.2) 133 (60.5) 105 (47.6) 134 (60.9)

90 (40.8) 119 (54.1)

99 (44.9) 128 (58.2) 100 (45.4) 129 (58.6)

94 (42.6) 123 (55.4)

95 (43.1) 124 (55.9) 104 (47.2) 133 (60.5) 105 (47.6) 134 (60.9)

90 (40.8) 119 (54.1)

99 (44.9) 128 (58.2) 100 (45.4) 129 (58.6)

Cart

Mount

128 (58.2) 129 (58.6)

* Fluid filter includes fluid drain valve.

14 312799L

Installation

ti15363b

Use alternate mounting holes (on bracket, see page 39) to mount air controls vertically.

General Information

NOTE: Reference numbers and letters in parentheses in

the text refer to the callouts in the figures and the parts drawing.

Installation

IG. 1 and FIG. 2 are only guides for selecting and

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

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.

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.

FIG. 1. Typical Wall-Mount Installation

312799L 15

Installation

ti15362a

H J

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.

FIG. 2. Typical Cart-Mount Installation

Key: F

IG. 1 and FIG. 2

A Air Shutoff Valve 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

(not visible) 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 Pump Fluid Inlet U Suction Hose V Fluid Drain Valve

16 312799L

Installation

Mount the Pump

Mount the pump directly to the wall (order Wall Mounting Kit, page 39) or to a Graco cart (order Cart Mounting Kit 24E879).

Wall-Mounted Pumps

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 45.

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

NOTE: Be sure the pump is level.

Cart-Mounted Pumps

•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 automati-

cally 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) dis-

penses 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.

•The suction hose (U) allows the pump to draw fluid

from a 5 gallon (19 liter) pail. A strainer also is supplied. If using non-Graco supplied suction hose, see inlet pressure notice, page 20.

Kit 24E885 is available if you plan to bolt your cart to the floor. It includes two spacers that keep the legs stable. Bolts not included.

Supplied Components

See FIG. 1 and FIG. 2. Components vary by package ordered. See tables on pages 9 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.

Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.

Be sure the valve is easily accessible from the pump and located downstream from the air regulator.

•A fluid filter (P) with a 60 mesh (250 micron) stain-

less steel element filters particles from fluid as it leaves the pump.

•A fluid drain valve (V) relieves fluid pressure in the

hose and gun.

• DataTrak (F) provides pump diagnostics and mate-

rial usage information. See page 23.

312799L 17

Installation

ti12914a

Air Line Accessories

Install the following accessories in the order shown in F

IG. 1 and FIG. 2, using adapters as necessary.

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

ture from the compressed air supply.

•A second bleed-type air shutoff valve (A) isolates

the air line accessories for servicing. Locate upstream from all other air line accessories.

Grounding

The equipment must be grounded to reduce the risk of static sparking. Static sparking can cause fumes to ignite or explode. Grounding provides an escape wire for the electric current.

Pump: See FIG. 3. 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.

Fluid supply container: follow local code.

Object being sprayed: follow local code.

Solvent pails used when flushing: follow local code.

Use only conductive metal pails, placed on a grounded surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

To maintain grounding continuity when flushing or relieving pressure: hold metal part of the spray

gun/dispense valve firmly to the side of a grounded metal pail, then trigger the gun/valve.

Setup

1. See FIG. 2. Attach end of blue fluid hose (M) without gun swivel (K) 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 other end of blue fluid hose (M), with gun swivel (K), to gun fluid inlet.

FIG. 3. Ground the Pump.

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 hose. If total resistance to ground exceeds 25 megohms, replace hose immediately.

Air compressor: follow manufacturer’s recommendations.

Spray gun / Dispense valve: Ground the spray gun through connection to a Graco-approved grounded fluid hose.

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

6. Apply lens cover to both regulator gauge lenses. Order Kit 24A540 for 5 sheets of 12 lens covers.

7. Verify that suction hose fittings are tight.

18 312799L

Operation

ti6581b

ti6582A

Gun Trigger Locked

Gun Trigger Unlocked

Operation

Pressure Relief Procedure

Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.

1. Lock the gun trigger.

2. See F

3. Unlock the gun trigger.

4. Hold a metal part of the gun firmly to a grounded

5. Lock the gun trigger.

6. Open all fluid drain valves in the system, having a

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

(E).

metal waste container. Trigger the gun to relieve fluid pressure.

waste container ready to catch the drainage. Leave the drain valve(s) open until you are ready to spray again.

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 Flushing, page 22.

Trigger Lock

See FIG. 4. Always lock the gun trigger when you stop spraying to prevent gun from being triggered accidentally by hand or if dropped or bumped.

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 com-

pletely 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.

FIG. 4. Gun Trigger Lock

312799L 19

Operation

ti15364a

Prime and Adjust the Pump

NOTICE

TO PREVENT A BELLOWS FAILURE:

• Do not exceed fluid inlet pressure of 15 psi (0.1 MPa, 1.0 bar).

• Do not use a ball check pump on the inlet side of this pump.

• Do not use a suction tube with a check valve on the inlet side of this pump.

1. Lock the gun trigger. Remove tip guard and spray tip from gun. 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. Check that all fittings throughout system are tightened securely.

4. Position pail close to pump. Do not stretch suction hose tight; let it hang to assist fluid flow into pump.

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

9. Pumps with runaway protection: Disable the prime/flush function by pushing the prime/flush button on the DataTrak.

10. Release the gun trigger and engage the trigger lock. Pump should stall against pressure.

11. In a direct supply system, with the pump and lines primed, and with adequate air pressure and volume supplied, the pump will start and stop as the gun/valve is opened and closed.

12. In a circulating system, the pump runs continuously and speeds up or slows down as the system demands until the air supply is shut off.

13. Use the air regulator to control the pump speed and the fluid pressure. Always use the lowest air pressure necessary to get the desired results. Higher pressures cause premature tip/nozzle and pump wear.

NOTICE

Never allow the pump to run dry of the fluid being pumped. A dry pump quickly accelerates to a high speed, possibly damaging itself. If your pump accelerates quickly, or is running too fast, stop it immediately and check the fluid supply. If the supply container is empty and air has been pumped into the lines, refill the container and prime the pump and the lines with fluid, or flush and leave it filled with a compatible solvent. Be sure to eliminate all air from the fluid system.

Install the Spray Tip

IG. 5. Air Controls

Follow Pressure Relief Procedure, page 19. Install the

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

6. Pumps with runaway protection: Enable the prime/flush function by pushing the prime/flush button on the DataTrak.

7. Open bleed-type air valve (E). Slowly open the pump air regulator (H) until the pump starts.

20 312799L

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 Spray Pattern

ti6559a

OUT (narrower pattern)

IN (wider pattern)

no air

too little air correct

amount of

air

ti0792A

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:

Operation

FIG. 6. Pattern Air Adjustment

Pump

Ratio

Pump Air

Regulator Setting

psi (MPa, bar)

Approximate Fluid Pressure psig (MPa, bar)

15:1 x 20 (0.14, 1.4) = 300 (2.1, 21) 30:1 x 20 (0.14, 1.4) = 600 (4.2, 42)

2. Trigger gun to check atomization; do not be concerned about pattern shape.

3. Hold gun perpendicular and approximately 12 inches (304 mm) from surface.

4. Move gun first, then pull gun trigger to spray onto test paper.

5. Increase fluid pressure in 100 psi (0.7 MPa, 7 bar) increments, just to the point where a further increase in fluid pressure does not significantly improve fluid atomization. Refer to the following example.

Example:

Pump Air Regulator

Pump

Ratio

15:1 x 7 (.05, 0.5) = 100 (0.7, 7.0)

Increment

psi (MPa, bar)

Incremental

Fluid Pressure

psi (MPa, bar)

30:1 x 3.3 (0.02, 0.2) = 100 (0.7, 7.0)

6. See F

IG. 6. Close off pattern adjustment air by turn-

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

7. See F

IG. 7. 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.

See F

IG. 6. For narrower pattern, turn pattern

adjustment valve knob (W) counterclockwise (out). If pattern is still not narrow enough, increase air pressure to gun slightly or use different size tip.

IG. 7

312799L 21

Maintenance

Shutdown

Follow Pressure Relief Procedure, page 19.

Always flush the pump before the fluid dries on the displacement rod. See Flushing on page 22.

NOTE: If the overflow chamber (optional accessory) contains fluid, unscrew the bottle (103) and discard. If it has not been used, the bottle can remain attached to the cap.

To avoid the buildup of static charge, do not rub the plastic bottle with a dry cloth while it is attached to the pump. Remove the bottle to clean, if needed.

Flushing

Read all Warnings. Follow all Grounding instructions. See page 18.

Flush the pump:

• Before first use

• When changing colors or fluids

• Before fluid dries or settles out in a dormant pump (check the pot life of catalyzed fluids)

• Before storing the pump.

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 19.

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.

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

3. Place suction hose in container of solvent.

4. Hold metal part of gun firmly to side of grounded metal pail.

5. Start pump. Always use lowest possible fluid pressure when flushing.

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 19.

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

11. Clean inside and outside of suction hose.

22 312799L

DataTrak Controls and Indicators

/min,

AE, see details at right

CF BT

Run Mode

Setup Mode

ti11883a

ti8622b

ti8623b

Key for FIG. 8

DataTrak Controls and Indicators

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

00=OFF)

AB Lower Displacement (user settable)

AC Flow Rate Units (user settable to 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 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

NOTICE

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

FIG. 8. DataTrak Controls and Indicators

312799L 23

DataTrak Operation

ti11902a

DataTrak Operation

NOTE: The display (AE) will turn off after 1 minute to

save battery life. Press any key to wake up the display.

Setup Mode

1. See FIG. 8. Press and hold for 5 seconds until Setup menu appears.

2. To enter settings for runaway, 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 cursor to the next data field. See page 26 for a description of

E1, E2, and E5 error codes.

NOTE: Graco recommends setting runaway to 60 . All DataTrak modules are shipped with runaway monitor-

ing not enabled.

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

IG. 8.

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

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.

FIG. 9: Solenoid Release Button

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

Run Mode

Runaway

1. See FIG. 8. 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.

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.

24 312799L

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 F

IG. 8).

DataTrak Operation

Prime/Flush

1. See FIG. 8. 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 sym-

bol will disappear from the display and the LED will stop flashing.

Counter/Totalizer

See FIG. 8. 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.

Display

See FIG. 8. 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

8) will flash and a diagnostic code will appear on the display. 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.

IG.

• If AC is set to gallons or ounces, BT and GT dis-

play 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.

312799L 25

DataTrak Operation

Symbol Code Code Name Diagnosis Cause

Table 1: Diagnostic Codes

Runaway Pump running faster than set

runaway limit.

E-1 Diving Up Leak during upstroke. Worn piston valve or packings.

E-2 Diving Down Leak during downstroke. Worn intake valve.

• Increased air pressure.

• Increased fluid output.

• Exhausted fluid supply.

E-3 Low Battery Battery voltage too low to stop

runaway.

E-4 Service

Problem with stopping runaway. • Damaged solenoid.

Component 1

E-4 Disconnected

Solenoid is disconnected. • Solenoid unplugged.

Solenoid

Solenoid is not engaging piston cup.

E-5 Service

Component 2

Problem with sensing valve movement.

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

see page 27.

Low battery. Replace battery; see page 27.

• Damaged valve carriage.

•Runaway (RT, F

IG. 8) protec-

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

• Damaged solenoid wires.

• Bracket and solenoid not tight against air valve housing.

• Sensors unplugged.

• Sensors mounted incorrectly.

• Damaged sensors.

• Damaged valve carriage.

• Faulty solenoid or solenoid wiring.

• Extreme temperatures (above 140°F [60°C]).

•Runaway (RT, F

IG. 8) protec-

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

26 312799L

Replace DataTrak Battery or Fuse

ti11992a

ti11884a

DataTrak Operation

5. Disconnect the used battery and replace with an approved battery. See Table 2.

To reduce the risk of fire and explosion, the battery and fuse must be replaced in a non-hazardous location.

Use only an approved replacement battery, shown in T

ABLE 2, and an approved fuse, shown in TABLE 3. Use

of an unapproved battery or fuse will void Graco’s warranty and Intertek and Ex approvals.

Replace Battery

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

2. Remove the cable from the two cable clips.

IG. 10.

Table 2. Approved Batteries

Energizer alkaline # 522 Varta alkaline # 4922 Ultralife lithium # U9V Duracell alkaline # MN1604

IG. 10. Disconnect DataTrak

3. Remove DataTrak module from bracket. See F

IG.

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

IG. 11. Remove DataTrak

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

312799L 27

DataTrak Operation

ti11994b

Battery

Fuse

Solenoid Cable Connec-

Sensor Cable Connection

Series Letter (last digit of code)

Replace Fuse

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

2. Pull the fuse away from the board.

3. Replace with an approved fuse from Table 3.

Table 3. Approved Fuses

DataTrak Part

Number Series*

289822

A or B 24C580

C and later 24V216

All other part

numbers

B and later 24V216

A 24C580

Required

* Fig. 12 shows where to find the Series letter.

Fuse

FIG. 12. DataTrak Battery and Fuse Location

28 312799L

Troubleshooting

Follow Pressure Relief Procedure, page 19, before checking or servicing the equipment.

Problem Cause Solution

Troubleshooting

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

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

ply; closed or clogged valves. Obstructed fluid hose or gun; fluid

hose ID is too small. Dirty, worn, or damaged air motor

parts. DataTrak models only: Extended

solenoid pin is stopping the air valve from cycling.

Pump operates, but output is low on both strokes.

Pump operates, but output is low on downstroke.

Erratic or accelerated pump speed. Exhausted fluid supply. Refill and prime.

Fluid is visible in the overflow chamber.

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.

Held open or worn ball check valves or packings.

Damaged bellows. Replace. See Bellows Displacement

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

Open, clear*; use hose with larger ID.

Clean or repair air motor. See NXT Air Motor manual.**

Enable runaway protection (see Data- Trak Operation, Setup Mode, page

24). Bleed 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 Bellows Displacement Pump manual.**

Clear valve; replace packings. See Bellows Displacement Pump manual.**

Clear valve, replace packings. See Bellows Displacement Pump manual.**

Pump manual.**

* 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.

**See Related Manuals, page 3, for manual numbers.

312799L 29

Parts

ti15429a

Parts

Cart Mount

30 312799L

Wall Mount

ti15430b

Parts

NOTE:

• See page 39 for mounting kits for all packages.

• See pages 38-44 for repair parts and accessories.

Package

G05Bxx 32 G12Bxx 32 G15Bxx 33 G23Bxx 34 G24Bxx 35 G25Bxx 36 G35Bxx 37

Parts List

Page

312799L 31

Parts

G05Bxx Models

This list includes all possible parts for G05Bxx packages. See page 9 to check whether a part is included in your particular package.

Ref Part Description Qty

1 Pump Assembly; see Manual 312795 1

B05FA0 M04LN0 x LB150A B05FB0 M04LT0 x LB150A B05FA1 M04LN0 x LB150B

B05FB1 M04LT0 x LB150B 2 24A586 PANEL, air control; see page 41 1 3a 24A575 DATATRAK, assembly; see page 42 1 3b ----- INSERT, panel; included with Part 2 1 6 24A587 FILTER, fluid (if equipped); includes Part 7 1 7 235208 FITTING, union, 3/8-18 npsm x

3/8-18 npt; included with Part 6

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

packages with fluid filter 15† 100023 WASHER; included with Part 30 2 16† 107557 SCREW, M8 x 75; included with Part 30 2

17†◆ 111799 SCREW, M8 x 16 mm; included with

Part 28 and Part 30 18† ----- SPACER; included with Part 30 2 21 ----- HOSE CLAMP; included with Part 3a 2 25 24E991 RING, lift, wall mount, not shown 1 28◆ ----- BRACKET, air control panel, wall mount 1 29 238909 GROUNDING WIRE assembly 1 30 24E880 PLATE, mounting; includes Parts 15-18,

see Wall Mounting Kit, page 39

32‡◆ 105332 LOCK NUT, M5 x 0.8 2 38 107204 O-RING, lift ring or plug 1 55‡ ----- MOUNTING WEDGE, left, air control

panel, cart mount 56‡ ----- MOUNTING WEDGE, right, air control

panel, cart mount 57‡ 110873 SCREW, M5 x 0.8 2 58† 104541 LOCK NUT, M8 4 60 24E879 CART MOUNTING KIT; see page 38 1 61▲ 290079 TAG, warning, grounding, not shown 1 62▲ 15W718 LABEL, warning, not shown 1 63▲ 15W719 LABEL, warning, not shown 1

----- Not sold separately. ▲ Replacement Warning labels, signs, tags, and cards are

available at no cost.

† Included in Mounting Hardware Kit, page 39.

◆ Included in Air Control Mounting Kit-Wall, page 39. ‡ Included in Air Control Mounting Kit-Cart, page 39.

G12Bxx Models

This list includes all possible parts for G12Bxx packages. See page 9 to check whether a part is included in your particular package.

Ref Part Description Qty

1 Pump Assembly; see Manual 312795 1

B12DA0 M07LN0 x LB100A B12DB0 M07LT0 x LB100A B12DA1 M07LN0 x LB100B

B12DB1 M07LT0 x LB100B 2 24A583 PANEL, air control; see page 41 1 3a 24A576 DATATRAK, assembly; see page 42 1 3b ----- INSERT, panel; included with Part 2 1 6 24A587 FILTER, fluid (if equipped); includes Part 7 1

7 235208 FITTING, union, 3/8-18 npsm x

3/8-18 npt; included with Part 6

15† 100023 WASHER; included with Part 30 2 16† 117080 SCREW, M8 x 60; included with Part 30 2

17†◆ 111799 SCREW, M8 x 16 mm; included with

Part 28 and Part 30

18† ----- SPACER; included with Part 30 2 21 ----- HOSE CLAMP; included with Part 3a 2 25 24E991 RING, lift, wall mount, not shown 1 28◆ ----- BRACKET, air control panel, wall mount 1 29 238909 GROUNDING WIRE assembly 1 30 24E880 PLATE, mounting; includes Parts 15-18,

see Wall Mounting Kit, page 39

32‡◆ 105332 LOCK NUT, M5 x 0.8 2 38 107204 O-RING, lift ring or plug 1 55‡ ----- MOUNTING WEDGE, left, air control

panel, cart mount

56‡ ----- MOUNTING WEDGE, right, air control

panel, cart mount

57‡ 110873 SCREW, M5 x 0.8 2 58 104541 LOCK NUT, M8 4 60 24E879 CART MOUNTING KIT; see page 38 1 61▲ 290079 TAG, warning, grounding, not shown 1 62▲ 15W718 LABEL, warning, not shown 1 63▲ 15W719 LABEL, warning, not shown 1

----- Not sold separately. ▲ Replacement Warning labels, signs, tags, and cards are

available at no cost.

† Included in Mounting Hardware Kit, page 39.

◆ Included in Air Control Mounting Kit-Wall, page 39. ‡ Included in Air Control Mounting Kit-Cart, page 39.

32 312799L

Parts

G15Bxx Models

This list includes all possible parts for G15Bxx packages. See page 10 to check whether a part is included in your particular package.

Ref Part Description Qty

1 Pump Assembly; see Manual 312795 1

B15BA0 M04LN0 x LB050A B15BB0 M04LT0 x LB050A B15BA1 M04LN0 x LB050B B15BB1 M04LT0 x LB050B B15FA0 M12LN0 x LB150A B15FB0 M12LT0 x LB150A B15FA1 M12LN0 x LB150B B15FB1 M12LT0 x LB150B

2 PANEL, air control 1

24A586 M04xxx motor, pump only;

see page 41

24A583 M12xxx motor, pump only;

see page 41

24A585 M04xxx motor, pump and gun;

see page 40

24A581 M12xxx motor, pump and gun;

see page 40

3a DATATRAK, assembly; see page 42 1

24A575 M04xxx motor

24A576 M12xxx motor 3b ----- INSERT, panel; included with Part 2 1 4 HOSE, suction; includes part 5 1

256420 LB050x displacement pump

256422 LB150x displacement pump 5 ----- STRAINER; included with Part 4 1 6 24A587 FILTER, fluid; if equipped includes Part 71

7 235208 ADAPTER, fluid filter, 3/8-18 npsm x

3/8-18 npt; included with Part 6, connects fluid filter to outlet adapter (Part

13)

8 189018 SWIVEL, fluid hose (packages with

gun); see page 44

9 241812 HOSE, fluid (packages with gun); see

page 44

10 24C853 GUN, G15 carbide; see page 44 1 11 AAM413 TIP (packages with gun); see page 44 1 12 AAMxxx TIP OPTION (packages with gun); see

page 44

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

LB150x displacement pumps; connects outlet to hose adapter (Part 46) or fluid filter adapter (Part 7)

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

page 44

15† 100023 WASHER; included with Part 30;

M04xxx motor

16† 107557 SCREW, M8 x 75; included with Part

30; M04xxx motor

Ref Part Description Qty

17†◆ 111799 SCREW, M8 x 16; included with Part 28

and Part 30 M04xxx motor M12xxx motor

18† ----- SPACER; included with Part 30;

M04xxx motor 21 ----- HOSE CLAMP; included with Part 3a 2 22 ----- CLIP, hose (all AA packages), see page

44 for packages of 10

25 24E991 RING, lift, wall mount, not shown 1 28◆ ----- BRACKET, air control panel, wall mount 1 29 238909 GROUNDING WIRE assembly 1 30 PLATE, mounting; see Wall Mounting

Kit, page 39

24E880 M04xxx motor, includes Parts 15-18

24E882 M12xxx motor, includes Part 17 32‡◆ 105332 LOCK NUT, M5 x 0.8 2 38 107204 O-RING, lift ring or plug 1 43 256425 DRAIN VALVE (if equipped); includes

Parts 44 and 45

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

Part 43 45 ----- HOSE, drain; included with Part 43 1 46 512351 ADAPTER, hose, 1/4-18 npt x 3/8-18

npt; connects fluid hose to outlet

adapter (Part 13) 55‡ ----- MOUNTING WEDGE, left, air control

panel, cart mount 56‡ ----- MOUNTING WEDGE, right, air control

57‡ 110873 SCREW, M5 x 0.8 2 58† 104541 LOCK NUT, M8 4 60 24E879 CART MOUNTING KIT; see page 38 1

61▲ 290079 TAG, warning, grounding, not shown 1 62▲ 15W718 LABEL, warning, not shown 1

63▲ 15W719 LABEL, warning, not shown 1

----- Not sold separately.

▲ Replacement Warning labels, signs, tags, and cards are

available at no cost.

† Included in Mounting Hardware Kit, page 39.

◆ Included in Air Control Mounting Kit-Wall, page 39. ‡ Included in Air Control Mounting Kit-Cart, page 39.

panel, cart mount

312799L 33

Parts

G23Bxx Models

This list includes all possible parts for G23Bxx packages. See page 11 to check whether a part is included in your particular package.

Ref Part Description Qty

1 Pump Assembly; see Manual 312795 1

B23DA0 M12LN0 x LB100A B23DB0 M12LT0 x LB100A B23DA1 M12LN0 x LB100B B23DB1 M12LT0 x LB100B

2 PANEL, air control 1

24A583 pump only; see page 41

24A581 pump and gun; see page 40 3a 24A576 DATATRAK, assembly; see page 42 1 3b ----- INSERT, panel; included with Part 2 1 4 256423 HOSE, suction; includes Part 5 1 5 ----- STRAINER; included with Part 4 1 6 24A587 FILTER, fluid (if equipped); includes Part 7 1 7 235208 ADAPTER, fluid filter, 3/8-18 npsm x

3/8-18 npt; included with Part 6, connects fluid filter to outlet

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

see page 44

9 241812 HOSE, fluid (packages with gun); see

page 44

10 GUN; see page 44 1

24C855 G40

XTR501 XTR 5 11 AAM413 TIP (packages with G40 gun); see page

12 AAMxxx TIP OPTION (packages with G40 gun);

see page 44

14 256390 AIR HOSE, gun, (packages with G40

gun); see page 44

17†◆ 111799 SCREW, M8 x 16; included with Part 28

and Part 30 21 ----- HOSE CLAMP; included with Part 3a 2 22 ----- CLIP, hose (all AA packages), see page

44 for packages of 10

25 24E991 RING, lift, wall mount, not shown 1 28◆ ----- BRACKET, air control panel, wall mount 1 29 238909 GROUNDING WIRE assembly 1 30 24E880 PLATE, mounting; includes Part 17, see

Wall Mounting Kit, page 39

32‡◆ 105332 LOCK NUT, M5 x 0.8 2 38 107204 O-RING, lift ring or plug 1 43 256425 DRAIN VALVE (if equipped); includes

Parts 44 and 45 44 ----- COUPLING, hose, drain; included with

Part 43 45 ----- HOSE, drain; included with Part 43 1 46 512351 ADAPTER, fluid hose, 1/4-18 npt x 3/8-18

npt; connects fluid hose to outlet (pack-

ages with gun and no fluid filter)

Ref Part Description Qty

55‡ ----- MOUNTING WEDGE, left, air control

panel, cart mount

56‡ ----- MOUNTING WEDGE, right, air control

----- Not sold separately. ▲ Replacement Warning labels, signs, tags, and cards are

available at no cost.

† Included in Mounting Hardware Kit, page 39.

◆ Included in Air Control Mounting Kit-Wall, page 39. ‡ Included in Air Control Mounting Kit-Cart, page 39.

34 312799L

Parts

G24Bxx Models

This list includes all possible parts for G24Bxx packages. See page 12 to check whether a part is included in your particular package.

Ref Part Description Qty

1 Pump Assembly; see Manual 312795 1

B24FA0 M18LN0 x LB150A B24FB0 M18LT0 x LB150A B24FA1 M18LN0 x LB150B B24FB1 M18LT0 x LB150B

2 PANEL, air control 1

24A583 pump only; see page 41

24A581 pump and gun; see page 40 3a 24A576 DATATRAK, assembly; see page 1 3b ----- INSERT, panel; included with Part 2 1 4 256424 HOSE, suction; includes Part 5 1 5 ----- STRAINER; included with Part 4 1 6 24A587 FILTER, fluid (if equipped); includes Part 7 1 7 235208 ADAPTER, fluid filter, 3/8-18 npsm x

3/8-18 npt; included with Part 6, connects fluid filter to outlet adapter (Part 13)

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

see page 44

9 241812 HOSE, fluid (packages with gun); see

page 44

10 GUN; see page 44 1

24C855 G40

XTR501 XTR 5 11 AAM413 TIP (packages with G40 gun); see page

12 AAMxxx TIP OPTION (packages with G40 gun);

see page 44

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

connects outlet to hose adapter (Part 46) or fluid filter adapter (Part 7)

14 256390 AIR HOSE, gun, (packages with G40

gun); see page 44

17†◆ 111799 SCREW, M8 x 16; included with Part 28

and Part 30 21 ----- HOSE CLAMP; included with Part 3a 2 22 ----- CLIP, hose (all AA packages), see page

44 for packages of 10

25 24E991 RING, lift, wall mount, not shown 1 28◆ ----- BRACKET, air control panel, wall mount 1 29 238909 GROUNDING WIRE assembly 1 30 24E880 PLATE, mounting; includes Part 17, see

Wall Mounting Kit, page 39

32‡◆ 105332 LOCK NUT, M5 x 0.8 2 38 107204 O-RING, lift ring or plug 1 43 256425 DRAIN VALVE (if equipped); includes

Parts 44 and 45 44 ----- COUPLING, hose, drain; included with

Part 43 45 ----- HOSE, drain; included with Part 43 1

Ref Part Description Qty

46 512351 ADAPTER, hose, 1/4-18 npt x 3/8-18 npt;

connects fluid hose to outlet adapter (Part

13)

55‡ ----- MOUNTING WEDGE, left, air control

panel, cart mount

56‡ ----- MOUNTING WEDGE, right, air control

----- Not sold separately. ▲ Replacement Warning labels, signs, tags, and cards are

available at no cost.

† Included in Mounting Hardware Kit, page 39.

◆ Included in Air Control Mounting Kit-Wall, page 39. ‡ Included in Air Control Mounting Kit-Cart, page 39.

312799L 35

Parts

G25Bxx Models

This list includes all possible parts for G25Bxx packages. See page 13 to check whether a part is included in your particular package.

Ref Part Description Qty

1 Pump Assembly; see Manual 312795 1

B25BA0 M07LN0 x LB050A B25BB0 M07LT0 x LB050A B25BA1 M07LN0 x LB050B B25BB1 M07LT0 x LB050B

2 PANEL, air control 1

24A583 Pump only; see page 41

24A581 Pump and gun; see page 40 3a 24A576 DATATRAK, assembly; see page 42 1 3b ----- INSERT, panel; included with Part 2 1 4 256420 HOSE, suction; includes part 5 1 5 ----- STRAINER; included with Part 4 1 6 24A587 FILTER, fluid; if equipped includes Part 71

7 235208 ADAPTER, fluid filter, 3/8-18 npsm x

3/8-18 npt; included with Part 6, connects fluid filter to outlet adapter (Part

13)

8 189018 SWIVEL, fluid hose (packages with

gun); see page 44

9 241812 HOSE, fluid (packages with gun); see

page 44

10 GUN; see page 44 1

24C855 G40

XTR501 XTR 5 11 AAM413 TIP (packages with gun); see page 44 1 12 AAMxxx TIP OPTION (packages with gun); see

page 44

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

page 44

15† 100023 WASHER; included with Part 30 2 16† 117080 SCREW, M8 x 60; included with Part 30 2

Ref Part Description Qty

45 ----- HOSE, drain; included with Part 43 1 46 512351 ADAPTER, fluid hose, 1/4-18 npt x

3/8-18 npt; connects fluid hose to outlet (packages with gun and no fluid filter)

55‡ ----- MOUNTING WEDGE, left, air control

panel, cart mount

56‡ ----- MOUNTING WEDGE, right, air control

----- Not sold separately. ▲ Replacement Warning labels, signs, tags, and cards are

available at no cost.

† Included in Mounting Hardware Kit, page 39.

◆ Included in Air Control Mounting Kit-Wall, page 39.

‡ Included in Air Control Mounting Kit-Cart, page 39.

17†◆ 111799 SCREW, M8 x 16; included with Part 28

and Part 30 18† ----- SPACER; included with Part 30 2 21 ----- HOSE CLAMP; included with Part 3a 2 22 ----- CLIP, hose (all AA packages), see page

44 for packages of 10

25 24E991 RING, lift, wall mount, not shown 1 28◆ ----- BRACKET, air control panel, wall mount 1 29 238909 GROUNDING WIRE assembly 1 30 24E881 PLATE, mounting; includes Part 17, see

Wall Mounting Kit, page 39

32‡◆ 105332 LOCK NUT, M5 x 0.8 2 38 107204 O-RING, lift ring or plug 1 43 256425 DRAIN VALVE (if equipped); includes

Parts 44 and 45 44 ----- COUPLING, hose, drain; included with

Part 43

36 312799L

Parts

G35Bxx Models

This list includes all possible parts for G35Bxx packages. See page 14 to check whether a part is included in your particular package.

Ref Part Description Qty

1 Pump Assembly; see Manual 312795 1

B35DA0 M18LN0 x LB100A B35DB0 M18LT0 x LB100A B35DA1 M18LN0 x LB100B B35DB1 M18LT0 x LB100B

2 PANEL, air control 1

24A583 pump only; see page 41

3/8-18 npt; included with Part 6, connects fluid filter to outlet

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

see page 44

9 24A446 HOSE, fluid (packages with gun); see

page 44

10 GUN; see page 44 1

24C855 G40

XTR501 XTR 5 11 AAM413 TIP (packages with G40 gun); see page

12 AAMxxx TIP OPTION (packages with G40 gun);

see page 44

14 256390 AIR HOSE, gun, (packages with G40

gun); see page 44

17†◆ 111799 SCREW, M8 x 16, included with Part 28

and Part 30 21 ----- HOSE CLAMP; included with Part 3a 2 22 ----- CLIP, hose (all AA packages), see page

44 for packages of 10

25 24E991 RING, lift, wall mount, not shown 1 28◆ ----- BRACKET, air control panel, wall mount 1 29 238909 GROUNDING WIRE assembly 1 30 24E880 PLATE, mounting; includes Part 17, see

Wall Mounting Kit, page 39

32‡◆ 105332 LOCK NUT, M5 x 0.8 2 38 107204 O-RING, lift ring or plug 1 40 166846 ADAPTER, 1/4 npt x 1/4 npsm 1 42 239069 WHIP HOSE; see page 44 1 43 256425 DRAIN VALVE (if equipped); includes

Parts 44 and 45 44 ----- COUPLING, hose, drain; included with

Part 43 45 ----- HOSE, drain; included with Part 43 1 46 512351 ADAPTER, fluid hose, 1/4-18 npt x 3/8-18

npt; connects fluid hose to outlet (pack-

ages with gun and no fluid filter)

Ref Part Description Qty

55‡ ----- MOUNTING WEDGE, left, air control

panel, cart mount

56‡ ----- MOUNTING WEDGE, right, air control

----- Not sold separately. ▲ Replacement Warning labels, signs, tags, and cards are

available at no cost.

† Included in Mounting Hardware Kit, page 39.

◆ Included in Air Control Mounting Kit-Wall, page 39. ‡ Included in Air Control Mounting Kit-Cart, page 39.

312799L 37

Kits

101

102

106

105

103

104

107

108

ti15482a

161518

Apply high-strength thread locker approximately

0.25 in. on screw thread.

Kits

Cart Mounting Kit

Kit 24E879 Includes the cart, mounting plate (30), and hardware for all pump sizes. Use to mount a bare pump on a cart. See details in kit parts list to determine the hardware needed for your pump.

Ref. Part Description Qty.

101 ----- CART, frame 1 102 ----- HANDLE, cart 1 103 119451 WHEEL, semi-pneumatic 2 104 119452 CAP, hub 2 105 ----- SLEEVE, cart handle 2 106 15C871 CAP, leg 2 107 115480 KNOB, t-handle 2 108 116630 SCREW, carriage 2 15 100023 WASHER 2 16

107557 117080

17 111799 SCREW, M8 x 16

18 ----- SPACER

30 ----- MOUNTING PLATE 1 58 104541 NUT, M8 4

SCREW M8 x 75, M04xxx motor M8 x 60, M07xxx motor

M04xxx and M07xxx use only 6 M12xxx and M18xxx use all 8

M04xxx motor- use longer M07xxx motor - use shorter

Cart Floor Mounting Kit

Kit 24E885 includes two spacers. Remove the caps on the cart legs. Insert spacers to keep the legs stable when bolting the cart to the floor. Bolts not included.

38 312799L

Kits

ti15484b

Use alternate mounting holes to mount the air controls at an angle on the bracket.

ti15483a

Wall Mounting Kit

Includes mounting plate (30) and hardware (see Mounting Hardware Kits). Use to mount a bare pump on the

wall.

Air Motor on

Kit Description

24E880 Plate plus Mounting

Hardware Kit 24E886

24E881 Plate plus Mounting

Hardware Kit 24E887

24E882 Plate plus Mounting

Hardware Kit 24E888

Package

M04xxx

M07xxx

M12xxx or M18xxx

Mounting Hardware Kits

Includes all hardware needed for wall or cart mounting, but does not include the plate. Use for replacement parts.

Kit 24E886, packages with M04xxx motor

Ref Part Description Qty.

15 100023 Washer 2 16 107557 Screw, M8 x 75 2 17 111799 Screw, M8 x 16 6 18 ----- Spacers 2 58 104541 LOCK NUT, M8 4

Air Control Mounting Kit-Wall

Kit 24E883 includes bracket (28), hex nuts (32), and screws (17). Use if adding air controls to a wall mount package, or for replacement parts.

Air Control Mounting Kit-Cart

Kit 24E884 includes right and left mounting wedges (55 and 56), hex nuts (32) and screws (37). Use if adding air controls to a cart mount package, or for replacement parts.

Kit 24E887, packages with M07xxx motor

Ref Part Description Qty.

15 100023 Washer 2 16 117080 Screw, M8 x 60 2 17 111799 Screw, M8 x 16 6 18 ----- Spacers 2 58 104541 LOCK NUT, M8 4

Kit 24E888, packages with M12xxx or M18xxx motor

Ref Part Description Qty.

17 111799 Screw, M8 x 16 8 58 104541 LOCK NUT, M8 4

312799L 39

Kits

301

302

303

304

305

312

314

317

309

308304

310

316

ti13565b

311

307

313

319

321

303

310

ti13467a

315

327

328

Pump and Gun Control Panel Kits

M07xxx, M12xxx, and M18xxx air motors

Kits 24A581

Ref. Part Description Qty.

301 114362 VALVE, ball 1 302 15T643 SWIVEL, tee, 3/8 npt(m) x 1/2T 1 303 ----- TUBE, 1/2 OD, cut to fit,

order Tubing Kit 24D496 304 121212 ELBOW, swivel, 1/2T x 3/8 npt(m) 3 305 15T536 REGULATOR, air, pump, 3/8 npt 1 306 ----- ELBOW, swivel, 5/32 T x 1/4 npt 1 307 ----- TUBE, black, cut to fit,

order Tubing Kit 24D496 308 ----- SWIVEL, 90°, 5/32T x 1/8 npt(f) 2 309 ----- ELBOW, swivel, 5/32T x 1/8 npt 1 310 15T500 GAUGE, pressure 2 311 113498 VALVE, pressure relief 1 312 164672 ADAPTER 1 313 15T538 NUT, regulator 1 314 114381 SCREW, cap, button head 2 315 15T539 REGULATOR, air, gun, 3/8 npt 1 316 116514 NUT, regulator 1 317 ----- PANEL 1 318 ----- LABEL, panel (not shown) 1 319 ----- INSERT 1 320 105332 NUT, lock (not shown) 2 321 ----- ELBOW, 1/2T x 1/2 npt 1 322 ----- COVER, lens, 12 sticker sheet (not

327 24P814 RING, grounding 1 328 24P813 RING, grounding 1

shown), order Kit 24A540 for 5 sheets

40 312799L

1.3 ft.

4 in.

M04xxx air motors

Kit 24A585

Ref. Part Description Qty.

301 114362 VALVE, ball 1 302 ----- SWIVEL, tee 1 303 ----- TUBE, 3/8 OD, cut to fit,

order Tubing Kit 24D496 304 121141 ELBOW, swivel, 3/8T x 1/4 npt(m) 3 305 15T499 REGULATOR, air, pump, 1/4 npt 1 306 15T866 ELBOW, swivel, 5/32T x 1/8 npt 1 307 ----- TUBE, black, cut to fit,

order Tubing Kit 24D496 308 15T498 SWIVEL, 90°, 5/32T x 1/8 npt(f) 2 309 15T866 ELBOW, swivel, 5/32T x 1/8 npt 1 310 15T500 GAUGE, pressure 2 311 113498 VALVE, safety 1 312 162453 ADAPTER, 1/4 nps(m) x 1/4 npt 1 313 115244 NUT, regulator 2 314 114381 SCREW, cap, button head 2 315 15T499 REGULATOR, air, gun, 1/4 npt 1 316 115244 NUT, regulator 1 317 ----- PANEL 1 318 ----- LABEL, panel (not shown) 1 319 ----- INSERT 1 320 ----- NUT, lock (not shown) 2

321 121141 ELBOW, 3/8T x 1/4 npt(m) 1 322 ----- COVER, lens, 12 sticker sheet (not

323 ----- ELBOW, 1/4 npt(f) x 1/8 npt(m) 1 327 24P812 RING, grounding 1 328 24P812 RING, grounding 1

shown), order Kit 24A540 for 5 sheets

1.3 ft.

4 in.

Pump Only Control Panel Kits

306

307

308

301

303

314

317

310

313

326

324

305

304

311

325

301

303

314

317

326

311

305

304

310

313

306

307 308 304

ti13567b

ti13566b

327

Kits

M07xxx, M12xxx, and M18xxx air motors

Kit 24A583

Ref. Part Description Qty.

301 114362 VALVE, ball 1 303 ----- TUBE, 1/2 OD, cut to fit,

304 121212 ELBOW, swivel, 1/2T x 3/8 npt(m) 2 305 15T536 REGULATOR, air, 3/8 npt 1 306 ----- ELBOW, swivel, 5/32 T x 1/4 npt 1 307 ----- TUBE, black, cut to fit,

308 ----- SWIVEL, 90°, 5/32T x 1/8 npt(f) 1 310 15T500 GAUGE, pressure 1 311 113498 VALVE, pressure relief 1 313 15T538 NUT, regulator 1 314 114381 SCREW, cap, button head 2 317 ----- PANEL 1 318 ----- LABEL, panel (not shown) 1 319 ----- INSERT (see inset illustration on

320 105332 NUT, lock (not shown) 2 321 ----- ELBOW, 1/2T x 1/2 npt (see inset

322 ----- COVER, lens, 12 sticker sheet (not

326 ----- FITTING, straight, 1/2T x 3/8 npt(m) 1 327 24P814 RING, grounding 1

312799L 41

order Tubing Kit 24D496

page 40)

illustration on page 40)

shown), order Kit 24A540 for 5 sheets

1.5 ft.

5 in.

M04xxx air motors

Kit 24A586

Ref. Part Description Qty.

301 114362 VALVE, ball 1 303 ----- TUBE, 3/8 OD, cut to fit,

order Tubing Kit 24D496 304 121141 ELBOW, swivel, 3/8T x 1/4 npt(m) 1 305 ----- REGULATOR, air, 1/4 npt 1 306 ----- ELBOW, swivel, 5/32T x 1/8 npt 1 307 ----- TUBE, black, cut to fit,

order Tubing Kit 24D496 308 ----- SWIVEL, 90°, 5/32T x 1/8 npt(f) 1 309 ----- ELBOW, swivel, 5/32T x 1/8 npt 1 310 15T500 GAUGE, pressure 1 311 113498 VALVE, pressure relief 1 313 115244 NUT, regulator 1 314 114381 SCREW, cap, button head 2 317 ----- PANEL 1 318 ----- LABEL, panel (not shown) 1

319 ----- INSERT (see inset illustration on

page 40) 320 105332 NUT, lock (not shown) 2

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

322 ----- COVER, lens, 12 sticker sheet (not

323 ----- ELBOW, 1/4 npt(f) x 1/8 npt(m) 1 324 ----- FITTING, straight, 3/8T x 1/4 npt(m) 1 326 ----- FITTING, straight, 3/8T x 3/8 npt(m) 1 327 24P812 RING, grounding 1

(see inset illustration on page 40)

shown), order Kit 24A540 for 5

sheets

1.3 ft.

4 in.

Kits

ti13531a

401

402

DataTrak Kits

Ref. No. Part No. Description Qty.

401 24B563 DATATRAK, module (includes

Part 403)

402 SOLENOID/REED SWITCH, kit 1

24B565 M04xxx air motors 24B566 M07xxx-M18xxx air motors

403 ----- CLAMP, hose (not shown)

Order kit 24A548 for package of 10

404▲ 15V262 LABEL, warning (not shown) 1

DataTrak Conversion Kits

Fits NXT

Air Motor

Part Description

DataTrak with

24A575

24A576

24A592

* Purchase and install the Air Valve Replacement Kit

listed to make your MxxLN0 air motor compatible with DataTrak with Runaway Protection.

Runaway

Protection Kit

DataTrak with

Runaway

Protection Kit

DataTrak with

Cycle Count

Only Kit

Models

M04LN0 24A353

M04LT0 -----

M07LN0–

M18LN0

M07LT0–

M18LT0

MxxLN0 -----

Air Valve

Replacement Kit

Required*

24A354

-----

Suction Hose Kits

Kit Size

5-Gallon

256420 1/2 in. Suction hose

256423 3/4 in. G23Bxx and G35Bxx

256424 1 in. G15Bxx and G24Bxx

Parts Included Fits Packages

G15Bxx and G25Bxx (4), reducing bushing (as needed) and strainer (5)

(50cc)

(100cc)

(150cc)

----- Not sold separately. ▲ Replacement Warning labels, signs, tags, and cards

are available at no cost.

DataTrak Replacement Parts Kits

Part

No. Description

24B563

24B565

24B566

24B564

42 312799L

DataTrak Module All

Solenoid/Reed Switch

Assembly M04LT0

Solenoid/Reed Switch

Assembly

Reed Switch Assembly MxxLN0

Fits Air Motor

Models

M07LT0 -

M18LT0

55-Gallon

24A954 3/4 in. Suction hose,

bung adapter, and strainer

24B598 1 in. G15Bxx and G24Bxx

G15Bxx, G23Bxx,

G25Bxx, and G35Bxx

(50cc and 100cc)

(150cc)

PTFE*

24B424 3/4 in. Suction hose,

straight swivel, and

24B425 1 in. G15Bxx and G24Bxx

* For pumping acid materials that are compatible with

PTFE.

strainer

G15Bxx, G23Bxx,

G25Bxx, and G35Bxx

(50cc and 100cc)

(150cc)

Drain Valve Kit 256425

Includes drain valve (43), coupling (44), and hose (45).

Overflow Chamber Kit 24E298

Includes overflow cup, with seals and necessary hardware.

Reinforced PTFE V-Packing Kits and PTFE Bellows Kits

NOTE: See manual 312793 for information related to

optional kits with reinforced PTFE seals and optional kits with PTFE bellows. These kits are intended for use with materials that cause chemical compatibility concerns with UHMWPE, such as acid catalyst materials.

Kits

312799L 43

Kits

XTR 5

ti12636a

G15 and G40

ti11993a

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.

Ref. Part Description Qty.

9 HOSE, fluid 1

241812 G05xxx-G24xxx, 25 ft (7.6 m),

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

24A446 G35xxx, 23 ft (7 m),

4100 psi (28.3 MPa, 283 bar) maxi-

mum working pressure 10 XTR501 GUN 1 40 166846 ADAPTER, for whip hose 1 42 239069 HOSE, whip (G35xxx packages

only); see G40 illustration at right),

2 ft (0.6m);

4100 psi (28.3 MPa, 283 bar) maxi-

mum working pressure

Ref. Part Description Qty.

8 189018 SWIVEL, fluid hose 1 9 HOSE, fluid 1

241812 G05xxx-G24xxx, 25 ft (7.6 m),

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

24A446 G35xxx, 23 ft (7 m);

4100 psi (28.3 MPa, 283 bar) maximum working pressure

10 24C855 GUN, G40 1

24C853 GUN, G15 1 11 AAM413 TIP 1 12 AAMxxx TIP, option, see gun manual 1 14 256390 HOSE, air, 27 ft (8.2 m);

100 psi (0.7 MPa, 7 bar) maximum

working pressure 22 24A588 CLIP, hose; package of 10 1 40 166846 ADAPTER, for whip hose 1 42 239069 HOSE, whip (G35xxx packages

only); 2 ft (0.6m);

4100 psi (28.3 MPa, 283 bar)

maximum working pressure

44 312799L

Mounting Plate Dimensions

8.5 in. (216 mm)

17.0 in. (432 mm)

2.167 in. (55 mm)

6 x 0.400 in. (10 mm)

6.9 in. (175 mm)

ti15369a

Mounting Plate Dimensions

312799L 45

Mounting Plate Dimensions

46 312799L

Technical Data

Maximum fluid working pressure . . . . . . . . . . . . . See Models tables on pages 9-13.

Maximum fluid inlet pressure . . . . . . . . . . . . . . . . 15 psi (0.1 MPa, 1.0 bar)

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

Minimum air inlet pressure . . . . . . . . . . . . . . . . . . 10 psi (0.07 MPa, 0.7 bar)

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

Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Models tables on pages 9-13.

Maximum fluid temperature . . . . . . . . . . . . . . . . . 120°F (49°C)

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

Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Models tables on pages 9-13.

Sound data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Technical Data in NXT Air Motor manual.*

Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PEEK, PTFE, stainless steel, tungsten carbide,

UHMWPE

* See Related Manuals, page 3, for manual number.

Technical Data

312799L 47

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 312799

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revision L - July 2014

Graco 312799L User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Related Manuals

Warnings

Important Two-Component Material Information

Isocyanate Conditions

Material Self-ignition

Moisture Sensitivity of Isocyanates

Changing Materials

Keep Components A and B Separate

Models

5:1 Packages (G05Bxx)

12:1 Packages (G12Bxx)

15:1 Packages (G15Bxx)

23:1 Packages (G23Bxx)

24:1 Packages (G24Bxx)

25:1 Packages (G25Bxx)

35:1 Packages (G35Bxx)

Installation

General Information

Prepare the Operator

Prepare the Site

Mount the Pump

Supplied Components

Air Line Accessories

Grounding

Setup

Operation

Pressure Relief Procedure

Flush the Pump Before First Use

Trigger Lock

Prime and Adjust the Pump

Install the Spray Tip

Adjust the Spray Pattern

Maintenance

Shutdown

Flushing

Preventive Maintenance Schedule

Tighten Threaded Connections

DataTrak Controls and Indicators

DataTrak Operation

Setup Mode

Run Mode

Replace DataTrak Battery or Fuse

Troubleshooting

Parts

Cart Mount

Wall Mount

G05Bxx Models

G12Bxx Models

G15Bxx Models

G23Bxx Models

G24Bxx Models

G25Bxx Models

G35Bxx Models

Kits

Cart Mounting Kit

Cart Floor Mounting Kit

Wall Mounting Kit

Mounting Hardware Kits

Air Control Mounting Kit-Wall

Air Control Mounting Kit-Cart

Pump and Gun Control Panel Kits

Pump Only Control Panel Kits

DataTrak Kits

Suction Hose Kits

Drain Valve Kit 256425

Overflow Chamber Kit 24E298

Reinforced PTFE V-Packing Kits and PTFE Bellows Kits

Guns and Hoses

Mounting Plate Dimensions

Technical Data

Graco Standard Warranty

Graco Information