Instructions-Parts
®
Merkur
Heated
313255F
Spray Packages
For finishing and coating applications requiring heated materials, 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 page 5 for model information, including maximum working pressures and approvals.
ENG
Model
G28C18
ti13017a
Model
G30W82
ti13016a
ll 2 G c T2
Related Manuals
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Merkur 28:1 Heated Packages
(G28Wxx and G28Cxx) . . . . . . . . . . . . . . . . 6
Merkur 30:1 Heated Packages
(G30Wxx and G30Cxx) . . . . . . . . . . . . . . . . 6
Merkur 48:1 Heated Packages
(G48Wxx) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Information . . . . . . . . . . . . . . . . . . . . . . 9
Prepare the Operator . . . . . . . . . . . . . . . . . . . . . 9
Prepare the Site . . . . . . . . . . . . . . . . . . . . . . . . . 9
Wall Mount Packages . . . . . . . . . . . . . . . . . . . . . 9
Ventilate the Spray Booth . . . . . . . . . . . . . . . . . . 9
Supplied Components . . . . . . . . . . . . . . . . . . . . 10
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Relief Procedure . . . . . . . . . . . . . . . . 13
Flush Before Using Equipment . . . . . . . . . . . . . 13
Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . 14
Install the Spray Tip . . . . . . . . . . . . . . . . . . . . . 14
Adjust the Atomization . . . . . . . . . . . . . . . . . . . 15
Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . 15
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Preventive Maintenance Schedule . . . . . . . . . . 17
Tighten Threaded Connections . . . . . . . . . . . . . 17
Flush the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DataTrak Controls and Indicators . . . . . . . . . . . . . 19
DataTrak Operation . . . . . . . . . . . . . . . . . . . . . . . . 20
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Replace DataTrak Battery or Fuse . . . . . . . . . . 23
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
G28xxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 26
G30xxx Models . . . . . . . . . . . . . . . . . . . . . . . . . 27
G48Wxx Models . . . . . . . . . . . . . . . . . . . . . . . . 28
Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Wall Mount Kit 24A578 . . . . . . . . . . . . . . . . . . . 29
Heated Cart Mount Kit 256427 . . . . . . . . . . . . . 29
Pump and Gun Control Panel Kit . . . . . . . . . . . 30
Pump Only Control Panel Kit . . . . . . . . . . . . . . . 31
DataTrak Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
PTFE Suction Hose Kits . . . . . . . . . . . . . . . . . . 32
Wall Bracket Mounting Dimensions . . . . . . . . . . . 33
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 34
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 34
Related Manuals
Manual Description
312792 Merkur Displacement Pump
312794 Merkur Pump Assembly
312796
312797 Merkur Spray Packages, Ambient
312798 Merkur Electrostatic Spray
3A0149 AA Series Spray Gun (G15, G40, and
2 313255F
™
NXT
Air Motor
Packages, Ambient and Heated
G40 with RAC)
Manual Description
312145
309524
307273 Fluid Outlet Filter
306860 Back Pressure Regulator
307892 Back Pressure Valve
™
5 and XTR™7 Airless Spray Gun
XTR
®
Viscon
HP Heater
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. 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.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause
electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
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.
313255F 3
Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure in this manual 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 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.
• Always wear impervious gloves when spraying 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, 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
4 313255F
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 G30W80 represents a Merkur package (G),
with a 30:1 ratio pump (30), wall mounting (W), and the components shown for (80) in the table on page 6.
Wall mount
ID
ti12326a
ti12327a
G30 W 80
First Digit
G
(Merkur
Package)
Second and Third Digits
(Ratio)
28
30
48
28:1
30:1
48:1
Fourth Digit
(Mounting Type)
C
W
Cart See Tables, page 6
Wall
Fifth and Sixth Digit
(Components Included)
Cart mount
ID
DataTrak™ has the following agency approvals.
#53
Conforms to
FM std 3600 & 3610
for use in Class I Div 1
Group D
T3C Hazardous locations
313255F 5
0359
II 1 G
EEx ia IIA T3
Nemko
06ATEX1124
Models
Merkur 28:1 Heated Packages (G28Wxx and G28Cxx)
Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar)
Maximum Fluid Working Pressure: 2800 psi (19.3 MPa, 193 bar)
Model
Wall
Mount
G28W07 G28C05 W28EAS 120V XTR
G28W08 G28C06 W28EBS 120V XTR
G28W09 G28C07 W28EAS 240V XTR
G28W10 G28C08 W28EBS 240V XTR
G28W17 G28C15 W28EAS 120V G40
G28W18 G28C16 W28EBS 120V G40
G28W19 G28C17 W28EAS 240V G40
G28W20 G28C18 W28EBS 240V G40
Cart
Mount
Pump
Assembly Heater Gun
Air Controls Hoses Options
Pump
Pump
Only
✔✔✔ ✔✔
✔✔✔ ✔✔✔
✔ ✔ ✔ ✔ ✔
✔ ✔ ✔ ✔ ✔ ✔
Gun
and
Fluid
Gun
Hose
✔✔ ✔ ✔ ✔
✔✔ ✔ ✔ ✔ ✔
✔ ✔ ✔ ✔ ✔
✔ ✔ ✔ ✔ ✔ ✔
Merkur 30:1 Heated Packages (G30Wxx and G30Cxx)
Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar)
Maximum Fluid Working Pressure: 3000 psi (20.7 MPa, 207 bar)
Model
Wall
Mount
G30W67 G30C59 W30CAS 120V XTR
G30W68 G30C60 W30CBS 120V XTR
G30W69 G30C61 W30CAS 240V XTR
G30W70 G30C62 W30CBS 240V XTR
G30W79 G30C77 W30CAS 120V G40
G30W80 G30C78 W30CBS 120V G40
G30W81 G30C79 W30CAS 240V G40
G30W82 G30C80 W30CBS 240V G40
Cart
Mount
Pump
Assembly Heater Gun
Air Controls Hose Options
Pump
Pump
Only
✔ ✔ ✔ ✔ ✔
✔ ✔ ✔ ✔ ✔ ✔
✔✔✔ ✔✔
✔✔✔ ✔✔✔
Gun
and
Fluid
Gun
Hose
✔ ✔ ✔ ✔ ✔
✔ ✔ ✔ ✔ ✔ ✔
✔✔ ✔ ✔ ✔
✔✔ ✔ ✔ ✔ ✔
Gun
Fluid
Whip
Hose
Gun
Fluid
Whip
Hose
Gun
Air
Hose
Gun
Air
Hose
Siphon
Kit
Siphon
Kit
Fluid
Filter DataTrak
Fluid
Filter DataTrak
Maximum
Fluid Flow
Rate
gpm (lpm)
2.0 (7.5)
Maximum
Fluid Flow
Rate
gpm (lpm)
1.2 (4.5)
6 313255F
Merkur 48:1 Heated Packages (G48Wxx)
Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar)
Maximum Fluid Working Pressure: 4800 psi (33.1 MPa, 331 bar)
Models
Model
Wall
Mount
G48W17 ----- W48CAS 120V
G48W18 ----- W48CBS 120V
0
Cart
Mount
Pump
Assembly Heater Gun
Air Controls Hose Options
Gun
Pump
Pump
Only
and
Gun
Gun
Fluid
Hose
Fluid
Whip
Hose
Gun
Air
Hose
Siphon
Kit
Fluid
Filter DataTrak
✔
✔
Maximum
Fluid Flow
Rate
gpm (lpm)
1.2 (4.5)
✔
313255F 7
Installation
Installation
V
A
Y
B
S
W
T
ti13112a
X
U
C
D
E
F
R
G
P
H
J
MN
K
L
ti13007a
FIG. 1: Typical Installation (Your package may not include all items shown.)
Key:
A Air Shutoff Valve (optional
accessory)
B Air Filter (optional accessory)
C Air Line Moisture Trap and Drain
Valve (optional accessory)
D Fluid Heater
E Back Pressure Regulator
F Fluid Filter
G Fluid Drain Valve
8 313255F
HSpray Gun
J Gun Swivel
K Fluid Whip Hose
L Electrically Conductive, Air and
Heated Fluid Supply/Return Hose
M 3 Way Valve
N Suction Hose and Tube
PStrainer
R Pump Ground Wire
S Gun Air Pressure Gauge
T Gun Air Pressure Regulator
U Bleed Type Master Air Valve
V DataTrak
W Pump Air Pressure Gauge
X Pump Air Pressure Regulator
Y Insert (for models without
DataTrak)
Installation
General Information
Reference numbers and letters in parentheses in
the text refer to the callouts in the figures and the
parts drawing.
Always use Genuine Graco Parts and Accessories,
available from your Graco distributor. If you supply
your own accessories, be sure they are adequately
sized and pressure-rated for your system.
FIG. 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.
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. Refer to the performance
charts in your pump assembly manual to find the air
consumption of your pump. 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.
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 4–5 ft (1.2–1.5 m)
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 0.4 in.
(10 mm) mounting holes in the wall. Wall mounting
dimensions are shown on page 33.
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.
Ventilate the Spray Booth
Provide fresh air ventilation to avoid the buildup of
flammable or toxic vapors. Do not operate the gun
unless ventilation fans are operating.
Electrically interlock the gun air supply with the ventilators to prevent gun operation without ventilating fans
operating. Check and follow all National, State, and
Local codes regarding air exhaust velocity requirements.
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.
313255F 9
Installation
Supplied Components
See FIG. 1. Components vary by package ordered.
See tables on pages 6 to 7. Your package may include:
• The red-handled bleed-type master air valve (U) is
required in your system to relieve air trapped
between it and the air motor and gun when the valve
is closed.
Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.
• The pump air regulator (X) 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.
Do not block access to the valve.
• The 3-way valve (M) allows choice to circulate fluid
back to the pump or return it to the supply container.
• A fluid drain valve (G) relieves fluid pressure in the
hose and gun.
•The fluid heater (D) heats the fluid as it passes
through, to maintain the correct spraying viscosity.
Read and understand all instructions in the supplied
heater manual 309524 before operating the heater.
Heat causes fluid to expand. If the heated fluid is
trapped with nowhere to expand, it can cause component rupture. Be sure to keep the heated fluid circulating (turn the 3-way valve to CIRC). Do not install a
fluid shutoff device between the heater and the gun.
• The gun air regulator (T) adjusts the air pressure to
the air-assisted spray gun (H).
• The air-assisted or airless spray gun (H) dispenses
the fluid. The gun houses the spray tip (not shown),
which is available in a wide range of sizes for different spray patterns and rates of flow. Refer to gun
manual for tip installation.
• The hose bundle (L) supplies fluid (and air for AA
guns) to the gun, and allows recirculation of fluid
when the gun is not triggered.
• The gun swivel (J) allows for freer gun movement.
• The suction hose (N) with strainer (P) allows the
pump to draw fluid from a 5 gallon (19 liter) pail.
• A fluid filter (F) with a 60 mesh (250 micron) stainless steel element filters particles from fluid as it
leaves the pump.
• DataTrak (V) provides pump diagnostics and material usage information. See page 19.
• The back pressure regulator (E) controls pressure
back to the gun and maintains proper circulation
pressure.
10 313255F
Installation
Grounding
The equipment must be grounded. Grounding reduces
the risk of static and electric shock by providing an
escape wire for the electrical current due to static build
up or in the event of a short circuit.
1. Pump: See F
is attached and tightened securely to the air motor.
Connect the other end of the ground wire (R) to a
true earth ground.
FIG. 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. Viscon HP Heater: refer to the heater manual,
supplied.
4. Air compressor: follow manufacturer's recommendations.
IG. 2. Verify that the ground screw (GS)
R
GS
ti12914a
8. 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.
9. 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.
Setup
The Viscon HP Heater must be installed by a qualified electrician in compliance with all state and local
codes and regulations.
Wall Mount Electrical Connections. Follow all
directions and requirements in the Viscon HP Heater
manual 309524.
Cart Mount Hazardous Location Wiring. The heater is
shipped with a fitting that is suitable for wiring in
hazardous locations. Follow all directions and
requirements in the Viscon HP Heater manual 309524.
Do not use the supplied electrical cord, which is
suitable only for non-hazardous location wiring.
Cart Mount Non-Hazardous Location Wiring. See
F
IG. 3. Replace installed fitting with bushing (80),
shipped loose. Attach strain relief bushing (79). Follow
all directions in the Viscon HP Heater manual 309524 to
connect the 120V supplied electrical cord (78), or
user-supplied cord for 240V applications.
5. Spray gun: ground through connection to a properly
grounded fluid hose and pump.
6. Fluid supply container: follow your local code.
7. Object being sprayed: follow your local code.
80
79
78
(120V only)
ti13261a
F
IG. 3. Non-Hazardous Location Electrical Cord
313255F 11
Installation
Electrical Housing Access
Remove
outer two
heater8
bracket
screws.
ti13358a
Tilt the heater away from the pump for easier access to
the screws on the cover of the electrical housing.
Electrical
housing
Loosen
inner two
heater
bracket
screws.
Hose Connections
See FIG. 1, page 8.
1. Attach one end of the air hose to the gun air regulator (T, G40 spray guns only).
2. Attach the other end of the air hose to the air inlet at
the base of the gun (G40 spray guns only).
3. Attach gun swivel (J) to the gun fluid inlet.
4. Attach one end of the fluid whip hose (K) to the gun
swivel and the other end to the recirculating manifold.
5. Attach one blue fluid hose to the recirculating manifold and to the back pressure regulator (E).
6. Attach the other blue fluid hose to the recirculating
manifold and to the filter (F) outlet.
7. Apply lens cover to both regulator gauge lenses.
8. Verify that suction hose fittings and drain hose fittings are tight.
ti13359a
12 313255F
Operation
Operation
Pressure Relief Procedure
1. Engage the trigger lock.
2. See F
3. Disengage the trigger lock.
4. Hold a metal part of the gun firmly to a grounded
5. Engage the trigger lock.
6. Open all fluid drain valves in the system, having a
7. If you suspect that pressure has not been fully
IG. 1. Turn off the bleed-type master air valve
(U).
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.
relieved after following the steps above, check the
following:
Flush Before Using Equipment
The equipment was tested with lightweight oil, which is
left in the fluid passages to protect parts. To avoid contaminating your fluid with oil, flush the equipment with a
compatible solvent before using the equipment. See
Flush the Pump, page 17.
Trigger Lock
See FIG. 4. Always engage gun trigger lock when you
stop spraying to prevent gun from being triggered accidentally by hand or if dropped or bumped.
Gun Trigger
Safety Locked
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.
TI6581A
Gun Trigger
Safety Unlocked
TI6582A
FIG. 4. Trigger Lock
313255F 13
Operation
Wet Cup
Before starting, fill wet cup 1/3 full with Graco Throat
Seal Liquid (TSL) or compatible solvent.
Wet
Cup
ti11927a
FIG. 5. Wet Cup
Prime the Pump
1. See FIG. 1. Lock gun trigger. Remove tip guard and
spray tip from gun (H). Refer to gun manual.
8. Open bleed-type air valve (U). Slowly turn pump air
regulator (X) clockwise, 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 but-
ton 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 13. 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.
2. Close gun air regulator (T) and pump air regulator
(X) by turning knobs counterclockwise reducing
pressure to zero. Close bleed-type air valve (U).
Also verify that all drain valves are closed.
3. Connect air line to bleed type air valve (U).
4. Check that all fittings throughout system are tightened securely.
5. Position pail close to pump. Suction hose is about
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 (H) 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 but-
ton on the DataTrak.
14 313255F
Operation
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 Air
Pump
Ratio
15:1 x 20 (0.14, 1.4) = 300 (2.1, 21)
30:1 x 20 (0.14, 1.4) = 600 (4.2, 42)
Regulator Setting
psi (MPa, bar)
Approximate
Fluid Pressure
psig (MPa, bar)
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 FIG. 6. Close off pattern adjustment air by turning knob (AA) clockwise (in) all the way. This sets
gun for its widest pattern.
AA
OUT (narrower
pattern)
AA
IN (wider
pattern)
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 Air Regulator
Pump
Ratio
15:1 x 7 (.05, 0.5) = 100 (0.7, 7.0)
30:1 x 3.3 (0.02, 0.2) = 100 (0.7, 7.0)
Increment
psi (MPa, bar)
Incremental
Fluid Pressure
psi (MPa, bar)
FIG. 6. Pattern Air Knob
2. 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.
TI6559A
313255F 15
Operation
3. See FIG. 7. 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
ti0792A
air
F
IG. 7. Spray Pattern Problems
Shutdown
Follow Pressure Relief Procedure, page 13.
Always flush the pump before the fluid dries on the displacement rod. See Flush the Pump on page 17.
16 313255F
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
1. Follow Pressure Relief Procedure, page 13.
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 but-
ton 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 but-
ton on the DataTrak.
Read all Warnings. Follow all Grounding instruc-
tions. See page 11.
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.
9. Follow Pressure Relief Procedure, page 13.
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.
313255F 17
Troubleshooting
Troubleshooting
NOTE: Check all possible problems and causes before
disassembling the pump.
Relieve the pressure before checking or servicing
the equipment.
F
Problem Cause Solution
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.
Fluid dried on the displacement rod. Clean; always stop the pump at the
Dirty, worn, or damaged air motor
parts.
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 being pumped is visible in the
TSL reservoir.
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.
Worn throat packings. Replace throat packings. See manual
Clear line or increase air supply.
Check that the valves are open.
Open, clear*; use hose with larger ID.
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.
Clear line or increase air supply.
Check that the valves are open.
Open, clear*; use hose with larger ID.
Replace packings. See manual
312794.
Clear valve; replace packings. See
manual 312794.
Clear valve, replace packings; see
manual 312794.
312794.
* 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.
18 313255F
DataTrak Controls and Indicators
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.
/min,
AE, see details at right
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.
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
Run Mode
PFRK
AD
ti11883a
FIG. 8. DataTrak Controls and Indicators
AC
AB
RK
AA
CF BT
Setup Mode
ti8622b
RT
UT
DT
PF
ti8623b
ST
313255F 19
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 FIG. 8. Press and hold for 5 seconds until
Setup menu appears.
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 cursor to the next data field. See page 22 for a descrip-
tion of E1, E2, and E5 error codes.
NOTE: Graco recommends setting runaway (if
equipped) to 60 .
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.
J
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.
Run Mode
Runaway
NOTE: DataTrak is available with and without runaway
protection. Packages with M02xxx air motors ship without a runaway solenoid. All other DataTrak packages are
equipped with a runaway solenoid.
1. See F
IG. 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.
ti11902a
FIG. 9. Solenoid Release Button
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 F
IG. 8).
20 313255F
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.
313255F 21
DataTrak Operation
Symbol Code Code Name Diagnosis Cause
Table 1:Diagnostic Codes
Runaway
(DataTrak only)
Pump running faster
than set runaway
limit.
• Increased air pressure.
• Increased fluid output.
• Exhausted fluid supply.
E-1 Diving Up Leak during
upstroke.
E-2 Diving Down Leak during
downstroke.
E-3 Low Battery Battery voltage too
low to stop runaway.
E-4 Service Component
1
Problem with
stopping runaway.
(units with runaway
protection only)
E-4 Disconnected
Solenoid
(units with runaway
protection only)
Solenoid is
disconnected.
Solenoid is not
engaging piston cup
(112).
E-5 Service Component 2Problem with
sensing valve
movement.
Worn piston valve or packings.
Worn intake valve.
Low battery. Replace battery; see
page 23.
• Damaged solenoid.
• Damaged valve carriage.
• Runaway (RT, FIG. 8) protection
may be enabled with pump that
is not equipped with a runaway
solenoid valve. Enter setup
screen and disable runaway protection.
• Solenoid unplugged.
• Damaged solenoid wires.
• Bracket and solenoid not tight
against air valve housing.
• Sensors unplugged.
• Sensors mounted incorrectly.
• Damaged sensors.
• Damaged valve carriage.
E-6 Blown Fuse Fuse is blown.
Replace fuse; see
page 23.
• Faulty solenoid or solenoid wiring.
• Extreme temperatures (above
140°F [60°C]).
• Runaway (RT, F
IG. 8) protection
may be enabled with pump that
is not equipped with a runaway
solenoid valve. Enter setup
screen and disable runaway protection.
22 313255F
Replace DataTrak Battery or Fuse
DataTrak Operation
4. Remove two screws on back of module to access
battery.
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
2. Remove the cable from the two cable clips.
IG. 10.
5. Disconnect the used battery and replace with an
approved battery. See F
IG. 12.
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. 10. Disconnect DataTrak
3. Remove DataTrak module from bracket. See F
11. Take module and attached cable to a non-hazardous location.
ti11884a
FIG. 11. Remove DataTrak
IG.
Battery
ti11994a
FIG. 12. DataTrak Battery and Fuse Location
313255F 23
Parts
Parts
NOTE: Parts vary by model. See Parts Lists on pages 26 to 28.
3a
2
67
66
67
63
62
64
48
76
77
85
84
86
3b
G48xxx
Models
G28xxx
and
G30xxx
Models
77
1
76
60
64
74
73
81
61
82
6
83a
(wall mount
models)
83b
(cart mount
models)
75
76
72
45
69 70 71
ti13018a
24 313255F
Parts
60
53
16
49
60
54
16
65
50
51
ti13111a
Non-Hazardous Location Electrical
Cord Parts (120V Cart Mount Only)
80
79
78 (120V
only)
ti13261a
G40 Gun
Shown
ti13114a
65
10
8
22
68
9
ti13143a
313255F 25
Parts
G28xxx Models
Ref.
No. Part No. Description Qty.
1
W28EAS
W28EBS
2
24A583
24A581
3a 24A576 DATATRAK, assembly, see page 32 and
3b ----- INSERT, panel (included with Part 2) 1
4 256422 HOSE, suction, assembly (includes Part 5)1
5 ----- STRAINER, suction (included with Part 4) 1
6 239300 FILTER, fluid, sst, see manual 307273 1
8 189018 SWIVEL, fluid hose (packages with AA
9
239342
239311
10
XTR501
24C855
11 AAM413 GUN TIP (not shown, packages with G40
12 AAMxxx TIP OPTION (not shown, packages with
16 ----- NUT, lock, M5 x 0.08 (included with Parts
22 239069 HOSE, fluid, whip, 2 ft (0.6 m) 1
32 ----- COVER, gauge, not shown, 12 per sheet
48 238909 GROUND WIRE, pump 1
49 24A372 MOUNTING ARMS KIT, wall mount,
50 ----- WASHER (included with Part 49) 4
51 ----- SCREW, machine, M5 x 25 (included with
53 256427 CART MOUNTING KIT, see page 29
54 24A578 WALL MOUNTING KIT, see page 29
60 24A590 BRACKET, heated, kit, includes 64, 65,
61
245848
245863
62 100022 CAPSCREW, hex hd,
63 100527 WASHER, 1/4 in. 2
64 ----- SCREW, M8 x 25 8
65 ----- NUT 4
PUMP ASSEMBLY
M18LN0 x LW125A
M18LT0 x LW125A
PANEL, air controls
Pump only (see page 31)
Pump and gun, see page 30
manual 313541.
gun)
HOSE BUNDLE
Packages with XTR gun
Packages with G40 gun
GUN
XTR 5
G40
gun)
G40 gun)
2 and 49)
Cart Mount
Wall Mount
(see page 30 for package of 5
sheets)
(includes 16, 50, and 51)
Part 49)
(GxxCxx models only)
(GxxWxx models only)
and 66)
HEATER, fluid
120V, see manual 309524
240V, see manual 309524
1/4-20 x 3/4 in. (19mm)
1
1
1
1
1
1
1
1
2
8
1
2
4
1
1
1
1
2
Ref.
No. Part No. Description Qty.
66 ----- SCREW, M8 x 1.25 4
67 167002 INSULATOR, heat 4
68 239864 MANIFOLD, recirculating, 1/4 npsm 1
69 15V521 UNION, swivel 1
70 113834 BALL VALVE, 3 way, 1/4 npt(m), sst 1
71 239062 HOSE, drain, nylon, sst fittings,
1/4 in. (6 mm) ID; 1/4 npsm(f)
72 166866 ELBOW, 1/4 npt (m x f), sst 2
73 117627 FITTING, coupler 1
74 114190 UNION, swivel 1
75 239153 HOSE, fluid, nylon, sst fittings; 1/2 in (13
mm) ID, 1/2 npt (mbe), 19.5 in. (0.5
m) long
76 239108 HOSE, fluid, recirculation 1
77 166846 ADAPTER, 1/4-18 npsm x 1/4-18 npt 3
78 15W730 CORD, electrical (120V cart mount
packages only)
79 112408 STRAIN RELIEF, 90° (120V cart mount
packages only)
80
107219
185065
81 113934 UNION, swivel, heater inlet, 90°, sst, 1/2
82 502265 BUSHING, reducer, pipe 1
83a 235207 UNION, swivel, sst, 3/8 npt(m) x 3/8
83b 207123 UNION, swivel, 90°, cart mount packages
84 238926 REGULATOR, back pressure, sst, see
----- Not sold separately.
NOTE: Replacement Warning labels, signs, tags, and cards
are available at no cost.
BUSHING
For use with supplied cord (120V
cart mount packages only),
3/4 npt(m) x 1/2 nptf
Supplied with heater for conduit
applications
npt(fbe)
npsm(f), wall mount packages only
only
manual 306860
1
1
1
1
1
1
1
1
1
26 313255F
G30xxx Models
Parts
Ref.
No. Part No. Description Qty.
1
W30CAS
W30CBS
2
24A583
24A581
3a 24A576 DATATRAK, assembly, see page 32 and
3b ----- INSERT, panel (included with Part 2) 1
4 256423 HOSE, suction, assembly (includes Part 5)1
5 ----- STRAINER, suction (included with Part 4) 1
6 239300 FILTER, fluid, sst, see manual 307273 1
8 189018 SWIVEL, fluid hose (packages with AA
9
239342
239311
10
XTR501
24C855
11 AAM413 GUN TIP (not shown, packages with G40
12 AAMxxx TIP OPTION (not shown, packages with
16 ----- NUT, lock, M5 x 0.08 (included with Parts
22 239069 HOSE, fluid, whip, 2 ft (0.6 m) 1
32 ----- COVER, gauge, not shown, 12 per sheet
48 238909 GROUND WIRE, pump 1
49 24A372 MOUNTING ARMS KIT, wall mount
50 ----- WASHER (included with Part 49) 4
51 ----- SCREW, machine, M5 x 25 (included with
53 256427 CART MOUNTING KIT, see page 29
54 24A578 WALL MOUNTING KIT, see page 29
60 24A590 BRACKET, heated, kit, includes 64, 65,
61
245848
245863
62 100022 CAPSCREW, hex hd,
63 100527 WASHER, 1/4 in. 2
64 ----- SCREW, M8 x 25 8
PUMP ASSEMBLY
M12LNO x LW075A
M12LT0 x LW075A
PANEL, air controls (includes 3b, 42, and
43)
Pump only, see page 31
Pump and gun, see page 30
manual 313541
gun)
HOSE BUNDLE
Packages with XTR gun
Packages with G40 gun
GUN
XTR 5
G40
gun)
G40 gun)
2 and 49)
Cart Mount
Wall Mount
(see page 30 for package of 5
sheets)
(includes 16, 50, and 51)
Part 49)
(GxxCxx models only)
(GxxWxx models only)
and 66)
HEATER, fluid
120V, see manual 309524
240V, see manual 309524
1/4-20 x 3/4 in. (19mm)
1
1
1
1
1
1
1
1
2
8
1
2
4
1
1
1
1
2
Ref.
No. Part No. Description Qty.
65 ----- NUT 4
66 ----- SCREW, M8 x 1.25 4
67 167002 INSULATOR, heat 4
68 239864 MANIFOLD, recirculating, 1/4 npsm 1
69 15V522 UNION, swivel 1
70 113834 BALL VALVE, 3 way, 1/4 npt(m), sst 1
71 239062 HOSE, drain, nylon, sst fittings,
1/4 in. (6 mm) ID; 1/4 npsm(f)
72 166866 ELBOW, 1/4 npt (m x f), sst 2
73 117627 FITTING, coupler 1
74 236892 UNION, swivel 1
75 239153 HOSE, fluid, nylon, sst fittings; 1/2 in (13
mm) ID, 1/2 npt (mbe), 19.5 in. (0.5
m) long
76 239108 HOSE, fluid, recirculation 1
77 166846 ADAPTER, 1/4-18 npsm x 1/4-18 npt 3
78 15W730 CORD, electrical (120V cart mount
packages only)
79 112408 STRAIN RELIEF, 90° (120V cart mount
packages only)
80
107219
185065
81 113934 UNION, swivel, heater inlet, 90°, sst, 1/2
82 502265 BUSHING, reducer, pipe 1
83a 235207 UNION, swivel, sst, 3/8 npt(m) x 3/8
83b 207123 UNION, swivel, 90°, cart mount packages
84 238926 REGULATOR, back pressure, sst, see
----- Not sold separately.
NOTE: Replacement Warning labels, signs, tags, and cards
are available at no cost.
BUSHING
For use with supplied cord (120V
cart mount packages only),
3/4 npt(m) x 1/2 nptf
Supplied with heater for conduit
applications
npt(fbe)
npsm(f), wall mount packages only
only
manual 306860
1
1
1
1
1
1
1
1
1
313255F 27
Parts
G48Wxx Models
Ref.
No. Part No. Description Qty.
1
W48CAS
W48CBS
2 24A581 PANEL, air controls, pump and gun
3a 24A576 DATATRAK, assembly, see page 32 and
3b ----- INSERT, panel (included with Part 2) 1
16 ----- NUT, lock, M5 x 0.08 (included with Parts 2
32 ----- COVER, gauge, not shown, 12 per sheet
48 238909 GROUND WIRE, pump 1
49 24A372 MOUNTING ARMS KIT, wall mount
50 ----- WASHER (included with Part 49) 4
51 ----- SCREW, machine, M5 x 25 (included with
54 24A578 WALL MOUNTING KIT, see page 29 1
60 24A590 BRACKET, heated, kit, includes 64, 65,
61 245848 HEATER, fluid, 120V, see manual 309524 1
62 100014 CAPSCREW, hex hd,
PUMP ASSEMBLY
M18LNO x LW075A
M18LT0 x LW075A
(includes 3b, 42, and 43; see page 30)
manual 313541
and 49)
(see page 30 for package of 5 sheets)
(includes 16, 50, and 51)
Part 49)
and 66)
1/4-20 x 1.25 in. (31 mm)
1
1
1
8
1
2
4
1
2
Ref.
No. Part No. Description Qty.
63 100527 WASHER, 1/4 in. 2
64 ----- SCREW, M8 x 25 8
65 ----- NUT 4
66 ----- SCREW, M8 x 1.25 4
67 167002 INSULATOR, heat 4
69 15V522 UNION, swivel 1
70 113834 BALL VALVE, 3 way, 1/4 npt(m), sst 1
71 239062 HOSE, drain, nylon, sst fittings,
1/4 in. (6 mm) ID; 1/4 npsm(f)
72 166866 ELBOW, 1/4 npt (m x f), sst 2
74 236892 UNION, swivel 1
75 24C406 HOSE, fluid, nylon, sst fittings;
1/2 in (13 mm) ID, 1/2-14 nps(m),
3 ft (0.9 m) long
76 239108 HOSE, fluid, recirculation 1
77 112494 ADAPTER, 3/8-18 nps(m) x 1/4-18 npt 1
81 114874 UNION, swivel, heater inlet, 90°, sst,
1/2-14 nps(m) x 1/2-14 npt
82 502265 BUSHING, reducer, pipe 1
84 222200 VALVE, back pressure, sst;
see manual 307892
85 16A619 SPACER 2
86 114593 KNOB 1
----- Not sold separately.
NOTE: Replacement Warning labels, signs, tags, and cards
are available at no cost.
1
1
1
1
28 313255F
Kits
Wall Mount Kit 24A578
ti12633a
102
101
Kits
Ref
No. Description Qty.
101 WALL PLATE, kit, includes screws 1
102 SCREW (included with 101) 4
NOTE: Mounting Arms Kit 24A372 (Part 49, see page
26 or 27) also is required for wall mounting a package
that has a control panel.
Heated Cart Mount Kit 256427
205
208
215
209
210
202
212
207
201
Ref
No. Part No. Description Qty.
201 ----- CART, frame 1
202 ----- HANDLE, cart 1
203 119451 WHEEL, semi-pneumatic 2
204 119452 CAP, hub 2
205 277790 SLEEVE, cart handle 1
206 15C871 CAP, leg 2
207 115480 KNOB, t-handle 2
208 116630 SCREW, carriage 2
209 ----- BRACKET, heater, cart 1
210 111799 SCREW, cap, hex head 4
211 104541 NUT, lock 4
212 115643 SCREW, hex, washer head 8
213 100022 SCREW, cap, hex head 2
214 100527 WASHER, plain 2
215 167002 INSULATOR, heat 4
----- Not sold separately.
203
204
211
313255F 29
214213
206
ti13357a
Kits
Pump and Gun Control Panel Kit
308
307
306
305
304
303
302
304
311 307 313
308
Kit 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 15T937 ELBOW, swivel, 5/32 T x 1/4 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 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 15T555 PANEL 1
318 15U666 LABEL, panel (not shown) 1
319 277794 INSERT 1
320 105332 NUT, lock (not shown) 2
321 15V204 ELBOW, 1/2T x 1/2 npt 1
322 ----- COVER, lens, 12 sticker sheet (not
shown), order Kit 24A540 for 5
sheets
1.3 ft.
4 in.
310
316
303
314
317
309
315
312
301
1
ti13565a
319
ti13467a
321
30 313255F
Pump Only Control Panel Kit
Kits
307 308 304
311
304
305
306
Kit 24A583
Ref. Part Description Qty.
301 114362 VALVE, ball 1
303 ----- TUBE, 1/2 OD, cut to fit,
order Tubing Kit 24D496
304 121212 ELBOW, swivel, 1/2T x 3/8 npt(m) 2
305 15T536 REGULATOR, air, 3/8 npt 1
306 15T937 ELBOW, swivel, 5/32 T x 1/4 npt 1
307 ----- TUBE, black, cut to fit,
order Tubing Kit 24D496
308 15T498 SWIVEL, 90°, 5/32T x 1/8 npt(f) 1
310 15T500 GAUGE, pressure 1
311 113498 VALVE, safety 1
313 15T538 NUT, regulator 1
314 114381 SCREW, cap, button head 2
317 15T557 PANEL 1
318 15U667 LABEL, panel (not shown) 1
319 277794 INSERT (see inset illustration on
page 30)
320 105332 NUT, lock (not shown) 2
321 15V204 ELBOW, 1/2T x 1/2 npt (see inset
illustration on page 30)
322 ----- COVER, lens, 12 sticker sheet (not
shown), order Kit 24A540 for 5
sheets
326 121210 FITTING, straight, 1/2T x 3/8 npt(m) 1
1.5 ft.
5 in.
303
1
1
1
326
301
310
317
313
ti13567a
314
313255F 31
Kits
DataTrak Kits
Kit 24A576 (with Runaway Protection)
401
402
ti13531a
PTFE Suction Hose Kits
For pumping acid materials that are compatible with
PTFE. Includes suction hose, swivel, and strainer.
Kit Description Wall/Cart
24B424 3/4 in. hose, PTFE lined, with
straight swivel
24B425 1 in. hose, PTFE lined, with straight
swivel
Wall
Wall
Ref.
No. Part No. Description Qty.
401 24B563 DATATRAK, assembly (includes
Part 3)
402 24B566 SOLENOID/REED SWITCH, kit 1
403 ----- CLAMP, hose (not shown)
Order kit 24A548 for package of 10
404▲ 15V262 LABEL, warning (not shown) 1
----- Not sold separately.
▲ Replacement Warning labels, signs, tags, and cards
are available at no cost.
1
2
Kit 24C580
Replacement DataTrak fuse.
Kit 24A592 (with Cycle Count Only)
Optional conversion kit available for packages with
MxxLN0 air motors (air valves not compatible with runaway protection solenoid). Provides monitoring and
diagnostics without runaway protection.
32 313255F
Wall Bracket Mounting Dimensions
11 in.
(279 mm)
Wall Bracket Mounting Dimensions
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 working pressure . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7.0 bar)
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Models table on page 5.
Maximum ambient air temperature 120°F (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 gun).
Fluid hoses: nylon
Suction assembly: stainless steel, nylon
Fluid filter: See Manual 307273.
Heater: Stainless steel
Back pressure regulator: See Manual 306860.
Back pressure valve: See Manual 307892.
Drain valve: stainless steel, nylon
313255F 33
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 313255
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2009, Graco Inc. is registered to ISO 9001
www.graco.com
Revised 05/2010
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