Graco 332245E User Manual

Instructions-Parts

Repair Kits

Accessory Kits

See page 25

Merkur

332245E

High Pressure Sprayer

For protective coating applications in hazardous or non-hazardous locations. For professional use only.

See page 2 for model information, including maximum working pressures.

Important Safety Instructions

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

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Related Manuals

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Merkur X48 Package . . . . . . . . . . . . . . . . . . . . . 3

Merkur X72 Package . . . . . . . . . . . . . . . . . . . . . 3

Bare Package . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

General Information . . . . . . . . . . . . . . . . . . . . . . 7

Prepare the Operator . . . . . . . . . . . . . . . . . . . . . 7

Prepare the Site . . . . . . . . . . . . . . . . . . . . . . . . . 7

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Air Lines Accessories . . . . . . . . . . . . . . . . . . . . . 7

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pressure Relief Procedure . . . . . . . . . . . . . . . . . 9

Flush the Pump Before First Use . . . . . . . . . . . . 9

Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Install the Spray Tip . . . . . . . . . . . . . . . . . . . . . 12

Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Preventive Maintenance Schedule . . . . . . . . . . 14

Tighten Threaded Connections . . . . . . . . . . . . . 14

Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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

Disconnect the Displacement Pump . . . . . . . . . 16

Reconnect the Displacement Pump . . . . . . . . . 17

Disconnect the Air Motor . . . . . . . . . . . . . . . . . . 18

Reconnect the Air Motor . . . . . . . . . . . . . . . . . . 18

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

System Packages . . . . . . . . . . . . . . . . . . . . . . . 20

Pump System Parts . . . . . . . . . . . . . . . . . . . . . 22

Cart Mount Kit 289694 . . . . . . . . . . . . . . . . . . . 23

Pump Only Control Panel Kits . . . . . . . . . . . . . 24

Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 26

Merkur X48

48:1 Ratio, 75 cc/cycle . . . . . . . . . . . . . . . . 26

Merkur X72

72:1 Ratio, 50 cc/cycle . . . . . . . . . . . . . . . . 27

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 30

Related Manuals

Manual Description

312796

312145

332246 Merkur High Pressure Displacement

407055 Air Control Panel Kit

407053 Merkur X48 Seal Repair Kit

407054 Merkur X72 Seal Repair Kit

307296 High Pressure Surge Tanks and Fluid Fil-

308169 Air Filters and Lubricators

™

Air Motor

NXT

™

5 and XTR™7 Airless Spray Gun

XTR

Pump

ters

2 332245E

Models

Merkur X48 Package

Gun Hoses Accessories

Gun

Fluid

Part

16U920 XTR504 0.019

Gun Tip Size

Merkur X72 Package

Gun Hoses Accessories

Part

16U918 XTR704 0.019

Gun Tip Size

Hose

✔ ✔ ✔ ✔

Gun

Fluid

Hose

✔ ✔ ✔ ✔

Gun Fluid Whip Hose

Suction

Tube

Suction

Tube

Fluid Filter

Drain Valve

Kit

Drain Valve

Kit

Maximum

Inlet Air

Pressure

psi (MPa, bar)

100 4800 (33, 330) 1.2 (4.5)

Maximum

Inlet Air

Pressure

psi (MPa, bar)

100 7200 (50, 500) 0.8 (3)

Maximum

Fluid Working

Pressure

psi (MPa, bar)

Maximum

Fluid Working

Pressure

psi (MPa, bar)

Models

Maximum

Fluid Flow

Rate

gpm (lpm)

Maximum

Fluid Flow

Rate

gpm (lpm)

Bare Package

Bare packages do not include a gun or hose.

Maximum

Inlet Air

Pressure

Part

16V174 Merkur X72 100 7200 (50, 500) 0.8 (3)

16V175 Merkur X48 100 4800 (33, 330) 1.2 (4.5)

Description

psi (MPa, bar)

Maximum

Fluid Working

Pressure

psi (MPa, bar)

Maximum Recommended Tip Size

Model Tip Size

Merkur X72 0.021

Merkur X48

0.025

Maximum

Fluid Flow

Rate

gpm (lpm)

332245E 3

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 or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

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. Do not use pail liners unless they are antistatic or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, 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.

• Engage trigger lock when not dispensing.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

•Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

4 332245E

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.

• 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. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

TOXIC FLUID OR FUMES HAZARD

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

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

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

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

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective 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

332245E 5

Installation

FIG. 1: Typical Installation

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Key:

A Air Shutoff Valve (optional accessory) B Air Filter (optional accessory) C Bleed Type Master Air Valve D Pump Air Pressure Gauge E Pump Air Pressure Regulator FCart G Fluid Drain Valve HSpray Gun J Gun Fluid Supply Hose

6 332245E

K Whip Hose L Pump Fluid Outlet M Grounding Wire NWet-Cup P Pump Fluid Inlet R Suction Hose

Installation

General Information

NOTE: Reference numbers and letters in parentheses

in the text refer to the callouts in the figures.

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.

. 1 is only a guide for selecting and installing system

components and accessories.

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. 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. For best performance, use 1/2 in. air line or larger.

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.

Components

See FIG. 1.

• The red-handled bleed-type master air valve (C) is required in your system to relieve air trapped between it and the air motor 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.

• The pump air regulator (E) controls pump speed and outlet pressure by adjusting the air pressure to the pump.

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

• The 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 (J) provides the gun fluid supply.

• The suction hose (R) with strainer allows the pump to draw fluid from a 5 gallon (19 liter) pail.

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

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

Air Lines Accessories

Install the following accessories in the order shown in F

. 1, using adapters as necessary.

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

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

332245E 7

Installation

Grounding

The equipment and flush pail 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.

1. Pump: See FIG. 2. Verify that the ground screw (MS) is attached and tightened securely to the air motor. Connect the other end of the ground wire (M) to a true earth ground.

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. 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. Genuine Graco hoses are conductive.

Setup

1. If it is necessary to filter the material at the pump fluid outlet, install optional Fluid Outlet Filter Kit 16V583. See Accessories, page 25, for parts.

a. Use a wrench to hold the pump fluid outlet fitting

in place and a second wrench on the drain valve tee fitting. Remove drain valve tee fitting (G).

b. Place fluid filter (401) in a vise. Apply thread

sealant on threads and install fittings as shown.

401

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If necessary, remove barbed fitting (13) from tee fitting (G) and install in fluid filter kit drain valve.

FIG. 3: Optional Fluid Outlet Filter Kit

3. Air compressor: follow manufacturer's recommendations.

4. Spray gun: ground through connection to a properly grounded fluid hose and pump.

5. Fluid supply container: follow your local code.

6. Object being sprayed: follow your local code.

7. Solvent pails used when flushing: follow your local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts the grounding continuity.

8. To maintain grounding continuity when flushing or relieving pressure, hold a metal part of the spray gun firmly to the side of a grounded metal pail, then trigger the gun.

2. See F

. 1. Attach end of fluid hose (J) to pump out-

let (L), or filter, and tighten.

3. Attach other end of fluid hose (J) to reducing nipple and whip hose (K). Attach whip hose to gun and tighten.

4. Close bleed type master air valve (C). Connect air supply hose to air inlet.

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5. Verify that suction hose fittings are tight.

6. Flush before using. See page 10.

7. Prime before using. See page 11.

8 332245E

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

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

. 1. Turn off the bleed-type master air valve

(C).

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

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

TI5049a

Gun Trigger Safety Unlocked

5. Engage the trigger lock.

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

7. If you suspect the spray tip or hose is completely clogged, or that pressure has not been fully relieved after following the previous steps, 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 bucket.

Flush the Pump Before First Use

The pump is tested with lightweight oil, which is left in to protect the pump parts. If the fluid you are using may be contaminated by the oil, flush it out with a compatible solvent. See Flush on page 10.

TI5048a

FIG. 4. Trigger Lock

Wet Cup

Before starting, fill wet cup (N) 1/2 full with Graco Throat Seal Liquid (TSL) Part No. 206994, or compatible solvent.

FIG. 5. Wet Cup

332245E 9

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