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.
EN
ti21103a
ll 2 G c T3
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
Gun
Fluid
Whip
Hose
Suction
Tube
Suction
Tube
Fluid
Filter
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
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
Installation
A
F
B
C
D
E
H
FIG. 1: Typical Installation
M
N
L
G
P
J
K
R
ti21104a
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.
F
IG
. 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
IG
. 1, using adapters as necessary.
• An air-line filter (B) removes harmful dirt and moisture from the compressed air supply.
• A second bleed-type air shutoff valve (A) isolates
the air line accessories for servicing. Locate
upstream from all other air line accessories.
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.
M
MS
ti12914a
F
IG
. 2. Ground screw and wire
2. Pump fluid hoses: use only electrically conductive
fluid hoses. Check electrical resistance of hoses. If
total resistance to ground exceeds 25 megohms,
replace hose immediately. 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
G
1
ti21356a
1
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
1
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
IG
. 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.
C
ti21105a
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
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
IG
. 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.
N
FIG. 5. Wet Cup
332245E 9
Operation
Flush
Flush the pump:
• Before first use
• When changing colors or fluids
• Before repairing equipment
• Before fluid dries or settles out in a dormant pump
(check the pot life of catalyzed fluids)
• At the end of the day
• Before storing the pump.
Flush at the lowest pressure possible. Flush with a fluid
that is compatible with the fluid you are pumping and
with the wetted parts in your system. Check with your
fluid manufacturer or supplier for recommended flushing
fluids and flushing frequency.
1. Follow Pressure Relief Procedure, page 9.
4. Turn regulator adjustment knob (E) counterclockwise until it stops, and gauge (D) reads zero.
D
C
ti21106a
5. Open bleed type master air valve (C).
6. Flush hose and gun:
a. Disengage gun trigger lock.
TI5048a
E
2. See F
IG
. 1. Lock gun trigger. Remove tip guard and
spray tip from gun (H). Refer to gun manual.
3. Place suction tube in a compatible solvent.
NOTE: Do not stretch hose tight; let it hang to assist
fluid flow into pump.
b. Trigger gun slowly open regulator adjustment
knob (E) until pump begins to cycle. Trigger gun
into grounded pail until a steady stream comes
from gun. Trigger gun for 10-15 seconds.
TI8727a
c. Engage trigger lock.
10 332245E
Operation
7. Place drain tube in a grounded waste pail.
Open drain/purge valve (S) slightly by rotating counterclockwise.
S
ti21107a
8. Start the pump by rotating the air regulator adjustment knob (E) clockwise until pump begins to move.
Prime
1. Follow Pressure Relief Procedure, page 9.
2. See F
3. Place suction tube in a compatible fluid.
NOTE: Do not stretch hose tight; let it hang to assist
fluid flow into pump.
4. Turn regulator adjustment knob (E) counterclock-
IG
. 1. Lock gun trigger. Remove tip guard and
spray tip from gun (H). Refer to gun manual.
wise until it stops, and gauge (D) reads zero.
E
ti21108a
9. When clean solvent flows from drain tube close
drain/purge valve (S) by rotating clockwise. Pump
will stall.
S
ti21109a
10. Follow Pressure Relief Procedure, page 9. Leave
solvent in and store sprayer.
C
5. Open bleed type master air valve (C).
D
E
ti21106a
332245E 11
Operation
6. Prime through drain valve:
7. Place drain tube in a grounded waste pail.
Open drain/purge valve (S) slightly by rotating counterclockwise.
S
ti21107a
8. Start the pump by rotating the air regulator adjustment knob (E) clockwise until pump begins to move.
b. Trigger gun slowly open regulator adjustment
knob (E) until pump begins to cycle. Trigger gun
into grounded pail until a steady stream comes
from gun.
TI8727a
c. Engage trigger lock.
11. Equipment is now ready to spray; go to Spray, page
13.
NOTICE
Do not prime pump through drain valve using two
component materials. Mixed two component materials will harden in valve and result in clogging.
E
ti21108a
9. When clean material flows from drain tube close
drain/purge valve (S) by rotating clockwise. Pump
will stall.
S
ti21109a
10. Prime hose and gun:
a. Disengage gun trigger lock.
Install the Spray Tip
Follow Pressure Relief Procedure, page 9. 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.
Maximum Tip Size
Larger tips can be used with less viscous material.
Model Maximum Tip Size
Merkur X72 0.021
Merkur X48
0.025
TI5048a
12 332245E
Operation
Spray
NOTICE
Do not allow pump to run dry. It will quickly accelerate
to a high speed causing damage.
1. Prime. See Prime, page 11.
2. Follow Pressure Relief Procedure, page 9.
3. Install tip and tip guard on gun.
4. Open bleed type master air valve (C).
C
6. Disengage gun trigger lock.
TI5048a
7. Spray a test pattern. Read fluid manufacturer’s recommendations.
8. Flush when done spraying. See Flush, page 10.
9. Follow Pressure Relief Procedure, page 9.
Shutdown
ti21110a
5. Turn regulator adjustment knob (E) until gauge (D)
reads desired pressure. Turn clockwise to increase
pressure, counterclockwise to decrease pressure.
D
E
ti21111a
Follow Pressure Relief Procedure, page 9.
Always flush the pump before the fluid dries on the displacement rod. See Flush on page 10.
332245E 13
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.
Wet Cup
Fill the wet cup one-half full with Graco Throat Seal Liquid (TSL). Maintain level daily.
14 332245E
Troubleshooting
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.
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 dis-
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
1/2 filled with Graco throat seal liquid
(TSL).
Clean or repair air motor. See air
motor manual.
Clear line or increase air supply.
Check that the valves are open.
Open, clear*; use hose with larger ID.
Replace packings. See displacement pump manual.
Clear valve; replace packings. See
displacement pump manual.
Clear valve, replace packings; see
displacement pump manual.
placement 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.
332245E 15
Repair
Repair
5. Lower the coupling nut (106) enough to remove the
coupling collars (107), and then remove the coupling nut (106).
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.
Disconnect the Displacement Pump
1. Stop the pump in the middle of the stroke.
2. Flush the pump, if possible. See Flush, page 10.
Relieve the pressure. See Pressure Relief Proce-
dure, page 9.
3. Disconnect the air and fluid hoses and the ground
wire (109).
4. Move the spring guard
(118) upwards or
downwards. Hold the
flats of the air motor
piston rod with a
wrench. Use another
wrench to loosen the
coupling nut (106).
107
106
ti21113a
6. Use a hammer and
brass rod to loosen the
jam nut (105). Unscrew
the jam nut as far as
possible.
7. Unscrew the displacement pump by hand
and place on work
bench.
Threads are very sharp. To avoid cuts, use a rag to
protect hands when hand turning or carrying the displacement pump.
ti21114a
ti21115a
ti21112a
16 332245E
Repair
Reconnect the Displacement Pump
1. Tilt the air motor onto its back, then hand turn the
displacement pump into the adapter plate. Set the
pump upright again.
2. Hold the air motor piston rod up with one hand. With
your other hand, put the coupling nut (106) on the
displacement rod.
3. Put the coupling
collars (107) into
the coupling nut
(106) so large
flanges point
upward.
4. Place spring
(118) over coupling nut (106).
Hold spring down
to connect the air
motor rod and coupling nut (106).
5. Gently let the air motor piston rod drop onto the displacement rod. Hand tighten the coupling nut (106).
107
106
ti12817a
6. Screw the displacement pump into the adapter plate
(103) until the cylinder top is flush with the top of the
adapter plate.
Cylinder, not
wet cup, should
be flush with
plate.
103
FIG. 6. Align cylinder and adapter plate.
7. Align fluid outlet as shown and tighten the jam nut.
8. Hold the flats of the motor rod with a wrench. Use
another wrench to tighten the coupling nut (106).
Torque to 75-80 ft-lb (102-108 N•m).
332245E 17
Repair
Disconnect the Air Motor
1. Flush the pump, if possible. See Flush, page 10.
Relieve the pressure. See Pressure Relief Proce-
dure, page 9.
2. Disconnect the air hose, fluid hoses, and the ground
wire (109).
3. Hold the flats of the air motor piston rod with a
wrench. Use another wrench to loosen the coupling
nut (106).
4. Use a 23 mm socket to remove the tie rod nuts
(105).
5. Use a 13 mm socket to remove the top two mounting screws (209).
6. Lift up on the air motor to remove it. The tie rods
(104) and will remain attached.
NOTE: Remove the two screws on the arms and tip
back or remove the air control panel for easier removal
of the air motor.
Reconnect the Air Motor
1. Screw the tie rods (104) into the bottom cover of the
air motor. Torque to 50-55 ft-lb (68-75 N•m).
2. Align the tie rods (104) with the holes in the pump
adapter (103). Carefully lower the air motor into
place.
3. Attach the tie rod nuts (105) and torque to 50-60
ft-lb (68-81 N•m).
4. Tighten the mounting screws (209).
5. Hand tighten the coupling nut (106), then torque to
75-80 ft-lb (102-108 N•m).
6. Connect the air hose, fluid hose, and the ground
wire.
209
104
103
105
ti12819a
7. Use a socket on the flats of the tie rods (104) to
remove them from the bottom cover of the air motor.
NOTE: See air motor manual for service and parts information.
18 332245E
Repair
332245E 19
Parts
Parts
System Packages
10
19
18
2
1
12
13
9
11
14
3
1
Apply stainless steel pipe sealant to
all non-swiveling pipe threads.
15
23
17
16
4
5
6
7
8
20 332245E
ti21118a
System Packages
Parts
Quantity
System Packages Bare Packages
16U918,
Merkur X72
Ref Part Description
1 ----- SYSTEM, pump, 48:1;
see page 22
-----
2 16U947 KIT, air control, X72
16U948 KIT, air control, X48
3 277794 INSERT, control panel
4 116401 ADAPTER, elbow
5 116402 ADAPTER, quick connect
6 247301 HOSE, suction, 1 in. npt x quick
7 197682 TUBE, suction
8 187147 STRAINER, inlet
9 H53825 HOSE, coupled; 5600 psi, 0.375
H73825 HOSE, coupled; 7250 psi, 0.375
10 XTR504 GUN, XTR5 with RAC tip
XTR704 GUN, XTR7 with RAC tip
11* 15R874 FITTING, tee; 3/8 mxfxf
12* 245143 VALVE, pressure, bleed
13* 116746 FITTING, barbed, plated
14* 116750 TUBE, nylon
15 105332 NUT, lock
16 15V204 FITTING, elbow, 1/2 npt x 1/2
17 ----- TUBE, nylon; 1/2 OD x 3/8 ID;
18 164856 FITTING, nipple, reducing; 3/8 x
19 H52506 HOSE, coupled; 5600 psi, 0.25
H72506 HOSE, coupled; 7250 psi, 0.25
22 206994 FLUID, TSL 8 oz bottle
23 ----- LABEL, identification
24 ----- COVER, lens, 12 sticker sheet;
* Parts included in Drain Valve Kit 16U950 (purchase separately).
SYSTEM, pump, 72:1;
see page 22
connect
in. (9.5 mm) ID, 25 ft (7.6 m)
in. (9.5 mm) ID, 25 ft (7.6 m)
tube
0.65 ft (0.2 m)
1/4 nptm
(6 mm) ID, 6 ft (1.8 m)
(6 mm) ID, 6 ft (1.8 m)
(not shown), order Kit 24A540
for 5 sheets
72:1, 50cc
1 1
1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1
1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
2 2 2 2
1 1 1 1
1 1 1 1
1 1
1
1 1 1 1
1 1 1 1
1 1 1 1
16U920,
Merkur X48
48:1, 75cc
1 1
1 1
1
1
1
16V174,
Merkur X72
72:1, 50cc
16V175,
Merkur X48
48:1, 75cc
332245E 21
Parts
Pump System Parts
101
1
Torque to 50-55 ft-lb (68-75 N•m).
2
Torque to 50-60 ft-lb (68-81 N•m).
3
Torque to 75-80 ft-lb (102-108 N•m).
4
Assemble pump (102) to top of within +/one thread. Torque jam nut of pump to
70-75 ft-lb (95-102 N•m).
108
104
1
107
3
106
109
110
103
105
2
4
ti21119a
102
22 332245E
Parts
16V175, Merkur X48 Pump System
16V174, Merkur X72 Pump System
Ref. Part Description Qty.
101 M18LN0 MOTOR, air, 7.5 in 1
102 16U916 LOWER, assy, 50cc; 16V174 1
16U917 LOWER, assy, 75cc; 16V175 1
103 15T392 ADAPTER, pump lower 1
104 15M662 ROD, tie 3
105 15U606 NUT, lock, m16 x 2 3
106 15T311 NUT, coupler 1
107 184128 COLLAR, coupling 2
108 111799 SCREW, cap, hex hd 4
109 238909 WIRE, grounding assembly 1
110 289694 KIT, cart 1
118 16U944 GUARD, spring 1
Cart Mount Kit 289694
204
208
202
207
209
201
205
206
203
ti12634a
Qty
Ref. Part Description
201 ----- CART, frame 1
202 ----- HANDLE, cart 1
203 15C871 CAP, leg 2
204 ----- SLEEVE, cart handle 2
205 119451 WHEEL, semi-pneumatic 2
206 119452 CAP, hub 2
207 115480 KNOB, t-handle 2
208 116630 SCREW, carriage 2
209 111799 SCREW, cap, M8 x 1.25 4
.
332245E 23
Parts
Pump Only Control Panel Kits
307 308 304
311
304
305
306
327
303
326
16U948, X48 Air Control Kit
16U947, X72 Air Control Kit
301
310
317
313
314
ti13567a
ti13567b
319
303
ti13468a
321
Ref. Part Description Qty.
301 114362 VALVE, ball 1
303 ----- TUBE, 1/2 OD, cut to fit,
1.5 ft.
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 ----- ELBOW, swivel, 5/32 T x 1/4 npt 1
307 ----- TUBE, black, cut to fit,
5 in.
order Tubing Kit 24D496
308 ----- 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 ----- 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
shown), order Kit 24A540 for 5
sheets
326 ----- FITTING, straight, 1/2T x 3/8 npt(m) 1
327 24P814 RING, grounding 1
1
24 332245E
Repair Kits
Description
Repair Kits
Sprayer Models
Merkur X48 Merkur X72
Drain Valve Kit
Includes tee fitting (11), bleed valve (12), barbed
fitting (13), and nylon tube (14).
Displacement Pump Rebuild Kit
See manual displacement pump manual.
XTR Gun Repair Kit
See gun manual.
Accessories
Fluid Outlet Filter, 16V583
402
404
401
1
Apply thread sealant to all pipe threads.
403
16U950 16U950
16U925 16U924
248837 248837
Ref. Part Description Qty
401 155665 UNION, adapter 1
402 16W395 BUSHING, PIPE, 3/4-14(m) x
403 237069 FILTER, paint, 7252 psi (50 MPa,
404 159239 NIPPLE, pipe, reducing, 1/2 x 3/8
1
3/8-18(f) npt
1
500 bar)
1
npt
Sprayer Models
Description
Air Filter Kit
1/2 npt(fbe) inlet and outlet, 20 micron filter. See air filter manual.
50 ft. Fluid Hose (5200 psi rated)
Optional 50-foot hose, 3/8 in. ID, 5600 psi (38.6 MPa, 386 bar) maximum
working pressure.
50 ft. Fluid Hose (7200 psi rated)
Optional 50-foot hose, 3/8 in. ID, 7250psi (50 MPa, 500 bar) maximum
working pressure.
Whip Hose
Replacement 6 ft (1.8 m) hose, 1/4 in. ID, 5600 psi (38.6 MPa, 386 bar)
maximum working pressure.
Whip Hose
Replacement 6 ft (1.8 m) hose, 1/4 in. ID, 7250psi (50 MPa, 500 bar)
maximum working pressure.
332245E 25
Merkur X48 Merkur X72
106149 106149
H53850
H73850
H52506
H72506
Performance Charts
Performance Charts
Calculate Fluid Outlet Pressure
To calculate fluid outlet pressure (psi/MPa/bar) at a specific fluid flow (gpm/lpm) and operating air pressure
(psi/MPa/bar), use the following instructions and pump
data charts.
1. Locate desired flow along bottom of chart.
2. Follow vertical line up to intersection with selected
fluid outlet pressure curve. Follow left to scale to
read fluid outlet pressure.
Merkur X48 48:1 Ratio, 75 cc/cycle
Cycles per Minute
6000
(42, 420)
5000
(35, 350)
4000
(28, 280)
3000
(21, 210)
2000
(14, 140)
1000
(7, 70)
Fluid Outlet Pressure psi (MPa, bar)
10
A
B
C
0
0
0.2
(0.75)
20 30
0.4
(1.5)
(2.3)
0.6
Calculate Pump Air Flow/Consumption
To calculate pump air flow/consumption (scfm or
3
/min) at a specific fluid flow (gpm/lpm) and air pres-
m
sure (psi/MPa/bar), use the following instructions and
pump data charts.
1. Locate desired flow along bottom of chart.
2. Follow vertical line up to intersection with selected
air flow/consumption curve. Follow right to scale to
read air flow/consumption
40
0.8
(3.0)
50 60
B
C
1.0
(3.8)
A
1.2
(4.5)
60
(1.7)
50
(1.4)
40
(1.1)
30
(0.9)
20
(0.6)
10
(0.3)
/min)
3
Air Flow scfm (m
Fluid Flow gpm (lpm) tested in No. 10 weight oil
Key:
A 100 psi (0.69 MPa, 6.9 bar)
B 70 psi (0.48 MPa, 4.8 bar)
C 40 psi (0.28 MPa, 2.8 bar)
Fluid Flow
Air Flow
26 332245E
Merkur X72 72:1 Ratio, 50 cc/cycle
15
7000
(48, 483)
6000
(42, 420)
5000
(35, 350)
4000
(28, 280)
3000
(21, 210)
2000
(14, 140)
1000
(7, 70)
Fluid Outlet Pressure psi (MPa, bar)
0
A
B
C
0
0.2
(0.75)
Cycles per Minute
30 45
C
0.4
(1.5)
0.6
(2.3)
B
A
61
0.8
(3.0)
Performance Charts
120
(3.4)
100
(2.8)
80
(2.3)
60
(1.7)
40
(1.1)
20
(0.6)
/min)
3
Air Flow scfm (m
Fluid Flow gpm (lpm) tested in No. 10 weight oil
Key:
A 100 psi (0.69 MPa, 6.9 bar)
B 70 psi (0.48 MPa, 4.8 bar)
C 40 psi (0.28 MPa, 2.8 bar)
Fluid Flow
Air Flow
332245E 27
Dimensions
Dimensions
38.6 in.
(980 mm)
18 in.
(457 mm)
20.5 in.
(521 mm)
28 332245E
Technical Data
Merkur High Pressure Sprayers
US Metric
Maximum pump air inlet pressure 100 psi 0.7 MPa, 7 bar
Ambient air temperature range 35°–120°F 2°–49°C
Maximum fluid temperature 160°F 71°C
Sound data See Merkur Air Motor Technical Data
Weight 99 lb 45 kg
Maximum fluid working pressure
16U920, 16V175 4800 psi 33 MPa, 330 bar
16U918, 16V174 7200 psi 50 MPa, 500 bar
Ratio
16U920, 16V175
16U918, 16V174
Wetted Parts
Displacement pump
Spray gun
Fluid hoses nylon
Suction assembly carbon steel, aluminum, nylon
48:1
72:1
Stainless steel, plated carbon steel, tungsten carbide with
6% nickel, UHMWPE, PTFE
See manual XTR guns technical data
Technical Data
332245E 29
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 reconnaissen
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.
t avoir convenu que la
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 INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2013, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Graco reserves the right to make changes at any time without notice.
For patent information,
Original instructions.
This manual contains English. MM 332245
see www.graco.com/patents.
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
www.graco.com
Revision E, September 2014
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