Graco Merkur series, Merkur X48, Merkur X72 Instructions-parts List Manual
Instructions-Parts
Repair Kits
Accessory Kits
See page 25
®
Merkur
332245G
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
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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 ................................10
Pressure Relief Procedure ................10
Trigger Lock ...........................10
Flush .................................11
Prime.................................12
InstalltheSprayTip .....................13
Spray.................................14
Shutdown .............................14
Maintenance ..............................15
Preventive Maintenance Schedule ..........15
Tighten Threaded Connections .............15
WetCup ..............................15
Troubleshooting ..........................16
Repair ...................................17
General Information .....................17
Disconnect the Displacement Pump .........17
Reconnect the Displacement Pump .........18
Disconnect the Air Motor ..................19
Reconnect the Air Motor ..................19
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
NXT™Air Motor
XTR™5 and XTR™7 Airless Spray Gun
Pump
ters
2 332245G
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 Recommended Tip Size
Model Tip Size
Merkur X72 0.021
Merkur X48
0.025
Maximum
Fluid Working
Pressure
psi (MPa, bar)
Maximum
Fluid Flow
Rate
gpm (lpm)
332245G 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 oron 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 ignitionsources; 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 332245G
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 alterormodify equipment. Alterations or modifications may voidagencyapprovals 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
332245G 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
F Cart
G Fluid Drain Valve
H Spray Gun
J GunFluid Supply Hose
6 332245G
K Whip Hose
L Pump Fluid Outlet
M Grounding Wire
N Wet-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 Accesso-
ries, 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.
Prepare the Operator
All persons who operate the equipment must be trained
in the operation of all system components aswell 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 bestperformance, 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.
332245G 7
Air Lines Accessories
Install the following accessories in the order shown in
FIG. 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.
Installation
Grounding
The equipment and flush pail must be grounded to
reduce the risk of static sparking. Static sparking can
cause fumes toigniteorexplode.Groundingprovides
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 ofthe ground wire (M)
to a true earth ground.
M
MS
ti12914a
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. Genuine Graco hoses
are conductive.
3. Air compressor: follow manufacturer's recommendations.
Setup
1. Apply warning label that matches your local language.
2. Attach a muffler to each side of the air manifold on
the motor.
3. 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. Useawrench 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
1
4. Spray gun: ground throughconnection 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,
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
4. Attach the siphon hose to the pump inlet. Use a
non-sparking hammer to tighten hose fitting lugs.
G
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1
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
5. See FIG. 1. Attach end of fluid hose (J) to pump outlet (L), or filter, and tighten.
6. Attach other end of fluid hose (J) to reducing nipple
and whip hose (K). Attach whip hose to gun and
tighten.
trigger the gun.
8 332245G
7. Close bleed type master air valve (C). Connect air
supply hose to air inlet.
C
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8. Flush before using. See page 11.
9. Prime before using. See page 12.
Wet Cup
Installation
Before starting, fill wet cup (N) 1/2 full with Graco Throat
Seal Liquid (TSL) Part No. 206994, or compatible solvent.
N
FIG. 4. Wet Cup
332245G 9
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