Graco Merkur series, Merkur X48, Merkur X72 Instructions-parts List Manual

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Page 1

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.

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Page 2

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

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Page 3

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 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

Page 4

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

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Page 5

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

Page 6

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 F Cart G Fluid Drain Valve H Spray Gun J GunFluid Supply Hose

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

Page 7

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.

Page 8

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.

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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

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,

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.

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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.

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Page 9

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

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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.

FIG. 4. Wet Cup

332245G 9

Page 10

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 FIG. 1. Turn off the bleed-type master air valve (C).

3. Disengage the trigger lock.

4. Hold a metal part of the gun firmly to a grounded metal waste container. Trigger the gun to relieve fluid pressure.

Trigger Lock

See FIG. 5. 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. After the fluid is drained, close the valves.

7. If you suspect the spray tip or hose is completely clogged, or that pressurehas 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.

TI5048a

FIG. 5. Trigger Lock

10 332245G

Page 11

Operation

Flush

To avoid fire and explosion, always groundequipment and waste container. To avoid static sparking and injury from splashing, always flush at the lowest possible pressure.

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 11.

Flush the pump:

• Before first use

• When changing colors or fluids

• Before repairing equipment

4. Turn regulator adjustment knob (E) counterclockwise until it stops, and gauge (D) reads zero.

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5. Open bleed type master air valve (C).

6. Flush hose and gun: a. Disengage gun trigger lock. Hold gun against a

grounded metal pail.

• 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 10.

2. See FIG. 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.

TI5048a

b. Trigger gun. Slowly open regulator adjustment

knob (E) until pump begins to cycle and a steady stream comes from gun. Trigger gun for 10-15 seconds.

TI8727a

c. After solvent is running clean, stop pump by

turning the regulator adjustment knob (E) counter-clockwise until it stops and the gauge (D) reads zero. Once thematerial stops flowing, release the trigger and engage the trigger lock. Stop pump with rod buried in the pump.

d. Close bleed type master air valve (C).

332245G 11

Page 12

Operation

7. If flushing through drain/purge valve: a. Place drain tube in a grounded waste pail.

Open drain/purge valve (S) slightly by rotating counterclockwise.

b. Start the pump by rotating the air regulator

adjustment knob (E) clockwise until pump begins to move.

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Prime

1. Follow Pressure Relief Procedure, page 10.

2. See F

3. Place suction tube in the material that will be

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.

sprayed.

wise until it stops, and gauge (D) reads zero.

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c. When clean solvent flows from drain tube close

drain/purge valve (S) by rotating clockwise. Pump will stall.

ti21109a

d. Stop pump with rod buried in pump.

e. Follow Pressure Relief Procedure, page 10.

Leave solvent in and store sprayer.

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5. Open bleed type master air valve (C).

12 332245G

Page 13

Operation

6. Prime through drain valve, if necessary (usually for one component, high viscosity materials):

a. Place drain tube in a grounded waste pail.

Open drain/purge valve (S) slightly by rotating

counterclockwise.

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b. Start the pump by rotating the air regulator

adjustment knob (E) clockwise until pump begins to move.

7. Prime hose and gun: a. Disengage gun trigger lock.

TI5048a

b. Trigger gun slowly open regulator adjustment

knob (E) until pump begins tocycle. Trigger gun into grounded pail until a steady stream comes from gun.

TI8727a

c. Engage trigger lock.

8. Equipmentisnow ready to spray; go to Spray, page

14.

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c. When clean material flows from drain tube close

drain/purge valve (S) by rotating clockwise. Pump will stall.

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NOTICE

Do not prime pump through drain valve using two component materials. Mixed two component materi-

als will harden in valve and result in clogging.

Install the Spray Tip

Follow Pressure Relief Procedure, page 10. 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.

332245G 13

Model Maximum Tip Size

Merkur X72 0.021 Merkur X48

0.025

Page 14

Operation

Spray

NOTICE

Do not allow pump to run dry. It willquicklyaccelerate to a high speed causing damage.

1. Prime. See Prime, page 12.

2. Follow Pressure Relief Procedure, page 10.

3. Install tip and tip guard on gun.

4. Open bleed type master air valve (C).

6. Disengage gun trigger lock.

TI5048a

7. Spray a test pattern. Adjust pressure as necessary. Read fluid manufacturer’s recommendations.

8. Flush when done spraying. See Flush, page 11.

9. Follow Pressure Relief Procedure, page 10.

Shutdown

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5. Turn regulator adjustment knob (E) until gauge (D) reads desired pressure. Turn clockwise to increase pressure, counterclockwise to decrease pressure.

ti21111a

Follow Pressure Relief Procedure, page 10. Always flush the pump before the fluid dries on the dis-

placement rod. See Flush on page 11.

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Page 15

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.

Maintenance

Wet Cup

Fill the wet cup one-half full with Graco Throat Seal Liquid (TSL). Maintain level daily.

332245G 15

Page 16

Troubleshooting

Problem Cause Solution

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;keepthewet-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 fluidoutlet to catch any fluid.Turn on the air just enoughto start the pump. It the pump starts when the air is turned on, the obstruction is in the hose or gun.

16 332245G

Page 17

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 11. Relieve the pressure. See Pressure Relief Proce- dure, page 10.

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

332245G 17

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Page 18

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. Holdthe 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. Screwthedisplacementpumpinto the adapter plate (103) until the cylindertop is flush with thetop 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).

18 332245G

Page 19

Repair

Disconnect the Air Motor

1. Flush the pump, if possible. See Flush, page 11. Relieve the pressure. See Pressure Relief Proce- dure, page 10.

2. Disconnecttheair 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.

332245G 19

Page 20

Parts

System Packages

Apply stainlesssteel pipe sealantto all non-swiveling pipe threads.

15 23

20 332245G

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Page 21

System Packages

Parts

Quantity

System Packages Bare Packages

16U918,

Merkur X72

Ref Part Description

72:1, 50cc

1 ----- SYSTEM, pump, 48:1;

see page 22

----- SYSTEM, pump, 72:1; see page 22

2 16U947 KIT, air control, X72

1 1 1 1

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

connect

7 197682 TUBE, suction 8 187147 STRAINER, inlet

1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1

1 1 1 1

9 H53825 HOSE, coupled; 5600 psi, 0.375

in.(9.5mm)ID,25ft(7.6m)

H73825 HOSE, coupled;7250psi,0.375

in.(9.5mm)ID,25ft(7.6m)

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

tube

17 ----- TUBE, nylon; 1/2 OD x 3/8 ID;

0.65 ft (0.2 m)

18 164856 FITTING, nipple, reducing; 3/8 x

1/4 nptm

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

19 H52506 HOSE, coupled; 5600 psi, 0.25

(6mm)ID,6ft(1.8m)

H72506 HOSE, coupled; 7250 psi, 0.25

(6mm)ID,6ft(1.8m)

22 206994 FLUID, TSL 8 oz bottle 23 ----- LABEL, identification

1 1 1 1 1

1 1 1 1

24 ----- COVER, lens, 12 sticker sheet;

(not shown), order Kit 24A540

1 1 1 1

for 5 sheets

* Parts included in Drain Valve Kit 16U950 (purchase separately).

16U920,

Merkur X48

48:1, 75cc

16V174,

Merkur X72

72:1, 50cc

1 1

16V175,

Merkur X48

48:1, 75cc

332245G 21

Page 22

Parts

Pump System Parts

101

Torque to 50-55 ft-lb (68-75 N•m).

Torque to 50-60 ft-lb (68-81 N•m).

Torque to 75-80 ft-lb (102-108 N•m).

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

107

106

109

110

103

105

102

22 332245G

ti21119a

Page 23

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

332245G 23

Page 24

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, 5/32Tx1/4npt 1 307 ----- TUBE, black, cut to fit,

5in.

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

1 shown), order Kit 24A540 for 5 sheets

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

24 332245G

Page 25

Repair Kits

Description 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

Repair Kits

Sprayer Models

Merkur X48 Merkur X72

16U950 16U950

16U925 16U924

248837 248837

Ref. Part Description Qty

401 155665 UNION, adapter 1 402 16W395 BUSHING, PIPE, 3/4-14(m) x

402

404

401

Apply thread sealant to all pipe threads.

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.

403

403 237069 FILTER, paint, 7252 psi (50 MPa, 404 159239 NIPPLE, pipe, reducing, 1/2 x 3/8

3/8-18(f) npt

500 bar)

npt

Sprayer Models

Merkur X48 Merkur X72

106149 106149

H53850

H73850

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.

332245G 25

H52506

H72506

Page 26

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)

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 m3/min) at a specific fluid flow (gpm/lpm) and air pres-

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

0.8

(3.0)

50 60

1.0

(3.8)

1.2

(4.5)

(1.7)

(1.4)

(1.1)

(0.9)

(0.6)

(0.3)

/min)

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 332245G

Page 27

Merkur X72 72:1 Ratio, 50 cc/cycle

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)

0.2

(0.75)

Cycles per Minute

30 45

0.4

(1.5)

0.6

(2.3)

0.8

(3.0)

Performance Charts

120

(3.4)

100

(2.8)

(2.3)

(1.7)

(1.1)

(0.6)

/min)

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

332245G 27

Page 28

Dimensions

38.6 in.

(980 mm)

18 in.

(457 mm)

20.5 in.

(521 mm)

28 332245G

Page 29

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

332245G 29

Page 30

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 returnofthe equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified,Gracowill 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 damagesfor 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 beliablefor indirect, incidental, special or consequential damages resulting from Graco supplying equipmenthereunder,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 Partiesacknowledge that they have requiredthat the present document,as well as alldocuments, notices and legalproceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les partiesreconnaissentavoirconvenu que la rédaction duprésente document sera enAnglais, ainsi que tousdocuments, avis et procéduresjudiciaires exécutés, donnés ouintentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com. For patent information, see www.graco.com/patents.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

2ULJLQDOLQVWUXFWLRQV This manual contains English. MM 332245

International Offices: Belgium, China, Japan, Korea

Graco Headquarters: Minneapolis

www.graco.com

Revision G, June 2018