Instructions/Parts ® Merkur Non-Heated Spray Packages 312797P EN For high-performance finishing and coating applications in hazardous or non-hazardous locations. For professional use only. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See the charts beginning on page 5 for model information, including maximum air inlet pressures and maximum fluid working pressures. For patent information, see www.graco.
Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Merkur 10:1 Packages (G10Cxx and G10Wxx) . . . . . . . . . . . . . . . . 6 Merkur 15:1 Packages (G15Wxx, G15Cxx, and G15Txx) . . . . . . . . . 7 Merkur 18:1 Packages (G18Wxx and G18Cxx) . . . . . . . . . . . . . . . . 8 Merkur 23:1 Packages (G23Wxx and G23Cxx) . . . . . . .
Related Manuals Related Manuals . DataTrak™ includes agency approvals listed below.
Warnings WARNING PRESSURIZED EQUIPMENT HAZARD Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury. • Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment. • Tighten all fluid connections before operating the equipment. • Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
Models Models Check the identification plate (ID) for the 6-digit part number of your package. Use the following matrix and tables to define the components of your package. For example, package number G30C26 represents a Merkur package (G), with a 30:1 ratio pump (30), cart mounting (C), and the components shown for (26) in the table on page 10.
Models Merkur 10:1 Packages (G10Cxx and G10Wxx) Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 1000 psi (6.
Models Merkur 15:1 Packages (G15Wxx, G15Cxx, and G15Txx) Maximum Inlet Air Pressure 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 1500 psi (10.
Models Merkur 18:1 Packages (G18Wxx and G18Cxx) Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 1800 psi (12.
Models Merkur 24:1 Packages (G24Wxx and G24Cxx) Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 2400 psi (16.
Models Merkur 30:1 Packages (G30Wxx, G30Cxx, and G30Txx) Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 3000 psi (20.
Models Model Wall Mount Cart Mount G30W57 ----- G30W58 ----- Air Controls Hoses Accessories Maximum Pump Gun Gun Fluid Flow Pump and Fluid Air Siphon Fluid Drain Rate Only Gun Hose Hose Kit Filter Hopper Valve DataTrak gpm (lpm) Stand Pump Mount Assembly Gun W30CAS XTR5 ✔ ✔ ✔ W30CBS XTR5 ✔ ✔ ✔ G30W59 G30C55 W30CAS XTR5 ✔ ✔ ✔ ✔ G30W60 G30C56 W30CBS XTR5 ✔ ✔ ✔ ✔ W30CAS XTR5 ✔ ✔** ✔ ✔ ----- G30C57 ✔ G30W71 ----- W30CAS None ✔ ----- G30C63 W30CAS None ✔ --
Models Merkur 36:1 Packages (G36Wxx and G36Cxx) Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 3600 psi (24.
Models Merkur 45:1 Packages (G45Wxx and G45Cxx) Table A: Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 4500 psi (31.
Models Merkur 48:1 Packages (G48Wxx and G48Cxx) Table A: Maximum Inlet Air Pressure: 100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure: 4800 psi (33.
Installation Installation Package configurations vary widely. See pages 6-14 to determine the components included in your model. Items designated as accessories are not included in the packages. A B C D E F G H J K Air Shutoff Valve (optional accessory) Air Filter (optional accessory) Gun Air Pressure Gauge Gun Air Pressure Regulator Bleed Type Master Air Valve DataTrak™ Pump Air Pressure Gauge Pump Air Pressure Regulator Solenoid Release Button (DataTrak equipped packages only, not visible, see FIG.
Installation General Information Wall Mount Packages NOTE: Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawing. 1. Be sure the wall can support the weight of the pump, bracket, hoses and accessories, as well as the stress caused during operation. NOTE: Always use Genuine Graco Parts and Accessories, available from your Graco distributor.
Installation Components Air Line Accessories See FIG. 1. Components vary by package ordered. See tables on pages 6 to 14. Your package may include: 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.
Operation Setup 1. See FIG. 1. Attach end of blue fluid hose (M) to pump outlet (R) or filter (P) outlet. Operation Pressure Relief Procedure 2. Attach one end of the air hose (N) to gun air regulator (D). 3. Attach remaining end of the air hose (N) to air inlet at base of gun (L). 4. Attach gun swivel (K) to gun fluid inlet. 5. Attach other end of blue fluid hose (M) to gun swivel (K). 6. Clip fluid and air hoses together with the supplied hose clips (qty. of 7). Space clips as needed. 1.
Operation Flush the Pump Before First Use Wet Cup 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 the Pump on page 22. Before starting, fill wet cup (T) 1/3 full with Graco Throat Seal Liquid (TSL) or compatible solvent. Trigger Lock See FIG. 3.
Operation 8. Open bleed-type air valve (E). Slowly turn clockwise pump air regulator (H) increasing pressure until pump starts. Adjust the Atomization 9. Cycle pump slowly until all air is pushed out and pump and hoses are fully primed. 10. Units with runaway protection only: disable the prime/flush function by pushing the prime/flush button on the DataTrak. 11. Release gun trigger and lock trigger safety. Pump should stall against pressure. Install the Spray Tip 1. Do not turn on atomizing air supply.
Operation Adjust the Spray Pattern 3. See FIG. 5. For narrower pattern, turn pattern adjustment valve knob (AA) counterclockwise (out). If pattern is still not narrow enough, increase air pressure to gun slightly or use different size tip. Packages with Airless Guns The spray tip orifice and spray angle determine pattern coverage and size. When you need more coverage, use a larger spray tip rather than increasing fluid pressure. Align guard horizontally to spray a horizontal pattern.
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.
Troubleshooting Troubleshooting NOTE: Check all possible problems and causes before disassembling the pump. Relieve the pressure before checking or servicing the equipment. Problem Pump fails to operate. Cause Solution Restricted line or inadequate air sup- Clear line or increase air supply. Check that ply; closed or clogged valves. the valves are open. Obstructed fluid hose or gun; fluid hose ID is too small. Open, clear*; use hose with larger ID. Fluid dried on the displacement rod.
DataTrak Controls and Indicators DataTrak Controls and Indicators Key for FIG. 7 AA Runaway Limit, in cycles per minute (user settable; 00=OFF) AB Lower Displacement (user settable) AC Flow Rate Units (user settable to RK Reset Key (Resets faults. Press and hold for 3 seconds to clear the batch totalizer.) Push to toggle between flow rate and cycle rate. With runaway protection enabled, push to extend and retract the solenoid pin.
DataTrak Operation DataTrak Operation NOTE: The display (AE) will turn off after 1 minute to save battery life. Press any key to wake up the display. NOTICE To prevent damage to the soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails. 2. Runaway Screens 1 and 2: To reset the runaway solenoid, close the master air valve (E). Wait for air to completely bleed off the air motor. Setup Mode 1. See FIG. 7. Press and hold Setup menu appears.
DataTrak Operation Prime/Flush Display 1. See FIG. 7. To enter Prime/Flush mode, press any See FIG. 7. The display (AE) will turn off after 1 minute of inactivity in Run mode or 3 minutes in Setup mode. Press any key to wake up the display. key to wake up the display, then press . The Prime/Flush symbol will appear in the display and the LED will flash . 2. While in Prime/Flush mode, runaway protection is disabled and the batch totalizer (BT) will not count.
DataTrak Operation . Table 1: Diagnostic Codes Symbol 312797P Code Code Name Diagnosis Cause Runaway Pump running faster than set (DataTrak only) runaway limit. • Increased air pressure. • Increased fluid output. • Exhausted fluid supply. E-1 Diving Up Leak during upstroke. Worn piston valve or packings. E-2 Diving Down Leak during downstroke. Worn intake valve. E-3 Low Battery Battery voltage too low to stop runaway. Low battery. Replace battery; see page 28.
DataTrak Operation Replace DataTrak Battery or Fuse 4. Remove two screws on back of module to access battery. The battery and fuse must be replaced in a non-hazardous location. 5. Disconnect the used battery and replace with an approved battery. See FIG. 11. Use only the following approved replacement batteries. Use of an unapproved battery will void Graco’s warranty and FM and Ex approvals.
DataTrak Operation 312797P 29
Parts Parts Cart Mount 3a 3b 2 16 48 1 23 13 6 7 53 41 44 45 4 15 21 20 17 5 30 19 ti12632a 312797P
Parts Wall Mount 3a 3b 23 1 16 2 49 23 6 41 48 54 13 7 4 5 44 ti12920a 45 312797P 31
Parts Stand Mount 3a 23 3b 16 1 48 55 2 23 6 41 4 13 44 7 45 15 21 17 20 19 ti12919a 5 32 312797P
Parts NOTE: • • See page 43 for mounting kits for all packages. See page 44 for repair parts and accessories. Package Parts List Page G10xxx 33 G15xxx 34 G18xxx 35 G23xxx 36 G24xxx 37 G28xxx 38 G30xxx 39 G36xxx 40 G45xxx 41 G48xxx 42 G10xxx Models This list includes all possible parts for G10xxx packages. See page 6 to check whether a part is included in your particular package.
Parts G15xxx Models This list includes all possible parts for G15xxx packages. See page 7 to check whether a part is included in your particular package. Ref.
Parts G18xxx Models This list includes all possible parts for G18xxx packages. See page 8 to check whether a part is included in your particular package. Ref.
Parts G23xxx Models This list includes all possible parts for G23xxx packages. See page 8 to check whether a part is included in your particular package. Ref.
Parts G24xxx Models This list includes all possible parts for G24xxx packages. See page 9 to check whether a part is included in your particular package. Ref.
Parts G28xxx Models This list includes all possible parts for G28xxx packages. See page 9 to check whether a part is included in your particular package. Ref.
Parts G30xxx Models This list includes all possible parts for G30xxx packages. See page 10 to check whether a part is included in your particular package. Ref.
Parts G36xxx Models This list includes all possible parts for G36xxx packages. See page 12 to check whether a part is included in your particular package. Ref.
Parts G45xxx Models This list includes all possible parts for G45xxx packages. See page 13 to check whether a part is included in your particular package. Ref.
Parts G48xxx Models This list includes all possible parts for G48xxx packages. See page 14 to check whether a part is included in your particular package. Ref.
Kits Kits Wall Mount Kit 24A578 Ref. 101 102 101 Description SCREW, cap, M8 x 1.25 PLATE, wall mount Qty. 4 1 NOTE: Air Control Mounting Kit 24E883 (see page 46) also is required for wall mounting a package that has a control panel. 102 ti12633a Cart Mount Kit 289694 Stand Mount Kit 24A577 202 302 304 204 207 209 301 208 201 205 206 303 203 ti12635a ti12634a Ref.
Kits Pump and Gun Control Panel Kits 304 310 311 307 308 313 310 319 308 316 307 303 314 306 317 305 309 315 304 312 303 ti13467a 301 302 ti13565a M12xxx and M18xxx air motors M02xxx and M04xxx air motors Kits 24A581, 24A582, and 24A584 Kit 24A585 Ref. Part 301 114362 302 15T643 303 ----- Ref.
Kits Pump Only Control Panel Kits 307 308 310 304 310 307 313 313 308 306 305 304 306 305 303 326 304 311 301 317 314 311 303 326 325 324 301 ti13567a 317 314 ti13566a M07xxx, M12xxx, and M18xxx air motors M02xxx and M04xxx air motors Kit 24A583 Kit 24A586 Ref. Part Description Qty. 301 114362 VALVE, ball 1 303 ----- TUBE, 1/2 OD, cut to fit, 1.5 ft.
Kits DataTrak 55-Gallon Suction Hose Kits NOTE: See DataTrak manual, 313541, for all DataTrak related part numbers and kit information, including the reed switch and solenoid. Includes suction hose, bung adapter, and strainer. 24A954 - 3/4 in. hose 24B598 - 1 in. hose Hopper Kit 256410 Includes hopper (15), inlet tube (17), o-ring (19), screen (20), and fitting (21, 25cc pumps only).
Kits Guns and Hoses G15 and G40 To find the correct parts for your model, locate the gun you have. The correct hoses and related parts are listed in the table below each gun. 10 8 14 XTR 5 18 22 10 37 9 9 ti11993a ti12636a Ref. Part Description Qty. 9 HOSE, fluid 1 241812 G10xxx-G30xxx; exceptions listed next in this table; 25 ft (7.6 m), 3300 psi (22.7 MPa, 227 bar) maximum working pressure H52525 G30W57-G30W60, G48xxx; 25 ft (7.6 m), 5600 psi (38.
Wall Bracket Mounting Dimensions Wall Bracket Mounting Dimensions 11 in. (279 mm) 4 in. (102 mm) ti12833a Four 0.40 in. (10 mm) mounting holes Technical Data Maximum fluid working pressure. . . . . . . . . . . . . . . .See Models table on page 5. Maximum pump air inlet pressure . . . . . . . . . . . . . . .100 psi (0.7 MPa, 7.0 bar) Maximum gun air inlet pressure . . . . . . . . . . . . . . . .100 psi (0.7 MPa, 7.0 bar) Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Package Weights Package Weights Weight in lb (kg) Ratio, Motor, Displacement Pump Mounted Mounted pump* pump* + + siphon kit or siphon kit or hopper + hopper gun and hoses + + gun and fluid filter hoses Mounted Pump* Mounted pump* + siphon kit Mounted pump + siphon kit + fluid filter 68 (31) 53 (24) 66 (30) 100 (45) 100 (45) 98 (45) 102 (46) 102 (46) 60 (28) 94 (43) 100 (45) 92 (42) 97 (44) 69 (32) 54 (25) 67 (31) 103 (47) 104 (47) 101 (46) --------61 (28) 98 (45) ----96 (43) ----- ---------109 (49
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.
