Graco 3A0732J User's Manual
Contents
1. Maximum Fluid Working Pressure Package Series Ratio psi MPa bar Package Type Gun Mounting Material 24F150 A 15 1 1500 10 3 103 Air assisted G15 Carbide Wall Plated Steel 24F151 A 15 1 1500 10 3 103 Air assisted G15 Carbide Stand Plated Steel 24F152 A 30 1 3000 20 7 207 Air assisted G40 Wall Stainless Steel 24F153 A 30 1 3000 20 7 207 Air assisted G40 Stand Stainless Steel 24F154 A 30 1 3000 20 7 207 Airless Silver Plus Wall Plated Steel 24F155 A 30 1 3000 20 7 207 Airless Silver Plus Stand Plated Steel 24F156 A 30 1 3000 20 7 207 Air assisted G40 Wall Plated Steel 24F157 A 30 1 3000 20 7 207 Air assisted G40 Stand Plated Steel 24F158 A 15 1 1500 10 3 103 Air assisted G15 Carbide Wall Stainless Steel 24F159 A 15 1 1500 10 3 103 Air assisted G15 Carbide Stand Stainless Steel 24N548 A 30 1 3000 20 7 207 WB3000 wee Stainless Steel 24W281 A 15 1 1500 10 3 103 Air assisted G15 Carbide Stand Plated Steel 24W283 A 15 1 1500 10 3 103 Air assisted G15 Carbide Stand Stainless Steel 24W285 A 30 1 3000 20 7 207 Air assisted G40 Stand Plated Steel 24W287 A 30 1 3000 20 7 207 Air assisted G40 Stand Stainless Steel Part No 24N548 is used as a supply pump in the WB3000 Waterborne Isolation System It includes a pump bracket and items 7 19 21 23 and 28 42 on page 25 See manual 3A2497 for warnings and instructions for a waterborne system2. Stainless steel nylon acetal fluoroelastomer polyethylene Sound power at 70 psi 0 48 MPa 4 8 bar 80 cpm Sound power measured per ISO 9614 2 Sound pressure was tested 3 28 feet 1 m from equipment 3A0732J 41 Performance Charts Performance Charts 15 1 Ratio Pumps 42 Fluid Outlet Pressure psi MPa bar 1400 10 100 1200 8 80 1000 7 70 800 b 5 55 600 4 40 400 3 30 200 1 4 14 KEY A 100 psi 0 7 MPa 7 bar B 70 psi 0 5 MPa 5 bar C 40 psi 0 3 MPa 3 bar fluid flow m air flow Cycles per Minute 60 90 120 150 0 10 015 0 20 0 25 0 4 0 6 0 75 0 9 Fluid Flow gpm Ipm tested in No 10 weight oil Air Flow scfm m3 min 3A0732J Performance Charts 30 1 Ratio Pumps KEY A z100 psi 0 7 MPa 7 bar B 70 psi 0 5 MPa 5 bar C 40 psi 0 3 MPa 3 bar fluid flow m air flow Cycles per Minute 30 60 90 120 150 180 210 240 3000 18 0 21 210 0 5 S 2500 15 S 17 5 175 0 42 2000 120 amp 14 140 0 34 E o S 1500 9 0 E 10 5 105 0 25 8 1000 6 0 2 7 70 0 17 E n fe 500 3 0 S 35 35 0 08 ir 0 05 0 10 045 020 025 030 035 040 0 2 0 4 0 6 0 75 0 9 1 1 1 3 1 5 Fluid Flow gpm Ipm tested in No 10 weight oil 3A0732J 43
3. Stop the pump Follow Pressure Relief Procedure page 10 Disconnect the air line to the motor See FIG 12 Push the safety spring 9 down and hold to access the pilot valve on the bottom cover See FIG 14 on page 23 Use a 10 mm wrench to remove the old pilot valves 213 from the top and bottom covers Lubricate and install the new pilot valves 213 Torque to 95 105 in Ib 11 12 Nem 3A0732J Disconnect the Air Motor ui vi 1 Stop the pump 2 Flush the pump if possible see page 13 Follow Pressure Relief Procedure page 10 3 Disconnect the air hose fluid hose and suction hose 4 See FIG 12 Push the safety spring 9 down and hold to access the coupling pin 18 Push the retaining spring 19 up and push out the pin using a screwdriver or punch 5 Remove the nuts 11 from the bottom of the tie rods 8 6 Remove the pump lower 12 The adapter plate 10 will remain attached to the lower 7 Remove the safety spring 9 8 Loosen the nuts 17 at the top of the tie rods then remove the tie rods The mounting bracket 1 is loosened from the motor as the tie rods are removed 9 Take the motor to a work bench See Repair Air Motor on page 22 3A0732J Repair TI16261A Fic 12 Disconnect the Air Motor Reconnect the Air Motor 1 Replace the motor on the mounting bracket 1 2 Screw the tie rods into the motor with the top hex nuts
4. On 3 5 in motors only remove the plug 231 and o ring 230 6 Remove the shield 206 and cylinder 205 7 Remove the o ring 204 from the piston 8 Secure the piston 219 in a vise with soft jaws Use a wrench on the flats of the rod 218 to remove the rod and bottom cover assembly 201 from the pis ton 9 Remove the rod from the bottom cover assembly 10 Remove retaining ring 217 u cup seals 207 and o ring 202 from the bottom cover 22 Reassemble the Air Motor NOTE For easier reassembly start with the top cover 210 turned over on the workbench and assemble the air motor upside down 1 Lubricate and install the o ring 202 on the top cover 210 2 Lubricate the inside of the cylinder 205 Lower the cylinder onto the top cover 210 3 Install the shield 206 around the cylinder 205 and in the groove on the top cover 210 4 See FIG 13 Lubricate and install new u cup seal 207 in the bottom of the bearing in the bottom cover 201 The lips must face down Lubricate and install new u cup seal 207 in the top of the bear ing Lips must face up Install retaining ring 217 207 ee Lips face up 207 2 Lips face down FIG 13 Air Motor U cup Installation ti16285a 3A0732J Repair A Apply lubricant co o e e F Fic 14 Air Motor Assembly 23 3A0732J Repair Lubricate and install the o ring 202 on the bottom cover
5. 3A0732J Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion 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 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 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 DE d ttt e 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 fthere is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area SPECIAL CONDITIONS FOR SAFE USE Static charge may build up on plastic
6. 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 f
7. 17 attached Torque the tie rods to 5 10 ft Ib 7 13 Nem NOTE Always tighten the tie rods before tightening the top hex nuts 17 3 Tighten the top hex nuts 17 to secure the mount ing bracket 1 4 Slide the pump with the adapter plate 10 attached onto the tie rods 8 Ensure that the safety spring 9 is in place and the pump outlet is oriented as desired 5 Install the tie rod nuts 11 Torque to 100 in Ib 11 Nem 6 Align the hole in the displacement rod with the hole in the air motor rod Use a screwdriver to push in the pin 18 7 Pushthe retaining spring 19 into place to cover the pin 21 Repair Repair Air Motor A A 2 NOTE Complete Air Motor Replacement Kits are avail able Order 24G693 2 5 in motor or 24G694 3 5 in motor NOTE Air Motor Seal Kits are available See page 33 for the correct kit for your motor Parts included in the kit are marked with an asterisk For best results use all the parts in the kit Disassemble the Air Motor 1 See FIG 14 Use a 10 mm socket wrench to remove four screws 211 Remove the air valve 214 and gasket 209 1 2 Remove four screws 211 and remove the manifold 220 and two gaskets 208 3 Usea 10 mm socket wrench to remove the pilot valves 213 from the top and bottom cover 4 Usea 13 mm socket wrench to remove the tie bolts 212 5 Remove the top cover 210 Remove the o ring 202
8. 201 Carefully push the threaded end of the rod 218 up through the bottom cover 201 Apply 16G561 adhesive to the threads of the rod 218 Screw the piston 219 onto the rod Place the piston in a vise with soft jaws and torque to 35 40 ft lb 47 54 Nem Lubricate and install the o ring 204 on the piston 219 See Fic 15 Carefully place the bottom cover piston assembly on the cylinder 205 sliding the piston 219 into the cylinder The manifold surfaces of the top and bottom covers must align Be sure the shield 206 is in the groove on both the top and bot tom covers 201 groove 210 L J ti16281a Fic 15 Align Shield in Grooves on Covers 24 10 11 Install the tie bolts 212 hand tight Install two gaskets 208 on the manifold 220 Install the manifold 220 Torque screws 211 to 95 105 in Ib 10 7 11 9 Nem NOTE The manifold is reversible for ease of placement of muffler or remote exhaust 12 Align the air valve gasket 209 T on the manifold then attach the air valve 214 Torque screws 211 to 95 105 in Ib 11 12 Nem Tighten the tie bolts 212 halfway Work in a criss cross pattern Check that the shield 206 remains in the grooves on both covers Continue tightening the bolts in pattern to 11 13 ft Ib 15 18 Nem On 8 5 in motors only lubricate the o ring 230 Install it and the plug 231 in the top cover 210 Lubricate and inst
9. Air continuously exhausting from muf fler Damaged air valve plate 305 or cup 312 Replace or service air valve 214 See page 18 Air motor bounces at top of stroke Air motor bounces at bottom of stroke Damaged bottom pilot valve 213 Damaged top pilot valve 213 Replace bottom pilot valve 213 See page 20 Replace top pilot valve 213 See page 20 Icing inside motor Air motor operating at high pressure or high cycle rate Reduce pressure cycle rate or duty cycle of motor Reduce dew point of compressed air in moisture coalescing filter Pump fails to operate Pump operates but does not prime Restricted line or inadequate air supply closed or clogged valves Clear line or increase air supply Check that 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 119 Held open or worn ball check valves or pis ton packings Worn suction hose o ring 38 Clean keep the packing nut wet cup filled with Graco throat seal liquid TSL Clear valve replace packings See page 16 Replace suction hose o ring 38 Pump operates but output is low on both strokes Restricted line or inadequate air supply closed or clogged valves Clear line or increase air supply Check that the valves are open Obstructed fluid hose or gun fluid hos
10. NUT jam 195150 195150 195150 195150 195150 195150 195150 195150 1 15 NIPPLE 1 4 npsm x 1 4 npt plated steel 162453 162453 162453 162453 162453 1 NIPPLE 1 4 npsm x 1 4 npt sst 166846 166846 166846 1 16 IKIT suction hose 5 gal 19 I 24F148 24F148 24F148 24F148 24F148 24F148 1 3 8 in 10 mm OD includes items 37 qty 1 38 and 42 17 NUT hex 7 16 20 Not sold separately Order Tie Rod Kit item 8 3 18 PIN straight 196762 196762 196762 196762 196762 196762 196762 196762 1 19 SPRING retaining 196750 196750 196750 196750 196750 196750 196750 196750 1 20 AIR CONTROL ASSEMBLY see page 36 24H162 24H163 24H163 24H164 24H165 24H162 24H163 24H163 1 21 ELBOW swivel 1 4 npt m x 3 8 in 10 121141 121141 121141 121141 121141 121141 121141 121141 1 mm OD tube 22 TUBE polyurethane 3 8 in 10 mm OD 24H008 24H008 24H008 24H008 24H008 24H008 24H008 24H008 1 2 ft 0 61 m 23 SCREW ground 116343 116343 116343 116343 116343 116343 116343 116343 1 26 WIRE grounding 238909 238909 238909 238909 238909 238909 238909 238909 1 28 THROAT SEAL LIQUID 4 oz not shown 238049 238049 238049 238049 238049 238049 238049 238049 1 37 STRAINER suction 3 8 in 10 mm OD 24F160 24F160 24F160 24F160 24F160 24F160 1 tube pack of 3 38 O RING fluoroelastomer 117559 117559 117559 117559 117559 117559 1 42 N
11. No 24G701 Plated Steel Part No 24G702 Stainless Steel 30 N a a ee i NN 15 see page 26 1074 109 1164 117 1114 110 TI16131a 3A0732J Displacement Pump Parts Part No 24G701 Plated Steel Part No 24G702 Stainless Steel Parts Ref Description 24G701 24G702 Qty 102 BUTTON plug 1 103 NUT packing plated steel 193047 1 NUT packing sst 24H161 1 104 O RING buna N 1 262 in 32 05 mm OD 1 105 CYLINDER pump 243176 24G706 1 106t V PACKING throat V Max UHMWPE e ss 3 107 O RING PTFE 1 254 in 31 85 mm OD 1 109 GUIDE ball 15C011 15C011 1 110 VALVE intake housing plated steel 15B611 1 VALVE intake housing sst 24H007 1 111 O RING PTFE 0 941 in 23 90 mm OD 1 112 GLAND female throat acetal 1 113 V PACKING throat leather 2 114 GLAND male throat acetal 1 116 BALL intake sst 0 500 in 13 mm dia 105445 105445 1 117 SEAT carbide 15A968 15A968 1 119 KIT rod displacement Chromex includes item 124 and items 18 and 19 24G703 246704 1 on page 25 120 BALL piston sst 0 3125 in 7 94 mm dia 105444 105444 1 121 GLAND male piston plated steel 1 GLAND male piston sst 1 122 GLAND female piston plated steel 1 GLAND female piston sst 1 123 WIPE
12. fluid pressure at low starting pressure For low viscosity fluids less than 25 sec 2 Zahn cup with lower percent solids typi cally less than 40 start at 300 psi 2 1 MPa 21 bar at pump outlet For fluids with higher viscosity or higher solids content start at 600 psi 4 2 MPa 42 bar Refer to the following example Example Pump Air Approximate Pump Regulator Setting Fluid Pressure Ratio psi MPa bar psig MPa bar 151 x 20 0 14 1 4 300 2 1 21 30 1 x 20 0 14 1 4 600 4 2 42 Hold gun perpendicular and approximately 12 inches 304 mm from surface Move gun first then pull gun trigger to spray onto test paper Increase fluid pressure in 100 psi 0 7 MPa 7 bar increments just to the point where a further increase in fluid pressure does not significantly improve fluid atomization Refer to the following example Example Pump Air Regulator Incremental Pump Increment Fluid Pressure Ratio psi MPa bar psi MPa bar 15 1 x 7 05 0 5 100 0 7 7 0 30 1 x 3 3 0 02 0 2 100 0 7 7 0 If you are using an air assisted spray gun see Adjust the Spray Pattern on page 12 11 Operation Adjust the Spray Pattern Mea NOTE Use this procedure with air assisted spray guns only 1 See FIG 4 Close off pattern adjustment air by turn ing knob AA clockwise in all the way This sets gun for its widest pattern OUT narrower pattern I 5 gt
13. this table 209 6t GASKET air valve Not sold separately See Air Motor Seal Kit Valve Repair Kit 244537 1 Valve Seal Kit 244535 below or Manifold Assembly 220 this table 210 KIT cover top includes 202 and 213 24H004 15X353 1 qty 1 of each 15X353 also includes 230 and 231 211 SCREW M6 x 25 Not sold separately See Manifold Assembly 220 this table or 8 Air Valve Replacement Kit page 35 212 BOLT tie hex head 15M314 2 BOLT tie hex head 15M314 3 213 VALVE pilot pack of 2 24A366 24A366 1 214 VALVE air includes items 209 and 211 24A351 24A351 1 aty 4 215 MUFFLER 15M213 15M213 217 RING retaining Not sold separately See Air Motor Seal Kit below or 1 Bottom Cover Kit 201 this table 218 ROD air motor Not sold separately See Motor Piston Kit 219 this table 1 219 KIT piston motor includes 204 and 24G697 24G698 1 218 and 16G561 adhesive 220 MANIFOLD assembly includes 208 24A579 24A579 1 209 and 211 qty 4 229A LABEL warning French and 15W719 15W719 1 Spanish 230 O RING top plug 24G694 only Not sold separately See Air Motor 1 Seal Kit below 231 PLUG top cover 24G694 only Not sold separately See Top 1 Cover Kit 210 this table A Replacement Danger and Warning labels tags and cards are available at no cost T Included in Air Valve Seal Kit 24A535 See page 35 Included in Air Motor Seal Kit Included in Air Valve Repair Kit 244537 See page 35 24G693 2
14. 1500 psi 10 3 MPa 103 bar 801 PUMPS iex oe de oett ge doe 3000 psi 20 7 MPa 207 bar Maximum air inlet pressure 100 psi 0 7 MPa 7 0 bar Ratio ce iet ooE Roxana EPA a 15 1 or 30 1 see Models page 3 Maximum fluid temperature 160 F 71 C Ambient air temperature range 35 120 F 2 49 C Package air inlet size 3 8 npt f Package fluid outlet size 1 4 npsm m Maximum motor speed 240 cycles per minute Do not exceed maximum recommended speed of fluid pump to prevent premature pump wear Maximum spray tip orifice size 019 in 0 483 mm Sound data 24G693 Air Motor Sound power 83 2 dBA Sound pressure 76 5 dBA 24G694 Air Motor Sound power 84 5 dBA Sound pressure 77 9 dBA Wetted parts Plated steel pumps Stainless steel nickel plated carbon steel tungsten carbide ptfe acetal leather ultra high molecular weight polyethylene Stainless steel pumps Stainless steel tungsten carbide ptfe acetal leather ultra high molecular weight polyethylene Spray guns See manual 3A0149 G15 and G40 AA guns or 311254 Silver Plus airless gun Fluid hose Nylon plated or stainless steel Suction assembly
15. 4G694 2 5 in Motor 3 5 in Motor 24G699 24G700 3A0732J 33 Parts Air Valve Parts 310 tE 306 305 ti16213a 34 3A0732J Parts Air Valve Parts Complete Air Valve Replacement Kit 24A351 To replace the complete air valve order Air Valve Replacement Kit 24A351 The kit includes items 301 312 below and items 209 and 211 on page 33 Air Valve Repair Kits Air valve parts are not sold individually The table below shows possible kit options for each part Air Valve Air Valve Air Valve Qty Repair Kit Seal Kit End Cap Kit Ref Description 24A537 24A535 24A360 301 HOUSING 1 302 AIR VALVE PISTON 1 v 303 DETENT PISTON ASSEMBLY 1 v 3046 DETENT CAM 1 v 305 PLATE air valve 1 v 306144 O RING 2 v v v 307 CAP 2 v 3081 U CUP 2 v v 30916 SCREW 2 v v 310 SNAP RING 2 v v 311 DETENT SPRING 1 v 312 CUP 1 v T Included in Air Valve Seal Kit 24A535 Included in Air Valve Repair Kit 24A537 Included in Air Valve End Cap Kit 24A360 Replacement screws 309 are available in a pack of 10 Order Kit 24A359 3A0732J 35 36 Parts Air Control Parts Part No 24H162 Air Assisted Wall Mount Part No 24H163 Air Assisted Stand Mount 401 A 405 yr am Part of 402 TI16132a 404 408 402 418 A Connect tubing 406 between these two fittings A Used on stand mount units only Part No 24H164 Airles
16. 7 and o ring 111 from the intake housing 110 4 Drive the rod and piston assembly out the bottom of the cylinder Remove the o ring 107 from the cylin der 5 Insert a plastic rod in the bottom of the cylinder and drive the throat packings and glands out the top 6 Putthe rod 119 in a vise and unscrew the piston 124 Be careful not to drop the piston ball 120 Disassemble the piston packings from the piston 7 Clean and inspect all parts Replace any damaged parts Reassemble the Pump NOTE Soak the leather packings 1134 1251 in hydraulic oil for one hour before installing them in the pump 1 Install the piston wiper 1231 on the piston 124 with the lips facing down Install the female gland 1221 Install the piston packings in the following order with the lips facing up blue UHMWPE 1261 leather 125 UHMWPE leather UHMWPE Install the male gland 1214 2 Put the displacement rod 119 in a vise Place the piston ball 1204 in the cavity of the rod Screw the piston assembly into the rod Torque to 24 30 ft lb 33 40 Nem 16 3 Install the male gland 1144 in the cylinder 105 Install the throat packings in the following order with the lips facing down blue UHMWPE 1061 leather 1133 UHMWPE leather UHMWPE Install the female gland 1124 4 Install the o ring 104 on the packing nut 103 Loosely install the packing nut in the cylinder 5 Liberally lubricate the
17. Connections 13 Flush the Pump 13 Troubleshooting 14 Repair coore radonin AB GC a RAI IE 15 General Information 15 To Remove Intake Valve Only 15 Disconnect the Displacement Pump 15 Disassemble the Pump 16 Reassemble the Pump 16 Reconnect the Displacement Pump 16 Repair Air Valve 18 Replace Pilot Valves 20 Disconnect the Air Motor 21 Reconnect the Air Motor 21 Repair Air Motor 22 Il o 25 Package Parts 25 Hose and Gun 29 Displacement Pump Parts 30 Air Motor Parts 32 Air Valve Parts 34 Air Control Parts 36 Kits and Accessories 38 Package Dimensions 39 Package Weights 39 Wall Bracket Mounting Hole Diagram 40 Technical Data 41 Performance Charts 42 15 1 Ratio Pumps 42 30 1 Ratio Pumps 43 Graco Standard Warranty 44 Graco Information 44 3A0732J Models Models
18. Instructions Parts G GRACO Merkur ES Spray Packages 7 For low volume fine finish spray applications For professional use only Read all warnings and instructions in this manual Save these instructions e Important Safety Instructions 15 1 Spray Packages 30 1 Spray Packages 100 psi 0 7 MPa 7 0 bar Maximum Air Inlet Pressure See page 3 for model information including maximum fluid working pressure ti15590a ti15589a C II2GcT5X PROVEN QUALITY LEADING TECHNOLOGY Contents Models ES eames 3 Warnings 4 eee RE ACH RG UA AR ACH eee ed 4 Installation 7 Prepare the Operator 7 Prepare the Site 7 Supplied Components 7 Inline Fluid Filter Kits 7 Air Line Accessories 7 Wall Mount Packages 8 Grounding 8 Flush Before Using Equipment 8 Setups tos rst Dossier LE P cvs Ah debts 9 Operation aceptei rre dates tete 10 Pressure Relief Procedure 10 Trigger Lock 10 Prime the Pump 10 Install the Spray Tip 11 Adjust the Atomization 11 Adjust the Spray Pattern 12 ShutdoWn sas ae re Rewards 12 Maintenance 13 Tighten Threaded
19. P IN wider pattern yu We ti6559A Fic 4 Pattern Air Knob 2 See FIG 5 Set atomizing air pressure at about 5 psi 0 35 bar 35 kPa when triggered Check spray pat tern then slowly increase air pressure until tails are completely atomized and pulled into spray pattern Do not exceed 100 psi 0 7 MPa 7 bar air pressure to gun 12 3 See FIG 4 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 correct amount of air TI0792A Fic 5 Spray Pattern Problems no air too little air Shutdown AS WA Follow Pressure Relief Procedure page 10 Always flush the pump before the fluid dries on the dis placement rod See Flush the Pump on page 13 3A0732J Maintenance Tighten Threaded Connections Before each use check all hoses for wear or damage Replace as necessary Check that all threaded connec tions are tight and leak free Flush the Pump Ww QD Read all Warnings Follow all Grounding instruc tions See page 8 Flush the pump e Before first use e When changing colors or fluids e Before repairing equipment e Before fluid dries or settles out in a dormant pump check the pot life of catalyzed fluids e At the end of the day e Before storing the pump 3A0732J Maintenan
20. R piston 1 124 VALVE piston plated steel Order 1 item 119 VALVE piston sst Order 1 item 119 125 V PACKING piston leather 2 126t V PACKING piston V Max UHMWPE se 3 t Included in Pump Lower Rebuild Kit Order Kit 24H006 for Pump 24G701 or Kit 24G705 for Pump 24G702 Included in Intake Check Valve Kit 246429 3A0732J 31 Parts Air Motor Parts Part No 24G693 2 5 in 63 5 mm Part No 24G694 3 5 in 88 9 mm shown 32 TI16130a 3A0732J Parts Air Motor Parts Part No 24G693 2 5 in 63 5 mm Part No 24G694 3 5 in 88 9 mm shown Ref Description 24G693 24G694 Qty 201 KIT cover bottom includes 202 qty 1 24G695 24G696 1 203 207 213 qty 1 and 217 202 O RING cover Not sold separately See Air Motor Seal Kit below Bottom Cover Kit 2 201 this table or Top Cover Kit 210 this table 203 BEARING Not sold separately See Bottom Cover Kit 201 this table 1 204 O RING piston Not sold separately See Air Motor Seal Kit below or 1 Piston Kit 219 this table CYLINDER motor 15M289 15M211 206A COVER oylinder includes English 15M302 15M212 1 warning label 207 SEAL u cup Not sold separately See Air Motor Seal Kit below or 2 Bottom Cover Kit 201 this table 208 GASKET manifold Not sold separately See Air Motor Seal Kit below or 2 Manifold Assembly 220
21. UT jam suction 15E813 15E813 15E813 15E813 15E813 15E813 1 43 WASHER lock 1 4 part of stand kit 2 6 44 HOPPER kit 17A493 17A493 1 t Included in Pump Lower Rebuild Kit See page 31 Not shown See Merkur ES Hopper Kit manual 334011 for more information 3A0732J 27 Parts 28 3A0732J Hose and Gun Air Assisted Packages Airless Packages Tl16231a 30 30 32 36 TI16230a Package 24F150 24F152 24F156 24F158 24F151 24F153 24F154 24F157 24F159 Ref No Description 24W281 24W287 24F155 24W285 24W283 Qty 29 HOSE air gun 241811 241811 241811 241811 1 30 GUN air assisted G15 see 3A0149 24C853 24C853 1 GUN air assisted G40 see 3A0149 24C855 24C855 1 GUN airless see 311254 235460 1 32 HOSE fluid 1 8 in 3 mm ID nylon 24F165 24F165 24F165 1 1 4 npsm f plated steel couplings 25 ft 7 6 m long HOSE fluid 1 8 in 3 mm ID nylon 24F166 24F166 1 1 4 npsm f sst couplings 25 ft 7 6 m long 33 CLIP hose pack of 7 24H005 24H005 24H005 24H005 7 36x TIP G15 G40 AAF412 AAF412 AAF412 AAF412 TIP airless 163515 1 Additional tip sizes are available See manual 3A0149 for G15 and G40 AA Guns See tip manual 306686 for Silver Plus Airless Guns 3A0732J Parts 29 Parts Displacement Pump Parts Part
22. all pilot valves 213 in top and bottom cover Torque to 95 105 in Ib 11 12 Nem See Reconnect the Air Motor on page 21 3A0732J Parts Parts Package Parts NOTE For hose and gun see page 29 Part of air motor 7 22 21 Detail of Stand Kit 2 1 Ref f 3 Cw TI16438a TI16129a 3A0732J 25 Parts Package Parts 15 1 Ratio Pumps Ref Package No Description 24F150 24F151 24W281 24F158 24F159 24W283 Qty 1 BRACKET wall 24H102 24H102 24H102 24H102 24H102 24H102 1 2 KIT stand includes items 3 4 5 6 and 43 24F164 24F164 24F164 24F164 1 below and 418 on page 36 3 PLUG 108175 108175 108175 108175 4 4 SCREW cap hex hd 1 4 20 x 1 5 in 38 mm 100058 100058 100058 100058 6 5 SPACER tube 4 6 NUT hex 1 4 20 100015 100015 100015 100015 6 7 MOTOR air see page 32 24G693 24G693 24G693 24G693 24G693 24G693 1 8 KIT rod tie includes rods and items 11 and 17 24G707 24G707 24G707 24G707 24G707 24G707 1 3 of each 9 SPRING safety 24H103 24H103 24H103 24H103 24H103 24H103 1 10 ADAPTER pump lower 24H104 24H104 24H104 24H104 24H104 24H104 1 11 NUT lock 104541 104541 104541 104541 104541 104541 3 12 LOWER pump see page 30 24G701 246701 24G701 24G702 24G702 24G702 1 also includ
23. bove check the following a The spray tip may be completely clogged Very slowly loosen the air cap retaining ring to relieve pressure in the cavity between the ball seat shutoff and the plugged tip Clear the tip orifice b The gun fluid filter or the fluid hose may be com pletely clogged Very slowly loosen the hose end coupling at the gun and relieve pressure gradually Then loosen completely to clear the obstruction c After following the steps above if the spray tip or hose still seems completely clogged very slowly loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually then loosen completely With tip removed trig ger gun into waste container 10 Trigger Lock me See FIG 3 Always engage gun trigger lock when you stop spraying to prevent gun from being triggered acci dentally by hand or if dropped or bumped 5 Gun Trigger Locked tile581A Gun Trigger Unlocked P K ti6582A Fic 3 Trigger Lock Prime the Pump V B Have safety spring 9 in place during operation to reduce risk of pinching or loss of fingers 1 See Fic 3 Lock gun trigger Remove tip guard and spray tip from gun Refer to gun manual 3A0732J 2 See FIG 2 Close gun air regulator E and pump air regulator F by turning knobs counterclockwise reducing pressure to zero Close bleed type air valve D 3 Connect air l
24. ce 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 Remove tip guard and spray tip from gun Refer to separate gun manual 3 Place suction tube in grounded metal pail containing cleaning fluid 4 Setpumpto lowest possible fluid pressure and start pump 5 Hold a metal part of the gun firmly to a grounded metal pail 6 Trigger gun Flush system until clear solvent flows from gun 7 Follow Pressure Relief Procedure page 10 8 Clean the tip guard spray tip and fluid filter element separately then reinstall them 9 Clean inside and outside of suction tube and suction hose 13 Troubleshooting Troubleshooting MPa bar PSI D the equipment Relieve the pressure before checking or servicing Problem Cause NOTE Check all possible problems and causes before disassembling the pump Solution Air motor will not run Damaged air valve 214 Replace or service air valve 214 See page 18 Damaged pilot valve 213 Replace pilot valves 213 See page 20 Air continuously exhausting around air motor piston rod Damaged u cups 207 Replace piston rod u cups 207 See page 22
25. e FIG 9 Remove the snap ring 310 from each end Use the piston to push the end caps 307 out of the ends Remove end cap o rings 306T 4 4 Remove the piston 302 Remove the u cup seals 3081 from each end and the detent assembly 803 and detent cam 3044 from the center 3A0732J Repair 310 AN T 306 305 N TE 306 RD ti16213a 310 AN Apply lubricant FIG 9 Air Valve Assembly 3A0732J 19 Repair Reassemble the Air Valve 1 See FIG 9 Lubricate detent cam 3044 and install into housing See Fic 10 Lubricate the u cups 30814 and install on the piston 302 with lips facing toward the center of the piston 19308 Lips face down a T9308 Lips face up ti12754a Fic 10 Air Valve U cup Installation 20 See FiG 9 Lubricate both ends of the piston 3024 and install it in the housing Lubricate and install the detent assembly 303 into the piston Lubricate new o rings 3061 and install on the end caps 307 Install the end caps into the hous ing Install a snap ring 310 on each end to hold end caps in place Install the spring 311 Lubricate and install the air valve cup 312 see FIG 11 Align the small round magnet with the air inlet Install the valve plate 305 Tighten the screws 30919 to hold it in place 312 ti16283a Fic 11 Air Valve Cup Installation Replace Pilot Valves 1
26. e ID is too small Open clear use hose with larger ID Worn packings in displacement pump Replace packings See page 16 Pump operates but output is low on downstroke Held open or worn ball check valves or pis ton packings Clear valve replace packings See page 16 Erratic or accelerated pump speed Exhausted fluid supply Refill and prime Held open or worn ball check valves or packings Clear valve replace packings See page 16 Fluid being pumped is visible in the packing nut wet cup Worn throat packings Tighten packing nut Replace throat packings See page 16 Bad spray pattern Clean or repair spray gun or tip See G15 G40 air assisted gun manual or Silver Plus airless gun manual 14 3A0732J Repair General Information e Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawing e 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 To Remove Intake Valve Only The intake ball and seat may be cleaned or serviced without disconnecting the displacement pump vi 1 Stop the pump 2 Flush the pump if possible see page 13 Follow Pressure Relief Procedure page 10 3 Disconnect the suction hose 4 R
27. emove the intake housing 110 See FIG 7 5 Clean or replace the ball guide 109 ball 116 seat 117 and o ring 111 6 Install the o ring 1111 seat 117 intake ball 1161 and ball guide 109 in the intake housing 110 7 Screw the intake housing 110 onto the cylinder 105 Torque to 70 80 ft lb 95 108 Nem 3A0732J Repair Disconnect the Displacement Pump vi 1 Stop the pump 2 Flush the pump if possible see page 13 Follow Pressure Relief Procedure page 10 3 Disconnect the air hose fluid hose and suction hose 4 See FiG 6 Push the safety spring 9 down and hold to access the coupling pin 18 Push the retaining spring 19 up and push out the pin using a screwdriver or punch 5 Loosen the jam nut 13 6 Unscrew the displacement pump by hand and place on work bench TI16261A 13 Fic 6 Safety Spring and Connecting Pin 15 Repair Disassemble the Pump NOTE Pump Repair Kits are available See page 31 to order the correct kit for Your pump Parts are marked with an t 1 Follow the instructions under Disconnect the Dis placement Pump page 15 1 See Fic 7 Loosen the packing nut 103 using a screwdriver and hammer Remove the o ring 104 2 Unscrew the cylinder 105 from the intake housing 110 The rod and piston assembly will come with the cylinder 3 Remove the ball guide 109 intake ball 116 seat 11
28. es items 15 18 and 19 13 NUT jam 195150 195150 195150 195150 195150 195150 1 15 NIPPLE 1 4 npsm x 1 4 npt plated steel 162453 162453 162453 1 NIPPLE 1 4 npsm x 1 4 npt sst 166846 166846 166846 1 16 KIT suction hose 5 gal 19 I 3 8 in 10 mm 24F148 24F148 24F148 24F148 1 OD includes items 37 qty 1 38 and 42 17 NUT hex 7 16 20 Not sold separately Order Tie Rod Kit item 8 3 184 IPIN straight 196762 196762 196762 196762 196762 196762 1 19 SPRING retaining 196750 196750 196750 196750 196750 196750 1 20 TAIR CONTROL ASSEMBLY see page 36 24H162 24H163 24H163 24H162 24H163 24H163 1 21 ELBOW swivel 121141 121141 121141 121141 121141 121141 1 1 4 npt m x 3 8 in 10 mm OD tube 22 TUBE polyurethane 3 8 in 10 mm OD 2 ft 24H008 24H008 24H008 24H008 24H008 24H008 1 0 61 m 23 SCREW ground 116343 116343 116343 116343 116343 116343 1 26 WIRE grounding 238909 238909 238909 238909 238909 238909 1 28 THROAT SEAL LIQUID 4 oz not shown 238049 238049 238049 238049 238049 238049 1 37 STRAINER suction 3 8 in 10 mm OD tube 24F160 24F160 24F160 24F160 1 pack of 3 38 O RING fluoroelastomer 117559 117559 117559 117559 42 NUT jam suction 15E813 15E813 15E813 15E813 1 43 WASHER lock 1 4 part of stand kit 2 6 44 HOPPER kit 17A493 17A493 1
29. hina Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2010 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revision G July 2014
30. id hoses Static electricity may build up when fluids flow through pumps hoses and spray ers At least one hose must be electrically conduc tive with a maximum of 500 ft 150 m combined hose length to ensure grounding continuity Check electrical resistance of hoses If total resistance to ground exceeds 25 megohms replace hose imme diately 3 Air compressor follow manufacturer s recommen dations 4 Spray gun ground through connection to a prop erly 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 conduc tive placed on a grounded surface Do not place the pail on a nonconductive surface such as paper or cardboard which interrupts the grounding continu ity 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 Flush Before Using Equipment The equipment was tested with lightweight oil which is left in the fluid passages to protect parts To avoid con taminating your fluid with oil flush the equipment with a compatible solvent before using the equipment See Prime the Pump page 10 3A0732J Installation Setup 1 UZEZI XCIQnmoou zm See FIG 2 Attach one end of fluid hose K to pump 4 Attach re
31. 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 reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es 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 Original instructions This manual contains English MM 3A0732 Graco Headquarters Minneapolis International Offices Belgium C
32. ine to bleed type air valve 4 Check that all fittings throughout system are tight ened securely 5 Position pail close to pump Suction hose is 3 ft 1 0 9 m long Do not stretch hose tight let it hang to assist fluid flow into pump 6 Hold metal part of gun firmly to side of grounded metal pail unlock trigger and hold trigger open 7 Open bleed type air valve Slowly turn pump air reg ulator clockwise increasing pressure until pump starts 8 Cycle pump slowly until all air is pushed out and pump and hoses are fully primed 9 Release gun trigger and lock trigger safety Pump should stall against pressure Install the Spray Tip ue 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 instruc tion manual as a guide for selecting an appropriate spray tip for your application NOTE The maximum recommended spray tip size is 019 in 0 483 mm 3A0732J Operation Adjust the Atomization ae NOTE Use this procedure with airless and air assisted spray guns a MPa bar PSI Do not turn on atomizing air supply Fluid pressure is controlled by the air pressure supplied to the pump pump air regulator Set
33. maining end of the air hose to air inlet at outlet or optional inline fluid filter outlet base of gun H Attach other end of fluid hose to gun fluid inlet at 5 Clip fluid and air hoses together with the supplied base of gun H hose clips qty of 7 Space clips as needed Attach one end of the air hose G to gun air regula 6 Attach the fluid suction kit J to the pump inlet tor E Main Air Supply Line Air Shutoff Valve Air Filter Bleed type Master Air Valve required Gun Air Pressure Regulator Pump Air Pressure Regulator Gun Air Supply Line Spray Gun Fluid Suction Kit Gun Fluid Supply Line Pump Ground Wire required Mounting Bracket used for wall mounting or stand Pump Stand Air Pressure Relief Valve ti15591a Fic 2 Typical Installation Air Assisted Stand Mount Package Shown 3A0732J 9 Operation Operation Pressure Relief Procedure 1 m h Nz 3 m Trapped air can cause the pump to cycle unexpect edly which could result in serious injury from skin injection splashing or moving parts 1 Lock the gun trigger 2 See FIG 2 Turn off the bleed type master air valve D 3 Unlock the gun trigger 4 Hold a metal part of the gun firmly to a grounded metal waste container Trigger the gun to relieve fluid pressure 5 Lockthe gun trigger 6 If you suspect that pressure has not been fully relieved after following the steps a
34. parts during cleaning and could discharge and ignite flammable vapors To help prevent fire and explosion Clean plastic parts only in well ventilated area Do not clean with a dry cloth Do not operate electrostatic guns in equipment work area a cut but it is a serious injury that can result in amputation Get immediate surgical treatment Do not spray without tip guard and trigger guard installed Engage trigger lock when not spraying paar PS Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Follow the Pressure Relief Procedure when you stop spraying 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 N SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just 3A0732J A Warnings 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 Da
35. piston packings and the top 2 in 51 mm of the displacement rod 119 6 Push the displacement rod 119 into the cylinder 105 from the bottom until the piston is completely in the cylinder and the rod protrudes from the pack ing nut 103 7 Grease the o ring 1071 and install it on the cylin der 105 8 Install the o ring 1111 seat 117 intake ball 1161 and ball guide 109 in the intake housing 110 9 Place the intake housing 110 in a vise Screw the cylinder 105 into the intake housing Torque to 70 80 ft Ib 95 108 Nem 10 Tighten the packing nut 103 1 2 turn past hand tight or torque to 60 80 in Ib 6 7 9 0 Nem 11 Ensure that the button plug 1021 is in place on the packing nut 103 12 Follow the instructions under Reconnect the Dis placement Pump page 16 Reconnect the Displacement Pump The displacement pump can be damaged if the stroke is not centered when the pump is reconnected Be sure to fully screw the displacement pump into the adapter plate 10 1 Screw the displacement pump into the adapter plate 10 until it stops Back off pump less than 1 turn to align pump outlet as desired 3A0732J Repair 2 Tighten the jam nut 13 Torque to 65 75 ft Ib 4 Pushthe retaining spring 19 into place to cover the 88 102 Nem pin 3 Align the hole in the displacement rod with the hole 5 Fill throat packing nut wet cup with TSL to prevent in the air motor rod U
36. proved containers and dispose of it according to applicable guidelines PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury hearing loss inhalation of toxic fumes and burns This 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 3A0732J Warnings 6 3A0732J Installation Prepare the Operator All persons who operate the equipment must be trained in the safe efficient 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 com pressor 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 A quick disconnect coupling is recommended Keep the site clear of any obstacles or debris that could interfere with the operators movement Have a grounded metal pail available for use when flushing
37. ree 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
38. s Wall Mount Part No 24H165 Airless Stand Mount A Connect tubing 406 between these two fittings A Used on stand mount units only 418 Tl16229a 3A0732J Air Control Parts Part No 24H162 Air Assisted Wall Mount Part No 24H163 Air Assisted Stand Mount Part No 24H164 Airless Wall Mount Part No 24H165 Airless Stand Mount Parts 3A0732J Ref Description 24H162 24H163 24H164 24H165 Qty 401 BRACKET handle 24H105 24H105 24H105 24H105 1 402 REGULATOR air 1517499 151499 2 REGULATOR air 151499 151499 1 403 TEE 1 4 npt m 115219 115219 1 404 GAUGE air pressure 108190 108190 2 GAUGE air pressure 108190 108190 1 405 ELBOW tube 1 4 npt f x 3 8 in 10 mm OD tube C38161 C38161 1 FITTING tube 1 4 npt m x 3 8 in 10 mm OD tube 120389 120389 1 406 TUBE polyurethane 3 8 in 10 mm OD tube 2 ft 0 61 m 24H008 24H008 24H008 24H008 1 407 VALVE ball air 3 8 npt fbe 114362 114362 114362 114362 1 408 NIPPLE 1 4 npsm x 1 4 npt 162453 162453 1 409 ELBOW swivel 3 8 npt m x 3 8 in 10 mm OD tube 16F151 16F151 16F151 16F151 1 410 ELBOW 1 4 npt f x 1 8 npt m 121150 121150 121150 121150 1 411 VALVE safety relief 110 psi 113498 113498 113498 113498 1 412 ELBOW swivel 1 4 npt m x 3 8 in 10 mm OD tube 121141 121141 121141 121141 1 413 NUT regula
39. se a screwdriver to push in the premature packing wear pin 18 1074 109 116 117 1114 110 A Lips must face down A Lips must face up 126 1254 122 A 123 s TH6131a FIG 7 Displacement Pump 3A0732J 17 Repair Repair Air Valve IPa bariPSI Replace Complete Air Valve 1 Stop the pump Follow Pressure Relief Procedure page 10 2 Disconnect the air line to the motor 3 See Fic 14 on page 23 Remove four screws 211 Remove the air valve 214 and gasket 209 4 4 To repair the air valve go to Disassemble the Air Valve page 18 To install a replacement air valve continue with step 5 5 Align the new air valve gasket 209 4 on the mani fold then attach the air valve 214 Torque screws 211 to 95 105 in Ib 11 12 Nem 6 Reconnect the air line to the motor Replace Seals or Rebuild Air Valve NOTE Air Valve Seal Kits are available See page 35 Parts are marked with an T Air Valve Repair Kits are available See page 35 Parts are marked with an Air Valve End Cap Kits are available See page 35 Parts are marked with an x Disassemble the Air Valve 1 Perform steps 1 3 under Replace Complete Air Valve page 18 2 See FIG 8 Use a 2 mm or 5 64 hex key to remove two screws 30914 Remove the valve plate 305 cup 312 and spring 311 18 3119 3129 E P S 30919 P ti16284a Fic 8 Air Plate Removal 3 Se
40. t Included in Pump Lower Rebuild Kit See page 31 Not shown See Merkur ES Hopper Kit manual 334011 for more information 26 3A0732J Package Parts 30 1 Ratio Pumps Parts Ref Package No Description 24F152 24F153 24W287 24F154 24F155 24F156 24F157 24W285 Qty 1 BRACKET wall 24H102 24H102 24H102 24H102 24H102 24H102 24H102 24H102 1 2 KIT stand includes items 3 4 5 6 and 24F164 24F164 24F164 24F164 24F164 1 43 below and 418 on page 36 3 PLUG 108175 108175 108175 108175 108175 4 4 SCREW cap hex hd 1 4 20 x 1 5 in 38 100058 100058 100058 100058 100058 6 mm 5 SPACER tube 4 6 NUT hex 1 4 20 100015 100015 100015 100015 100015 6 7 MOTOR air see page 32 24G694 24G694 24G694 24G694 24G694 24G694 24G694 24G694 1 8 KIT rod tie includes rods and items 11 24G707 24G707 24G707 24G707 24G707 24G707 24G707 248707 1 and 17 3 of each 9 SPRING safety 24H103 24H103 24H103 24H103 24H103 24H103 24H103 24H103 1 10 ADAPTER pump lower 24H104 24H104 24H104 24H104 24H104 24H104 24H104 24H104 1 11 NUT lock 104541 104541 104541 104541 104541 104541 104541 104541 3 12 LOWER pump see page 30 24G702 24G702 24G702 24G701 24G701 24G701 24G701 24G701 1 also includes items 15 18 and 19 13
41. ta 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 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 e Read MSDSs to know the specific hazards of the fluids you are using Store hazardous fluid in ap
42. the system Supplied Components See FIG 2 on page 9 e The red handled bleed type master air valve D is required in your system to relieve air trapped between it and the air motor and gun when the valve is closed Do not block access to the valve e The pump air regulator F controls pump speed and outlet pressure by adjusting the air pressure to the pump The air pressure relief valve P opens automati cally to prevent overpressurization of the pump e The gun air regulator E adjusts the air pressure to the air assisted spray gun 3A0732J Installation e The 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 instal lation e The red hose G provides the gun air supply e The blue hose K provides the gun fluid supply The suction kit with strainer J allows the pump to draw fluid from a 5 gallon 19 liter pail Inline Fluid Filter Kits Inline fluid filter kits are available as an accessory in stainless steel 24F271 or aluminum 24F272 to filter particles from fluid as it leaves the pump Kits include a 60 mesh 250 micron stainless steel element Air Line Accessories Install the following accessories in the order shown in FiG 2 using adapters as necessary Anair line filter C removes harmful dirt and mois ture from the compressed air suppl
43. ti16287a Package Description lb kg 24F150 15 1 plated steel AA wall 20 9 24F151 15 1 plated steel AA stand 23 10 24F152 30 1 stainless steel AA wall 23110 24F153 30 1 stainless steel AA stand 26 12 24F154 30 1 plated steel airless wall 22 10 24F155 30 1 plated steel airless stand 25 11 24F156 30 1 plated steel AA wall 23 10 24F157 30 1 plated steel AA stand 26112 3A0732J L Package Dimensions Top View ti16288a Package Description Ib kg 24F158 15 1 stainless steel AA wall 20 9 24F159 15 1 stainless steel AA stand 23 10 24W281 15 1 plated steel AA stand hopper 32 15 24W283 15 1 Stainless steel AA stand 32 15 hopper 24W285 30 1 plated steel AA stand hopper 35 16 24W287 30 1 stainless steel AA stand 35 16 hopper 39 Wall Bracket Mounting Hole Diagram Wall Bracket Mounting Hole Diagram 2 x 0 281 9 32 in 7 mm For wall mount only 2x0 35bin 9 mm 4 40 in 112 mm D p O z 2 x 0 312 5 16 in 8 mm For wall mount or to attach stand to bracket 40 5 10 in 130 mm De n 2 69 in 2x0 62in 68 mm 16 mm Y S 2 x 0 48 in 12 mm TI16289a 3A0732J Technical Data Technical Data Maximum fluid working pressure 15 1 Pumps uer RIA Pete
44. tor 115244 115244 2 NUT regulator 115244 115244 1 418 ELBOW street 45 1 8 npt mxf 113630 2 ELBOW street 45 1 8 npt mxf 113630 1 420 SCREW cap button hd 10 24 x 3 8 in 10 mm 114381 114381 114381 114381 2 421 PLUG panel 16F547 16F547 1 422 RING grounding 24P812 24P812 24P812 24P812 1 37 Kits and Accessories Kits and Accessories 38 Kit Description Part No Airless to Air Assisted Conversion Kit 24F161 Inline Fluid Filter stainless steel 24F271 Inline Fluid Filter aluminum 24F272 Standard Suction Hose 5 gal 19 I 3 8 in 10 mm OD 24F148 Suction Hose 5 gal 191 5 8 in 16 mm OD 24F149 Suction Tube 1 gal 3 8 I 11 32 in 9 mm OD 24F147 Standard Push on Strainer Kit 24F160 Screw on Strainer Kit for 24F149 5 8 in Suction Hose Kit 256426 Air Gauge Lens Cover Kit sheet of 12 covers 198199 Throat Seal Liquid TSL 4 oz 118 ml 238049 Throat Seal Liquid TSL 8 oz 236 ml 206994 Alternate U Cup Pump Packing Kit UHMWPE 24H665 Hopper Kit 17A493 Hopper Screens Pack of 5 17B207 Hopper O Ring Kit 17B208 Hopper Bungee Cord Kit 17C166 3A0732J Package Dimensions A inch B inch C D Package mm mm inch mm inch mm Wall Mount 20 2 513 Stand Mount 29 0 737 17 4 442 18 4 467 Stand Mount 29 0 737 17 4 442 26 5 673 with Hopper Front View Package Weights
45. y e A second bleed type air shutoff valve B isolates the air line accessories for servicing Locate upstream from all other air line accessories Installation Wall Mount Packages 1 Be sure the wall can support the weight of the pump bracket hoses and accessories as well as the stress caused during operation Position the wall bracket at a convenient height Do not stretch the suction hose tight let it hang to assist fluid flow into the pump For ease of operation and service make sure the pump air inlet fluid inlet and fluid outlet ports are easily accessible Using the wall bracket as a template drill mounting holes in the wall Hole diameters and wall mounting dimensions are shown on page 40 Attach the bracket to the wall Use screws that are long enough to keep the pump from vibrating during operation NOTE Be sure the bracket is level Grounding Aue The equipment must be grounded Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit 1 Pump See FiG 1 Verify that the ground wire 26 is attached to the ground screw 23 and the screw is tightened securely to the adapter plate 10 Use any of the three threaded holes in the adapter plate Connect the other end of the ground wire to a true earth ground ti16282a Fic 1 Ground Wire 2 Airand flu
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