Graco Merkur Parts list manual

3A7004B
EN
Instructions-Parts
Merkur®Electrostatic
Airspray Packages
For electrostatic finishing and coating applications in hazardous or non-hazardous
locations. For professional use only.
See pages 4 to 5 for model information, including
maximum working pressure and approvals.
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment.
Save these instructions.
ti36765a

23A7004B
Content
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Merkur 3:1 Packages. . . . . . . . . . . . . . . . . . . . . . 5
Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General Information . . . . . . . . . . . . . . . . . . . . . . 10
Prepare the Operator. . . . . . . . . . . . . . . . . . . . . 10
Prepare the Site. . . . . . . . . . . . . . . . . . . . . . . . . 10
Mount the Pump. . . . . . . . . . . . . . . . . . . . . . . . . 10
Ventilate the Spray Booth . . . . . . . . . . . . . . . . . 10
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Relief Procedure. . . . . . . . . . . . . . . . . 13
Flush Before Using Equipment . . . . . . . . . . . . . 13
Wet Cup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 14
Gun Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
See Pro Xp™ Electrostatic Air Spray Gun manual
(3A2494) for instructions on how to properly
setup the spray gun. . . . . . . . . . . . . . . . . . . 14
Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Preventive Maintenance Schedule. . . . . . . . . . . 15
Tighten Threaded Connections . . . . . . . . . . . . . 15
Flush the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DataTrak Controls and Indicators . . . . . . . . . . . . . 17
DataTrak Operation. . . . . . . . . . . . . . . . . . . . . . . . . 18
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Run Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Replace DataTrak Battery or Fuse. . . . . . . . . . . 22
Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cart Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Wall Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Wall Mount Kit 24A578 (non-Bellows) . . . . . . . . 27
Cart Mount Kit 256427 (non-Bellows). . . . . . . . . 27
Pump and Gun Control Panel Kits . . . . . . . . . . . 28
Air Controls Mounting Kit (non-Bellows). . . . . . . 29
DataTrak. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Drain Valve Kit 256425. . . . . . . . . . . . . . . . . . . . 29
Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . 30
Wall Bracket (Non-Bellows) . . . . . . . . . . . . . . . . 30
Technical Specifications . . . . . . . . . . . . . . . . . . . . 31
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 32
Graco Information. . . . . . . . . . . . . . . . . . . . . . . . . . 32

Related Manuals
3A7004B 3
Related Manuals
Manual Description
312792 Merkur® Displacement Pump
312794 Merkur® Pump Assembly
312796 NXT® Air Motor
3A2494 Pro Xp™Electrostatic Air Spray Gun
307273 Fluid Outlet Filter
313541 DataTrak Kits

Models
43A7004B
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 G03C10 represents a Merkur package (G),
with a 3:1 ratio pump (03), cart mounting (C), and the components shown for (10) in the table on page 5.
Wall mount
ID Cart mount
ID
ti12326a ti12327a
G03 C 10
First Digit Second and Third Digits (Ratio) Fourth Digit (Package Type) Fifth and Sixth Digit (Components Included)
G
(Merkur
Package)
03 3:1 CCart Mount See Table, page 24
WWall Mount

Models
3A7004B 5
Merkur 3:1 Packages
(G03Wxx and G03Cxx)
Maximum Inlet Air Pressure 50 psi (.34 MPa, 3.4 bar)
Maximum Fluid Working Pressure: 120 psi (.83 MPa, 8.3 bar)
NOTE: Fluid regulator 241976 is ACETAL and not compatible with a lacquer thinner.
Model
Pump
Assembly Gun
Fluid
Reg.
(241976)
(234272)*
Air Controls Hoses Accessories
Data-
Trak App- rovals
Wall
Mount Cart Mount Pump Only
Pump
and
Gun
Gun
Fluid
Hose
(25 ft.)
(50 ft.)‡
Gun Air
Hose
(25 ft.)
(50 ft.)‡ Siphon Kit Fluid Filter
G03W10 G03C10 W03EBS L60T10 †
G03W11 G03C11 W03EAS L60T10 
G03W12 G03C12 W03EBS L85T10        †
G03W13 G03C13 W03EAS L85T10       
G03W13 G03C13 W03EAS None 
----- G03C17 W03EAS None *  
----- G03C19 W03EAS None * ‡‡  
* Fluid regulator 234272 is an air piloted fluid regulator. The air pilot signal is to be provided by the end user.
‡Model G03C19 includes a 50 ft. Gun Fluid Hose and Gun Air Hose. All other models include only a 25 ft. Gun
Fluid Hose and Gun Air Hose.

†
DataTrak™ Module includes agency approvals listed below.
Pro Xp™ Manual Electrostatic Air Spray Gun includes agency approvals listed below.
II 2G Ex h IIB T6 Gb
II 2(1) G Ex h [ia Ga] IIA T3 Gb X
2575 II 1 G
Ex ia IIA T3 Ga
ITS13ATEX27862X
9902471
Class I, Div. 1,
Group D T3A
#53
For use in Class I Div. I hazardous locations
using Group D spray materials.
II 2 G
0.24 mJ T6
FM 12ATEX0068
EN 60060-1
Ta 0°C – 50°C
For use in Group II, Zone 1 areas using
Group IIA spray materials.

Models
63A7004B
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks.
When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings.
Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this
manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite orexplode. Paint or solvent
flowing through the equipment can cause static sparking. To help prevent fire, explosion, and electric
shock:
• Electrostatic equipment must be used only by trained, qualified personnel who understand the
requirements of this manual.
• Ground all equipment, personnel, object being sprayed, and conductive objects in or close to spray
area. Resistance must not exceed 1 megohm. See Grounding instructions.
• Only use grounded Graco conductive air supply hoses.
• Do not use pail liners unless they are conductive and grounded.
•Stop operation immediately ifstaticsparkingoccursoryoufeelashock.Donotuseequipmentuntil
you identify and correct the problem.
• Check gun resistance, hose resistance, and electrical grounding daily.
• Use and clean equipment only in well ventilated area.
• Interlock the gun air and fluid supply to prevent operation unless ventilation air flow is above the
minimum required value.
• Use only Group IIA or Group D materials.
• Never spray of flush solvent at high pressure.
• To clean the exterior of the equipment, cleaning solvents must have a flash point at least
15°C or 59° F above ambient temperature. Non-ignitable fluids are preferred.
• Always turn the electrostatics off when flushing, cleaning or servicing equipment.
• Eliminate all ignitionsources such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static sparking).
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Keep work area free of debris, including solvent, rags and gasoline.
• Keep the spray area clean at all times. Use non-sparking tools to clean residue from the booth and
hangers.
• Keep a working fire extinguisher in the work area.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause
serious injury.
• Follow the Pressure Relief Procedure when you stop spraying/dispensing 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
3A7004B 7
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 Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request Safety Data Sheets (SDSs) from distributor or
retailer.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals andcreate
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.
• 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 Safety Data Sheets (SDSs) 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.
WARNING

Models
83A7004B
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. 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.
SPECIFIC CONDITIONS OF SAFE USE
Equipment must comply with the following conditions to avoid a hazardous condition which can cause
fire or explosion.
• All labels and identification plates must be cleaned with a damp cloth (or equivalent).
• The electronic monitoring system is required to be grounded. See Grounding instructions.
WARNING

Typical Installation
3A7004B 9
Typical Installation
Package components vary. See page 24 to determine the components included in your model. Any item designated
as required is not included in the packages but is necessary for operation.
Key:
A Air Shutoff Valve (required)
BAirFilter
C Air Line Moisture Trap and Drain Valve
F Fluid Filter
G Fluid Regulator
H Electrostatic Air Spray Gun
N Suction Hose and Tube
P Strainer
R Pump Grounding Wire
S Gun Air Pressure Gauge
T Gun Air Pressure Regulator
U Bleed-type Master Air Valve
V DataTrak
W Pump Air Pressure Gauge
X Pump Air Pressure Regulator
Y Insert (for models without DataTrak)
Z Gun Fluid Hose
AA Electrically Conductive Gun Air Hose
AB Electrostatic Spray Gun Grounding Wire
AC Fluid Drain Valve
FIG. 1. Typical Installation
A
BC
R
U
V or Y
S
T
AA
ZNP
F
W
X
H
ti36766
AB
G
AC

Typical Installation
10 3A7004B
General Information
NOTE: Reference numbers and letters in parentheses in
the text refer to the callouts in the figures and the parts
drawing.
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. Contact your Graco dis-
tributor for assistance in designing a system to suit your
particular needs.
Prepare the Operator
All persons who operate the equipment must be trained
in the operation of all system components as well as the
proper handling of all fluids. All operators must thor-
oughly read all instruction manuals, tags, and labels
before operating the equipment.
Prepare the Site
Ensure that you have an adequate compressed air
supply.
NOTE: The compressed air supply to the gun must be
clean and dry, to prevent damage to the finish. Use a
coalescing air filter in the main air supply line.
Bring a compressed air supply line from the air com-
pressor to the pump location. Refer to the performance
charts in your pump assembly manual to find the air
consumption of your pump. 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.
Install a bleed-type shutoff valve (A) in the air line to iso-
late the air line components for servicing. Install an air
line filter (B) and a moisture trap and drain valve (C) to
help remove moisture and contaminants from the com-
pressed air supply.
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.
Mount the Pump
Mount the pump directly to the wall or to a Graco cart.
See page 27 for mounting kits.
Wall-Mounted Pumps
1. Be sure the wall can support the weight of the
pump, bracket, hoses and accessories, as well as
the stress caused during operation.
2. Position the wall bracket about 4-5 ft (1.2-1.5 m)
above the floor. For ease of operation and service,
make sure the pump air inlet, fluid inlet, and fluid
outlet ports are easily accessible.
3. Using the wall bracket as a template, drill 0.4 in. (10
mm) mounting holes in the wall. Wall mounting
dimensions are shown on page 30.
4. Attach the bracket to the wall. Use 3/8 in. (9 mm)
screws that are long enough to keep the pump from
vibrating during operation.
NOTE: Be sure the bracket is level.
Cart-Mounted Pumps
Kit 24E885 is available if you plan to bolt your cart to the
floor. It includes two spacers that keep the legs stable.
Bolts not included.
Ventilate the Spray Booth
Electrically interlock the gun air supply with the ventila-
tors to prevent gun operation without ventilating fans
operating. Check and follow all Local codes and regula-
tions regarding air exhaust velocity requirements.
Provide fresh air ventilation to avoid the buildup of
flammable or toxic vapors. Do not operate the gun
unless ventilation fans are operating.

Typical Installation
3A7004B 11
NOTE: High velocity air exhaust will decrease the oper-
ating efficiency of the electrostatic system. Air exhaust
velocity of 100 ft/min (31 linear meters/minute) should
be sufficient.
Components
See FIG. 1. Components vary by package ordered.
See table on page 24. Your package may include:
• A bleed-type master air valve (U) 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.
• The pump air regulator (X) 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 gun air regulator (T) adjusts the air pressure to
the electrostatic spray gun (H).
• The electrostatic air spray gun (H) dispenses the
fluid.
• The suction hose (N) with strainer (P) allows the
pump to draw fluid from a 5 gallon (19 liter) pail.
• A fluid filter (F) with a 60 mesh (250 micron) stain-
less steel element filters particles from fluid as it
leaves the pump.
• A fluid drain valve (AC) relieves fluid pressure in the
hose and gun.
• DataTrak (V) provides pump diagnostics and mate-
rial usage information. See page 17.
Air and Fluid Hoses
• The gray hose (AA) provides the gun air supply.
• The blue hose (Z) provides the gun fluid supply.
Grounding
The following are minimum grounding requirements for
a basic electrostatic system. Your system may include
other equipment or objects which must be grounded.
Check your local electrical code for detailed grounding
instructions. Your system must be connected to a true
earth ground.
Pump: Verify that the ground screw (GS) is attached
and tightened securely to the air motor. Connect the
other end of the ground wire (R) to a true earth ground.
Electrostatic Spray Gun: Use only the Graco Electri-
cally Conductive Air Supply Hose (supplied). Connect
the Gun Grounding Wire (AC) to the ground screw (GS)
on the air motor.
Air compressor: follow manufacturer’s recommenda-
tions.
All air and fluid lines must be properly grounded. Use
only grounded hoses with a maximum of 500 feet
(150m) combined hose length to ensure grounding con-
tinuity.
Object being sprayed: keep the workpiece hangers
clean and grounded at all times. Follow local code.
When operating the electrostatic gun, any
ungrounded objects in the spray area (people,
containers, tools, etc.) can become electrically
charged.The equipment must be grounded to reduce
the risk of static sparking and electric shock. Electric
or static sparking can cause fumes to ignite or
explode. Improper grounding can cause electric
shock. Grounding provides an escape wire for the
electric current.
FIG. 2. Ground Screw and Wire
GS R
ti12914a
AC

Typical Installation
12 3A7004B
All electrically conductive objects or devices in the
spray area, including paint containers, wash cans and
tools, must be properly grounded.
All persons entering
the spray area: shoes
must have conductive
soles, such as leather, or
personal grounding
straps must be worn.
Rubber or plastic shoe
soles are notconductive.
The operator must not
wear gloves that insu-
late the hand from the
spray gun. The gloves
must be conductive or
modified as shown.
The floor of the spray area must be electrically con-
ductive and grounded. Do not cover the floor with card-
board or any non-conductive material that would
interrupt grounding continuity.
Flammable liquids in the spray area must be kept in
approved, grounded containers. Do not store more than
the quantity needed for one shift.
Fluid supply container: follow local code.
All solvent pails: follow local code. Use only conductive
metal pails, placed on a grounded surface. Do not place
the pail on a non-conductive surface, such as paper or
cardboard, which interrupts grounding continuity.
DataTrak: The DataTrak electronic monitoring system is
required to be grounded. Do not remove it from its stan-
dard mounting location on the air control panel.
Setup
1. See FIG. 1. Attach the gun fluid hose (Z) to the fluid
regulator (G) outlet.
2. Attach other end of the gun fluid hose (Z) to the gun
fluid inlet.
3. Attach the right-hand thread end of the air hose
(AA) to the gun air regulator (T).
4. Attach the left-hand thread end of the gun air hose
(AA) to the Electrostatic air spray gun (H) air inlet.
5. Apply lens cover to both regulator gauge lenses.
6. Verify that suction hose fittings are tight.
Cut off
finger of
glove
Cut out 3 in.
(76 mm) square
from palm of
glove.

Operation
3A7004B 13
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Turn the gun’s ES ON/OFF lever to OFF.
2. Close the bleed-type master air valve (U).
3. Trigger the gun into a grounded metal waste con-
tainer to relieve pressure.
4. Open all fluid drain valves in the system, having a
waste container ready to catch drainage. Leave
drain valve(s) open until you are ready to spray
again.
5. If you suspect the nozzle or hose is clogged or that
pressure has not been fully relieved after following
the steps above, VERY SLOWLY loosen hose end
coupling to relieve pressure gradually, then remove
completely. Clear hose or nozzle obstruction.
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
Flush the Pump, page 15.
When operating the electrostatic gun, any
ungrounded objects in the spray area (people,
containers, tools, etc.) can become electrically
charged.The equipment must be grounded to reduce
the risk of static sparking and electric shock. Electric
or static sparking can cause fumes to ignite or
explode. Improper grounding can cause electric
shock. Grounding provides an escape wire for the
electric current.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as splashing fluid and moving
parts, follow the Pressure Relief Procedure when
you stop spraying and before cleaning, checking, or
servicing the equipment.
ti12582b

Operation
14 3A7004B
Wet Cup
Before starting, fill wet cup 1/3 full with Graco Throat
Seal Liquid (TSL) or compatible solvent.
Prime the Pump
1. Turn the gun’s ES ON/OFF lever to OFF.
2. Close gun air regulator (T) and pump air regulator
(X) by turning knobs counterclockwise reducing
pressure to zero. Close bleed-type air valve (U).
Also verify that all drain valves (C)are closed.
3. Connect air supply line to bleed-type master air
valve (U).
4. Check that all fittings throughout system are tight-
ened securely.
5. Position pail close to pump. Suction hose is approxi-
mately 4 ft (1.2 m) long. Do not stretch hose tight; let
it hang to assist fluid flow into pump.
6. Hold part of gun (H) firmly to side of grounded metal
pail, and hold trigger open.
NOTE: If your pump has DataTrak, see DataTrak
Operation on page 18 or your separate NXT air motor
manual for DataTrak instructions.
7. Datatrak equipped units with runaway protection
only: enable the prime/flush function by pushing the
prime/flush button on the DataTrak.
8. Open bleed-type master air valve (U). Slowly turn
clockwise pump air regulator (X) increasing pres-
sure until pump starts.
9. Cycle pump slowly until all air is pushed out and
pump and hoses are fully primed.
10. Datatrak equipped units with runaway protection
only: disable the prime/flush function by pushing the
prime/flush button on the DataTrak.
11. Release gun trigger. Pump should stall against
pressure.
Gun Setup
See Pro Xp™ Electrostatic Air Spray Gun manual
(3A2494) for instructions on how to properly setup the
spray gun.
Shutdown
Follow Pressure Relief Procedure, page 13.
Always flush the pump before the fluid dries on the dis-
placement rod. See Flush the Pump on page 15.
To avoid pinch hazard, do not operate pump with the
rod guard removed.
FIG. 3. Fill Wet Cup
Wet Cup
ti11927a
Rod Shield
NOTICE
Never allow the pump to run dry of the fluid being
pumped. A dry pump quickly accelerates to a high
speed, possibly damaging itself. If your pump
accelerates quickly, or is running too fast, stop it
immediately and check the fluid supply. If the supply
container is empty and air has been pumped into
the lines, refill the container and prime the pump
and the lines with fluid, or flush and leave it filled
with a compatible solvent. Be sure to eliminate all
air from the fluid system.

Maintenance
3A7004B 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 connec-
tions are tight and leak-free.
Flush the Pump
Flush the pump:
• Before first use
• When changing colors or fluids
• Before repairing equipment
• Before fluid dries or settles out in a dormant pump
(check the pot life of catalyzed fluids)
• At the end of the day
• Before storing the pump.
Flush at the lowest pressure possible. Flush with a fluid
that is compatible with the fluid you are pumping and
with the wetted parts in your system. Check with your
fluid manufacturer or supplier for recommended flushing
fluids and flushing frequency.
1. Follow Pressure Relief Procedure, page 13.
2. Be sure the ES ON/OFF lever is turned to OFF.
3. Place siphon tube in grounded metal pail containing
cleaning fluid.
4. Close gun air regulator (T) and pump air regulator
(X) by turning knob counterclockwise, reducing
pressure to zero.
5. Set pump to lowest possible fluid pressure, and start
pump.
6. Hold a part of the gun firmly to a grounded metal
pail.
7. DataTrak equipped units with runaway protection
only: enable the prime/flush function by pushing the
prime/flush button on the DataTrak.
8. Trigger gun. Flush system until clear solvent flows
from gun.
9. DataTrak equipped units with runaway protection
only: disable the prime/flush function by pushing the
prime/flush button on the DataTrak.
10. Follow Pressure Relief Procedure, page 13.
11. Clean the inside and outside of the suction tube.
Wet Cup
Fill the wet cup 1/3 full with Graco Throat Seal Liquid
(TSL). Maintain level daily.
To avoid fire and explosion, always ground equipment
and waste container. To avoid static sparking and
injury from splashing, always flush at the lowest
possible pressure.

Troubleshooting
16 3A7004B
Troubleshooting
1. Follow Pressure Relief Procedure, page 13,
before checking or repairing pump.
2. Check all possible problems and causes before
disassembling pump.
3. For all problems related to electrostatics, see
Troubleshooting, in your gun manual.
* To determine if the fluid hose or gun is obstructed, follow thePressure Relief Procedure. Disconnect the fluid hose
from the pump and place a container at the pump fluid outlet to catch any fluid. Turn on the air just enough to start the
pump. It the pump starts when the air is turned on, the obstruction is in the hose or gun.
Problem Cause Solution
Pump fails to operate. Restricted line or inadequate air sup-
ply; 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. Clean; always stop the pump at the bottom
of its stroke; keep the wet-cup 1/3 filled with
Graco throat seal liquid (TSL).
Dirty, worn, or damaged air motor
parts. Clean or repair air motor. See NXT Air Motor manual 312796.
DataTrak models only: Air valve can-
not cycle because solenoid pin is
extended
Enable runaway protection (See DataTrak
Operation, Setup Mode, page 18). Bleed
air from motor. Press on the DataTrak
display to retract solenoid pin.
Pump operates, but output is
low on both strokes. Restricted line or inadequate air sup- ply; 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.
Worn packings in displacement
pump. Replace packings. See manual Displace- ment Pump 312792.
Pump operates, but output is
low on downstroke. Held open or worn ball check valves or piston packings. Clear valve; replace packings. See Pump Assembly manual 312794.
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 Pump Assembly manual 312794.
Fluid being pumped is visible
in the TSL reservoir. Worn throat packings. Replace throat packings. See Pump Assem- bly manual 312794.
Fluid is visible in the overflow
chamber. Damaged bellows. Replace. See Displacement Pump manual 312793.

DataTrak Controls and Indicators
3A7004B 17
DataTrak Controls and Indicators
Key for FIG. 4
AA Runaway Limit, in cycles per minute (user settable;
00=OFF)
AB Lower Displacement (user settable)
AC Flow Rate Units (user settable to gpm [US], gpm
[Imperial], oz/min [US], oz/min [Imperial], l/min, or cc/min)
AD LED (fault indicator when lit)
AE Display
PF Prime/Flush Key (Enables Prime/Flush mode. While in
Prime/Flush mode, runaway protection is disabled and the
batch totalizer [BT] will not count.) LED will flash while in
Prime/Flush mode.
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.
CF Cycle/Flow Rate
BT Batch Totalizer
GT Grand Totalizer
RT Runaway Toggle (enable/disable)
UT E1 Toggle
DT E2 Toggle
ST E5 Toggle
/min,
FIG. 4. DataTrak Controls and Indicators
AD
AE, see details at right
CF BT
GT
AC
RT
AA
PF
RK
AB
UT
DT
ST
Run Mode
Setup Mode
TI11883a
RK
PF
ti8622b
ti8623b

DataTrak Operation
18 3A7004B
DataTrak Operation
NOTE: The display (AE) will turn off after 1 minute to
save battery life. Press any key to wake up the display.
Setup Mode
1. See FIG. 4. Press and hold for 5 seconds until
Setup menu appears.
2. To enter settings for runaway (if equipped), lower
size, and flow rate units, and to enable runaway, E1,
E2, and E5 error options, press to change the
value, then to save the value and move the cur-
sor to the next data field. See page 20 for a descrip-
tion of E1, E2, and E5 error codes.
NOTE: Graco recommends setting runaway (if
equipped) to 60 . All DataTrak modules are
shipped with runaway protection not enabled.
NOTE: When runaway, E1, E2, and E5 error options are
enabled, a will appear on the setup screen. See FIG.
4.
3. Move the cursor to the E5 error enable option field,
then press once more to exit Setup mode.
Run Mode
Pump Runaway
NOTE: DataTrak is available with and without runaway
protection.
1. See FIG. 4. If pump runaway occurs, the runaway
solenoid will actuate, stopping the pump. The LED
(AD) will flash and the display (AE) will indicate a
runaway condition (see Table 1). The display will
cycle through six instruction screens.
2. Runaway Screens 1 and 2: To reset the runaway
solenoid, close the master air valve (U). Wait for air
to completely bleed off the air motor.
3. Runaway Screens 3 and 4: After the air is bled off,
push the solenoid release button down to reset the
air valve. The button will pop back up when the air
valve is repressurized.
4. Runaway Screens 5 and 6: Press to clear the
diagnostic code and reset the runaway solenoid.
5. Open bleed-type master air valve (U) to restart
pump.
NOTE: To disable runaway monitoring, go to setup
mode and set runaway value to 0 (zero) or toggle (RT)
off (see FIG. 4).
NOTICE
To prevent damage to the softkeybuttons, do notpress
the buttons with sharp objects such as pens, plastic
cards, or fingernails.
FIG. 5. Reset the Air Valve
ti11902a
Solenoid release
button

DataTrak Operation
3A7004B 19
Prime/Flush
1. See FIG. 4. To enter Prime/Flush mode, press any
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.
The grand totalizer (GT) continues to count.
3. To exit Prime/Flush mode, press any key to wake up
the display, then press . The Prime/Flush sym-
bol will disappear from the display and the LED will
stop flashing.
Counter/Totalizer
See FIG. 4. The last digit of the batch totalizer (BT) rep-
resents tenths of gallons or liters. To reset the totalizer,
press any key to wake up the display, then press and
hold for 3 seconds.
• If AC is set to gallons or ounces, BT and GT dis-
play gallons.
• If AC is set to liters or cc, BT and GT display
liters.
• If AC is set to cycles, BT and GT display cycles.
Press to toggle between flow rate units and cycles.
A letter under the BT display indicates that both BT and
GT are displaying gallons (g) or liters (l). No letter
means both BT and GT are displaying cycles.
Display
See FIG. 4. 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.
NOTE: DataTrak will continue to count cycles when dis-
play is off.
NOTE: The display (AE) may turn off if a high-level static
discharge is applied to the DataTrak. Press any key to
wake up the display.
Diagnostics
DataTrakcandiagnoseseveral problems withthepump.
When the monitor detects a problem, the LED (AD, FIG.
4) will flash and a diagnostic code will appear on the dis-
play. See Table 1.
To acknowledge the diagnosis and return to the normal
operatingscreen, press oncetowake upthedisplay,
and once more to clear the diagnostic code screen.

DataTrak Operation
20 3A7004B
Table 1: Diagnostic Codes
Symbol Code Code Name Diagnosis Cause
Runaway
(DataTrak only) Pump running faster than set runaway limit. •Increased air pressure.
•Increased fluid output.
•Exhausted fluid supply.