Graco 309277ZAC User Manual

Instructions -- Parts List

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

Displacement Pump

3600 psi (250 bar, 24.8 MPa) Maximum Working Pressure

Model 244197, Series A

Ultra GMaxt 3900

Model 244224, Series A

Ultra Max and Ultimate Mx 1595 GMax 5900 and 5900 Convertible

Model 244201, Series A

245044, 245046, 245049 Mark Vt GMax 5900HD

Model 245904 Series A

245047 Mark V International (ceramic balls)

Model 244954, Series A, B, C

HydraMaxt 225

Model 244957, Series A, B, C

HydraMax 300/350

Model 245889, Series B

Mark V SpackMaxt

Model 246257, Series A

GMax 7900, GHt 200; Models 233940 -- 233943

Model 248971, Series A

GH 200; Models 248559 Series A -- 248567 Series A EHt 200

Model 248736, Series A

248561 Series A, 248563 Series A GH 230, GH 300

Model 277068, Series A

LineLazert IV 200 HS

Max and Ultimate Mxt 795 and 1095

309277ZAC

Model 287815, Series A

GH 230: Model 248561 Series B GH 300: Model 248563 Series B

Model 287814 Series A

GH 200: Model 248559 Series B

Model 287946, Series A

Mark X

Table of Contents

Warnings 2......................................

Service 4.......................................

Technical Data 16................................

Parts, Pump

244197 17.....................................

244224 18.....................................

244201 18.....................................

245904 18.....................................

244954 19.....................................

Symbols

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

244957 20.....................................

245889 21.....................................

287946 22.....................................

246257 23.....................................

287815 24.....................................

287814 25.....................................

248736 26.....................................

248971 27.....................................

277068 27.....................................

Warranty 28.....................................

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

2 309277

INSTRUCTIONS

WARNING

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

D This equipment is for professional use only.

D Read all instruction manuals, tags, and labels before operating the equipment.

D Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco

distributor.

D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

D Do not exceed the maximum working pressure of the lowest rated system component. Refer to the

Technical Data on page 16 for the maximum working pressure of this equipment.

D Use fluids and solvents compatible with the equipment wetted parts. Refer to the Technical Data

section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

D Do not use 1,1,1--trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or

fluids containing such solvents in pressurized aluminum equipment. Such use could result in a chemical reaction, with the possibility of explosion.

D Comply with all applicable local, state, and national fire, electrical, and safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers.

D Keep clear of all moving parts when starting or operating the pump.

D Before servicing the equipment, follow the Pressure Relief Procedure on page 4 to prevent the

equipment from starting unexpectedly.

SKIN INJECTION HAZARD

High--pressure fluid from dispense valve, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgi-

cal treatment.

D Do not point dispense valve at anyone or at any part of the body.

D Do not put your hand over the end of the dispense nozzle.

D Do not stop or deflect leaks with your hand, body, glove, or rag.

Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

3309277

Service

Pressure Relief Procedure

WARNING

PRESSURIZED EQUIPMENT HAZARD

The system pressure must be manually relieved to prevent the system from

starting or spraying accidentally. To reduce the risk of an injury from accidental spray from the gun, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you:

D areinstructedtorelievethepressure, D stop spraying, D check or service any of the system equipment, D or install or clean the spray nozzle.

1. Engage gun safety latch.

2. Turn ON/OFF switch to OFF.

3. Unplug power cord.

4. Disengage gun safety latch. Hold metal part of gun against grounded metal pail and trigger gun into pail to relieve pressure.

5. Engage gun safety latch.

6. Open any fluid drain valves in system. Leave drain valve open until ready to dispense again.

Tools Needed

Vise 12 in. adjustable, open end wrench (2) Hammer, 20 oz maximum Small screwdriver Throat Seal Liquid Pick or long small screwdriver

Cleaning and Inspectin g Parts

1. Clean and inspect parts. Pay particular attention to the ball seats in the intake valve and piston, which must have no nicks or wear, and to the inside of the sleeve and the outside of the piston rod, which must not be worn or scratched. Replace worn or damaged parts.

WARNING

COMPONENT RUPTURE HAZARD

Never use sharp or pointed tools to remove sleeve or other components

which could result in pump rupture and cause serious bodily injury. If the sleeve cannot be removed easily, return the sleeve and cylinder to your Graco distributor for removal.

Pump Repair Kits

Pump Repair Kit

244197 248212

244224 248213

244201 248213

244954 246341

244957 244958

245889 245819

245904 244200

246257 246341

248736 246341

248971 246341

277068 246341

287814 287813

287815 287813

287946 287945

2. Remove and clean the sleeve when you are repacking the pump.

4 309277

Service

Repair When Pump Is Off The Sprayer

Disassembling the pump

Fig. 1. Remove packing nut (202) and throat adjustment spacer (228).

202

228

Fig. 1

ti2332a

227

(o-ring on

bottom

all except

244957)

Fig. 3

245889, 287946 only

215

236

227

(o-ring on top

244957 only)

7570e

Fig. 2. Unscrew intake valve from cylinder.

Fig. 2

7569A

Fig. 4. Tap piston rod out of cylinder with a hammer or flip over and tap piston rod out against a bench.

Note: Sleeve may come out of cylinder with piston rod.

Fig. 4

7571a

Fig. 5. Remove piston rod from sleeve, or remove sleeve from cylinder.

Fig. 3. Disassemble intake valve. Clean and inspect. O-ring (227) may require a pick for removal.

Fig. 5

7572A

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WARNING

Service

COMPONENT RUPTURE HAZARD

Do not clean or wipe the piston valve threads. Cleaning the piston valve

threads could destroy the special sealing patch and cause the piston valve to come loose during operation, causing pump bursting and possible serious bodily injury.

Fig. 6. Unscrew piston valve from piston rod. Clean and inspect parts. The piston has a special thread locking/sealing patch. Do not remove the patch. The patch allows four disassembly/assembly procedures before it is necessary to apply Loctiter to the threads.

Not

used on

244197

Fig. 8

7573B

Assembling the pump

Fig. 9. Soak all leather packings in SAE 30W oil for 1 hour minimum prior to assembly. Stack male gland (204) on piston rod. Alternately stack UHMWPE (208) and leather (218) packings (note orientation) on piston rod. Install female gland (217). Install piston guide (216) (note orientation) on piston valve (210). The special sealing patch on piston valve threads is good for four repackings. Use Loctiter on piston valve threads after four repackings.

Fig. 6

7576A

Fig. 7. Remove packings and glands from piston rod.

used on 245889,

Not

used on

244197

287946, 287814,

287815

ti3940a

Fig. 7

Fig. 8. Remove throat packings and glands from cylinder. Discard throat packings and glands.

Not

used on

244197

1 1

218 208

204

244954, 246257, 245889; 208 and 218 are 203 and 223, respectively. 287946; 208 and 218 are 203 and 209, respectively.

210

216

Fig. 9

Note: Pump 287814 & 287815 do not use leather packings in piston stack. Alternately stack blue (208) and brown (218) packings on these pumps.

used on 245889, 287946, 287814,

287815

217

7574c

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Service

Fig. 10. Install ball (206) in piston rod. If Loctiter is applied to piston valve threads, ensure that none gets on ball.

206

Fig. 10

7575A

Fig. 11. Tighten piston valve to piston rod as specified:

Fig. 12. Soak all leather packings in SAE 30W oil for 1 hour minimum prior to assembly. Place male gland (204) in cylinder. Alternately stack UHMWPE (203) and leather packings (223) (note orientation). Place female gland (224) in top of cylinder. Seat packings.

224

Not

used on

244197

223

203

204

Fig. 12

7573B

Torque to 27 +/--3 ft-lb

(244197)

Torque to 55 +/--3 ft-lb

(244224, 244201,

287814, 287815)

Torque to 190 +/-- 10 ft--lb

(244957)

Torque to 120 +/-- 6 ft-lb

(244954, 246257, 245889,

287946, 277068, 248736,

248971)

Fig. 11

7576A

Fig. 13. Install seal (201) into packing nut (202). Install throat adjustment spacer (228) onto packing nut. Loosely install packing nut into cylinder.

201

202

228

ti2333a

Fig. 13

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Service

Fig. 14. Grease piston packings and sleeve top edge.

Fig. 16. Grease top inch or two of piston rod that will go through the cylinder throat packings.

Fig. 16

7579A

Fig. 17. Grease o-ring (221) and place on sleeve. Slide sleeve/piston rod assembly into bottom of cylinder. Replace o-ring (207) if desired.

Note: O-ring (207) is not required for safe pump operation.

Fig. 14

Fig. 15. Carefully slide piston assembly into top of sleeve.

Fig. 15

7578A

7577A

Fig. 17

207

221

7582A

8 309277

Service

Fig. 18. Reassemble intake valve with new o-ring (227), seat (212) and ball (214). Seat may be flipped over and used on other side. Clean seat thoroughly. Snap intake spring (236) into place inside ball guide (215).

Spring (236), for model 287946, is optional and not included with the pump.

245889, 287946 only

215

236

215

214

212

227

(o-ring on

bottom

all except

244957)

Fig.18

Fig. 19. Install intake valve on cylinder. If a wrench is used torque as follows:

67 +/--5 ft-lb (model 244197) 80 +/--5 ft--lb (models 244201, 244224, 245904) 200 +/--10 ft--lb (models 244954, 246257, 245889, 287946, 277068, 248736, 248971)

200 +/--15 ft--lb (model 244957, 287814, 287815) If a wrench is not used, be sure intake valve is bottomed out against cylinder.

227

215

214

227

212

(o-ring

on top

244957

only)

7570c

Fig. 19

Fig. 20. Torque seal and packing nut (202) down onto throat adjustment spacer (228) to 100 +/--10 in-lb (75 +/--5 in-lb for 246257) (140+/--10 in--lb for 287814,

287815).

Remove throat adjustment spacer (228) when pump packings begin to leak after much use. Then tighten packing nut down until leakage stops or lessens. This allows approximately 100 gallons of additional operation before a repacking is required.

202

228

ti2332a

Fig. 20

7569A

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