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

UltraR Max and Ultimate Mxt 795 and 1095

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

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

309277ZAC

EN

Table of Contents

Symbols

Warning Symbol

WARNING

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

Caution Symbol

CAUTION

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

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WARNING

EQUIPMENT MISUSE HAZARD

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

INSTRUCTIONS

D This equipment is for professional use only.

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

DUse 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.

DDo 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.

DUse 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.

DDo 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.

DBefore 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, check- ing, or servicing equipment.

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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 are instructed to relieve the pressure, D stop spraying,

D check or service any of the system equipment,

Dor 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.

Pump Repair Kits

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 Inspecting 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.

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

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Service

Repair When Pump Is Off The Sprayer

Disassembling the pump

Fig. 1. Remove packing nut (202) and throat adjust- ment spacer (228).

202

228

Fig. 2. Unscrew intake valve from cylinder.

245889, 287946 only

215

236

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

Service

WARNING

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.

Not used on 244197

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.

Fig. 8

7573B

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

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 spe- cial sealing patch on piston valve threads is good for four repackings. Use Loctiter on piston valve threads after four repackings.

1 244954, 246257, 245889; 208 and 218 are 203 and 223, respectively. 287946; 208 and 218 are

Fig. 7

ti3940a

Fig. 9

Fig. 8. Remove throat packings and glands from cylin- der. Discard throat packings and glands.

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

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

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.

206

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

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. 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

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

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

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

207

221

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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

bottom all except 244957)

7570c

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 bot- tomed out against cylinder.

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 opera- tion before a repacking is required.

202

228

ti2332a

Fig. 20

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Service

Repair When Pump Is On The Sprayer

WARNING

SKIN INJECTION HAZARD

To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief

Procedure on page 4.

Fig. 1. Remove intake valve.

Fig. 2. Use screwdriver to push retaining spring up and push pin out.

7674A

Fig. 2

Fig. 3. Disassemble intake valve. Clean and inspect.

O-ring (227) may require a pick for removal.

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Fig. 4. Remove piston rod and sleeve.

Fig. 4. Invert piston rod and sleeve and pound on hard surface until piston rod comes out of sleeve.

Fig. 7. Invert piston rod and insert into cylinder to force out throat packings.

Fig. 5

Fig. 6. Remove packing nut (202)

Fig. 8. Insert piston rod into cylinder with pin hole up and piston valve down. Insert pin into piston rod and crank shaft.

7572A

202

7675A

Fig. 8

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Fig. 9. Remove piston valve from piston rod with a wrench.

Fig. 11. Soak all leather packings in SAE 30W oil for 1 hour minimum prior to assembly. Stack male gland (204). Alternately stack UHMWPE (203) and leather (223) packings (note orientation). Install female gland (224). Install seal (201) and packing nut (202) and throat adjustment spacer (228).

Fig. 9

7748A

Fig. 10. Remove pin and piston rod from cylinder.

Fig. 12. Remove packings and glands from piston rod.

used on 245889, 287946, 287814, Not 287815

used on 244197

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Service

Fig. 13. Soak all leather packings in SAE 30W oil for 1 hour minimum prior to assembly. Stack male gland (219) 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 spe- cial sealing patch on piston valve threads is good for four repackings. Use Loctiter on piston valve threads after four repackings.

1244954, 246257, 245889; 208 and 218 are 203 and 223, respectively. 287946; 208 and 218 are 203 and 209, respectively.

Fig. 13

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

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

Torque as follows:

27 +/--3 ft-lb (for model 244197)

55 +/--3 ft-lb (for models 244224, 244201, 245904, 287814, 287815)

120 +/-- 6 ft-lb (for models 244954, 246257, 245889, 287946, 277068, 248736, 248971)

190 +/--10 ft--lb (for model 244957)

Fig. 15. Grease piston packings and sleeve top edge.

Fig. 16. Carefully slide piston assembly into top of sleeve. Assure u-cup is not rolled over or damaged.

Fig. 17. Grease top inch or two of piston rod that will go through the cylinder throat packings.

206

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Service

Fig. 18. Grease o-ring (221) and place on sleeve. Slide sleeve/piston rod assembly into bottom of cylinder. Re- place o-ring (207) if desired.

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

Fig. 20. Use screwdriver to push retaining spring up.

Fig. 18

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 opera- tion before a repacking is required.

7674B

Fig. 20 Note: Make sure retaining ring falls into slot.

Fig. 21. Push in pin.

202

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Service

Fig. 22. 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.

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

245889, 287946 only

215

236

Fig. 23. Install intake valve on cylinder. Torque: 67 +/--5 ft-lb (model 244197)

80 +/--5 ft-lb (model 244224, 244201, 245904) 200+/--10 ft-lb (model 244954, 246257, 245889, 287946, 244957, 248971, 248736, 277068, 287814, 287815)

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Service

Cross Sectional Reference

222

201

V-Maxt UHWMPE, brown on

287814 & 287815

Pump 245889

224

223

202

228

221

220

Pump 244197

206

207

210

2

V-Maxt UHWMPE, blue

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Parts -- Pump 244197

Model 244197, Series A

220

221*

222

219*

*208 218*

217*

216*

206*

210

215

???*214

212???

???*227

213

TI0716c

309277 17

Parts -- Pumps 244224, 244201, 245904

Models 244224, Series A; 244201, Series A; 245904, Series A

*These parts are also included in Repair Kit 248213 (pump 244224, 244201) or Repair Kit 244200 (pump 245904), which may be purchased separately.

???These parts are also included in Carbide Seat Kit 244199 (pump 244224, 244201) or Carbide Seat Kit 244571 (pump 245904), which may be purchased separately.

201

202

228

224*

*203

223*

204*

225

205

207*

221*

220

221*

222???

219*

*218 208*

217* 216* 206*

210

215

TI0717d

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Parts -- Pump 244954

Model 244954, Series A

222???

236

215

*These parts are also included in Repair Kit 246341, which may be purchased separately.

??? These parts are also included in Carbide Seat Kit

???*214

219*

212???

240918, which may be purchased separately.

223*

217* 216* 206*

210

213

TI1308cd

309277 19

Parts -- Pump 244957

Model 244957, Series A

*These parts are also included in Repair Kit 244958, which may be purchased separately.

??? These parts are also included in Carbide Seat Kit 244960, which may be purchased separately.

*203

*208

201

202

228

225

224*

205

223*

221*

218*

???*227

212??? 217*213

*216

206*

210

TI1317b

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Parts -- Pump 245889

Model 245889, Series B

*These parts are also included in Repair Kit 245819, which may be purchased separately.

??? These parts are also included in Carbide Seat Kit 245885, which may be purchased separately.

*223

1 *216

237

220

221*

222

219*

203*

217*

206

210

215

205

???214

207*???*227

221*

236

212???

213

ti2086c

309277 21

Parts -- Pump 287946

Model 287946, Series A

*These parts are also included in Repair Kit 287945, which may be purchased separately.

It is recommended that the check valve be repaired

at the same time as the pump. See manual 313773???214 and Kit 258650.

207*???*227

221*

220

221*

222

219*

203*

217*

206

210

215

236

212???

213

ti2086c

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Parts -- Pump 246257

Model 246257, Series A

221*

222

219*

*223 203*

1 *216

217*

??? These parts are also included in Carbide Seat Kit 240918, which may be purchased separately.

207*

221*

220

206*

210

236

215

???*214

212???

???*227

213

ti2331a

309277 23

Parts -- Pump 287815

Model 287815, Series A

221*

* These parts are also included in Repair Kit 287813, which may be purchased separately.

207*

??? These parts are also included in Carbide Seat Kit 240918, which may be purchased separately.

221*

ti2331c

238

217*

1*216

237

???*214

???*227

222

219*

203*

206*

210

236

215

212???

213

220

24 309277

Parts -- Pump 287814

Model 287814 Series A

221*

222

219*

203*

206*

210

236

215

212???

213

*These parts are also included in Repair Kit 287813, which may be purchased separately.

??? These parts are also included in Carbide Seat Kit 240918, which may be purchased separately.

221*

ti2331c

220

309277 25

Parts -- Pump 248736

Model 248736, Series A

221*

222

219*

*223 203*

1 *216

217*

206*

210

*These parts are also included in Repair Kit 246341, which may be purchased separately.

236

215

???*214

212???

???*227

213

ti2331a

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Parts -- Pump 248971, 277068

Model 248971, Series A; 277068, Series A

221*

222

219*

*223 203*

1 *216

217*

206*

210

236

215

???*214

212???

???*227

213

221*

220

ti2331a

309277 27

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 sub- stitution 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 free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT

NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco???s sole obligation and buyer???s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential 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 mak- ing any claim for breach of these warranties.

In no event will Graco be liable for indirect, 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 reconnais- sent 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 procedures concern??es.

ADDITIONAL WARRANTY COVERAGE

Graco does provide extended warranty and wear warranty for products described in the ???Graco Contractor Equipment Warranty Program???.

TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:

1--800--690--2894 Toll Free

All written and visual data contained in this document reflect 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 309277

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440--1441

Copyright 2000, Graco Inc. is registered to ISO 9001

www.graco.com

Rev. 08/2011

28 309277