Repair

-For portable spray application of architectural paints and coatings or replacement pump for Graco GMaxt II sprayers -

3300 psi (228 bar, 22.8 MPa) Maximum Working Pressure

Model 287512, Series A

GMax II 3900 Sprayer,

Rental Pro 360G

Model 287513, Series A

GMax II 5900 Sprayer,

UltraMax II 1095/1595 with ProConnect

Model 287579, Series A

GMax II 5900HD Sprayer

Model 249122, Series A

GMax II 7900 Sprayer,

Ultra Max II 1895

Model 287928, Series A

Mark Vt International

Model 287929, Series A

Mark V North America

Model 289590, Series A

TexSpray 7900HD,

Mark X, 230V, Domestic

ti6177a

Important Safety Instructions

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

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

Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001

Table of Contents

Warnings

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.

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

INSTRUCTIONS D Do not exceed the maximum working pressure temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

DUse fluids and solvents compatible with equipment wetted parts. See Technical Data in all equip- ment manuals. Read manufacturer fluid and solvent warnings.

D Check equipment daily. Repair or replace worn or damaged parts immediately. D Do not alter or modify equipment.

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

D Use equipment only for its intended purpose. Call your Graco distributor for information.

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 safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers.

D Keep clear of moving parts.

D Do not operate equipment with protective guards or covers removed.

DPressurized equipment can start without warning. Before checking, moving or servicing equipment, follow the Pressure Relief Procedure on page 3. Disconnect power cord.

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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,

D or install or clean the spray nozzle.

1.Lock gun trigger safety.

2.Turn engine ON/OFF switch to OFF.

3.Move pump switch to OFF and turn pressure control knob fully counterclockwise.

4.Unlock trigger safety. Hold metal part of gun firmly to side of grounded metal pail, and trigger gun to relieve pressure.

5.Lock gun trigger safety.

6.Open pressure drain valve. Leave open until ready to spray again.

If you suspect that the spray tip or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, VERY SLOWLY loos- en tip guard retaining nut or hose end coupling to re- lieve pressure gradually, then loosen completely. Now clear tip or hose.

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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Disassembling the pump

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

202

228

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

211 used on 249122, 289590

227

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Fig. 3

7570e

Fig. 1

Fig. 2. Unscrew intake valve from cylinder.

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

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

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Fig. 2

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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 287512

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

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Fig. 6

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

Not used on 287512

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 wiper (216) (note orientation) and backup washer (229) 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.

Not used on

287512

210

229

216

Fig. 7

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Note: pump 249122 and 289590 do not use leather packings in piston stack. Alternately stack blue (208) and brown (218) packings on this pump.

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

Fig. 9

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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

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Fig. 10

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

Torque to 27 +/--3 ft-lb (36.61 +/-- 4.06 N??? m)

(287512)

Torque to 55 +/--3 ft-lb (74.57 +/-- 4.06 N??? m)

(249122, 287513, 289590)

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Fig. 12

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 o--ring

on 249122, 228 289590 )

Fig. 11

Fig. 13

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CAUTION

Never slide piston assembly (222) into top of sleeve (220) as this may damage piston packings.

Fig. 14. Grease o-rings (221) and place inside cylinder (205) and on sleeve (220). Slide sleeve (220) into bottom of cylinder (205). Replace o-ring (207) if desired.

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

Fig. 15. Grease top inch or two of piston rod (222) that goes through the sleeve/cylinder assembly throat packings (205). Grease piston packings at bottom of piston rod.

Carefully slide piston assembly (222) into bottom of sleeve/cylinder assembly (205) until pump rod pro- trudes at the top and piston packings are totally inside the sleeve (220).

220

221

207

Fig. 15

205

207

222

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Fig. 16. 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.

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Fig. 16

Fig. 17. Install intake valve on cylinder. If a wrench is used torque as follows:

70 +/--5 ft-lb (94.91 +/-- 6.77 N???m) (Model 287512) 80 +/--5 ft--lb (108.5 +/-- 6.77 N???m)

(Model 287513, 287579 )

200 +/--15 ft--lb (271.2 +/-- 20.34 N???m) (Model 249122, 289590 )

If a wrench is not used, be sure intake valve is bot- tomed out against cylinder.

Fig. 18. Torque packing nut (202) down onto adjust- ment spacer (228) 140 +/--10 in-lb (15.82 +/-- 1.13 N???m).

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.

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Fig. 18

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Fig. 17

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Cross Sectional Reference

215

212

227

Fig 19

222

201

Pump 287512

202

228

203 V-Maxt UHWMPE, blue

204

Pump 287512

206

208 2 217

216 V-Maxt UHWMPE, blue

229

214

213

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Technical Data

acetal, polyethylene

NOTE: LoctiteR is a Loctite Company registered trademark.

310894 9

Parts -- Pump 287512

Model 287512, Series A

?????? These parts are included with pump 287512.

220 213

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221*

222

219*

218*

217*

216*

229

206*

210

215

212???

231

10 310894

Parts -- Pump 287513

Model 287513, Series A

201

202

228

224*

*203

223*

204*

221*

222

219*

*218 208*

*These parts are also included in Repair Kit 248213, which may be purchased separately.

??? These parts are also included in Carbide Seat Kit 244199, which may be purchased separately.

?????? These parts are included with pump 287513.

205

207*

221*

220

???*214

???*227

217*

216*

229

206*

210

215

212???

213

231

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310894 11

Parts -- Pump 249122

Model 249122, Series A;

221*

222

219*

218*

217* 216*

229

206*

210

211

215

212???

213

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Parts -- Pump 287579

Model 287579, Series A

201

202

228

224*

*203

223*

204*

221*

222

219*

*218 208*

*These parts are also included in Repair Kit 248213, which may be purchased separately.

??? These parts are also included in Carbide Seat Kit 244199, which may be purchased separately.

?????? These parts are included with pump 287579.

205

207*

221*

???*214

???*227

217*

216*

229*

206*

210

215

212???

213

220

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Parts -- Pump 287928

Model 287928, Series A

201

202

228

224*

*203

223*

204*

221*

222

219*

*218 208*

*These parts are also included in Repair Kit 249189, which may be purchased separately.

??? These parts are also included in Carbide Seat Kit 244571, which may be purchased separately.

?????? These parts are included with pump 287928.

205

207*

221*

???*214

???*227

217*

216*

229*

206*

210

215

212???

213

220

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Parts -- Pump 287929

Model 287929, Series A

201

202

228

224*

*203

223*

204*

221*

222

219*

*218 208*

*These parts are also included in Repair Kit 248213, which may be purchased separately.

??? These parts are also included in Carbide Seat Kit 244199, which may be purchased separately.

?????? These parts are included with pump 287929.

205

207*

221*

???*214

???*227

217*

216*

229*

206*

210

215

212???

213

220

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310894 15

Parts -- Pump 289590

Model 289590, Series A;

?????? These parts are included with pump 289590.

220

221*

222

219*

218*

217* 216*

229

206*

210

211

215

212???

213

ti5673a

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Notes

310894 17

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.

Graco Phone Number

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.

This manual contains English GN 310894 MM 310894

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

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

www.graco.com

2/2005, Rev 03/2008

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