Graco Ultra-Lite 240-200 Operation manual

308–807
Rev. B
Supersedes A
First choice when
quality counts.t
7903A
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
Ultra-LitetIn-Line Flow Gun
3400 psi (23.4 MPa, 234 bar) Maximum Working Pressure
Model 240–199
With Ball End Needle
Model 240–200
With Tapered Needle
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Graco Inc. is registered to I.S. EN ISO 9001

2 308-807
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 12. . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the corresponding
instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the cor-
responding instructions.
WARNING
INJECTION HAZARD
Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause an
extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin
can also cause a serious injury.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
DDo not point the gun at anyone or at any part of the body.
DDo not put your hand or fingers over the gun nozzle.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DDo not “blow back” fluid; this is not an air spray system.
DBe sure the gun trigger safety operates before dispensing.
DLock the gun trigger safety when you stop dispensing.
DFollow the Pressure Relief Procedure on page 5 if the gun nozzle clogs and before cleaning,
checking or servicing the equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

3308-807
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead 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.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure of the lowest rated system component. This equip-
ment has a 3400 psi (23.4 MPa, 234 bar) maximum working pressure.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 66_C (150_F) or below –40_C (–40_F).
DDo not use the hoses to pull the equipment.
DUse only Graco approved hoses. Do not remove hose spring guards, which help protect the hose
from rupture caused by kinks or bends near the couplings.
DUse fluids or solvents that are compatible with the equipment wetted parts. See the Technical
Data section of all the equipment manuals. Read the fluid and solvent manufacturer’s warnings.
DNever 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.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and re-
sult in a fire or explosion and serious injury.
DGround the equipment. Refer to Grounding on page 4.
DIf there is any static sparking or you feel an electric shock while using this equipment, stop dis-
pensing immediately. Do not use the equipment until you identify and correct the problem.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being dispensed.
DKeep the dispense area free of debris, including solvent, rags, and gasoline.
DBefore operating this equipment, electrically disconnect all equipment in the dispense area.
DBefore operating this equipment, extinguish all open flames or pilot lights in the dispense area.
DDo not smoke in the dispense area.
DDo not turn on or off any light switch in the dispense area while dispensing or while operating if
fumes are present.
DDo not operate a gasoline engine in the dispense area.

4 308-807
Installation
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE AND EXPLOSION
HAZARD on page 3.
1. Pump: use a ground wire and clamp as shown in
your separate pump manual.
2. Fluid hoses: use only electrically conductive fluid
hoses with a maximum of 500 feet (150 m) com-
bined hose length to ensure grounding continuity.
Check the electrical resistance of your fluid hoses
at least once a week. If your hose does not have a
tag on it which specifies the maximum electrical
resistance, contact the hose supplier or manufac-
turer for the maximum resistance limits. If the hose
resistance exceeds the recommended limits,
replace it immediately.
3. Air compressors and hydraulic power supplies:
ground the equipment according to the manufac-
turer’s recommendations.
4. Flow gun: ground through connection to a properly
grounded fluid hose and pump.
5. Fluid supply container: Ground according to your
local code.
6. Flammable liquids in the dispensing area: must be
kept in approved, grounded containers. Do not
store more than the quantity needed for one shift.
7. Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive,
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 gun
firmly to the side of a grounded metal pail, then
trigger the gun.

5308-807
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or dispensing accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
Dare instructed to relieve the pressure,
Dstop dispensing,
Dcheck or service any of the system equipment,
Dor install or clean the nozzle.
1. Fully release the gun trigger. Press the red button
to lock the trigger safety. See Fig. 1.
2. Shut off the fluid supply pump.
3. Hold a metal part of the gun firmly to the side of a
grounded metal pail. Press the silver button to
unlock the trigger safety. Trigger the gun to relieve
pressure.
4. Open the pump drain valve to help relieve pres-
sure in the pump, hose, and gun. Triggering the
gun to relieve pressure may not be sufficient. Have
a container ready to catch the drainage.
5. Leave the drain valve open until you are ready to
dispense again.
6. Fully release the gun trigger and lock the trigger
safety.
Flow Rate Adjustment
WARNING
To reduce the risk of serious injury, whenever the
gun is not in use, press the red button to lock the
trigger safety. See Fig. 1.
Fig. 1
Trigger Safety
Locked Trigger Safety
Unlocked
7901
To dispense material, unlock the trigger safety, then
fully squeeze the trigger. Flow begins with the slightest
pressure and continues until the trigger is released.
NOTE: A minimum of 1 pint (0.5 liters) of material
must be dispensed from the gun to remove all air from
the system. If the air is not completely removed, slow
shutoff may occur.
Adjust the pump to the minimum speed necessary to
deliver the material at a satisfactory rate, or adjust the
fluid/mastic regulator.
Lubrication and Care
Keep the gun clean, and oil the exposed portion of the
needle with a light, high grade machine oil daily.

6 308-807
Service
NOTE: Repair kits are available. See page 7 for the
kits for your gun model. For the best results, use all
the new parts in the kit. Kit parts are marked with an
asterisk, for example (2*).
NOTE: See the Parts Drawing on page 7 when
disassembling and reassembling the gun.
Disassembly
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 5.
1. Relieve the pressure.
2. Disconnect the gun from the hose.
3. Unscrew the nozzle nut (11) and nozzle (not
shown) from the seat (5*).
4. Unlock the trigger safety. See Fig. 1.
5. Depress the trigger (3) and remove the seat (5*)
from the gun.
CAUTION
Failure to depress the trigger while removing the seat
may damage the needle.
6. Loosen the hexnut (12) on the needle (2*) while
holding the adjustment screw (A) with a screwdriv-
er.
7. Unscrew the needle (2*) by turning the adjustment
screw (A) until the needle is unthreaded.
8. Remove the hexnut (12) and remove the needle
(2*) through the front of the gun.
Reassembly
1. Apply grease to the needle (2*) o-rings.
2. Put the needle (2*) in the gun, screwing the hexnut
(12) on the needle as it is going in.
3. Start threading the adjustment screw (A) until it
engages the threads of the needle (2). Continue
threading until the trigger (3) raises 1/2 in. (13
mm).
4. Grease the threads of the seat (5*) and the gasket
(10*)
5. Press the trigger (3) and install the gasket (10*)
and seat (5*).
6. Lift the trigger (3) and lock the trigger safety.
7. Trigger adjustment:
a. Turn the adjustment screw (A) clockwise until
the trigger (3) travels as far up as possible.
b. Turn the adjustment screw (A) counterclock-
wise until the trigger (3) stops falling, then turn
an additional 1/8 turn.
c. Tighten the hexnut (12) against the adjustment
screw (A). Hold the adjustment screw (A) to
prevent it from turning. Torque the hexnut to
18–22 in-lb (2.03–2.46 NSm).
d. Test the trigger safety (B) to ensure that it
operates properly. If the trigger safety does not
operate properly, loosen the hexnut (12) and
return to step 7a.
8. Screw the nozzle nut (11) and nozzle (not shown)
back onto the front of the gun.

7308-807
Parts
7904A
6
3
A
12
1
10
5
11
2
B
1
2
Greasetheneedleo-rings.
Torqueto 18–22in-lb(2.03–2.46NSm).
1
2
Models 240–199 and 240–200
Ref
No. Part No. Description Qty
1 240–208 BODY, Flow Gun 1
2* 240–201 NEEDLE, 3/16 ball
Model 240–199 only 1
240–202 NEEDLE, tapered
Model 240–200 only 1
3114–330 TRIGGER 1
5* 240–204 SEAT, 3/16 ball
Model 240–199 only 1
240–205 SEAT, tapered needle
Model 240–200 only 1
6 192–989 SCREW, pivot 1
10* 168–845 GASKET, copper 1
11 188–253 NUT, nozzle 1
12 114–357 NUT, hex 1
* Included in repair kit. Keep these parts on hand to reduce
down-time.
Repair Kits
Kit No. and
Description
Includes:
Description Ref. No. Part No. Description
240–206
For Model
240–199
2
5
10
240–201
240–204
168–845
NEEDLE, 3/16 ball
SEAT
GASKET
240–207
For Model
240–200
2
5
10
240–202
240–205
168–845
NEEDLE, tapered
SEAT
GASKET

8 308-807
Technical Data
Category Data
Maximum working pressure 3400 psi (23.4 MPa, 234 bar)
Maximum temperature 120_F (49_C)
Flow rate at 2000 psi (14 MPa, 138 bar)* Model 240–199: 158 oz/min (4.5 kg/min)
Model 240–200: 154 oz/min (4.4 kg/min)
Outlet port size 1/4 npt(f) and flange
Inlet port size 1/4 npt(f)
Dry weight Model 240–199: 11.6 oz (325 gm)
Model 240–200: 11.6 oz (325 gm)
Length 5.9 in (15.0 cm)
Width 2.6 in (6.6 cm)
Thickness 0.85 in (2.16 cm)
Pressure vessel material Aluminum
Pressure vessel ID 0.25 in (6.4 mm)
Gun seat diameter Model 240–199: 0.125 in (3.2 mm)
Model 240–200: 0.203 in (5.2 mm)
Needle seat type Model 240–199: Carbide ball
Model 240–200: 7_Tapered carbide
Inlet/outlet angle 20_
Trigger force –breakaway @ 1000 psi
(7 MPa, 69 bar) Model 240–199: 1.6 lb (0.73 kg) Model 240–200: 3.8 lb (1.72 kg)
Trigger force –breakaway @ 2000 psi
(14 MPa, 138 bar) Model 240–199: 2.2 lb (1.0 kg) Model 240–200: 7.3 lb (3.31 kg)
Trigger force –sustaining Model 240–199: 3.2 lb (1.45 kg)
Model 240–200: 2.8 lb (1.27 kg)
Wetted parts Aluminum, stainless steel, carbide, polyethylene, CV75r
CV75ris a registered trademark of the International Seal Co., Inc.
* Flow rates were measured using PVC sealer dispensed through a 1/8 in. diameter orifice nozzle and z-swivel con-
nected to inlet. Actual flow rates will vary depending on material type, fluid pressure, nozzle size, and system con-
figuration.

9308-807
Notes

10 308-807
Notes

11308-807
Notes

12 308-807
Graco Standard Warranty
GracowarrantsallequipmentmanufacturedbyGracoandbearingitsnametobefreefromdefectsinmaterialandworkmanshiponthe
dateofsaleby anauthorizedGracodistributortotheoriginalpurchaserforuse. Withtheexceptionofanyspecial,extended,orlimited
warrantypublishedbyGraco,Gracowill,foraperiodoftwelvemonthsfromthedateofsale,repairorreplaceanypartoftheequipment
determined by Graco to be defective. This warranty applies only when the equipment is installed,operated and maintainedin accor-
dance with Graco’s written recommendations.
This warranty does not cover, and Graco shall notbe liablefor general wearand tear, or anymalfunction, damageor wear causedby
faultyinstallation,misapplication,abrasion,corrosion,inadequateorimpropermaintenance,negligence,accident,tampering,orsub-
stitutionof 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
verificationof the claimed defect. If theclaimeddefect is verified, Gracowillrepair or replace freeofcharge any defective parts. The
equipmentwillbereturnedtotheoriginalpurchasertransportationprepaid. Ifinspectionoftheequipmentdoesnotdiscloseanydefect
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’ssoleobligationandbuyer’ssoleremedyforanybreachofwarrantyshallbeassetforthabove. Thebuyeragreesthatnoother
remedy(including,butnotlimitedto,incidentalorconsequentialdamagesforlostprofits,lostsales,injurytopersonorproperty,orany
otherincidentalorconsequentialloss)shallbeavailable. Anyactionforbreachofwarrantymustbebroughtwithintwo(2)yearsofthe
date of sale.
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
withaccessories, equipment,materialsorcomponentssold butnotmanufacturedby Graco. Theseitemssold,butnot manufactured
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of theirmanufacturer. 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, 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
Thepartiesacknowledge thattheyhaverequiredthatthepresentdocument,as wellasalldocuments,noticesandlegalproceedings
enteredinto,givenorinstitutedpursuantheretoorrelatingdirectlyorindirectlyhereto,bedrawnupinEnglish. Lespartiesreconnais-
sentavoir convenuque larédaction duprésente documentsera enAnglais, ainsique tousdocuments, aviset procéduresjudiciaires
exécutés, donnés ou intentés àla suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
Graco Phone Number
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1–800–367–4023 Toll Free
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.
Sales Offices: Minneapolis, Detroit, Los Angeles
Foreign Offices: Belgium, Canada, England, Korea, France, Germany, Hong Kong, Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
http://www.graco.com
e1998–1997Graco Inc. 308–807 Rev. B April 1998 PRINTED IN U.S.A.

13308-807
3X8–807
Rev. C
Supersedes Rev. B
Parts Change Notice
Some parts in Rev. B of manual 308–807 have changed but have not yet been changed in the
instruction manual. Please note the changes below and mark them in your manual or keep this
sheet with your manual.
Assembly No.
Series
Letter
Change Part That Changed Ref No. Part Description Description of Change
All Models B114–330 3 Trigger Replaced by Part No. 194–983 Trigger
OtherChanges
Page 1: Add: For use with fluids of viscosity less than 150,000 cps.
Before the Service Section: Add the following Troubleshooting Chart:
PROBLEM CAUSE SOLUTION
When using a small orifice wand
(approximately .040 in. diameter),
1/4 to 3/4 in. of material continues
to flow from the outlet of the
wand immediately after releasing
the trigger.
Air is trapped in the wand. Purge all air from the wand.
Helpful Tip: To verify that air is
trapped in the wand, trigger the gun,
then quickly shut off the material sup-
ply, relieve pressure in the gun, and
promptly remove the gun from the
supply hose. Then, without triggering
the gun, lay it on a bench and ob-
serve if material continues to flow
very slowly from the outlet of the
wand (approximately 0.1 in. per min-
ute from a .050 in. orifice). If this oc-
curs, there is air trapped in the wand.
Popping, snapping, spitting, gaps,
or irregularities in the material
stream as it flows from the wand.
Air in the material. Dispense material from the gun/wand
until the popping, snapping, and spit-
ting has stopped and the bead/extru-
sion is smooth and uninterrupted.
Gun does not shutoff completely. Needle is not fully seating. Readjust the trigger as described in
steps 6 and 7 under Reassembly, on
page 6 of your manual.
July 8, 1999
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.