Graco 245970 Use and care manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2003, Graco Inc. is registered to I.S. EN ISO 9001
309577A
Repair - Parts
Displacement
Pump
FOR USE WITH REACTOR™ELECTRIC
PROPORTIONERS
3500 psi (24.5 MPa, 245 bar) Maximum Working Pressure
Part No. 245970, Series A
21 cc, used on Model E-20 and E-XP1
Part No. 245971, Series A
41 cc, used on Model E-XP2
Part No. 245972, Series A
55 cc, used on Model E-30
TI2663A

Manual Conventions
2309577A
Contents
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 2
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 5
Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clean and Inspect Parts . . . . . . . . . . . . . . . . . . . . . 6
Cutaway View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 18
Manual Conventions
Warning
Caution
Note
Related Manuals
The following manuals are shipped with the Reactor™.
Refer to these manuals for detailed equipment informa-
tion.
WARNING
A warning alerts you to possible serious injury or
death if you do not follow instructions.
Symbols, such as fluid injection (shown), alert you to a
specific hazard and direct you to read the indicated
hazard warnings on pages 3-4.
CAUTION
A caution alerts you to possible equipment damage or
destruction if you do not follow instructions.
A note indicates additional helpful information.
Reactor Electric Proportioner
Part No. Description
309551 Reactor Electric Proportioner,
Operation Manual (English)
309574 Reactor Electric Proportioner,
Repair-Parts Manual (English)

Warning
309577A 3
WARNING
Injection Gu n Fusio n
INJECTION HAZARD
High-pressure fluid from gun, 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 medical attention.
• Do not point the gun at anyone or at any part of the body.
• Do not put your hand or fingers over the gun fluid nozzle.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not “blow back” fluid; this is not an air spray system.
•Follow
Pressure Relief Procedure, page 5, when you stop spraying and before cleaning, checking,
or servicing equipment.
• Use lowest possible pressure when flushing, priming, or troubleshooting.
• Engage spray gun piston safety lock when not spraying.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. High pres-
sure hose cannot be recoupled; replace the entire hose.
FIRE AND EXPLOSION HAZARD
Solvent and fumes in work area can ignite or explode. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources, such as pilot lights, cigarettes and plastic drop cloths (potential static
arc).
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Keep the work area free of debris, including solvent, rags, and gasoline.
• Ground equipment and conductive objects. See Grounding in your Reactor manual.
• Hold gun firmly to side of grounded pail when triggering into pail.
• Use only grounded hoses.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
EQUIPMENT MISUSE HAZARD
Misuse can cause serious injury or death.
• For professional use only.
• Use equipment only for its intended purpose. Call your Graco distributor for information.
• Read manuals, warnings, tags, and labels before operating equipment. Follow instructions.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not alter or modify equipment. Use only Graco parts and accessories.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not use hoses to pull equipment.
• Comply with all applicable safety regulations.

Warning
4309577A
BURN HAZARD
This equipment is used with heated fluid, which can cause equipment surfaces to become very hot. To
avoid severe burns:
•Do not touch hot fluid or equipment.
•Allow equipment to cool completely before touching it.
•Wear gloves if fluid temperature exceeds 110°F (43°C).
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 Material Safety Data Sheet (MSDS) 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.
PERSONAL PROTECTIVE EQUIPMENT
You must wear proper protective equipment when operating, servicing, or when in the operating area of
the equipment to help protect you from serious injury, including eye injury; inhalation of toxic fumes; and
hearing loss. This equipment includes but is not limited to:
•Protective eyewear
•Gloves, clothing, and respirator as recommended by the fluid and solvent manufacturer
•Hearing protection.
WARNING

Pressure Relief Procedure
309577A 5
Pressure Relief Procedure
WARNING
Read warnings, page 3.
1. Relieve pressure in gun and perform gun shut-
down procedure. See gun manual.
2. Close gun fluid manifold valves A and B.
TI2421A
3. Shut off feed pumps and agitator, if used.
4. Turn PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF. Route fluid to waste
containers or supply tanks. Ensure that gauges
drop to 0.
TI3171a
SA
SB

Tools Needed
6309577A
Tools Needed
•Vise with flat jaws
•12 in. adjustable, open end wrench (2)
•Non-sparking hammer, 20 oz maximum
•Small screwdriver
•ISO pump oil
•Pick or long small screwdriver
•Snap-ring pliers
•1/2 in. (13 mm) diameter plastic rod
•7/8 in. deep-well socket (245970 only)
Repair Kits
A repair kit is available for your pump. Kit parts are
marked with an asterisk, for example (3*). See page 17.
Kit must be purchased separately. For best results, use
all parts in the kit.
Clean and Inspect
Parts
Cutaway View
1. Clean and inspect all parts. Intake and piston
ball seats, sleeve, and displacement rod must
not be worn, scratched, or damaged.
2. Remove and clean sleeve when repacking
pump.
1
19*22
*21
18*
*17
*20
2
*16
*15
5
3*
4
14*
7
13*
6*
3*
11*
9
10*
*8
12
TI2668A

Disassembly
309577A 7
Disassembly
WARNING
Pump rod and connecting rod move during operation.
Moving parts can cause serious injury such as pinch-
ing or amputation. Keep hands and fingers away from
connecting rod during operation.
1. Shut off , , and heat zones.
2. Flush pumps. See Reactor manual.
3. Relieve pressure, page 5.
4. To disconnect pump A:
a. Turn PRESSURE RELIEF/SPRAY
valves (SA, SB) to PRESSURE RELIEF.
b. Press . Motor will run until compo-
nent A pump is at bottom of its stroke,
then shut off.
A
B
TI3171a
SA
SB
c. Shut main power OFF .
d. Disconnect fluid inlet (C) and outlet (D).
See FIG. 1.
e. Push retaining spring (E) up. Push pin
(F) out. Loosen locknut (G) by hitting
firmly with a non-sparking hammer.
Unscrew pump. See FIG. 1.
To disconnect pump B, see page 8. To continue
repairing pump A, see page 9.
FIG. 1. Disconnect Pump (Pump A Shown)
TI2602A
C
F
G
D
E

Disassembly
8309577A
5. To disconnect pump B:
a. Turn PRESSURE RELIEF/SPRAY
valves (SA, SB) to PRESSURE RELIEF.
b. Tu r n m a i n p o w e r O N .
TI3171a
SA
SB
c. Enter jog mode (see operation manual).
Run motor until component B pump is at
bottom of its stroke. Press pump
to stop.
d. Shut main power OFF .
e. Disconnect fluid inlet (C) and outlet (D).
See FIG. 1.
f. Push retaining spring (E) up. Push pin
(F) out. Loosen locknut (G) by hitting
firmly with a non-sparking hammer.
Unscrew pump. See FIG. 1.

Disassembly
309577A 9
6. Unscrew packing nut (19). Remove retaining
ring (22) and felt washers (21).
7. Loosen intake valve housing (5) with non-spark-
ing hammer, then unscrew. Remove o-ring (15).
TI2662A
19
22
21
TI2664A
15
5
8. Disassemble intake valve. Be sure to remove
o-ring (10).
Spring (8) is on Model 245972 only.
9. Tap rod (1) with non-sparking hammer to drive it
out of cylinder (2).
Sleeve (4) may come out with rod.
TI2665A
5
11
9
10
8
12
TI2672A
1
2
4

Disassembly
10 309577A
10. Using screwdriver in groove (H), remove sleeve
(4) from cylinder (2), or pull it off rod. Remove
o-rings (3).
Be sure top o-ring (3) comes out.
11. Remove scraper assembly (18, 245971 and
245972 only) and bushing (17).
TI2670A
2
3
4
H
3
TI2669A
18
17
2
12. Unscrew piston (7) from rod (1). Remove piston
guide (6) and ball (16). Remove u-cup (13) and
bushing (14).
13. Insert piston end of rod (1) into cylinder (2) and
push u-cup (20) out.
TI2666A
1
16
14
13
6
7
TI2671A
1
2
20

Reassembly
309577A 11
Reassembly
1. Install ball (16*) in rod (1). Slide bushing (14*)
onto rod (1). Install piston guide (6) and u-cup
(13*) on piston (7). Lips of u-cup must face up.
On Models 245970 and 245971, be sure lips of
piston guide (6) face down.
Sealing patch on piston threads is good for four
repackings. Use Loctite
®
on piston threads
after four repackings; be sure none gets on ball.
2. Hold u-cup centered and tighten piston valve (7)
to rod (1) slowly, to seat u-cup. Be careful not to
damage sealing edges of u-cup. Torque as
specified below.
Model Torque
ft-lb (N•m)
245970 24-30 (32-40)
245971 47-53 (63-71)
245972 47-53 (63-71)
TI2666A
1
16*
14*
*13
6*
7
TI2818A
1
Lips face up.
1
3. Install throat u-cup as follows:
a. Models 245971 and 245972: Grease
u-cup (20*) and cylinder (2). Place
u-cup in cylinder with lips facing down.
Be careful not to damage sealing edges
of u-cup. Install packing nut (19) to prop-
erly insert and align u-cup, then remove
packing nut.
b. Model 245970: Grease u-cup (20*) and
cylinder (2). Place seal installation tool
(23*) in cylinder. Place u-cup in tool with
lips facing down. Be careful not to dam-
age sealing edges of u-cup. Press u-cup
in place with 7/8 in. deep-well socket
(S). Remove socket and tool.
TI2675A
19
20*
2
TI2818A-1
1
Lips face down.
1
TI2700A
23*
20*
2
S

Reassembly
12 309577A
4. Install scraper kit (18*, 245971 and 245972 only)
in bushing. Ensure that slots (J) in scrapers do
not align and seal (K) fits under lip of bushing.
5. Insert bushing (17*), flat side down. Press bush-
ing in place to seat u-cup.
6. Install felt washers (21) into packing nut (19).
Install retaining ring (22). Soak assembly in ISO
pump oil for 10 minutes (minimum), then install
packing nut handtight.
TI2667A
J
K
TI2669A
*18
*17
2
TI2701A
22*
21*
19
Groove (H) in sleeve outer surface must be
toward bottom.
7. Grease piston u-cup and sleeve top edge. Push
piston assembly into top of sleeve (4). Drive in
with non-sparking hammer.
8. Grease top 1-2 in. (25-50 mm) of displacement
rod (1) and outside of sleeve (4). Grease o-rings
(3*) and place one in cylinder and other on bot-
tom of sleeve.
9. Slide sleeve/ rod assembly into bottom of cylin-
der (2). Drive in with hammer until top of groove
(H) aligns with bottom of cylinder (L). Use plastic
rod to drive displacement rod until 1/4-3/8 in.
(6-10 mm) of its greatest diameter is visible
above packing nut (19).
TI2673A
H
4
TI2674A
19
*3
2
L
4
3*
H

Reassembly
309577A 13
10. Reassemble intake valve with o-ring (10*), seat
(9), and ball (11*). Install ball guide (12) and
spring (8*, Model 245972 only; screw must be at
top).
Seat may be flipped over and used on other
side. Clean seat thoroughly. No scratches per-
mitted on sealing edge.
TI2665A
5
*11
9
10*
8*
12
11. Replace o-ring (15*). Install intake valve. Torque
housing (5) as follows, or be sure intake valve is
snug against cylinder.
Model Torque
ft-lb (N•m)
245970 65-75 (88-101)
245971 75-85 (101-114)
245972 145-155 (195-209)
12. Torque packing nut (19) to 90-110 in-lb (10-12
N•m).
TI2687A
15*
19
5

Reassembly
14 309577A
13. To reconnect pump B:
a. Tu r n m a i n p o w e r O N .
b. Enter jog mode. Run motor until compo-
nent B connecting rod is at bottom of its
stroke.
c. Shut main power OFF .
d. Ensure locknut (G) is screwed on pump
with flat side up. Screw pump into bear-
ing housing (M) until pin holes align.
Push pin (F) in. Pull retaining spring (E)
down. See FIG. 2.
e. Continue screwing pump into housing
until fluid outlet (D) is aligned with steel
tube and top threads are +/- 1/16 in. (2
mm) of bearing face (N). See FIG. 2.
f. Tighten locknut (G) by hitting firmly with
a non-sparking hammer. See FIG. 2.
g. Reconnect fluid inlet (C) and outlet (D).
To reconnect pump A, see page 15.
FIG. 2. Reconnect Pump (Pump A Shown)
C
D
F
E
G
M
N
1
Flat side faces up.
1
TI2602A

Reassembly
309577A 15
14. To reconnect pump A:
a. Tu r n m a i n p o w e r O N .
b. Press . Motor will run until compo-
nent A connecting rod is at bottom of its
stroke, then shut off. Pump B moves to
top of stroke; pumps must be opposed
(1 up, 1 down) for Reactor to run.
c. Shut main power OFF .
d. Ensure locknut (G) is screwed on pump
with flat side up. Screw pump into bear-
ing housing (M) until pin holes align.
Push pin (F) in. Pull retaining spring (E)
down. See FIG. 2.
e. Continue screwing pump into housing
until fluid outlet (D) is aligned with steel
tube and top threads are +/- 1/16 in. (2
mm) of bearing face (N). See FIG. 2.
f. Tighten locknut (G) by hitting firmly with
a non-sparking hammer. See FIG. 2.
g. Reconnect fluid inlet (C) and outlet (D).

Parts
16 309577A
Parts
Part No. 245970, Series A; includes items 1-7, 9-17, 19-22
Part No. 245971, Series A; includes items 1-7, 9-22
Part No. 245972, Series A; includes items 1-22 (shown)
1
2
*3
*3
4
5
*6
7
8*
10*
9
11*
12
*13
*14
15*
*16
*17
*18
19
*20
*21
*22
TI2577A

Parts
309577A 17
Part No. 245970, Series A; includes items 1-7, 9-17, 19-22
Part No. 245971, Series A; includes items 1-7, 9-22
Part No. 245972, Series A; includes items 1-22 (shown)
* These parts are also included in the Pump Repair Kits,
which may be purchased separately. Order the correct
kit for your pump from the table below.
Ref
No. Part No. Description Qty
1 240518 ROD, displacement; sst (245970) 1
240517 ROD, displacement; sst (245971) 1
246689 ROD, displacement; sst (245972) 1
2 243346 CYLINDER, pump (245970) 1
240520 CYLINDER, pump (245971) 1
245413 CYLINDER, pump (245972) 1
3* 108526 O-RING; (245970) 2
107098 O-RING; (245971) 2
108822 O-RING; (245972) 2
4 240521 SLEEVE, cylinder; sst (245970) 1
240525 SLEEVE, cylinder; sst (245971) 1
240921 SLEEVE, cylinder; sst (245972) 1
5 195892 HOUSING, valve, intake (245970) 1
193030 HOUSING, valve, intake (245971) 1
198219 HOUSING, valve, intake (245972) 1
6* 196758 GUIDE, piston (245970) 1
196757 GUIDE, piston (245971) 1
198303 GUIDE, piston (245972) 1
7 239932 VALVE, piston (245970) 1
240150 VALVE, piston (245971) 1
240580 VALVE, piston (245972) 1
8* 245256 SPRING, intake ball (245972 only) 1
9 239922 SEAT, intake; carbide (245970);
includes items 10 and 11
1
244199 SEAT, intake; carbide (245971);
includes items 10 and 11
1
240918 SEAT, intake; carbide (245972);
includes items 10 and 11
1
10* 107079 . O-RING; (245970) 1
108526 . O-RING; (245971) 1
107098 . O-RING; (245972) 1
11* 105445 . BALL, intake; sst; 0.5 in. (13 mm)
(245970)
1
102972 . BALL, intake; sst; 0.875 in. (22
mm) (245971)
1
107167 . BALL, intake; sst; 1 in. (25 mm)
(245972)
1
12 192624 GUIDE, ball (245970) 1
193027 GUIDE, ball (245971) 1
193391 GUIDE, ball (245972) 1
13* 117450 SEAL, u-cup, piston; UHMWPE
(245970)
1
117449 SEAL, u-cup, piston; UHMWPE
(245971)
1
117448 SEAL, u-cup, piston; UHMWPE
(245972)
1
14* 15B078 BUSHING, piston (245970) 1
15B077 BUSHING, piston (245971) 1
15B079 BUSHING, piston (245972) 1
15* 114054 O-RING; Viton
®
(245970) 1
106556 O-RING; Viton (245971) 1
107306 O-RING; Viton (245972) 1
16* 105444 BALL, piston; sst; 0.3125 in. (8 mm)
(245970)
1
101947 BALL, piston; sst; 0.375 in. (10 mm)
(245971)
1
107203 BALL, piston; sst; 0.5625 in. (14
mm) (245972)
1
17* 15B075 BUSHING, rod (245970) 1
15B074 BUSHING, rod (245971) 1
15B076 BUSHING, rod (245972) 1
18* 113938 KIT, scraper (245971) 1
117452 KIT, scraper (245972) 1
19 193046 NUT, packing (245970) 1
193032 NUT, packing (245971) 1
189589 NUT, packing (245972) 1
20* 117447 SEAL, u-cup, throat; UHMWPE
(245970)
1
117446 SEAL, u-cup, throat; UHMWPE
(245971)
1
117448 SEAL, u-cup, throat; UHMWPE
(245972)
1
21* 117597 WASHER, felt (245970) 2
117599 WASHER, felt (245971) 2
117600 WASHER, felt (245972) 2
22* 551528 RING, retaining (245970) 1
117718 RING, retaining (245971) 1
117719 RING, retaining (245972) 1
23* 15B661 TOOL, installation, seal (245970);
not shown; part of Repair Kit
246420
1
Pump Part No. Repair Kit
245970 246420
245971 246421
245972 246422
Ref
No. Part No. Description Qty
PTFE
PTFE
PTFE
PTFE
PTFE
PTFE
PTFE

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. (SRC309577)
Sales Offices: Minneapolis, Detroit
International Offices: Belgium Korea, Hong Kong, Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
www.graco.com
Printed in USA 309577A (English)
Technical Data
Viton
®
and
Loctite
®
is a registered trademark of the Loctite Company.
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 by an authorized Graco distributor 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 substitution 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 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
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 reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, àla suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Category Data
Maximum working pressure 3500 psi (24.5 MPa, 245 bar)
Effective area of displacement
245970: 0.394 in.2 (2.54 cm2)
245971: 0.554 in.2 (3.57 cm2)
245972: 0.743 in.2 (4.79 cm2)
Fluid inlet size
245970 and 245971: 3/4 npt(m)
245972: 1 npsm(m)
Fluid outlet size
245970: 1/4 npt(f)
245971 and 245972: 3/8 npt(f)
Wetted parts stainless steel, zinc-plated carbon steel, brass, tungsten carbide, chrome plating,
ultra-high molecular weight polyethylene
02/2003
PTFE
PTFE
PTFE