Graco Series A Operation manual

309277TINSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
Displacement Pump
3600 psi (250 bar, 24.8 MPa) Maximum Working Pressure
Model 244197, Series A
UltraMax and Ultimate Mx795 and 1095
GMax3900
Model 244224, Series A
Ultra Max and Ultimate Mx 1595
GMax 5900 and 5900 Convertible
Model 244201, Series A
245044, 245046, 245049 Mark V
GMax 5900HD
Model 244409, 245904 Series A
245045, 245047 Mark V International (ceramic balls)
Model 244954, Series A
HydraMax225
Model 244957, Series A
HydraMax 300/350
Model 245889, Series B
Mark V SpackMax
Model 245902, Series A
245048 Ultra Max 1595, International
Model 246257, Series A
GMax 7900, GH200; Models 233940 – 233943
Model 248971, Series A
GH 200; Models 248559 – 248567, 248561 – 248564
EH200
Model 248736, Series A
GH 230, GH 300
Model 277068, Series A
LineLazer IV 200 HS
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 2000, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
8016A
Parts

2 309277
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts, Pump
244197 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
244224 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
244201 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
244409 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
245902 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
245904 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
244954 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
244957 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
245889 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
246257 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 15 for the maximum working pressure of this equipment.
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.
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.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
Keep clear of all moving parts when starting or operating the pump.
Before servicing the equipment, follow the Pressure Relief Procedure on page 3 to prevent the
equipment from starting unexpectedly.

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:
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
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.
Pump Repair Kits
Pump Repair Kit
244197 244196
244224 244198
244201 244198
244409 244200
244954 246341
244957 244958
245889 245819
245902 244198
245904 244200
246257 246341
248736 246341
248971 246341
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.

4 309277
Service
Repair When Pump Is Off The Sprayer
Disassembling the pump
Fig. 1. Remove packing nut (202) and throat adjust-
ment spacer (228).
Fig. 1 7568A
228 (228, o-ring
on 246257)
ti2332a
202
Fig. 2. Unscrew intake valve from cylinder.
Fig. 2 7569A
Fig. 3. Disassemble intake valve. Clean and inspect.
O-ring (227) may require a pick for removal.
Fig. 3
227
227
(o-ring on top
244957 only)
(o-ring on
bottom
all except
244957)
7570e
236
215
245889 only
Fig. 4. Tap piston rod out of cylinder with a hammer or
flip over and tap piston rod out against a bench.
Fig. 4 7571a
Note: Sleeve may come out
of cylinder with piston rod.
Fig. 5. Remove piston rod from sleeve, or remove
sleeve from cylinder.
Fig. 5 7572A

5309277
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.
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 Loctiteto the threads.
Fig. 6 7576A
Fig. 7. Remove packings and glands from piston rod.
Fig. 7
Not
used on
244197
used on
245889
ti3940a
Fig. 8. Remove throat packings and glands from cylin-
der. Discard throat packings and glands.
Fig. 8 7573B
Not
used on
244197
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 Loctiteon piston valve threads
after four repackings.
Fig. 9
216
218 208204
217
210
Not
used on
244197
244954, 246257, 245889; 208 and 218 are 203
and 223, respectively
1 1
1
7574c
used on
245889

6 309277
Service
Fig. 10. Install ball (206) in piston rod. If Loctiteis ap-
plied to piston valve threads, ensure that none gets on
ball.
Fig. 10
206
7575A
Fig. 11. Tighten piston valve to piston rod as specified:
Fig. 11
Torque to 27 +/–3 ft-lb
(244197)
Torque to 55 +/–3 ft-lb
(244224, 244201,
244409, 245902, 245904)
Torque to 55 +/–3 ft-lb
(244954)
Torque to 55 +/–3 ft-lb
(244957, 246257, 245889)
7576A
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.
7573B
Fig. 12
223
224
203
204
Not
used on
244197
Fig. 13. Install seal (201) into packing nut (202). Install
throat adjustment spacer (228) onto packing nut.
Loosely install packing nut into cylinder.
Fig. 13
201
202
7581A
(228 o-ring
on 246257) 228
ti2333a

7309277
Service
Fig. 14. Grease piston packings and sleeve top edge.
Fig. 14 7578A
Fig. 15. Carefully slide piston assembly into top of
sleeve.
Fig. 15 7577A
Fig. 16. Grease top inch or two of piston rod that will
go through the cylinder throat packings.
7579A
Fig. 16
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. 17 7582A
221
207

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).
Fig. 18
212
214
212
227
214
227 (o-ring
on to
p
244957
only
)
(o-ring on
bottom
all except
244957)
7570c
236
215
245889 only
215
215
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, 244409,
245902, 245904)
175 +/–8 ft–lb (models 244954, 246257, 245889)
175 +/–8 ft–lb (model 244957)
If a wrench is not used, be sure intake valve is bot-
tomed out against cylinder.
Fig. 19 7569A
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).
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.
7568A
Fig. 20
202
228
(228 o-ring
on 246257)
ti2332a

9309277
Service
Repair When Pump Is On The Sprayer
WARNING
INJECTION HAZARD
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 3.
Fig. 1. Remove intake valve.
Fig. 1 7673A
Fig. 2. Use screwdriver to push retaining spring up and
push pin out.
Fig. 2
7674A
Fig. 3. Disassemble intake valve. Clean and inspect.
O-ring (227) may require a pick for removal.
Fig. 3 7570
A
227
227
(o-ring on top
244957
only)
(o-ring on
bottom
all except
244957)

10 309277
Service
Fig. 4. Remove piston rod and sleeve.
7746A
Fig. 4
Fig. 4. Invert piston rod and sleeve and pound on hard
surface until piston rod comes out of sleeve.
Fig. 5 7572A
Fig. 6. Remove packing nut (202)
7726A
Fig. 6
202
Fig. 7. Invert piston rod and insert into cylinder to force
out throat packings.
Fig. 7 7747A
Fig. 8. Insert piston rod into cylinder with pin hole up
and piston valve down. Insert pin into piston rod and
crank shaft.
Fig. 8
7675A