Graco Series A Setup guide

ti6177a
Repair
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440--1441
Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001
Displacement Pump 310894G
- For portable spray application of architectural paints and coatings
or replacement pump for Graco GMax
t 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 VtInternational
Model 287929, Series A
Mark V North America
Model 289590, Series A
TexSpray 7900HD,
Mark X, 230V, Domestic
Important Safety Instructions
Read all warnings and instructions in this manual
and in your sprayer manual. Save these
instructions.
http://gracomanual.com

2 310894
Table of Contents
Warnings 2......................................
Service 3.......................................
Technical Data 9.................................
Parts, Pump
287512 10.....................................
287513 11.....................................
249122 12.....................................
287579 13.....................................
287928 14.....................................
287929 15.....................................
289590 16.....................................
Warranty 18.....................................
Graco Phone Number 18..........................
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
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
DDo 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.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not alter or modify equipment.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse 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.
DComply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
DKeep clear of moving parts.
DDo 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.
http://gracomanual.com

3310894
Service
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT H
A
Z
A
R
D
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:
Dareinstructedtorelievethepressure,
Dstop spraying,
Dcheck or service any of the system equipment,
Dor 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
Pump Repair Kit
287512 248212
287513 248213
287579 248213
249122 249123
287928 249189
287929 248213
289590 249123
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.
http://gracomanual.com

4 310894
Service
Disassembling the pump
Fig. 1. Remove packing nut (202) and throat adjust-
ment spacer (228).
Fig. 1
228
202
ti6178b
Fig. 2. Unscrew intake valve from cylinder.
ti6179a
Fig. 2
Fig. 3. Disassemble intake valve. Clean and inspect.
O-ring (227) may require a pick for removal.
Fig. 3
227
7570e
211
used on
249122,
289590
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.
ti6180a
Fig. 4
Fig. 5. Remove piston rod from sleeve, or remove
sleeve from cylinder.
ti6181a
Fig. 5

5310894
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 Loctiterto the threads.
ti6183a
Fig. 6
Fig. 7. Remove packings and glands from piston rod.
Not
used on
287512
ti6184a
Fig. 7
Fig. 8. Remove throat packings and glands from cylin-
der. Discard throat packings and glands.
Not used
on
287512
ti6182a
Fig. 8
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
ti6185a 217
216
210
229
218 208204
Fig. 9
Note: pump 249122 and 289590 do not use
leather packings in piston stack. Alternately
stack blue (208) and brown (218) packings
on this pump.

6 310894
Service
Fig. 10. Install ball (206) in piston rod. If Loctiteris ap-
plied to piston valve threads, ensure that none gets on
ball.
ti6186a
Fig. 10
206
Fig. 11. Tighten piston valve to piston rod as specified:
ti6187a
Fig. 11
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)
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.
Fig. 12
203
224
223
204
Not
used on
287512
ti6188a
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 ti6189a
201
202
228
(228 o--ring
on 249122,
289590 )

7310894
Service
C
A
UTION
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.
Fig. 14 ti6193a
221
207
205
220
Place inside cyl-
inder (205) and
push to shoulder
with sleeve (220).
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).
Fig. 15
222
ti6273a
205
207

8 310894
Service
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.
ti6197a
Fig. 16
227
212
214
211
used on
249122,
289590
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.
ti6194a
Fig. 17
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.
Fig. 18
202
228
ti6195a
(228 o--ring
on 249122,
289590)

9310894
Service
Cross Sectional Reference
Pump 287512
ti6196a
Pump 287512
Fig 19
223 203
218 208
217
213
214
204
221
224
205
219
215
212
227
222
202
221
216
206
210
201
220
228
207
229
2
V-MaxtUHWMPE, blue
V-MaxtUHWMPE, blue
Leather
Leather
V-MaxtUHWMPE,
brown on 249122,
289590
211
Only on
249122,
289590
Technical Data
Maximum working pressure 3300 psi...............
(228 bar, 22.8 MPa)
Fluid inlet size 1-5/16 npt(m)......................
Fluid outlet size 3/8 npt(f).................
Wetted parts stainless steel, PTFE,.................
leather, nylon, zinc-plated carbon steel,
tungsten carbide, brass, fluoroelastomer,
acetal, polyethylene
NOTE: LoctiteRis a Loctite Company registered
trademark.

10 310894
Parts -- Pump 287512
Model 287512, Series A
Ref
No. Part No. Description Qty.
201 179810 SEAL, throat 1
202 193046 NUT, packing 1
203* 192692 V-PACKING, throat, 3
V-MaxtUHMWPE, blue
204* 15C987 GLAND, male, throat 1
205 287551 CYLINDER, pump
206* 105444 BALL, sst, 0.3125 in. 1
207* 114054 PACKING, o-ring 1
208* 192693 V-PACKING, piston 3
V-MaxtUHMWPE, blue
210 239932 VALVE, piston 1
212† 239922 KIT, seat, carbide 1
includes 214 and 227
213 15C785 VALVE, intake (foot) 1
214*† 105445 BALL, sst, 0.5000 in. 1
215 192624 GUIDE, ball 1
216* 118503 WIPER, piston 1
217* 178969 GLAND, female, piston 1
218* 178939 V-PACKING, leather, piston 2
219* 196880 GLAND, male 1
220 248209 SLEEVE, cylinder 1
221* 108526 O-RING, PTFE 2
222 248206 ROD, piston 1
223* 178940 V-PACKING, leather, throat 2
224* 15C988 GLAND, female
227*† 107079 PACKING, o-ring 1
228 192714 SPACER, throat, nut 1
229* 15C997 WASHER, backup 1
230†† 15E802 FITTING, pump (not shown) 1
231 118494 O-RING, acetal 1
232†† 15E807 TUBE, intake (not shown) 1
* These parts are also included in Repair Kit 248212,
which may be purchased separately.
†These parts are also included in Carbide Seat Kit
239922, which may be purchased separately.
†† These parts are included with pump 287512.
ti5491a
*223
216*
201
202
224*
203*
204*
205
221*
220
222
206*
219*
218*
217*
210
215
212†
213
†*214
*208
221*
207*
†*227
228
229
231