Graco 240291 Operation manual

308798

Rev. W

INSTRUCTIONS-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 239923, Series A

Used in the Ultra Max and Ultimate Mx 795 and 1095 Sprayers

Used in the GMax and GMx 3900 Sprayers

Model 240291, Series A

Used in the Ultra Max and Ultimate Mx 1595 Sprayers

Used in the GMax and GMx 5900 Sprayers

Used in the GMax 10000 Sprayers

Model 240917, Series A

Used in the GMax and GMx 7900 Sprayers

Model 240800, Series A

Used in the GMax 5900HD and Mark V Sprayers

Model 243344, Series A

Used in the LineLazer II 3900 Sprayers

Model 243345, Series A

Used in the LineLazer II 5900 Sprayers

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

Graco Inc. is registered to I.S. EN ISO 9001

8016A

Parts

2 308798

Table of Contents

Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts, Pump

239923 and 243344 16. . . . . . . . . . . . . . . . . . . . . . . . . .

240291 and 243345 17. . . . . . . . . . . . . . . . . . . . . . . . . .

240917 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

240800 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Phone Number 20. . . . . . . . . . . . . . . . . . . . . . . . . .

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 which are compatible with the equipment wetted parts. Refer to the Tech-

nical 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.

3308798

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 Kit

239923 244196

240291 244198

240917 240916

240800 244198

243344 244196

243345 244198

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 308798

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

202

228

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.

7570A

Fig. 3

227

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 7571a

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

sleeve from cylinder. Remove o-ring (221) from top of

sleeve (or from inside of cylinder if o-ring did not come

out with sleeve).

Fig. 5 7572A

5308798

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.

7574B

Fig. 7

Used on

240291

240800

240917

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

der. Discard throat packings and glands.

Fig. 8 7573B

Used on

240291

240800

240917

Assembling the pump

Fig. 9. Soak all leather packings in SAE 30W oil for 1

hour minimum prior to assembly. Stack male gland

(219) on piston rod. Alternately stack UHMWPE (208)

and leather (218) packings (note orientation) on piston

rod. Install female gland (217). Install backup washer

(216) and u-cup (209) (note orientation) on piston

valve (210). The special sealing patch on piston valve

threads is good for four repackings. Use Loctiteon

piston valve threads after four repackings.

7574B

Fig. 9

216

218

209

208219

217

210

Used on

240291

240800

240917

6 308798

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

(239923)

Torque to 55 +/–3 ft-lb

(240291, 240800)

Torque to 55 +/–5 ft-lb

(240917)

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

Used on

240291

240800

240917

Fig. 13. Install seal (201) into packing nut (202). Install

throat adjustment spacer onto packing nut. Loosely

install packing nut into cylinder.

Fig. 13

201

202

7581A

7308798

Service

Fig. 14. Grease piston packings and sleeve top edge.

Fig. 14 7578A

Fig. 15. Carefully slide piston assembly into top of

sleeve. Assure u-cup is not rolled over or damaged.

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 308798

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.

Fig. 18

214

212

7570A

227

Fig. 19. Install intake valve on cylinder. If a wrench is

used torque as follows:

67 +/–5 ft-lb (for model 239923)

80 +/–5 ft–lb (for models 240291 & 240800)

150 +/–5 ft–lb (for model 240917).

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 nut spacer (228) to 100 +/–10 in-lb.

Remove throat nut 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 operation

before a repacking is required.

7568A

Fig. 20

202

228

9308798

Notes

10 308798

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.

7570A

Fig. 3

227

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