Graco Series A Operating instructions

332922D

Repair

Displacement Pump

For professional use only.

3300 psi (22.7 MPa, 227 bar) Maximum Working Pressure

Model 16X414, Series A

UltraMax II and Ultimate MX II 695/795

GMAX II 3900

Model 16X418, Series A

TexSpray Mark IV

Model 16X419, Series A

UltraMax II and Ultimate MX II 1095/1595

GMAX II 5900

Model 16X420, Series A

UltraMax II and Ultimate MX II 1095/1595 IronMan

GMAX 5900 IronMan

Model 16X421, Series A

TexSpray Mark V and 5900 HD

Model 16Y602, Series A

TexSpray Mark VII

Model 16X426, Series A

GMAX II 7900

Model 16X427, Series A

TexSpray Mark X and 7900HD

Model 16Y599, Series A

TexSpray Mark V and IronMan

Model 17N693, Series A

APX 6200 (MaxLife)

Model 17R044, Series A

APX 6200 (Chrome)

Model 17N694, Series A

APX 8200 (MaxLife)

Model 17R042, Series A

APX 8200 (Chrome)

Important Safety Instructions

Read all warnings and instructions in this

manual. Save these instructions.

ti23273a

2332922D

Table of Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Pressure Relief Procedure . . . . . . . . . . . . . . . . . 4

Pump Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . 4

Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Cleaning and Inspecting Parts . . . . . . . . . . . . . . 4

Repair When Pump is Separated From Sprayer . 5

Cross-Section Reference . . . . . . . . . . . . . . . . . 11

Parts - Pump 16X414, 16X418 . . . . . . . . . . . . . . . . 12

Parts - Pump 16X420, 16Y599 . . . . . . . . . . . . . . . . 13

Parts - Pump 16X419, 16X421, 16Y602 . . . . . . . . . 14

Parts - Pump 16X426, 16X427 . . . . . . . . . . . . . . . . 15

Parts - Pump 17N693, 17R044 . . . . . . . . . . . . . . . . 16

Parts - Pump 17N694, 17R042 . . . . . . . . . . . . . . . . 17

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 20

Warnings

332922D 3

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation

point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these

symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard

symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• 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. For complete information

about your material, request MSDS from distributor or retailer.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine man-

ufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and cre-

ate safety hazards.

• Use equipment only for its intended purpose. Call your distributor for information.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or

fluids containing such solvents.

• Comply with all applicable safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equip-

ment, follow the Pressure Relief Procedure and disconnect all power sources.

SKIN INJECTION HAZARD

High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event

that injection occurs, get immediate surgical treatment.

• Do not aim the gun at, or spray any person or animal.

• Keep hands and other body parts away from the discharge. For example, do not try to stop leaks

with any part of the body.

• Always use the nozzle tip guard. Do not spray without nozzle tip guard in place.

• Do not leave the unit energized or under pressure while unattended. When the unit is not in use,

turn off the unit and follow the Pressure Relief Procedure for turning off the unit.

• Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.

Service

4332922D

Service

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever

you see this symbol.

1. Engage trigger lock.

2. Turn ON/OFF switch to OFF.

3. Unplug power cord.

4. Disengage trigger lock. Hold metal part of gun

against grounded metal pail and trigger gun into pail

to relieve pressure.

5. Engage the trigger lock.

6. Open all fluid drain valves in the system, having a

waste container ready to catch drainage. Leave drain

valve(s) open until you are ready to spray again.

7. If you suspect the spray tip or hose is clogged or

that pressure has not been fully relieved after follow-

ing the steps above, VERY SLOWLY loosen tip

guard retaining nut or hose end coupling to relieve

pressure gradually, then loosen completely. Clear

hose or tip obstruction.

Pump Repair Kits

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

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.

NOTE:

Remove and clean sleeve when repacking pump.

This equipment stays pressurized until pressure is

manually relieved. To help prevent serious injury from

pressurized fluid, such as skin injection, splashing

fluid and moving parts, follow the Pressure Relief Pro-

cedure when you stop spraying and before cleaning,

checking, or servicing the equipment.

Pump Repair Kit

16X414 248212

16X419 248213 (stainless steel check balls)

249189 (ceramic check balls)

16X426 249123 (stainless steel check balls)

17A578 (ceramic check balls)

16X427,

17N694

17A578 (ceramic check balls)

16X418 24V063

16X421 249189

16Y602 24M830

16X420 17K162 (stainless steel check balls)

16Y599 17K475 (ceramic check balls)

17N693 17N703 (ceramic check balls)

17R042 17R119 (ceramic SI-N check balls)

17R044 17R114 (ceramic SI-N check balls)

COMPONENT RUPTURE HAZARD

To reduce the risk of serious injury from pressurized

fluid, never use sharp or pointed tools to remove

sleeve. If the sleeve cannot be removed easily, return

the sleeve and cylinder to a Graco distributor for

removal.

Service

332922D 5

Repair When Pump is Separated

From Sprayer

Disassembling the Pump

1. Remove packing nut (202) and o-ring (228).

2. Unscrew intake valve from cylinder.

3. Disassemble intake valve. Clean and inspect o-ring

(227). NOTE: A pick may be required to remove

o-ring.

4. Tap piston rod out of cylinder with a hammer or flip

over and tap piston rod out against a bench.

ti7566C

ti7569c

233

215

214

212

213

227

ti23115a

NOTE: Spring (233)

only used on 16X426,

16X427, 16Y602,

17N693, 17N694,

17R042, and 17R044.

ti7571c

NOTE: Sleeve may come out

of cylinder with piston rod.

Service

6332922D

5. Remove piston rod from sleeve, or remove sleeve

from cylinder. Mark IV, Mark VII, and APX 6200

models: Remove sleeve spacer (230) from sleeve.

6. Unscrew piston valve from piston rod. Clean and

inspect parts. The piston has a special thread lock-

ing/sealing patch. Do not remove the patch. The

patch allows four disassembly/assembly procedures

before it is necessary to apply thread sealant to the

threads.

7. Remove packings and glands from piston rod.

COMPONENT RUPTURE HAZARD

To reduce the risk of serious injury from pressurized

fluid, never use sharp or pointed tools to remove

sleeve. If the sleeve cannot be removed easily, return

the sleeve and cylinder to a Graco distributor for

removal.

ti7572b

ti7576c

ti3940c

Not

used on

16X414,

16X418

Service

332922D 7

8. Remove throat packings and glands from cylinder.

Discard throat packings and glands.

Assembling the Pump

1. 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, threads are good for four repackings.

Use thread sealant on piston valve threads after

four repackings.

2. Install ball (206) in piston rod. If thread sealant is

applied to piston valve threads, make sure that none

gets on ball.

3. Tighten piston valve to piston rod as specified:

ti7573c

Not

used on

16X414,

16X418

216

218 208

204

217

210

229

ti7574e

Not

used on

16X414,

16X418

Models Torque

16X414, 16X418 27 ± 3 ft-lb.

(36.1 ± 4.1 N•m)

16X419, 16X420, 16X421,

16Y602, 16Y599,17N693,

17R044

55 ± 3 ft-lb.

(74.6 ± 4.1 N•m)

16X426, 16X427, 17N694,

17R042

100 ± 5 ft-lb.

(136 ± 7 N•m)

206

ti7575c

ti7576c

Service

8332922D

4. Soak all leather packings in SAE 30W oil for one

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.

5. Install seal (201) into packing nut (202). Install

o-ring (228) onto packing nut. Loosely install pack-

ing nut into cylinder.

6. Grease piston packings.

7. Slide piston assembly into bottom of sleeve.

8. Grease top inch or two of piston rod that will go

through the cylinder throat packings.

203

224

223

204

ti7573g

Not

used on

16X414,

16X418

201

202

228

ti7581b

NOTICE

Do not slide piston assembly into top of sleeve as this

may damage piston packing.

ti7578d

ti7577b

ti7579b

Service

332922D 9

9. Grease o-rings (221) and place on sleeve. Slide

sleeve/piston rod assembly into bottom of cylinder.

Replace o-ring (207) if desired.

NOTE: O-ring (207) is not required for safe pump

operation.

10. Mark IV, Mark VII, and APX6200 models: Install

o-ring (231) on sleeve spacer (230) and install

sleeve spacer on sleeve.

11. 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.

12. Install intake valve on cylinder. If a wrench is used

torque as follows:

221

207

ti7582b

231

230

Models Torque

16X414, 16X418 67 ± 5 ft-lb (90.8 ± 6.8 N•m)

16X419, 16X420,

16X421, 16Y602,

16Y599

80 ± 5 ft-lb (108.5 ± 6.8 N•m)

16X426, 16X427,

17N693, 17N694,

17R041, 17R044

200 ± 15 ft-lb (271.2 ± 20.3 N•m)

233

215

214

212

213

227

ti23115a

NOTE: Spring (233) only

used on 16X426, 16X427,

16Y602, 17N693, 17N694,

17R042, and 17R044.

ti7569d

Service

10 332922D

13. Torque packing nut (202) as follows: 14. Remove o-ring (228) when pump packings begin to

leak after extended use. Then tighten packing nut

down until leakage stops or lessens. This allows

approximately 100 gallons of additional operation

before a repacking is required.

Models Torque

16X414, 16X418, 16X419, 16X420,

16X421, 16Y602, 16Y599, 17N693,

17R044

100 ± 10 in-lb

(11.3 ± 1.1 N•m)

16X426, 16X427, 17N694, 17R042 140 ± 10 in-lb

(15.8 ± 1.1 N•m)

202

228

ti7568b

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