Repair

Displacement Pump

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

Model 248204, Series A

Ultrar Max II and Ultimate Mx II 695 and 795

ASM Zip--Sprayt 2700 Plus, 3100 Plus

ASM AllPro Mach 8600 Plus and 11000 Plus

ASM H2700 Plus

Model 255968, Series A

ASM 3600G Plus

Model 248205, Series A

Ultra Max II and Ultimate Mx II 1095 and 1595

Model 249059, Series A

TexSprayt Mark V

Model 249057, Series A

TexSpray Mark V

Model 277069, Series A

LineLazert IV 3900, R300

Model 277070, Series A

LineLazert IV 5900

Model 253056, Series A

Mark IV

Model 257146, Series A

Ironman 300E and Ironman 500G

Important Safety instructions

Read all warnings and instructions in this manual.

Save these instructions.

310643T

EN

8016A

Table of Contents

WARNING

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.

D Check equipment daily. Repair or replace worn or damaged parts immediately. D Do not alter or modify equipment.

D Read all instruction manuals, tags, and labels before operating the equipment.

D Use 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.

D Comply with all applicable safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers.

D Keep clear of moving parts.

D Do 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.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks or ruptured components will pierce skin. This may look like just cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

D Do not point the gun at anyone or at any part of the body.

D Do not put your hand over the spray tip.

D Do not stop or deflect leaks with your hand, body, glove or rag.

D Do not spray without tip guard and trigger guard installed.

D Engage the gun trigger safety when you stop spraying.

DFollow the Pressure Relief Procedure on page 3 if the spray tip clogs and before cleaning, checking or servicing the equipment.

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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:

D are instructed to relieve the pressure, D stop spraying,

D check or service any of the system equipment,

Dor 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

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.

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Repair When Pump Is Off The Sprayer

Disassembling the pump

Fig. 1. Remove packing nut (202) and throat adjust- ment spacer (228).

202 228

Fig. 3. Disassemble intake valve. Clean and inspect. O-ring (227) may require a pick for removal.

227

Fig. 3

7570e

ti2332a

Fig. 2. Unscrew intake valve from cylinder.

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. 5. Remove piston rod from sleeve, or remove sleeve from cylinder. Mark IV: Remove sleeve spacer (230) from sleeve.

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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 Loctiter to the threads.

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

Not used on 248204 253056 255968

Fig. 8

7573B

Fig. 7. Remove packings and glands from piston rod.

Not used on 248204 253056 255968

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.

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Fig. 10. Install ball (206) in piston rod. If Loctiter is ap- plied to piston valve threads, ensure that none gets on ball.

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.

206

Fig. 11. Tighten piston valve to piston rod as specified:

Fig. 12

7573f

Torque to 27 +/--3 ft-lb (248204, 253056, 255968, 277069)

Torque to 55 +/--3 ft-lb (248205, 249057, 249059, 277070, 257146)

Fig. 13. Install seal (201) into packing nut (202). Install throat adjustment spacer (228) onto packing nut. Loosely install packing nut into cylinder.

201 202 228

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Fig. 14. Grease piston packings.

Fig. 16. Grease top inch or two of piston rod that will go through the cylinder throat packings.

CAUTION

Do not slide piston assembly into top of sleeve as this may damage piston packing.

Fig. 15. Slide piston assembly into bottom of sleeve.

Fig. 17. Grease o-rings (221) and place on sleeve. Slide sleeve/piston rod assembly into bottom of cylind- er. Replace o-ring (207) if desired.

Note: O-ring (207) is not required for safe pump opera- tion.

207

221

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Fig. 18. Mark IV: Install o-ring (231) on sleeve spacer (230) and install sleeve spacer on sleeve.

ti7340a

230

231

Fig. 18

Fig. 19. 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.

214

212

227

Fig. 21. Torque packing nut (202) down onto adjust- ment spacer (228) 100 +/--10 in-lb.

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.

202 228

Fig. 19

7570f

Fig. 20. Install intake valve on cylinder. If a wrench is used torque as follows:

67 +/--5 ft-lb (Model 248204, 253056, 255968, 277069)

80 +/--5 ft-lb (Model 248205, 249057, 249059, 277070, 257146 )

If a wrench is not used, be sure intake valve is bot- tomed out against cylinder.

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Repair When Pump Is On The Sprayer

WARNING

SKIN 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. 2. Push up retaining spring (26).

Fig. 3. Push out pin (29). 29

26

Fig. 4. Disassemble intake valve. Clean and inspect. O-ring (227) may require a pick for removal.

227

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Fig. 5. Remove piston rod and sleeve.

Fig. 5. Invert piston rod and sleeve and pound on hard surface until piston rod comes out of sleeve. Mark IV: Remove sleeve spacer from sleeve.

Fig. 8. Invert piston rod and insert into cylinder to force out throat packings.

ti7339a

Fig. 6

Fig. 7. Remove packing nut (202)

Fig. 9. Insert piston rod into cylinder with pin hole up and piston valve down. Insert pin into piston rod and crank shaft.

7572A

202

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Fig. 10. Remove piston valve from piston rod with a wrench.

Fig. 12. Soak all leather packings in SAE 30W oil for 1 hour minimum prior to assembly. Stack male gland (204). Alternately stack UHMWPE (203) and leather (223) packings (note orientation). Install female gland (224). Install seal (201) and packing nut (202) and throat adjustment spacer (228).

Fig. 11. Remove pin and piston rod from cylinder.

Fig. 12

7573c

Fig. 13. Remove packings and glands from piston rod.

Not used on 248204 253056 255968

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Service

Fig. 14. 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 piston wiper (216) and backup washer (229) (note orientation) 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.

Fig. 10. Install ball (206) in piston rod. If Loctiter is ap- plied to piston valve threads, ensure that none gets on ball. Install piston valve on piston rod.

Torque as follows:

27 +/--3 ft-lb (Model 248204, 253056, 255968, 277069)

55 +/--3 ft-lb (Model 248205, 249057, 249059, 277070, 257146)

206

Fig. 16. Grease piston packings.

CAUTION

Do not slide piston assembly into top of sleeve as this may damage piston packing.

Fig. 17. Slide piston assembly into bottom of sleeve. Assure V-packing and u-cup are not rolled over or damaged. Mark IV: Install o-ring (231) on sleeve spacer (230). Install sleeve spacer on sleeve.

ti7341a

Mark IV

7577b

Fig. 17

Fig. 18. Grease top inch or two of piston rod that will go through the cylinder throat packings.

Service

Fig. 19. 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.

207

221

Fig. 21. Torque seal and packing nut (202) down onto throat adjustment spacer (228) to 100 +/--10 in-lb.

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.

202

228

Fig. 21. Push up retaining spring (26) with screwdriver.

Fig. 22. Push in pin (29).

29

26

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Fig. 23. Reassemble intake valve with new o-rings (227) and (230), seat (212) and ball (214). Seat may be flipped over and used on other side. Clean seat thoroughly.

214

212

227

Fig. 24. Install intake valve on cylinder. Torque: 70 +/--5 ft-lb (model 248204, 253056, 255968,

277069)

80 +/--5 ft-lb (Model 248205, 249057, 249059, 277070, 257146)

230

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222 201

202

228

V-Maxt UHWMPE, blue

Pump 248204

V-Maxt UHWMPE, blue

7683d

Fig 25

Technical Data

310643 15

Parts -- Pump 248204, 277069, 255968

Model 248204, Series A; 277069, Series A; 255968, Series A

*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.

224*

*223

203*

204*

205

207*

221*

220 (Not an

222

219*

*208 218*

217*

216*

229

206*

210

215

???*214

212???

???*227

213

ti4255a

16 310643

Parts - Pumps 248205, 249057, 249059, 277070, 257146

Model 248205, Series A; 249057, Series A; 249059, Series A; 277070, Series A; 257146, Series A

*These parts are also included in Repair Kit 248213, which may be purchased separately.

???These parts are also included in Carbide Seat Kit 244199, which may be purchased separately

+ These parts are included in Pump Repair Kit 249189.

201

202 228

224*

*223

203*

204*

205

207*

221*

220

221*

222

219*

*208 218*

217*

216*

229

206* 210

215

???*214

212???

???*227

213

(Not an O--ring groove)

230*

310643 17

Parts -- Pump 253056

*These parts are also included in Repair Kit with stainless steel ball, 287825, purchased separately.

?? These parts are also included in Repair Kit with ceramic ball, 24V063, purchased separately.

??? These parts are also included in Carbide Seat Kit with stainless steel ball, 244199, purchased sepa- rately.

n These parts are also included in Carbide Seat Kit with ceramic ball, 2V071, purchased separately.

18 310643

201*??

202

221*??

228*??

222

224*?? *??223

220

(Not an O--ring groove)

231*??

Notes

310643 19

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 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 sub- stitution 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 mak- ing 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 reconnais- sent avoir convenu que la r??daction du pr??sente document sera en Anglais, ainsi que tous documents, avis et proc??dures judiciaires ex??cut??s, donn??s ou intent??s ?? la suite de ou en rapport, directement ou indirectement, avec les procedures concern??es.

ADDITIONAL WARRANTY COVERAGE

Graco does provide extended warranty and wear warranty for products described in the ???Graco Contractor Equipment Warranty Program???.

TO PLACE AN ORDER, contact your Graco distributor, or call 1--800--690--2894 to identify the nearest distributor.

All written and visual data contained in this document reflect the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

Original insttructions. This manual contains English. MM 310643

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES P.O. BOX 1441 MINNEAPOLIS, MN 55440--1441 USA Copyright 2003, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. www.graco.com

12/2003, Revised January 2014

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