Graco 248204, 249057, 249059, 253056, 257146 User Manual

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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

310643T

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.

8016A

Table of Contents

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

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

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

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

D Do not exceed the maximum working pressure temperature rating of the lowest rated system

component. See Technical Data in all equipment manuals.

D Use 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.

Parts, Pump

248204, 255968 16.............................

248205, 249057, 249059, 277070, 257146 17.....

253056 18.....................................

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

D 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.

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.

D Pressurized 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.

D Follow the Pressure Relief Procedure on page 3 if the spray tip clogs and before cleaning,

2 310643

checking or servicing the equipment.

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:

D areinstructedtorelievethepressure, D stop spraying, D check or service any of the system equipment, D 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.

To o ls 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.

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

248204, 255968 248212

253056 287825

248205, 249057, 249059, 257146

248213

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.

3310643

Service

Repair When Pump Is Off T h e Sprayer

Disassembling the pump

Fig. 1. Remove packing nut (202) and throat adjustment spacer (228).

202

228

ti2332a

Fig. 1

7568A

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

227

7570e

Fig. 3

Fig. 4. T ap 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. 2. Unscrew intake valve from cylinder.

Fig. 2

7569A

Fig. 4

7571a

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

Fig. 5

7572A

4 310643

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 Loctiter to the threads.

Fig. 8. Remove throat packings and glands from cylinder. Discard throat packings and glands.

Not

used on

248204 253056 255968

Fig. 6

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

Not

used on

248204 253056 255968

7576A

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

248204 253056 255968

210

7573B

229

216

Fig. 7

ti3940b

Fig. 9

204

218 208

217

7574d

5310643

Service

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

206

Fig. 10

7575A

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

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.

224

Not

used on

248204 253056

203

223

255968

204

Torque to 27 +/-- 3 ft-lb

(248204, 253056, 255968,

277069)

Torque to 55 +/--3 ft-lb

(248205, 249057, 249059,

277070, 257146)

Fig. 11

7576A

Fig. 12

7573f

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

Fig. 13

7581A

6 310643

+ 14 hidden pages