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
EN
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
Warnings2......................................
Service3.......................................
Technical Data15................................
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, 25596816.............................
248205, 249057, 249059, 277070, 25714617.....
25305618.....................................
Warranty20.....................................
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,
2310643
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
PumpRepair Kit
248204, 255968248212
253056287825
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.
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
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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
218208
217
7574d
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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
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Service
Fig. 14. Grease piston packings.
Fig. 14
CAUTION
ti7578c
Fig. 16. Grease top inch or two of piston rod that will
go through the cylinder throat packings.
Fig. 16
Fig. 17. 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.
7579A
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. 15
7577A
Fig. 17
207
221
7582A
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Service
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. 20
7569A
Fig. 21. T orque packing nut (202) down onto adjustment 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 operation before a repacking is required.
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 bottomed out against cylinder.
Fig. 21
202
228
7568A
8310643
Service
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. 2
Fig. 3. Push out pin (29).
26
ti4258a
Fig. 1
ti4258a
29
26
Fig. 3
Fig. 4. Disassemble intake valve. Clean and inspect.
O-ring (227) may require a pick for removal.
227
ti4258a
Fig. 4
7570A
9310643
Service
Fig. 5. Remove piston rod and sleeve.
Fig. 5
7746A
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. 8
ti4258a
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
Fig. 7
10310643
7726A
Fig. 9
ti4258a
Service
Fig. 10. Remove piston valve from piston rod with a
wrench.
Fig. 10
ti4258a
Fig. 11. Remove pin and piston rod from cylinder.
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).
Not
used on
224
248204
253056
255968
203
223
201
228
202
204
Fig. 11
ti4258a
Fig. 12
7573c
Fig. 13. Remove packings and glands from piston rod.
Not
used on
248204
253056
255968
Fig. 13
ti3939a
11310643
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.
219
217
Not
used on
248204
216
253056
255968
229
206
210
ti3941a
Fig. 14
218
208
Fig. 16. Grease piston packings.
Fig. 16
ti7578c
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.
Fig. 10. Install ball (206) in piston rod. If Loctiter is applied 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
ti7341a
Mark IV
7577b
Fig. 17
Fig. 18. Grease top inch or two of piston rod that will
go through the cylinder throat packings.
Fig. 15
12310643
7575A
Fig. 18
7579A
Service
Fig. 19. Grease o-ring (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.
207
221
Fig. 19
ti4258a
Fig. 21. T orque 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 operation before a repacking is required.
Fig. 21. Push up retaining spring (26) with screwdriver.
Fig. 21
26
ti4258a
Fig. 22. Push in pin (29).
29
Fig. 20
7726b
202
228
Fig. 22
26
Note: Make sure retaining ring falls into slot.
ti4258a
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Service
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
230
Fig. 23
7570f
Fig. 24. Install intake valve on cylinder. Torque:
§ These parts are also included in Repair Kit with
ceramic ball, 24V063, purchased separately.
*§223
202
228*§
224*§
203*§
204*§
*§208
205
207*§
221*§
220
(Not an O--ring groove)
230
231*§
†*§n214
†*§n227
221*§
222
219*§
218*
217*§
216*
229*§
206*
210
215
212†
213
ti7338a
† These parts are also included in Carbide Seat Kit
with stainless steel ball, 244199, purchased separately.
n These parts are also included in Carbide Seat Kit
with ceramic ball, 2V071, purchased separately.
18310643
Notes
19310643
Graco Standard Wa rranty
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 thedate of sale to the original purchaser for use. With the exception ofany special, extended,
or limited warranty published by Graco, Graco will, fora period of twelve months fromthe date of sale, repair or replace any part of the
equipmentdetermined by Graco tobe defective. This warrantyapplies onlywhen 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
faultyinstallation, misapplication,abrasion, corrosion, inadequate or improper maintenance, negligence, accident,tampering, or substitution 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
equipmentwill be returned to the original purchaser transportationprepaid. If inspection ofthe equipmentdoes notdisclose 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’ssole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agreesthat no other
remedy (including, but not limited to, incidentalor consequentialdamages for lost profits,lost sales, injury to person or property, or any
other incidental or consequentialloss) 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 making 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 CUST
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 reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsique tous documents, avis et procédures judiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
OMERS
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 INC. AND SUBSIDIARIES P.O. BOX 1441 MINNEAPOLIS, MN55440--1441 USA
Copyright 2003, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
20310643
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
www.graco.com
12/2003, Revised January 2014
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