Graco Series A Operating instructions

Repair
Displacement Pump 310643T
EN
8016A
3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure
Model 248204, Series A
UltrarMax II and Ultimate Mx II 695 and 795
ASM Zip--Sprayt2700 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
TexSpraytMark V
Model 249057, Series A
TexSpray Mark V
Model 277069, Series A
LineLazertIV 3900, R300
Model 277070, Series A
LineLazertIV 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.

2 310643
Table of Contents
Warnings 2......................................
Service 3.......................................
Technical Data 15................................
Parts, Pump
248204, 255968 16.............................
248205, 249057, 249059, 277070, 257146 17.....
253056 18.....................................
Warranty 20.....................................
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.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not alter or modify equipment.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse 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.
DComply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
DKeep clear of moving parts.
DDo 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.
DDo not point the gun at anyone or at any part of the body.
DDo not put your hand over the spray tip.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DDo not spray without tip guard and trigger guard installed.
DEngage 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.

3310643
Service
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT H
A
Z
A
RD
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:
Dareinstructedtorelievethepressure,
Dstop spraying,
Dcheck 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
Pump Repair Kit
248204, 255968 248212
253056 287825
248205, 249057, 249059,
257146
248213
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 310643
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
228
ti2332a
202
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.
Fig. 3
227
7570e
Fig. 4. Tap piston rod out of cylinder with a hammer or
flip over and tap piston rod out against a bench.
Fig. 4 7571a
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.
Fig. 5 7572A

5310643
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 Loctiterto the threads.
Fig. 6 7576A
Fig. 7. Remove packings and glands from piston rod.
Fig. 7
Not
used on
248204
253056
255968
ti3940b
Fig. 8. Remove throat packings and glands from cylin-
der. Discard throat packings and glands.
Fig. 8 7573B
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.
Fig. 9
216
218 208
204
217
210
Not
used on
248204
253056
255968
7574d
229

6 310643
Service
Fig. 10. Install ball (206) in piston rod. If Loctiteris 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
(248204, 253056, 255968,
277069)
Torque to 55 +/--3 ft-lb
(248205, 249057, 249059,
277070, 257146)
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.
Fig. 12
203
224
223
204
Not
used on
248204
253056
255968
7573f
Fig. 13. Install seal (201) into packing nut (202). Install
throat adjustment spacer (228) onto packing nut.
Loosely install packing nut into cylinder.
Fig. 13
201
202
7581A
228

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Service
Fig. 14. Grease piston packings.
Fig. 14 ti7578c
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. 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-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.
Fig. 17 7582A
221
207

8 310643
Service
Fig. 18. Mark IV: Install o-ring (231) on sleeve spacer
(230) and install sleeve spacer on sleeve.
Fig. 18
ti7340a
231
230
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.
Fig. 19
227
7570f
212
214
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.
Fig. 20 7569A
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.
Fig. 21
202
228
7568A

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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. 1 ti4258a
Fig. 2. Push up retaining spring (26).
Fig. 2 26 ti4258a
Fig. 3. Push out pin (29).
Fig. 3
29
26
ti4258a
Fig. 4. Disassemble intake valve. Clean and inspect.
O-ring (227) may require a pick for removal.
Fig. 4 7570A
227

10 310643
Service
Fig. 5. Remove piston rod and sleeve.
7746A
Fig. 5
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. 6 7572A
ti7339a
Fig. 7. Remove packing nut (202)
7726A
Fig. 7
202
Fig. 8. Invert piston rod and insert into cylinder to force
out throat packings.
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.
Fig. 9 ti4258a