Repair
310643U
Displacement Pump
EN
Use only genuine Graco replacement parts. Use of non-Graco replacement parts may void
warranty.
3300 psi (22.7 MPa, 227 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this manual.
Be familiar with the controls and the proper usage
of the equipment. Save these instructions.
Model 248204, Series A
UltraMax II and Ultimate MX II 695/795
ASM Zip-Spray 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
UltraMax II and Ultimate MX II 1095/1595
Model 249059, Series A
TexSpray Mark V
Model 249057, Series A
TexSpray Mark V
Model 277069, Series A
LineLazer IV 3900, R300
Model 277070, Series A
LineLazer IV5900
Model 253056, Series A
Mark IV
Model 257146, Series A
Ironman 300E and Ironman 500G
ti2311
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Service
Service
Pressure Relief Procedure
Pump Repair Kits
Follow the Pressure Relief Procedure whenever
you see this symbol.
Pump
Repair Kit
248204, 255968
253056
248212
287825
248205, 249057, 249059, 248213
257146
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
Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.
Tools Needed
•
•
•
•
•
•
Vise
12 in. adjustable, open-end wrench (2)
Hammer (20 oz maximum)
Small screwdriver
1. Engage trigger lock.
Throat Seal Liquid
2. Turn ON/OFF switch to OFF.
3. Unplug power cord.
Pick or long small screwdriver
Cleaning and Inspecting Parts
4. Disengage trigger lock. Hold metal part of gun
against grounded metal pail and trigger gun into pail
to relieve pressure.
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 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.
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.
NOTE: Remove and clean sleeve when repacking pump.
310643U
3
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Service
4. Tap piston rod out of cylinder with a hammer or flip
over and tap piston rod out against a bench.
Repair When Pump is Separated
From Sprayer
Disassembling the Pump
NOTE: Sleeve may come out
of cylinder with piston rod.
1. Remove packing nut (202) and o-ring (228).
202
228
ti7571a
5. Remove piston rod from sleeve, or remove sleeve
from cylinder. Mark IV models: Remove sleeve
spacer (230) from sleeve.
ti7566a
2. Unscrew intake valve from cylinder.
ti7572a
ti7569a
3. Disassemble intake valve. Clean and inspect o-ring
(227). NOTE: A pick may be required to remove
o-ring.
233
215
214
212
227
ti7570e
213
ti23115a
4
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Service
8. Remove throat packings and glands from cylinder.
Discard throat packings and glands.
Not
used on
248204,
253056,
255968
COMPONENT RUPTURE HAZARD
To reduce the risk of serious injury from pressurized
fluid, 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.
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.
ti7573b
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 (210). Threads are good for four
repackings. Use thread sealant on piston valve
threads after four repackings.
Not
ti7576a
used on
248204,
210
253056,
255968
7. Remove packings and glands from piston rod.
229
216
Not
used on
248204,
253056,
255968
217
ti7574d
218 204 208
ti3940b
310643U
5
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Service
2. Install ball (206) in piston rod. If thread sealant is
applied to piston valve threads, make sure that none
gets on ball.
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.
206
Not
224
used on
248204,
253056,
255968
203
223
204
ti7573f
ti7575a
5. Install seal (201) into packing nut (202). Install
o-ring (228) onto packing nut. Loosely install pack-
ing nut into cylinder.
3. Tighten piston valve to piston rod as specified:
Models
Torque
248204, 253056,
255968, 244069
248205, 249057,
249059, 277070,
257146
27 +/-3 ft-lb.(36.1 +/-4.1 N•m)
201
202
228
55 +/-3 ft-lb.(74.6 +/-4.1 N•m)
ti7581a
6. Grease piston packings.
ti7576a
ti7578c
NOTICE
Do not slide piston assembly into top of sleeve as this
may damage piston packing.
6
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Service
7. Slide piston assembly into bottom of sleeve.
10. Mark IV models: Install o-ring (231) on sleeve
spacer (230) and install sleeve spacer on sleeve.
230
231
ti7577a
ti7340a
ti7340b
8. Grease top inch or two of piston rod that will go
through the cylinder throat packings.
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.
215
214
212
227
ti7579a
9. Grease o-rings (221) and place on sleeve. Slide
sleeve/piston rod assembly into bottom of cylinder.
Replace o-ring (207) if desired.
213
NOTE: O-ring (207) is not required for safe pump
ti23115a
operation.
207
221
ti7582a
310643U
7
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Service
12. Install intake valve on cylinder. If a wrench is used
torque 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
248204, 253056, 67 +/- 5 ft-lb (90.8 +/-6.8 N•m)
255968, 277069
248205, 249057, 80 +/- 5 ft-lb (108.5 +/-6.8 N•m)
249059, 277070,
257146
202
228
ti7568a
ti7569a
13. Torque packing nut (202) down onto adjustment
spacer (228) 100 +/- 10 in-lb. (11.3 +/- 1.1 N•m)
8
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Service
4. Push out pin (29).
Repair When Pump is On
Sprayer
29
1. Perform Pressure Relief Procedure, page 3.
2. Remove intake valve.
26
ti4258b
ti4258b
5. Disassemble intake valve. Clean and inspect.
O-ring (227) may require a pick for removal.
215
214
212
227
ti4258c
3. Push up retaining spring (26).
213
ti23115a
6. Remove piston rod and sleeve.
ti4258a
26
ti7746a
310643U
9
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Service
7. Invert piston rod and sleeve and pound on hard sur-
face until piston rod comes out of sleeve.
11. Remove piston valve from piston rod with a wrench.
Mark IV models: Remove sleeve spacer from sleeve.
ti4258g
ti4258g
12. Remove pin and piston rod from cylinder.
ti7572a
8. Remove packing nut (202).
202
ti4258h
13. 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
o-ring (228).
ti7726a
9. Invert piston rod and insert into cylinder to force out
throat packings.
Not used on
248204,
253056,
224
255968
201
203
223
204
228
202
ti4258e
10. Insert piston rod into cylinder with pin hole up and
piston valve down. Insert pin into piston rod and
crank shaft.
ti7573c
ti4258f
10
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Service
14. Remove packings and glands from piston rod.
16. Install ball (206) in piston rod. NOTE: If thread seal-
ant is applied to piston valve threads, make sure
none gets on ball. Install piston valve on piston rod.
Torque as follows:
Not used on
248204,
253056,
Models
Torque
255968
248204, 253056,
255968, 277069
248205, 249057,
27 +/- 3 ft-lb (36.6 +/-4.1 N•m)
249059, 277070, 55 +/- 3 ft-lb (74.6 +/-4.1 N•m)
257146
ti3939a
15. Soak all leather packings in SAE 30W oil for one 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 pis-
ton valve threads is good for four repackings. Use
thread sealant on piston valve threads after four
repackings.
206
219
217
ti7575b
Not
used on
ti7575b
216
248204,
253056,
17. Grease piston packings.
229
255968
206
210
218
208
ti3941a
ti7578c
310643U
11
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Service
21. Torque seal and packing nut (202) down onto throat
adjustment spacer (228) to 100 +/- 10 in-lb (11.3 +/-
1.1 N•m).
NOTICE
Do not slide piston assembly into top of sleeve as this
may damage piston packing.
Remove o-ring when pump packings begin to leak
after extended use. Then tighten packing nut down
until leakage stops or reduces. This allows approxi-
mately 100 gallons of additional operation before a
repacking is required.
18. Slide piston assembly into bottom of sleeve. Make
sure V-packing and u-cup are not rolled over or
damaged. Mark IV models: Install o-ring (231) on
sleeve spacer (230). Install sleeve spacer on
sleeve.
Mark IV
202
228
ti7726b
ti7341a
22. Push up retaining spring (26) with screwdriver.
19. Grease top inch or two of piston rod that will go
through the cylinder throat packings.
ti4258k
26
ti7579a
23. Push in pin (29). NOTE: Make sure retaining ring
falls into slot.
20. 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.
29
26
ti4258m
207
221
ti4258j
12
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Service
24. 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.
Pump Packings
222
201
215
214
202
228
212
227
224
™
203
204
V-Max
223
Leather
UHWMPE,
blue
205
213
221
220
ti23115a
206
207
219
25. Install intake valve on cylinder. Torque as follows:
Models
Torque
208
217
216
218
Leather
248204, 253056,
255968, 277069
248205, 249057,
70 +/- 5 ft-lb (94.9 +/-6.8 N•m)
™
V-Max
210
UHWMPE,
blue
229
249059, 277070, 80 +/- 5 ft-lb (108.5 +/-6.8 N•m)
257146
221
215
214
213
212
227
230
Pump 248204
ti7683d
ti4258n
310643U
13
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Parts - Pump 248204, 277069, 255968
Parts - Pump 248204, 277069, 255968
Series A
Ref.
201
202
Part
179810
193046
Description
SEAL, throat
NUT, packing
V-PACKING, throat, V-Max,
UHMWPE, blue
Qty.
201
1
1
3
203* 192692
202
228
221
222
204* 15C987 GLAND, male, throat,
205
1
CYLINDER, pump
Model 248204, 255968
Model 16X428
BALL, sst, 0.3125 in.
PACKING, o-ring
V-PACKING, piston, V-MAX,
UHMWPE, blue
243346
243346
1
1
1
1
3
206* 105444
207* 114054
208* 192693
224
210
239932
VALVE, piston
KIT, seat, carbide (includes 214 and
227)
1
1
223
212† 239922
219
218
203
204
213
VALVE, intake (foot)
15C785 Model 248204, 255968
1
195892
Model 277069
214*† 105445* BALL, sst. 0.5000 in.
215
1
1
1
1
2
1
1
2
1
2
208
192624
GUIDE, ball
WIPER, piston
GLAND, female, piston
V-PACKING, leather, piston
GLAND, male
SLEEVE, cylinder
O-RING, ptfe
216* 118503
217* 178969
218* 178939
219* 196880
220
221* 108526
222 248206
223* 178940
224* 15C988 GLAND, female
227*† 107079
228 192714
229* 15C997 WASHER, backup
230* 118494 O-RING, fluoroelastomer
(not used on Lo-Boy)
217
216
248209
229
ROD, piston
V-PACKING, leather, throat
206
210
PACKING, o-ring
SPACER, throat, nut
1
1
1
1
215
205
214
227
* These parts are also included in Repair Kit 248212, which
may be purchased separately.
212
213
207
221
† These parts are also included in Carbide Seat Kit 239922,
which may be purchased separately.
220
(Not an O-ring groove)
230
ti4255a
14
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Parts - Pump 248205, 249057, 249059, 277070, 257146
Parts - Pump 248205, 249057, 249059, 277070, 257146
Series A
Ref.
Part
Description
Qty.
201
202
203*
183171
193032
193124
PLUG
NUT, packing
V-PACKING, throat, V-Max,
UHMWPE, blue
GLAND, packing, male, throat
CYLINDER, pump
Model 248205, 277070
Model 249057, 249059, 257146
BALL, 0.375 in.
1
1
4
201
202
221
222
204*
205
15C989
1
1
243347
196754
228
224
203
206
1
101947*
Model 248205, 249057, 277070, 257146
116327 Model 249059, ceramic
156633
193125
219
218
207*
208*
PACKING, o-ring
V-PACKING, piston, V-MAX,
UHMWPE, blue
1
4
208
223
210
212
240150
VALVE, piston
1
1
KIT, seat, carbide (includes 214, 227)
Model 248205, 249057, 277070, 257146
Model 249059
244199
244571
217
216
229
206
213
214
215
HOUSING, intake (foot)
Model 248205
Model 249059, 249057
Model 277070, 257146
BALL
1
1
15C783
196753
195894
204
222
102972*† Model 248205, 249057, 277070, 257146,
0.875 in.
111453 Model 249059, ceramic, 0.750 in.
GUIDE, ball
1
1
210
231
196967
193027
118504
183185
15E329
183178
Model 249059, 249057
Model 248205, 277070, 257146
WIPER, piston
GLAND, female, piston
V-PACKING, leather, piston
GLAND, packing, male
SLEEVE, cylinder
1
1
1
3
1
1
216*
217*
218*
219*
220
232
205
248210
257031
107098
Model 248205, 249057, 249059, 277070
Model 257146
PACKING, o-ring
215
214
221*
222
2
ROD, piston
212
227
248207
249028
183175
15C990
Model 248205, 277070
Model 249059, 249057, 257146
V-PACKING, leather, throat
GLAND, female, throat
PACKING, o-ring
SPACER, nut
WASHER, backup
O-RING, fluoroelastomer (not used on
249057, 249059, 257146)
NIPPLE, straight
Model 249057, 249059 (not shown)
ADAPTER, 3/8 npt x 3/8 npsm
Model 249057, 249059, 257146 (not
shown)
1
1
3
1
1
1
1
1
207
221
223*
224*
227*† 108526
228
229*
230*
C20987
15C998
118494
213
230
220
231
232
117608
162485
1
1
1
(Not an O-ring groove)
ti23114a
* 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 also included in Pump Repair Kit 249189, which
may be purchased separately.
310643U
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Parts - Pump 253056
Parts - Pump 253056
Ref.
201* 179810
202 193046
Part
Description
SEAL, throat
NUT, packing
V-PACKING, throat, V-Max,
UHMWPE, blue
Qty.
1
1
3
201
203* 192692
202
228
204* 15C987
GLAND, male, throat
CYLINDER, pump
BALL, check
1
1
1
221
222
205
287876
206*
105444* BALL, sst, 0.3125 in. (optional)
119259 BALL, ceramic, 0.3125 in. (standard)
207* 156593
208* 192693
PACKING, o-ring
V-PACKING, piston, V-MAX,
UHMWPE, blue
1
3
224
210
287877
VALVE, piston
SEAT, carbide
HOUSING, intake
BALL, check, inlet
1
1
1
1
212† ^ 197470
213
214
223
287878
102972*† BALL, sst, 0.875 in. (optional)
111453 ^ BALL, ceramic, 0.750 (standard)
219
203
204
215
196967
216* 118503
217* 178969
GUIDE, ball
WIPER, piston
GLAND, female, piston
V-PACKING, leather, piston
GLAND, male
SLEEVE, cylinder
O-RING, ptfe
ROD, piston (Mark IV)
V-PACKING, leather, throat
GLAND, female
PACKING, o-ring
SPACER, throat, nut
WASHER, backup
SPACER, sleeve
O-RING
1
1
1
2
1
1
2
1
2
218
219* 196880
220 248209
221* 108526
222 249969
178939
218
217
208
223* 178940
224* 15C988
227*† ^ 108526
228* 158776
229* 15C997
216
229
1
1
1
1
1
206
210
230
15G494
231* 107098
* These parts are also included in Repair Kit with stainless steel
ball,287825, which may be purchased separately.
These parts are also included in Repair Kit with ceramic ball,
24V063, which may be purchased separately.
215
† These parts are also included in Carbide Seat Kit with stainless
steel ball, 244199, which may be purchased separately.
^ These parts are also included in Carbide Seat Kit with ceramic ball,
24V071, which may be purchased separately.
205
214
227
207
221
212
213
220
(Not an O-ring groove)
230
231
16
310643U
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Technical Data
Technical Data
U.S.
Metric
227 bar, 22.7 MPa
1-5/16-12 un(m)
Maximum Working Pressure
Fluid Inlet Size
3300 psi
1-5/16-12 un(m)
Fluid Outlet Size
248204, 255968, 277069
248205, 249057, 249059,
253056, 277070, 257146
1/4 npt(f)
3/8 npt(f)
stainless steel, PTFE, leather, nylon, zinc-plated carbon steel, tungsten
carbide, chrome plating, fluoroelastomer, acetal, polyethylene
Wetted Parts
310643U
17
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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 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 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 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 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 reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
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 reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. 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 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Revised U, April 2015
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