Repair

Parts

Displacement Pump

3600 psi (250 bar, 24.8 MPa) Maximum Working Pressure

Model 248204, Series A

Ultra Max II and Ultimate Mx II 695 and 795

Model 248205, Series A

Ultra Max II and Ultimate Mx II 1095 and 1595

310643

Rev. B

GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441

Copyright 2003, Graco Inc. is registered to I.S. EN ISO 9001

8016A

Table of Contents

Warnings

Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

3

Technical Data

Parts, Pump

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

248204

248205

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . .

18

18

2

WARNING

EQUIPMENT MISUSE HAZARD

INSTRUCTIONS

Misuse can cause death or serious injury.

Do not exceed the maximum working pressure temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

Use fluids and solvents compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read manufacturer fluid and solvent warnings.

Check equipment daily. Repair or replace worn or damaged parts immediately.

Do not alter or modify equipment.

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

Use equipment only for its intended purpose. Call your Graco distributor for information.

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.

Comply with all applicable safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers.

Keep clear of moving parts.

Do not operate equipment with protective guards or covers removed.

Pressurized equipment can start without warning. Before checking, moving or servicing equipment, follow the Pressure Relief Procedure on page 3. Disconnect power cord.

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 medical attention.

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

Do not put your hand over the spray tip.

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

Do not spray without tip guard and trigger guard installed.

Engage the gun trigger safety when you stop spraying.

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

310643

Service

Tools Needed 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: are instructed to relieve the pressure, stop spraying, check or service any of the system equipment, 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.

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

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.

Pump

248204

248205

Repair Kit

248212

248213

2.

Remove and clean the sleeve when you are repacking the pump.

310643 3

Repair When Pump Is Off The Sprayer

Disassembling the pump

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

Service

Fig. 3. Disassemble intake valve. Clean and inspect.

O-ring (227) may require a pick for removal.

202

228

227

Fig. 1 7568A

Fig. 2. Unscrew intake valve from cylinder.

ti2332a

7570e

Fig. 3

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. 4

Fig. 5.

Remove piston rod from sleeve, or remove sleeve from cylinder.

7571a

Fig. 2

7569A

Fig. 5

7572A

4 310643

Service

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

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.

Not used on

248204

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 Loctite to the threads.

Fig. 6

7576A

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

Not used on

248204

7573B

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 Loctite on piston valve threads after four repackings.

Not used on

248204

210

229

216

Fig. 7 ti3940b

Fig. 9

218 204 208

217

7574d

310643 5

Service

Fig. 10. Install ball (206) in piston rod. If Loctite is applied 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

224

Not used on

248204

203

223

204

Fig. 10

7575A

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

Torque to 27 +/–3 ft-lb

(248204)

Torque to 55 +/–3 ft-lb

(248205)

7573f

Fig. 12

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. 11

7576A

Fig. 13

7581A

6 310643

Fig. 14. Grease piston packings.

Service

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

Fig. 14

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.

ti7578c

Fig. 16

7579A

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.

Fig. 15

7577A

Fig. 17

221

207

7582A

310643 7

214

212

227

Service

Fig. 18. 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. 20. Torque 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.

202

228

Fig. 18 7570f

Fig. 19. Install intake valve on cylinder. If a wrench is used torque as follows:

67 +/–5 ft-lb (model 248204)

80 +/–5 ft–lb (model 248205)

If a wrench is not used, be sure intake valve is bottomed out against cylinder.

Fig. 20

7568A

Fig. 19

8 310643

7569A

Repair When Pump Is On The Sprayer

WARNING

INJECTION HAZARD

To reduce the risk of serious injury, whenever you are instructed to relieve pressure, follow the Pressure Relief

Procedure on page 3.

Service

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

Fig. 1. Remove intake valve.

Fig. 1

Fig. 2

Fig. 3. Push out pin (29).

29

26 ti4258a ti4258a

26 ti4258a

Fig. 3

Fig. 4. Disassemble intake valve. Clean and inspect.

O-ring (227) may require a pick for removal.

227

Fig. 4 7570A

310643 9

Fig. 5. Remove piston rod and sleeve.

Service

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

Fig. 5

7746A

Fig. 5. Invert piston rod and sleeve and pound on hard surface until piston rod comes out of sleeve.

ti4258a

Fig. 8

7572A

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

Fig. 6

Fig. 7. Remove packing nut (202)

202

7726A

Fig. 9 ti4258a

Fig. 7

10 310643

Service

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. 10

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

ti4258a

203

224

223

204

Not used on

24804

201

228

202

Fig. 11 ti4258a

7573c

Fig. 12

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

Not used on

248204 ti3939a Fig. 13

310643 11

Service

Fig. 16. Grease piston packings.

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 Loctite on piston valve threads after four repackings.

219

217

Not used on

248204

216

229

206

210 ti3941a Fig. 14

218 208

Fig. 10. Install ball (206) in piston rod. If Loctite 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)

55 +/–3 ft-lb (model 248205) ti7578c Fig. 16

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.

7577b

Fig. 17

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

206

7575A

Fig. 18

Fig. 15

12 310643

7579A

Service

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

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. 20. 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 operation before a repacking is required.

Fig. 21

Fig. 22. Push in pin (29).

29

202

228

Fig. 22

26 ti4258a

26 ti4258a

Note: Make sure retaining ring falls into slot.

Fig. 20

7726b

310643 13

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.

Fig. 24. Install intake valve on cylinder. Torque:

70 +/–5 ft-lb (model 248204)

80 +/–5 ft-lb (model 248205)

214

212

227

230

7570f

Fig. 24

Fig. 23 ti4258a

14 310643

Service

222

201

202

228

224

223

Leather

205

203 V-Max UHWMPE, blue

204

221

220

Pump 248204

206

207

219

218

Leather

210

221

215

212

227

208 2

217

216 V-Max UHWMPE, blue

229

214

213

230

7683d

Fig 25

Technical Data

Maximum working pressure

Fluid inlet size

. . . . . . . . . . . . . . . 3600 psi

(250 bar, 24.8 MPa)

. . . . . . . . . . . . . . . . . . . 1-5/16–12 un(m)

Fluid outlet size

248204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 npt(f)

248205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wetted parts . . . . . . . . . . . . . . . . .

3/8 npt(f) stainless steel, PTFE, leather, nylon, zinc-plated carbon steel, tungsten carbide, chrome plating, Viton ,

Delrin , polyethylene

NOTE : Delrin and Viton are Company registered trademarks. Loctite is a Loctite Company registered trademark.

310643 15

Parts – Pump 248204

Model 248204, Series A

Ref

No.

Part No.

Description Qty.

201 179810 SEAL, throat

202 193046 NUT, packing

203* 192692 V-PACKING, throat,

V-Max UHMWPE, blue

204* 15C987 GLAND, male, throat

205 243346 CYLINDER, pump

206* 105444 BALL, sst, 0.3125 in.

207* 114054 PACKING, o-ring

1

208* 192693 V-PACKING, piston

V-Max UHMWPE, blue

210 239932 VALVE, piston

212† 239922 KIT, seat, carbide

213

215

15C785

214*† 105445

192624 includes 214 and 227

VALVE, intake (foot)

BALL, sst, 0.5000 in.

GUIDE, ball

216* 118503 WIPER, piston

217* 178969 GLAND, female, piston

218* 178939 V-PACKING, leather, piston

219* 196880 GLAND, male

220

221*

222*

248209 SLEEVE, cylinder

108526 O-RING,

248206 ROD, piston

223* 178940 V-PACKING, throat

224* 15C988 GLAND, female

227*† 107079 PACKING, o-ring

228 192714 SPACER, throat, nut

229* 15C997 WASHER, backup 1

230* 118494 O-RING, Viton (not used on Lo-boy) 1

1

1

1

2

1

2

2

1

1

1

1

1

1

1

1

1

1

3

1

1

3

* 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.

*223

201

202

228

224*

203*

204*

205

207*

221*

*208

†*214

†*227

220

221*

222*

219*

218*

217*

216*

229

206*

210

215

212†

213 ti4255a

230*

16 310643

Model 248205, Series A

Ref

No.

Part No.

Description

Parts – Pump 248205

Qty.

201

201 183171 PLUG

202 193032 NUT, packing

203* 193124 V-PACKING

V-Max UHMWPE, blue

204* 15C989 GLAND, packing, male, throat

205 243347 CYLINDER, pump

206* 101947 BALL, sst, 0.375 in.

207* 106556 PACKING, o-ring

208* 193125 V-PACKING, piston

V-Max UHMWPE, blue

210 240150 VALVE, piston

212† 244199 KIT, SEAT, carbide includes 214 and 227

213

215

216*

217*

218*

219*

15C783

214*† 102972

196967

118504

183185

15E329

183178

HOUSING, intake (foot)

BALL, sst, 0.875 in.

GUIDE, ball

WIPER, piston

GLAND, female, piston

V-PACKING, leather, piston

GLAND, packing, male

220 248210 SLEEVE,

221* 107098 PACKING,

222

223*

248207 ROD, piston

183175 V-PACKING, throat

224* 15C990 GLAND, packing, female

227*† 108526 PACKING, o-ring

228 193127 SPACER, nut

229* 15C998 WASHER, backup

230* 118494 O-RING, Viton (not used on Lo-boy) 1

1

1

1

1

1

3

1

1

2

1

3

1

1

1

1

1

1

1

1

4

1

1

1

1

4

*223

202

228

224*

203*

204*

205

* 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.

207*

221*

*208

†*214

†*227

220

221*

222**

219*

218*

217*

216*

229

206*

210

215

212†

213

230*

310643 17

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 procedures concernées.

ADDITIONAL WARRANTY COVERAGE

Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment Warranty

Program”.

Graco Phone Number

TO PLACE AN ORDER , contact your Graco distributor, or call this number to identify the distributor closest to you:

1–800–690–2894 Toll Free

18

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.

Sales Offices: Minneapolis

International Offices: Belgium, Korea, Hong Kong, Japan

GRACO INC.

P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

http://www.graco.com

PRINTED IN U.S.A. 310643 12/2003, Revised 4/2004

310643