Graco Mark IV 249636 Operation - Repair - Parts
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Graco Mark IV 249636 Operation - Repair - Parts

Graco Mark IV 249636 Operation - Repair - Parts

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Operation/Repair/Parts
™
Mark IV
- For Portable Airless Spraying of Skim Coat Materials, Architectural Coatings and Paints -
Model 249636
3300psi (228 bar, 22.8 MPa) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
311254
310643
310657
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001
311287A

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Summary of Contents for Graco Mark IV 249636

  • Page 1 3300psi (228 bar, 22.8 MPa) Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. 311254 310643 310657 Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441 Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001...

  • Page 2: Fire And Explosion Hazard

    Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS forms from distributor or retailer. • Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only. •...
  • Page 3 Warning WARNING ELECTRIC SHOCK HAZARD Improper grounding, setup, or usage of the system can cause electric shock. • Turn off and disconnect power cord before servicing equipment. • Use only grounded electrical outlets. • Use only 3-wire extension cords. • Ensure ground prongs are intact on sprayer and extension cords.
  • Page 4 Warning Grounding All Graco sprayer cords include a Power requirement: Do not alter ground prong Plug sprayer cord into ground wire to reduce the risk of 120 Vac, 50/60 Hz, 20A or use adapter grounded outlet installed to static and electric shock...
  • Page 5 Warning Use grounded metal pails Place pail on grounded Hold spray gun against for solvent and oil-based surface such as concrete grounded metal pail when fluids. Connect ground wire and not on non-conductive flushing or relieving from metal pail to true earth materials which will isolate pressure to maintain ground such as a water...

  • Page 6: Component Identification

    Component Identification Component Identification English Français Español Display Afficheur Visualización ON/OFF switch Bouton MARCHE/ARRÊT Interruptor de encendido/apagado Pressure control Commande de la pression Dispositivo de control de la presión Prime/Spray valve Vanne d’amorçage/ de pulvérisation Válvula de cebado/ pulverización Trigger Lock Loquet de sécurité...
  • Page 7 Setup Setup Connect Graco 50-ft airless Install adapter, swivel and Put end of 3-ft whip hose Tighten securely hose to sprayer. 3-ft whip hose to other end of through spring guard and Tighten securely. 50-ft airless hose. Apply connect to gun...
  • Page 8 Setup Approximate Fill Level Remove inlet strainer and Fill throat packing nut with Turn power OFF. Plug power supply cord filter bowl screen when TSL to prevent premature into a properly grounded spraying dry-wall mud or packing wear. electrical outlet. joint compound materials.
  • Page 9 Setup Turn prime valve down. Place pump in grounded metal pail partially filled with flushing fluid. Attach ground wire to pail and to true earth ground, page 5. Do 1. - 5. of Startup to flush out storage oil shipped in sprayer. Use water to flush water-base paint and appropriate solvent to flush oil-base paint and storage oil.
  • Page 10 Startup Startup Turn pressure control to Turn power ON. Increase pressure 1/2 to Turn prime valve horizon- lowest pressure. start motor and allow fluid tal.Take spray gun trigger to circulate through drain safety OFF. tube for 15 seconds; turn pressure down. 311287A...
  • Page 11 Startup Hold gun against grounded Inspect for leaks. Do not stop Place pump in paint pail. Trigger gun again into flush- metal flushing pail. Trigger leaks with hand or a rag! If leaks ing pail until paint appears. gun and increase fluid pres- occur, do Pressure Relief.
  • Page 12 Startup 311287A...

  • Page 13: Install Spray Tip

    Startup Install Spray Tip Insert housing into retaining Insert tip cylinder into hous- Insert assembly into tip Install and tighten screw nut. Install fluid seal (flat ing (arrow points forward). guard side in) into housing. Install gasket into housing. Install Spray Tip Install Spray Tip 311287A...
  • Page 14 Startup Spray Clear Clog 1 Spray test pattern. Adjust pres- 2 Hold gun perpendicular, 1 Release trigger, put safety ON. 2 Put safety ON. Return sure to eliminate heavy edges. 10-12 in. from surface. Spray Rotate SwitchTip. Take safety SwitchTip to original position. Use smaller tip size if pressure back and forth.

  • Page 15: Digital Tracking System (Dts)

    Digital Tracking System (DTS) Digital Tracking System (DTS) Operation Main Menu Change Display Units Short press moves to next display. Turn pressure to lowest setting. 2 Turn power ON. Pressure display Press and hold DTS button for Press and hold (8 seconds) changes Trigger gun to relieve pressure.
  • Page 16 Digital Tracking System (DTS) Operation Main Menu Short press DTS button to move Press and hold to reset to zero, Short press DTS button to move Short press DTS button to return to Job Gallons (or Liters x 10). or short press DTS button to to AutoClean Timer display.

  • Page 17: Secondary Menu

    Digital Tracking System (DTS) Secondary Menu Do Pressure Relief, page Press DTS button and turn The sprayer model briefly Short press DTS button 19, steps 1 - 4 if they have power switch ON. displays (e.g. MARK4). and MOTOR ON scrolls not already been done.
  • Page 18 Digital Tracking System (DTS) Secondary Menu Short press DTS button. Press and hold DTS button Short press DTS button. Short press to move to to clear error code to zero. LAST ERROR CODE W-DOG scrolls past, then SOFTWARE REV scrolls by and last error OFF displays.

  • Page 19: Pressure Relief

    Pressure Relief Pressure Relief Turn power OFF. Wait Lock gun trigger safety. Turn pressure to lowest Put drain tube in pail. Turn 7 seconds for power to Remove guard and setting. Trigger gun to relieve prime valve down. dissipate. SwitchTip. pressure.
  • Page 20 Cleanup Cleanup Do Pressure Relief, steps Note Use water for water base Increase pressure to 1/2. Move gun to waste pail, 1 - 4, page 19. Remove paint and appropriate solvent for Hold gun against paint pail. hold gun against pail, trig- pump from paint and place oil base paint.
  • Page 21 Cleanup Turn prime valve down and Raise pump above flushing Close drain valve. Trigger Open prime valve. Unplug allow flushing fluid to circu- fluid and run sprayer for 15 gun into flushing pail to sprayer. late for 15 seconds to clean to 30 seconds to drain fluid.
  • Page 22 Cleanup Remove filters from gun and sprayer, if If flushing with water, flush again with Wipe sprayer, hose and gun with a rag installed. Clean and inspect. Install fil- mineral spirits, or Pump Armor, to leave soaked in water or mineral spirits. ters.

  • Page 23: Troubleshooting

    Troubleshooting Troubleshooting Relieve pressure; page 5. Mechanical/Fluid Flow PROBLEM CAUSE SOLUTION Low or No Fluid/Pressure Output Spray tip worn Follow Pressure Relief Procedure Warning, then replace tip. See your separate gun or tip manual. Spray tip clogged Relieve pressure. Check and clean spray tip.
  • Page 24 Troubleshooting Electrical Symptom: Sprayer does not run or stops running Relieve pressure; page To avoid electrical shock or moving parts hazards when covers are removed for troubleshooting, wait 30 sec- • Plug sprayer into correct voltage, grounded outlet onds after unplugging power cord for stored electricity to dissipate.
  • Page 25 Troubleshooting Electrical DIGITAL CONTROL BOARD INDICATION WHAT TO DO DISPLAY STATUS LIGHT Displays high Improper pressure Open prime valve. Connect a known good transducer in pressure when signal to control place of the sprayer transducer. Set sprayer ON. Replace prime valve is transducer If sprayer runs.
  • Page 26 Troubleshooting Electrical DIGITAL CONTROL BOARD INDICATION WHAT TO DO DISPLAY STATUS LIGHT E=05 Blinks 5 x repeatedly Possible locked Check motor wiring connections pump or drive. May Check for locked or frozen pump or drive train be motor connection If all motor wiring connections are OK and pump/drive train or wiring error.

  • Page 27: Displacement Pump Replacement

    Repair Repair Displacement Pump Replacement Pump Removal Flush pump (91). Do Pressure Remove screw and slide pump Cycle pump in JOG mode until Remove strainer (48), hose (94) pump pin (44) is in position to and any washers and o-rings. Relief, page 19.

  • Page 28: Pump Installation

    Repair Pump Installation Warning: If pump pin works Extend pump piston rod Install pump pin (44). Screw in pump until loose, parts could break off due fully. Apply grease to top Verify retainer spring threads are flush with to force of pumping action. Parts of pump rod at (A) or (43) is in groove of pump drive housing opening.
  • Page 29 Repair Pump Installation Install washers, o-rings Screw jam nut (12) up onto Fill packing nut with Graco Install pump rod shield with strainer (76) and hose (94). pump until nut stops. Tighten TSL until fluid flows onto top screw; tighten screw.

  • Page 30: Drive And Bearing Housing Replacement

    Repair Drive and Bearing Housing Replacement Drive and Bearing Housing Removal Warning: Relieve pressure, Remove screw (31), two Remove pump; Remove two screws page 19. Caution: Do not drop nuts (24), pail hanger Displacement Pump (158) and shroud (58) gear cluster (89) when removing (55) and pump rod cover Replacement, page 27.
  • Page 31 Repair 311287A...

  • Page 32: Drive And Bearing Housing Installation

    Repair Drive and Bearing Housing Installation Make sure gear (89) and thrust Push drive housing (90) onto motor (84) and install with five Install bearing housing (83) washers (28, 30, 90a, 36) are in screws (6). Torque to 190-210 in-lb (21-23 N·m). with four screws (14) and place.
  • Page 33 Repair Drive and Bearing Housing Installation Install front cover (51) with Install shroud (58) with two Install pump (91); Install pump rod cover four screws (31). screws (158). Displacement Pump (108) and pail hanger (55) Replacement, page 27. with screw (31) and two nuts (24).

  • Page 34: Motor Replacement

    Repair Motor Replacement Motor Removal Warning: Relieve pressure; Remove pump (91); Remove drive housing (90) Remove four screws (38) page 19. Wait 5 minutes before Displacement Pump and bearing housing (83); and control cover (169). servicing. Replacement, page 27. Drive and Bearing Caution: Do not drop gear clus- Housing Replacement, ter (89) when removing drive...
  • Page 35 Repair Motor Removal Remove bottom two screws Disconnect all three motor Remove top two screws Remove strain relief (29) (39) and allow control panel connectors from motor (39) and control housing from motor wires and power (68) to hang down freely. control board (95) (61).
  • Page 36 Repair Motor Removal Remove two screws (37) Loosen two nuts (19) on and nuts (19) on side side near control and opposite control. remove motor (84) from cart frame (62). Motor Removal Motor Removal 311287A...

  • Page 37: Motor Installation

    Repair Motor Installation Slide new motor (84) under Install two screws (37) and Install strain relief (29) onto Connect all three motor two screws (37) in cart nuts (19) on motor side motor wires and into power connectors to motor control frame (62) near control.
  • Page 38 Repair Motor Installation Install control panel (68) Install control cover (169) Install drive housing(90) Install pump (91); with two screws (39). with four screws (38). and bearing housing (83); Displacement Pump Drive and Bearing Replacement, page 27. Housing Replacement, page 27 Motor Installation Motor Installation 311287A...

  • Page 39: Pressure Control Replacement

    Repair Pressure Control Replacement Pressure Control Removal Remove four screws (38) Disconnect display connector Remove bottom two screws (39) Disconnect control board power from motor control board (95). and allow control panel (68) to lead(s) (D) from ON/OFF switch and cover (169). hang down freely.
  • Page 40 Repair Pressure Control Removal Disconnect potentiometer Disconnect transducer Disconnect motor connectors Remove top two screws (39) connector from motor control from motor control board. and control box (61). connector from motor board. Remove five screws (27), control board. three screws (102) and motor control board Pressure Control Removal Pressure Control Removal...
  • Page 41 Repair Pressure Control Installation Apply small amount of Caution: To reduce risk of motor Install motor control board (95) Connect motor connectors to with five screws (27). Torque to motor control board. thermal compound 110009 control board failure, do not over- 9-11 in-lb (1.02 - 1.24 N·m).
  • Page 42 Repair Pressure Control Installation Install control box (61) with Connect transducer Connect potentiometer Connect motor control board connector to motor control board. power lead(s) to ON/OFF top two screws (39). connector to motor control switch (33). board. 311287A...
  • Page 43 Repair Pressure Control Installation Install control panel (68) with Connect display connector to Install cover (96) with four screws (38). two screws (39). motor control board. 311287A...

  • Page 44: Pressure Adjust Potentiometer Removal

    Repair Pressure Adjust Potentiometer Replacement Pressure Adjust Potentiometer Removal Remove four screws (38) Disconnect potentiometer Remove pressure control Remove gasket (115), nut and cover (96). connector (C) from motor knob (34) with a hex and potentiometer (82) control board (95). wrench from control panel (68).

  • Page 45: Pressure Adjust Potentiometer Installation

    Repair Pressure Adjust Potentiometer Installation Install gasket (115), nut and Install pressure control Connect potentiometer Install cover (96) with four potentiometer (82) on knob (34): Check pressure connector to motor control screws (38). control panel (68). Torque control knob alignment to board.

  • Page 46: Pressure Control Transducer Removal

    Repair Pressure Control Transducer Replacement Pressure Control Transducer Removal Remove four screws (38) Disconnect transducer Remove four screws (39) Remove grommet from and cover (96). connector from motor and control box (61). Allow control box Remove control board (95). control panel to hang down transducer (86) and o-ring freely.

  • Page 47: Pressure Control Transducer Installation

    Repair Pressure Control Transducer Installation Install o-ring and Install control box (61) and Connect transducer Install cover (96) with four transducer in filter base. control panel (68) with four connector to motor control screws (38). Torque to 35-45 ft-lb (47-61 screws (39).
  • Page 48 Parts - Mark IV Parts - Mark IV 158 157 311287A...
  • Page 49 Parts - Mark IV Part Description 241920 DEFLECTOR, threaded Part Description 287289 GEAR, combination; 15C753 SCREW, mach, torx, hex wash hd includes 28, 30 15E891 RING, retaining, ext. 287284 HOUSING, drive, M2; 119420 WHEEL, pneumatic includes 6, 36, 90a 106115 WASHER, lock spring (hi-collar) 107089 WASHER, thrust 107210 SCREW, cap, sch 253056 PUMP, displacement, MARK IV...
  • Page 50 173a 173b 173c Torque to 14 - 17 in-lb 311287A...
  • Page 51 Part Description 111699 GASKET, seat, valve Part Description 187615 SEAT, valve 100721 PLUG, pipe 224807 BASE, valve 117285 O-RING 236352 POTENTIOMETER, adj, pressure C19817 SCREW, cap, socket hd 243222 TRANSDUCER, pressure control; 107505 O-RING includes 20 111457 O-RING 244067 FILTER, fluid; 15C972 PIN, grooved 60 mesh, original equipment 114391 SCREW, grounding...
  • Page 52 311287A...

  • Page 53: Technical Data

    Technical Data Electric Motor Power requirement 120 Vac, 60 Hz, 15A HP (W) 2.0 (1490) Maximum working pressure 3300 psi (227 bar, 22.7 MPa) Noise Level Sound power 100 dBa per ISO 3744 Sound pressure 86 dBa measured at 3.1 feet (1 m) Vibration Level * Left hand 3.89 m/sec...

  • Page 54: Warranty

    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.

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