Graco 3A1495C User's Manual
Contents
1. Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses and couplings daily Replace worn or damaged parts immediately PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture Failure to follow this warning can result in death serious injury or property damage e Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents e Many other fluids may contain chemicals that can react with aluminum Contact your material supplier for compatibility PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury hearing loss inhalation of toxic fumes and burns This equipment includes but is not limited to e Protective eyewear and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer 2 3A1495C Instructions Always use all new parts included in your kit and dis pose of replaced parts according to all state and local regulations for disposal of discarded components Inspect all parts when disasse2. Fig 16 8 Secure pump assembly in a vise as shown in Fig 17 9 Perform any air valve repairs maintenance needed See separate instruction manual included with the related air valve repair kit 10 Be sure seals 18 are lightly greased and installed on air valve 40 Install air valve on air cylinder 21 NOTE The air valve 40 can be installed in any configuration There is not just one correct way to install these parts Fig 17 11 Install screws 43 Torque to 60 70 in Ibs 6 8 7 9 N m 12 Torque screws 4 installed in Step 6 to 60 70 in lbs 6 8 7 9 N m Muffler 17 Installation Fig 17 13 Depending on your installation the air valve 40 can be mounted with the muffler 17 on either side of the air valve To change the installation location a Remove the 4 screws 43 b Remove the air valve 40 from its current mounted position on the air cylinder 21 and rotate the air valve 180 degrees which will reposition the muffler to face the other side of the pump NOTE When installing the pin 8 in Steps 14 20 it is helpful to place a support such as a piece of wood below the rods 14 Screw the connecting rod 32 and the displacement rod 25 together aligning the pin hole in both pieces to allow the pin to be pushed through Fig 18 Fig 18 15 Replace the pin 8 Use a rubber hammer to tap the pin into place being careful to make sure the sides of the pi
3. 10 1 Follow Pump Disassembly instructions Steps 1 3 rN ri beginning on page 3 a L y I N 2 Secure a strap wrench around the spacer cylinder Fd AS NES ati J 36 and use it to turn the cylinder counter clockwise oer to loosen and remove it from the flange 22 Fig 29 So 36 Fig 34 NOTE After a few turns the spacer cylinder should be loose enough to finish loosening it with your 5 Reassemble the pump as described in the Reas hand to remove this part sembly instructions page 7 3A1495C 13 Instructions 3 Pull spacer cylinder 86 away from pump to access pin 8 Fig 36 Fig 36 4 Use a rubber hammer and small punch to drive the pin 8 out 5 Unscrew the pump lower from displacement rod 25 Set aside pump lower for reassembly 6 Use a pick to remove gasket 30 from inside the flange 22 7 Continue pump disassembly instructions Steps 15 19 beginning on page 5 8 Discard pin 8 air piston 15 and displacement rod 25 according to all applicable safety regulations for disposal of these parts 14 Pump Reassembly Always use all new parts included in the kit for reas sembly 1 Apply a thin coat of grease around the threaded end of the new displacement rod 25 2 Assemble washer 38 air piston 15 gasket 13 o ring 5 and hex nut 19 to displacement rod 25 as shown in Fig 37 Be sure the male boss on gas ket 13 mates with the counter bore in air piston 15
4. Tighten and torque nut 19 to 155 165 in pounds 17 5 18 6 N m Fig 37 3 Apply a thin coat of grease around the chamfered end of the displacement rod assembly 25 Push the displacement rod through the opening in the bot tom cover and into the flange assembly as shown in 3A1495C Instructions the bottom cover firmly into the air cylinder Fig 40 Fig 40 Fig 38 7 Install the 5 screws 4 wrench tight only NOTE If installing a new air cylinder 27 the mating 4 Remove pilot valve 20 from the old air cylinder ules Semon ate agee OY CERION se Soe Ou ing screws 4 to form threads as they are being E APPI a OnE Cosh Or Grease to esas installed Torque to 95 105 in Ibs 10 7 11 8 N m to ensure full thread formation 5 Install pilot valve 20 into new air cylinder included 8 To ensure there is a proper seal between the air in the kit Fig 39 Torque to 95 105 in lbs valve and manifold loosen all 5 screws 4 approxi 10 7 11 9 N m mately 1 8 to 1 4 turn Fig 41 These screws will be torqued AFTER the air valve 40 is installed 20 Fig 41 Fig 39 9 Continue reassembly instructions Steps 8 13 6 Apply a thin coat of grease to o rings 5 and o ring beginning on page 8 on bottom cover 14 Install the air cylinder 21 10 Install gasket 30 into bottom cover 14 Fig 42 over the bottom cover 14 air piston 15 assem bly Place the top of the air cylinder
5. small 2 30 GASKET 1 3 Useapick to remove o ring 7 and gasket 30 from 37 NUT retainer 1 inside flange 22 Fig 27 Grease the o ring and replace the o ring and gasket in flange Fig 25 30 1 Disassemble the pump following Disassembly Steps 1 3 page 3 Steps 9 12 page 5 and 15 21 pages 5 6 3A1495C 17 Instructions 4 Remove nut retainer 37 from flange 22 Fig 28 the new o rings 12 and o ring 6 included in the kit and install them in the bottom cover housing Fig 28 Remove u cup seal 11 from flange 22 Fig 29 Grease and replace the u cup seal with the new part included in the kit and install them in the order shown in Fig 29 NOTE e The bearing 31 is not included in the kit This part is reused The bearing can be installed with either side facing up There is not just one way to install this part e The bearing 31 is a transition fit and in some installations it may not be removed e Be sure u cup seal 11 is installed with the lips facing down as shown in Fig 29 Fig 29 12 Install displacement rod 25 through flange assem bly 22 Fig 30 Remove and discard the 3 small o rings 12 and o ring 6 in the bottom cover 14 Fig 30 Grease Fig 30 8 Reassemble the pump as described in the Reas sembly instructions page 7 O Ring and Seal Replacement Kit 24H856 Fig 31 Replacement parts for gasket 30 installed in the flange and arou
6. rods continue instructions beginning with Step 14 page 8 of the Reassembly instructions and the related O Ring and Seal Replacement Kit 24H856 page 12 15 Clamp the air cylinder 21 horizontally in a vise as shown in Fig 9 NOTE Take care to only use enough clamping Instructions force to hold the pump in position The pump cylin der is aluminum and could be damaged by using excessive clamping force 16 Using a 10 mm socket wrench remove the 4 screws 43 from the air valve 40 and completely remove air valve assembly from air cylinder 21 Also remove the two cover gaskets 18 If you are replac ing these parts discard gaskets Fig 9 Co I i 40 43 21 Fig 9 Repair and replacement instructions for the Air Valve are included in a separate repair manual included with the kit e Air Valve Replacement Kit 24H848 24H849 24H850 e Air Valve Repair Kit 24H798 e Air Motor Service Kit 24J757 24J758 24J759 e Pilot Valve Kit 24H749 e Air Valve Seal Kit 24H851 e Air Valve End Cap Kit 24H852 17 Using a 10 mm socket wrench remove the 5 screws 4 from the flange 22 18 Using your hand firmly grasp the flange 22 and remove the entire assembly from inside the air cylin der 21 NOTE Sliding the flat blade of a screw driver between the flange 22 and air cylinder 21 will help separate the two parts Be careful not to damage the o ring 6 Fig 10 wal Fig 10 19 Pu
7. 3 e Unless otherwise stated entirely disassemble pump as described in the pump disassembly instruction 19 35 section of this manual NW ees 4 pan e Properly discard all replaced parts according to k i f local and state regulations for disposal of discarded components e Always use all new parts included in the kit to replace the identical part on the pump ee e Grease all parts prior to reassembly with a thin coat of lightweight grease Fig 23 e Reassemble pump as described in the reassembly instruction section of this manual 29 Install shovel cylinder 27 over priming rod 34 Fig 24 Use a strap wrench to tighten shovel cylin 10 3A1495C Instructions Throat and Piston Seal Replacement Kit 2 Use a pick to remove the o ring 5 installed around 24H854 Fig 25 the circumference of the air piston 15 Fig 26 Grease the new o ring included in the kit and install Replacement parts for o ring 5 installed on air piston it around the air piston 15 o rings 6 and 12 installed in bottom cover 14 o ring 7 u cup seal 11 and gasket 30 installed on flange 22 pin 8 used to reassemble rod sections and gasket 18 used later in reassembly of the air valve 40 A replacement part for the retainer nut 37 is also included in this kit Qty Ref Description 5 O RING air piston 1 6 O RING 1 7 O RING 1 8 PIN slotted straight 3 11 SEAL u cu 1 12 ORING 3 Fig 26 18 GASKET cover
8. Relief Procedure page 3 2 Disconnect and remove the pump from its installed location 3 Clamp the pump 1 upside down in a vise as shown in Fig 1 NOTE Take care to only use enough clamping force to hold the pump in position The pump cylin der is aluminum and could be damaged by using excessive clamping force Fig 1 If you are only servicing the air valve 40 and seals 18 or air piston 15 skip Steps 4 14 Instructions 4 Secure a strap wrench around the shovel cylinder 6 Use a wrench to loosen and remove the seal 27 Use the strap wrench to turn the shovel cylin retainer 29 Fig 4 der counter clockwise to loosen and remove it from the pump assembly Fig 2 NOTE After a few turns the shovel cylinder should be loose enough to finish turning it with your hand to remove this part 34 Fig 4 7 Tighten a strap wrench on the spacer cylinder 36 and use it to prevent this part from moving Secure a strap wrench around the cylinder 26 and use it to turn the cylinder to loosen and remove it from the Fig 2 pump assembly Fig 5 Remove the intake seal 28 5 Use an adjustable wrench to hold the priming rod 34 securely Use a second adjustable wrench to loosen and remove the nut 19 and priming piston 35 Fig 3 Fig 4 Fig 3 Fig 5 3A1495C Fig 6 i pi n a o O Sd 10 11 12 3A1495C Instructions If the gasket 30 is still inside the sp
9. Repair Instructions gt g GRACO LD Grease Pump Repair Kits iii Instructions for repairing the LD Grease Pump Maximum Fluid Pressure 7500 psi 51 7 MPa 517 bar Maximum Air Pressure 150 psi 1 03 MPa 10 3 bar Read all warnings and instructions in this manual and in your LD Series Oil or Grease Pump manual Save all instructions ee Important Safety Instructions Repair Kits 24H854 Throat and Piston Seal Replacement Kit 24H856 O Ring and Seal Replacement Kit 24U984 Air Piston Replacement Kit PROVEN QUALITY LEADING TECHNOLOGY Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion point symbol alerts you to a general warning and the hazard symbols refer to procedure specific risks When these symbols appear in the body of this manual refer back to these Warnings Product specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable SKIN INJECTION HAZARD High pressure fluid from dispense valve hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment Do not point dispense valve at anyone or at any part of the body Do not put your hand over the end of the dispense nozzle Do not stop or deflect leaks with your hand body glove or rag
10. acer cylinder 13 Use a rubber hammer and small punch to drive out 36 use a pick to remove pin 8 holding together the priming rod 34 and piston rod 23 Turn the priming rod 34 counter Secure a strap wrench around the spacer cylinder clockwise to loosen and remove it from the piston 36 and use it to turn the cylinder counter clockwise rod Fig 7 to loosen and remove it from the flange 22 Fig 6 NOTE After a few turns the spacer cylinder should be loose enough to finish loosening it with your hand to remove this part Fig 7 14 Use a rubber hammer and small punch to drive out pin 8 holding together the connection rod 32 and displacement rod 25 Turn the connection rod 32 counter clockwise to loosen and remove it from the displacement rod Fig 8 Use a pick to remove gasket 30 from inside the re flange 22 Use a rubber hammer and small punch to drive out pin 8 holding together the piston rod 23 and the 93 connection rod 82 Turn the piston rod 23 34 6 counter clockwise to loosen and remove it from the bn Q connection rod Remove the piston seal 24 from PA rags 24 the piston rod Fig 8 32 ayo Remove the pump assembly from the vise and set it a down on a clean hard work surface 28 Fig 8 NOTE When removing the pin 8 in Steps 12 14 T it is helpful to place a support such as a piece of If you are only replacing or repairing the pump lower wood below the
11. bel 101 to the new cylinder Apply the clear overlay 102 over the new label Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6928 or Toll Free 1 800 533 9655 Fax 612 378 3590 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 For patent information see www graco conypatents Original instructions This manual contains English MM3A1495 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2011 Graco Inc is registered to ISO 9001 www graco com June 2011 revised November 2014
12. down ona clean 11 Screw the connecting rod 32 and the displacement hard surface Use the palms of your hands to press rod 25 together aligning the pin hole in both 3A1495C 15 pieces to allow the pin to be pushed through Fig NOTE When there is end play at the pinned connec 42 tion you should be able to slightly move from side to side the displacement rod 25 pinned to the connecting rod 32 and the connecting rod 32 pinned to the piston rod 23 and piston rod 23 pinned to the priming rod 34 14 If these connections seem too rigid remove the pin and adjust hole alignment by 1 2 turn in the direction that aligns the through holes as close as possible axis to axis Fig 21 Improper alignment will take the self aligning feature out of the design which could result in damage to the Fig 42 pump 12 Replace the pin 8 Use a rubber hammer totapthe 15 Slide spacer cylinder 36 into bottom cover 14 pin into place being careful to make sure the sides of the pin are flush with the outside surface of the connecting rod Fig 42 16 Using a strap wrench tighten and torque spacer cyl inder 36 to 45 55 ft Ibs 61 0 74 5 N m 17 Use a permanent marker to record the pump part number serial number and series code shown the original label located on the old air cylinder onto the new label 101 included in the kit 13 Check to make sure there is end play at all pinned connections 18 Apply la
13. hes or wear Fig 13 Lubricate all parts with a light water resistant 4 Apply a thin coat of grease round the top of the dis grease placement rod 50 Push the displacement rod through the opening in the bottom cover and into the Install new o rings and seals in bottom cover 14 flange assembly as shown in Fig 14 and flange 22 as described in the Throat and Pis ton Seal Replacement Kit 24H854 page 11 Be sure to apply a thin coat of water resistant grease to all o rings and seals 2 Align pilot valve 20 installed in bottom cover with opening a in flange 22 as shown in Fig 12 Com press the bottom cover 14 and flange 22 together Fig 14 5 Install the air cylinder 21 over the bottom cover 14 Place the top of the air cylinder down on a clean hard surface Use the palms of your hands to press the bottom cover firmly into the air cylinder Fig 15 Fig 12 21 al Fig 15 3A1495C Instructions 6 Install the 5 screws 4 wrench tight only NOTE If installing a new air cylinder 27 the mat ing holes are not threaded by design Use thread forming screws 4 to form threads as they are being installed Torque to 95 105 in lbs 10 7 11 8 N m to ensure full thread formation 7 To ensure there is a proper seal between the air valve and manifold loosen all 5 screws Fig 16 approximately 1 8 to 1 4 turn These screws will be torqued in Step 12 AFTER the air valve 40 is installed
14. ll the flange assembly off the displacement rod 25 Set the displacement rod aside You will not need it until you reassemble the pump 20 Using a5 mm socket wrench remove the 3 screws 3 from the bottom cover 14 Fig 11 Fig 11 21 Separate the bottom cover 14 from the flange 22 Fig 11 NOTE Insert the flat blade of a screwdriver between the flange and bottom cover to help loosen the seal between these two pieces and pull them apart more easily If you are replacing the o rings and seals installed in the flange bottom cover and air piston continue instructions with Step 1 page 7 of the Reassembly instructions and the Throat and Piston Seal Replacement Kit 24H854 instructions beginning on page 11 3A1495C Instructions Pump Reassem bly 3 Install 3 screws 8 Fig 13 Tighten with a 5 mm socket wrench and torque to 60 70 in lbs 6 8 7 9 NOTE The following instructions describe the proce N m dure to follow to reassemble a completely disassembled LD grease pump Depending on the repair maintenance procedure you are performing on the pump it may not be entirely disassembled See the specific section s related to your repair replacement kit For all reassembly procedures Clean all the parts carefully in a compatible solvent and inspect for wear or damage Use all the repair kit parts during reassembly and replace other parts as necessary Check the all polished surfaces for scratc
15. mbling the pump Replace any and all worn and damaged parts Pressure Relief Procedure The equipment stays pressurized until pressure is manually relieved To reduce the risk of serious injury from pressur ized fluid fluid from the valve or splashing fluid follow the procedure whenever you are instructed to relieve pressure stop dispensing check clean or service any system equipment install or clean dispensing devices 1 Close the pump s bleed type master air valve 2 Close the pump air regulator and disconnect the air supply hose 3 Open the dispensing valve and dispense fluid into a waste bucket container until pressure is fully relieved If you suspect that the dispensing valve is clogged or that pressure has not been fully relieved after following the steps above very slowly oosen the dispensing valve coupler or hose end coupling to relieve pressure gradually then loosen completely 3A1495C Instructions Disassembly The following disassembly instructions describe the pro cedure for completely disassembling the LD grease pump Depending on the repair maintenance procedure you are performing on the pump it may not be neces sary to entirely disassemble the pump or perform all steps in this procedure The reference numbers used in the following instruc tions correspond to the reference numbers used in the LD Series Oil and Grease Pump instruction manual 1 Stop the pump Follow Pressure
16. n are flush with the outside surface of the connecting rod Fig 18 16 Install piston seal 24 over the end of the piston rod 23 Note the correct orientation of the piston seal on the piston rod as shown in Fig 19 3A1495C 17 Screw the piston rod 23 and the connecting rod 32 together aligning the pin hole in both pieces to allow the pin to be pushed through Fig 19 Fig 19 18 Replace the pin 8 Use a rubber hammer to tap the pin into place being careful to make sure the sides of the pin are flush with the outside surface of the connecting rod Fig 19 19 Screw the piston rod 23 and priming rod 34 together aligning the pin hole in both pieces to allow the pin to be pushed through Fig 20 8 2 34 Fig 20 20 Replace the pin 8 Use a rubber hammer to tap the pin into place being careful to make sure the sides of the pin are flush with the outside surface of the piston rod Fig 20 21 Check to make sure there is end play at all pinned connections 3A1495C Instructions NOTE When there is end play at the pinned connec tion you should be able to slightly move from side to side the displacement rod 25 pinned to the connecting rod 32 and the connecting rod 32 pinned to the piston rod 23 and piston rod 23 pinned to the priming rod 34 22 If these connections seem too rigid remove the pin and adjust hole alignment by 1 2 turn in the direction that aligns the th
17. nd the circumference of the cylinder 26 o ring 10 installed around the seal retainer 29 pin 8 used to reassemble rod sections and replacement seals 24 and 28 installed on the displacement rod assembly Qty Ref Description 8 PIN slotted straight 3 10 O RING 1 24 SEAL piston 1 28 SEAL intake 1 30 GASKET 2 C D 30 Qa a D m 28 C 10 Fig 31 3A1495C Instructions 1 Disassemble the pump following Disassembly Air Piston Replacement Kit 24U984 Fig 35 Steps 1 14 pages 3 5 only Qty 2 Use a pick to remove the gasket 30 installed Ref Description between the flange 22 and tube 36 Fig 32 5 O RING 1 Grease the new gasket included in the kit and install 8 PIN straight slotted 2 5 x 16 1 it inside the flange 13 GASKET 32 OD 1 15 PISTON air plastic 1 18 GASKET cover small 2 19 NUT hex 1 21 CYLINDER air machined 1 25 ROD displacement 50 1 1 30 GASKET 1 38 WASHER 32 OD 1 101 LABEL identification 1 102 LABEL overlay clear 1 Fig 32 101 102 gt 3 Use a pick to remove the other gasket 30 installed between the cylinder 26 and tube 36 Fig 33 Grease the new gasket included in the kit and install it around the cylinder 24 a 4 Use a pick to remove the o ring 10 installed around the top of the seal retainer 29 Fig 34 AO 8 Grease the new o ring included in the kit and install Fig 35 7 it over the seal retainer Pump Disassembly 7 gt
18. rough holes as close as possible axis to axis Fig 21 Improper alignment will take the self aligning feature out of the design which could result in damage to the pump Fig 1 1 2 Turn Too Shallow Does not permit e end play K i a H a j ti10469a Incorrect Alignment Fig 2 1 2 Turn Too Deep oOo T N i o B ti10479a i Does not permit end play Fig 3 Correct ee Permits end play te A EE P _ H TN a 410468 _ Correct Alignment Fig 21 23 Install spacer cylinder 36 over rod assembly Use a strap wrench to tighten spacer cylinder securely 24 Install cylinder 26 and seal 80 Torque to 45 55 ft Ibs 61 75 N m 25 Install the intake seal 28 over the end of the prim ing rod 34 Note the correct orientation of the Instructions intake seal on the priming rod as shown in Fig 20 der securely then torque to 45 55 ft lbs 61 75 N m 26 Install seal retainer 29 over priming rod 34 Fig 22 27 Use an adjustable wrench to tighten seal retainer securely then torque to 45 55 ft Ibs 61 75 N m Fig 24 Fig 22 Repair Kits 28 Install the priming piston 35 and nut 19 Fig 3 All Repairs Fig 4 on priming rod 34 Use an adjustable wrench to hold the priming rod 34 securely Use a second adjustable wrench to tighten nut Then torque nut to 70 80 in Ibs 7 9 9 0 N m Fig 22 and Fig 2
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