Graco 198466 User manual

Instructions
PROVEN QUALITY. LEADING TECHNOLOGY.
CARBON STEEL
Check–Mate™800 Pumps 308351N
EN
With Priming Piston and Severe–Duty Rod and Cylinder
Refer to page 2 for Table of Contents.
Models 198466
and 246938
Models
237265, 246940
and 246941
Models 236471
and 246942
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions. See page 2 for model
numbers and maximum working pressures.

2 308351
List of Models
Table of Contents
List of Models .............................................................. 2
Symbols ...................................................................... 3
Warnings ..................................................................... 3
Installation ................................................................... 6
Operation/Maintenance ............................................. 12
Service
Troubleshooting ................................................... 17
Required Tools ..................................................... 18
Disconnecting the Displacement Pump ............... 18
Reconnecting the Displacement Pump ................. 19
Displacement Pump Service ................................. 20
Parts .......................................................................... 28
Technical Data and Performance Chart ..................... 38
Dimensions ................................................................ 49
Mounting Hole Layout ............................................... 49
Graco Standard Warranty ......................................... 50
Graco Information ...................................................... 50
Part No. Series Pump Model Ratio
Maximum Fluid
Working Pressure
Maximum Air
(or Hydraulic*)
Input Pressure
236471 BKing™65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
237265 BReduced Icing
Quiet King™
65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
240945 BQuiet King™65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
253376 CQuiet King™65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
237261 ABulldog®31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)
241901 ABulldog®
(55 Gallon/200
Liter Size)
31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)
237274 AReduced Icing
Quiet Bulldog®
31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)
237264 ASenator®19:1 15 MPa, 157 bar (2280 psi) 0.8 MPa, 8.4 bar (120 psi)
198475 AQuiet King™65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
198466 AViscount®II 40 MPa, 403 bar (5850 psi) 10.3 MPa*, 103 bar* (1500 psi*)
246942 BKing™65:1 48 MPa, 483 bar (7000 psi) 0.7 MPa, 7 bar (100 psi)
246940 BBulldog®31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)
246941 BSenator®19:1 15 MPa, 157 bar (2280 psi) 0.8 MPa, 8.4 bar (120 psi)
246938 BViscount®II 40 MPa, 403 bar (5850 psi) 10.3 MPa*, 103 bar* (1500 psi*)

308351 3
Symbols
Warning Symbol Caution Symbol
WARNING CAUTION
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
This symbol alerts you to the possibility of damage
to or destruction of equipment if you do not follow
the instructions.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
• This equipment is for professional use only.
• Read all instruction manuals, tags, and labels before operating the equipment.
• Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
• Do not alter or modify this equipment.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not exceed the maximum working pressure stated on the equipment or in the Technical Data
for your equipment. Do not exceed the maximum working pressure of the lowest rated component
in your system.
• Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Techni-
cal Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
• Do not use hoses to pull equipment.
• Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82°C (180°F) or below -40°C (-40°F).
• Wear hearing protection when operating this equipment.
• Do not lift pressurized equipment.
• Comply with all applicable local, state, and national fire, electrical, and safety regulations.

4 308351
WARNING
SKIN INJECTION HAZARD
Spray from the spray gun/dispense valve, leaks or ruptured components can inject fluid into your body
and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on
the skin can also cause serious injury.
• Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgi-
cal treatment.
• Do not point the gun/valve at anyone or at any part of the body.
• Do not put your hand or fingers over the spray tip/nozzle.
• Do not stop or deflect leaks with your hand, body, glove or rag.
• Do not “blow back” fluid; this is not an air spray system.
• Always have the tip guard and the trigger guard on the gun when spraying.
• Check the gun diffuser operation weekly. Refer to the gun manual.
• Be sure the gun/valve trigger safety operates before spraying.
• Lock the gun/valve trigger safety when you stop spraying.
• Follow the Pressure Relief Procedure on page 12 if the spray tip/nozzle clogs and before clean-
ing, checking or servicing the equipment.
• Tighten all fluid connections before operating the equipment.
• Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not
repair high pressure couplings; you must replace the entire hose.
• Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
MOVING PARTS HAZARD
Moving parts, such as the priming piston, can pinch or amputate your fingers.
• Keep clear of all moving parts when starting or operating the pump.
• Before servicing the equipment, follow the Pressure Relief Procedure on page 12 to prevent the
equipment from starting unexpectedly.

308351 5
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
• Ground the equipment and the object being sprayed. Refer to Grounding on page 6.
• If there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing dispensing immediately. Do not use the equipment until you identify and correct the prob-
lem.
• Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed/dispensed.
• Keep the spray/dispense area free of debris, including solvent, rags, and gasoline.
• Electrically disconnect all equipment in the spray/dispense area.
• Extinguish all open flames or pilot lights in the spray/dispense area.
• Do not smoke in the spray/dispense area.
• Do not turn on or off any light switch in the spray/dispense area while operating or if fumes are
present.
• Do not operate a gasoline engine in the spray/dispense area.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
• Know the specific hazards of the fluid you are using.
• Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
• Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

6 308351
Installation
Grounding
2. Air and fluid hoses: use only electrically
conductive hoses.
3. Air compressor: follow manufacturer’s
recommendations.
4. Spray gun/dispense valve: ground through
connection to a properly grounded fluid hose
and pump.
5. Fluid supply container: follow your local code.
6. Object being sprayed: follow your local code.
7. All solvent pails used when flushing: follow
your local code. Use only metal pails, which
are conductive, placed on a grounded surface.
Do not place the pail on a nonconductive
surface, such as paper or cardboard, which
interrupts the grounding continuity.
8. To maintain grounding continuity when
flushing or relieving pressure, always hold a
metal part of the gun/valve firmly to the side of
a grounded metal pail, then trigger the gun/
valve.
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground
the system as explained below. Also
read the section FIRE AND
EXPLOSION HAZARD on page 5.
1. King Pumps: use a ground wire and clamp. See
Fig. 1. Remove the ground screw (Z) and insert
through eye of ring terminal at the end of
ground wire (Y). Fasten ground screw back
onto pump and tighten securely. Connect the
other end of the wire to a true earth ground.
Order Part No. 222011 Ground Wire and
Clamp.
All other Pumps: use a ground wire and clamp.
See Fig. 2. Loosen the grounding lug locknut
(W) and washer (X). Insert one end of a 1.5
mm2(12 ga) minimum ground wire (Y) into the
slot in lug (Z) and tighten the locknut securely.
Connect the other end of the wire to a true earth
ground. Order Part No. 222011 Ground Wire
and Clamp.
Fig. 2
Fig. 1

308351 7
Installation
All Systems
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and parts
drawings.
The Typical Installations shown in Figs. 3 and 4 are
only guides for selecting and installing system
components and accessories. Contact your Graco
distributor for assistance in designing a system to suit
your particular needs.
Accessories are available from Graco. If you supply
your own accessories, be sure they are adequately
sized and pressure–rated to meet the system’s
requirements.
System Accessories
Air and Fluid Hoses
Be sure all air hoses and fluid hoses are properly
sized and pressure-rated for your system. Use only
electrically conductive hoses. Fluid hoses must
have spring guards on both ends.
Mounting Accessories (Except 198466, 198475
and 246938)
Mount the pump (A) to suit the type of installation
planned. Fig. 3 on page 8 illustrates a ram-
mounted pump in a multi-gun header system.
Pump dimensions and the mounting hole layout
are shown on page 49.
If you are mounting the pump on a ram, refer to the
separate ram manual for installation and operation
instructions. Mounting Kit 222776 is available to
mount the pump on a 55 gallon (200 liter) ram.

8 308351
Installation (Air–Powered Pumps)
KEY
APump
B200 Liter (55 Gallon) Air-Powered Ram
CMain Air Bleed Valve (required, for pump and ram)
DAir Line Lubricator (position only)
EPump Air Bleed Valve (required, for pump)
FPump Air Regulator
GAir Manifold
HElectrically Conductive Air Supply Hose
JAir Line Filter
KAir Shutoff Valve (for accessories)
LFluid Regulator
MFluid Drain Valve (required)
NElectrically Conductive Fluid Supply Hose
PFluid Shutoff Valve
RGun/Valve Swivel
SAirless Spray Gun or Dispensing Valve
TRam Air Regulator
URam Director Valve
VPump Runaway Valve (position only)
WAir LIne Drain Valve
YGround Wire (required, see page 6 for
installation instructions)
MAIN AIR LINE
FLUID HEADER PIPE
(3 in. Diameter
Fig.3

308351 9
Installation (Air–Powered Pumps)
Air Line Accessories
Install the following accessories in the order shown in
Fig. 3, using adapters as necessary:
•An air line lubricator (D) provides automatic air
motor lubrication. Locate in the position shown.
•A main air bleed valve (C) is required in your sys-
tem to shut off the air supply to the pump and ram
(see the WARNING above). When closed, the valve
will bleed off all air in the ram and pump, and the ram
will slowly lower. Be sure the valve is easily accessi-
ble from the pump, and is located upstream from the
air manifold (G).
•A pump air bleed valve (E) is required in your sys-
tem to relieve air trapped between it and the air
motor when the valve is closed (see the WARNING
at left). Be sure the bleed valve is easily accessible
from the pump, and is located downstream from the
air regulator.
•An air regulator (F) controls pump speed and outlet
pressure by adjusting the air pressure to the pump.
Locate the regulator close to the pump, but
upstream from the pump air bleed valve.
•A pump runaway valve (V) senses when the pump
is running too fast and automatically shuts off the air
to the motor. A pump which runs too fast can be seri-
ously damaged. Locate in the position shown.
•An air manifold (G) has a swivel air inlet. It mounts
to a ram, and has ports for connecting lines to air
accessories, such as the ram air regulator (T) and
ram director valve (U).
•An air line filter (J) removes harmful dirt and mois-
ture from the compressed air supply. Also, install a
drain valve (W) at the bottom of each air line drop, to
drain off moisture.
•An air shutoff valve (K) isolates the air line acces-
sories for servicing. Locate upstream from all other
air line accessories.
Fluid Line Accessories
Install the following accessories in the positions shown
in Figs. 3 and 4, using adapters as necessary:
• Install a fluid shutoff valve (P) at each gun/valve
drop, to isolate the gun/valve and fluid accessories
for servicing.
• Install a fluid drain valve (M) near the pump fluid
outlet, and at each gun/valve station. The drain
valves are required in your system to relieve fluid
pressure in the displacement pump, hose and gun/
valve (see the WARNING at left). Drain valves at the
gun/valve stations may be mounted in the base of a
fluid regulator (L), using an adapter.
•A fluid regulator (L) controls fluid pressure to the
gun/valve, and dampens pressure surges.
•A gun or dispense valve (S) dispenses the fluid.
The gun shown in Fig. 3 is a high pressure dispens-
ing gun for highly viscous fluids.
•A gun/valve swivel (R) allows freer gun/valve move-
ment
WARNING
A main air bleed valve (C), pump air bleed valve
(E), and fluid drain valve (M) are required. These
accessories help reduce the risk of serious injury,
including fluid injection and splashing of fluid in the
eyes or on the skin, and injury from moving parts if
you are adjusting or repairing the pump.
The main air bleed valve (C) shuts off the air to the
pump and ram. The pump air bleed valve (E)
relieves air trapped between this valve and the
pump after the air is shut off. Trapped air can
cause the pump to cycle unexpectedly. Locate the
valve close to the pump. Order Part No. 107141.
The fluid drain valve assists in relieving fluid
pressure in the displacement pump, hose, and gun.
Triggering the gun to relieve pressure may not be
sufficient. Order Part No. 210658.

10 308351
Installation (Hydraulic–Powered Pumps)
Fig. 4
KEY
AAccessory Pump Stand HHydraulic Pressure Gauge
(P/N 218742) JFlow Control Valve
BSurge Tank (P/N 218509 or KPressure Reducing Valve
238983) LDrain Line
C50 mm (2 in.) Diameter Pipe MHydraulic Return Line
DFull Flow, Non-Restrictive Shutoff Valve
Fluid Shutoff Valve NAccumulator
EFluid Supply Line PHydraulic Supply Line
FMix Tank QHydraulic Return Line
GHydraulic Supply Line YGround Wire (required,
Shutoff Valve see page 6)L-

308351 11
Installation (Hydraulic–Powered Pumps)
Always plug the hydraulic inlets, outlets and lines when
disconnecting them for any reason to avoid introducing
dirt and other contaminants into the system.
Be sure that your hydraulic power supply is equipped
with a suction filter to the hydraulic pump and a system
return line filter of 10 micron size. Carefully follow the
manufacturer’s recommendations on reservoir and filter
cleaning and periodic changes of hydraulic fluid.in
NOTE: Hydraulic fluid is exhausted from differential hy-
draulic motors only on the upstroke of the operating cy-
cle. The oil return line must have at least twice the flow
capacity as the oil supply line. Otherwise, back pressure
on the hydraulic motor piston will slow down the motor
and the fluid displacement pump, resulting in a loss of
pump performance.
On the hydraulic oil supply line (P), install a shutoff valve
(G) to isolate the system for servicing; a fluid pressure
gauge (H) to monitor hydraulic oil pressure to the motor
and avoid overpressurizing the motor or displacement
pump; a pressure- and temperature-compensated flow
control valve (J) to prevent the motor from running too
fast; a pressure reducing valve (K) with a drain line (L)
running directly into the hydraulic return line (Q); and an
accumulator (N) to reduce the hammering effect caused
by the motor reversing direction.
On the hydraulic return line (Q), install a shutoff valve (M)
for isolating the motor for servicing.
CAUTION
The Hydraulic Power Supply must be kept clean at
all times to avoid damage to the motor and hydraulic
power supply.
1. Blow out hydraulic lines with air and flush
thoroughly before connection to the
motor.
2. Plug hydraulic inlets, outlets, and line ends
when disconnecting them for any reason.

12 308351
Operation
Pressure Relief Procedure
1. Lock the gun/valve trigger safety.
2. Shut off the power to the pump.
3. In an air-powered system, close the air regulator
and close the bleed-type master air valve.
4. In a hydraulic-powered system, close the
hydraulic supply line shutoff valve first, then the
return line shutoff valve.
5. Unlock the gun/valve trigger safety.
6. Hold a metal part of the gun/valve firmly to the side
of a grounded metal pail, and trigger the gun/valve
to relieve pressure.
7. Lock the gun/valve trigger safety.
8. In an air–powered system, open the drain valve
(required in your system), having a container ready
to catch the drainage. Leave the drain valve open
until you are ready to spray/dispense again.
If you suspect that the spray tip/nozzle or hose is
completely clogged, or that pressure has not been fully
relieved after following the steps above, very slowly
loosen the tip guard retaining nut or hose end coupling
and relieve pressure gradually, then loosen completely.
Now clear the tip/nozzle or hose.
Packing Nut/Wet-Cup
Before starting, fill the packing nut (2) 1/3 full with Graco Throat
Seal Liquid (TSL) or compatible solvent. See Fig. 5.
The packing nut is torqued at the factory and is ready for
operation. If it becomes loose and there is leaking from
the throat packings, relieve pressure, then torque the nut
to 128–156 N.m (95–115 ft-lb) using the supplied wrench
(109). Do this whenever necessary. Do not overtighten
the packing nut.
WARNING
SKIN INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally.
Fluid under high pressure can be
injected through the skin and cause serious injury.
To reduce the risk of an injury from injection,
splashing fluid, or moving parts, follow the
Pressure Relief Procedure whenever you:
• are instructed to relieve the pressure,
• stop spraying/dispensing,
• check or service any of the system equipment,
• or install or clean the spray tip/nozzle.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
Fig.5

308351 13
Operation
Flush the Pump Before First Use
The pump is tested with lightweight oil, which is left in to
protect the pump parts. If the fluid you are using may be
contaminated by the oil, flush it out with a compatible
solvent. See Flushing on page 16.
Starting and Adjusting the Pump
Air–Powered Systems
1. Supply fluid to the pump, per the requirements of
your system.
2. See Fig. 3. Close the air regulator (F).
3. Open all air bleed valves (C, E).
4. Hold a metal part of the gun/valve (S) firmly to the
side of a grounded metal pail and hold the trigger
open.
5. Slowly open the air regulator until the pump starts.
6. Cycle the pump slowly until all air is pushed out and
the pump and hoses are fully primed.
7. Release the gun/valve trigger and lock the trigger
safety. The pump should stall against pressure.
8. If the pump fails to prime properly, open the bleeder
valve plug (20) slightly. Use the bleed hole, on the
underside of the valve body (29), as a priming valve
until the fluid appears at the hole. See Fig. 5. Close
the plug.
NOTE: When changing fluid containers with the hose
and gun/valve already primed, open the bleeder valve
plug (20), to help prime the pump and vent air before it
enters the hose. Close the plug when all air is
eliminated.
9. With the pump and lines primed, and with adequate
air pressure and volume supplied, the pump will start
and stop as you open and close the gun/valve. In a
circulating system, the pump will speed up or slow
down on demand, until the air supply is shut off.
10.Use the air regulator (F) to control the pump speed
and the fluid pressure. Always use the lowest air
pressure necessary to get the desired results. Higher
pressures cause premature tip/nozzle and pump
wear.
WARNING
MOVING PARTS HAZARD
Keep hands and fingers away from the
priming piston (21) during operation and
whenever the pump is charged with air.
The priming piston extends beyond the intake
housing (19) to pull material into the pump and can
amputate a hand or finger caught between it and the
intake housing. Follow the Pressure Relief
Procedure on page 12, before checking, clearing, or
cleaning the priming piston.
WARNING
SKIN INJECTION HAZARD To reduce the risk of fluid
injection, do not use your hand or fingers to cover the
bleed hole on the underside of the bleeder valve body
(29) when priming the pump. Use a crescent wrench to
open and close the bleeder plug (20). Keep your hands
away from the bleed hole.
CAUTION
Do not allow the pump to run dry. It will quickly
accelerate to a high speed, causing damage. If your
pump is running too fast, stop it immediately and
check the fluid supply. If the container is empty and air
has been pumped into the lines, refill the container
and prime the pump and the lines, or flush and leave it
filled with a compatible solvent. Eliminate all air from
WARNING
COMPONENT RUPTURE HAZARD
To reduce the risk of overpressurizing
your system, which could cause
component rupture and serious injury,
never exceed the Maximum Input Pressure to the
pump (see the Technical Data on pages 38-46).

14 308351
Operation
Hydraulic–Powered Systems
Refer to the warnings on page 13.
1. Supply fluid to the pump, per the requirements of
your system.
2. Open the shutoff valves between the pump and sup-
ply tanks.
3. Open the dispensing valve(s) or spray gun(s).
4. To adjust the system, perform the following proce-
dure:
a. Turn on the hydraulic power supply.
b. Open the flow control valve all the way.
c. Adjust the pressure–reducing valve until you
get the desired fluid pressure. Run the pump
until all air is purged from the fluid lines.
d. Count the cycle rate of the pump.
e. Close the flow control valve until the cycle rate
and fluid pressure start to drop.
f. Open the flow control valve slightly until the cycle
rate and fluid pressure return to the desired level.
This method of setting the hydraulic controls
ensures proper pump operation and will prevent
pump runaway and damage if the fluid supply
runs out.
g. Close the gun or valve.

308351 15
Notes

16 308351
Maintenance
Shutdown and Care of the Pump
For overnight shutdown, stop the pump at the bottom of
the stroke to prevent fluid from drying on the exposed
displacement rod and damaging the throat packings.
Relieve the pressure.
Always flush the pump before the fluid dries on the
displacement rod. Refer to Flushing below.
Flushing
Flush with a fluid that is compatible with the fluid you are
pumping and with the wetted parts in your system.
Check with your fluid manufacturer or supplier for rec-
ommended flushing fluids and flushing frequency.
Always flush the pump before fluid dries on the displace-
ment rod.
1. Relieve the pressure.
2. Remove the spray tip/nozzle from the gun/valve.
3. Hold a metal part of the gun/valve firmly to the side of
a grounded metal pail.
4. Start the pump. Always use the lowest possible fluid
pressure when flushing.
5. Trigger the gun/valve.
6. Flush the system until clear solvent flows from the
gun/valve.
7. Relieve the pressure.
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
WARNING
FIRE AND EXPLOSION HAZARD
Before flushing, read the section FIRE
AND EXPLOSION HAZARD on page 5.
Be sure the entire system and flushing
pails are properly grounded. Refer to
Grounding on page 6.
CAUTION
Never leave water or water-base fluid in the pump
overnight. If you are pumping water-base fluid,
flush with water first, then with a rust inhibitor such
as mineral spirits. Relieve the pressure, but leave
the rust inhibitor in the pump to protect the parts
from corrosion.
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.

308351 17
Troubleshooting
1. Relieve the pressure.
2. Check all possible problems and causes before
disassembling the pump.
* To determine if the fluid hose or gun is obstructed, follow the Pressure Relief Procedure on page 12. Disconnect
the fluid hose and place a container at the pump fluid outlet to catch any fluid. Turn on the air or hydraulic power just
enough to start the pump. If the pump starts, the obstruction is in the fluid hose or gun.
NOTE: If you experience air motor icing, call your Graco distributor.
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
PROBLEM CAUSE SOLUTION
Pump fails to
operate.
Restricted air or hydraulic line or inade-
quate air supply; closed or clogged
valves.
Clear any obstructions; check that all valves
are open; increase pressure.
Obstructed fluid hose or gun/valve;
fluid hose ID is too small. Open, clear*; use a hose with a larger ID.
Fluid dried on the displacement rod.
Clean; always stop the pump at the bottom of
its stroke; keep the wet-cup 1/3 filled with a
compatible solvent.
Dirty, worn, or damaged motor parts. Clean or repair; see the separate motor
manual.
Pump operates,
but output low on
both strokes.
Restricted air or hydraulic line or inade-
quate air supply; closed or clogged
valves.
Clear any obstructions; check that all valves
are open; increase pressure.
Obstructed fluid hose or gun/valve;
fluid hose ID is too small. Open, clear*; use a hose with a larger ID.
Bleeder valve is open. Close the valve.
Air is leaking into the supply
container. Check the ram plate seal.
Fluid is too heavy for pump priming. Use the bleeder valve (see page 13); use a
ram.
Held open or worn intake valve or seals. Clear the valve; replace the seals.
Worn packings in the displacement
pump. Replace the packings.
Pump operates,
but output low on
down- stroke.
Fluid too heavy for pump priming. Use the bleeder valve (see page 13); use a
ram.
Held open or worn intake valve or seals. Clear the valve; replace the seals.
Pump operates,
but output low on
upstroke.
Held open or worn piston valve or seals. Clear the valve; replace the seals.
Erratic or accelerated
pump speed. Exhausted fluid supply. Refill and prime.
Fluid is too heavy for pump priming. Use the bleeder valve (see page 13 or 14); use a
ram.
Held open or worn piston valve or seals. Clear the valve; replace the seals.
Held open or worn priming piston. Clear; service.
Worn packings in the displacement
pump. Replace the packings.

18 308351
Service
Required Tools
• Torque wrench
• Bench vise, with soft jaws
• Rubber mallet
• Hammer
• O-ring pick
• 13mm(1/2in.)dia.brassrod
• Set of socket wrenches
• Set of adjustable wrenches
• Pipe wrench
• Packing nut wrench (109, supplied)
• Thread lubricant
• Thread sealant
Disconnecting the Displacement Pump
1. Flush the pump, if possible. Stop the pump at the
bottom of its stroke.
2. Relieve the pressure.
3. Disconnect all hoses from the pump and motor.
4. Disconnect the displacement pump (106) from the
motor (101) as follows. See Fig. 6. Be sure to note
the relative position of the pump’s fluid outlet (X) to
the motor inlet (Y). If the motor does not require ser-
vicing, leave it attached to its mounting.
5. Using an adjustable wrench (or a hammer and rod),
unscrew the coupling nut (104) from the motor shaft
(Z). Do not lose or drop the coupling collars (105).
See Fig. 6.
6. Hold the tie rod flats with a wrench to keep the rods
from turning. Unscrew the nuts (103) from the tie
rods (102). Carefully remove the displacement pump
(106) from the motor (101).
7. Refer to page 20 for displacement pump service.
To service the motor, refer to the separate motor
manual, supplied.
WARNING
To reduce the risk of serious injury whenever you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
CAUTION
Be sure to use at least two people when lifting,
moving, or disconnecting the pump. This pump is too
heavy for one person. If you are disconnecting the
displacement pump from a motor which is still
mounted (for example, on a ram), be sure to support
the displacement pump while it is being
disconnected, to prevent it from falling and causing
injury or property damage. Do this by securely
bracing the pump, or by having at least two people
hold it while another disconnects it.

308351 19
Service
Reconnecting the Displacement Pump
1. Make sure the coupling nut (104) and the coupling
collars (105) are in place on the displacement rod (1).
See Fig. 6.
2. Use at least two people to hold the displacement
pump while another reconnects it to the motor (see
the CAUTION on page 18). Orient the pump’s fluid
outlet (X) to the air or hydraulic inlet (Y) as was noted
in step 4 under Disconnecting the Displacement
Pump. Position the displacement pump (106) on the
tie rods (102).
3. Screw the nuts (103) onto the tie rods (102) and
torque to 68–81 N.m (50–60 ft-lb).
4. Screw the coupling nut onto the motor shaft loosely.
Hold the motor shaft (Z) flats with a wrench to keep it
from turning. Use an adjustable wrench to tighten the
coupling nut. Torque to 196–210 N.m (145–155 ft-lb).
5. Torque the packing nut (2) to 128–156 N.m
(95–115 ft-lb).
6. Reconnect all hoses. Reconnect the ground wire if it
was disconnected. Fill the wet-cup (2) 1/3 full of
Graco Throat Seal Liquid or compatible solvent.
7. Turn on the power supply. Run the pump slowly to
ensure proper operation.
8. Before returning the pump to production, relieve the
pressure and retorque the packing nut (2) to 128–
156 N.m (95–115 ft-lb).
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
Torque to 68–81 N.m
(50–60 ft-lb).
Torque to 68–81 N.m
(50–60 ft-lb).
Torque to 196–210 N.m
(145–155 ft-lb).
Torque to 128–156 N.m
(95–115 ft-lb).
Square hole is for use
with torque wrench.
Fig. 6

20 308351
Displacement Pump Service
Disassembly
When disassembling the pump, lay out all the removed
parts in sequence, to ease reassembly. Clean all parts
with a compatible solvent and inspect them for wear or
damage. Refer to Fig. 9 for a cutaway view of the pump.
NOTE: Packing Repair Kits are available. See page 36.
For the best results, use all the new parts in the kit. Kit
parts are marked with an asterisk, for example (7*).
1. Remove the displacement pump from the motor as
explained on page 18. Place the pump in a vise,
with the outlet housing (9) positioned as shown in
Fig. 8.
2. Hold the flats of the priming piston rod (18) with an
adjustable wrench, and use a second wrench to
unscrew the priming piston seat (22) from the rod.
Slide the priming piston (21) off the rod. Inspect the
inner and outer surfaces of the piston (21) for
scoring, wear, or other damage.
3. Loosen the packing nut (2) using the wrench (109)
supplied.
4. Using a pipe wrench on the hex of the intake
cylinder (19), unscrew it from the intake valve
housing (17). The pump may separate at joints A, B,
or C. See Fig. 8.
NOTE: These instructions are written with the pump
separating at joint A. If it separates at joints B or C,
disassemble it at that joint, place the intake housing (17)
in a vise, and continue with step 5.
5. Unscrew the intake valve housing (17) from the
cylinder (10). Pull the housing off the pump. The
intake check valve assembly (V, see Fig. 7) should
slide down the priming piston rod (18) as you
remove the housing; if it does not slide easily, firmly
tap on the top of the housing (17) with a rubber
mallet to loosen.
DETAIL OF INTAKE CHECK VALVE
Fig. 7
Fig. 8