Graco 25T818 Use and care manual

3A8571A
EN
Instructions-Repair-Parts
12 VDC EGP
On-Demand Pump
For pumping non-flammable fluids, including motor oils, hydraulic fluid, and antifreeze. Do
not use to pump water. For professional use only.
Not approved for use in explosive atmospheres or hazardous (classified) locations.
25T818 Gear Pump
3.8 gpm (14.4 lpm)
300 psi (2.07 MPa, 20.7 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment.
Save these instructions.

Contents
2 3A8571A
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Component Identification . . . . . . . . . . . . . . . . . . 7
Pump Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System Plumbing. . . . . . . . . . . . . . . . . . . . . . . . . 9
Mount Pump on Tank with Suction Tube . . . . . . . 9
Electrical Installation . . . . . . . . . . . . . . . . . . . . . 10
Priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 11
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . 12
Thermal Induced Pressure Relief . . . . . . . . . . . . 12
Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . 13
End of Product Life . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replace/Clean Suction Screen P/N 133377 . . . 16
Outlet Assembly Kit P/N 133413 . . . . . . . . . . . . 17
Pump Housing Assembly P/N 133374 . . . . . . . 19
Clean and Inspect Pump Gears. . . . . . . . . . . . . 22
Clean and Inspect Pressure Relief
Valve Assembly . . . . . . . . . . . . . . . . . . . . . . 26
Pump Outlet Check Valve Replacement with
Thermal Relief P/N 133097 . . . . . . . . . . . . . 27
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . . 30
Pump Performance Chart . . . . . . . . . . . . . . . . . . . 31
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Technical Specifications . . . . . . . . . . . . . . . . . . . . 33
California Proposition 65 . . . . . . . . . . . . . . . . . . . . 33
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 34

Warnings
3A8571A 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation 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 or on warning labels, 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.
WARNING
FIRE AND EXPLOSION HAZARD
When flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be
aware that flammable fumes can ignite or explode. To help prevent fire and explosion:
• Use equipment only in well-ventilated area.
• Eliminate all ignition sources, such as cigarettes and portable electric lamps.
• Ground all equipment in the work area.
• Keep work area free of debris, including rags and spilled or open containers of solvent and gasoline.
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Use only grounded hoses.
•Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request Safety Data Sheets (SDSs) from distributor or
retailer.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and
create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.

Warnings
4 3A8571A
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin and cause
serious injury.
• Follow the Pressure Relief Procedure when you stop spraying/dispensing and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is not
limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
WARNING

Typical Installation
3A8571A 5
Typical Installation
The installations shown in FIG. 1 - FIG. 3 are only guides for selecting and installing system components. Contact
your local Graco Distributor for assistance with planning a system to suit your needs.
NOTE: The output line fluid pressure should not exceed 200 psi (1.38 MPa, 13.8 bar) while pumping the fluid.
Exceeding this pressure can cause the motor to cycle on and off repeatedly.
The output pressure varies at the time of pump shut off. It is determined by many factors including: hose length,
type of fittings used, and the speed that the outlet valve is closed. If pressure sensitive devices are installed
downstream from the pump, an external pressure relief/bypass must be installed in order to vent excess pressure
back to the tank.
FIG. 1: Typical Installation - Option 1: Pump and Dispense Valve

Typical Installation
6 3A8571A
FIG. 2: Typical Installation - Option 2: Pump with Hose Reel
FIG. 3: Typical Installation - Option 3: Pump with More Than One Hose Reel

Typical Installation
3A8571A 7
Component Identification
Key:
A Motor with relay
B Pressure switch
C Pressure relief valve
D Outlet check valve
G Inlet check with thermal relief
H Outlet 1/2 npt
J Pump
K Power Switch
FIG. 4
A
B
C
D
G
H
J
K

Typical Installation
8 3A8571A
Pump Wiring
FIG. 5

Installation
3A8571A 9
Installation
Grounding
NOTE: The reference numbers in the following
instructions refer to Parts, page 28.
System Plumbing
The On-Demand pump delivers a constant output flow,
even with a varying load.
It is important that the system plumbing be of adequate
size so that the back pressure does not exceed 200 psi
(1.38 MPa, 13.8 bar).
All plumbing and hoses used in the installation should
have a minimum pressure rating of 325 psi (2.24 MPa,
22.4 bar).
If the system pressure drop at the rated pump flow is
greater than, or close to, the pressure switch setting,
the motor will cycle on and off when the dispense valve
is opened to dispense fluid. If this happens, reduce
system pressure by using a larger diameter hose or by
using a less restrictive valve.
Graco recommends using 1/2 in. ID hose to keep the
working pressure low while the dispense valve is being
triggered. The output line fluid pressure should not
exceed 200 psi (1.3 8 MPa, 13.8 bar) while pumping
fluid.
The pump design includes a self-contained pressure
relief valve (C), Component Identification, page 7.
When activated, the valve relieves pressure back to the
tank.
Mount Pump on Tank with
Suction Tube
1. Install the bung adapter (15) in the tank bung and
tighten.
2. Use a 3/4 in. (19 mm) steel or PVC pipe with a
3/4 npt pipe threads on one end as a suction tube.
3. Measure the length from the top of the bung
adapter to the bottom of the tank. Cut the suction
tube length to 1/2 in. (13 mm) less than this
measurement.
4. Apply pipe thread sealant to suction tube threads
and install the pipe into the pump inlet.
5. Insert suction tube assembly through the bung
adapter and lower the pump onto the bung
adapter.
6. Position the pump so that the outlet port is in the
desired position. Tighten the swivel nut (20) on the
pump to the bung adapter.
The equipment must be grounded to reduce the risk
of static sparking. Static sparking can cause fumes
to ignite or explode. Grounding provides an escape
wire for the electric current.
NOTICE
Never allow the pump to operate dry. Make sure that
the pump has fluid in it when the pump is initially
installed. Do not run the pump for more than five (5)
minutes with the pump discharge blocked. Do not
operate the pump continuously more than 30 minutes
in one (1) hour. Failure to follow these instructions can
result in damage to the pump.

Installation
10 3A8571A
Electrical Installation
Motor current rating: 60 amps full load. Use 8 AWG or
larger for supply wires.
1. Turn the power switch OFF.
2. Use an appropriate size ring terminal to attach the
black (negative) supply wire to the negative post
near the back of the motor. Ensure that the existing
small black wire remains on the post.
Use an appropriate size ring terminal to connect the
red (positive) supply wire to the relay post at the
front of the motor. This post is the one closest to
the pump inlet and outlet. Do not connect the
positive supply wire directly to the positive post of
the motor, or the motor will run continuously.
Ensure that the small red wire remains on the front
post (FIG. 6).
Priming
1. Attach a priming hose to the outlet of the pump.
Insert the opposite end of the hose into the tank
through the fill opening.
2. Turn the power switch ON. The pump should prime
in a few seconds.
NOTE: If priming does not start:
Remove the priming plug (21) from the pump
housing.
Using an oil can, fill the pump with 8 oz. (0.24 L) of
oil.
Replace the priming plug (21).
Turn the power switch ON. The pump should prime
in a few seconds.
Once the pump is primed, the inlet check valve will
prevent loss of prime.
3. When the pump starts to prime, turn the power
switch OFF.
4. Disconnect the priming hose.
Attach system plumbing to the pump outlet.
FIG. 6
Connect positive
wire to this post
FIG. 7

Installation
3A8571A 11
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Turn off and disconnect the power to the pump.
2. Open the dispense valve into a grounded waste
container to relieve pressure.
3. Close the dispense valve.
Duty Cycle
The pump is designed to operate at a 50% duty cycle.
It can operate up to a maximum of 30 minutes of run
time, with an equal amount of down time.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as splashing fluid and moving
parts, follow the Pressure Relief Procedure when you
stop dispensing and before cleaning, checking, or
servicing the equipment.
NOTICE
Never allow the pump to operate dry. Make sure that
the pump has fluid in it when the pump is initially
installed. Do not run the pump for more than five (5)
minutes with the pump discharge blocked. Do not
operate the pump continuously more than 30 minutes
in one (1) hour. Failure to follow these instructions can
result in damage to the pump.

Operation
12 3A8571A
Operation
NOTE: When the system is not in use, always turn the
power switch (K) (Component Identification, page 7),
located on the terminal box of the motor, off. Failure to
do so can result in a spill if a hose ruptures or a leak
occurs in the system plumbing. If a leak occurs, the
pressure in the system will drop, signaling the pump to
turn on.
See FIG. 4, page 7 for reference numbers.
The on-demand dispensing pump turns on or off
depending upon the pump outlet pressure. When the
dispensing valve is open, the system pressure
decreases and the pump will begin pumping fluid.
When the dispensing valve is closed, the system
pressure increases and the pump will stop pumping
fluid.
1. Turn the power switch, located on the terminal box
of the motor, ON.
2. Place the outlet of the dispensing valve into the fill
container.
3. Open the dispensing valve to the full open position,
until the desired amount of fluid is dispensed.
4. Close the dispensing valve to stop dispensing.
Pressure Switch
The pressure switch (B) (Component Identification,
page 7) is factory set to 290 psi (2.00 MPa, 20.0 bar).
Once the pressure in the system reaches 290 psi (2.00
MPa, 20.0 bar), the pressure switch opens and stops
the motor (FIG. 8).
Thermal Induced Pressure
Relief
The pump is equipped with a standard outlet check
valve (E) (Component Identification, page 7). If a
check valve with thermal relief is required, purchase PN
133097 and replace the standard check valve (FIG. 8).
NOTICE
Do not operate the pump continuously more than 30
minutes in one (1) hour. Failure to follow these
instructions can result in damage to the pump.
FIG. 8

Recycling and Disposal
3A8571A 13
Recycling and Disposal
End of Product Life
At the end of the product’s useful life, dismantle and
recycle it in a responsible manner.
• Perform the Pressure Relief Procedure.
• Drain and dispose of fluids according to applicable
regulations. Refer to the material manufacturer’s
Safety Data Sheet.
• Remove motor and power cord components.
Recycle according to applicable regulations.
• Deliver remaining product to a recycling facility.

Troubleshooting
14 3A8571A
Troubleshooting
1. Follow Pressure Relief Procedure, page 11,
before checking or repairing the equipment.
2. Check all possible problems and causes before
disassembling the equipment.
Problem Cause Solution
Motor is running, but the pump
will not prime.
The pump lost the prime. Refer to Priming, page 10.
There is dirt under the pressure relief valve. Remove the pressure relief valve and
inspect. Clean or replace the pump
housing assembly.
The gears are worn or damaged. Remove the pump body and inspect the
gears. If damaged, replace the pump
housing assembly.
The oil level is low. Refill or replace the tank.
There is an air leak in the suction tube. Inspect all joints in the suction tube
making sure that all threaded joints have
sealant applied properly.
There is an air lock in the system. Fill the system with fluid by keeping
nozzle open by operating the pump.
The motor does not run at the proper speed. Check the electric connections.
Ensure the supply voltage is at the proper
level.
Oil is leaking in the motor
mount.
A faulty or damaged motor shaft seal. Replace the pump housing assembly.
Pressure switch is not activating.
Pressure relief is relieving pressure internally.
Pressure switch is faulty.
Replace the pump outlet assembly with
new pressure switch.
Dirt is under the pressure relief valve.
Remove the pressure relief valve and
inspect. Clean or replace the pump
housing assembly.
A worn motor shaft. Replace with a new pump.

Troubleshooting
3A8571A 15
The unit pumps, but the output
flow is low.
The inlet suction screen is clogged (used oil). Remove the inlet suction screen
using a 3/4 in. (19 mm) hex wrench.
Clean or replace the inlet suction
screen.
There is an air leak in the suction tube. Inspect all joints in the suction tube
making sure that they are sealed.
The suction tube is too close to the tank
bottom.
The suction tube must have a 1 in.
(25.4 mm) minimum clearance.
The tank is empty. Refill or replace the tank.
The tank is not vented. Vent the tank to atmosphere.
The gears are worn or damaged. Inspect the gears. If damaged, replace
the pump housing assembly.
The motor does not run at the proper speed. Check the electrical connection and verify
the supply voltage.
The suction tube, hose, or nozzle is clogged. Inspect and clean the suction tube, hose,
or nozzle, and replace as needed.
Pressure relief is relieving pressure internally.
There is dirt under the pressure relief valve.
Remove the pressure relief valve and
inspect. Clean or replace the pump
housing assembly.
The motor overheats. The gears are binding. Make sure that the gears turn freely. If
not, inspect the gears. If damaged,
replace the pump housing assembly.
Pressure relief is relieving pressure internally
at low pressure, not reading pressure switch
set pressure.
Remove and inspect the pressure relief
valve.
Clean or replace the pump.
Operating the pump for more than 30
minutes of continuous duty.
Limit operation to 30 minutes per hour.
Defective pressure switch or electrical
connection is wrong,
Inspect the electrical connection,
Electrical Installation, page 10. Replace
the pump outlet assembly with pressure
switch.
Motor cycle On and Off System pressure is close to the pressure
switch setting.
Reduce system pressure by using a larger
diameter hose or using a less restrictive
dispense valve.
The switch does not turn the
pump on.
The fuse or circuit breaker is blown. Check the electrical supply.
There is an electrical problem. Check that proper supply voltage is
getting to the pump. Inspect the electrical
connection, Electrical Installation, page
10; and Pump Wiring, page 8.
There is a defective switch. Replace the pump
The motor is damaged or defective.
The pressure in the system is not being
relieved. The pressure switch is activated.
Relieve pressure by dispensing oil.
Problem Cause Solution

Repair
16 3A8571A
Repair
Refer to Parts, on page 28 for this section.
Replace/Clean Suction Screen
P/N 133377
Disassembly
1. Follow Pressure Relief Procedure. page 11.
2. Turn off and disconnect the power to the pump.
3. Remove the pump from the tank.
4. Remove the suction tube from the pump.
5. Remove the inlet check valve assembly (12) using a
1 3/8 in. wrench (FIG. 9).
6. Remove the seal (14) (FIG. 9).
7. Remove the suction filter (13) using a 3/4 in.
(19 mm) hex wrench from the pump inlet (FIG. 10).
8. Inspect the suction filter (13) and either clean or
replace, as needed.
Reassembly
1. Place the suction filter (13) into the pump inlet,
using a 3/4 in. (19 mm) hex wrench (Torque 30
ft-lbs, 40.7 N•m) (FIG. 10).
2. Place the seal (14) (FIG. 9).
3. Put PTFE thread seal tape onto the inlet check
valve assembly (12) threads.
4. Insert the inlet check valve assembly (12) and hand
tighten.
5. Turn the inlet check valve assembly (12) one-half to
three-quarters of a turn, using a 1 3/8 in. wrench.
Do not over-tighten.
6. Complete using the Installation information
beginning on page 9.
FIG. 9
14
12
FIG. 10
13

Repair
3A8571A 17
Outlet Assembly Kit P/N 133413
Disassembly
1. Follow Pressure Relief Procedure. page 11.
2. Turn off and disconnect the power to the pump.
3. Remove the pump from the tank.
4. Remove the suction tube from the pump.
5. Remove the four terminal box cover screws
(FIG. 11).
6. Pull the terminal box cover gently upward off of the
terminal box (FIG. 12).
7. Remove the gasket.
8. Remove the pressure switch wires from the toggle
switch and relay terminal (FIG. 12).
9. Cut the pressure switch wire connectors off of the
pressure switch wires (FIG. 13).
10. Unscrew the strain relief nut (FIG. 14).
11. Pull the pressure switch wires out of the terminal
box through the strain relief (FIG. 14).
FIG. 11
Terminal Box
Cover Screws
FIG. 12
FIG. 13
Pressure
Switch Wires
Toggle Switch and
Relay Terminal

Repair
18 3A8571A
12. Pull the pressure switch wires out of the wire clamp
(FIG. 15).
13. Remove the outlet check valve assembly (16, 17,
and 18) from the pump (1) (FIG. 15).
Reassembly
1. Tighten the new outlet check valve assembly
(16, 17, and 18) into the pump (1), so the pressure
switch faces the motor (19) (Torque 20 ft-lbs, 27.1
N•m) (see FIG. 15).
2. Push the pressure switch wires into the wire clamp
and into the terminal box through the strain relief
(FIG. 14 and FIG. 15).
3. Crimp the connectors to the end of the pressure
switch wires (FIG. 16).
4. Twist the strain relief nut on using a wrench until
tightened (see FIG. 14).
5. Connect the pressure switch wires to the toggle
switch and relay terminal (FIG. 16).
6. Place the gasket onto the terminal box.
7. Replace the terminal box cover.
8. Insert the four terminal box cover screws and
tighten, making sure that the grounding wire is
connected properly (FIG. 17).
FIG. 14
FIG. 15
Strain Relief
Strain Relief Nut
16
Wire Clamp 17
18
FIG. 16
Pressure
Switch Wires
Toggle Switch and
Relay Terminal

Repair
3A8571A 19
9. Complete using the Installation information
beginning on page 9.
Pump Housing Assembly P/N
133374
Disassembly
1. Follow Pressure Relief Procedure. page 11.
2. Turn off and disconnect the power to the pump.
3. Remove the pump from the tank.
4. Remove the suction tube from the pump.
5. Remove the four terminal box cover screws
(FIG. 18).
6. Pull the terminal box cover gently upward off of the
terminal box.
7. Remove the gasket.
8. Remove the pressure switch wires from the toggle
switch and relay terminal (FIG. 19).
9. Cut the pressure switch wire connectors off of the
pressure switch wires (FIG. 20).
FIG. 17
Grounding Wire
FIG. 18
FIG. 19
Terminal Box
Cover Screws
Pressure
Switch Wires
Toggle Switch and
Relay Terminal

Repair
20 3A8571A
10. Unscrew the strain relief nut (FIG. 21).
11. Pull the pressure switch wires out of the terminal
box through the strain relief (FIG. 21).
12. Pull the pressure switch wires out of the wire clamp
(FIG. 21).
13. Remove the four Allen screws (6) using a 5/16 in.
(8 mm) hex wrench (FIG. 22).
14. Remove the pump housing assembly (FIG. 23).
FIG. 20
FIG. 21
Strain Relief
Strain Relief Nut
Wire Clamp
FIG. 22
FIG. 23
6
Motor
Pump Housing Assembly