Graco Check-Mate 1000 Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1997, Graco Inc. is registered to I.S. EN ISO 9001
308356E
Important Safety Instructions
Read all warnings and instructions
in this manual. Save these instructions.
See page 2 for Table of Contents.
03820
05014B
Model 237708
Model 237520
STAINLESS STEEL
Check-Matet1000 Pumps
With Priming Piston, and Severe-Duty Rod and Cylinder
Part No. 237708 Pump, Series B,
50:1 Ratio, with KingtAir Motor
34.5 MPa, 345 bar (5000 psi) Maximum Fluid Working Pressure
0.7 MPa, 7 bar (100 psi) Maximum Air Input Pressure
Part No. 237520 Pump, Series A,
80:1 Ratio, with PremiertAir Motor
40.3 MPa, 403 bar (5850 psi) Maximum Fluid Working Pressure
0.5 MPa, 5 bar (73 psi) Maximum Air Input Pressure
US Patent Nos. 5,147,188 and 5,154,532.
Other Patents Pending.
Parts

2 308356
Table of Contents
Symbols 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation/Maintenance 9. . . . . . . . . . . . . . . . . . . . . . . . .
Service
Troubleshooting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnecting the Displacement Pump 14. . . . . . . .
Reconnecting the Displacement Pump 14. . . . . . . .
Displacement Pump Service 16. . . . . . . . . . . . . . . . .
Parts 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data and Performance Chart 28. . . . . . . . . . .
Dimensions 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 31. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 32. . . . . . . . . . . . . . . . . . . . . .
Graco Information 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.

308356 3
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are not sure, contact your Graco distributor.
DDo not alter or modify this equipment.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo 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.
DUse fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
DDo not kink or overbend hoses or use hoses to pull equipment.
DRoute 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).
DWear hearing protection when operating this equipment.
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.

4 308356
WARNING
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.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgi-
cal treatment.
DDo not point the gun/valve at anyone or at any part of the body.
DDo not put your hand or fingers over the spray tip/nozzle.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DDo not “blow back” fluid; this is not an air spray system.
DAlways have the tip guard and the trigger guard on the gun when spraying.
DCheck the gun diffuser operation weekly. Refer to the gun manual.
DBe sure the gun/valve trigger safety operates before spraying.
DLock the gun/valve trigger safety when you stop spraying.
DFollow the Pressure Relief Procedure on page 9 if the spray tip/nozzle clogs and before clean-
ing, checking or servicing the equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not
repair high pressure couplings; you must replace the entire hose.
DFluid 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.
DKeep clear of all moving parts when starting or operating the pump.
DKeep hands and fingers away from the priming piston during operation and whenever the pump is
charged with air.
DBefore servicing the equipment, follow the Pressure Relief Procedure on page 9 to prevent the
equipment from starting unexpectedly.

308356 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.
DGround the equipment and the object being sprayed. Refer to Grounding on page 6.
DIf 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 problem.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed/dispensed.
DKeep the spray/dispense area free of debris, including solvent, rags, and gasoline.
DElectrically disconnect all equipment in the spray/dispense area.
DExtinguish all open flames or pilot lights in the spray/dispense area.
DDo not smoke in the spray/dispense area.
DDo not turn on or off any light switch in the spray/dispense area while operating or if fumes are
present.
DDo not operate a gasoline engine in the spray/dispense area.
DKeep a fire extinguisher in the work 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.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

6 308356
Installation
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE OR EXPLOSION HAZ-
ARD 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.
Premier 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 mm@(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. 1 TI1052
Y
Z
Fig. 2
W
X
Y
Z
0864
2. Air and fluid hoses: use only electrically conductive
hoses.
3. Air compressor: follow manufacturer’s recommen-
dations.
4. Spray gun/dispense valve: ground through connec-
tion 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 con-
ductive, 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.

Fig. 3
05097
A
B
C
E
F
G
H
JK
M
Y
MAIN AIR LINE
R
S
TL
M
N
P
R
S
FLUID HEADER PIPE
(3 in. Diameter)
LP
M
N
D
W
U
V
N
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)
308356 7
Installation
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawings.
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 require-
ments.
The Typical Installation shown in Fig. 3 is only a guide
for selecting and installing system components and
accessories. Contact your Graco distributor for assis-
tance in designing a system to suit your particular
needs.
Assembling Model 237520
If you have Model 237520 Pump, assemble the dis-
placement pump (106) to the Premier air motor (101)
as explained on page 14. Install the designation plate
kit (108) as explained in the instructions supplied with
the kit.

8 308356
Installation
System Accessories
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 pres-
sure in the displacement pump, hose, and gun/
valve. Triggering the gun/valve to relieve pressure
may not be sufficient. Order Part No. 235992.
Air and Fluid Hoses
Be sure all air hoses (H) and fluid hoses (N) are prop-
erly sized and pressure-rated for your system. Use
only electrically conductive hoses. Fluid hoses must
have spring guards on both ends.
Mounting Accessories
Mount the pump (A) to suit the type of installation
planned. Fig. 3 on page 7 illustrates a ram-mounted
pump in a multi-gun header system. Pump dimensions
and the mounting hole layout are shown on page 31.
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.
Air Line Accessories
Install the following accessories in the order shown in
Fig. 3, using adapters as necessary:
DAn air line lubricator (D) provides automatic air
motor lubrication. Locate in the position shown.
DA main air bleed valve (C) is required in your
system 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
accessible from the pump, and is located upstream
from the air manifold (G).
DA pump air bleed valve (E) is required in your
system 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.
DAn 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 bleed-type master air valve.
DApump runaway valve (C) 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 seriously damaged. Locate in the position
shown.
DAn 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).
DAn air line filter (J) removes harmful dirt and
moisture from the compressed air supply. Also,
install a drain valve (W) at the bottom of each air
line drop, to drain off moisture.
DAn 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 Fig. 3, using adapters as necessary:
DInstall a fluid shutoff valve (P) at each gun/valve
drop, to isolate the gun/valve and fluid accessories
for servicing.
DInstall 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.
DA fluid regulator (L) controls fluid pressure to the
gun/valve, and dampens pressure surges.
DA 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.
DA gun/valve swivel (R) allows freer gun/valve
movement.

308356 9
Operation
Pressure Relief Procedure
WARNING
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:
Dare instructed to relieve the pressure,
Dstop spraying/dispensing,
Dcheck or service any of the system equipment,
Dor install or clean the spray tip/nozzle.
1. Lock the gun/valve trigger safety.
2. Shut off the air supply to the pump.
3. Close all air bleed valves (required in your sys-
tem).
4. Unlock the gun/valve trigger safety.
5. 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.
6. Lock the gun/valve trigger safety.
7. Open the drain valve (required in your system),
having a container ready to catch the drainage.
8. 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. 4.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
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 136–149 N.m (100–110 ft-lb) using the
supplied wrench (109). Do this whenever necessary.
Do not overtighten the packing nut.
03820
Fig. 4
1Bleed hole must
face down.
109
2
129
19
21 2Torque to 136–149
N.m (100–110 ft-lb).
2
20

10 308356
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 11.
Starting and Adjusting the Pump
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 9, before checking, clearing,
or cleaning the priming piston.
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.
WARNING
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.
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. 4. 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 elimi-
nated.
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 con-
tainer and prime the pump and the lines, or flush and
leave it filled with a compatible solvent. Eliminate all
air from the fluid system.
9. With the pump and lines primed, and with ade-
quate 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.
WARNING
COMPONENT RUPTURE HAZARD
To reduce the risk of overpressurizing
your system, which could cause compo-
nent rupture and serious injury, never
exceed the Maximum Incoming Air Pressure to the
pump (see the Technical Data on pages 28–29).
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.

308356 11
Operation
Shutdown and Care of the Pump
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
For overnight shutdown, stop the pump at the bottom
of the stroke to prevent fluid from drying on the ex-
posed 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
WARNING
FIRE AND EXPLOSION HAZARD
Before flushing, read the section FIRE
OR EXPLOSION HAZARD on page 5.
Be sure the entire system and flushing
pails are properly grounded. Refer to
Grounding on page 6.
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
recommended flushing fluids and flushing frequency.
Always flush the pump before fluid dries on the dis-
placement rod.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
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.

12 308356
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
1. Relieve the pressure.
2. Check all possible problems and causes before
disassembling the pump.
PROBLEM CAUSE SOLUTION
Pump fails to operate. Restricted line or inadequate air supply;
closed or clogged valves.
Clear; increase the air supply.
Check that all valves are open.
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 compat-
ible solvent.
Dirty, worn, or damaged motor parts. Clean or repair; see the separate motor manual.
Pump operates, but
output low on both
strokes.
Restricted line or inadequate air supply;
closed or clogged valves.
Clear; increase the air supply.
Check that all valves are open.
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 10); 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.
THE TROUBLESHOOTING CHART IS CONTINUED ON PAGE 13.
* To determine if the fluid hose or gun is obstructed, follow the Pressure Relief Procedure on page 9. Dis-
connect the fluid hose and place a container at the pump fluid outlet to catch any fluid. Turn on the air just enough
to start the pump. If the pump starts when the air is turned on, the obstruction is in the fluid hose or gun.
NOTE: If you experience air motor icing, contact your Graco distributor.

308356 13
Troubleshooting
PROBLEM CAUSE SOLUTION
Pump operates, but
output low on down-
stroke.
Fluid too heavy for pump priming. Use the bleeder valve (see page 10); 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 10); 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.

14 308356
Service
Required Tools
DTorque wrench
DBench vise, with soft jaws
DRubber mallet
DHammer
DO-ring pick
D13 mm (1/2 in.) dia. brass rod
DSet of socket wrenches
DSet of adjustable wrenches
DPipe wrench
DPacking nut wrench (109, supplied)
DThread lubricant
DLoctiteR2760tor equivalent
Disconnecting the Displacement Pump
1. Flush the pump, if possible. Stop the pump at the
bottom of its stroke.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
2. Relieve the pressure.
3. Disconnect the air and fluid hoses.
4. Disconnect the displacement pump (106) from the
motor (101) as follows. Be sure to note the relative
position of the pump’s fluid outlet (X) to the motor
air inlet (Y). If the motor does not require servicing,
leave it attached to its mounting.
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 discon-
nected, 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.
5. Using an adjustable wrench (or a hammer and
rod), unscrew the coupling nut (104) from the
motor shaft (Z, Model 237708) or adapter (107,
Model 237520). Do not lose or drop the coupling
collars (105). See Fig. 5.
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 16 for displacement pump service.
To service the air motor, refer to the separate
motor manual, supplied.
Reconnecting the Displacement Pump
NOTE: On Premier models, ensure that the rod adapt-
er (107) has not loosened during maintenance. Proper
torque is necessary to prevent the rod adapter from
loosening during the pump operation.
If the rod adapter (107) has loosened during mainte-
nance, remove the adapter and apply LoctiteR2760t
(or equivalent) to the rod adapter and air motor piston
threads, and then torque as specified in Fig. 5.
1. Make sure the coupling nut (104) and the coupling
collars (105) are in place on the displacement rod
(1). See Fig. 5.
2. Use at least two people to hold the displacement
pump while another reconnects it to the motor (see
the CAUTION above). Orient the pump’s fluid
outlet (X) to the air 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 81–89 N.m (60–66 ft-lb).
4. Loosely screw the coupling nut onto the motor
shaft (Z, Model 237708) or adapter (107, Model
237520). Hold the motor shaft (Z) or adapter (107)
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 136–149 N.m
(100–110 ft-lb).
Continued on page 14.

308356 15
Service
6. On Model 237520 only, install the designation label
(108) according to the instructions supplied.
7. 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.
8. Turn on the air supply. Run the pump slowly to
ensure proper operation.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
9. Before returning the pump to production, relieve
the pressure and retorque the packing nut (2) to
136–149 N.m (100–110 ft-lb).
03821
05015B
Fig. 5
1
3
4
2
Torque to 81–89 N.m (60–66 ft-lb).
Torque to 196–210 N.m (145–155 ft-lb).
Torque to 136–149 N.m (100–110 ft-lb).
Square hole is for use with torque wrench.
101
102 105
104
1
2
106
103 109
1
1
3
4
2
Z
X
Y
106
103
1
X
109 4
102
105
104
1
2
1
3
6
107
101
Y
Model 237708
Model 237520
6
108
5
5Apply LoctiteR2760t(or equivalent) to threads.
6Torque to 312–340 N.m (231–252 ft–lb).
110 6

16 308356
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. 8 for a cutaway view of the
pump.
NOTE: Repair Kit 222871 is available. See page 27.
For the best results, use all the new parts in the kit. Kit
parts are marked with an asterisk, for example (4*).
1. Remove the displacement pump from the air motor
as explained on page 14. Place the pump in a
vise, with the outlet housing (9) positioned as
shown in Fig. 7.
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. 7.
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) and outlet housing (9). Pull the hous-
ing off the pump. The intake check valve assembly
(V, see Fig. 6) 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.
05013
Fig. 6
39
17
18
38
37 16
15
N24
V
DETAIL OF INTAKE CHECK VALVE
03829
Fig. 7
2
9
18
22
21
19
17
10
A
B
C
1

308356 17
Displacement Pump Service
05013
Fig. 8
2
3
1
9
20
10
17
19
1
8
21
22
8
8
See Fig. 11
See Fig. 6
See Fig. 9 29
6. Pull the intake seat (37) and seal (38) out the
bottom of the intake valve housing (17). Take care
not to drop the check valve assembly (V) as it
comes free, and set it aside for later. See Fig. 6.
NOTE: If the seat (37) is difficult to remove, insert a
hammer and brass rod through the top of the housing
(17) and drive the seat out.
7. Using a rubber mallet, drive the displacement rod
(1) and the priming piston rod (18) out of the outlet
housing (9) and cylinder (10). Inspect the outer
surfaces of the rods for damage by running a
finger over the surface.
8. Unscrew the packing nut (2). Unscrew the packing
housing (3) and remove the seal (42). Remove the
throat glands and packings (T). See Fig. 9.
05013
42*
Fig. 9
T
2
3
THROAT PACKING DETAIL

18 308356
Displacement Pump Service
9. Remove the seal (8) from the bottom of the cylin-
der (10). See Fig. 11. Shine a light into the cylinder
to examine the inside surface for scoring or dam-
age. Only if the cylinder is damaged, or there is
evidence of leaking around the top cylinder
seal (8), unscrew the cylinder from the outlet
housing, using a pipe wrench. Remove the top
cylinder seal.
10. Place the flats of the displacement rod (1) in a
vise. Unscrew the piston (12) from the displace-
ment rod; the priming piston rod (18) will come
with it. Slide the piston guide (11) and seat (14) off
the piston (12).
11. It is not necessary to remove the priming piston
rod (18) from the piston (12) unless your inspec-
tion reveals damage to either part. To disas-
semble, place the piston flats in a vise and un-
screw the rod.
12. Place the piston guide (11) in a vise, as shown in
Fig. 10. Using an adjustable wrench, unscrew the
piston seat (14) from the guide. Remove the seal
(13); always replace it with a new one. Inspect the
mating surfaces (M) of the piston (12) and piston
seat (14) for damage or wear. See Fig. 11.
13. To disassemble the intake check valve assembly
(V), place the intake valve body (16) in a vise and
unscrew the packing nut (15). Remove the seal
(39) from the nut, and the packing (24) from the
valve body. Inspect the mating surfaces (N) of the
intake valve body (16) and seat (37) for damage or
wear. See Figs. 6 and 12.
NOTE: The seal (39) is press-fit in the nut (15) and
may require cutting to ease removal.
14. Unscrew the bleeder valve plug (20) completely
from the valve body (29). Clean the valve threads
and the bleed hole. It is not necessary to remove
the valve body from the pump outlet housing (9).
15. Inspect all parts for damage. Clean all parts and
threads with a compatible solvent. Reassemble as
explained on page 19.
03832
Fig. 10
1When reassembling items 11 and 14, torque
to approx. 75–88 N.m (55–65 ft-lb).
14
11
Fig. 11
1
11
12
*8
18
10
13*
14
17
M
1Torque to 125–137 N.m (92–101 ft-lb).
1
2Torque to 339–359 N.m (250–265 ft-lb).
2
3Lubricate.
3
DETAIL OF PISTON CHECK VALVE
3
05002

308356 19
Displacement Pump Service
Reassembly
Fig. 14 shows a cutaway of the entire pump.
1. Lubricate the intake packing (24*) and install it in
the valve body (16) as shown in Fig. 12.
2. With the beveled side facing up, press the intake
valve seal (39*) into the recess of the intake valve
packing nut (15) until it snaps into place. The nose
of the seal should be flush with or slightly recessed
into the face of the packing nut.
3. Place the flats of the valve body (16) in a vise.
Screw the packing nut (15) into the valve body
handtight. Set the intake housing assembly aside.
4. Lubricate the piston seal (13*) and install it on the
piston seat (14). Screw the piston guide (11) onto
the seat (14). Place the guide in a vise as shown in
Fig. 10 and torque the seat to 75–88 N.m (55–65
ft-lb).
5. If it was necessary to remove the priming piston
rod (18) from the piston (12), place the flats of the
piston in a vise. Using an adjustable wrench on the
flats of the rod, screw the rod into the piston.
Torque to 125–137 N.m (92–101 ft-lb). Be careful
not to create burrs on the flats of the rod.
6. Place the piston seat/guide assembly onto the
piston (12) so the 45_beveled seating surfaces
match. Screw the displacement rod (1) into the
piston (12) hand tight, then torque the rod to
339–359 N.m (250–265 ft-lb).
05008
Fig. 12
1
39*
15
Lubricate.
1
24*
16

20 308356
Displacement Pump Service
7. If the cylinder (10) was removed from the outlet
housing (9), lubricate the seal (8*) and place it on
the top of the cylinder. (The cylinder is symmetri-
cal, so either end can be the top.) Screw the
cylinder into the outlet housing. See Fig. 14.
8. Lubricate the seal (42*) and install it in the groove
on the bottom of the packing housing (3). Screw
the packing housing into the outlet housing (9) and
torque to 203–237 N.m (150–175 ft-lb). See the
Detail in Fig. 14.
9. Lubricate the throat packings and glands, and
install them in the packing housing (3) one at a
time, with the lips of the v-packings facing
down. Install the v-packings in the order shown in
the Detail in Fig. 14. Loosely install the packing nut
(2).
10. Lubricate the displacement rod (1). Slide the rod,
piston assembly, and priming piston rod (18) into
the cylinder (10) from the bottom, until the top of
the rod (1) protrudes from the packing nut (2).
11. Lubricate the seal (8*) and install it on the bottom
of the cylinder (10). Slide the intake valve housing
(17) onto the priming piston rod (18), making
certain that the smooth surface of the valve stop
(VS) is facing down toward the pump intake.
Screw the housing onto the cylinder. See Fig. 14.
12. Lubricate the priming piston rod (18), then slide the
assembled intake valve (V) onto the rod, making
certain that the packing nut (15) goes on the rod
first. Push the valve assembly up the rod, stopping
before it reaches the intake valve housing (17).
See Fig. 13.
13. Hold the valve body (16) steady with a wrench
while using an adjustable wrench to tighten the
packing nut (15). See Fig. 13. Torque to 97–106
N.m (71–78 ft-lb). Use a rubber mallet on the
priming piston rod (18), to drive the valve assem-
bly up to the stop (VS).
14. The intake seat (37) is reversible. Inspect both
sides of the seat and install it with the best side
facing into the housing (17). Push it into the hous-
ing until it seats securely. Lubricate the seal (38*)
and install in the bevel around the bottom of the
seat. See Fig. 14.
03830
Fig. 13
1Hold valve body (16) steady.
Torque packing nut (15) to
97–106 N.m (71–78 ft-lb).
1
17
18
16
15 V
10
2
1