Graco Check-Mate 200 A Series Operation manual

STAINLESS STEEL
Check–Mate 200 Pumpst
WITH PRIMING PISTON, AND
SEVERE-DUTY ROD AND CYLINDER
Model 222839, Series A
23:1 Ratio MonarkrPump
180 psi (1.2 MPa, 12 bar) Maximum Air Input Pressure
4140 psi (29 MPa, 285 bar) Maximum Fluid Working Pressure
Model 222907, Series A
46:1 Ratio PresidentrPump
100 psi (0.7 MPa, 7 bar) Maximum Air Input Pressure
4600 psi (32 MPa, 317 bar) Maximum Fluid Working Pressure
Table of Contents
Symbols 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service
Troubleshooting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnecting the Displacement Pump 12. . . . . . . .
Reconnecting the Displacement Pump 13. . . . . . . .
Displacement Pump Service 14. . . . . . . . . . . . . . . . .
Parts 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 29. . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 30. . . . . . . . . . . . . . . . . . . . . . . . .
Instructions–Parts List
308200D
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Model 222907 Shown
01057

2 308200
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.
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 uncertain about usage, call your Graco
distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
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 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.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.

308200 3
WARNING
SKIN INJECTION HAZARD
Spray from the spray gun/dispense valve, hose 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
surgical 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 spray gun when spraying.
DCheck the gun diffuser operation weekly. Refer to the gun manual.
DBe sure the gun/valve trigger safety operates before spraying/dispensing.
DLock the gun/valve trigger safety when you stop spraying/dispensing.
DFollow the Pressure Relief Procedure on page 8 whenever you: are instructed to relieve pres-
sure; stop spraying/dispensing; clean, check, or service the equipment; and install or clean the
spray tip/nozzle.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
DUse only Graco approved hoses. Do not remove any spring guard that is used to help protect the
hose 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 8 to prevent the
equipment from starting unexpectedly.

4 308200
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.
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.

308200 5
Installation
General Information
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawings.
NOTE: If you supply your own accessories, be sure
they are adequately sized and pressure–rated to meet
the system’s requirements.
Fig. 2 is only a guide for selecting and installing sys-
tem components and accessories. Contact your Graco
distributor for assistance in designing a system to suit
your particular needs.
System Accessories
WARNING
Two accessories are required in your system: a
bleed–type master air valve (J) and a fluid drain
valve (N). These accessories help reduce the risk
of serious bodily injury including fluid injection,
splashing in the eyes or on the skin, and injury from
moving parts if you are adjusting or repairing the
pump.
The bleed–type master air valve 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.
The fluid drain valve assists in relieving fluid pres-
sure in the displacement pump, hose, and gun.
Triggering the gun to relieve pressure may not be
sufficient.
Air and Fluid Hoses
Be sure all air and fluid hoses are properly sized and
pressure-rated for your system. Use only grounded air
and fluid hoses. Fluid hoses must have a braided
stainless steel cover (or have spring guards on both
ends).
Mounting Accessories
Mount the pump (A) to suit the type of installation
planned. The pump dimensions and mounting hole
layouts are shown on pages 28 and 29.
The Typical Installation on page 7 shows the pump
(A) mounted on a pneumatic elevator cart (B). The
pump may also be mounted on a 19 liter (5 gal.) pail
ram. In either case, it is used with a wiper plate (C).
Refer to the separate manuals for the cart, ram, and
wiper plate for further information.
Kits 223881 and 224829 are available to mount the
pump on a 200 liter (55 gallon) ram. Refer to the
separate manuals included with the kits for further
information.
Air Line Accessories
Install the following accessories as shown in Fig. 2,
using adapters as necessary:
DApump runaway valve (G) 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. Install closest to the pump
air inlet.
DAn air line lubricator (H) provides automatic air
motor lubrication.
DA bleed-type master air valve (J) 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 down-
stream from the air regulator.
DAn air regulator (K) 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.
DAn air line filter (L) removes harmful dirt and
moisture from the compressed air supply.
DA second bleed-type air valve (M) isolates the air
line accessories for servicing. Locate upstream
from all other air line accessories.
DAn air line quick disconnect coupler (F) is
required for pumps mounted on the pneumatic
elevator cart. The female coupler attaches to the
end of the air hose (D), and the male coupler
screws into the air manifold (E). See the separate
cart manual for further information.

6 308200
Installation
Fluid Line Accessories
Install the following accessories in the positions shown
in Fig. 2, using adapters as necessary:
DA fluid drain valve (N) is required in your system
to relieve fluid pressure in the hose and gun (see
the WARNING at left). Screw the drain valve into
the open branch of a tee mounted in the fluid line.
Install the drain valve pointing down, but so the
handle points up when opened.
DA fluid regulator (P) controls fluid pressure to the
gun/valve, and dampens pressure surges.
DA gun or valve (S) dispenses the fluid. The gun
shown in the Typical Installation is a dispensing gun
for highly viscous fluids.
DA gun swivel (T) allows freer gun movement.
Grounding
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 4.
1. Pump: use a ground wire and clamp. See Fig. 1.
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. 237569
Ground Wire and Clamp.
Fig. 1
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.

308200 7
Installation
Fig. 2 01058
KEY
APump
BPneumatic Elevator Cart
CWiper Plate
DAir Hose
EAir Manifold
FAir Line Quick Disconnect Coupler
GPump Runaway Valve
HAir Line Lubricator
JBleed-Type Master Air Valve (required, for pump)
KAir Regulator
LAir Line Filter
MBleed-Type Master Air Valve (for accessories)
NFluid Drain Valve (required)
PFluid Pressure Regulator
RFluid Hose
SGun or Dispensing Valve
TGun/Valve Swivel
YGround Wire (required)
A
B
C
D
E
F
G
H
J
K
LM
N
P
Y
19 LITER (5 GAL.) PAIL
MAIN AIR LINE
R
ST

8 308200
Operation
Pressure Relief Procedure
WARNING
SKIN INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or dispensing 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. Close the pump’s bleed-type air valve (required in
your system).
3. Shut off the master air bleed valve (required in
your system).
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. 3. Adjust the packing nut weekly so it is just
snug; do not overtighten.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
Fig. 3
23
2
Air Motor Plate
0105
7

308200 9
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 10.
Starting and Adjusting the Pump
WARNING
MOVING PARTS HAZARD
See Fig. 3. The priming piston (23) and
the air motor piston (located behind the
air motor plates) move during operation.
Keep hands and fingers away from the priming
piston (23) during operation and whenever the
pump is charged with air. The priming piston ex-
tends beyond the intake cylinder (20) to pull materi-
al into the pump and can amputate a hand or finger
caught between it and the intake cylinder. Follow
the Pressure Relief Procedure on page 8,
before checking, clearing, or cleaning the priming
piston to prevent the pump from starting acciden-
tally.
Never operate the pump with the air motor plates
removed.
See the Installation on page 7. If you are using a
pneumatic elevator cart or 19 liter (5 gallon) ram with
the pump, refer to the separate instructions for those
components for set-up and operation instructions.
Lower the pump into a fluid container. Be sure the air
regulator (K) and bleed-type master air valve (J) are
closed. Then open the bleed valve (J). Hold a metal
part of the spray gun/dispensing valve (S) firmly to the
side of a grounded metal pail and hold the trigger
open. Now slowly open the air regulator until the pump
starts.
Cycle the pump slowly until all the air is pushed out
and the pump and hoses are fully primed. Release the
spray gun/dispensing valve trigger and engage the
safety latch. The pump should stall against pressure
when the trigger is released.
If the pump fails to prime properly, open the bleeder
valve (33) slightly. See Fig. 7 on page 16. Use the
bleeder hole (on the underside of the valve housing) as
a priming valve until the fluid appears at the hole.
Close the bleeder valve.
NOTE: When changing fluid containers with the hose
and gun already primed, be sure to open the bleeder
valve (33), to assist in priming the pump and venting
air before it enters the hose. Close the valve when all
air has been eliminated.
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 when priming
the pump. Use a crescent wrench to open and
close the bleeder plug. Keep your hands away from
the bleed hole.
With the pump and lines primed, and with adequate air
pressure and volume supplied, the pump will start and
stop as the spray gun/dispensing valve is opened and
closed.
Use the air regulator (K) 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
To reduce the risk of overpressurizing the system,
which could result in component rupture and cause
serious injury, NEVER exceed the specified maxi-
mum incoming air pressure to the pump (see the
Technical Data on pages 24–27).
CAUTION
Do not allow the pump to run dry. It will quickly
accelerate to a high speed, causing damage. A
pump runaway valve (G), which shuts off the air
supply to the pump if the pump accelerates beyond
the pre-set speed, is available. See the Typical
Installation in Fig. 2. If your pump accelerates
quickly, or is running too fast, stop it immediately and
check the fluid supply. If the supply container is
empty and air has been pumped into the lines, refill
the container and prime the pump and the lines with
fluid, or flush and leave it filled with a compatible
solvent. Be sure to eliminate all air from the fluid
system.

10 308200
Operation
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 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 operating the pump, read the
section FIRE AND EXPLOSION HAZ-
ARD on page 4. 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 8.
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.

308200 11
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
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 Clear*; see Technical Data on pages 24–27.
Obstructed fluid hose or gun/valve;
fluid hose ID is too small. Clear*; use a hose with a larger ID.
Fluid dried on the displacement rod. Clean; see Service on pages 12–19.
Dirty or worn air motor parts. Clean or repair; see separate air motor manual.
Pump operates, but
output is low on both
strokes.
Restricted line or inadequate air supply. Clear*; see Technical Data on pages 24–27.
Obstructed fluid hose or gun/valve;
fluid hose ID is too small. Clear*; use a hose with a larger ID.
Bleeder valve is open. Close.
Air is leaking into the supply container. Check wiper plate seal.
Fluid is too heavy for pump priming. Use bleeder valve (see page 9); use wiper plate
with ram or pneumatic elevator cart.
Worn packings in displacement pump. Replace packings.
Pump operates, but
output is low on down-
stroke.
Fluid too heavy for pump priming. Use bleeder valve (see page 9); use wiper plate
with ram or pneumatic elevator cart.
Held open or worn intake valve or seals. Clear valve; replace seals.
Pump operates, but
output is low on up-
stroke.
Held open or worn piston valve or seals. Clear valve; replace 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 9); use wiper
plate with ram or pneumatic elevator cart.
Held open or worn piston valve or seals. Clear valve; replace seals.
Held open or worn priming piston. Clear; service.
Worn packings in displacement pump. Replace packings.
* To determine if the fluid hose or gun is obstructed, follow the Pressure Relief Procedure on page 8. Disconnect
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 (about 20–40 psi [0.14–0.3 MPa, 1.4–2.8 bar]). If the pump starts when the air is turned on, the obstruc-
tion is in the fluid hose or gun.
NOTE: If you experience air motor icing, contact your Graco distributor for assistance.

12 308200
Service
Required Tools
DTorque wrench
DBench vise, with soft jaws
DRubber mallet
DHammer
DRazor or other sharp tool
D8 mm (5/16 in.) dia. brass rod
D8 mm, 11 mm, 15 mm, 25 mm, 3/4 in., and 7/8 in.
open–end wrenches
D17 mm box or socket wrench
D22 mm crow’s–foot wrench
DAdjustable wrenches
D24 in. adjustable wrench
DThread lubricant
DAnaerobic thread sealant
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 8.
Keep hands and fingers away from the priming
piston during operation and whenever the pump is
charged with air. On the pump downstroke the
priming piston extends beyond the intake cylinder
to pull the material into the pump. The priming
piston works under extreme force. During operation
and whenever the pump is charged with air, the
priming piston can severely injure or amputate a
hand or finger, or break a tool, caught between it
and the intake cylinder.
The air motor piston (located behind the air motor
plates) also moves when air is supplied to the
motor. NEVER operate the pump with the air motor
plates removed.
2. Relieve the pressure.
3. Disconnect the air hose. Hold the fluid outlet fitting
(7) with an adjustable wrench to keep it from being
loosened while you disconnect the fluid hose.
Remove the pump from its mounting. Note the
relative position of the pump’s fluid outlet to the air
inlet.
4. Using an adjustable wrench, unscrew the coupling
nut (104) from the connecting rod (103). Remove
the coupling collars (105). Take care not to lose or
drop them. See Fig. 4.
5. Hold the tie rod flats with an 11 mm wrench to
keep them from turning. Use the wrench (113)
provided with the pump (or a 17 mm box or socket
wrench) to unscrew the locknuts (106) from the tie
rods (102). Carefully pull the displacement pump
(107) off the air motor (101).
6. Refer to page 14 for displacement pump service.
To service the air motor, refer to the separate air
motor manual, supplied.

308200 13
Service
Reconnecting the Displacement Pump
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
1. Orient the pump’s fluid outlet to the air motor’s air
inlet as was noted in step 3 under Disconnecting
the Displacement Pump. Position the displace-
ment pump (107) on the tie rods (102). See Fig. 4.
NOTE: If you removed the tie rods (102) from the air
motor (101) or air motor adapter plate, reinstall them
using an 11 mm wrench. Torque the rods to 20-25 N.m
(15-18 ft-lb) on Model 222907, and 34-41 N.m (25-30
ft-lb) on Model 222839.
2. Screw the locknuts (106) onto the tie rods (102)
and torque to 34-41 N.m (25-30 ft-lb), using the
wrench (113) provided (or a 17 mm box or socket
wrench).
3. Place the coupling nut (104) on the displacement
rod (1), then place the collars (105) in the nut.
Screw the nut onto the connecting rod (103)
loosely. Hold the connecting rod flats with an
adjustable wrench to keep it from turning. Using an
adjustable wrench, torque the nut to 41-48 N.m
(30-35 ft-lb).
4. Using a torque wrench in the square hole of the
supplied wrench (113), torque the packing nut (2)
to 27-34 N.m (20-25 ft-lb).
5. Mount the pump and reconnect all hoses. Recon-
nect the ground wire if it was disconnected during
repair. Turn on the air and run the pump slowly.
6. Fill the packing nut/wet-cup 1/3 full of Graco
Throat Seal Liquid or compatible solvent.
Fig. 4
01059
101
103
105
107
102
106
104
108
2
113
1
7
1
3
4
2
1
Torque to 30–35 ft–lb (41–48 NSm).
2
Torque to 15–18 ft–lb (20–25 NSm) on model 222907; 25–30
ft–lb (34–41 NSm) on model 222839.
3
Torque to 20–25 ft–lb (27–34 NSm).
4
Torque to 25–30 ft–lb (34–41 NSm).

14 308200
Service
Disassembly
When disassembling the pump, lay out all removed
parts in sequence, to ease reassembly. Refer to Fig. 7.
NOTE: Repair Kit 222784 is available separately to
replace the piston and intake valve seals. For the best
results, use all the new parts in the kit. Kit parts are
marked with one asterisk, for example (8*). See Dis-
placement Pump Parts on page 23.
Repair Kit 222785 is available to replace the throat
packings. For the best results, use all the new parts in
the kit. Kit parts are marked with a check mark, for
example (3n).
1. Disconnect the displacement pump from the air
motor as explained on page 12.
2. Place the pump in a vise, with the jaws on the
outlet housing (9).
3. Hold the flats of the priming piston rod (21) with an
8 mm wrench. Using a 3/4 in. wrench, unscrew the
priming piston nut (22) from the rod. Slide the
priming piston (23) and priming piston guide (24)
off the rod. Inspect the surfaces of the guide (24)
and piston (23) for scoring, wear, or other damage.
4. Loosen the packing nut (2) using the packing nut
wrench (113, supplied), or a hammer and brass
rod.
5. Remove the intake cylinder (20), using a 24 in.
adjustable wrench. Remove the seal (19) and seat
(18) from the intake valve housing (16); always
replace the seal with a new one.
6. Unscrew the intake valve housing (16) from the
cylinder (11), using a 24 in. adjustable wrench. Pull
the housing off the pump. The intake check valve
assembly (U) should slide down the priming piston
rod (21) as you remove the housing; if it does not
slide easily, loosen it by firmly tapping the top of
the housing (16) with a rubber mallet. Take care
not to drop the assembly (U) as it comes free. Set
the check valve assembly aside for disassembly
later.
7. Inspect the rod guide (17) while in place in the
housing (16). Remove the rod guide only if it is
visibly damaged. Using a hammer and brass rod,
gently tap around the outer edge of the guide to
loosen it.
8. Push the displacement rod (1) down as far as
possible, then pull it and the priming piston rod
(21) out of the outlet housing (9) and cylinder (11).
9. Remove the packing nut (2) and throat packings
from the outlet housing (9). Do not remove the
fluid outlet nipple (7) and o-ring (8) unless dam-
aged.
10. Unscrew the plug (AA) of the bleeder valve (33)
completely from the valve housing (BB). Do not
unscrew the valve housing from the outlet housing
(9), because the threads may gall. Clean the valve
threads and the bleed hole on the underside of the
valve housing.
11. Use a 24 in. adjustable wrench on the pump
cylinder (11) flats to unscrew it from the housing
(9). Remove the o-rings (10). Inspect the inside of
the cylinder for damage by holding it up to the light
at an angle or running a finger over the surface.
12. Inspect the surface of the displacement rod (1)
and priming piston rod (21) for wear, scoring or
other damage by running a finger over the surface.
13. Use a vise with soft jaws to hold the displacement
rod (1) by its flats. Place a 15 mm wrench on the
piston flats and unscrew the piston (13) and prim-
ing piston rod (21) from the displacement rod (1).
Remove the piston guide assembly (V) from the
piston (13), and set aside for disassembly later.
14. It is not necessary to remove the priming piston
rod (21) from the piston (13) unless you see scor-
ing, wear, or other damage to either part. To
disassemble, place the piston flats in a vise. Using
an 8 mm wrench on the rod flats, unscrew the rod.

308200 15
Service
15. To disassemble the piston guide assembly (V),
place the flats of the piston seat (15) in a vise.
Close the jaws just tight enough to hold the part; it
can be damaged by squeezing it too tightly. Using
an 8 mm (5/16 in.) dia. brass rod, unscrew the
piston guide (12) from the piston seat (15). See
Fig. 5. Remove the piston seal (14); always re-
place with a new one. Inspect the mating surfaces
of the piston (13) and piston seat (15) for nicks,
scoring or wear.
Fig. 5
12
15
0205
Brass
Rod
16. To disassemble the intake check valve assembly
(U), place the nut (27) in a vise and unscrew the
intake valve body (25) from the nut, using a 25 mm
wrench. See Fig. 6. Remove the seal (30) from the
nut (27) and the other seal (26) from the valve
body; always replace them with new ones. Inspect
the mating surfaces of the intake valve body (25)
and seat (18) for wear, scoring, or other damage.
Fig. 6
25
27
0206
NOTE: The seal (30) is press-fit in the nut (27), and
may require cutting with a razor to ease removal.
17. Inspect all parts and threads, and clean with a
compatible solvent. To reassemble, see page 17.

Fig. 7 01060
12
2
33
10
14 U (See detail below.)
24
22
20
16
15
21
4
5
6
3
DETAIL OF THROAT PACKINGS
7
11
8
23 25
9
10
1
DETAIL OF
INTAKE CHECK VALVE
17
18
26
19
13
DETAIL OF
PISTON CHECK VALVE
11 (REF)
17 (REF)
16 (REF)
V (See detail at left.)
27
30
AA
BB
1
3
2
1
Remove.
Leave installed; clean bleed hole on underside.
Remove only if damaged.
2
3
16 308200
Service

308200 17
Service
Reassembly
Refer to Fig. 8 for reassembly.
1. Place an 8 mm (5/16 in.) dia. brass rod lengthwise
in a vise. Install a new piston seal (14*) on the
piston seat (15). Apply thread lubricant to the
threads of the piston guide (12). Place the piston
guide (12) securely on the brass rod. Using a 22
mm crow’s-foot, screw the piston seat (15) into the
piston guide. Torque to 35–41 N.m (26–30 ft-lb).
2. If it was necessary to remove the priming piston
rod (21) from the piston (13), apply thread lubricant
to the female threads of the piston. Place the flats
of the piston (13) in a vise. Hold the flats of the rod
with an 8 mm wrench, and screw the rod into the
piston. Torque to 35-41 N.m (26-30 ft-lb). Be
careful not to create burrs on the flats of the rod.
3. Use a vise with soft jaws to hold the flats of the
displacement rod (1). Install the assembled piston
guide/seat on the piston (13). Apply thread lubri-
cant to the female threads of the piston, and screw
the piston assembly onto the rod, using a 15 mm
wrench on the piston flats. Torque to 35-41 N.m
(26-30 ft-lb). There will be a small gap between the
top of the piston (13) and the shoulder of the rod
(1).
4. Place the outlet housing (9) in a vise. If the bleeder
valve housing (BB) was removed, apply PTFE
tape to the threads and reinstall it in the outlet
housing (9), making sure the bleed hole faces
toward the bottom of the outlet housing. Then
screw the valve plug (AA) fully into the valve
housing (BB).
NOTE: The bleeder valve plug (AA) has two sets of
threads. When reassembling, be sure the plug is fully
screwed into the valve housing (BB).
NOTE: It is not ordinarily necessary to remove the
outlet nipple (7) and o-ring (8*). However, if they were
replaced because of damage, lubricate the o-ring (8*)
and place it on the nipple (7). Screw the nipple into the
outlet housing (9). Torque to 60-84 N.m (44–62 ft-lb).

18 308200
Service
5. Lubricate the o-rings (10*) and install them on the
cylinder (11). Apply thread lubricant to the top
threads of the cylinder. Using a 24 in. adjustable
wrench on the flats of the cylinder, screw it into the
outlet housing (9). Torque to 159–221 N.m
(117–163 ft-lb).
6. Lubricate the throat packings and glands, and
install them in the outlet housing (9) one at a time
in the following order, with the lips of the v-pack-
ings facing down: male gland (6n), UHMWPE
v-packing (5n), PTFE v-packing (3n), UHMWPE
(5n), PTFE (3n), UHMWPE (5n), and female
gland (4n). Apply thread lubricant to the packing
nut (2) and install it loosely in the outlet housing.
7. Carefully insert the displacement rod (1) into the
bottom of the cylinder (11). Push the rod up into
the cylinder and through the outlet housing (9),
until it protrudes from the packing nut (2). Be
careful not to damage the piston seal (14*) while
performing this step.
8. Apply thread lubricant to the bottom threads of the
cylinder (11). Be sure the o-ring (10*) is in place on
the cylinder. Guide the intake valve housing (16)
up onto the priming piston rod (21). Screw the
valve housing onto the cylinder, using a 24 in.
adjustable wrench. Torque to 159–221 N.m
(117–163 ft-lb).
9. If the rod guide (17) was removed from the intake
valve housing (16), reinstall it with the open end
facing down toward the pump intake.
10. With the beveled side facing up, press the seal
(30*) into the recess of the intake packing nut (27)
until it snaps into place. The nose of the seal
should be flush with or slightly recessed into the
face of the packing nut. With the threads facing
down toward the pump intake, slide the nut up
onto the priming piston rod (21) until it clears the
flats of the rod.
11. Lubricate a new intake valve seal (26*) and slide it
onto the rod, being careful not to damage the seal
when passing over the flats of the rod. Slide the
seal up until it reaches the packing nut (27). Apply
thread lubricant to the female threads of the intake
valve body (25), and slide it onto the rod until it
reaches the nut (27).
12. Place a 7/8 in. wrench on the hex of the packing
nut (27) and a 25 mm wrench on the flats of the
valve body (25). Screw the nut into the body,
making certain they remain in position above the
flats of the rod (21). Torque to 35–41 N.m (26–30
ft-lb). Slide the assembled intake check valve (U)
up the priming piston rod and into the rod guide
(17) as far as possible; this may be difficult due to
high friction between the seal (26*) and rod (21).
13. Position the intake valve seat (18) so its large
beveled side faces down toward the pump intake.
Slide the seat (18) onto the priming piston rod (21)
and into the intake valve housing (16) until it seats
on the rod guide (17) . Lubricate a new seal (19*)
and push it up into the beveled gap around the
bottom outer edge of the seat (18). Be sure the
seal is fully and uniformly positioned in the gap.
14. Apply thread lubricant to the threads of the intake
cylinder (20) and screw the cylinder into the intake
valve housing (16), using a 24 in. adjustable
wrench. Torque to 159–221 N.m (117–163 ft-lb).
Installation of the intake cylinder (20) will seat the
parts of the intake valve assembly (U) securely in
the proper position.
15. Slide the priming piston guide (24) onto the rod
(21) until it stops. Then install the priming piston
(23), with the flat side facing up toward the pump.
Apply thread lubricant to the female threads of the
priming piston nut (22). Hold the rod (21) steady
with an 8 mm wrench on the flats, and screw the
priming piston nut (22) onto the rod with a 3/4 in.
wrench. Torque to 35-41 N.m (26-30 ft-lb).
16. Reconnect the displacement pump to the air motor
as explained on page 13.

21
Fig. 8 01060
10*
14*
U (See detail below.)
24
n4
n5
n6
3n
DETAIL OF THROAT PACKINGS
*8
9
10*
1
DETAIL OF
PISTON CHECK VALVE
11 (REF)
17 (REF)
16 (REF)
V (See detail at left.)
2
33
22
20
16
7
11
23
1 (REF)
12
15
13
18
25
27
*30
DETAIL OF
INTAKE CHECK VALVE
*26
*19
BB
AA
17
3
2
6
5
4
1
3
2
6
5
7
9
10
8
11
7
9
10
8
11
Torque to 35–41 NSm (26–30 ft-lb).
If removed, apply PTFE tape to threads.
Bleed hole must face toward bottom of
outlet housing (9).
Torque to 159–221 NSm (117–163 ft-lb).
Flat side must face up.
Apply thread lubricant and torque to
35-41 NSm (26-30 ft-lb).
Lips of V–packings must face down.
Remove only if damaged. Torque to
60–84 NSm (44–62 ft-lb).
Apply lubricant to female threads.
Apply lubricant to threads.
Large bevel must face down.
1
4
6
9
1
4
4
1
1
308200 19
Service

20 308200
Parts
Model 222839, Series A
23:1 Ratio Monark Pump
(includes items 101–113)
Ref.
No. Part No. Description Qty.
101 222791 AIR MOTOR, Monark 1
(see 307043 for parts)
102 24B190 KIT, tie rod 3
103 184162 ROD, adapter 1
104 184100 NUT, coupling 1
105 184131 COLLAR, coupling 2
106 109209 NUT, hex, self-locking; with 3
nylon insert; M10 x 1.5
107 222814 PUMP, displacement 1
(see pages 23–22 for parts)
108 101946 PIN, cotter 1
109 109212 SCREW, cap, socket hd; 3
3/8–16 unc–3a x 0.75” (19 mm)
110 184077 PLATE, adapter 1
113 184119 WRENCH, packing nut 1
103
107
102
106
109
113
104
110
105
108
101