Graco Check-Mate 2100 Operation manual

0913A
308150P
EN
Instructions – Parts List
STAINLESS STEEL
Check-Mate™ 2100 Pump
A piston priming pump with severe–duty rod and cylinder for use with high viscosity materials.
Part No. 222903 Pump, Series A,
12:1 Ratio, with Quiet Bulldog® Air Motor
8.3 MPa, 83 bar (1200 psi) Maximum Fluid Working Pressure
0.7 MPa, 7 bar (100 psi) Maximum Air Input Pressure
Part No. 222836 Pump, Series B,
24:1 Ratio, with King™ Air Motor
16.6 MPa, 166 bar (2400 psi) Maximum Fluid Working Pressure
0.7 MPa, 7 bar (100 psi) Maximum Air Input Pressure
Part No. 222905 Pump, Series B,
24:1 Ratio, with Quiet King™ Air Motor
16.6 MPa, 166 bar (2400 psi) Maximum Fluid Working Pressure
0.7 MPa, 7 bar (100 psi) Maximum Air Input Pressure
See page 2 for Table of Contents.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Part No.
222836
Shown

2 308150P
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Technical Specifications . . . . . . . . . . . . . . . . . . . . 26
(Model 222903 Quiet Bulldog Pump) . . . . . . . . 26
(Model 222903 Quiet Bulldog Pump) . . . . . . . . 27
(Model 222836 King Pump) . . . . . . . . . . . . . . . 28
(Model 222836 King Pump) . . . . . . . . . . . . . . . 29
(Model 222905 Quiet King Pump) . . . . . . . . . . . 30
(Model 222905 Quiet King Pump) . . . . . . . . . . . 31
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Mounting Hole Layouts . . . . . . . . . . . . . . . . . . . . . 33
California Proposition 65 . . . . . . . . . . . . . . . . . . . 33
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 34

308150P 3
Symbols
Warning Symbol Caution Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
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.
• This equipment is for professional use only.
• Read all instruction manuals, tags, and labels before operating the equipment.
• Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
• Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Specifications on pages 26-31 for the maximum working pressure of this equipment.
• Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Technical
Specifications section of all equipment manuals. Read the fluid and solvent manufacturer's warnings.
• Do not use hoses to pull equipment.
• Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco
hoses to temperatures above 82°C (180°F) or below -40°C (-40°F).
• Wear hearing protection when operating this equipment.
• Do not lift pressurized equipment.
• Comply with all applicable local, state, and national fire, electrical, and safety regulations.

4 308150P
WARNING
SKIN INJECTION HAZARD
Spray from the gun/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.
• Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgical
treatment.
• Do not point the gun/valve at anyone or at any part of the body.
• Do not put your hand or fingers over the spray tip/nozzle.
• Do not stop or deflect leaks with your hand, body, glove or rag.
• Do not "blow back" fluid; this is not an air spray system.
• Always have the tip guard and the trigger guard on the gun/valve when spraying.
• Be sure the gun/valve trigger safety operates before spraying.
• Lock the gun/valve trigger safety when you stop spraying.
• Follow the Pressure Relief Procedure on page 9 whenever you: are instructed to relieve pressure;
stop spraying; clean, check, or service the equipment; and install or clean the spray tip/ nozzle.
• Tighten all fluid connections before operating the equipment.
• Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
• Use 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 air motor piston, can pinch or amputate your fingers.
• Keep clear of all moving parts when starting or operating the pump.
• Before servicing the equipment, follow the Pressure Relief Procedure on page 9 to prevent the
equipment from starting unexpectedly.

308150P 5
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result
in a fire or explosion and serious injury.
• Ground the equipment and the object being sprayed. Refer to Grounding on page 6.
• If there is any static sparking or you feel an electric shock while using this equipment, stop spraying
immediately. Do not use the equipment until you identify and correct the problem.
• Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being
sprayed.
• Keep the spray area free of debris, including solvent, rags, and gasoline.
• Electrically disconnect all equipment in the spray area.
• Extinguish all open flames or pilot lights in the spray area.
• Do not smoke in the spray area.
• Do not turn on or off any light switch in the spray area while operating or if fumes are present.
• Do not operate a gasoline engine in the spray area.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
• Know the specific hazards of the fluid you are using.
• Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
• Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent
manufacturer.

6 308150P
Installation
Grounding
1. King Pumps : use a ground wire and clamp. See Fig.
1. Remove the ground screw (Z) and insert through
eye of ring terminal at the end of ground wire (Y).
Fasten ground screw back onto pump and tighten
securely. Connect the other end of the wire to a
true earth ground. Order Part No. 222011 Ground
Wire and Clamp.
All Other Pumps : use a ground wire and clamp. See
Fig. 2. Loosen the grounding lug locknut (W) and
washer (X). Insert one end of a 1.5 mm² (12 ga)
minimum ground wire (Y) into the slot in lug (Z) and
tighten the locknut securely. Connect the other end
of the wire to a true earth ground. Order Part
No.
237569 Ground Wire and Clamp.Air and hydraulic
hoses:
use only electrically conductive hoses.
2.
Air hoses: use only electrically conductive hoses.
3. Fluid hoses: use only electrically conductive fluid
hoses.
4.
Air compressor: follow manufacturer’s
recommendations.
5.
Spray gun/dispensing valve: grounding is obtained
through connection to a properly grounded fluid
hose and pump.
6.
Fluid supply container: according to your local
code.
7.
Object being sprayed: according to your local code.
8.
All solvent pails used when flushing , according to
your local code. Use only metal pails, which are
conductive, placed on a grounded surface. Do not
place the pail on a nonconductive surface, such as
paper or cardboard, which interrupts the grounding
continuity.
9.
To maintain grounding continuity when flushing or
relieving pressure,
always hold a metal part of the
spray gun/dispensing valve firmly to the side of a
grounded metal pail, then trigger the gun/valve.
FIG. 1 ___________________________________________
FIG. 2 ___________________________________________
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read the
section FIRE AND EXPLOSION HAZARD
on page 5.
TI1052
Y
Z
W
X
Y
Z
0864

308150P 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 your Graco distributor. If
you supply your own accessories, be sure they are
adequately sized and pressure-rated to meet the
system’s requirements.
The Typical Installation shown in Fig. 3 is only a guide
for selecting and installing system components and
accessories. Contact your Graco distributor for
assistance in designing a system to suit your particular
needs.
KEY
APump
B200 Liter (55 Gallon) Air-Powered Ram
CPump Runaway Valve
DAir Line Lubricator
EBleed-Type Master Air Valve
(required, for pump)
FPump Air Regulator
GAir Manifold
HElectrically Conductive Air Supply Hose
JAir Line Filter
KBleed-Type Master Air 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
YGround Wire (required, see page 6 for installation
instructions)
FIG. 3 _________________________________________________________________________________________________
01177A
A
B
D
E
F
G
H
JK
M
Y
R
S
T
L
M
N
P
R
S
LP
M
N
C
MAIN AIR VALVE
FLUID HEADER PIPE
(3 in. Diameter)

8 308150P
Installation
SYSTEM ACCESSORIES
Air and Fluid Hoses
Be sure all air hoses (H) and fluid hoses (N) are properly
sized and pressure-rated for your system. Use only
electrically conductive hoses. Fluid hoses must have
spring guards on both ends.
Mounting Accessories
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 pages 32
and 33.
If you are mounting the pump on a ram, refer to the
separate ram manual for installation and operation
instructions.
Air Line Accessories
Install the following accessories in the order shown in
Fig. 3, using adapters as necessary:
•An air line lubricator (D) provides automatic air
motor lubrication.
•A bleed-type master air 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 above). Be sure the bleed valve is easily
accessible from the pump, and is located
downstream from the air regulator.
•An air regulator (F) controls pump speed and
outlet pressure by adjusting the air pressure to the
pump. Locate the regulator close to the pump, but
upstream from the bleed-type master air valve.
•A pump 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.
•An air manifold (G) has a swivel air inlet. It mounts
to a ram, and has ports for connecting lines to air
accessories, such as the ram air regulator (T).
•An air line filter (J) removes harmful dirt and
moisture from the compressed air supply.
•A second bleed-type air valve (K) isolates the air
line accessories 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:
• Install a fluid shutoff valve (P) at each gun drop, to
isolate the gun and fluid accessories for servicing.
• Install a fluid drain valve (M) near the pump fluid
outlet, and at each gun station. The drain valves are
required in your system to relieve fluid pressure in
the displacement pump, hose and gun (see the
WARNING at left). Drain valves at the gun stations
may be mounted in the base of a fluid regulator
(L), using an adapter.
•A fluid regulator (L) controls fluid pressure to the
gun/valve, and dampens pressure surges.
•A gun or valve (S) dispenses the fluid. The gun
shown in Fig. 3 is a high pressure dispensing gun
for highly viscous fluids.
•A gun swivel (R) allows freer gun movement.
WARNING
A bleed-type master air valve (E) and a fluid drain
valve (M) are required in your system. 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 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
pressure in the displacement pump, hose, and
gun. Triggering the gun to relieve pressure may not
be sufficient.

308150P 9
Operation
Pressure Relief Procedure
1. Lock the gun/valve trigger safety.
2. Shut off the air supply to the pump.
3. In air-powered systems, close the bleed-type
master air 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)
and/or the pump bleeder valve, 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, nozzle, or hose end
coupling and relieve pressure gradually, then loosen
completely. Now clear the tip/nozzle or hose.
Packing Nut/Wet-Cup
Fill the packing nut/wet-cup (2) 1/3 full with Graco
Throat Seal Liquid (TSL) or compatible solvent. See Fig.
4. Using the supplied wrench (104), adjust the packing
nut weekly so it is just snug; do not overtighten.
Follow the Pressure Relief Procedure above before
adjusting the packing nut.
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 before using the pump.
Starting and Adjusting the Pump
Supply fluid to the pump, per the requirements of your
system.
Refer to Fig. 3 on page 7. Be sure the air regulator (F) is
closed. Then open the pump's bleed-type master air
valve (E). 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 (35) slightly. Use the bleed hole on the underside
of the valve body (34) as a priming valve until the fluid
appears at the hole. See Fig. 4. Close the plug (35).
NOTE: When changing fluid containers with the hose
and gun already primed, open the bleeder valve plug
(35), to assist in priming the pump and venting air
before it enters the hose. Close the bleeder valve plug
when all air has been eliminated.
WARNING
INJECTION HAZARD
Fluid under high pressure can be
injected through the skin and cause
serious injury. To reduce the risk of an
injury from injection, splashing fluid,
or moving parts, follow the Pressure Relief
Procedure whenever you:
• are instructed to relieve the pressure,
• stop spraying/dispensing,
• check or service any of the system equipment,
• or install or clean the spray tip/nozzle.
WARNING
For your safety, read the warning section FIRE
AND EXPLOSION HAZARD on page 5 before
flushing, and follow all the recommendations given
there.
WARNING
To reduce the risk of fluid injection, do not use your
hand or fingers to cover the bleed hole when
priming the pump.

10 308150P
Operation
With the pump and lines primed, and with adequate air
pressure and volume supplied, the pump will start and
stop as the gun/valve is opened and closed. In a
circulating system, the pump will speed up or slow
down on demand, until the air supply is shut off.
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.
Never allow the pump to run dry of the fluid being
pumped. A dry pump will quickly accelerate to a high
speed, possibly damaging itself. A pump runaway valve
(C), which shuts off the air supply to the pump if the
pump accelerates beyond the preset speed, is
available. See Fig. 3 on page 7. 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.
Shutdown and Care of the Pump
For overnight shutdown, relieve the pressure. Stop
the pump at the bottom of the stroke to prevent fluid
from drying on the exposed displacement rod and
damaging the throat packings.
Always flush the pump before the fluid dries on the
displacement rod. Flush with water or a compatible
solvent. Relieve the pressure after flushing.
FIG. 4 ___________________________________________
WARNING
To reduce the risk of overpressurizing your system,
which could result in component rupture and cause
serious injury, never exceed the specified
maximum incoming air pressure to the pump (see
the Technical Specifications on pages 26-31).
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
104
0913A
2
1
34, 35
Bleed hole must
face down.
1

308150P 11
Troubleshooting
1. Relieve the pressure.
2. Check all possible causes and problems before
disassembling the pump.
* To determine if the fluid hose or gun is obstructed, relieve the pressure. 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. 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, call your Graco distributor.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow
the Pressure Relief Procedure on page 9.
PROBLEM CAUSE SOLUTION
Pump fails to operate Restricted line or inadequate air
supply; closed or clogged valves
Clear; increase air supply. Check that valves are
open.
Obstructed fluid hose or gun/valve;
fluid hose ID is too small
Open, clear*; use hose with larger ID.
Fluid dried on the displacement rod Clean; always stop pump at bottom of stroke;
keep wet-cup 1/3 filled with compatible solvent.
Dirty, worn, or damaged motor parts Clean or repair; see separate motor manual.
Pump operates, but
output low on both
strokes
Restricted line or inadequate air
supply; closed or clogged valves
Clear; increase air supply. Check that valves are
open.
Obstructed fluid hose or gun/valve;
fluid hose ID is too small
Open, clear*; use hose with larger ID.
Bleeder valve open Close.
Air leaking into supply container Check ram plate seal.
Fluid too heavy for pump priming Use bleeder valve (see page 9); use ram.
Worn packings in displacement pump Replace packings.
Pump operates, but
output low on
downstroke
Fluid too heavy for pump priming Use bleeder valve (see page 9); use ram.
Held open or worn intake valve or seals Clear valve; replace seals.
Pump operates, but
output low on upstroke
Held open or worn piston valve or seals Clear valve; replace seals.
Erratic or accelerated
pump speed
Exhausted fluid supply Refill and prime.
Fluid too heavy for pump priming Use bleeder valve (see page 9); use ram.
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.

12 308150P
Service
Required Tools
• Torque wrench
• Bench vise, with soft jaws
• Rubber mallet
• Hammer
• O-ring pick
• 13 mm (1/2 in.) dia. brass rod
• Set of socket wrenches
• Set of adjustable wrenches
• 24 in. adjustable wrench
• Thread lubricant
• Thread sealant
Disconnecting the Displacement Pump
1. Flush the pump, if possible. Stop the pump at the
bottom of its stroke. Relieve the pressure.
2. Disconnect the air hose. Hold the fluid outlet fitting
(20) with a wrench to keep it from being loosened
while you disconnect the fluid hose.
3. Disconnect the displacement pump (105) from the
motor (101) as follows. Be sure to note the relative
position of the pump's fluid outlet to the air inlet of
the motor. If the motor does not require servicing,
leave it attached to its mounting.
4. Using an adjustable wrench, unscrew the coupling
nut (103). Remove the coupling collars (108). Take
care not to lose or drop them. See Fig. 5.
5. Hold the tie rod flats with a wrench to keep the rods
from turning. Unscrew the nuts (106) from the tie
rods (107). Carefully remove the displacement
pump (105) from the motor (101).
6. Refer to page 15 for displacement pump service.
To service the air motor, refer to the separate motor
manual, supplied.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow
the Pressure Relief Procedure on page 9.
WARNING
Keep hands and fingers away from the priming
piston during operation and whenever the pump is
charged with air to reduce the risk of injury! On the
pump downstroke the priming piston extends
beyond the intake housing 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 housing. Always
relieve the pressure before checking, clearing,
cleaning, flushing, or servicing any part of the pump.
On King and Bulldog air-powered pumps, the air
motor piston (located behind the air motor shield)
moves when air is supplied to the motor. Never
operate the pump with the air motor shield removed.
Before servicing the pump, relieve the pressure to
prevent the pump from starting accidentally.
CAUTION
Be sure to use at least two people when lifting,
moving, or disconnecting the pump. This pump is
too heavy for one person. If you are disconnecting
the displacement pump from a motor which is still
mounted (for example, on a ram), be sure to
support the displacement pump while it is being
disconnected, to prevent it from falling and causing
injury or property damage. Do this by securely
bracing the pump, or by having at least two people
hold it while another disconnects it.

308150P 13
Service
Torque to 129–142 N.m (95–105 ft–lb).
Torque to 196–210 N.m (145–155 ft–lb).
Torque to 135–169 N.m (100–125 ft–lb).
Square hole is for use with torque wrench.
FIG. 5 _________________________________________________________________________________________________
0914A
101
107
102
108
103
1
2
105
20106
104
1
1
2
3
4
2
King and Bulldog Pumps
(Model 222836 Shown)
1
2
3
4

14 308150P
Service
Reconnecting the Displacement Pump
1. 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
to the air inlet as noted in step 3 under
Disconnecting the Displacement Pump. Position
the displacement pump (105) on the tie rods (107).
See Fig. 5.
2. Screw the nuts (106) onto the tie rods (107) and
torque as noted in Fig. 5.
3. Place the coupling nut (103) on the displacement
rod (1), then place the coupling collars (108) into the
nut. Loosely screw the coupling nut onto the
connecting rod adapter (102) or connecting rod
(109, Model 222940 only). Hold the adapter or
connecting rod flats with a wrench to keep it from
turning. Use an adjustable wrench to tighten the
coupling nut. Torque as noted in Fig. 5.
4. Torque the packing nut (2) to 135-169 N.m
(100-125 ft-lb).
5. 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.
6. Turn on the air supply. Run the pump slowly to
ensure that it is operating properly.
CAUTION
Be sure to use at least two people when lifting,
moving, or disconnecting the pump. This pump is
too heavy for one person. if you are disconnecting
the displacement pump from a motor which is still
mounted (for example, on a ram), be sure to
support the displacement pump while it is being
disconnected, to prevent it from falling and causing
injury or property damage. Do this by securely
bracing the pump, or by having at least two people
hold it while another disconnects it.

308150P 15
Service
Displacement Pump Disassembly
When disassembling the pump, lay out all the removed
parts in sequence, to ease reassembly. Clean all parts
with a compatible solvent and inspect them for wear or
damage. Refer to Fig. 9.
NOTE: Repair Kit 222860 is available to replace the
packings and seals. Parts included are denoted with an
asterisk, for example (7*). Repair Kit 222974 is available
to repair the intake valve. Parts included are denoted
with a symbol, for example (10 ). For the best results,
use all the new parts in the kits. Conversion Kit 222861
is also available to convert the pump to all PTFE
v-packings. See page 25.
1. Remove the displacement pump from the air motor
as explained on page 12.
2. Hold the flats of the priming piston rod (12) with an
adjustable wrench, and use a second wrench to
unscrew the priming piston nut (14) from the rod.
Slide the priming piston (15) and guide (13) off the
rod. Inspect the outer surface of the guide (13) and
the inner and outer surfaces of the piston (15) for
scoring, wear, or other damage.
3. Stand the pump upright in a vise. Loosen the
packing nut (2) using the packing nut wrench (104)
supplied, or a hammer and brass rod. Using a
socket wrench, remove the six capscrews (32) and
washers (43, if present).
4. Tap the underside of the outlet housing (19) with a
rubber mallet to loosen the housing from the
cylinder (4). Lift the outlet housing off the pump and
set it aside. Be careful not to scratch the
displacement rod (1) while removing the housing.
Remove the seal (39) from the top of the cylinder.
5. Lift the cylinder (4) up off the intake housing (17).
The displacement rod (1), piston assembly, intake
valve assembly, and priming piston rod (12) will
come with the cylinder.
6. Place the cylinder (4) sideways in a vise with soft
jaws. Using a rubber mallet on the end of the
priming piston rod (12), drive the displacement rod
(1) and piston assembly out the top of the cylinder.
Continue to pull the rod out of the cylinder until the
priming piston rod (12) comes free.
7. Remove the seal (39) from the bottom of the
cylinder (4). Hold the cylinder up to the light at an
angle to examine the inside surface for scoring or
damage.
8. Place the flats of the displacement rod (1) in a vise.
Using a 13 mm (1/2 in.) diameter brass rod, pry the
intake check valve assembly away from the rod
guide (18) far enough to apply wrenches to the
valve assembly. See Fig. 6.
FIG. 6____________________________________________
9. Hold the valve body (10) steady with a wrench on
the flats. Using an adjustable wrench, loosen the
intake packing nut (9) to decrease tension on the
priming piston rod (12). Now slide the intake valve
assembly off the rod and set it aside. See Fig. 7.
FIG. 7____________________________________________
01171
12
18
6
10 9
1
INTAKE CHECK VALVE
13 mm (1/2 in.) Diameter Brass Rod.
1
01172
12
1 3
2 3
Hold valve body (10)
steady.
Loosen intake
packing nut (9)
When reassembling
items 9 and 10,
torque to 97-106 N.m
(71-78 ft-lb).
See page 18.
1
2
3

16 308150P
Service
10. Pull the seal (39) and seat (11) out the top of the
intake housing (17). See Fig. 9. If the seat is difficult
to remove, turn the housing upside down and drive
the seat out using a hammer and brass rod.
11. Examine the mating surfaces of the seat (11) and
the intake valve body (10) for damage.
12. Slide the rod guide (18) off the priming piston rod
(12). Unscrew the priming piston rod from the
piston (6). Run a finger over the surface of the rod
to check for scratches or scoring.
13. Place the flats of the piston (6) in a vise. Unscrew
the displacement rod (1) from the piston (6). Lift the
piston seat and guide assembly off the piston.
Inspect the mating surfaces of the piston (6) and
piston seat (8) for damage. See the Detail in Fig. 9.
14. Remove the displacement rod (1) from the vise and
inspect it for scratches and scoring by running a
finger over the surface.
15. Place the piston seat and guide assembly in the
vise and close the jaws on the flats of the seat (8)
just tight enough to hold the part. Slide a brass rod
through the openings in the piston guide (5) and
unscrew it from the seat as shown in Fig. 8.
Remove the piston seal (7).
FIG. 8 ___________________________________________
16. Take the intake valve assembly removed in step 9
and unscrew the packing nut (9) from the valve
body (10). Using an o-ring pick, remove the glands
(16, 41) and v-packings (40 and 42) from the valve
body. See the Detail in Fig. 9.
17. Unscrew the handle of the bleeder valve (28)
completely from the valve housing. Clean the valve
threads and the bleed hole in the valve housing. It is
not necessary to remove the valve housing from the
outlet housing (19).
18. Remove the packing nut (2) from the outlet housing
(19). Remove the throat packings (22, 24) and
glands (21, 23) from the outlet housing (19). Do not
remove the fluid outlet nipple (20) and o-ring (25)
from the outlet housing unless they need
replacement.
19. Inspect all parts for damage. Clean all parts and
threads with a compatible solvent. Reassemble as
explained on page 18.
01173
5
8
13 mm (1/2 in.) Diameter Brass Rod.
When reassembling items 5 and 8,
apply thread sealant and torque to
approx. 125- 137 N.m (92- 101 ft- lb).
1
2

308150P 17
Service
THROAT PACKING DETAIL
FIG. 9 _________________________________________________________________________________________________
0920
2
11
13
14
21
22
23
24
20
25
15
1
17
12
39
35
19
4
01120
01166
32
1
5
4
6
8
7
12
16
42
40
42
41
12
39
10
39
17
18
9
40
1
2
3
4
5
6
6
43 7
34
DETAIL OF PISTON
CHECK VALVE
DETAIL OF INTAKE
CHECK VALVE
Piston check valve
(see detail at right)
Intake check valve
(see detail at right)
Remove only if damaged.
Remove and clean plug.
Leave valve housing in place
Inspect mating surfaces.
Included on standard
displacement pump
222911 only.
1
2
3
4
5
6
7

18 308150P
Service
Reassembly
Refer to Fig. 10 for reassembly.
1. Install the intake valve seat (11 ) in the intake
housing (17), with the large bevel of the seat facing
the bottom of the housing. Lubricate the seal (39*†)
and install it in the housing. Set the intake housing
aside.
2. Install the piston seal (7*) on the piston seat (8).
Place the seat in a vise and close the jaws tight
enough to hold it securely, without placing too
much stress on the part. Apply thread sealant to the
threads of the seat and the piston guide (5). Screw
the guide onto the seat (8). Tighten using a brass
rod until the guide is securely seated,
approximately 125-137 N.m (92-101 ft-lb). See
Figs. 8 and 10.
3. Place the flats of the piston (6) in a vise. Apply
thread sealant to the threads of the rod (1) and the
top threads of the piston. Set the piston seat/guide
assembly onto the piston.
4. Screw the rod (1) into the piston (6) hand tight.
Torque the rod to 459-481 N.m (338-354 ft-lb).
There will be a small gap between the top of the
piston (6) and the shoulder of the rod (1).
5. Apply thread sealant to the bottom threads of the
piston and the top threads of the priming piston rod
(12). 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. Slide the rod guide (18) onto the priming piston rod
(12), making certain that the end nearest the valve
stop (VS) goes on the rod first. See the Detail in
Fig. 10.
7. Lubricate the intake valve packings and the inner
diameter of the valve body (10 ). Install the
packings one at a time in the following order,
with
the lips of the v-packings facing up : the female
gland (41*), one PTFE v-packing (40*), one
UHMWPE v-packing (42*), PTFE (40*), UHMWPE
(42*), and the male gland (16*). Screw the intake
packing nut (9) into the valve body (10) handtight.
See the Detail in Fig. 10.
8. Slide the assembled intake valve onto the priming
piston rod (12), making certain that the packing nut
(9) goes on the rod first. Push the valve assembly
up the rod, stopping before it reaches the rod guide
(18).
9. Hold the valve body (10) steady with a wrench
while using an adjustable wrench to tighten the
packing nut (9). See Fig. 7. Torque to 97-106 N.m
(71-78 ft-lb). Use a hammer and brass rod to
carefully drive the valve assembly further up the rod
until it reaches the stop (VS).
10. Remove the displacement rod (1) from the vise.
Place the cylinder (4) sideways in the vise with soft
jaws.
11. Lubricate the seal (39*) and place it on the bottom
of the cylinder (4). (The cylinder is symmetrical, so
either end can be the bottom.) See Fig. 10.
12. Slide the displacement rod (1), piston assembly,
intake valve assembly, and priming piston rod (12)
into the cylinder (4) from the bottom, until the
mating surfaces of the rod guide (18) and cylinder
(4) meet.
13. Put the intake housing (17) upright in a vise, making
sure it is off-center so there is sufficient clearance
for the priming piston rod (12) to be lowered
through the housing. Take the rod and cylinder
assembly and lower it into the intake housing until
the rod guide (18) bottoms on the intake seat (11)
and the priming piston rod (12) protrudes from the
bottom of the intake housing (17).
14. Lubricate the threads of the bleeder valve plug (35).
The plug has two sets of threads. Be sure to screw
the plug completely into the valve body (34). Torque
the plug to 30-38 N.m (22-28 ft-lb).
NOTE: It is not ordinarily necessary to remove the
outlet nipple (20) and o-ring (25*). However, if they were
replaced because of damage, lubricate the o-ring (25*)
and place it on the nipple (20). Screw the nipple into the
outlet housing (19). Torque to 156-171 N.m (115-126
ft-lb).
15. Lubricate the throat packings and glands, and
install them in the outlet housing (19) one at a time
in the following order,
with the lips of the
v-packings facing down
: the male gland (23*), one
UHMWPE v-packing (22*), one PTFE v-packing
(24*), UHMWPE (22*), PTFE (24*), UHMWPE (22*),
and the female gland (21*). Apply thread lubricant
to the packing nut (2) and install it loosely in the
outlet housing.

308150P 19
Service
FIG. 10________________________________________________________________________________________________
0920
21
22
23
24*
*25
1
17
34
19
4
01120
01166
1
5
4
6
8
7*
12
16*
42*
40*
42*
41*
12
17
18
9
40*
20
*39
2
39*
12
13
15
14
*39
11
39*
1
2
3
4
6
5
10
13
VS
14
12
9
10 11
78
10
10
10 15
13
32
43 16
35
DETAIL OF INTAKE
CHECK VALVE
Piston check valve
(see detail at right)
Intake check valve
(see detail at right)
Remove only if damaged.
Torque to 156-171 N.m
(115-126 ft-lb)
Screw valve plug completely
into valve housing.
Lips of v-packings must face down.
Lips of v-packings must face up.
Large bevel must face down.
Apply lubricant to inner diameter.
Flat side must face up.
Apply thread sealant.
Torque to 97- 106 N.m (71- 78 ft- lb).
Torque to 244- 264 N.m (180- 195 ft- lb).
Torque to 125- 137 N.m (92- 101 ft- lb).
Torque to 135- 169 N.m (100- 125 ft- lb).
Torque to 459- 481 N.m (338- 354 ft- lb).
Included on standard displacement pump
222811 only.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
THROAT PACKING DETAIL DETAIL OF PISTON
CHECK VALVE

20 308150P
Service
16. Lubricate the seal (39*) and place it on the top edge
of the cylinder (4). Set the outlet housing (19) on top
of the cylinder.
17. Install the washers (33, if present) and six long
capscrews (32) through the outlet housing (19)
and into the intake housing (17). Using a socket
wrench, torque the screws oppositely and evenly to
244–264 N.m (180–195 ft–lb). Remove the pump
from the vise and place it on its side.
18. Check that the flats of the priming piston rod (12)
are accessible below the intake housing (17). If not,
tap on the top of the displacement rod (1) with a
rubber mallet, until the flats are exposed.
19. Slide the priming piston guide (13) onto the rod (12)
until it stops. Then install the priming piston (15),
with the flat side facing up toward the pump. Apply
thread sealant to the threads of the priming piston
nut (14). Hold the rod (12) steady with an adjustable
wrench on the flats, and screw the nut (14) onto the
rod with another wrench. Torque to 97–106 N.m
(71–78 ft–lb). See Fig. 11. FIG. 11 __________________________________________
20. Reconnect the displacement pump to the air motor
as explained on page 14.
21. Allow 2 hours for the thread sealant to cure before
returning the pump to service.
01165
12
13
15 14
1 2 3
Flat side must face up.
Apply thread sealant.
Torque to 97- 106 N.m (71- 78 ft- lb).
1
2
3