Graco Check-Mate 800 Series User manual

Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions. See page 2 for model
numbers and maximum working pressures.
Instructions
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1995, Graco Inc. is registered to I.S. EN ISO 9001
CARBON STEEL
Check–Mate™800 Pumps
With Priming Piston and Severe–Duty Rod and Cylinder
Refer to page 2 for Table of Contents.
US Patent Nos. 5,147,188 and 5,154,532.
Other patents pending.
308351K
Models 236471
and 246942
Models 237265,
246940 and 246941
ti1447a
Models 198466
and 246938
4990B
04995
Parts

2 308351
Table of Contents
List of Models 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation/Maintenance 12. . . . . . . . . . . . . . . . . . . . . . . .
Service
Troubleshooting 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnecting the Displacement Pump 18. . . . . . . .
Reconnecting the Displacement Pump 19. . . . . . . .
Displacement Pump Service 20. . . . . . . . . . . . . . . . .
Parts 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data and Performance Chart 38. . . . . . . . . . .
Dimensions 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 49. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 50. . . . . . . . . . . . . . . . . . . . . .
Graco Information 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Models
Part No. Series Pump Model Ratio
Maximum Fluid
Working Pressure
Maximum Air
(or Hydraulic*)
Input Pressure
236471 B Kingt65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
237265 B Reduced Icing
Quiet Kingt
65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
240945 B Quiet Kingt65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
253376 B Quiet Kingt65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
237261 A Bulldogr31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)
241901 A Bulldogr
(55 Gallon/200
Liter Size)
31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)
237274 A Reduced Icing
Quiet Bulldogr
31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)
237264 A Senatorr19:1 15 MPa, 157 bar (2280 psi) 0.8 MPa, 8.4 bar (120 psi)
198475 A Quiet Kingt65:1 40 MPa, 403 bar (5850 psi) 0.6 MPa, 6 bar (90 psi)
198466 A ViscountrII 40 MPa, 403 bar (5850 psi) 10.3 MPa*, 103 bar* (1500 psi*)
246942 A Kingt65:1 48 MPa, 483 bar (7000 psi) 0.7 MPa, 7 bar (100 psi)
246940 A Bulldogr31:1 21 MPa, 214 bar (3100 psi) 0.7 MPa, 7 bar (100 psi)
246941 A Senatorr19:1 15 MPa, 157 bar (2280 psi) 0.8 MPa, 8.4 bar (120 psi)
246938 A ViscountrII 40 MPa, 403 bar (5850 psi) 10.3 MPa*, 103 bar* (1500 psi*)

308351 3
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 not sure, call 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 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 308351
WARNING
SKIN INJECTION HAZARD
Spray from the spray gun/dispense valve, leaks or ruptured components can inject fluid into your body
and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on
the skin can also cause serious injury.
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 12 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.
DBefore servicing the equipment, follow the Pressure Relief Procedure on page 12 to prevent the
equipment from starting unexpectedly.

308351 5
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
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.

6 308351
Installation
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 5.
1. King Pumps: use a ground wire and clamp. See
Fig. 1. Remove the ground screw (Z) and insert
through eye of ring terminal at the end of ground
wire (Y). Fasten ground screw back onto pump
and tighten securely. Connect the other end of the
wire to a true earth ground. Order Part No. 222011
Ground Wire and Clamp.
All other Pumps: use a ground wire and clamp.
See Fig. 2. Loosen the grounding lug locknut (W)
and washer (X). Insert one end of a 1.5 mm2(12
ga) minimum ground wire (Y) into the slot in lug (Z)
and tighten the locknut securely. Connect the other
end of the wire to a true earth ground. Order Part
No. 222011 Ground Wire and Clamp.
Fig. 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.

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

8 308351
Installation (Air–Powered Pumps)
05097
Fig. 3
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)
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

308351 9
Installation (Air–Powered Pumps)
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.
Triggering the gun to relieve pressure may not be
sufficient. Order Part No. 210658.
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 pump air bleed valve.
DApump runaway valve (V) senses when the
pump is running too fast and automatically shuts off
the air to the motor. A pump which runs too fast can
be 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 Figs. 3 and 4, 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.

10 308351
Installation (Hydraulic–Powered Pumps)
KEY
A Accessory Pump Stand
(P/N 218742)
B Surge Tank (P/N 218509 or
238983)
C 50 mm (2 in.) Diameter Pipe
D Full Flow, Non-Restrictive
Fluid Shutoff Valve
E Fluid Supply Line
F Mix Tank
G Hydraulic Supply Line
Shutoff Valve
H Hydraulic Pressure Gauge
J Flow Control Valve
K Pressure Reducing Valve
L Drain Line
M Hydraulic Return Line
Shutoff Valve
N Accumulator
P Hydraulic Supply Line
Q Hydraulic Return Line
Y Ground Wire (required,
see page 6)
Fig. 4 01408
F
ED
A
ED
B
Y
D
F
K
J
L
HM
YC
N
GPQ

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

12 308351
Operation
Pressure Relief Procedure
WARNING
SKIN INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
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 power to the pump.
3. In an air-powered system, close the air regulator
and close the bleed-type master air valve.
4. In a hydraulic-powered system, close the hy-
draulic supply line shutoff valve first, then the
return line shutoff valve.
5. Unlock the gun/valve trigger safety.
6. Hold a metal part of the gun/valve firmly to the side
of a grounded metal pail, and trigger the gun/valve
to relieve pressure.
7. Lock the gun/valve trigger safety.
8. In an air–powered system, open the drain valve
(required in your system), having a container ready
to catch the drainage. Leave the drain valve open
until you are ready to spray/dispense again.
If you suspect that the spray tip/nozzle or hose is
completely clogged, or that pressure has not been fully
relieved after following the steps above, very slowly
loosen the tip guard retaining nut or hose end coupling
and relieve pressure gradually, then loosen completely.
Now clear the tip/nozzle or hose.
Packing Nut/Wet-Cup
Before starting, fill the packing nut (2) 1/3 full with
Graco Throat Seal Liquid (TSL) or compatible solvent.
See Fig. 5.
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 128–156 N.m (95–115 ft-lb) using the
supplied wrench (109). Do this whenever necessary.
Do not overtighten the packing nut.
04995
Fig. 5
1Bleed hole must
face down.
109
2
129
19
21 2Torque to 128–156 N.m
(95–115 ft-lb).
2
20

308351 13
Operation
Flush the Pump Before First Use
The pump is tested with lightweight oil, which is left in
to protect the pump parts. If the fluid you are using
may be contaminated by the oil, flush it out with a
compatible solvent. See Flushing on page 16.
Starting and Adjusting the Pump
WARNING
MOVING PARTS HAZARD
Keep hands and fingers away from the
priming piston (21) during operation and
whenever the pump is charged with air.
The priming piston extends beyond the intake
housing (19) to pull material into the pump and can
amputate a hand or finger caught between it and
the intake housing. Follow the Pressure Relief
Procedure on page 12, before checking, clearing,
or cleaning the priming piston.
WARNING
SKIN INJECTION HAZARD
To reduce the risk of fluid injection, do not use
your hand or fingers to cover the bleed hole on the
underside of the bleeder valve body (29) when
priming the pump. Use a crescent wrench to open
and close the bleeder plug (20). Keep your hands
away from the bleed hole.
CAUTION
Do not allow the pump to run dry. It will quickly
accelerate to a high speed, causing damage. If your
pump is running too fast, stop it immediately and
check the fluid supply. If the container is empty and
air has been pumped into the lines, refill the 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.
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 Input Pressure to the pump
(see the Technical Data on pages 38–46).
Air–Powered Systems
1. Supply fluid to the pump, per the requirements of
your system.
2. See Fig. 3. Close the air regulator (F).
3. Open all air bleed valves (C, E).
4. Hold a metal part of the gun/valve (S) firmly to the
side of a grounded metal pail and hold the trigger
open.
5. Slowly open the air regulator until the pump starts.
6. Cycle the pump slowly until all air is pushed out
and the pump and hoses are fully primed.
7. Release the gun/valve trigger and lock the trigger
safety. The pump should stall against pressure.
8. If the pump fails to prime properly, open the
bleeder valve plug (20) slightly. Use the bleed hole,
on the underside of the valve body (29), as a
priming valve until the fluid appears at the hole.
See Fig. 5. Close the plug.
NOTE: When changing fluid containers with the hose
and gun/valve already primed, open the bleeder valve
plug (20), to help prime the pump and vent air before it
enters the hose. Close the plug when all air is elimi-
nated.
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.
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.

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

308351 15
Notes

16 308351
Maintenance
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 12.
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
AND EXPLOSION HAZARD on page
5. Be sure the entire system and flush-
ing 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.
CAUTION
Never leave water or water-base fluid in the pump
overnight. If you are pumping water-base fluid, flush
with water first, then with a rust inhibitor such as
mineral spirits. Relieve the pressure, but leave the
rust inhibitor in the pump to protect the parts from
corrosion.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
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.

308351 17
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
1. Relieve the pressure.
2. Check all possible problems and causes before
disassembling the pump.
PROBLEM CAUSE SOLUTION
Pump fails to operate. Restricted air or hydraulic line or inade-
quate air supply; closed or clogged
valves.
Clear any obstructions; check that all valves are
open; increase pressure.
Obstructed fluid hose or gun/valve;
fluid hose ID is too small.
Open, clear*; use a hose with a larger ID.
Fluid dried on the displacement rod. Clean; always stop the pump at the bottom of its
stroke; keep the wet-cup 1/3 filled with a 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 air or hydraulic line or inade-
quate air supply; closed or clogged
valves.
Clear any obstructions; check that all valves are
open; increase pressure.
Obstructed fluid hose or gun/valve;
fluid hose ID is too small.
Open, clear*; use a hose with a larger ID.
Bleeder valve is open. Close the valve.
Air is leaking into the supply container. Check the ram plate seal.
Fluid is too heavy for pump priming. Use the bleeder valve (see page 13); use a ram.
Held open or worn intake valve or seals. Clear the valve; replace the seals.
Worn packings in the displacement
pump.
Replace the packings.
Pump operates, but
output low on down-
stroke.
Fluid too heavy for pump priming. Use the bleeder valve (see page 13); use a ram.
Held open or worn intake valve or seals. Clear the valve; replace the seals.
Pump operates, but
output low on upstroke.
Held open or worn piston valve or seals. Clear the valve; replace the seals.
THE TROUBLESHOOTING CHART IS CONTINUED ON PAGE 18.
* To determine if the fluid hose or gun is obstructed, follow the Pressure Relief Procedure on page 12. Dis-
connect the fluid hose and place a container at the pump fluid outlet to catch any fluid. Turn on the air or hydraulic
power just enough to start the pump. If the pump starts, the obstruction is in the fluid hose or gun.
NOTE: If you experience air motor icing, call your Graco distributor.

18 308351
Troubleshooting
PROBLEM CAUSE SOLUTION
Erratic or accelerated
pump speed.
Exhausted fluid supply. Refill and prime.
Fluid is too heavy for pump priming. Use the bleeder valve (see page 13 or 14); use a
ram.
Held open or worn piston valve or seals. Clear the valve; replace the seals.
Held open or worn priming piston. Clear; service.
Worn packings in the displacement
pump.
Replace the packings.
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
DThread 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 12.
2. Relieve the pressure.
3. Disconnect all hoses from the pump and motor.
4. Disconnect the displacement pump (106) from the
motor (101) as follows. See Fig. 6. Be sure to note
the relative position of the pump’s fluid outlet (X) to
the motor inlet (Y). If the motor does not require
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). Do not lose or drop the coupling
collars (105). See Fig. 6.
6. Hold the tie rod flats with a wrench to keep the
rods from turning. Unscrew the nuts (103) from the
tie rods (102). Carefully remove the displacement
pump (106) from the motor (101).
7. Refer to page 20 for displacement pump service.
To service the motor, refer to the separate motor
manual, supplied.

308351 19
Service
Reconnecting the Displacement Pump
1. Make sure the coupling nut (104) and the coupling
collars (105) are in place on the displacement rod
(1). See Fig. 6.
2. Use at least two people to hold the displacement
pump while another reconnects it to the motor (see
the CAUTION on page 18). Orient the pump’s fluid
outlet (X) to the air or hydraulic inlet (Y) as was
noted in step 4 under Disconnecting the Dis-
placement Pump. Position the displacement
pump (106) on the tie rods (102).
3. Screw the nuts (103) onto the tie rods (102) and
torque to 68–81 N.m (50–60 ft-lb).
4. Screw the coupling nut onto the motor shaft loose-
ly. Hold the motor shaft (Z) flats with a wrench to
keep it from turning. Use an adjustable wrench to
tighten the coupling nut. Torque to 196–210 N.m
(145–155 ft-lb).
5. Torque the packing nut (2) to 128–156 N.m
(95–115 ft-lb).
6. Reconnect all hoses. Reconnect the ground wire if
it was disconnected. Fill the wet-cup (2) 1/3 full of
Graco Throat Seal Liquid or compatible solvent.
7. Turn on the power supply. Run the pump slowly to
ensure proper operation.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
8. Before returning the pump to production, relieve
the pressure and retorque the packing nut (2) to
128–156 N.m (95–115 ft-lb).
04994
Fig. 6
1
3
4
2
Torque to 68–81 N.m
(50–60 ft-lb).
Torque to 196–210 N.m
(145–155 ft-lb).
Torque to 128–156 N.m
(95–115 ft-lb).
Square hole is for use
with torque wrench.
101
102 105
104
1
2
106
103
109
1
1
3
4
2
Z
X
Y

20 308351
Displacement Pump Service
Disassembly
When disassembling the pump, lay out all the removed
parts in sequence, to ease reassembly. Clean all parts
with a compatible solvent and inspect them for wear or
damage. Refer to Fig. 9 for a cutaway view of the
pump.
NOTE: Packing Repair Kits are available. See page
36. For the best results, use all the new parts in the kit.
Kit parts are marked with an asterisk, for example (7*).
1. Remove the displacement pump from the motor as
explained on page 18. Place the pump in a vise,
with the outlet housing (9) positioned as shown in
Fig. 8.
2. Hold the flats of the priming piston rod (18) with an
adjustable wrench, and use a second wrench to
unscrew the priming piston seat (22) from the rod.
Slide the priming piston (21) off the rod. Inspect
the inner and outer surfaces of the piston (21) for
scoring, wear, or other damage.
3. Loosen the packing nut (2) using the wrench (109)
supplied.
4. Using a pipe wrench on the hex of the intake
cylinder (19), unscrew it from the intake valve
housing (17). The pump may separate at joints A,
B, or C. See Fig. 8.
NOTE: These instructions are written with the pump
separating at joint A. If it separates at joints B or C,
disassemble it at that joint, place the intake housing
(17) in a vise, and continue with step 5.
5. Unscrew the intake valve housing (17) from the
cylinder (10). Pull the housing off the pump. The
intake check valve assembly (V, see Fig. 7) should
slide down the priming piston rod (18) as you
remove the housing; if it does not slide easily,
firmly tap on the top of the housing (17) with a
rubber mallet to loosen.
05002
Fig. 7
39
17a, b, c
18
38
37 16
15
NP
V
DETAIL OF INTAKE CHECK VALVE
04993
Fig. 8
2
9
18
22
21
19
17a, b, c
10
A
B
C
1