Graco Check-Mate 800 User manual

308352E
EN
Instructions
Check-Mate®800 Pumps
Stainless Steel
Stainless Steel pumps with Priming Piston and Severe-Duty® Rod Cylinder for transferring
common industrial coatings and adhesives. For professional use only.
Model 236462, Series B, 65:1 Ratio
with King®Air Motor and 236612 Displacement Pump
5850 psi (40 MPa, 403 bar) Maximum Working Pressure
90 psi (0.6 MPa, 6.2 bar) Maximum Air Input Pressure
Model 241519, Series B, 65:1 Ratio
with Quiet King®Air Motor and 236612 Displacement Pump
5850 psi (40 MPa, 403 bar) Maximum Working Pressure
90 psi (0.6 MPa, 6.2 bar) Maximum Air Input Pressure
Model 234978, Series A, 31:1 Ratio
with Bulldog®Air Motor and 236612 Displacement Pump
3100 psi (21 MPa, 214 bar) Maximum Working Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Input Pressure
See page 28 for technical specifications.
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment.
Save these instructions.
TI03820

2 308352E
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Flush Before Using Equipment . . . . . . . . . . . . . . 6
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Relief Procedure. . . . . . . . . . . . . . . . . . 8
Packing Nut/Wet Cup. . . . . . . . . . . . . . . . . . . . . . 8
Flush the Equipment . . . . . . . . . . . . . . . . . . . . . . 9
Start and Adjust the Pump . . . . . . . . . . . . . . . . . . 9
Shutdown and Care of the Pump. . . . . . . . . . . . 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Required Tools. . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disconnect the Displacement Pump . . . . . . . . . 13
Connect the Displacement Pump . . . . . . . . . . . 14
Disassemble the Displacement Pump . . . . . . . . 15
Assemble the Displacement Pump . . . . . . . . . . 18
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Model 236462 Pump, Series B, 65:1 Ratio, with
King Air Motor (shown). . . . . . . . . . . . . . . . . 22
Model 241519 Pump, Series B, 65:1 Ratio, with
Quiet King Air Motor. . . . . . . . . . . . . . . . . . . 22
Model 234978 Pump, Series A, 31:1 Ratio, with
Bulldog Air Motor . . . . . . . . . . . . . . . . . . . . . 22
Part 236612, Series A, Displacement Pump . . . 23
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 25
Model 23462 and 241519. . . . . . . . . . . . . . . . . . 25
Model 234978. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Technical Specifications . . . . . . . . . . . . . . . . . . . . 28
Models 236462 and 241519 . . . . . . . . . . . . . . . . 28
Model 234978. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
California Proposition 65 . . . . . . . . . . . . . . . . . . . . 29
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 30
Related Manuals
Manuals are available at www.graco.com
Manual in
English Description
309347 King Air Motor Repair-Instructions
309348 King Quiet Air Motor Repair-Instructions
307049 Bulldog Air Motor Parts-Instructions

Warnings
308352E 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks.
When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings.
Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this
manual where applicable.
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Engage trigger lock when not dispensing.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or
solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:
• Use equipment only in well-ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Use only grounded hoses.
• Hold dispense valve firmly to side of grounded pail when triggering into pail. Do not use pail liners
unless they are anti-static or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment until
you identify and correct the problem.
• Keep a working fire extinguisher in the work area.

Warnings
4 308352E
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request Safety Data Sheets (SDSs) from distributor or
retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read Safety Data Sheets (SDSs) to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is not
limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
WARNING

Installation
308352E 5
Installation
Grounding
Pump: use ground wire and clamp (supplied). 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 222011 Ground Wire and Clamp.
Air and fluid hoses: use only electrically conductive
hoses.
Air compressor: follow manufacturer’s
recommendations.
Dispense valve: ground through connection to a
properly grounded fluid hose and pump.
Fluid supply container: follow local code.
Solvent pails used when flushing: follow local code.
Use only conductive metal pails, placed on a grounded
surface. Do not place the pail on a nonconductive
surface, such as paper or cardboard, which interrupts
grounding continuity.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the dispense
valve firmly to the side of a grounded metal pail, then
trigger the dispense valve.
Accessories
Install the following accessories in the order shown in
FIG. 2, page 7, using adapters as necessary.
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.
The equipment must be grounded to reduce the risk
of static sparking. Static sparking can cause fumes to
ignite or explode. Grounding provides an escape wire
for the electric current.
FIG. 1
TI1052
Y
Z
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 107141.
The fluid drain valve assists in relieving fluid pressure
in the displacement pump, hose, and dispense valve.
Triggering the dispense valve to relieve pressure may
not be sufficient. Order Part 235992.

Installation
6 308352E
Mounting
Mount the pump (A) to suit the type of installation
planned. FIG. 2 on page 7 illustrates a ram-mounted
pump in a multi-valve header system. Pump dimensions
and the mounting hole layout are shown in
Dimensions, page 27.
If you are mounting the pump on a ram, refer to your
separate ram manual for installation and operation
instructions. Mounting Kit 222776 is available to mount
the pump on a 55 gallon (200 liter) ram.
Air Line
•Main air bleed valve (C): is required in your system
to shut off the air supply to the pump and ram.
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,
located upstream from the air manifold (G), and
downstream from the air regulator.
•Air line lubricator (D): provides automatic air
• motor lubrication. Locate in the position shown.
•Pump air bleed valve (E): required in your system,
to relieve air trapped between it and the air motor
when the valve is closed. Be sure the bleed valve is
easily accessible from the pump, and is located
downstream from the air regulator.
•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.
•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).
•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.
•Air shutoff valve (K): isolates the air line
accessories for servicing. Locate upstream from all
other air line accessories.
•Pump 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.
Fluid Line
•Fluid drain valve (M): required in your system, to
relieve fluid pressure in the hose and dispense
valve
•Fluid shutoff valve (P): shuts off fluid flow.
•Fluid pressure regulator (L): for more precise
adjustment of the fluid pressure.
•Dispense valve (S): to dispense fluid.
•Fluid line swivel (R): for easier dispense valve
movement.
Flush Before Using Equipment
The equipment was tested with lightweight oil, which is
left in the fluid passages to protect parts. To avoid
contaminating your fluid with oil, flush the equipment
with a compatible solvent before using the equipment.
See Flush the Equipment, page 9.
Trapped air can cause the pump to cycle
unexpectedly, which could result in serious injury from
splashing or moving parts.

Installation
308352E 7
Typical Installation
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
requirements.
The Typical Installation shown in FIG. 2 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:
A Pump
B 200 L (55 gal) Air-Powered Ram
C Main Air Bleed Valve (required, for pump and ram)
D Air Line Lubricator
E Pump Air Bleed Valve (required, for pump)
F Pump Air Regulator
G Air Manifold
H Electrically Conductive Air Supply Hose
J Air Line Filter
K Air Shutoff Valve (for accessories)
L Fluid Regulator
M Fluid Drain Valve (required)
N Electrically Conductive Fluid Hose
P Fluid Shutoff Valve
R Valve Swivel
S Dispense Valve
T Ram Air Regulator
U Ram Director Valve
V Pump Runaway Valve (position only)
W Air Line Drain Valve
Y Ground Wire (required, see Grounding, page 5, for
installation)
FIG. 2: Typical Installation
D
BK J
FLUID HEADER PIPE
(3in. Diameter)
MAIN AIR
LINE
T
U
C
V
M
E
F
G
H
N
NN
M
M
P
LLP
R
S
R
S
W
X
A

Operation
8 308352E
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Engage trigger lock.
2. Close all air bleed valves.
3. Disengage the trigger lock.
4. Hold a metal part of the dispense valve firmly to a
grounded metal pail. Trigger the dispense valve to
relieve pressure.
5. Engage the trigger lock.
6. Open all fluid drain valves in the system, having a
waste container ready to catch drainage. Leave
drain valve(s) open until you are ready to dispense
again.
7. If you suspect the nozzle or hose is clogged or that
pressure has not been fully relieved:
a. VERY SLOWLY loosen the tip guard retaining
nut or the hose end coupling to relieve pressure
gradually.
b. Loosen the nut or the coupling completely.
c. Clear the obstruction in the hose or nozzle.
Packing Nut/Wet Cup
Before starting, fill the packing nut (2) 1/3 full with Graco
Throat Seal Liquid (TSL) or compatible solvent.
The packing nut is torqued at the factory and is ready for
operation. If it becomes loose and there is leaking from
the throat packings, relieve pressure, then torque the
nut to 136–149 N•m (100–110 ft-lb) using the supplied
wrench (109). Do this whenever necessary. Do not
overtighten the packing nut.
NOTE: The bleed hole must face down.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop dispensing and before
cleaning, checking, or servicing the equipment.
FIG. 3
03820
2
19
21
29
109
20

Operation
308352E 9
Flush the Equipment
• Flush before fluid can dry in the equipment, at the
end of the day, before storing, and before repairing
equipment.
• Flush at the lowest pressure possible. Check
connectors for leaks and tighten as necessary.
• Flush with a fluid that is compatible with the fluid
being dispensed and the equipment wetted parts.
1. Perform Pressure Relief Procedure, page 8.
2. Remove nozzle and soak in solvent.
3. Set pump to lowest possible fluid pressure, and start
pump.
4. Hold a metal part of the dispense valve (S) firmly to
a grounded metal pail. Trigger the dispense valve
until clean solvent dispenses.
5. Perform Pressure Relief Procedure, page 8.
Start and Adjust the Pump
1. Supply fluid to the pump, per the requirements of
your system.
2. Close the air regulator (F).
3. Open all air bleed valves (C, E).
4. Hold a metal part of the 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 valve trigger and lock the trigger safety.
The pump should stall against pressure.
To avoid fire and explosion, always ground equipment
and waste container. To avoid static sparking and
injury from splashing, always flush at the lowest
possible pressure.
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 8, before checking, clearing, or
cleaning the priming piston.

Operation
10 308352E
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. 3, page
8. Close the plug.
NOTE: When changing fluid containers with the hose
and dispense 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
eliminated.
NOTE: With the pump and lines primed, and with
adequate air pressure and volume supplied, the pump
will start and stop as you open and close the dispense
valve. In a circulating system, the pump will speed up or
slow down on demand, until the air supply is shut off.
9. Use the air regulator (F) to control the pump speed
and the fluid pressure.
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 exposed
displacement rod and damaging the throat packings.
Relieve the pressure according to the Pressure Relief
Procedure, page 8.
Always flush the pump before the fluid dries on the
displacement rod. Refer to Flush the Equipment, page
9.
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
NOTICE
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 container
and prime the pump and the lines, or flush and
leave it filled with a compatible solvent. Eliminate all
air from the fluid system.
To reduce the risk of overpressurizing your system,
which could cause component rupture and serious
injury, never exceed the Maximum Incoming Air
Pressure to the pump (see the Technical
Specifications on page 28).
NOTICE
Always use the lowest air pressure necessary to get
the desired results. Higher pressures cause
premature nozzle and pump wear.

Troubleshooting
308352E 11
Troubleshooting
1. Follow Pressure Relief Procedure, page 8, before
checking or repairing the pump.
2. Check all possible problems and causes before
disassembling pump.
Problem Cause Solution
Pump fails to operate The air supply is inadequate or air
lines are restricted.
Increase the air supply; clear the air
line.
The valves are closed or clogged. Check that all valves are open and
clear clogs.
The fluid hose or dispense valve is
obstructed.*
Open and clear the hose or
dispense valve.
The fluid hose ID is too small. Use a hose with a larger ID.
Fluid has dried on the displacement
rod.
Clean the displacement rod. Always
stop the pump at the bottom or its
stroke. Keep the wet-cup 1/3 filled
with a compatible solvent.
Motor parts are dirty, worn, or
damaged.
Clean or repair motor parts; see
your motor manual.
Pump operates, but output is low on
both strokes.
The air supply is inadequate or air
lines are restricted.
Increase the air supply; clear the air
line.
The valves are closed or clogged. Check that all valves are open and
clear clogs.
The fluid hose or dispense valve is
obstructed.*
Open and clear the hose or
dispense valve.
The fluid hose inner diameter (ID) is
too small.
Use a hose with a larger ID.
The bleeder valve is open. Close the bleeder valve.
Air is leaking into the supply
container.
Check the ram plate seal.
The fluid is too heavy for pump
priming.
Use the bleeder valve or a ram.
Follow the Start and Adjust the
Pump procedure, page 9.
The intake valve or seals are held
open or worn.
Clear the valve and replace seals.
Packings in the displacement pump
are worn.
Replace the packings.

Troubleshooting
12 308352E
* To determine if the fluid hose or dispense valve is
obstructed:
1. Follow the Pressure Relief Procedure, page 8.
2. Disconnect the fluid hose and place a container at
the pump fluid outlet to catch any fluid.
3. 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 dispense valve.
NOTE: If you experience air motor icing, call your Graco
distributor.
Pump operates, but output is low on
downstroke.
The fluid is too heavy for pump
priming.
Use the bleeder valve or a ram.
Follow the Start and Adjust the
Pump procedure, page 9.
The intake valve or seals are held
open or worn.
Clear the valve and replace seals.
Pump operates, but output is low on
upstroke
The piston valve or seals are held
open or worn.
Clear the valve and replace seals.
Erratic or accelerated pump speed The fluid supply is exhausted. Refill and prime.
The fluid is too heavy for pump
priming.
Use the bleeder valve or a ram.
Follow the Start and Adjust the
Pump procedure, page 9.
The piston valve or seals are held
open or worn.
Clear the valve and replace seals.
The priming piston is held open or
worn.
Clear and service the piston.
Packing in the displacement pump
are worn.
Replace the packings.
Problem Cause Solution

Repair
308352E 13
Repair
Required Tools
• Torque wrench
• Bench vise, with soft jaws
• Rubber mallet
• Hammer
• O-ring pick
• 13 mm (1/2 in.) diameter brass rod
• Set of socket wrenches
• Set of adjustable wrenches
• Pipe wrench
• Packing nut wrench (109, supplied)
• Thread lubricant
Disconnect the Displacement
Pump
1. Perform the Flush the Equipment procedure,
page 9. Stop the pump at the bottom of its stroke.
2. Follow the Pressure Relief Procedure, page 8.
3. Disconnect the air and fluid hoses.
4. Disconnect the displacement pump (106) from the
motor (101). Note the relative position of the pump
fluid outlet (ZA) to the motor air inlet (ZB).
NOTE: If the motor does not require servicing, leave it
attached to its mounting.
a. Use an adjustable wrench (or a hammer and
rod) to unscrew the coupling nut (104) from the
motor shaft (ZC). Do not lose or drop the
coupling collars (105). See FIG. 4, page 14.
b. 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).
NOTE: To service the displacement pump, refer to
Disassemble the Displacement Pump, page 15, and
Assemble the Displacement Pump, 18. To service the
air motor, refer to the separate motor manual, supplied.
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.

Repair
14 308352E
Connect the Displacement
Pump
1. Ensure the coupling nut (104) and the coupling
collars (105) are in place on the displacement rod
(1).
2. Align the pump fluid outlet (ZA) with the motor air
inlet (ZB) as noted in Disconnect the
Displacement Pump, page 13. Position the
displacement pump (106) on the tie rods (102).
3. Screw the nuts (103) onto the tie rods (102). Torque
the nuts to 81–89 N•m (60–66 ft-lb).
4. Screw the coupling nut onto the motor shaft loosely.
Hold the motor shaft (ZC) flat with a wrench to keep
it from turning. Use an adjustable wrench to torque
the coupling nut to 196–210 N•m (145–155 ft-lb).
5. Torque the packing nut (2) to 136–149 N•m (100–
110 ft-lb).
6. Reconnect all hoses. Reconnect the ground wire if it
was disconnected.
7. Fill the wet-cup (2) 1/3 full of TSL or compatible
solvent. See Packing Nut/Wet Cup, page 8.
8. Turn on the air supply. Run the pump slowly to
ensure proper operation.
9. Follow the Pressure Relief Procedure, page 8.
10. Torque the packing nut (2) to 136–149 N•m (100–
110 ft-lb).
Be sure to use at least two people when lifting,
moving, or connecting the pump. This pump is too
heavy for one person. If you are connecting the
displacement pump to a motor which is still mounted
(for example, on a ram), be sure to support the
displacement pump while it is being connected, 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
connects it.
FIG. 4
03821
ZB
101
ZC
105
104
109
106
103
102
2
1
ZA
Torque to 81–89 N•m
(60–66 ft-lb).
1
Torque to 196–210
N•m (145–155 ft-lb).
Torque to 136–149
N•m (100–110 ft-lb).
Square hole is for use
with torque wrench.
2
4
3
1
1
2
3
4

Repair
308352E 15
Disassemble the Displacement
Pump
When disassembling the pump, lay out removed parts in
sequence to ease reassembly. Clean all parts with a
compatible solvent and inspect them for wear or
damage. Refer to FIG. 7, page 16, for a cutaway view of
the pump.
NOTE: Repair Kit 222866 is available to replace the
packings and seals. Parts included are denoted with an
asterisk (*). For the best results, use all the new parts in
the kit. See Parts, page 22.
1. Follow the Disconnect the Displacement Pump
procedure, page 13.
2. Place the pump in a vise, with the outlet housing (9)
positioned as shown in FIG. 6.
3. Hold the flats of the priming piston rod (18) with an
adjustable wrench. 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.
4. Loosen the packing nut (2) using the wrench (109)
supplied.
5. Use a pipe wrench to unscrew the hex (19)of the
intake cylinder from the intake valve housing (17).
NOTE: The pump may separate at joints A, B, or C. See
FIG. 6.
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 7.
6. Unscrew the intake valve housing (17) from the
cylinder (10). Pull the housing off the pump.
NOTE: The intake check valve assembly (ZE) 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.
FIG. 5 Intake Valve Detail
17
ZD
37
38
18
16
ZG
15
39
ZE
FIG. 6
03829
22
21
18
19
Joint A
17
Joint B
10
Joint C
9
2
1

Repair
16 308352E
7. Pull the intake seat (37) and seal (38) out the
bottom of the intake valve housing (17). Refer to
FIG. 5, page 15.
NOTE: Do not drop the check valve assembly (ZE) as it
comes free. Set the check valve aside for later.
NOTE: If the seat (37) is difficult to remove, insert a
hammer and brass rod through the top of the housing
(17) and drive the seat out.
8. Use a rubber mallet to drive the displacement rod
(1) and the priming piston rod (18) out of the outlet
housing (9) and cylinder (10). Inspect the outer
surfaces of the rods for damage by running a finger
over the surface.
9. Unscrew the packing nut (2). Unscrew the packing
housing (3) and remove the seal (42). Remove the
throat glands and packings (ZF).
10. Remove the seal (8) from the bottom of the cylinder
(10). Shine a light into the cylinder to examine the
inside surface for scoring or damage. Refer to FIG.
10, page 17.
11. If the cylinder is damaged, or there is evidence
of leaking around the top cylinder seal (8):
unscrew the cylinder from the outlet housing with a
pipe wrench. Remove the top cylinder seal.
12. Place the flats of the displacement rod (1) in a vise.
Unscrew the piston (12) from the displacement rod.
The priming piston rod (18) will release as well.
Slide the piston guide (11) and seat (14) off the
piston (12). Refer to FIG. 10, page 17.
NOTE: It is not necessary to remove the priming piston
rod (18) from the piston (12) unless your inspection
reveals damage to either part.
FIG. 7
03819
2
3
See FIG. 10,
page 17
9
1
See FIG. 5,
page 15
8
18
19
17
8
10
8
20
29
21
22
FIG. 8 Throat Packing Detail
03819
ZF
42*
3
2

Repair
308352E 17
13. If the priming piston rod (18) or piston (12) are
damaged: Place the piston flats in a vise. Unscrew
the priming piston rod (18).
14. Place the piston guide (11) in a vise, as shown in
FIG. 9. Use an adjustable wrench to unscrew the
piston seat (14) from the guide. Remove the seal
(13).
NOTE: Always replace the seal with a new one.
15. Inspect the mating surfaces (ZH) of the piston (12)
and piston seat (14) for damage or wear.
16. Disassemble the intake check valve assembly (ZE).
a. Place the intake valve body (16) in a vise.
Unscrew the packing nut (15).
b. Remove the seal (39) from the packing nut.
Remove the glands and packings (ZG) from the
valve body.
17. Inspect the mating surfaces (ZD) of the intake valve
body (16) and seat (37) for damage or wear. See
FIG. 5, page 15, and FIG. 11, page 18.
NOTE: The seal (39) is press-fit in the nut (15) and may
require cutting to ease removal.
18. Unscrew the bleeder valve plug (20) completely
from the valve body (29). Clean the valve threads
and the bleed hole.
NOTE: It is not necessary to remove the valve body
from the pump outlet housing (9).
19. Inspect all parts for damage. Clean all parts and
threads with a compatible solvent.
20. Follow the Assemble the Displacement Pump
procedure, page 18.
FIG. 9
03832
14
11
When reassembling items 11 and
14, torque to approx. 75–88 N•m
(55–65 ft-lb).
1
FIG. 10 Piston Check Valve Detail
03819
1
11
12
ZH
*8
18
17
14
13*
10
Piston check valve (see Fig. 10).
1
Intake check valve (see Fig. 11).
Lubricate.
2
3
3
1
2
3

Repair
18 308352E
Assemble the Displacement
Pump
1. Lubricate the intake packings and install them in the
valve body (16), with the lips of the v-packings
facing up, in the following order (see FIG. 11):
- the female gland (25*)
- one PTFE packing (24*)
- one UHMWPE packing (26*)
- one PTFE (24*)
- one UHMWPE (26*)
- the male gland (23*)
2. With the beveled side facing up, press the intake
valve seal (39*) into the recess of the intake valve
packing nut (15) until it snaps into place.
NOTE: The nose of the seal should be flush with or
slightly recessed into the face of the packing nut.
3. Place the flats of the valve body (16) in a vise.
Screw the packing nut into the valve body handtight.
Set the intake housing assembly aside.
4. Lubricate the piston seal (13*) and install it on the
piston seat (14). Screw the piston guide (11) onto
the seat (14).
5. Place the guide in a vise as shown in FIG. 9, page
17, and torque the seat to 75–88 N•m (55–65 ft-lb).
6. If the priming piston rod (18) was removed from
the piston (12):
a. Place the flats of the piston in a vise.
b. Use an adjustable wrench on the flats of the rod
to screw the rod into the piston. Torque the rod
to 125–137 N•m (92–101 ft-lb).
NOTE: Be careful not to create burrs on the flats of the
rod.
7. Place the piston seat/guide assembly onto the
piston (12) so the 45° beveled seating surfaces
match.
8. Screw the displacement rod (1) into the piston (12)
hand tight.
9. Torque the displacement rod (1) to 339–359 N•m
(250–265 ft-lb).
10. If the cylinder (10) was removed from the outlet
housing (9):
a. Lubricate the seal (8*) and place it on the top of
the cylinder.
NOTE: The cylinder is symmetrical, so either end can
be the top.
b. Screw the cylinder into the outlet housing. See
FIG. 13, page 20.
11. Lubricate the seal (42*) and install it in the groove
on the bottom of the packing housing (3).
12. Screw the packing housing (3) into the outlet
housing (9). Torque the packing housing to 203–
237 N•m(150–175 ft-lb). See the Detail in FIG. 13,
page 20.
FIG. 11
04225
Lubricate.
1
Lips of v-packings must face up.
2
39*
15
23*
24*
25*
16
26*
21
21

Repair
308352E 19
13. Lubricate and install the throat packings and glands
in the packing housing (3) one at a time, with the
lips of the v-packings facing down, in the following
order. Refer to FIG. 13, page 20:
- the male gland (7*)
- one UHMWPE v-packing (6*)
- one PTFE v-packing (4*)
- UHMWPE (6*)
- PTFE (4*)
- UHMWPE (6*)
- the female gland (5*)
14. Loosely install the packing nut (2).
15. Lubricate the displacement rod (1). Slide the rod,
piston assembly, and priming piston rod (18) into
the cylinder (10) from the bottom, until the top of the
rod (1) protrudes from the packing nut (2).
16. Lubricate the seal (8*) and install on the bottom of
the cylinder (10). Slide the intake valve housing (17)
onto the priming piston rod (18). Ensure that the
smooth surface of the valve stop (VS) is facing
down toward the pump intake.
17. Screw the housing onto the cylinder. See FIG. 13,
page 20.
18. Lubricate the priming piston rod (18), then slide the
assembled intake valve (ZE) onto the rod, making
certain that the packing nut (15) goes on the rod
first.
19. Push the valve assembly up the rod, stopping
before it reaches the intake valve housing (17). See
FIG. 12 page 19.
20. Hold the valve body (16) steady with a wrench. Use
an adjustable wrench to torque the packing nut (15)
to 97–106 N•m (71–78 ft-lb).
21. Use a rubber mallet on the priming piston rod (18),
to drive the valve assembly up to the stop (VS).
22. The intake seat (37) is reversible. Inspect both sides
of the seat and install it with the best side facing into
the housing (17). Push it into the housing until it
seats securely.
23. Lubricate the seal (38*) and install in the bevel
around the bottom of the seat. Refer to FIG. 13,
page 20.
FIG. 12
03830
16
15
17
10
2
1
18
ZE
Hold valve body (16) steady. Torque packing
nut (15) to 97–106 N•m (71–78 ft-lb).
1
1

Repair
20 308352E
FIG. 13
03819
9
1
*8
VS
18
21
22
19
38
9
17
10
8*
42*
20
29
1
2
3
37
5*
6* 4*
7*
Piston check valve (see Fig. 10).
1
Intake check valve (see Fig. 11).
Lubricate.
Lips of v-packings must face down.
Screw valve plug (20) completely into
valve body (29).
Torque to 136–149 N•m (100–110 ft-lb).
Torque to 203–237 N•m (150–175 ft-lb).
Torque to 522–542 N•m (385–400 ft-lb).
Torque to 125–137 N•m (92–101 ft-lb).
Torque to 75–88 N•m (55–65 ft-lb).
1
2
10
9
8
7
6
5
4
3
6
7
3
5
3
3
8
10
9
2
3
4