Graco Check-Mate P20LCM User manual

Instructions - Parts
Check-Mate®Pump
Packages
For use with non-heated bulk supply of medium to high viscosity sealant and adhesive
materials. For professional use only.
Not approved for use in European explosive atmosphere locations.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
WLD
ti10420a
P40RCM Model Shown
See page 3 for model information. See page 32
for maximum working pressure and approvals.
P42LCS Model Shown
P20LCM Model Shown
r_p20lcs_312376_1e
312376N
EN

Related Manuals
2312376N
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component Identification, Supply Unit Installation 6
Component Identification, Typical Installation . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System Accessories . . . . . . . . . . . . . . . . . . . . . 10
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 12
Prime/Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Start Up and Adjust Pump . . . . . . . . . . . . . . . . . . 13
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Overnight Shutdown . . . . . . . . . . . . . . . . . . . . . 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disconnect Displacement Pump . . . . . . . . . . . . 18
Reconnect Displacement Pump . . . . . . . . . . . . 20
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pump Packages with L060xx Displacement Pumps
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pump Packages with L100xx Displacement Pumps
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Pump Packages with L200xx Displacement Pumps
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Pump Packages with L250xx Displacement Pumps
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Pump Packages with L500xx Displacement Pumps
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . 33
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 40
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 40
Related Manuals
Component Manuals in U.S. English
:
Manual Description
312375 Check-Mate®Displacement Pump
Instructions-Parts
312889 60 cc Check-Mate Displacement
Pump Repair Parts Manual
312467 100 cc Check-Mate Displacement
Pump Repair Parts Manual
312468 200 cc Check-Mate Displacement
Pump Repair Parts Manual
312469 250 cc Check-Mate Displacement
Pump Repair Parts Manual
312470 500 cc Check-Mate Displacement
Pump Repair Parts Manual
311238 2200-6500 NXT Air Motor Instruc
tions-Parts
312796 200-1800 NXT Air Motor Instruc
tions-Parts
334644 Xtreme®XL Air Motor Instruc
tions-Parts
313526 Supply Units Operation
313527 Supply Units Repair-Parts
313528 Tandem Supply Units Operation
313529 Tandem Supply Units Repair-Parts

Models
312376N 3
Models
Check your pump package’s identification (ID) plate (located on side of air
motor) for the 6-digit part number of your pump package. Use the following
matrix to define the construction of your pump package, based on the six dig
its. For example, pump package P29RSM represents the pump package (P); a
pressure ratio of 29:1 with an NXT3400 motor and a 250cc displacement pump
(29); a low noise motor with remote DataTrak (R); and a displacement pump
constructed of stainless steel (S) with MaxLife®coatings, packings, and
enclosed wet cup (M).
To order replacement parts, see Parts section starting on page 22. The digits in the matrix do not correspond to the
Ref. Nos. in the Parts drawings and lists.
Some configurations in the following matrix cannot be built.
See the Product Selection Guide for available systems.
PART NO. SERIAL SERIES
Artwork 293287
MAX AIR WPR RATIOMAX FLUID WPR
MPa
bar
PSI
MPa
bar
PSI
GRACO INC.
MPLS, MN
ID plate located on side of
air motor.
P29 R SM
First
Digit Second and Third Digits Fourth Digit Fifth Digit Sixth Digit
Pressure
Ratio
(xx:1) Motor
Displacement
PumpVolume
(cc) Motor / Remote DataTrak Displacement Pump Material
Coatings,
Packings,
Enclosed Wet
Cup
P
(pump)
05 NXT200 60 L Low Noise; NO Data
Trak C Carbon Steel S Severe Duty®
11 NXT400 60 R Low Noise;
Remote DataTrak S Stainless Steel M MaxLife®
14 NXT3400 500 M Low Noise; Data Trak
20 NXT700 60 S Low Noise, High Level
Sensor
23 NXT2200 200 D De-Icing; NO Data Trak
26 NXT6500 500 E De-Icing; Data Trak
29 NXT3400 250
36 NXT3400 200
38 NXT1200 60
40 NXT2200 100
42 Xtreme XL 500
55 NXT6500 250
61 NXT1800 60
63 NXT3400 100
68 NXT6500 200
85 Xtreme XL 250

Warnings
4312376N
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama
tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from gun, 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.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. 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 arc).
• 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.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.

Warnings
312376N 5
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 Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu
facturer’s replacement parts only.
• Do not alter or modify equipment.
• 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.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on sprayer and extension cords.
• Do not expose to rain. Store indoors.
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 MSDS’s 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.
• Always wear impervious gloves when spraying or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
• Gloves
• Hearing protection
WARNING

Component Identification, Supply Unit Installation
6312376N
Component Identification, Supply Unit Installation
Key:
ARamAssembly
B Air Motor
C Check-Mate Displacement Pump
DPlaten
E Remote DataTrak (single systems) or Display Module
(tandem systems)
F Fluid Control Module (tandem systems only; under
shroud)
G Air Control Module
J Platen Bleed Port
K Power Supply Box
L Blowoff Air Supply Line
M Lift Rod
P Pump Bleed Valve
RWetCup
S Fluid Line (not supplied)
T Air Line (not supplied)
U Air Line Drain Valve (not supplied)
V Air Filter (not supplied)
W Air Shutoff Relief Valve (for accessories, not supplied)
X Drum Low/Empty Sensor
Y Air Motor Solenoid
FIG. 1
ti10430a
CM14BA Model Shown
W
V
U
T
L
G
F
K
E
A
M
R
J
DP
C
S
B
X
Y

Component Identification, Supply Unit Installation
312376N 7
Key:
BA Elevator Cart
BB Air Motor
BC Displacement Pump
BD Platen
BF Elevator and Pump Air Controls
J Platen Bleed Port
P Pump Bleed Valve
R Wet Cup (behind air controls)
FIG. 2
BF
BB BA
BC
BD
R
r_257032_312376_1e
CM7B1G Model Shown
P
J

Component Identification, Typical Installation
8312376N
Component Identification, Typical Installation
Key:
AA Air Motor
AB Coupling Assembly
AC Tie Rods
AE Displacement Pump
AF Fluid Outlet
AG Fluid Inlet (not shown)
AH Air Regulator
AJ Bleed Type Air Motor Valve
AK Pump Runaway Valve
P Pump Bleed Valve
RWetCup
U Air Line Drain Valve (not supplied)
V Air Filter (not supplied)
W Air Shutoff Relief Valve (for accessories, not supplied)
FIG. 3
AA
AB
AC
R
AE
AF
ti11128a
P40RCM Model Shown W
V
U
P
AH
AJ
AK

Installation
312376N 9
Installation
Grounding
The equipment must be grounded. Grounding reduces
the risk of static and electric shock by providing an
escape wire for the electrical current due to static build
up or in the event of a short circuit.
Pump: use a ground wire and clamp. Loosen the
grounding lug locknut and washer. Insert one end of a
1.5 mm2(12 ga) minimum ground wire into the slot in
lug and tighten the locknut securely. Connect the other
end of the wire to a true earth ground. Order Part
237569 Ground Wire and Clamp.
Air and fluid hoses: use only electrically conductive
hoses.
Air compressor: follow manufacturer's recommenda
tions.
Spray gun/dispense valve: ground through connection
to a properly grounded fluid hose and pump.
Fluid supply container: follow your local code.
Object being sprayed: follow your 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 sur
face, such as paper or cardboard, which interrupts
grounding continuity.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the spray
gun/dispense valve firmly to the side of a grounded
metal pail, then trigger the gun/valve.
FIG. 4
ti8250a

Installation
10 312376N
System Accessories
Be sure all air lines (T) and fluid lines (S) 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 package to suit the type of installation
planned. Pump dimensions are shown on page 30.
Refer to Check-Mate Displacement Pump manual
312375 for mounting hole layout.
Air Line Accessories
Install the following accessories as listed. Refer to FIG. 1
to see air line accessories represented in a typical sup
ply unit installation.
•Main air shutoff valve (W) isolates the air line
accessories for servicing. Locate upstream from all
other air line accessories.
•Air line filter (V) removes harmful dirt and moisture
from the compressed air supply. Also, install a drain
valve at the bottom of each air line drop, to drain off
moisture.
•Air regulator (G and AH) 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.
•Air motor valve (AJ) is required in your system to
shut off the air supply to the pump (see WARNING).
When closed, the valve will bleed off all air in the
pump. Be sure the valve is easily accessible from
the pump.
•Pump runaway valve (AK) 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.
•Pump bleed valve (P) is required in your system to
relieve fluid pressure in hose and gun (see WARN
ING).
Fluid Line Accessories
Install the following accessories as listed. Refer to FIG. 2
to see fluid line accessories represented in a typical
supply unit installation.
• Install a fluid shutoff valve at each gun/valve drop,
to isolate the gun/valve and fluid accessories for
servicing.
• Install a fluid drain valve near the pump fluidoutlet,
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
WARNING). Drain valves at the gun/valve stations
may be mounted in the base of a fluid regulator,
using an adapter.
•Fluid regulator controls fluid pressure to the
gun/valve, and dampens pressure surges.
•Gun or dispense valve dispenses the fluid.
•Gun/valve swivel allows freer gun/valve move
ment.
A main air bleed valve and pump bleed valve (P) 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 shutoff valve shuts off the air to the pump
and ram. The air motor valve relieves air trapped
between this valve and the pump after the air is shut
off. Trapped air can cause the pump to cycle unexpect
edly. Locate the valve close to the pump.
The pump bleed valve assists in relieving fluid pres
sure in the displacement pump, hose, and gun/valve.
Triggering the gun/valve to relieve pressure may not be
sufficient.
If using Check-Mate pump with Graco Supply Sys
tems, refer to Supply Systems Operation manual
for system accessory installation instructions.
For use with all other systems, use this section for
accessory installation instructions.

Setup
312376N 11
Setup
Wet Cup
Before starting, fill the wet cup (R) 1/3 full with Graco
Throat Seal Liquid (TSL) or compatible solvent.
Torque Wet Cup
The wet cup is torqued at the factory; however, throat
packing seals on Severe Duty pumps may relax over
time. Check wet cup torque frequently after initial
start-up and periodically after the first week of produc
tion. Maintaining proper wet cup torque is important to
extending seal life.
To torque the wet cup, use the following steps.
1. Follow Pressure Relief Procedure on page 12.
2. Use the packing nut wrench (supplied) to torque the
wet cup; see the following table for torque values.
Do this whenever necessary. Do not overtighten the
wet cup.
The enclosed wet cup has a fill port in the cover.
MaxLife pumps use a special u-cup throat seal that
is non-adjustable and does not require periodic
torquing.
Displacement Pump Torque
100cc, 60cc 28-44 ft-lbs (38-59 N•m)
200c, 250cc, 500cc 95-115 ft-lbs (128-155 N•m)
FIG. 5
R
ti10514a

Pressure Relief Procedure
12 312376N
Pressure Relief Procedure
1. Lock the gun/valve trigger.
2. For D200s, D200, D60 and S20 Air Controls: See
FIG. 6.
a. Close the air motor slider valve and the main air
slider valve.
b. Set the ram director valve to DOWN. The ram
will slowly drop.
c. Jog the director valve up and down to bleed air
from ram cylinders.
3. For L20c Air Controls: See FIG. 7.
a. Close the air motor valve and the elevator direc
tor valve. The ram will slowly drop.
4. Unlock the gun/valve trigger.
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.
7. Open the fluid line drain valve and the pump bleed
valve (P). Have a container ready to catch the drain
age.
8. Leave the pump bleed valve open until ready to
spray again.
If you suspect that the spray tip/nozzle or hose is com
pletely 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.
FIG. 6: Air Control Module
Main Air Valve
Ram Director
Valve
ti10438a
Air Motor Valve
FIG. 7: L20c Air Control Panel
FIG. 8
Elevator Direc
tor Valve
Air Motor Valve r_257302_312376_2e
ti10420a
P

Prime/Flush
312376N 13
Prime/Flush
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 rec
ommended flushing fluids and flushing frequency.
Always flush the pump before fluid dries on the displace
ment rod.
1. Follow Pressure Relief Procedure on page 12.
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.
Start Up and Adjust Pump
1. Supply fluid to the pump, per the requirements of
your system.
2. Be sure the pump air regulator is closed.
3. For D200s, D200, D60, and S20 Air Controls:
a. Set ram air regulator to about 50 psi (3.5 bar).
b. Set the ram director valve to down.
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.
CAUTION
Never leave water or water-based fluid in a carbon
steel pump overnight. If you are pumping a
water-based fluid, flush with water first. Then flush
with a rust inhibitor, such as mineral spirits. Relieve
pressure, but leave rust inhibitor in pump to protect
parts from corrosion.
Keep hands and fingers away from the priming piston
during operation and whenever the pump is charged
with air. The priming piston extends beyond the intake
housing to pull material into the pump and can ampu
tate 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.
FIG. 9: D200s, D200, D60, and S20 Systems
Ram Air Regulator
Ram Director Valve
ti10438a
Air Motor Regulator
Air Motor Valve

Start Up and Adjust Pump
14 312376N
4. For L20c Air Controls:
a. Close elevator director valve. The ram will
slowly drop.
b. If necessary, press blowoff push button to
pause elevator descent.
5. Reduce the air motor regulator pressure and open
the air motor valve.
6. Adjust air motor regulator until the pump starts.
7. Cycle the pump slowly until all air is pushed out and
the pump and hoses are fully primed.
8. Release the gun/valve trigger and lock the trigger
safety. The pump should stall against pressure.
9. If the pump fails to prime properly, open the pump
bleed valve (P) slightly. Use the bleed hole, on the
underside of the valve, as a priming valve until the
fluid appears at the hole. Close the plug.
10. 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 gun/valve.
In a circulating system, the pump will speed up or
slow down on demand, until the air supply is shut
off.
11. Use the air motor regulator (see FIG. 10) 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/noz
zle and pump wear.
FIG. 10: L20c Air Controls
To reduce the risk of fluid injection, do not use your
hand or fingers to cover the bleed hole on the under
side of the bleed valve body (P) when priming the
pump. Use the handle or a crescent wrench to open
and close the bleed plug. Keep your hands away from
the bleed hole.
Always use lowest possible fluid pressure to bleed
air out of pump.
Air Motor Regulator
Elevator Direc
tor Valve
Air Motor Valve r_257302_312376_2e
Blowoff Push Button
FIG. 11
When changing fluid containers with the hose and
gun/valve already primed, open the pump bleed
valve (P), to help prime the pump and vent air
before it enters the hose. Close the valve when all
air is eliminated.
CAUTION
Do not allow the pump to run dry. It will quickly accel
erate 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.
ti10420a
P

Shutdown
312376N 15
Shutdown
Overnight Shutdown
1. Stop the pump at the bottom of the stroke to prevent
fluid from drying on the exposed displacement rod
and damaging the throat packings.
2. For D200s, D200, D60, and S20 Supply Systems:
Set the ram director valve to the neutral position.
3. For L20c Supply Systems: Set the elevator direc
tor valve to DOWN.
4. Follow Pressure Relief Procedure, page 12.
5. Always flush the pump before the fluid dries on the
displacement rod. See Prime/Flush on page 13.
CAUTION
Never leave water or water-based fluid in a carbon
steel pump overnight. If you are pumping
water-based fluid, flush with water first, then with a
rust inhibitor, such as mineral spirits. Relieve pres
sure, but leave rust inhibitor in pump to protect parts
from corrosion. FIG. 12: D200s, D200, D60, and S20 Air Controls
FIG. 13: L20c Air Controls
Ram Director Valve
ti10438a
Elevator Director
Valve
r_257302_312376_2e

Troubleshooting
16 312376N
Troubleshooting
1. Follow Pressure Relief Procedure, page 12. 2. Check all possible problems and causes before dis
assembling pump.
Problem Cause Solution
Pump fails to operate. Restricted line or inadequate air supply;
closed or clogged valves. Clear; increase air supply. Ensure that all valves are open.
Obstructed fluid hose or gun/valve;
fluid hose ID is too small. Open, clear*; use a hose with a larger ID.
Fluid dried on displacement rod. Clean. Always stop pump at bottom of
stroke. Keep enclosed wet cup 1/3 filled
with a compatible solvent.
Dirty, worn, or damaged motor parts. Clean or repair; see separate motor man
ual.
Runaway occurred. See runaway section of Supply Units Oper
ation manual 313526.
Pump operates but output is
low on both strokes. Restricted line or inadequate air supply; closed or clogged valves. Clear; increase air supply. Ensure all valves are open.
Increase air pressure to ram for better load
ing.
Obstructed fluid hose or gun/valve;
fluid hose ID is too small. Open, clear*; use a hose with a larger ID.
Bleed-type air valve is partially open. Close bleed-type air valve.
Air is leaking into supply container. Check ram plate seal.
Fluid is too heavy for pump priming. Use drain/purge valve. Use a ram. See
Supply Units Operation manual 313526.
Held open or worn intake valve or
seals. Clear valve; replace seals. See separate Check-Mate Displacement Pump manual
312375.
Worn packings in displacement pump. Replace packings. See separate
Check-Mate Displacement Pump manual
312375.
Pump operates, but output is
low on downstroke. Fluid is too heavy for pump priming. Use drain/purge valve. Use a ram. See Supply Units Operation manual 313526.
Held open or worn intake valve or
seals. Clear valve. Replace seals. See separate Check-Mate Displacement Pump manual
312375.
Pump operates, but output is
low on upstroke. Held open or worn intake valve or seals. Clear valve. Replace seals. See separate Check-Mate Displacement Pump manual
312375.

Troubleshooting
312376N 17
* To determine if fluid hose or gun is obstructed, follow Pressure Relief Procedure, page 12. Disconnect fluid
hose and place a container at pump fluid outlet to catch any fluid. Turn on air just enough to start pump. If pump
starts when air is turned on, the obstruction is in the fluid hose or gun.
Erratic or accelerated pump
speed. Exhausted fluid supply. Refill and prime.
Fluid is too heavy for pump priming. Use drain/purge valve. Use a ram. See
Supply Units Operation manual 313526.
Increase ram air pressure.
Held open or worn intake valve or
seals. Clear valve. Replace seals. See separate Check-Mate Displacement Pump manual
312375.
Held open or worn priming piston. Clear; service. See separate Check-Mate
Displacement Pump manual 312375.
Worn packings in displacement pump. Replace packings.See separate
Check-Mate Displacement Pump manual
312375.
Problem Cause Solution

Repair
18 312376N
Repair
Required Tools
• Torque wrench
•Hammer
• Packing nut wrench (suppliedwith displacement
pump)
• Set of socket wrenches
• Set of adjustable wrenches
•Loctite
®2760™or equivalent
• Brass rod (pumps with 500cc displacement
pumps only)
• Torque wrench with claw foot (pumps with 60cc
and 500cc displacement pumps only)
Disconnect Displacement Pump
1. Flush pump; see Prime/Flush, page 13. Stop pump
at bottom of its stroke. Follow Pressure Relief Pro
cedure, page 12.
2. Disconnect air hose.
3. Disconnect fluid hose. Hold fluid outlet fitting with a
wrench to keep it from being loosened while you
disconnect fluid hose.
4. Remove platen from displacement pump. Refer to
Supply Units Repair-Parts manual 313527 for
instructions.
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 down
stroke 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 prim
ing piston can severely injure or amputate a hand or
finger, or break a tool, caughtbetween it and the intake
housing. Always relieve the pressure before checking,
clearing, cleaning, flushing, or servicing any part of the
pump.
On Xtreme XL air-powered pumps, the rocker arms
(located beneath the rocker arm covers) move when
air is supplied to the motor. Never operate the pump
with the rocker arm covers removed.
If your system includes a remote DataTrak, discon
nect the air motor harness from the motor as well.
FIG. 14
FIG. 15
Air Hose
Air Motor
ti10515a
Harness
Fluid Hose
ti10516a

Repair
312376N 19
5. If the air motor does not require servicing, leave it
attached to its mounting. However, if the air motor
does need to be removed, refer to the Supply Units
Repair-Parts manual 313527 for instructions.
6. Pumps with 100cc, 200cc, and 250cc displacement
pumps only: Remove clip (9), and slide coupling
cover (8) up to remove coupling (7).
7. Pumps with 500cc displacement pumps only: Use a
hammer and brass rod to loosen coupling nut (8).
When coupling nut drops down remove coupling
collars (7) and coupling nut from displacement rod.
8. Pumps with 60cc displacement pumps only: Use
two wrenches to loosen coupling nut (8). When cou
pling nut drops down remove coupling collars (7)
and coupling nut from displacement rod.
9. Use a wrench to hold the tie rod flats to keep the
rods from turning. Unscrew the nuts (5) from the tie
rods (3) and carefully remove the displacement
pump (2).
10. Refer to the Check-Mate Displacement Pump man
ual 312375 to service the displacement pump. To
service the air or hydraulic motor, refer to the sepa
rate motor manual, supplied.
CAUTION
Be sure to use at least two people when lifting, mov
ing, or disconnecting the pump. This pump is too
heavy for one person. If you are disconnecting the
displacement pump from a motor that is still mounted
(for example, on a ram), be sure to support the dis
placement pump while it is being disconnected, to
prevent it from falling and causing injury or property
damage. Do this by securely bracing the displace
ment pump, or by having at least two people hold it
while another disconnects it.
FIG. 16
FIG. 17
ti10508a
ti10717a
FIG. 18
ti10510a

Repair
20 312376N
Reconnect Displacement Pump
1. If the air motor was removed, refer to the Supply
Units Repair-Parts manual for installation instruc
tions.
2. Use caution when reconnecting displacement
pump. Place displacement pump (2) on tie rods (3).
3. Screw nuts (5) onto tie rods (3) and torque to 50-60
ft-lb (68-81 N•m).
4. Pumps with 100cc, 200cc, and 250cc displacement
pumps only: Install coupling (7), and slide coupling
cover (8) down. Install clip (9).
5. Pumps with 60cc and 500cc displacement pumps
only: Reinstall coupling nut and coupling covers on
displacement rod. Slide coupling nut up and tighten
using a torque wrench with a claw foot; see the fol
lowing table for torque values.
6. Reconnect all hoses. Reconnect ground wire and
reed switch cable (units with remote DataTrak) if
they were disconnected. Fill wet cup (R) 1/3 full of
Graco Throat Seal Liquid or a compatible solvent.
7. Attach platen to displacement pump. Refer to the
Supply Units Repair-Parts manual for instructions
8. Turn on the air power supply. Run the pump slowly
to ensure that it is operating properly.
9. Allow 2 hours for the thread sealant to cure before
returning the pump to service.
CAUTION
Be sure to use at least two people when lifting, mov
ing, or connecting the pump. This pump is too heavy
for one person. If you are connecting the displace
ment pump to a motor that is still mounted (for exam
ple, 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 displacement pump, or by
having at least two people hold it while another con
nects it.
On Xtreme XL models, ensure that the rod adapter
(6) has not loosened during maintenance. Proper
torque is necessary to prevent the rod adapter from
loosening during the pump operation.
If the rod adapter (6) has loosened during mainte
nance, remove the adapter and apply Loctite 2760
(or equivalent) to the rod adapter and air motor pis
ton threads, and then torque to 230-250 ft-lbs
(312-340 N•m).
FIG. 19
ti10511a
FIG. 20
Displacement
Pump Torque
60cc 75-80 ft-lbs (102-108 N•m)
500cc 230-250 ft-lbs (312-340 N•m)
FIG. 21
ti10509a
ti10718a