Graco HIGH-FLO 243737 User manual

Instructions
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 2000, Graco Inc. is registered to I.S. EN ISO 9001
HIGH–FLOrPumps
Designed for low pressure, high volume circulation of finishing
materials. Do not use for flushing or purging lines with caustics,
acids, abrasive line strippers, or other similar fluids.
309136N
01405
Stainless Steel Model Shown,
Mounted on Accessory Stand 218742
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for table of contents and page 4 for
pump part nos., ratios, and working pressures.

2 309136
Table of Contents
Symbols 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Models 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Parts 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Parts 27. . . . . . . . . . . . . . . . . . . . . .
Repair and Conversion Kits 30. . . . . . . . . . . . . . . . . . . . .
Technical Data 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Stand Hole Layout 38. . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 40. . . . . . . . . . . . . . . . . . . . . .
Graco Information 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure stated on the equipment or in the Technical Data
section 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.

309136 3
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and re-
sult 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 be-
ing 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.
MOVING PARTS HAZARD
Moving parts, such as the air motor 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 13 to prevent the
equipment from starting unexpectedly.

4 309136
High–FloRPump Models
CARBON STEEL MODELS WITH NPT THREADS
Maximum Air
(or Hydraulic*)
Working Pressure Maximum Fluid Working Pressure
Pump
Part No. Series Ratio and Type (parts list page) Displacement Pump, Series
(parts list page) MPa, bar (psi) MPa, bar (psi)
243737 B3:1 Bulldog (27) 243731, Series D
(27) 0.7, 7.0 (100) 2.1, 21 (300)
243738 C6:1 King (27) 243731, Series D
(27) 0.7, 7, (100) 4.1, 41 (600)
243739 C4:1 King (27) 243732, Series D
(27) 0.7, 7, (100) 2.8, 28 (400)
243740 BViscount II 600 (27) 243731, Series D
(27) 10.3*, 103* (1500*) 4.1, 41 (600)
243741 BViscount II 400 (27) 243732, Series D
(27) 10.3*, 103* (1500*) 2.8, 28 (400)
243742 BViscount II 300 (27) 243733, Series D
(27) 10.3*, 103* (1500*) 2.1, 21 (300)
SEVERE-DUTY ELECTROPOLISHED STAINLESS STEEL MODELS WITH NPT THREADS
Maximum Air
(or Hydraulic*)
Working Pressure Maximum Fluid Working Pressure
Pump
Part No. Series Ratio and Type
(parts list page) Displacement Pump, Series
(parts list page) MPa, bar (psi) MPa, bar (psi)
243743 B3:1 Bulldog (27) 243771, Series D
(27)
0.7, 7.0 (100) 2.1, 21 (300)
243745 C6:1 King (27) 243771, Series D
(27)
0.7, 7, (100) 4.1, 41 (600)
243747 C4:1 King (27) 243772, Series D
(27)
0.7, 7, (100) 2.8, 28 (400)
243749 C3:1 King (27) 243773, Series D
(27)
0.7, 7, (100) 2.1, 21 (300)
243751 BViscount II 600
(27) 243771, Series D
(27)
10.3*, 103* (1500*) 4.1, 41 (600)
243753 BViscount II 400
(27) 243772, Series D
(27)
10.3*, 103* (1500*) 2.8, 28 (400)
243755 BViscount II 300
(27) 243773, Series D
(27)
10.3*, 103* (1500*) 2.1, 21 (300)

309136 5
SEVERE-DUTY ELECTROPOLISHED STAINLESS STEEL MODELS WITH BSPP THREADS
Displacement
Maximum Air
(or Hydraulic*)
Working Pressure
Maximum Fluid
Working Pressure
Pump
Part No. Series
Ratio and Type
(parts list page)
Displacement
Pump, Series
(parts list page) MPa, bar (psi) MPa, bar (psi)
243744 B3:1 Bulldog (27) 243734, Series D
(27) 0.7, 7 (100) 2.1, 21 (300)
243746 C6:1 King (27) 243734, Series D
(27) 0.7, 7 (100) 4.1, 41 (600)
243748 C4:1 King (27) 243735, Series D
(27) 0.7, 7 (100) 2.8, 28 (400)
243750 C3:1 King (27) 243736, Series D
(27) 0.7, 7 (100) 2.1, 21 (300)
243752 B600 Viscount II (27) 243734, Series D
(27) 10, 103 (1500) 4.1, 41 (600)
243754 B400 Viscount II (27) 243735, Series D
(27) 10, 103 (1500) 2.8, 28 (400)
243756 B300 Viscount II (27) 243736, Series D
(27) 10, 103 (1500) 2.1, 21 (300)
SEVERE-DUTY CHROME STAINLESS STEEL MODELS WITH NPT THREADS
Displacement
Maximum Air
(or Hydraulic*)
Working Pressure
Maximum Fluid
Working Pressure
Pump
Part No. Series
Ratio and Type
(parts list page)
Displacement
Pump, Series
(parts list page) MPa, bar (psi) MPa, bar (psi)
248343 A400 Viscount II (27) 248333, Series B
(27) 10, 103 (1500) 2.8, 28 (400)
248345 A300 Viscount II (27) 248334, Series B
(27) 10, 103 (1500) 2.1, 21 (300)
SEVERE-DUTY CHROME STAINLESS STEEL MODELS WITH BSPP THREADS
Di l t
Maximum Air
(or Hydraulic*)
Working Pressure
Maximum Fluid
Working Pressure
Pump
Part No. Series
Ratio and Type
(parts list page)
Displacement
Pump, Series
(parts list page) MPa, bar (psi) MPa, bar (psi)
248344 A400 Viscount II (27) 248330, Series B
(27) 10, 103 (1500) 2.8, 28 (400)
248346 A300 Viscount II (27) 248331, Series B
(27) 10, 103 (1500) 2.1, 21 (300)

6 309136
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 3.
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 mm@(12
ga) minimum ground wire (Y) into the slot in lug (Z)
and tighten the locknut securely. Connect the other
end of the wire to a true earth ground. Order Part
No. 237569 Ground Wire and Clamp.
Fig. 1 TI1052
Y
Z
Fig. 2
W
X
Y
Z
0864
2. Air and fluid hoses: use only electrically conductive
hoses.
3. Air compressor or hydraulic power supply: follow
manufacturer’s recommendations.
4. Surge tank: use a ground wire and clamp. See Fig.
2.
5. Spray gun: ground through connection to a prop-
erly grounded fluid hose and pump.
6. Fluid supply container: follow your local code.
7. Object being sprayed: follow your local code.
8. Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place the
pail on a nonconductive surface, such as paper or
cardboard, which interrupts the grounding continu-
ity.
9. To maintain grounding continuity when flushing or
relieving pressure, hold a metal part of the spray
gun firmly to the side of a grounded metal pail,
then trigger the gun.

309136 7
Installation
Plumbing
Displacement pump models have a 2 in. npt(f) fluid
inlet and a 2 in. npt(f) fluid outlet or have a 2 in.
bspp(f) fluid inlet and a 2 in. bspp(f) fluid outlet.
Use 50 mm (2 in.) diameter pipe and plumbing. Install
a fluid shutoff valve (D) between each tank and the
pump.
When using a stainless steel pump, use stainless steel
plumbing to maintain a corrosion-resistant system.
Tri-Clamp Adapters
Tri-clamp adapters are available which allow sanitary
pipe to be connected to a pump with bspp inlet and
outlet. Refer to Fig. 3.
Install a 2 in. tri-clamp gasket (GG) in the groove of the
tri-clamp adapter (HH). Mate the tri-clamp adapter with
the sanitary pipe and secure with two clamps (JJ),
bolts (KK), and nuts (MM). Install the bolts in opposite
directions.
8689A
Fig. 3
GG*
HH JJ*
KK*
MM*
1
1
* Customer must supply.
Graco adapter 193202. Requires seal 193424.

8 309136
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. 5 and 6 are
only examples. Contact your Graco distributor for
system design assistance.
An accessory surge tank (B), Part No. 218509 (cst) or
238983 (sst) should be used to reduce fluid surging
and to prevent backflow into the pump. Install a full
flow, non-restrictive fluid shutoff valve (D) before and
after the surge tank to isolate it for servicing. The
surge tank also uses the accessory stand (218742).
WARNING
COMPONENT RUPTURE HAZARD
To reduce the risk of component rupture,
which can cause serious injury, be sure
that all accessories and system compo-
nents can withstand the pressure and flow in this
system.
Mount the Pump
Mount the pump in the accessory pump stand (A), Part
No. 218742. Secure the stand to the floor with M19
(5/8 in.) bolts which engage at least 152 mm (6 in.) into
the concrete floor to prevent the pump from tipping.
Non-Circulating Systems
In non-circulating systems with a fluid outlet that can
be closed off (causing the pump to stall), install a fluid
pressure relief valve (AA) and a return line (BB). See
Fig. 4.
WARNING
COMPONENT RUPTURE HAZARD
The pressure relief valve reduces the
risk of the pump overpressurizing if the
piston seal is worn and leaking, and the
fluid outlet is closed off. Install the valve so the ar-
row on its body matches the direction of fluid flow.
Do not install a fluid shutoff valve in the fluid line
between the pump outlet (DD) and the pump inlet
(CC). Doing so defeats the purpose of the pressure
relief valve if the shutoff valve is closed, resulting in
pump overpressurization. Overpressurization can
cause the pump or components to rupture, result-
ing in serious injury and property damage.
01407
DD C
AA
BB
ED
CC
A
ED
1
Fig. 4
1Do not install a fluid shutoff valve in the fluid line
between the pump outlet (DD) and the pump inlet (CC).
See the WARNING above.
Pressure Relief Valve
(for non-circulating systems)
KEY
A Accessory Pump Stand (P/N 218742)
C 50 mm (2 in.) Diameter Pipe
D Full Flow, Non-Restrictive Fluid Shutoff Valve
E Fluid Supply Line
AA External Pressure Relief Valve
BB Fluid Return Line
CC Pump Fluid Inlet
DD Pump Fluid Outlet

309136 9
Installation (Air-Powered Pumps)
WARNING
A bleed-type master air valve (L) is required in your
system, to help reduce the risk of serious injury
including splashing fluid in the eyes or on the skin,
and injury from moving parts if you are adjusting or
repairing the pump.
The bleed-type master air valve relieves air trapped
between this valve and the pump after the air is
shut off. Trapped air can cause the pump to cycle
unexpectedly. Locate the valve close to the pump.
CAUTION
Do not hang the air accessories directly on the
pump’s air inlet. The fittings are not strong enough to
support the accessories and may cause one or more
to break. Provide a bracket on which to mount the
accessories.
In an air-powered system, install the air line accesso-
ries in the order shown in Fig. 5. Working upstream
from the pump air inlet, install an air line lubricator (H)
for automatic air motor lubrication. Next, install a
bleed-type master air valve (L) to relieve air trapped
between the valve and the pump, and an air regulator
and gauge (J) to control pump speed.
Install a pump runaway valve (G) to shut off the air to
the pump if the pump accelerates beyond the pre-
adjusted setting. A pump which runs too fast can be
seriously damaged.
Install an air filter (K) to remove harmful dirt and mois-
ture from the compressed air supply, and a second
bleed-type master air valve to isolate the air line ac-
cessories for servicing. Last, install a drain valve (W)
at the bottom of each air line drop, to drain off mois-
ture.

10 309136
Installation (Air-Powered Pumps)
01406
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 Pump Runaway Control Valve
H Air Line Lubricator
J Air Regulator and Gauge
K Air Line Filter
L Bleed-type Master Air Valve
W Air Line Drain Valve
Y Ground Wire
F
ED
A
ED
BY
D
F
K
J
LHG
Y
C
Fig. 5
1Do not hang the air accessories directly on the
pump’s air inlet. Provide a bracket on which to
mount the accessories.
L
1
1
W

309136 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.
The motor has a 3/4 npt hydraulic oil inlet, and a 1 in.
npt hydraulic oil outlet. Use a minimum 1/2 in. ID
hydraulic supply line and a minimum 5/8 in. ID return
line.
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 309136
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
Fig. 6 01408
F
ED
A
ED
B
Y
D
F
K
J
L
HM
YC
N
GPQ

309136 13
Operation
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The system pressure must be manually relieved to
prevent the system from starting or spraying acci-
dentally. To reduce the risk of an injury from acci-
dental spray from the gun, splashing fluid, or
moving parts, follow the Pressure Relief Proce-
dure whenever you:
Dare instructed to relieve the pressure,
Dstop spraying,
Dcheck or service any of the system equipment,
Dor install or clean the spray nozzle.
1. Shut off the power to the pump.
2. In an air-powered system, close the air regulator
(J) and close the bleed-type master air valve (L).
3. In a hydraulic-powered system, close the hy-
draulic supply line shutoff valve (G) first, then the
return line shutoff valve (M).
4. Close the fluid shutoff valves from the supply
tanks.
5. Open the dispensing valve, if used, or slowly and
carefully loosen a fluid fitting near the pump to
relieve pressure.
Flush the Pump
Flush the pump before using it the first time to remove
the lightweight oil which was left in the pump after
factory testing to protect it from corrosion. Flush with a
compatible solvent until your pump and lines are
thoroughly cleaned. Follow the Pressure Relief Pro-
cedure at left and remove the spray tip before flush-
ing. Hold a metal part of the gun firmly to the side of a
grounded metal pail, and always use the lowest possi-
ble pressure when flushing.

14 309136
Operation
Starting and Adjusting the Pump
1. Fill the wet-cup/packing nut (12) one half full with
Graco Throat Seal Liquid (TSL). See Fig. 7.
2. Charge the surge tank, if you are using one. See
the separate instruction manual, 307707.
3. Open the shutoff valves between the pump and
supply tanks, and between the pump and surge
tank.
4. Open the dispensing valve(s) or spray gun(s).
5. To adjust the system, perform the following appli-
cable procedure:
In an air-powered system:
a. Open the bleed-type master air valve.
b. Adjust the air regulator to the minimum pres-
sure necessary for the pump to cycle slowly.
c. Operate the pump slowly until all air is purged
from the fluid lines.
d. Close the gun or valve.
e. Adjust the setting on the pump runaway valve,
if used.
In a hydraulic-powered system:
f. Turn on the hydraulic power supply.
g. Open the flow control valve all the way.
h. Adjust the pressure-reducing valve until you
get the desired fluid pressure. Run the pump
until all air is purged from the fluid lines.
i. Count the cycle rate of the pump.
j. Close the flow control valve until the cycle rate
and fluid pressure start to drop.
k. 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.
l. Close the gun or valve.
In a circulating system, the pump operates continu-
ously until the power supply is shut off. In a direct
supply system, the pump starts when the gun or
valve is opened, and stops when the gun or valve is
closed.
WARNING
COMPONENT RUPTURE HAZARD
To reduce the risk of serious injury, in-
cluding splashing in the eyes or on the
skin, and property damage, never ex-
ceed the maximum air/hydraulic and fluid working
pressure of the lowest rated component in your
system. See EQUIPMENT MISUSE HAZARD,
System Pressure, on page 3.

309136 15
Maintenance
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 13.
Check the tightness of the packing nut (12) weekly.
Shut off the pump and relieve pressure before check-
ing the packing nut. The nut should be tight enough to
stop leakage, about 27–34 NSm (20–25 ft-lb). Over-
tightening will compress and damage the packings and
cause the pump to leak.
CAUTION
Always flush the pump before any fluid can dry in it.
Always stop the pump at the bottom of its stroke to
prevent the fluid from drying on the piston rod and
damaging the throat packings.
Read all other instruction manuals supplied with your
pump and with all accessories you add to the system.
Monitor the fluid supply carefully. If air is sucked into
the pump due to an empty supply container, the pump
will accelerate quickly and can damage the pump
packings. If your pump begins running too fast, shut it
off immediately. Refill the supply container and prime
the pump to remove all air from the fluid line. In an
air-powered system, the accessory pump runaway
valve automatically senses when a pump is running
too fast and shuts off the air to stop the pump.
01411
12
Torque to 27–34 NSm (20–25 ft-lb).
Fig. 7
1
1

16 309136
Troubleshooting
PROBLEM CAUSE SOLUTION
Pump output low on both strokes Restricted air or hydraulic lines Clear any obstructions; be sure all
valves are open; increase pressure.
Empty fluid supply Refill and reprime pump. In an air-pow-
ered system, use pump runaway valve.
Clogged fluid outlet line, valves, etc. Clear.
Worn packings Tighten packing nut; replace all pack-
ings.
Pump output low on only one stroke Held open or worn check valve Check and repair.
Worn piston packings Replace.
No output Improperly installed ball check valves Check and correct; see page 22, start-
ing at step 24.
Pump operates erratically Exhausted fluid supply Refill and reprime pump. In an air-pow-
ered system, use pump runaway valve.
Held open or worn check valves Check and repair.
Worn piston packings Replace.
Excessive hydraulic fluid supply pres-
sure to Viscount motor See hydraulic motor manual, 308048.
Pump does not operate Restricted air or hydraulic power sup-
ply lines Clear any obstructions; be sure all shut- off valves are open; increase pressure.
Exhausted fluid supply Refill and reprime pump.
Clogged fluid outlet line, valves, etc. Clear.
Damaged air motor or hydraulic motor See motor manual.
Fluid dried on piston rod Disassemble and clean pump. Stop
pump at bottom of stroke.

309136 17
Service
To Remove the Motor (See Fig. 8)
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 13.
1. Relieve the pressure.
2. Disconnect all hoses from the pump and motor.
3. Unscrew the coupling nut (106), holding your hand
around the nut and shaft to catch the two couplers
(105) as you lower the nut (106).
4. Remove the tie rod locknuts (104) and lift the
motor off the pump.
To Reattach the Motor (See Fig. 8)
CAUTION
On stainless steel pumps, be sure to lubricate the
threads of the tie rods and apply PTFE tape to the
bottom threads of the rods before reattaching the air
motor. The bottom threads are farthest from the tie
rod flats.
1. Position the air motor on the pump. On stainless
steel pumps, lubricate and tape the tie rod threads
(see the CAUTION above). Screw the tie rod
locknuts (104) onto the tie rods (103).
2. Place the two couplers (105) in the coupling nut
(106). Screw the nut up onto the motor shaft.
Torque to 195–210 NSm (145–155 ft-lb).
CAUTION
Torque the coupling nut (106) to 195–210 NSm
(145–155 ft-lb). Do not exceed this torque specifica-
tion, to prevent damage to the piston shaft (29).
3. Reconnect all hoses. Reconnect the ground wire if
it was disconnected.
Fig. 8 01412
7, 8
4
12
105
D
104
106 1
1
1Torque to 195–210 NSm (145–155 ft-lb).
5
103
2Apply PTFE tape or auto–seize lubricant
to bottom threads .
2
29

18 309136
Service
NOTES:
1. This repair procedure can be used for any High-
Flo pump model. The reference numbers used in
the text and illustrations correspond to all of the
displacement pump parts drawings.
2. Packing repair kits are available for each pump.
Refer to the parts pages for your pump. Parts
included in the pump seal repair kit are marked
with an asterisk in the text (for example, 16*).
Parts included in the throat packing kit are marked
with a symbol (for example, 39{). Conversion kits
are also available. See page 30. Use all the new
parts in the kits for the best results.
3. This pump is easiest to repair when left in the Part
No. 218742 accessory pump stand and disas-
sembled as instructed. For repair at a remote
location, have another pump stand available.
4. When reassembling, apply anti-seize lubricant
222955 on the threads of the piston shaft (29) and
piston (23).
Displacement Pump Repair
1. Use a 13 mm socket wrench to loosen and remove
the twelve capscrews (2) and lockwashers (3) on
the outlet manifold (1). See Fig.16.
2. Lift the manifold (1) off the outlet valve housing (5)
and remove the ball guides (14), balls (13), seats
(17) and seals (15). Remove the o-ring (16) from
the seats (17).
NOTE: Seat Puller Kit 220384 is available to make
removal of the seats from the manifolds easier. See
Fig. 9.
CAUTION
Be careful not to drop or damage the balls (13) or
seats (17). A damaged ball or seat cannot seal
properly and the pump will leak. The outlet valve
seats (17) can be reversed to provide longer use of
the seat.
Fig. 9
Screw bolt (X) into Seat Puller (Y).
Seat Puller Kit 220384
KEY
S Seat (item 21 or 46)
X 108481 Bolt
Y 181630 Seat Puller
Z 181629 Seat Puller X
Y
Position Seat Puller (Y) under the seat (21
or 46) by slipping it through at an angle.
S
Y
01414
Place Seat Puller (Z) on top of seat.
Turn bolt (X) to pull the seat out.
Z
X

309136 19
Service
3. Remove the nuts (8), lockwashers (7) and six
cylinder capscrews (4). Loosen the packing nut
(12). Lift off the outlet valve housing (5). See Fig.
8.
4. Lift the riser tubes (20) and cylinder (27) off the
inlet valve housing (6). The piston assembly may
stay in the cylinder. Remove the seals (21 and 28)
from the inlet and outlet housings (5, 6).
See Fig.16.
NOTE: Tap on the valve housings with a plastic mallet
and use a slight rocking motion to help loosen and
remove the cylinder and tubes.
5. Screw out packing nut (12). Using a small, flat–
blade screwdriver, pry out male gland assembly
(32) using the groove on outer surface. Remove
remaining packings (31, 35) and glands (30, 42)
from the nut. See Fig. 10.
6. Unscrew and remove the three pump stand bolts
(D). See Fig. 8. Lift the inlet valve assembly off the
stand. Place the inlet valve housing (6) face down
on a protected surface.
Fig. 9
42
12
30†
35
5
35
31
31
34
1
Lips of v–packings face up.
2
Lips of v–packings face down.
32
1
1
2
2

20 309136
Service
7. Use a 13 mm socket wrench to loosen and remove
the twelve capscrews (2) and lockwashers (3) from
the inlet manifold (1). See Fig 16.
8. Lift the manifold (1) off the inlet valve housing (6)
and remove the seats (17 and 22). Remove the
o-ring (16) from the seats.
CAUTION
If the pressure relief valve in the inlet seat (22) is
clogged or filled with material, soak the inlet seat in a
compatible solvent. Make sure all material residue is
cleaned from the ball and seat area.
If the relief valve cannot be thoroughly cleaned so
that the ball and spring are free to move, replace the
seat (22).
9. Inspect the pressure relief valve in the fluid inlet
seat (22) to make sure it is not clogged. Press
down on the valve’s ball to see if the ball and
spring are free to move. See the detail in Fig. 16.
CAUTION
Be careful not to drop or damage the balls (13) or
seats (17 or 22). A damaged ball or seat cannot seal
properly and the pump will leak. One inlet valve seat
(17) can be reversed to provide longer use of the
seat. However, the fluid inlet seat (22) contains a
pressure relief valve and is not reversible. See the
detail in Fig. 16 for proper orientation.
10. Remove the balls (13), ball guides (14) and seals
(15) from the inlet valve housing (6).
11. Push the piston assembly through the cylinder just
enough to expose the piston (23) flats. Secure the
piston flats in a vise. Use a plastic mallet to tap the
cylinder (27) up and off the piston assembly.
NOTE: Refer to Fig. 11 for Steps 12–16.
12. Loosen the piston nut (26). Use Tool Kit 220385 to
remove the piston shaft (29) and piston nut (26).
See Fig. 12. Remove the piston nut o–ring (18)
and o–ring retainer (43) from the shaft. Remove
the plate (25) and the seal (24) from the piston
(23).
13. Inspect the piston shaft (29). If it is damaged or
the surface is scored, replace it.
14. Clean all piston parts and the cylinder thoroughly
in a compatible solvent. Inspect the inner surface
of the cylinder for scoring, and replace it if neces-
sary. A scored cylinder will quickly damage the
packings.
15. Lubricate the new piston seal (24*) and install it on
the piston.
16. Install the piston plate (25) with the beveled edge
facing away from the piston seal.
TI0219
Torque to 270–284 NSm (200–210 ft-lb).
Apply medium strength sealant to threads.
25
24*
23
29
26
Fig. 11
1
2
21
3Lubricate.
3
2
18
19
43
4Apply anti-seize lubricant 222955 to the face of pis-
ton nut (26)
4
Fig. 12 01413
Tool Kit 220385
Tighten the tool on the widest
part of the shaft (29). Grip the
tool with a wrench and
unscrew the shaft.
29