Graco LD 24U984 Setup guide

Repair Instructions
LD Grease Pump
Repair Kits 3A1495C
Instructions for repairing the LD Grease Pump.
Maximum Fluid Pressure - 7500 psi (51.7 MPa, 517 bar)
Maximum Air Pressure - 150 psi (1.03 MPa, 10.3 bar)
Repair Kits:
24H854: Throat and Piston Seal Replacement Kit
24H856: O-Ring and Seal Replacement Kit
24U984: Air Piston Replacement Kit
Important Safety Instructions
Read all warnings and instructions in this manual and
in your LD Series Oil or Grease Pump manual. Save
all instructions.
EN

Warnings
23A1495C
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 symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual, 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 dispense valve, 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 dispense valve at anyone or at any part of the body.
• Do not put your hand over the end of the dispense nozzle.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow Pressure Relief Procedure in this manual, when you stop spraying 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.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical
reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or
property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier
for compatibility.
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, hearing loss, inhalation of
toxic fumes, and burns. This 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.

Instructions
3A1495C 3
Instructions
Always use all new parts included in your kit and dis-
pose of replaced parts according to all state and local
regulations for disposal of discarded components.
Inspect all parts when disassembling the pump. Replace
any and all worn and damaged parts.
Pressure Relief Procedure
1. Close the pump’s bleed-type master air valve.
2. Close the pump air regulator and disconnect the air
supply hose.
3. Open the dispensing valve and dispense fluid into a
waste bucket/container until pressure is fully
relieved.
If you suspect that the dispensing valve is clogged, or
that pressure has not been fully relieved after following
the steps above, very slowly loosen the dispensing
valve coupler or hose end coupling to relieve pressure
gradually, then loosen completely.
Disassembly
The following disassembly instructions describe the pro-
cedure for completely disassembling the LD grease
pump. Depending on the repair/maintenance procedure
you are performing on the pump, it may not be neces-
sary to entirely disassemble the pump or perform all
steps in this procedure.
The reference numbers used in the following instruc-
tions correspond to the reference numbers used in the
LD Series Oil and Grease Pump instruction manual.
1. Stop the pump. Follow Pressure Relief Procedure,
page 3.
2. Disconnect and remove the pump from its installed
location.
3. Clamp the pump (1) upside down in a vise as shown
in Fig. 1.
NOTE: Take care to only use enough clamping
force to hold the pump in position. The pump cylin-
der is aluminum and could be damaged by using
excessive clamping force.
If you are only servicing the air valve (40) and seals
(18) or air piston (15), skip Steps 4 - 14.
The equipment stays pressurized until pressure is manually
relieved. To reduce the risk of serious injury from pressur-
ized fluid, fluid from the valve, or splashing fluid, follow the
procedure whenever you:
• are instructed to relieve pressure
• stop dispensing
• check, clean, or service any system equipment
• install or clean dispensing devices.
Fig. 1
1

Instructions
43A1495C
4. Secure a strap wrench around the shovel cylinder
(27). Use the strap wrench to turn the shovel cylin-
der counter-clockwise to loosen and remove it from
the pump assembly (Fig. 2).
NOTE: After a few turns, the shovel cylinder should
be loose enough to finish turning it with your hand to
remove this part.
5. Use an adjustable wrench to hold the priming rod
(34) securely. Use a second adjustable wrench to
loosen and remove the nut (19) and priming piston
(35) (Fig. 3, Fig. 4).
6. Use a wrench to loosen and remove the seal
retainer (29) (Fig. 4).
7. Tighten a strap wrench on the spacer cylinder (36)
and use it to prevent this part from moving. Secure a
strap wrench around the cylinder (26) and use it to
turn the cylinder to loosen and remove it from the
pump assembly. (Fig. 5). Remove the intake seal
(28).
Fig. 2
Fig. 3
34
27
34
19, 35
Fig. 4
Fig. 5
29
19
35
34
36
26
28
30

Instructions
3A1495C 5
8. If the gasket (30) is still inside the spacer cylinder
(36) use a pick to remove.
9. Secure a strap wrench around the spacer cylinder
(36) and use it to turn the cylinder counter clockwise
to loosen and remove it from the flange (22) (Fig. 6).
NOTE: After a few turns, the spacer cylinder should
be loose enough to finish loosening it with your
hand to remove this part.
10. Use a pick to remove gasket (30) from inside the
flange (22).
11. Use a rubber hammer and small punch to drive out
pin (8), holding together the piston rod (23) and the
connection rod (32). Turn the piston rod (23)
counter clockwise to loosen and remove it from the
connection rod. Remove the piston seal (24) from
the piston rod (Fig. 8).
12. Remove the pump assembly from the vise and set it
down on a clean, hard work surface.
NOTE: When removing the pin (8) in Steps 12 - 14,
it is helpful to place a support such as a piece of
wood, below the rods.
13. Use a rubber hammer and small punch to drive out
pin (8), holding together the priming rod (34) and
piston rod (23). Turn the priming rod (34) counter
clockwise to loosen and remove it from the piston
rod (Fig. 7).
14. Use a rubber hammer and small punch to drive out
pin (8), holding together the connection rod (32) and
displacement rod (25). Turn the connection rod (32)
counter clockwise to loosen and remove it from the
displacement rod (Fig. 8).
If you are only replacing or repairing the pump lower
continue instructions beginning with Step 14, page
8 of the Reassembly instructions and the related
O-Ring and Seal Replacement Kit 24H856, page 12.
15. Clamp the air cylinder (21) horizontally in a vise as
shown in Fig. 9.
NOTE: Take care to only use enough clamping
Fig. 6
22
36
PULL
830
Fig. 7
Fig. 8
8
34
23
8
28
32
24
24
23
34
28
32
25

Instructions
63A1495C
force to hold the pump in position. The pump cylin-
der is aluminum and could be damaged by using
excessive clamping force.
16. Using a 10 mm socket wrench, remove the 4 screws
(43) from the air valve (40) and completely remove
air valve assembly from air cylinder (21). Also
remove the two cover gaskets 18). If you are replac-
ing these parts, discard gaskets. (Fig. 9).
Repair and replacement instructions for the Air
Valve are included in a separate repair manual
included with the kit:
• Air Valve Replacement Kit - 24H848, 24H849,
24H850
• Air Valve Repair Kit - 24H798
• Air Motor Service Kit - 24J757, 24J758, 24J759
• Pilot Valve Kit - 24H749
• Air Valve Seal Kit - 24H851
• Air Valve End Cap Kit - 24H852
17. Using a 10 mm socket wrench, remove the 5 screws
(4) from the flange (22).
18. Using your hand, firmly grasp the flange (22) and
remove the entire assembly from inside the air cylin-
der (21).
NOTE: Sliding the flat blade of a screw driver between
the flange (22) and air cylinder (21) will help separate
the two parts. Be careful not to damage the o-ring (6)
(Fig. 10).
19. Pull the flange assembly off the displacement rod
(25). Set the displacement rod aside. You will not
need it until you reassemble the pump.
20. Using a 5 mm socket wrench remove the 3 screws
(3) from the bottom cover (14) (Fig. 11).
21. Separate the bottom cover (14) from the flange (22)
(Fig. 11).
NOTE: Insert the flat blade of a screwdriver
between the flange and bottom cover to help loosen
the seal between these two pieces and pull them
apart more easily.
If you are replacing the o-rings and seals installed in
the flange, bottom cover, and air piston continue
instructions with Step 1, page 7 of the Reassembly
instructions and the Throat and Piston Seal
Replacement Kit 24H854 instructions beginning on
page 11.
Fig. 9
43
40
21
18
21
Fig. 10
Fig. 11
21
6
3
14
22

Instructions
3A1495C 7
Pump Reassembly
NOTE: The following instructions describe the proce-
dure to follow to reassemble a completely disassembled
LD grease pump. Depending on the repair/maintenance
procedure you are performing on the pump, it may not
be entirely disassembled. See the specific section(s)
related to your repair/replacement kit.
For all reassembly procedures:
• Clean all the parts carefully in a compatible solvent,
and inspect for wear or damage. Use all the repair
kit parts during reassembly, and replace other parts
as necessary.
• Check the all polished surfaces for scratches or
wear.
• Lubricate all parts with a light, water-resistant
grease.
1. Install new o-rings and seals in bottom cover (14)
and flange (22) as described in the Throat and Pis-
ton Seal Replacement Kit 24H854, page 11. Be
sure to apply a thin coat of water-resistant grease to
all o-rings and seals.
2. Align pilot valve (20) installed in bottom cover with
opening (a) in flange (22) as shown in Fig. 12. Com-
press the bottom cover (14) and flange (22)
together.
3. Install 3 screws (3) (Fig. 13). Tighten with a 5 mm
socket wrench and torque to 60-70 in lbs (6.8 – 7.9
N.m).
4. Apply a thin coat of grease round the top of the dis-
placement rod (50). Push the displacement rod
through the opening in the bottom cover and into the
flange assembly as shown in Fig. 14.
5. Install the air cylinder (21) over the bottom cover
(14). Place the top of the air cylinder down on a
clean hard surface. Use the palms of your hands to
press the bottom cover firmly into the air cylinder
(Fig. 15).
Fig. 12
20 a
22
Fig. 13
Fig. 14
Fig. 15
3
50
14
22
14
21

Instructions
83A1495C
6. Install the 5 screws (4) wrench tight only.
NOTE: If installing a new air cylinder (27), the mat-
ing holes are not threaded by design. Use thread
forming screws (4) to form threads as they are being
installed. Torque to 95-105 in.-lbs (10.7 - 11.8 N.m)
to ensure full thread formation.
7. To ensure there is a proper seal between the air
valve and manifold, loosen all 5 screws (Fig. 16)
approximately 1/8 to 1/4 turn. These screws will be
torqued in Step 12, AFTER the air valve (40) is
installed.
8. Secure pump assembly in a vise as shown in Fig.
17.
9. Perform any air valve repairs / maintenance
needed. See separate instruction manual included
with the related air valve repair kit.
10. Be sure seals (18) are lightly greased and installed
on air valve (40). Install air valve on air cylinder (21).
NOTE: The air valve (40) can be installed in any
configuration. There is not just one correct way to
install these parts.
11. Install screws (43). Torque to 60-70 in. lbs (6.8 - 7.9
N.m).
12. Torque screws (4) installed in Step 6 to 60-70 in. lbs
(6.8 - 7.9 N.m).
Muffler (17) Installation (Fig. 17)
13. Depending on your installation, the air valve (40)
can be mounted with the muffler (17) on either side
of the air valve.
To change the installation location:
a. Remove the 4 screws (43).
b. Remove the air valve (40) from its current
mounted position on the air cylinder (21) and
rotate the air valve 180 degrees, which will
reposition the muffler to face the other side of
the pump.
NOTE: When installing the pin (8) in Steps 14 - 20, it is
helpful to place a support, such as a piece of wood,
below the rods.
14. Screw the connecting rod (32) and the displacement
rod (25) together, aligning the pin hole in both
pieces to allow the pin to be pushed through (Fig.
18).
15. Replace the pin (8). Use a rubber hammer to tap the
pin into place, being careful to make sure the sides
of the pin are flush with the outside surface of the
connecting rod (Fig. 18).
16. Install piston seal (24) over the end of the piston rod
(23). Note the correct orientation of the piston seal
on the piston rod as shown in Fig. 19.
Fig. 16
Fig. 17
4
14
43
40
21
18
17
Fig. 18
25
32
8

Instructions
3A1495C 9
17. Screw the piston rod (23) and the connecting rod
(32) together aligning the pin hole in both pieces to
allow the pin to be pushed through (Fig. 19).
18. Replace the pin (8). Use a rubber hammer to tap the
pin into place, being careful to make sure the sides
of the pin are flush with the outside surface of the
connecting rod (Fig. 19).
19. Screw the piston rod (23) and priming rod (34)
together aligning the pin hole in both pieces to allow
the pin to be pushed through (Fig. 20).
20. Replace the pin (8). Use a rubber hammer to tap the
pin into place, being careful to make sure the sides
of the pin are flush with the outside surface of the
piston rod (Fig. 20)
21. Check to make sure there is end play at all pinned
connections.
NOTE: When there is end play at the pinned connec-
tion, you should be able to slightly move from
side-to-side, the displacement rod (25) pinned to the
connecting rod (32) and the connecting rod (32) pinned
to the piston rod (23) and piston rod (23) pinned to the
priming rod (34).
22. If these connections seem too rigid remove the pin
and adjust hole alignment by 1/2 turn in the direction
that aligns the through holes as close as possible,
axis-to-axis (Fig. 21).
23. Install spacer cylinder (36) over rod assembly. Use
a strap wrench to tighten spacer cylinder securely.
24. Install cylinder (26) and seal (30). Torque to 45 - 55
ft. lbs (61 - 75 N.m).
25. Install the intake seal (28) over the end of the prim-
ing rod (34). Note the correct orientation of the
Fig. 19
Fig. 20
24
23
32
8
30
28
34
23
NOTICE
Improper alignment will take the self-aligning feature
out of the design which could result in damage to the
pump.
Fig. 21
Correct Alignment
Permits end play
Fig 3 - Correct
Fig 1 - 1/2 Turn Too Shallow
Incorrect Alignment
Fig 2 - 1/2 Turn Too Deep
Does not permit
end play
ti10469a
ti10468a
Does not permit
end play
ti10479a

Instructions
10 3A1495C
intake seal on the priming rod as shown in Fig. 20.
26. Install seal retainer (29) over priming rod (34) (Fig.
22).
27. Use an adjustable wrench to tighten seal retainer
securely, then torque to 45 - 55 ft lbs (61 - 75 N.m).
28. Install the priming piston (35 and nut (19) (Fig. 3,
Fig. 4) on priming rod (34) Use an adjustable
wrench to hold the priming rod (34) securely. Use a
second adjustable wrench to tighten nut. Then
torque nut to 70 - 80 in. lbs (7.9 - 9.0 N.m) (Fig. 22
and Fig. 23).
29. Install shovel cylinder (27) over priming rod (34)
(Fig. 24). Use a strap wrench to tighten shovel cylin-
der securely then torque to 45 - 55 ft. lbs (61 - 75
N.m).
Repair Kits
All Repairs:
• Unless otherwise stated, entirely disassemble pump
as described in the pump disassembly instruction
section of this manual.
• Properly discard all replaced parts according to
local and state regulations for disposal of discarded
components.
• Always use all new parts included in the kit to
replace the identical part on the pump.
• Grease all parts prior to reassembly with a thin coat
of lightweight grease.
• Reassemble pump as described in the reassembly
instruction section of this manual.
Fig. 22
Fig. 23
29
19
35
34
34
19, 35
Fig. 24
34
27