Graco Lube Master User manual

3A2781B
EN
Instructions
Lube Master®Floor
Mount or Wall Mount
Pump Package
Provides a constant supply of lubrication to pump components. For professional use only.
Maximum Working Pressure: 5000 psi (340 bar, 34.0 MPa)
See page 3 for part number information.
Important Safety Instructions
Read all warnings and instructions in this manual
before using the equipment. Save these
instructions.

Table of Contents
23A2781B
Table of Contents
Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component Identification . . . . . . . . . . . . . . . . . . . . 6
(Pump Assembly) . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Identification . . . . . . . . . . . . . . . . . . . . 7
Reservoir - Oil or Grease . . . . . . . . . . . . . . . . . . 7
Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 7
Motor and Drive Options . . . . . . . . . . . . . . . . . . . 7
Installation Instructions . . . . . . . . . . . . . . . . . . . . . 8
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . 8
Choose an Installation Location . . . . . . . . . . . . . 8
Pump Package Installation Procedure . . . . . . . . 8
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fill the Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fill the System . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bleed the Manifold . . . . . . . . . . . . . . . . . . . . . . 11
Clutch Drive Adjustment . . . . . . . . . . . . . . . . . . 11
Standard Pump Adjustment . . . . . . . . . . . . . . . 12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Relief Procedure . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance and Repair . . . . . . . . . . . . . . . . . . . . 16
Pumps: Oil and Grease Models . . . . . . . . . . . . 16
Grease Reservoir Models . . . . . . . . . . . . . . . . . 17
Low-Level Switch Assemblies . . . . . . . . . . . . . . 18
Oil Reservoir Models . . . . . . . . . . . . . . . . . . . . . 19
Post Maintenance . . . . . . . . . . . . . . . . . . . . . . . 23
Clutch Drive Maintenance . . . . . . . . . . . . . . . . . 23
Recommended Lubricants for Enclosed
Gear Reducers . . . . . . . . . . . . . . . . . . . . . . 23
Alternative AGMA Lubricants . . . . . . . . . . . . . . 23
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Grease Reservoir Models:
562896, 562897, 562898, 562899 . . . . . . . 24
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Oil Reservoir Models:
562892, 562893, 562894, 562895 . . . . . . . 25
Overhead Supply Adapter Assembly 562908 . . 26
Pump Body Assembly: 563380 . . . . . . . . . . . . . 27
Clutch Drive Assembly: 563383 . . . . . . . . . . . . 28
Lube Master Pump Package . . . . . . . . . . . . . . . 29
Lube Master Pump Package with Gear
Reducer and Motor (Up to 20 lbs):
Floor Mounting . . . . . . . . . . . . . . . . . . . . . . 30
Lube Master Pump Package with
Gear Reducer and Motor (Up to 20 lbs):
Wall Mounting . . . . . . . . . . . . . . . . . . . . . . . 31
Oil Reservoir Model with 15 Amp Low-Level
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Oil Reservoir Model with 10 Watt Low-Level
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Grease Reservoir Model Low-Level Switch
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Clutch Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Lube Master (Up to 20lbs): Wall Mounting . . . . 38
Lube Master (Up to 20lbs): Floor Mounting . . . . 39
Lube Master (Up to 20lbs) . . . . . . . . . . . . . . . . . 40
Technical Specifications . . . . . . . . . . . . . . . . . . . . 41
California Proposition 65 . . . . . . . . . . . . . . . . . . 42
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 44

Part Number
3A2781B 3
Part Number
Use the Part Number Key provided below to identify each component included in the Lube Master pump package Part Number.
The Codes associated with each Option (A-D) that make up the Part Number are provided in the tables below. For example, Part
Number - LM1321 is a Lube Master pump package with a 12 pint plastic oil reservoir. It has a 10:1 reduction ratio and is floor
mounted. It is powered with a 115/230V, 1/2 hp, 1 PH, 60 hz, 1725 RPM motor and does not have a low-level switch.
NOTE: Some part number configurations are not available. Contact Graco Customer Service or your local Graco distributor for
assistance.
LM = Lube Master
Option A: Reservoir Options
Option B: Drive Options
Option C: Motor Options
Option D: Low-Level Switch Options
Part Key: LM A - B - C - D
Part Example: LM 1 3 2 1
Code Reservoir Size:
pints (liters) Oil or Grease Plastic or
Metal
1 12 (5.68) Oil Plastic
2 20 (9.46) Oil Plastic
3 12 (5.68) Oil Metal
4 20 (9.46) Oil Metal
Code Reservoir Size:
pounds (kg) Oil or Grease Plastic or Metal
5 12 (5.44) Grease Plastic
6 20 (9.07) Grease Plastic
7 12 (5.44) Grease Metal
8 20 (9.46 L) Grease Metal
9 No Reservoir, Overhead Supply
Code Description
Reduction Ratio Mounting Option
1None
2 Clutch Drive With Arm
3 10:1 Floor Mounting
4 10:1 Wall Mounting
5 60:1 Floor Mounting
6 60:1 Wall Mounting
Code Voltage Horsepower PH Hz RPM
1None
2 115/230 1/2 1 60 1725
3 230/460 1/2 3 60 1725
4 115/230 1/2 1 60 1140
5 230/460 1/2 3 60 1140
Code Size Oil or
Grease SPDT Amps Watts
1No low-level switch
2 12 (5.68 L) Oil X 15
3 20 (9.46 L) Oil X 15
412 and 20 pounds
(5.44 and 9.07 kg) Grease
5 12 (5.68 L) Oil X 10
6 20 (9.46 L) Oil X 10

Warnings
43A2781B
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 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.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause elec-
tric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
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.
• 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
When flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be
aware that flammable fumes can ignite or explode. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources, such as cigarettes and portable electric lamps.
• Ground all equipment in the work area.
• Keep work area free of debris, including rags and spilled or open containers of solvent and gasoline.
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Use only grounded hoses.
•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.
BURN HAZARD
Equipment and surfaces can become very hot during operation. To avoid severed burns:
• Do not touch hot equipment.

Warnings
3A2781B 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 com-
ponent. See in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See in all equipment man-
uals. Read fluid and solvent manufacturer’s warnings. For complete information about your material,
request Safety Data Sheet (SDS) from distributor or retailer.
• 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 manu-
facturer’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.
ENTANGLEMENT HAZARD
Rotating parts can cause serious injury.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Do not wear loose clothing, jewelry or long hair while operating equipment.
• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
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.

Component Identification
63A2781B
Component Identification
(Pump Assembly)
A Pump Adjustment Nut
B Pump Inlet
C Drive Shaft
D Pressure Gauge
E Drain and Drain Plug (Oil Models: one on each side of
base); (Grease Models: one on the opposite side of the
base from the fill stud (13)
F Pump Outlet
11 Reservoir (Oil or Grease)
12 Fill Cap (Grease Only)
13 Fill Stud (Grease Only)
30 Fill Cap (Oil Only)
31 Filter Screen (Oil Only)
101 Pump Body
FIG. 1: Pump Assembly
11 Oil Model
Grease Model
A
D
B
30
31
C
101
E
FE
13
12
Side View

Component Identification
3A2781B 7
Component Identification
Every Lube Master pump package includes a pump
assembly and a reservoir.
Reservoir - Oil or Grease
• Container for holding oil or grease.
• Grease models include a follower plate.
• The reservoir mounts directly to the Lube Master
pump.
Oil Reservoir
• The oil reservoir has a fill cap (30) and screen (31),
located on top (FIG. 2).
Grease Reservoir
• The grease reservoir requires an external air-free
supply source connected to the fill stud (13).
Pump Assembly
• The pump assembly can be driven by an electric
motor or by a rotating or oscillating machine motion.
• The pump assembly must always be installed with
the reservoir (11) in a vertical position to ensure
proper operation.
• Always use lock washers with mounting bolts and
make certain that the bolts are properly torqued.
Motor and Drive Options
Gear Reducer
Gear reducers have either a 10:1 or 60:1 reduction or an
oscillating clutch drive that can be activated by a
machine motion.
Low-Level Switch (Optional)
A Low-level switch provides a signal when the lubricant
level in the reservoir is low.
FIG. 2: Oil Reservoir
FIG. 3: Grease Reservoir
31
30
13
To avoid injury from any rotating parts, all of the
exposed drive shafts must be guarded.
NOTICE
Gear reducer units are shipped without lubricant.
Before operating, always check lubricant level and fill
per manufacturers instructions. Operation without lubri-
cant will damage the gear reducer. A table of sug-
gested lubricants is provided on page 23.

Installation
83A2781B
Installation
The reference letters and numbers used in the following
sections, refer to FIG. 1.
Components are completely assembled when the Lube
Master pump package is received from the factory.
Reassembly instructions for these components are pro-
vided in Maintenance and Repair, beginning on page
16.
Grounding
Install a 12 gauge (1.5 mm) minimum ground wire
between the Lube Master pump package and a true
earth ground.
Pressure Relief Valve
Pressure Relief Valve
• The pressure relief valve must be rated for no more
than the working pressure of any component
installed in the system.
• Install a pressure relief valve close to every pump
assembly outlet and before any auxiliary fitting.
Choose an Installation Location
• Select a location that will adequately support
the weight of the pump package and lubricant,
as well as all plumbing and electrical connec-
tions.
• Refer to the mounting hole layouts provided in
Dimensions, beginning on page 34. No other
installation configuration should be used.
• Use only the designated mounting holes and
provided configurations.
• Use fasteners that are strong enough to support
the weight of the pump package and lubricant
when securing the pump package to the mount-
ing surface.
Pump Package Installation
Procedure
1. Secure the pump package with user supplied
attaching hardware to the installation location. All
fasteners should be tightened to the proper torque.
2. Install all guards and mechanical linkages or con-
nections.
3. Connect the power source to the pump package
drive.
4. Fill with lubricant. See Fill the Reservoir, beginning
on page 9.
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.
To prevent over-pressurization, which can result in
serious injury from splashing fluids due to equipment
rupture, a pressure relief valve must be installed
close to every pump assembly outlet to alleviate
unintended pressure rises in the system and protect
the pump assembly from damage.
AUTOMATIC SYSTEM ACTIVATION HAZARD
If the system is equipped with an automatic timer that
activates the pump lubrication system, unexpected
activation of the system could occur. This could result
in serious injury, including skin injection and amputa-
tion from moving parts.
Before installation or removal of the pump package
from the system, disconnect power and relieve pres-
sure.

Setup
3A2781B 9
Setup
Fill the Reservoir
Material Cleanliness
The lubricant used to fill the system must be clean. If
there is doubt about cleanliness, the lubricant should be
filtered before using in the system. System life and con-
sistent operation will both be improved by using clean
lubricant.
After filtering the lubricant, protect the lubricant supply
from debris.
On all pump packages, the lube piston diameter is very
close to the diameter of the chamber in the pump body.
Contaminants in the lubricant could cause scoring,
resulting in erratic pump operation and costly parts
replacement.
Temperature Effects
Flow characteristics of the lubricant may change due to
drastic temperature changes. Choose a lubricant that
flows properly at all temperatures expected in the sys-
tem environment.
Overhead Supply Adapter Assemblies Only
The recommended inlet pressure is 15 psi (0.103 MPa,
1.03 bar) or less.
Fill Oil Reservoir Model
The reservoir on oil models has a fill cap (30) and filter
screen (31).
1. Clean the area around the fill cup to avoid contami-
nation during filling.
2. Open the fill cap (30) and slowly pour oil into the
reservoir (11) through the filter screen (31).
NOTE: The filter screen (31) removes any large par-
ticles present in the oil.
3. When filling is complete, close the fill cap (30) and
clean up any spillage.
FIG. 4: Oil Reservoir
31
30

Setup
10 3A2781B
Fill Grease Reservoir Model
• Filling the grease reservoir requires an external,
air-free supply source connected to the fill stud (13).
• Avoid introducing air into the system, by keeping
enough grease in the supply source to fill the reser-
voir without being disconnected.
• Operate the supply source at a steady speed to
allow air-free filling of the reservoir. Filling the
reservoir too fast may result in air pockets.
• Visually check the level of grease.
- For reservoirs with plastic cylinders, the grease
level can be viewed through the cylinder.
1. Remove the fill cap (12)
2. Connect the grease supply source to the fill stud
(13).
3. Loosen the drain plug (E), located on the opposite
side of the base from the fill stud (13) (FIG. 6).
4. Begin to slowly fill the reservoir, allowing for air
trapped under the follower to exhaust out the open
drain plug.
5. After grease that is free of air flows from the drain,
tighten the plug (E) and continue to fill the reservoir
until follower is at the vent hole in reservoir tube
(any remaining air and small amount of grease will
exit drain).
6. When filling is complete, turn off the supply source
and disconnect it from the fill stud (13). Replace the
cover (12).
NOTE: Integrating a check valve inside of the fill
stud prevents lubricant from being forced back out.
7. Loosen the pump assembly outlet fitting.
8. Operate the pump until lubricant that is free of air
flows from the outlet port.
9. Tighten the mainline connection at the pump. The
pump is now free of air.
NOTE: If the pump will not take a prime, inject sev-
eral ounces of heavy oil through the fill stud. The
pump primes on the oil pulling the grease behind it.
If this method is used, all injected oil should be dis-
charged at the loosened system mainline connec-
tion, in addition to any air.
OVER PRESSURIZATION HAZARD
Over pressurization can result in serious injury from
splashing fluids due to equipment rupture. Fill slowly
to avoid over pressurizing the reservoir.
FIG. 5: Fill Grease Reservoirs
12 E
13
FIG. 6: Drain Plug
E

Setup
3A2781B 11
Fill the System
Fill the pump package reservoir, as described in Fill the
Reservoir, page 9. After it is filled, the remainder of the
system is filled by attaching a hand pump to the system
downstream from the pump manifold block assembly,
then cycle the hand pump until the system is filled.
Clutch Drive Adjustment (if
equipped)
The clutch lever throw is adjustable between 12 and 60
degrees. Table 1 (page 12) provides the minimum/maxi-
mum pump outputs. The actual pump output of the
installation is computed using the Calculating Pump
Output procedure found on page 12.
Use the clutch lever diagram (FIG. 7) to determine the
anticipated clutch lever throw angle.
FIG. 7: Clutch Lever Diagram

Setup
12 3A2781B
Clutch Drive - Calculating Pump Output (if equipped)
The standard pump output varies from 0.010 to 0.050 cubic in. (0.1639 to 0.8195 cu. cm) per cycle, by changing the
position of the pump adjustment nut (A) (FIG. 1, page 6), located below the pressure gauge (D) (FIG. 1, page 6).
Use the following formulas to calculate the pump output per hour:
Table 1: Minimum / Maximum Pump Output
Standard Pump Adjustment
Table 2: Standard Output/Stroke Adjustment
360° = Effective Ratio
Degrees of Throw
* Degrees of Throw can be found by using clutch lever diagram (FIG. 7, page 11)
IMPULSES/HOUR =PUMP STROKE PER HOUR
RATIO
Pump strokes per hour x 0.010 = Minimum Pump Output per Hour
Pump strokes per hour x 0.050 = Maximum Pump Output per Hour
Degrees of
Throw
Effective Ratio Impulses Per
Minute
Output Per Hour
Pump Strokes Per
Hour
Cubic Inches (Cubic Centimeters)/hour
Minimum Maximum
12 30:1 5 Minimum 10 0.100 (1.639) 0.500 (8.195)
60 6:1 150 Maximum 1500 15.00 (245.8) 75.00 (1229)
FIG. 8: Standard Pump Adjustment
Percent of
Output
Output Per Stroke Cubic
Inches (Cubic Centimeters)
Adjustment
Mark
100 0.050 (0.820) Max.
90 0.045 (0.737) *1st
80 0.040 (0.656) *2nd
70 0.035 (0.574) *3rd
60 0.030 (0.492) *4th
50 0.025 (0.410) *5th
40 0.020 (0.328) *6th
30 0.015 (0.246) *7th
20 0.010 (0.164) Min.
* All marks are counting clockwise from the maximum
setting.

Operation
3A2781B 13
Operation
Startup
Before operating any component in the system,
check the following:
• The reservoir is securely fastened in the pump
assembly and that the fill cap or grease-fill fitting is
easily reached.
• The pump package is securely fastened in place.
• The gear reducer is filled with the proper lubricant,
see page 23.
• The electrical connections to any controllers, level
switches or pressure switches used on the system
are tight.
• All of the accessories plumbed into the output mani-
fold block assembly are secure.
• All of the hose or tube connections are tight.
• The reservoir is filled with lubricant. See Fill the
Reservoir, page 9.
• All filling and bleeding steps have been completed.
• The output of the pump assembly. To adjust the out-
put, see page 12.
• For models equipped with a clutch drive, verify it is
properly adjusted, see Clutch Drive Adjustment (if
equipped), page 11.
The pump package is ready for operation.
While the system is operating, periodically check
the following components:
• The pump is cycling according to schedule.
• Visually check the unit for leaks and loose fittings.
Make sure that the hoses are not kinked or rubbing
on anything.
• If the reservoir is not equipped with a low-level
switch, visually check the lubricant level and refill
before all lubricant is used.
NOTE: If the reservoir is allowed to run out of lubri-
cant, excess air will be introduced into the system,
requiring that the system be bled.
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Verify pump is stopped and disconnected from the
power source.
2. Using a wrench, slowly loosen the outlet fitting (a,
FIG. 9) connected to the pump assembly until the fit-
ting is loose and no more lubricant or air is leaking
from the fitting.
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 Pro-
cedure when you stop dispensing and before clean-
ing, checking, or servicing the equipment.
FIG. 9: Pressure Relief
a

Troubleshooting
14 3A2781B
Troubleshooting
1. Follow Pressure Relief Procedure, page 13,
before checking or repairing the pump.
2. Check all possible problems and causes before
disassembling the pump, including loose
connections or air trapped in the system.
Problem Cause Solution
No lubrication is dispensed from pump,
but pump is rotating
Reservoir is empty Refill as required. See Filling The Res-
ervoir, page 9.
Check valve is defective Clean and install seal repair kit.
Adjustment sleeve seals are defective
Problem is in the pump
See Pump is Not Running or Requires
Servicing section of this Troubleshoot-
ing Table.
Pump is Not Running or Requires Ser-
vice
Yoke connector pin and piston are
defective
Replace defective parts using Pump
Drive Repair Kit.
Sheared drive motor key Replace key.
Broken pump drive shaft Replace defective parts using Pump
Drive Repair Kit.
Piston is not engaged in sleeve Replace defective parts using Output
Manifold Kit.
No lubrication is dispensed from pump
and drive shaft is not rotating
Motor is not running Refer to Motor is Not Running section
of this Troubleshooting Table.
No gear reducer output Refer to No Gear Reducer Output sec-
tion of this Troubleshooting Table.
Defective pump input shaft Replace defective parts using Pump
Drive Repair Kit.
Motor is Not Running
Power is off Turn power on.
Electric connections to motor or timer
are loose
Check all connections and tighten
securely.
Timer/controller is set incorrectly or
defective
Set timer/controller to correct setting. If
unit is still not functioning, repair or
replace timer/controller.
No Gear Reducer Output
Key is sheared or missing at coupling Replace key.
Defective gearbox
Gearbox must be replaced. For this
repair unit must be returned to an
authorized Graco repair facility.

Troubleshooting
3A2781B 15
Clutch drive is operating but there is no
flow
Reservoir is empty Refill as required. See Filling The Res-
ervoir, page 9.
Clutch is defective
Remove clutch and operate pump man-
ually.
•If there is output, replace clutch. For
this repair unit must be returned to
an authorized Graco repair facility.
•If there is no output, see Pump is
Not Running or Requires Servicing
section of this Troubleshooting
Table.
Fluid temperature is below 12°F
(-11°C)
Do not attempt to operate until tem-
perature problem is corrected.
Erratic pump output
System was not bled properly Bleed manifold. See Manifold Bleeding,
page 11.
Pump seals, check valves or o-rings
are defective
Replace defective parts using Pump
Drive Repair Kit.
Pump adjustment assembly is leaking
or sucking air during return stroke
Tighten output manifold block assembly
components.
Piston or bore is worn Replace defective parts using Output
Manifold Kit.
Grease Models
Lubricant is leaking from the reservoir
Hex nuts (1) are not tight Tighten hex nuts (1). Torque to 5 ft. lbs
(6.78 N•m).
Damaged or worn gasket (8) Replace gasket (8).
Cracks or nicks in reservoir tube (11) or
reservoir is dented or out-of-round Replace reservoir tube (11).
Restricted movement of follower plate Dented or out-of-round reservoir tube
(11) Replace reservoir tube (11).
Pump will not take a prime Grease will not pull into pump through
quick disconnect
Inject several ounces of heavy oil
through the grease fill quick discon-
nect. The pump will then prime on oil,
pulling the grease behind it. If it
becomes necessary to use this
method, all injected oil should be dis-
charged at the loosened system supply
connection along with any air.
Oil Models
Oil reservoir is filling very slowly Fill screen (31) located in fill cap (30) is
clogged Clean or replace fill screen (31).
Lubricant is leaking from the reservoir
Hex nuts (1) are not tight Tighten hex nuts (1). Torque to 5 ft. lbs
(6.78 N•m)
Damaged or worn gasket (8) Replace gasket (8)
Cracks or nicks in reservoir tube (11) or
reservoir is dented or out-of-round Replace reservoir tube (11)
Overhead supply adapter only:
Exceeded recommended inlet pressure
of 15 psi (0.103 MPa, 1.03 bar)
Decrease pressure to 15 psi (0.103
MPa, 1.03 bar) or less
Problem Cause Solution

Maintenance and Repair
16 3A2781B
Maintenance and Repair
Pumps: Oil and Grease Models
Prepare for Maintenance
Refer to FIG. 10 for reference numbers used in the fol-
lowing instructions.
Before proceeding with any maintenance, the following
procedure must be completed:
1. Disconnect all power to the pump.
2. Follow the Pressure Relief Procedure, page 13.
3. Remove pipe plug (116, FIG. 10) and drain oil or
grease into a suitable, clean container.
4. Install plug (116) after draining is complete.
5. Remove the reservoir.
6. Remove pump body assembly from the mounting:
a. Remove all guards and mechanical linkages or
connections at the pump drive shaft (104).
b. Remove all attaching hardware securing pump
body (101) in place.
c. Remove all grease or oil from the pump body
(101).
AUTOMATIC SYSTEM ACTIVATION HAZARD
If the system is equipped with an automatic timer that
activates the pump package, unexpected activation of
the pump package could occur. This could result in
serious injury, including skin injection and amputation
from moving parts.
Before installation or removal of the pump assembly
from the system, disconnect power and relieve pres-
sure.
FIG. 10:
101
116
104

Maintenance and Repair
3A2781B 17
Grease Reservoir Models
Refer to FIG. 11 for reference numbers used in the fol-
lowing instructions.
Disassembly
The disassembly procedure may be performed with the
reservoir mounted on the pump assembly. However,
some mounting locations are too restrictive to provide
access to all components.
If installation requires dismounting of the reservoir, drain
the reservoir of lubricant before removing the attaching
hardware. This reduces the weight of the reservoir and
reduces the chance of spillage.
1. Follow Prepare for Maintenance, page 16.
2. Slowly open the reservoir drain (E), FIG. 1, page 6,
and allow the lubricant to flow into a container.
Drain all lubricant before removing the attaching hard-
ware to reduce the weight of the reservoir and to reduce
the chance of spillage.
3. Properly dispose of emptied grease adhering to all
applicable safety regulations and municipality
codes.
4. Remove the fill stud (13), if necessary (FIG. 11).
5. Remove hex nuts (1) and lock washers (5) from the
tie rods (3) (FIG. 11).
6. Remove tie rods (3) from reservoir cap (9) (FIG. 11).
7. Lift the reservoir (11) from the pump, keeping the
reservoir cap (9) in position on top of the tube (FIG.
11).
8. Slide the reservoir (11) away from the reservoir cap
(9) until it is free from the follower cups (15 and 17)
(FIG. 11).
9. Remove the gasket (8) from the pump (FIG. 11).
NOTE: Further disassembly is only possible at the
factory. If damage is apparent on the follower cups
(15 and 17), cable assembly (19), spring (10) or res-
ervoir cap (9) the unit cannot be serviced and the
reservoir assembly must be replaced.
FIG. 11:
9
3
11
4
23 25
10
19
15
6
17
8
5
1
13
12
FLYING PARTS HAZARD
The expansion spring (10) is always under great ten-
sion and could be propelled with enough force to
cause serious injury. Never remove retaining ring (4)
or cable assembly (19).

Maintenance and Repair
18 3A2781B
Reassembly
Lubricate the follower cups (15 and 17) (FIG. 11) and the
inner diameter of the reservoir tube (11) before reas-
sembling the pump assembly with the same lubricant
used in the system.
1. Slide the reservoir (11) over the follower cups (15
and 17) upwards until it contacts the reservoir cap
(9), being careful not to distort the follower cup lips.
2. Install a new gasket (8) on the pump.
3. Place the reservoir (11) on the gasket (8) and rotate
the reservoir cap (9) until the holes in the cap line up
with the holes in the pump.
4. Install the tie rods (3) through the holes in the reser-
voir cap (9) and pump.
5. Install lock washers (5) and hex nuts (1) onto the tie
rods (3) and torque to 5 ft-lbs (6.78 N•m).
6. Install the fill stud (13) and dust cap (12) in the
pump.
NOTE: After reassembly, any components removed to
ease disassembly should be reinstalled on the reservoir.
Low-Level Switch Assembly
Refer to FIG. 12 for reference numbers used in the fol-
lowing instructions.
If the grease level is too low and the switch assembly
fails to perform as required:
• check that the electrical connections are secure.
• check for any physical obstructions that prevent the
switch from operating. If an obstruction is found, dis-
assemble the unit and clear the obstruction.
If the switch assembly is damaged, replace it using the
following procedure:
Remove
1. Follow Prepare for Maintenance, page 16.
2. Disconnect the wiring from the low-level switch ter-
minals (304) (FIG. 13).
3. Remove the nuts attaching the low-level switch
(304) to the bracket (A) (FIG. 12).
4. Remove the low-level switch (304) from the bracket
(A).
5. Remove the retainer ring (B) and spring (C).
6. Remove the three screws (D) and the bracket (A).
Install
1. Attach the bracket (A) to the grease reservoir cover
using the three screws (D) (FIG. 12).
2. Place the spring (C) (FIG. 12) over the tip of the level
indicator.
3. Compress the spring (C) and place the retainer ring
(B) between the spring and the tip of level indicator
(FIG. 12).
4. Attach the low-level switch (304) to the bracket (A)
with the nuts (FIG. 12).
5. Wire the low-level switch (304) in accordance with
local electrical codes. Refer to wiring diagram, FIG.
13.
A Normally closed
B Normally open
C Common
FIG. 12:
FIG. 13: Low-Level Switch Wiring
304
A
B
DC
Nuts
Level Indicator
ABC

Maintenance and Repair
3A2781B 19
Oil Reservoir Models
Refer to FIG. 14 for reference numbers used in the
following instructions.
Disassembly
The disassembly procedure may be performed with the
reservoir mounted on the pump assembly. However,
some mounting locations may be too restrictive to pro-
vide access to all components.
If installation requires dismounting of the reservoir, drain
the reservoir of lubricant before removing the attaching
hardware. This reduces the weight of the reservoir and
reduces the chance of spillage.
1. Follow Prepare for Maintenance, see page 16.
2. Drain the oil into a container and properly dispose of
emptied oil.
3. Remove the three hex nuts (1) and lock washers (5)
from the tie rods (3).
4. Remove the tie rods (3) from the reservoir cover (9).
5. Remove the reservoir cover (9) from the reservoir
(11).
6. Remove the fill screen (30) from the fill cap (31) and
clean the screen.
7. Remove the reservoir (11) from the pump.
8. Remove and discard the gasket (8) from the pump.
Reassembly
1. Install the fill screen (30) in the fill cap (31).
2. Install a new gasket (8) in the pump.
3. Position the reservoir (11) on the pump and position
the reservoir cover (9) on the tube.
4. Align the holes in the reservoir cover (9) and the
holes in pump.
5. Install the tie rods (3) through the holes in the cover
and the pump. The heads of the tie rods (3) must fit
into the hexagonal depressions on the upper sur-
face of the reservoir cover (9).
6. Install the lock washers (5) and hex nuts (1) on the
tie rods (3).
7. Torque the hex nuts to 5 ft-lbs (6.78 N.m).
NOTE: After reassembly, any components removed to
ease disassembly should be reinstalled on the reservoir.
FIG. 14
31 30
3
11
9
8
5
1

Maintenance and Repair
20 3A2781B
15 Amp Low-Level Switch Assembly Option
Refer to FIG. 15 for reference numbers used in the fol-
lowing instructions.
If the oil level is too low and the assembly fails to per-
form as required, the pump assembly may have to be
disassembled to replace a defective switch assembly.
Before disassembling, check that all electrical connec-
tions are secure and check for any physical obstruction
preventing the float (304h) from operating.
Disassembly
1. Follow Prepare for Maintenance, page 16.
2. Remove the cover (9) from the reservoir (11).
3. Unscrew the union nut (304c) from the switch
adapter (304a).
4. Unscrew the switch adapter (304a) from the switch
(304).
5. Remove the actuating rod (304e), part of low-level
lower assembly (304f), from the remaining assem-
bly.
6. Unscrew the low-level lower assembly (304f) from
the low-level adapter (304b).
7. Unscrew the low-level adapter (304b) from the res-
ervoir cover.
8. Remove the low-level adapter (304b) from the union
nut (304c).
Reassembly
The following procedure is used for installing a new
assembly in a reservoir. If the assembly was removed
for repairs, Steps 1 and 2 do not apply.
1. Remove the cover (9) from the reservoir (11).
2. Remove 1/4 in. plug (7) from the reservoir cover (9).
3. Insert the low-level adapter (304b) into the union nut
(304c).
4. Insert the low-level adapter (304b) into the reservoir
cover (9) and tighten securely.
5. Place the low-level lower assembly (304e) into the
low-level adapter (304b) and tighten securely.
If the float (304h) from the low-level lower assembly was
removed during disassembly, apply medium strength
thread lock to the attaching bolt and securely attach the
float (304h) to the arm (304f).
6. Insert the actuating rod (304e), part of low-level
lower assembly (304f), into this assembly.
7. Place the switch adapter (304a) into the switch
(304) and tighten securely.
8. Insert the union nut (304c) onto switch adapter
(304a) and tighten securely.
9. Install the cover (9) on the reservoir (11).
10. Wire the switch (304) in accordance with local elec-
trical codes. Refer to wiring diagram (FIG. 16).
A Normally closed
B Normally open
C Common
FIG. 15
304
304a
9
304b
304e
304c
304f
304h
FIG. 16: Wire Switch
C
BA