Graco Lube Pro 24Z020 User manual

3A4033J
EN
Instructions
28:1 Lube Pro™
Vertical Oil Pump
For pumping non-corrosive and non-abrasive lubricants only. For professional use only.
Not approved for use in European explosive atmosphere locations.
Models:
See page 2 for model information, including maximum working
pressure and approvals.
3500psi (24 MPa, 241 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.

Contents
2 3A4033J
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mount the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 7
Low Level Models Only . . . . . . . . . . . . . . . . . . . . 7
DIN Connector . . . . . . . . . . . . . . . . . . . . . . . 7
Air and Fluid Line Accessories . . . . . . . . . . . . . . 8
Air Supply Lines. . . . . . . . . . . . . . . . . . . . . . . 8
Fill Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Supply Lines . . . . . . . . . . . . . . . . . . . . . . . . . 9
Feeder Lines . . . . . . . . . . . . . . . . . . . . . . . . . 9
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air Lock Procedure . . . . . . . . . . . . . . . . . . . . . . 10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Relief Procedure . . . . . . . . . . . . . . . . 11
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Low Level Switch . . . . . . . . . . . . . . . . . . . . . . . 12
Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lubrication System Sizing and Calculation
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Table 1: Lubricant Output and
Pressure - US . . . . . . . . . . . . . . . . . . . . 13
Table 2: Lubricant Output and
Pressure - Metric . . . . . . . . . . . . . . . . . 13
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 14
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 19
Recycling and Disposal . . . . . . . . . . . . . . . . . . . . 24
End of Product Life . . . . . . . . . . . . . . . . . . . . . . 24
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Dimensions and Mounting Layout . . . . . . . . . . . . 28
Dimensions: US - inches . . . . . . . . . . . . . . 29
Dimensions: Metric - mm . . . . . . . . . . . . . . 29
Technical Specifications . . . . . . . . . . . . . . . . . . . . 30
California Proposition 65 . . . . . . . . . . . . . . . . . . . 31
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 32

Models
3A4033J 3
Models
Part No. Size Low Level
Normally
Open
Normally
Closed EU
24Z020 0.6 L
24Z021 0.6 L X X
24Z022 0.6 L X X
24Z023 0.6 L X
24Z024 0.6 L X X X
24Z025 0.6 L X X X
24Z026 2 L
24Z027 2 L X X
24Z028 2 L X X
24Z029 2 L X
24Z030 2 L X X X
24Z050 2 L X X X

Warnings
4 3A4033J
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-spe-
cific hazard symbols and warnings not covered in this section may appear throughout the body of this manual
where applicable.
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• 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.
PRESSURIZED EQUIPMENT HAZARD
Over-pressurization can result in equipment rupture and serious injury.
• Do not exceed the maximum air input pressure.
• Fill slowly to avoid over pressurizing reservoir.
• Use tubing, hoses and other components with pressure ratings equal to or higher than the pump
rating.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause
electric 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.
PLASTIC PARTS CLEANING SOLVENT HAZARD
Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or
property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing parts.
• See Technical Specifications in this and all other equipment instruction manuals. Read fluid and
solvent manufacturer’s Safety Data Sheets (SDSs) and recommendations.

Warnings
3A4033J 5
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause
electric 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.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request 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 cre-
ate 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.
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 SDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equip-
ment, 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.
WARNING

Typical Installation
6 3A4033J
Typical Installation
Key:
A Main Air Supply Line
B Filter/Regulator/Lubricator Assembly
B1 - Air Filter
B2 - Air Regulator
B3 - Air Lubricator
C Air solenoid valve (3-way)
D Pump module
E Pump outlet
F Bleed-type master air valve (required)
G High pressure lubricant supply lines (user supplied)
H Injector
J Lubricator controller
K Pump reservoir
L Pump reservoir fill cover
M Ground
P Pump air inlet - forward stroke
R Air outlet
S Feeder lines
T Low level
U Air supply lines
FIG. 1: Typical Installation
J
A
B1 B3
B2
C
U
F
LE
K
U
R
D
P
M
T
G
H
S

Installation
3A4033J 7
Installation
Grounding
To ground the pump (FIG. 2):
1. Remove the ground screw (Z) located on the side of
the pump base.
2. Insert the ground screw (Z) through the eye of the
ring terminal (W) located at the end of the ground
wire (Y).
3. Fasten the ground screw (Z) back onto the back of
the pump and tighten the screw securely.
4. Connect the other end of the ground wire (Y) to a
true earth ground.
Mount the Pump
Install the pump in a location that will adequately sup-
port the weight of the pump when it is filled with lubri-
cant and also provides easy operator access to the
pump air controls. The pump must be mounted in a ver-
tical position with the reservoir up. See Technical
Specifications, page 29 for pump weight information
and the Dimensions and Mounting Layout, page 28.
Low Level Models Only
DIN Connector
Connection is made to PINS 1 and 3 of the DIN Field
Wire-able Connector. See FIG. 3.
Grounding is necessary when voltages above 30
VAC or 42 VDC are used for the low level switch or an
air valved is attached to the pump. Improper ground-
ing can cause electric shock. Grounding reduces the
risk of electric shock by providing an escape wire for
the electric current in the event of malfunction or
breakdown.
FIG. 2
Mount the pump securely so that it cannot move
around during operation. Failure to do so could result
in injury or equipment damage.
FIG. 3

Installation
8 3A4033J
Air and Fluid Line Accessories
Refer to FIG. 1, page 6, for the following instruction.
Install the air line accessories in the order shown in FIG.
1, page 6.
Bleed-type master air valve (F): Required in the sys-
tem to relieve air trapped between it and the pump.
Air line filter (B1): Removes harmful dirt and moisture
from compressed air supply.
Pump air regulator (B2): To control pump speed and
outlet pressure. Locate it close to the pump.
1. Install a bleed-type master air valve (F) to relieve air
trapped between it and the pump. Install the valve
in a location that is easily accessible from the pump
and located downstream of the air regulator.
2. Install an air line filter (B1) to remove harmful dirt
and contaminants from the compressed air supply.
3. Install the air regulator (B2) to control pressure.
4. Install an air line lubricator (B3) to lubricate the air
cylinder.
5. Install the (3-way) air solenoid valve (C) for control
of the pump forward and return strokes.
To use the air regulator reading to determine the fluid
output pressure, multiply the ratio of the pump (28:1)
by the air pressure shown on the regulator gauge or
see Table 1: Lubricant Output and Pressure - US
PSI or Table 2: Lubricant Output and Pressure -
Metric MPa (bar), provided on page 13.
Limit the air to the pump so that no air line or fluid line
component or accessory is over pressurized.
Air Supply Lines (U)
1. Install two air supply lines (U) between the air sole-
noid outlets (C) and the pump (D) as shown in
FIG. 1, page 6.
2. Install an air supply line (U) between the air solenoid
valve inlet (C) and the Filter/Regulator/Lubricator
Assembly (B) as shown in FIG. 1, page 6.
Fill Reservoir
1. Open the oil fill cap (oc) located on the top of the
reservoir.
NOTE: A strainer is installed at the oil fill cap (oc) to pre-
vent contamination of the lubricant with foreign materi-
als (FIG. 4).
a. Inspect the strainer before filling the reservoir.
b. When needed, remove the strainer and clean
thoroughly.
c. If removed in Step b, install the strainer prior to
adding lubricant.
Trapped air can cause the pump to cycle unexpect-
edly which could result in serious injury from moving
parts or splashing.
NOTICE
Do not mount the air accessories directly on the
solenoid valve air inlet. The air inlet and fittings are
not strong enough to support the accessories and
may break. Provide a bracket on which to mount the
accessories.
The maximum working pressure of each
component in the system may not be the same.
To reduce the risk of over-pressurizing any part of
your system, know the maximum working
pressure rating of each component and its
connected components. Never exceed the
maximum working pressure of the lowest rated
components connected to a particular pump. FIG. 4
oc

Installation
3A4033J 9
2. Slowly add oil (ol) until the reservoir is filled to
capacity (FIG. 5).
NOTE: Do not fill the reservoir too quickly and overflow
the reservoir capacity.
3. Close the oil fill cover (oc) to prevent contamination
and spillage (FIG. 5).
Prime
NOTE:
• Prime the pump before connecting the outlet to
supply line (G).
• Before priming the pump, the reservoir must be
filled with lubricant. See Fill Reservoir, page 8.
Run the pump until oil (ol), free of air, comes out of the
pump outlet (E). See Operation, page 11.
• It may take up to 20 the pump strokes to expel the
air from the pump and deliver a continuous flow of
oil. This depends upon the viscosity of the lubricant
and temperature.
• Allow 5 seconds ON time for the forward stroke and
5 seconds OFF time for the return stroke.
Supply Lines
1. Prime the pump until oil (ol) comes out of the pump
outlet (E).
2. Connect the supply line (G) to the pump outlet (E).
3. If there are multiple pumps on the air line, close the
air regulators and bleed-type master air valves to all
but one the pumps. If there is only one pump, open
its air regulator and bleed-type master air valve.
4. Open the master air valve from the compressor.
5. Set the air pressure to each pump at the lowest
pressure needed to get the desired results. See
Recommended Pressure provided in Table 1:
Lubricant Output and Pressure - US or Table 2:
Lubricant Output and Pressure - Metric provided
on page 13.
Feeder Lines (S)
Fill each feeder line (S) with lubricant prior to connect-
ing lines to the injector outlet.
Injectors
1. Check each injector for proper operation. The injec-
tor stem should move when lubricant is discharged.
2. Adjust the injector output if needed to ensure that
the output volume discharged is sufficient.
FIG. 5
oc
ol

Installation
10 3A4033J
Air Lock Procedure
Refer to FIG. 1, page 6, for the following instruction.
An air lock occurs when a bubble or pocket of air pre-
vents the normal flow of the lubricant.
If an air lock occurs:
1. Refill the reservoir to the full level (Fill Reservoir,
page 8).
2. Relieve pressure following the Pressure Relief
Procedure, page 11.
3. Disconnect the lubricant supply line (G) from the
pump outlet (E) (FIG. 6).
4. Open the bleed-type master air valve (F, page 6).
5. Run the pump a few strokes until oil, free of air,
comes out of the pump outlet (E) (FIG. 6).
• It may take up to 20 the pump strokes to expel the
air from the pump and deliver a continuous flow of
oil. This depends upon the viscosity of the lubricant
and temperature.
• Allow a minimum of 5 seconds ON time for the for-
ward stroke and 5 seconds OFF time for the return
stroke.
6. Connect the pump outlet (E) to the lubrication line
(G) (FIG. 7).
NOTICE
Running the pump dry will cause an air lock. To pre-
vent an air lock, do not run the pump without lubricant.
Always refill the pump before it is empty.
FIG. 6
FIG. 7
E
G
E
G

Operation
3A4033J 11
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Close the bleed-type master air valve (F, FIG. 1,
page 6) (required in the system).
2. Relieve pressure in system using two wrenches
working in opposite directions on the pump outlet
(E) and lubrication line fitting (G) to slowly loosen
the fitting until it is loose and no more lubricant or
air is leaking out of the fitting (FIG. 8).
Pump
Start Up
1. Verify reservoir is filled with lubricant and system
has been primed (see Prime, page 9).
2. Turn on the lubrication controller (J) power switch.
3. Program the lubrication controller to actuate the
solenoid valve (C).
NOTE: See the lubrication controller instruction
manual included with the system for these instruc-
tions.
4. Open air regulators and master air valves.
NOTE: Never allow the pump to run dry of the material
being the pumped.
At the start of a the pump cycle:
a. The air solenoid (C) supplies air to the pump air
inlet (P).
b. On the pump forward stroke, lubricant is dis-
pensed to all the injectors.
c. The pump is supplied with air through the air
inlet (R).
d. The pump makes a return stroke, venting the
system pressure back to the pump and reset-
ting all of the injector.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop dispensing and before
cleaning, checking, or servicing the equipment.
FIG. 8
E
G
NOTICE
Running the pump dry will cause an air lock. To pre-
vent an air lock, do not run the pump without lubricant.
Always refill the pump before it is empty.

Operation
12 3A4033J
Low Level Switch
When the oil reservoir is full, the low level float (llf) sits in
the high, raised position as shown in FIG. 9.
As oil is dispensed, the low level float travels down.
When the oil in the reservoir reaches low level, the fully
traveled down float (FIG. 10) closes the normally open
low level switch and a low level signal is sent to the
lubricator controller (J).
Shut Down
Refer to FIG. 1, page 6, for the following instruction.
To shut down the system:
a. Close the bleed-type master air valve (F).
b. Turn off electrical supply to the lubrication
controller (J).
FIG. 9: Low level float in raised position
FIG. 10: Low level float in fully traveled down position
llf
llf

Operation
3A4033J 13
Lubrication System Sizing and Calculation Guidelines
Table 1: Lubricant Output and Pressure - US
NOTE: The lubricant output per pump stroke must be less than the amount of lubricant discharged per pump
stroke.
Table 2: Lubricant Output and Pressure - Metric
1. Total Injector Volume to Dispense and Charge
a. Add together the total number of injectors in
the system.
b. From Table 1 or Table 2, find the Injector Type
in the first column and the related Injector Vol-
ume to Charge in the third column. Multiply this
value by the total number of injectors deter-
mined in Step a.
2. Calculate the volume of lubricant in the Pipeline (G):
a. Use the pipe’s inside diameter (ID) measure-
ment to calculate the area of the pipe.
b. Measure the length of the pipe (G) only. Do not
include the feeder lines (S) in this calculation.
c. Multiply the area of the pipe calculated in
Step a by the length of the pipe measured in
Step b.
3. Calculate line expansion and fluid compression in
the pipe using the 10% Rule - multiply the volume
calculated in Step 2 by 10%.
4. Calculate the Total System Volume required.
a. Add together the total from Step 1 and Step 3
only. Do not include Step 2.
b. The Total System Volume required must be
less than the Pump Lubricant Output / Stroke
provided in the fourth column of Table 1 or
Table 2.
c. If the Total System Volume required is greater
than the Pump Lubricant Output / Stroke pro-
vided in the fourth column of Table 1 or Table 2,
split the system into two or more systems.
1 2 3 4 5 6 7
Injector
Type
Max
Injector
Output
cu. in.
Injector
Volume to
Dispense
and Charge
cu. in.
Max Pump
Lubricant
Output /
Stroke
cu. in.
Maximum Pressure Minimum
Pressure Recommended Pressure
Output PSI
Required Air
PSI Output PSI
Required
Air PSI Output PSI
Required Air
PSI
GL-43 0.008 0.016 0.56 1000 40 750 31 850 35
GL42 0.003 0.006
1 2 3 4 5 6 7
Injector
Type
Max
Injector
Output
cc
Injector
Volume to
Dispense
and Charge
cc
Max Pump
Lubricant
Output /
Stroke
cc
Maximum Pressure Minimum
Pressure Recommended Pressure
Output
MPA (bar)
Required Air
MPA (bar)
Output
MPA (bar)
Required Air
MPA (bar)
Output
MPA (bar)
Required Air
MPA (bar)
GL-43 0.131 0.262 9.18 6.9 (68.9) 0.27 (2.7) 5.2 (51.7) 0.21 (2.1) 5.9 (58.6) 0.24 (2.4)
GL42 0.049 0.098

Repair
14 3A4033J
Repair
Seal Replacement
NOTE: For most seal replacement procedures, the
pump should be completely removed from service and
clamped in a vise. For only replacing the reservoir
and/or reservoir seals, it is not necessary to remove the
pump from the service location. The following instruc-
tions cover the complete disassembly of the pump. The
pump repair may not require total pump disassembly.
Disassembly
1. Turn off the air supply and disconnect the air lines
to the pump.
2. Disconnect electrical connections to the lubrication
controller.
3. Follow the Pressure Relief Procedure, page 11.
4. Disconnect the supply line (G, page 6) from the
pump outlet (E, page 6).
5. Use a hex wrench to slowly loosen and remove the
drain plug (40) from the pump base and drain oil
from the pump (FIG. 11).
NOTE: Removing the plug slowly prevents splash-
ing while the oil drains from the reservoir.
6. Collect the drained oil in a pail or waste container.
Dispose of oil according to all regulations for proper
disposal.
7. Replace drain plug (40).
8. Remove the mounting bolts (FIG. 12) and remove
the pump from service.
9. Clamp the air motor cylinder (3) in a vise as shown
in FIG. 13. Use a soft-jaw vise or place a rag in the
vise jaws to protect the surface of the pump base.
FIG. 11
40
FIG. 12
FIG. 13

Repair
3A4033J 15
Reservoir Gaskets (10)
10. Use a wrench to loosen and remove the nut (17)
from the reservoir cover (18) (FIG. 14).
11. Remove the cover (18) from the reservoir (11).
12. Remove reservoir (11) from the air motor cylinder
(3) (FIG. 15). If replacing the reservoir gaskets (10),
remove gaskets from the reservoir. Dispose of the
gaskets according to all regulations for proper dis-
posal.
FIG. 14
17
18
FIG. 15
11
10
18
17
10
3

Repair
16 3A4033J
Outlet Tube O-Ring (13) and Pump Cylinder
O-Ring (9).
13. Securely hold the nut (3a), located on the bottom of
the pump cylinder (12), in place with a wrench.
Secure a second wrench on the flats of the outlet
tube (14). Turn the outlet tube counter-clockwise to
loosen and remove it from the pump cylinder (12)
(FIG. 16).
14. Loosen the nut (3a) and remove the pump cylinder
(12) from the air motor cylinder (3) (FIG. 17).
15. Remove the o-ring (13) from the outlet tube (14).
Remove the o-ring (9) from the pump cylinder (12).
Dispose of the o-rings according to all regulations
for proper disposal (FIG. 18).
FIG. 16
14
12
3a
flats
FIG. 17
FIG. 18
3a
12
3
12
9
13
14
19

Repair
3A4033J 17
Pump Piston Subassembly (33).
16. Secure a wrench on the flats of piston rod (34). Use
a second wrench to remove the lock nut (31) and
star washer (32) from top of the piston (FIG. 19).
17. Remove the lock nut and star washer. Keep these
parts for reassembly.
18. Examine the piston assembly (33) for scratches and
other wear and damage. If damaged, replace the
pump piston assembly (33).
19. Reposition the air motor cylinder in vise to access
the bottom of the air motor cylinder (FIG. 20).
20. Secure a wrench on the cover nut (1a). Turn it
counter-clockwise loosen and remove the cover (1)
from bottom or air motor cylinder. (FIG. 20).
NOTE: There is a spring (6) inside the air motor cylinder
(3) under the piston (5). Hold hand on the cover (1) for
resistance and hold it down while loosening the cover
screws (1a) (FIG. 21).
FIG. 19
33
32
31
31
32
34
33
FIG. 20
FIG. 21
1A 1
5
6
3
34

Repair
18 3A4033J
21. Remove the cover (1), the cover o-ring (2) and the
spring (6). Dispose of the o-ring according to all
regulations for proper disposal (FIG. 22).
Piston Rod O-Ring (36) and Piston Seal (4)
22. Remove the piston rod (34), the piston (5), and the
spring (6) from the air motor cylinder (3) (see FIG.
21, page 17).
23. Separate the piston rod (34) and the piston (5) using
two wrenches, working in opposite directions.
Secure one wrench to flats of piston rod and the
second wrench to loosen the nut (37) (FIG. 23).
24. Remove the o-ring (4) from the piston (5) (FIG. 24).
25. Dispose of the piston seal (4), the o-ring (34a) and
the nut (37) according to all regulations for proper
disposal.
26. Use a pick to remove the o-ring (34a) from the pis-
ton rod (34) (FIG. 25).
FIG. 22
FIG. 23
1
2
3
34
37
5
FIG. 24
FIG. 25
5
4
34
34a

Repair
3A4033J 19
27. Use a pick to remove the bushing (35) and u-cup
seal (36) (FIG. 26).
28. Use a smooth, long brass or aluminum rod, free of
sharp edges and burrs, to push the check valve
assembly (19) out of the outlet tube (14) (FIG. 27).
29. Dispose of the check valve assembly (19) accord-
ing to all regulations for proper disposal.
Reassembly
Use all of the new parts included in the repair / service
kit even if the old parts do not appear to be worn or
damaged and dispose of the old parts according to all
regulations for proper disposal.
1. Install u-cup seal (36) with lips facing up, and bush-
ing (35) in air cylinder (3) (FIG. 28).
Check Valve Assembly (19)
2. Coat the new check valve assembly (19) with a thin
layer of grease.
3. Use a smooth, long brass or aluminum rod, free of
sharp edges and burrs, to push the check valve
assembly (19) into place in the outlet tube (14)
(FIG. 29).
FIG. 26
FIG. 27
35
36
19 14
FIG. 28
FIG. 29
36 35
19
14

Repair
20 3A4033J
Piston Rod-O-Ring (34a) and Piston Seal (4)
NOTE: Do not clamp the piston rod (34) in vise.
4. Use a clean cloth to wipe down the piston rod (34)
and the piston (5) to remove any dirt or contami-
nants. Inspect surfaces for any scratches or dam-
age. Replace damaged parts.
5. Apply a thin layer of grease to the o-ring (34a).
Install the o-ring over the grooves of the piston rod
(34) (FIG. 30).
NOTE: If needed, a pick can be used to seat the
o-ring over the grooves of the piston rod (13).
6. Push the piston (5) over end of the piston rod (34)
until seated on the rod (FIG. 31).
NOTE: A pop sound occurs when placed correctly.
7. Install the nut (37) over the end of the piston rod
(34). Use two wrenches, working in opposite direc-
tions to tighten the nut. Secure one open end
wrench to flats of piston rod and use the second
wrench to tighten the nut. Torque nut to 13 to 15 ft.
lbs (17.6 to 20.3 N.m) (FIG. 32).
8. Apply a thin layer of grease to the piston seal (4).
Install the seal around the piston (5) as shown in
FIG. 33.
FIG. 30
FIG. 31
34
34a
5
34
FIG. 32
FIG. 33
34
37
5
4
5