Graco LubePro A4000 User manual

Instructions
Grease or Oil A4000
Reciprocating
LubePro™ Pump 3A5266G
EN
For pumping non-corrosive and non-abrasive lubricants only. For professional use only.
Models: Page 2
4000 psi (27.58 MPa, 275.8 bar) Maximum Working
Pressure
Related Manuals
406900 - Air Motor Repair Kit
Important Safety Instructions
Read all warnings and instructions in
this manual. Save these instructions.

Contents
2 3A5266G
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Typical Installation: Injector System . . . . . . . . . . 5
Typical Installation: Divider Valve System . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Low Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air and Fluid Line Accessories . . . . . . . . . . . . . . 8
Electric Vent Valve Kit . . . . . . . . . . . . . . . . . . . . . 8
Fill Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Set System Pressure . . . . . . . . . . . . . . . . . . . . . 11
Pressure Relief Procedure . . . . . . . . . . . . . . . . 11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove Air Motor . . . . . . . . . . . . . . . . . . . . . . . 14
Pump Lower Disassembly . . . . . . . . . . . . . . . . 14
Pump Lower Reassembly . . . . . . . . . . . . . . . . . 16
Parts: Grease Models . . . . . . . . . . . . . . . . . . . . . . 18
Parts: Grease Models . . . . . . . . . . . . . . . . . . . . . . 19
Parts: Oil Models . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Parts: Oil Models . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Repair Air Valve . . . . . . . . . . . . . . . . . . . . . . . . . 22
Replace Pilot Valves . . . . . . . . . . . . . . . . . . . . . 24
Repair Air Motor . . . . . . . . . . . . . . . . . . . . . . . . 24
Air Motor Installation . . . . . . . . . . . . . . . . . . . . . 27
Air Motor Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Air Motor Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Complete Air Valve Replacement Kit . . . . . . . . 30
Air Valve Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Pump Kits Parts . . . . . . . . . . . . . . . . . . . . . . . . 32
Additional Pump Kits . . . . . . . . . . . . . . . . . . . . . 32
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Grease Pump Dimensions and Mounting . . . . . . 34
Oil Pump Dimensions and Mounting . . . . . . . . . . 35
Performance Curve . . . . . . . . . . . . . . . . . . . . . . . . 36
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 38
Models
Pneumatic
Vent Valve
Series
Progressive
Electric Vent
Valve
Low Level
Detection Fluid
Reservoir
Size Ratio
Pressure
PSI Bar
17U217 - - • Grease 12 lbs (6 L)
40:1 4000 275.8
17P750 17T176 17T193 6 lbs (3 L)
17P751 17T177 17T194 •
17P752 17T178 17T195 Oil 12 pints
(5.5 L)
17P753 17T179 17T196 •

Warnings
3A5266G 3
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.
PLASTIC PARTS CLEANING SOLVENT HAZARD
Many cleaning solvents can degrade plastic parts and cause them to fail, which could cause serious
injury or property damage.
• Use only compatible solvents to clean plastic structural or pressure-containing parts.
• See Technical Specifications in all equipment manuals for materials of construction. Consult the
solvent manufacturer for information and recommendations about compatibility.

Warnings
4 3A5266G
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 Specifi-
cations in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request Safety Data Sheets (SDSs) 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 man-
ufacturer’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.
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 manufac-
turer.
CALIFORNIA PROPOSITION 65
This product contains a chemical known to the State of California to cause cancer, birth defects or
other reproductive harm. Wash hands after handling.
WARNING

Installation
3A5266G 5
Installation
Typical Installation: Injector System
(grease model pump shown)
Key:
A Main Air Supply
A1 Switched Air Supply
A2 Vent Valve Air Supply
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
H Injector
J Lubricator Controller
K Pump Reservoir
L Ground
M Vent Valve
N Low Level Switch (not installed on all pump models)
P Tee-fitting to Vent Valve
R Pump Air Inlet
S Pressure Switch
T Air Motor
FIG. 1: Typical Installation
J
B2
B1
F
B3
C
H
K
G
A
R
E
A1
M
N
D
A2
L
S
P
T
Power to
Controller

Installation
6 3A5266G
Typical Installation: Divider Valve System
(oil model pump shown)
Key:
A Main Air Supply
A1 Switch 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
J Lubricator Controller
K Pump Reservoir
L Ground
R Pump Air Inlet
T Air Motor
U Cycle Switch
V Divider Valve
FIG. 2: Typical Installation
J
B2
B1
F
B3
C
K
G
A
L
E
A1
V
N
D
U
R
T
Power to
Controller

Installation
3A5266G 7
Grounding
Secure ground wire to grounding screw (66) as shown
in FIG. 3.
Mounting
Install the pump in a location that will adequately sup-
port the weight of the pump when filled with lubricant
and also provides easy operator access to the pump air
controls. See Technical Data, page 35 for pump weight
information and the Dimensions and Mounting layout,
page 28.
1. Secure wall bracket (39) to mounting location. (User
must provide mounting hardware.)
2. Install pump bracket (38) to wall bracket (39).
Secure pump bracket to wall bracket using wash-
ers (60) and nuts (44).
Low Level
For models equipped with a low level switch, connec-
tion is made to pins 1 and 2 for normally closed opera-
tion or pins 1 and 3 for normally open operation. See
FIG. 4.
Grounding is required if a low level switch and/or
an air valve using voltages above 30 VAC or 42
VDC are 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 malfunc-
tion or breakdown.
FIG. 3
66
Mount the pump securely so that it cannot move
around during operation. Failure to do so could result
in injury or equipment damage.
FIG. 4

Installation
8 3A5266G
Air and Fluid Line Accessories
Refer to FIG. 1 and FIG. 2, pages 5 and 6, for the follow-
ing instructions.
Install the air line accessories in the order shown in FIG.
1 and FIG. 2, pages 5 and 6.
1. Install an air line filter (B1) to remove harmful dirt
and contaminants from the compressed air supply
2. Install the air regulator (B2) to control pressure.
3. Install an air line lubricator (B3) to lubricate the air
cylinder.
4. 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 and located
downstream of the air regulator.
5. Install the(3-way) air solenoid valve (C) for control of
the pump strokes.
6. Connect the vent valve (M).
-Pneumatic Vent Valve
Connect the air powered vent valve to the
pump supply air (A1).
a. Install a t-fitting (P) at the pump inlet.
b. Install a hose between the t-fitting and vent
valve.
-Electric Vent Valve
Connect to pump air control valve power.
a. Install a DIN connector into the vent valve.
b. Connect the leads to the controller output
that signals the pump to turn on.
7. To use the air regulator reading to determine the
fluid output pressure, multiply the ratio of the pump
(40:1) by the air pressure shown on the regulator
gauge; i.e., 40 psi x 40 = 1600 psi (2.75 bar x 40 =
110 bar; 0.27 MPa, x 40 = 10.8 MPa).
8. Limit the air pressure to the pump so that no air line
or fluid line component or accessory is over pres-
surized.
Electric Vent Valve Kit 129713
Grease Models 17T193 and 17T194; Oil
Models 17T195 and 17T196
1. Stop pump. Relieve pressure. See Pressure Relief
Procedure, page 11.
2. Disconnect air line from pump.
3. Remove plug (57) from pump base (2) (FIG. 5).
4. Install valve cartridge (68) in pump base (FIG. 5).
Torque coil nut (a) to 4 to 5 ft-lbs (5.42 to 6.78
N•m). Torque cartridge nut (b) to 16 to 20 ft-lbs
(21.69 to 27.12 N•m).
Trapped air can cause the pump to cycle unexpect-
edly, which could result in serious injury from splash-
ing or moving parts. An air shut off valve (bleed-type
master air valve) is required for the system to protect
you from injury when you are adjusting or repairing
the pump. The air bleed device relieves air trapped
between it and pump after the air supply is shut off.
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 the 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. 5
57 68
a
b

Installation
3A5266G 9
Fill Reservoir
Oil Models
1. Open oil fill cap (32) on the top of the reservoir.
NOTE: A filter (33) is installed at the oil fill cap (32) to
prevent lubricant contamination (FIG. 6).
a. Inspect filter (33) before filling reservoir.
b. When needed, remove filter (33) and clean it
thoroughly.
c. If removed in Step b, install filter (33) prior to
adding lubricant.
2. Slowly add oil (ol) until reservoir is filled to capacity
(FIG. 7). Take care to not fill reservoir too quickly
and overflow the reservoir capacity.
3. Close oil fill cap (32) to prevent contamination and
spillage (FIG. 7).
Grease Models
1. Remove dust cap (42) (FIG. 8) from fill stud (26).
2. Connect the quick connect fitting on the fill pump
to the fill stud (26) on the reservoir.
FIG. 6
32
33
FIG. 7
FIG. 8
32
ol
26
42

Installation
10 3A5266G
3. Slowly dispense grease from the fill pump into the
reservoir until the grease in the reservoir lifts the fol-
lower plate (45) above the reservoir vent hole (vh)
and air is expended from under the follower plate
(FIG. 9). A small amount of grease may come out of
the vent hole at this time.
Care must be taken not to overfill the reservoir. An
over filled reservoir will vent the excess grease out
of the vent hole (vh) until enough grease is expelled
for the follower plate (45) to block the vent hole.
Overfilling the reservoir could also cause the reser-
voir to rupture due to over-pressurization.
NOTE: The vent hole (vh) is located toward the back
right side of the reservoir and cannot be seen in FIG. 9.
The approximate location of the vent hole is identified
as vh in the illustration.
4. Disconnect the fill pump from the fill stud (26, FIG.
8).
5. Secure dust cap (42) over fill stud (26) (FIG. 8).
Priming
Refer to FIG. 1 and FIG. 2, pages 5 and 6, for the follow-
ing instructions.
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 instructions,
page 8).
Run the pump until lubricant, free of air, comes out of
the pump outlet (E). It may take up to 20 pump strokes
to expel the air from the pump and deliver a continuous
flow of lubricant. This will depend on the viscosity of the
lubricant and temperature.
Supply Lines
1. Run the pump until the oil (ol), free of air, comes out
of the pump outlet (E). Connect the supply line (G)
to the pump outlet (E).
2. If there are multiple pumps on the air line, close the
air regulators and bleed-type master air valves to all
but one of the pumps. If there is only one pump,
open its air regulator and bleed-type master air
valve.
3. Open the master air valve from the compressor.
4. Set the air pressure to each pump at the lowest
pressure needed to get the desired results.
Feeder Lines
Fill each feeder line with lubricant prior to connecting
feeder lines to the injector outlet or divider valve.
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.
Over-pressurization can result in equipment rupture
and serious injury. Fill slowly to avoid over pressuriz-
ing reservoir.
FIG. 9
45
(vh) (gr)

Installation
3A5266G 11
Divider Valves
1. Check for valve operation by
- using a performance indicator (shows that the
valve has cycled),
- or, checking for lubricant dispensing at each
lube point.
2. Adjust the injector output if needed to ensure that
the output volume discharged is sufficient.
Pressure Relief Valve
Adjustment
The pressure relief valve is factory set to 4000 psi
(275.8 bar, 27.6 MPa) for grease models and 1000 psi
(68.95 bar, 6.89 MPa) for oil models.
The relief point may require adjustment in systems that
have components that are rated higher or lower than
the factory presets. Do not exceed 4000 psi (275.8
bar, 27.6 MPa) in either grease or oil systems.
To adjust the pressure relief
valve, turn the pressure
adjustment screw (a) clock-
wise to increase the pres-
sure relief point or
counter-clockwise to
decrease the pressure relief
point.
Whenever the valve is
set/adjusted (after the set
point is found) it is import-
ant to ensure that the valve is not bottomed out and
there is at least 1/2 turn of adjustment remaining. This
is determined by turning the screw (a) 1/2 turn and then
back turning it out again.
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Close the bleed-type master air valve (F, page 5)
(required in the system).
2. To relieve pressure in the system use a wrench to
slowly loosen the lubrication line fitting (G) until no
lubricant or air is leaking out of the fitting (FIG. 10).
a
locking
nut
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. 10
G

Operation
12 3A5266G
Operation
Refer to FIG. 1 and FIG. 2, pages 5 and 6, for the follow-
ing instructions.
Pump
Start Up
1. Verify reservoir is filled with lubricant and system
has been Primed (see Prime System, page 10).
2. Turn on the lubrication controller (J) power switch.
3. Program the lubrication controller to actuate the air
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 pump is supplied with air through the air
solenoid valve (C) and then to the pump air inlet
(R).
b. Fluid is pumped to the lube metering device
until the air solenoid valve (C) is turned off.
c. After the air solenoid valve (C) shuts off, the
pneumatic vent valve relieves the pressure in
the lubricant lines (A1 and A2).
d. In systems using a vent valve, fluid pressure is
vented to the pump reservoir.
In systems using an electric vent valve, an elec-
trical signal to the vent valve is required to build
pressure. The same signal can be used to cycle
the air valve and close the vent valve.
Low Level Switch
(Models 17P751 (grease) and 17P753 (oil) only)
Oil Model 17P753
When the oil reservoir is full, the low level float (37) sits
in the high, raised position as shown in FIG. 11.
As oil is dispensed, the low level float (37) begins to
travel downward. When the oil in the reservoir reaches
a low level, the magnet in the bottom of the float acti-
vates the low level switch (35), changing its state to
either open or closed.
Grease Model 17P751
As the grease is dispensed, the follower plate (45) trav-
els down the reservoir. When it gets close to the low
level switch (35), the magnet on the bottom of the fol-
lower plate assembly activates the switch, changing its
state to either open or closed.
Shut Down
To shut down the system, close the bleed-type master
air valve (F, page 5 and 6) and turn off the electric
power to the controller.
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 reservoir before it is empty.
FIG. 11: Low level float in raised position
FIG. 12
37
35
45
35
35

Troubleshooting
3A5266G 13
Troubleshooting
Problem Cause Solution
Pump is not operating. No lubricant
flow.
No air 1. Adjust air pressure/supply.
2. Open bleed-type master air valve (F)
(page 5 and 6).
Pump is operating. No lubricant flow.
No lubricant in reservoir Fill the reservoir.
Losing prime 1. Remove trapped air (see Priming,
page 10).
2. Prime pump.
Injectors not cycling or only some of the
injectors are operating
No lubricant flow See Pump is not operating. No lubri-
cant flow in Troubleshooting table.
Low pressure or no pressure 1. Check piping for leaks. If a leak is
detected, repair or replace piping.
2. Check injectors for leaks. If a leak is
detected, repair or replace injector.
3. If the pressure relief valve is set
below the injector firing pressure,
the injector will not operate. See
page 11 for pressure relief setup
instructions.
4. Check vent and relief valve o-rings.
Damaged/worn o-rings will not allow
pump to reach full pressure.
Pump seals are bad Replace seals. See Parts, page 18
and 20.
Divider valve not cycling
No lubricant flow See Troubleshooting, Pump is not
operating.
Low lube point pressure or no pressure
See Troubleshooting, Pump is not
operating.
Check valve block for leaks.
Check valve block for stuck pistons.
Pump seals are damaged Replace seals.

Repair
14 3A5266G
Repair
Remove Air Motor
See Oil and Grease Parts, pages 18 and 20.
1. Shut down pump, page 12. Relieve pressure. See
Pressure Relief Procedure, page 11.
2. Disconnect air line from pump.
3. Remove screws, (40), washers (41) and finger guard
(58) from pump base (2) (FIG. 13).
4. Slide the retaining spring (22) off of the pin (21) and
remove pin (FIG. 14).
5. Remove the three screws (16) and washers (59)
holding air motor (1) to pump base (2). Remove air
motor from pump base (FIG. 15).
Pump Lower Disassembly
1. Follow the Remove Air Motor instructions to
remove the air motor (1) from the pump base (2) (if
required).
OR
Shut down pump, page 12. Relieve pressure. See
Pressure Relief Procedure, page 11.
NOTE: It is not necessary to remove the air motor (1)
from the pump base (2) to disassemble the pump lower.
However, it is easier to access all of seals with the air
motor removed.
2. Remove the pump end nut (15) and o-ring (8) from
pump base (2) (FIG. 16).
3. Remove take up nut (14) from the pump base (2).
FIG. 13
FIG. 14
58
41
40
2
22
21
FIG. 15
FIG. 16
16
59
1
2
15
8
14
2

Repair
3A5266G 15
4. Pry the pump cylinder (11) out of the pump base (2)
(FIG. 17).
NOTE: Be careful not to scratch or damage the
outside surface of the pump cylinder and/or inside
cavity of the pump base (2) when removing the
pump cylinder
5. Remove o-ring (6) from shovel seal retainer (10).
6. Remove pump cylinder (11) and piston rod assem-
bly from pump base (2) casting.
7. Inspect H-wiper seal (3) for damage and wear. If it
is damaged and/or worn, remove it from pump
base (2) (FIG. 19).
8. Remove seal retainer (9) from pump base (2).
Remove u-cup seal (4), o-ring (6) and bearing (5)
from seal retainer (FIG. 19).
9. Separate the piston rod assembly from pump cylin-
der (11).
10. Remove the spring pin (20) securing the piston rod
(19) to the shovel rod (12). Unscrew the piston rod
to separate if from the shovel rod (FIG. 20).
11. Remove intake seal (17) from shovel rod (12).
12. Remove o-ring (7) from shovel seal retainer (10).
13. Unscrew alignment rod (13) to separate it from the
piston rod (19).
NOTE:
- It may be easier to separate the two parts by
clamping the piston rod in a vise. Take care
when clamping the rod in a vise to not
over-tighten the vise around the rod which
could damage the rod or scratch the outside
surface. Clamp only on recessed surface of
piston rod (19).
- If using a vise, to prevent the rod from rotating
while separating the two parts, insert a pin that
is longer than the spring pin (20) through the
pin holes.
14. Remove the piston seal (18) from piston rod (19).
15. Remove shovel seal retainer (10) from the shovel
rod (12).
16. Remove u-cup seal (4), bearing (5) and two o-rings
(6) from the pump cylinder (11).
17. Clean and inspect all parts for scratches and or
scoring. If damage is found or a loss of perfor-
mance was noted during pump operation, replace
parts.
FIG. 17
FIG. 18
FIG. 19
2
11
610
3
94 5
2 6
FIG. 20
NOTICE
Be careful when tightening piston rod in vise to not
crush, scratch or damage the outside surface of the
piston rod and/or alignment rod. A scratched or
damaged surface can create a leak path for fluid.
20
18
12 10 6717 13
19

Repair
16 3A5266G
18. Inspect pump base (2) casting for scratches and
scoring. If excessive damage is found, replace
pump.
Pump Lower Reassembly
See Oil and Grease Parts, pages 18 and 20.
NOTE:
Pump Lower Soft Seal Kit 17T654 is available (see page
30). Parts marked with ‡.
Hard Parts and Seal Kit 17T655 is available (see page
30). Parts marked with ❖.
For best results, use all of the parts in the kit.
1. Press bearing (5❖) into the pump cylinder (11❖).
2. Install two o-rings (6‡❖) around pump cylinder
(11❖).
3. Install shovel seal retainer (10❖) on piston shovel
rod (12❖).
4. Lubricate o-ring (7‡❖) and install on the end of the
shovel seal retainer (10❖).
5. Install intake seal (17‡❖) on the shovel rod (12❖)
(FIG. 21).
NOTE: When installed correctly the flat end of the
intake seal (17‡❖) meets the flat surface of the
shovel rod retainer (10❖). The jagged end of the
intake seal will be facing the piston rod (19).
6. Install piston seal (18‡❖) to piston rod (19❖).
7. Clean threads of piston rod (19❖) and alignment
rod (13❖) with solvent to prepare it for thread lock-
ing compound (FIG. 21).
8. Apply oil resistant, thread locking compound (user
supplied) to threads of piston rod (19❖) and align-
ment rod (13❖). Screw the two rods together.
Torque to 25-35 ft-lbs (34 to 47.5 N•m).
NOTE:
- It may be easier to assemble the two parts by
clamping the piston rod in a vise. Take care
when clamping the rod in vise to not
over-tighten the vise around the rod which
could damage the rod or scratch the outside
surface. Clamp only on recessed surface of
piston rod (19).
- If using a vise, to prevent the rod from rotating
while torquing the two parts. insert a pin that is
longer than the spring pin (20) through the pin
holes.
9. Screw shovel rod (12❖) into piston rod (19❖).
Tighten until pin holes in each rod (FIG. 21) align.
10. Install spring pin (20‡❖) through holes aligned in
Step 6 (FIG. 21).
11. Install piston rod (19❖) and shovel rod (12❖)
assembly inside pump cylinder (11❖).
12. Install bearing (5❖) in seal retainer (9❖).
13. Lubricate wiper seal (4‡❖) and install in the seal
retainer (9❖).
NOTE: The lips of the wiper seal (4‡❖) should be
facing out; toward the piston shovel rod (12❖).
14. Lubricate o-ring (6‡❖) and install o-ring around the
seal retainer (9❖).
15. If the H-wiper seal (3‡❖) was removed in Pump
Lower Disassembly, Step 7, page 15, lubricate new
seal from kit and install it in pump base (2).
NOTE: The lips of the H-wiper seal (3‡❖) should be
facing in; toward the pump cylinder (11❖).
FIG. 21
20
18
12 10 6
17
13
19
❖❖‡❖
‡❖
7
‡❖‡❖
❖‡❖❖
FIG. 22
3‡
11

Repair
3A5266G 17
16. Push seal retainer (9❖) into pump base (2).
17. Partially install pump cylinder (11❖) in pump base
(2).
18. Lubricate o-ring (6‡❖) and install it around the
shovel seal retainer (10❖) (FIG. 23).
19. Press pump cylinder assembly into pump base (2).
20. Lubricate u-cup (4‡❖) and install it in the pump cyl-
inder (11).
NOTE: The lips of the u-cup seal (4‡❖) should be
facing in; toward the piston rod (19❖).
21. Install nut (14) in pump base (2). Torque to 100 to
105 ft.-lbs (135.6 to 142.4 N•m) (FIG. 24).
22. Lubricate o-ring (8‡❖). Install o-ring and pump end
nut (15) in pump base (FIG. 24). Torque end nut to
45 to 50 ft.-lbs (61.01 to 67.79 N•m).
23. If the air motor does not require maintenance or
repair, install air motor. See Air Motor Installation
instructions, page 27.
FIG. 23
FIG. 24
610
‡❖❖
15
8
14
2
‡❖

Parts: Grease Models
18 3A5266G
Parts: Grease Models
▲Replacement Danger and Warning labels, tags, and
cards are available at no cost.
‡ Included Soft Seal Kit 17T654. See page
❖ Included in Hard Part and Seal Kit 17T655. See page
✺ Included in Low Level Grease Kit 17T657. Kit also includes
125520 - DIN Connector and 17C623 - Magnet.
Ref Part No. Description Qty
1 25D081 MOTOR, air 1
2 BASE, pump 1
3 ‡❖SEAL, H-wiper, 0.625 ID 1
4 ‡❖SEAL, u-cup, quad ring,
0.625 ID
2
5❖BEARING, 0.625 x 0.875 x
0.375LNG
2
6 ‡❖PACKING, o-ring 4
7 ‡❖O-RING 1
8 ‡❖O-RING, 030 Buna 1
9❖RETAINER, seal 1
10 ❖RETAINER, seal, shovel 1
11 ❖CYLINDER, pump 1
12 ❖ROD, shovel, piston 1
13 ❖ROD, alignment 1
14 NUT, take up 1
15 NUT, pump end 1
16 SCREW, cap, hex head 3
17 ‡❖SEAL, intake 1
18 ‡❖SEAL, piston 1
19 ❖ROD, piston, 50:1 1
20 ‡❖PIN, spring 1
21 ❖PIN, straight 1
22 ❖SPRING, retaining 1
23 102814 GAUGE, pressure, fluid 1
24 24Z687 VALVE, cartridge, air 1
25 125495 VALVE, pressure relief
cartridge
1
26 STUD, fill 1
27 ROD, tie 5/12# reservoir 3
28 GASKET, reservoir 1
29 CAP, reservoir 1
30 RESERVOIR, plastic 1
31 ✺PACKING, o-ring 1
34 SPACER, aluminum, 0.343I inch.
5 hex, 0.25
3
35
17C665 PLUG, low level switch, model
17P750, 17T176, 17T193
1
✺SWITCH, low level, NO and NC,
model 17P751, 17T177, 17T194
1
36 NUT, low level float mount 1
38 BRACKET, pump, top 1
39 BRACKET, pump, wall 1
40 SCREW, cap, hex head 6
41 WASHER, lock 9
42 CAP, dust 1
43 597151 FITTING, elbow, 1/4 OD x 1/8
NPT, 17P750, 17P751
1
44 NUT, nylock st 5/16-18 4
45 PLATE, follower 1
55▲16W503 LABEL, ground (not shown) 1
56▲130175 LABEL, warning, pressurized
equipment
1
57 17T189 PLUG, SAE-08, models 17T176,
17T177, 17T193, 17T194
1
58 GUARD, finger 1
59 WASHER, lock, 3/8 inch 3
60 WASHER, plain 4
66 SCREW, ground 1/4-20, green 1
67▲15H108 LABEL, warning, pinch 1
68 129713 VALVE, HF, cartridge, 24VDC,
DIN, 17T193, 17T194
1
69 125520 CONNECTOR, DIN, form A,
4-pin
1
Ref Part No. Description Qty

Parts: Grease Models
3A5266G 19
Parts: Grease Models
35
31
58
40
41
16
59
3
6
5912
6
6
11
17
7
10
24
38
44
60
39
13
20
18
19 414 15
21 22
1
23
28
66
56
41
40
25
26/42
30
27
29
34
41 52
45/49
46
45
2
67
46
8
5
43 68
69

Parts: Oil Models
20 3A5266G
Parts: Oil Models
▲Replacement Danger and Warning labels, tags, and cards
are available at no cost.
‡ Included Soft Seal Kit 17T654. See page 28.
❖ Included in Hard Part and Seal Kit 17T655. See page 28.
✖ Included in Low Level Oil Kit 17T656. Kit also includes
125520 - DIN Connector.
Ref Part No. Description Qty
1 25D081 MOTOR, air 1
2 BASE, pump 1
3 ‡❖SEAL, H-wiper, 0.625 ID 1
4 ‡❖SEAL, u-cup, quad ring,
0.625 ID
2
5❖BEARING, 0.625 x 0.875 x
0.375LNG
2
6 ‡❖PACKING, o-ring 4
7 ‡❖O-RING 1
8 ‡❖O-RING, 030 Buna 1
9❖RETAINER, seal 1
10 ❖RETAINER, seal, shovel 1
11 ❖CYLINDER, pump 1
12 ❖ROD, shovel, piston 1
13 ❖ROD, alignment 1
14 NUT, take up 1
15 NUT, pump end 1
16 SCREW, cap, hex head 3
17 ‡❖SEAL, intake 1
18 ‡❖SEAL, piston 1
19 ❖ROD, piston, 50:1 1
20 ‡❖PIN, spring 1
21 ❖PIN, straight 1
22 ❖SPRING, retaining 1
23 102814 GAUGE, pressure, fluid 1
24 24Z687 VALVE, cartridge, air, models
17P752 and 17P753
1
25 125495 VALVE, pressure relief
cartridge
1
27 ROD, tie 5/12# reservoir 3
28 GASKET, reservoir 1
29 CAP, reservoir 1
30 RESERVOIR, plastic, 12 L 1
31 ✖PACKING, o-ring 1
32 557797 CAP, fill, reservoir 1
33 557799 SCREEN, filter 1
34 SPACER, aluminum, 0.343I inch.
5 hex, 0.25
3
35
17C665 PLUG, low level switch, model
17P752, 17T178, 17T195
1
✖SWITCH, low level, NO and NC,
model 17P753, 17T179, 17T196
1
36 NUT, low level float mount 1
37 ✖FLOAT, low level, oil, model
17P753
1
38 BRACKET, pump, top 1
39 BRACKET, pump, wall 1
40 SCREW, cap, hex head 6
41 WASHER, lock 9
43 FITTING, elbow, 1/4 OD x 1/8
NPT
1
44 NUT, nylock st 5/16-18 4
45 PLUG, SAE-08, models 17T178,
17T179, 17T195, 17T196
1
55▲16W503 LABEL, ground (not shown) 1
56▲130175 LABEL, warning, pressurized
equipment
1
58 GUARD, finger 1
59 WASHER, lock, 3/8 inch 3
60 WASHER, plain 4
62 PLUG, dry seal, 1/4 NPTF 1
63 PLUG, pipe, 3/8 NPTF 1
66 SCREW, ground 1/4-20, green 1
67▲15H108 LABEL, warning, pinch 1
68 129713 VALVE, HF, cartridge, 24VDC,
DIN, 17T195, 17T196
1
69 125520 CONNECTOR, DIN, form A,
4-pin
1
Ref Part No. Description Qty