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)