Graco Modu-Flo AL-5M User manual

332042D
EN
Instructions
Modu-Flo® Pumps
For dispensing a specific volume of lubricant. For use with Graco Modu-Flo manifold
packages. For professional use only.
Part No.:
Pneumatic - 563304, 563306, 563308, 563347, 563348, 563351, 563353, 563354
Hydraulic - 563305, 563307, 563345
See page 2 for model information, including maximum working pressure.
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment. Save all
instructions.
ti20035
ti20044
Hydraulic Pump Pneumatic Pump

Models
2 332042D
Models
*Refers to motor action, not lube piston action: all lube
pistons are single-acting
**Do not exceed 10 cpm with grease (3 seconds on, 3
seconds off)
***Pneumatic or hydraulic cylinder displacement volume
at maximum output setting
General Information
• AL or models may be single or double acting.
• ALJ and HLJ refer to double acting motors.
- Double acting air motors require 4-way air
valve.
- All hydraulic models are double acting.
• All models have single acting lube piston.
• All models are designed to mount directly to either
a pump-to-reservoir manifold or a pump-to-wall
manifold.
- See manual 313830 for information on
manifolds.
Part No. Model Actuation Pump
Ratio
Air or
Hydraulic
Motor
Action*
Output
Displacement
Range cu.in. (cm³)
per stroke
Max.
Cycles
per
Minute**
Approx.
Weight,
lb (kg)
Input
Operating
Volume
per Full
stroke/cycle
cu.in. (cm³)***
Input Air/
Hydraulic
Pressure
PSI (bar)
Max.
Fluid
Output
Pressure
PSI (bar)
Min. Max.
563304 AL-5M Pneumatic 30:1 Single 0.010 to 0.030
(0.164 to 0.492)
30 3.75
(1.7)
1.06 (17.4) 40 (2.76) 150
(10.3)
3000
(206.8)
Double 60 2.09 (34.3)
563306 AL-25M Pneumatic 30:1 Single 0.030 to 0.120
(0.492 to 1.966)
30 4.75
(2.15)
4.20 (68.8) 40 (2.76) 150
(10.3)
3000
(206.8)
Double 60 8.28 (135.7)
563308 AL-50M Pneumatic 30:1 Single 0.060 to 0.240
(0.983 to 3.933)
30 6.5
(2.9)
8.40 (137.6) 40 (2.76) 150
(10.3)
3000
(206.8)
Double 60 16.56 (271.4)
563305 HLJ-5M Hydraulic 5.5:1 Double 0.010 to 0.030
(0.164 to 0.492) 100 3.375 (1.53) 0.35 (5.7) 200 (13.8)
2000
(138)
3000
(206.8)
563307 HLJ-25M Hydraulic 5.5:1 Double 0.030 to 0.120
(0.492 to 1.966) 50 5.5 (2.49) 1.38 (22.6) 200 (13.8)
2000
(138)
3000
(206.8)
563345 HLJ-5X Hydraulic 2.2:1 Double 0.030 to 0.092
(0.492 to 1.51) 50 3.375 (1.53) 0.28 (4.7) 200 (13.8)
3000
(207)
3000
(206.8)
563351 ALJ-5M Pneumatic 30:1 Double 0.010 to 0.030
(0.164 to 0.492) 60 3.75 (1.7) 2.09 (34.4) 40 (2.76) 150 (10.3)
3000
(206.8)
563348 ALJ-25M Pneumatic 30:1 Double 0.030 to 0.120
(0.492 to 1.966) 60 4.75 (2.15) 4.2 (68.8) 40 (2.76) 150 (10.3)
3000
(206.8)
563347 ALJ-50M Pneumatic 30:1 Double 0.060 to 0.240
(0.983 to 3.933) 60 6.5 (2.9) 16.56 (271.4) 40 (2.76) 150 (10.3)
3000
(206.8)
563353
AL-5M
Fixed
Output
Pneumatic 30:1
Single Fixed at 0.030
(0.492)
30 3.75
(1.7)
1.06 (17.4)
40 (2.76) 150
(10.3)
3000
(206.8)
Double 60 2.09 (34.3)
563354
AL-25M
Fixed
Output
Pneumatic 30:1
Single Fixed at 0.120
(0.492)
30 4.75
(2.15)
4.2 (68.8)
40 (2.76) 150
(10.3)
3000
(206.8)
Double 60 8.28 (135.7)

Warnings
332042D 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation 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.
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 surgi-
cal 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.

Warnings
4 332042D
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 Notes in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Notes in all equip-
ment 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
manufacturer’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.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, includ-
ing 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.
WARNING

Installation
332042D 5
Installation
Component Identification
Key:
A Single Acting (S.A.) Port
B Double Acting (D.A.) Port
C Mounting Holes
D Lube Inlet Port
E Lube Outlet Port
F Adjustment Cover
G Bleed Screw
FIG. 1
F
B
A
C
D
EGti20035

Installation
6 332042D
Installation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Disable the pump’s pneumatic or hydraulic supply.
2. Slowly loosen output connection fitting.
Bleeding Air
After assembly, disassembly and reassembly, it may be
necessary to bleed air from the pump. Follow the
procedure below:
1. After reinstalling the pump, cycle the pump a few
times. This should bleed out the air.
2. If cycling the pump does not bleed out the air,
loosen the bleed screw (29). Cycle the pump a few
times.
NOTE: Do not remove the ball (28) or bleed screw (29).
3. Re-tighten the bleed screw (29).
4. Operate the pump as usual.
Output Adjustment Procedure
Reference numbers used in the following procedure
refer to the Parts table, page 8.
1. Follow the Pressure Relief Procedure, page 6.
2. Remove adjustment screw cap (12) and gasket (8)
from adjustment screw (11), holding jam nut (9) with
a wrench if necessary (FIG. 2).
3. Place the adjustment screw cap (12) against the
jam nut (9) and use the stamped numbers on the
cap (cu. in. per stroke) to determine how much
adjustment is needed.
4. Loosen jam nut (9) and use a flat screwdriver to turn
adjustment screw (11). Turn adjustment screw in for
less output and turn out for more output (FIG. 3).
5. Tighten jam nut (9) and install gasket (8) and adjust-
ment screw cap (12) over the adjustment screw
(11).
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. 2
FIG. 3 AL-5 model shown
9
11
12
8
11
9
12
ti20036
ti20037

Troubleshooting
332042D 7
Troubleshooting
1. Follow Pressure Relief Procedure, page 6, before
checking or repairing gun.
Reference numbers used in the following procedure
refer to the Parts table, pages 8, 10, or 11.
Problem Cause Solution
Inconsistent Pump Output Air and/or lubricant leak between
the pump and the manifold
1. Check four socket head screws
(7) to make sure they are tight.
Torque to 60 to 70 in.lbs. (6.77 to
7.90 N•m).
Loose screws could allow air
and/or lubricant to leak between
the pump and the manifold.
1. Check for leakage past gasket
(8). Replace gasket if required.
Jam nut is loose Check jam nut (9) to make sure it is
tight against adjustment screw body
(10).
If the jam nut is loose, the
adjustment screw (11) could rotate
and cause the pump output to
change. This condition could also
result in either lubricant leakage or
air infiltrating the lubricant.
Irregular Lubricant Flow Air trapped in pump/system 1. Cycle the pump a few times.
This should bleed out the air.
2. If cycling the pump does not
bleed out the air, loosen the
bleed screw (29). Cycle the
pump a few times.
NOTE: Do not remove the ball (28) or
bleed screw (29).
3. Re-tighten the bleed screw (29).

Parts
8 332042D
Parts
Pneumatic Pump
Part No./Description
6
8
2
33
27
3
7
29
34
12
9
10
11
25
1
22
19
5
13
14
21
35
17
31
15
23
4
16
30
20 26
34
28
18
24
28
Ref. Part Description Qty.
563304 PUMP ASSEMBLY, AL-5M
563306 PUMP ASSEMBLY, AL-25M
563308 PUMP ASSEMBLY, AL-50M
1❄BODY, pump 1
2✿★◆ SPRING, check valve 1
3✿★◆ SEAT, check valve 1
4✿★◆ O-RING 1
5✿★◆ PIN, 1/8” dia x 1/4 lg 1
6 557617 SCREW, check valve enclosure 1
7 103345 SCREW, socket-head, 1/4-20 x
1-1/4
4
8✿★◆ GASKET 1
9✿NUT, jam, hexagon, 5/16-24 1
★NUT, jam, hexagon, 7/16-20 1
◆NUT, jam, hexagon, 1/2-20 1
10 560741 BODY, adjustment screw, AL-5M 1
15R127 BODY, adjustment screw, AL-25M 1
557592 BODY, adjustment screw, AL-50M 1
11 557589 SCREW, adjustment, AL-5M 1
15R126 SCREW, adjustment, AL-25M 1
560740 SCREW, adjustment, AL-50M 1
12 560737 CAP, adjustment screw, AL-5M 1
560738 CAP, adjustment screw, AL-25M 1
560739 CAP, adjustment screw, AL-50M 1
13 15M726 RETAINER, air cylinder 1
14 ✿★◆ SPRING, piston return 1
15 557563 PISTON, air, AL-5M 1
557567 PISTON, air, AL-25M 1
557570 PISTON, air, AL-50M 1
16 557562 CAP, cylinder, AL-5M 1
557566 CAP, cylinder, AL-25M 1
557569 CAP, cylinder, AL-50M 1
17 560728 RETAINER, spring, AL-5M 1
560727 RETAINER, spring, AL-25M 1
560721 RETAINER, spring, AL-50M 1
18❄PISTON, lube 1
Ref. Part Description Qty.

Parts
332042D 9
✿ Parts included in Kit 563902 (purchase separately)
★ Parts included in Kit 563903 (purchase separately)
◆ Parts included in Kit 563904 (purchase separately)
❄ Not available as replacement part
19 560708 CYLINDER, air, AL-5M 1
557565 CYLINDER, air, AL-25M 1
560723 CYLINDER, air, AL-50M 1
20❄LABEL, name serial 1
21 ✿★◆ O-RING 1
22 ✿★◆ O-RING 1
23 ✿★◆ O-RING 1
24 ✿★◆ O-RING 5
25 ✿★◆ O-RING 1
26 ✿★◆ O-RING 1
27 ✿★◆ O-RING 1
28 ✿★◆ BALL, sst 1/8” dia 2
29 ✿★◆ SCREW, bleed, 10-32” x 1/4” 1
30 ✿★◆ RING, retainer 1
31 ✿★◆ RING, retainer 1
33 ✿★◆ BALL, check, chrome stl, 3/16”
dia
1
34 ✿SEAL, washer, 5/16-24 thd 2
★SEAL, washer, 7/16-20 thd 2
◆SEAL, washer, 1/2-20 thd 2
35 ✿★◆ RING, retainer 1
✿563902 REPAIR KIT, AL-5M, includes 2 -
5, 8, 9, 14, 21 - 31, 33 - 35
1
★563903 REPAIR KIT, AL-25M, includes 2 -
5, 8, 9, 14, 21 - 31, 33 - 35
1
◆563904 REPAIR KIT, AL-50M, includes 2 -
5, 8, 9, 14, 21 - 31, 33 - 35
1
Ref. Part Description Qty.

Parts
10 332042D
Hydraulic Pump (HLJ-5M and HLJ-5X)
Part No./Description
❖Parts included in Kit 563905 (purchase separately).
✿Parts included in Kit 563925 (purchase separately).
❄ Not available as replacement parts
12
22
9
10
20
11
16
6
23
2
8
13
1
7
15
19
24
5
21
4
30
26 27
14
25
18 17
HL-5 model
3
HL-5X model
28 29
5
ti20046
Ref. Part Description Qty.
563305 PUMP ASSEMBLY, HLJ-5M
563345 PUMP ASSEMBLY, HLJ-5X
1❄LABEL, name serial 1
2❖✿ SPRING, check valve modu-flo 1
3❄BODY, pump 1
4 560711 PLUG, end 1
5❄PISTON, hydraulic 1
6❖✿ SEAT, check valve 1
7 103345 SCREW, cap sch 4
8❖✿ GASKET, copper 1
9 556379 NUT, 5/16-24 heavy hex hd 1
10 560741 BODY, adjustment 1
11 557589 SCREW, adjustment 1
12 560737 CAP, adjustment screw, HLJ-5M 1
560756 CAP, adjustment screw, HLJ-5X 1
13 ❖✿ SCREW, check valve enclosure 1
14 ✿O-RING 1
15 ❖O-RING 1
16 ❖✿ O-RING 1
17 ❖✿ O-RING 3
18 ❖✿ O-RING 1
19 ❖O-RING 1
20 ❖✿ O-RING 1
21 ❖✿ O-RING 1
22 ❖✿ SEAL, washer, 5/16-24 2
23 ❖✿ BALL, check, chrome stl 3/16” dia 1
24 ❖PIN, 1/8” dia grv type 1
25 ✿O-RING 1
26 ✿RING, back up 2
27 ✿RING, back up 2
28 ❖✿ BALL, sst 1/8” dia 1
29 ❖✿ SCREW, bleed, 10-32” x 1/4” 1
30 PISTON, lube 1
Ref. Part Description Qty.