Graco Python XL-DA25 Series Parts list manual

3A6831A
EN
Instructions-Parts
Python®XL-DA25
Pump
Pneumatic pump for injecting chemicals at well sites. Not for use with sour gas.
For professional use only.
Not approved for use in European explosive atmosphere locations.
See page 3 for model information, including maximum working pressures.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save all instructions.

23A6831A
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pump Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Configuration Number Matrix . . . . . . . . . . . . . . . . . 4
Pump Configuration . . . . . . . . . . . . . . . . . . . . . . 4
Lower Configuration . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . .5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Required Accessories . . . . . . . . . . . . . . . . . . . . . 7
Flush Before Using Equipment . . . . . . . . . . . . . . 7
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 8
Mount the Pump and Connect Chemical Supply 8
Connect Pneumatic Supply . . . . . . . . . . . . . . . . . 9
Route Exhaust to Remote Location . . . . . . . . . . 9
Connect Chemical Outlet . . . . . . . . . . . . . . . . . . 9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Relief Procedure . . . . . . . . . . . . . . . . 11
Flush the Equipment . . . . . . . . . . . . . . . . . . . . . 11
Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . 12
Calibrate Chemical Dosage . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Preventive Maintenance Schedule . . . . . . . . . . 13
Tighten Threaded Connections . . . . . . . . . . . . . 13
Tighten Packings . . . . . . . . . . . . . . . . . . . . . . . 13
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Repair - Pump Lower . . . . . . . . . . . . . . . . . . . . . . . 15
Disconnect the Pump Lower . . . . . . . . . . . . . . . 15
Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Reconnect the Pump Lower . . . . . . . . . . . . . . . 18
Repair - Pneumatic Motor . . . . . . . . . . . . . . . . . . . 19
Pneumatic Valve . . . . . . . . . . . . . . . . . . . . . . . . 19
Replace Pilot Valves . . . . . . . . . . . . . . . . . . . . . 22
Repair Pneumatic Motor . . . . . . . . . . . . . . . . . . 23
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Python XL-DA25 Pneumatic Pump . . . . . . . . . . 27
Pump Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Pneumatic Motor Parts . . . . . . . . . . . . . . . . . . . 31
Pneumatic Valve Parts . . . . . . . . . . . . . . . . . . . 33
Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . 35
Pump Lower Models . . . . . . . . . . . . . . . . . . . . . 35
Additional Kits & Accessories . . . . . . . . . . . . . . 35
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Python XL-DA25 Pump Dimensions . . . . . . . . . 36
Wall Bracket Mounting Hole Diagram . . . . . . . . 37
Pneumatic Mounting Hole Diagrams . . . . . . . . . 38
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 39
6 in. Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.5 in. Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Technical Specifications . . . . . . . . . . . . . . . . . . . . 41
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 42

Models
3A6831A 3
Models
NOTE: See the Configuration Number Matrix, page 4, to find the plunger and pneumatic motor size for your unit.
Pump Models
Plunger Size Pneumatic
Motor Size Maximum Working Pressure psi (MPa, bar) Maximum Pneumatic Inlet Pressure psi (MPa, bar)
3/4 in. 6.0 in. 6,400 (44.1, 441)
100 (0.69, 6.9)
1 in. 3,800 (2.6, 26)
3/4 in. 7.5 in. 10,000 (68.9, 689)
1 in. 6,100 (42.1, 421)
Part Number Configuration Code Motor Size Lower Size Lower Coating Seal Material
A22606 PCI-0600-075-113-XC-2-0
6.0 in.
3/4 in. Chromex HNBR A22607 PCI-0600-075-113-XD-2-0 FFKM
A22608 PCI-0600-075-113-XE-2-0 TFE/P
A22612 PCI-0600-100-138-XC-2-0 1 in. Chromex HNBR
A22613 PCI-0600-100-138-XD-2-0 FFKM
A22614 PCI-0600-100-138-XE-2-0 TFE/P
A22706 PCI-0750-075-113-XC-2-0
7.5 in.
3/4 in. Chromex HNBR A22707 PCI-0750-075-113-XD-2-0 FFKM
A22708 PCI-0750-075-113-XE-2-0 TFE/P
A22712 PCI-0750-100-138-XC-2-0 1 in. Chromex HNBR
A22713 PCI-0750-100-138-XD-2-0 FFKM
A22714 PCI-0750-100-138-XE-2-0 TFE/P

Configuration Number Matrix
43A6831A
Configuration Number Matrix
Check the identification plate (ID) for the 17-digit Configuration Number of your pump. Use the following matrix to
define the components of your pump.
NOTE: Not all combinations are possible.
Sample Configuration Number: PCI-0600-075-113-XC-2-0
Pump Configuration
PCI 0600 075 113 X C 2 0
Pneumatic
Chemical
Injection
Pneumatic
Motor Size Pump Lower Primary Seal
Size
Pump Lower
Secondary
Seal Size
Pump Lower
Coating Seal Material Pump Stroke Length Qualifier
Pneumatic
Motor Size Pump Lower Primary Seal Size Pump Lower Secondary Seal Size PumpLower Coating Seal Material PumpStroke Length Qualifier
0600 6.0 in. 075 3/4 in. diameter 113 1-1/8 in. diameter X Chromex C HNBR 2 2.5 inch 0 None
0750 7.5 in. 100 1 in. diameter 138 1-3/8 in. diameter DFFKM
ETFE/P

Warnings
3A6831A 5
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.
FIRE AND EXPLOSION HAZARD
When flammable fluids are present in the work area 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.
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Use only grounded hoses.
•Stopoperation immediatelyifstatic sparking occursoryou feelashock.Do notuse equipmentuntil
you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
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 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.
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 Safety Data Sheet (SDS) 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.

Warnings
63A6831A
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.
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 Technical Data 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 Safety Data Sheet (SDS) from distributor or retailer.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Checkequipmentregularly.Repairorreplacewornordamagedpartsimmediatelywithgenuineman-
ufacturer’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.

Installation
3A6831A 7
Installation
Grounding
Pump: ground through electrically conductive pneu-
matic and fluid lines.
Pneumatic and fluid lines: use only electrically con-
ductive lines.
Air compressor: follow manufacturer’s recommenda-
tions.
Fluid supply container: follow local code.
Required Accessories
Install the following required accessories in the order
shown in FIG. 1, using adapters as necessary.
Pneumatic Line
•Bleed-type master pneumatic valve (D): required
in your system to relieve air/gas trapped between it
and the pneumatic motor when the valve is closed.
• Be sure the valve is easily accessible from the
pump and located downstream from the pneu-
matic regulator.
•Pump pneumatic regulator (E): to control pump
speed and outlet pressure. Locate it close to the
pump.
•Pneumatic line filter (C): removes harmful dirt and
moisture from compressed air/gas supply.
•Second bleed-type pneumatic valve (pneumatic
shutoff valve) (B): isolates pneumatic line acces-
sories for servicing. Locate upstream from all other
pneumatic line accessories.
Fluid Line
•Fluid filter (Y-Strainer) (included in G): with a 60
mesh (250 micron) stainless steel element to filter
particles from the fluid before in reaches the pump.
•Fluid shutoff valve (H): shuts off fluid flow.
•Pressure relief valve (J): overload protection.
Flush Before Using Equipment
The equipment was tested with lightweight oil, which is
left in the fluid passages to protect parts. To avoid con-
taminating your fluid with oil, flush the equipment with a
compatible solvent before using the equipment. See
Flush the Equipment, page 11.
If using a flammable gas to drive the motor, to reduce
the risk of fire or explosion, route the exhaust away
from all sources of ignition. See Route Exhaust to
Remote Location on page 9.
NOTE: A small amount of the exhaust is not recover-
able, and will vent to atmosphere at the pump. How-
ever, a 100% Exhaust Capture Kit, B32651, is
available.
To reduce the risk of injury from ejected ice, do not
operate the motor without a plumbed exhaust line or
muffler installed.
Installation must comply with all local codes and regu-
lations.
The equipment must be grounded to reduce the risk
of static sparking. Static sparking can cause fumes to
ignite or explode. Grounding provides an escape wire
for the electric current.

Installation
83A6831A
Typical Installation
FIG. 1 is an example of an installation with a Python
XL-DA25 chemical injection pump. Your installation may
differ from what is shown here. (See Required Acces-
sories, page 7.) The Python XL-DA25 pump (F) and
pneumatic needle valve (B) are the only components in
FIG. 1 supplied by Graco. All other components are sup-
plied by customer.
Key:
A Main Pneumatic Supply Line
B Secondary Pneumatic Bleed-Type Valve
C Pneumatic Filter
D Primary Bleed-type Master Pneumatic Valve
E Pneumatic Pressure Regulator
FPump
G Manifold Assembly (includes y-strainer and fluid shutoff
valve (H))
H Fluid Shutoff Valve (inlet & outlet)
J Fluid Pressure Relief Valve
K Fluid Inlet Line
LInletPort
MOutletPort
N Pneumatic Lubricator
P Fluid Outlet Line
R Speed Control Valve
S Lift Ring (for lifting the pump only)
Mount the Pump and Connect
Chemical Supply
The pump can be bolted to a wall or skid by the attached
bracket.
NOTE: The pump must always be mounted vertically.
If you have an application, or mounting configuration,
that requires installation in a manner different than
depicted in FIG. 1, please contact your Graco distributor
for assistance.
NOTE: A y-strainer (G) or chemical filter is required
before the pump inlet. This will keep any debris from the
tank from reaching the pump seals. Fluid filters are
available from Graco.
1. Mount the pump (F) and connect the fluid inlet
line (K).
FIG. 1:
A
C
ED
R
F
J
K
H
G
L
M
N
HP
S
B

Installation
3A6831A 9
Connect Pneumatic Supply
1. Install the pneumatic regulator (E) and gauge to
control the inlet pressure. See Models on page 3for
your model’s maximum pneumatic pressure.
NOTE: If less than 100 psi supply pressure is used, the
pump’s maximum output pressure will be decreased
proportionally.
Minimum Pneumatic Pressure can be found by first find-
ing the table that corresponds to the plunger size (see
Minimum Pneumatic Pressures by Fluid Plunger
Size and Outlet Pressures on page 10). Next, using
the column that corresponds to the pneumatic motor
size, find the row equal to or slightly greater than the
outlet pressure of the pump. The value is the Minimum
Pneumatic Pressure required to achieve the fluid outlet
pressure.
2. Install a pneumatic line filter (C) to keep debris from
affecting pump performance and to increase pump
life.
NOTE: Keep the needle valve (B) closed at this point to
keep the pump from operating without fluid, which mini-
mizes seal wear.
3. Attach a pneumatic line to the 1/4 in. female NPT
port on the needle valve (B).
Route Exhaust to Remote
Location
Replace the muffler (18) with a pneumatic line to route
exhaust to a remote location.
Connect Chemical Outlet
1. Connect a fluid line from the pump outlet port (M) to
the injection point.
2. Install a fluid pressure relief valve (J) on the outlet
side of the pump.
NOTE: A pressure relief valve is available from Graco
and can be connected back to the tank or directly to the
inlet side of the pump. See Kits and Accessories on
page 35.
3. Set the pressure relief valve at or below the maxi-
mum working pressure of the pump.
NOTICE
Due to the operational design of the pneumatic valve,
a small amount of the exhaust is not recoverable, and
will vent to atmosphere. However, a 100% Exhaust
Capture Kit, B32651, is available.
In the event of an injection line blockage, to reduce the
risk of skin injection and damage to the pump, ensure
the pressure relief valve is set at or below the maxi-
mum working pressure of the pump.

Installation
10 3A6831A
Minimum Pneumatic Pressures by Fluid Plunger Size and Outlet Pressures
Actual running pressure must be set in field to avoid stalling. See Performance Charts, starting on page 39, for max-
imum flows at any given pressure.
0600 (6.0 in) Pneumatic Motor Minimum Gas Pressure
psi (MPa, bar)
Outlet Pressure psi
(MPa, bar)
3/4 Inch
Fluid Plunger
1 Inch
Fluid Plunger
0 (0, 0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0)
500 (3.4, 34.5) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0)
1000 (6.9, 68.9) 15.6 (0.1, 1.1) 26.3 (0.2, 1.8)
1500 (10.3, 103.4) 23.4 (0.2, 1.6) 39.5 (0.3, 2.7)
2000 (13.8, 137.9) 31.3 (0.2, 2.2) 52.6 (0.4, 3.6)
2500 (17.2, 172.4) 39.1 (0.3, 2.7) 65.8 (0.5, 4.5)
3000 (20.7, 206.8) 46.9 (0.3, 3.2) 79.0 (0.5, 5.4)
3500 (24.1, 241.3) 54.7 (0.4, 3.8) 92.1 (0.6, 6.4)
4000 (27.6, 275.8) 62.5 (0.4, 4.3)
4500 (31.0, 310.3) 70.3 (0.5, 4.8)
5000 (34.5, 344.7) 78.1 (0.5, 5.4)
5500 (37.9, 379.2) 85.9 (0.6, 5.9)
6000 (41.4, 413.7) 93.8 (0.6, 6.5)
6400 (44.1, 441.3) 100.0 (0.7, 6.9)
0750 (7.5 in) Pneumatic Motor Minimum Gas Pressure
psi (MPa, bar)
Outlet Pressure psi
(MPa, bar)
3/4 Inch
Fluid Plunger
1 Inch
Fluid Plunger
0 (0, 0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0)
500 (3.4, 34.5) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0)
1000 (6.9, 68.9) 15.0 (0.1, 1.0) 16.4 (0.1, 1.1)
1500 (10.3, 103.4) 15.0 (0.1, 1.0) 24.6 (0.2, 1.7)
2000 (13.8, 137.9) 20.0 (0.1, 1.4) 32.8 (0.2, 2.3)
2500 (17.2, 172.4) 25.0 (0.2, 1.7) 41.0 (0.3, 2.8)
3000 (20.7, 206.8) 30.0 (0.2, 2.1) 49.2 (0.3, 3.4)
3500 (24.1, 241.3) 35.0 (0.2, 2.4) 57.4 (0.4, 4.0)
4000 (27.6, 275.8) 40.0 (0.3, 2.8) 65.6 (0.5, 4.5)
4500 (31.0, 310.3) 45.0 (0.3, 3.1) 73.8 (0.5, 5.1)
5000 (34.5, 344.7) 50.0 (0.3, 3.4) 82.0 (0.6, 5.7)
5500 (37.9, 379.2) 55.0 (0.4, 3.8) 90.2 (0.6, 6.2)
6000 (41.4, 413.7) 60.0 (0.4, 4.1) 98.4 (0.7, 6.8)
6500 (44.8, 448.2) 65.0 (0.4, 4.5)
7000 (48.3, 482.6) 70.0 (0.5, 4.8)
7500 (51.7, 517.1) 75.0 (0.5, 5.2)
8000 (55.2, 551.6) 80.0 (0.6, 5.5)
8500 (58.6, 586.1) 85.0 (0.6, 5.9)
9000 (62.1, 620.5) 90.0 (0.6, 6.2)
9500 (65.5, 655.0) 95.0 (0.7, 6.6)
10,000 (68.9, 689.5) 100.0 (0.7, 6.9)
For applications where the exhaust is ported to
a pressurized location, compute the difference
between the inlet and outlet pressures to get
the pneumatic pressure to be used in the
above tables. Minimum pressure differential is
15 psi (0.1 MPa, 1.0 bar).

Operation
3A6831A 11
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
NOTE: Always discharge fluid into an approved con-
tainer or location.
1. Shut off all fluid and pneumatic lines (A, K, & P)
using the two fluid shutoff valves (H) and the pneu-
matic needle valve (B).
2. Slowly loosen the fluid lines to (K & P) at the pump
outlets (L & M) to bleed off any residual pressure.
3. Disconnect the fluid lines (K & P) from pump outlets
(L & M).
Flush the Equipment
• Flush with a fluid that is compatible with the fluid
being dispensed and the equipment wetted parts.
1. Follow the Pressure Relief Procedure.
2. Connect the inlet port to the flushing fluid supply
source.
3. Connect the outlet port to the waste reservoir.
4. Run the pump until the dispensed fluid is predomi-
nately flushing fluid.
5. Follow the Pressure Relief Procedure.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection and splashing
fluid, follow the Pressure Relief Procedure when
you stop dispensing and before cleaning, checking, or
servicing the equipment.
To avoid fire and explosion, always ground equipment
and waste container. To avoid static sparking and
injury from splashing, always flush at the lowest pos-
sible pressure.

Operation
12 3A6831A
Prime the Pump
1. Verify all connections and fluid lines are tight.
NOTE: The pressure regulator (E) and inlet pneumatic
needle valve (B) both effect the pump cycle rate. After
inlet pressure is set, the needle valve can serve as a
speed control.
2. Adjust pneumatic regulator (E) to desired pressure.
3. Open bleed-type pneumatic valve (D). Slowly turn
pump needle valve (B) counter-clockwise, increas-
ing air/gas flow to the pump.
4. Keep the pump cycle rate less than 1 cycle every 3
seconds only while priming the pump.
Calibrate Chemical Dosage
1. Set the pump to an estimated setting of the flow
rate.
2. Follow the instructions provided with your calibration
gauge.
3. Adjust the cycle rate with the inlet pneumatic needle
valve (B) and/or the pressure regulator (E).
4. Repeat the steps 2 and 3 to verify your changes.
Repeat as necessary until the desired flow rate is
achieved.
Baseline Chemical Dosage Settings
See Performance Charts, starting on page 39, for max-
imum flows at any given pressure.
NOTE: Maximum cycle rate is 60 CPM (cycles per min-
ute), and the minimum cycle rate is 10 CPM. All values
are at 0 psi back pressure. Cycle rates over 60 may
cause excess wear and premature seal failure.
NOTICE
Pump runaway may occur if the needle valve (B) is
opened too far for pressure settings, causing damage
to the packing sets (102 and 107).
CPM
3/4 in. Fluid
Plunger Pumps 1 in. Fluid Plunger Pumps
GPD LPD GPD LPD
10 180 680 269 1017
20 359 1360 537 2033
30 539 2041 806 3050
40 719 2721 1074 4066
50 899 3401 1343 5083
60 1078 4081 1611 6100

Maintenance
3A6831A 13
Maintenance
Preventive Maintenance
Schedule
The operating conditions of your particular pump deter-
mines how often maintenance is required. Establish a
preventive maintenance schedule by recording when
and what kind of maintenance is needed, and then
determine a regular schedule for checking your pump.
Tighten Threaded Connections
Check that all threaded connections are tight at routine
intervals.
Tighten Packings
The packings included in your pump have the ability to
be adjusted to stop leaks that develop when the seals
are worn. If a leak develops in the pump’s fluid section,
tighten the packing nut clockwise by 1/16 of a turn, or
lower, until the leak is eliminated. The life of the packing
can be affected by over-tightening the packings. If the
packing nut needs to be tightened repeatedly after short
intervals, replace the packing.
Storage
If the pump is going to be stored for long periods, it is
recommended that the pump be flushed with a
light-weight oil or rust prohibiter to protect pump compo-
nents. Store the pump with protective fluid inside when-
ever possible.

Troubleshooting
14 3A6831A
Troubleshooting 1. Follow Pressure Relief Procedure, page 11,
before checking or repairing pump.
2. Check all possible problems and causes before dis-
assembling pump.
Problem Cause Solution
Air bubbles in fluid. Fluid inlet line is loose. Tighten.
Fluid leaking. Loose fittings. Tighten fittings.
Worn seals. Adjust packing (if leak persists, replace
packing).
Pump stroking, but no fluid moving. Air in pump. Prime pump.
Worn or damaged check valve seals. Rebuild top and bottom poppets.
Pneumatic motor will not run. Damaged pneumatic valve (217). Replace or service pneumatic valve (217).
See page 19.
Damaged pilot valve (219). Replace pilot valves (219).
See page 22.
Air continuously exhausting around
pneumatic motor plunger. Damaged u-cups (203). Replace plunger u-cups (203). See page 25.
Air continuously exhausting from muffler. Damaged pneumatic valve plate (305) or
cup (312). Replace or service pneumatic valve (217). See page 19.
Pneumatic motor “bounces” at top of
stroke. Damaged bottom pilot valve (219). Replace bottom pilot valve (219). See page 22.
Pneumatic motor “bounces” at bottom of
stroke. Damaged top pilot valve (219). Replace top pilot valve (219). See page 22.
Icing inside motor. Pneumatic motor operating at high
pressure or high cycle rate. Reduce pressure, cycle rate, orduty cycle of motor.
Reduce dew point of compressed air in
moisture coalescing filter.
Pump fails to operate. Restricted line or inadequate air/gas
supply; closed or clogged valves. Clear line or increase air/gas supply. Check that the valves are open.
Obstructed fluid line; fluid line ID is too
small. Open, clear*; use line with larger ID.
Pump operates but does not prime. Held open or worn check valves or
packings. Clear valve; replace packings. See page 16.
Pump operates, but output is low on both
strokes. Restricted line or inadequate air/gas supply; closed or clogged valves. Clear line or increase air/gas supply. Check that the valves are open.
Obstructed fluid line; fluid line ID is too
small. Open, clear*; use line with larger ID.
Worn packings in pump. Replace packings. See page 16.
Pump operates, but output is low on
downstroke. Held open or worn check valves or packings. Clear valve; replace packings. See page 16.
Erratic or accelerated pump speed. Exhausted fluid supply. Refill and prime.
Held open or worn check valves or
packings. Clear valve, replace packings. See page 16.
Fluid being pumped is visible on the pack-
ing nut. Worn packings. Tighten packing nut.
Replace packings. See page 16.

Repair - Pump Lower
3A6831A 15
Repair - Pump Lower
• Always use Genuine Graco Parts and Accessories,
available from your Graco distributor. If you supply
your own accessories, be sure they are adequately
sized and pressure rated for your system.
Disconnect the Pump Lower
1. Stop the pump in the middle of the stroke.
2. Follow the Pressure Relief Procedure, page 11.
3. Disconnect the fluid lines.
4. Loosen the screw (16) and remove the tie rod shield
(15). The drip shield (4) may slide down the tie rods
once the rod shield is removed.
5. Hold the drip shield (4) out of the way if it is blocking
the pneumatic motor plunger (206). Hold the flats of
the pneumatic motor plunger (206) with a wrench.
Use another wrench to loosen the coupler nut (11).
6. Lower the coupler nut (11) enough to remove the
coupling collars (10), and then remove the coupler
nut (11).
Before servicing or repairing your pump, verify that
pressure is relieved according to the Pressure Relief
Procedure, page 11, and that all fluid and pneumatic
lines are properly shut off, or sealed with compatible
valves and disconnected.
Threads are very sharp. Use a rag to protect hands
when turning or carrying the pump.
FIG. 2
15
16
FIG. 3
FIG. 4
11
206
11
10

Repair - Pump Lower
16 3A6831A
7. Use a hammer and brass rod to loosen the jam
nut (119). Unscrew the jam nut as far as possible.
8. Unscrew the pump lower (9) by hand and place on
work bench.
Pump Repair
1. Remove the lower fluid cylinder (113) and cylinder
cap (117) assembly from the primary fluid cylinder
(101).
2. Remove the cylinder cap (117) from the lower fluid
cylinder (113).
3. Remove the plunger (109).
4. Remove the cylinder cap check valve retainer (116)
and cylinder cap check valve poppet (114).
FIG. 5
9
119
206
FIG. 6
118
118
116
114
115
117
109
113
101

Repair - Pump Lower
3A6831A 17
5. Remove the plunger check valve seat (112) and
plunger check valve poppet (110).
6. Remove the o-rings (118) from the lower fluid cylin-
der (113).
7. Remove the bearing (108) and secondary seal
stack (107) from the fluid cylinder (101).
8. Remove the packing nut (106), shim (105), bearing
(103) and primary seal stack (102) from the fluid cyl-
inder (101).
9. Install the new primary seal stacking (102) including
bearing (103). Use grease during installation.
10. Install the packing nut (106) with pipe sealant until
finger tight.
11. Install the new secondary seal stack (107), including
bearing (108). Use grease during installation.
FIG. 7
109
107
108
110
111
112
FIG. 8
FIG. 9
Primary
Seal Stack (102) Secondary
Seal Stack (107)
103
108
106
105
103
102
101
119

Repair - Pump Lower
18 3A6831A
12. Install two new o-rings (118) on the lower fluid cylin-
der (113). Orientation does not matter for this part.
13. Apply anti-seize to both lower fluid cylinder (113)
threads and install into the fluid cylinder (101).
Torque to 100 ft-lb.
14. Inspect and replace the plunger o-ring (111), as
required, and insert the plunger poppet (110) into
the plunger (109) in the direction shown. Apply
medium strength (blue) thread locker to the check
seat (112). Torque to the following values depend-
ing on the size of your pump lower:
15. Apply petroleum-based lubricant to the fluid plunger
(109) and install into the fluid cylinder (101).
16. Inspect and replace the cylinder o-ring (115), as
required, and insert the cylinder poppet (114) into
the cylinder cap (117) in the direction shown. Install
the check retainer (116). Torque to 10 ft-lb
(14 N•m).
17. Install the cylinder cap (117) onto the lower fluid cyl-
inder (113). Torque to 100 ft-lb (136 N•m).
18. Install the packing nut shim (105) and torque the
packing nut (106) to 20 ft-lb (27 N•m).
Reconnect the Pump Lower
1. Tilt the pneumatic motor (1) onto its back, then hand
turn the pump lower (9) into the adapter plate (6).
Set the pump upright again.
2. Hold the pneumatic motor plunger (109) up with one
hand. With your other hand, put the coupler nut (11)
on the plunger.
3. Put the coupling collars (10) into the coupler nut
(11) so the large flanges point upward.
4. Gently let the pneumatic motor plunger (206) drop
onto the fluid plunger (109). Hand tighten the cou-
pler nut (11).
5. Screw the pump lower (9) into the adapter nut (5)
until the cylinder top is flush with the top of the
adapter plate (6).
6. Align the fluid outlet as shown and tighten the jam
nut.
7. Hold the flats of the motor plunger (206) with a
wrench. Use another wrench to tighten the coupler
nut (11). Torque the coupler nut (11) to 75-80 ft-lbs
(102-108 N•m).
8. Hold the drip shield (4) out of the way and replace
the tie rod shield (15).
Pump Lower Size Torque
075 40 ft-lb (54 N•m)
100 90 ft-lb (122 N•m)
FIG. 10
FIG. 11
11
10
109
206
6
5
109
11
206

Repair - Pneumatic Motor
3A6831A 19
Repair - Pneumatic Motor
Pneumatic Valve
Replace Complete Pneumatic Valve
1. Stop the pump. Follow Pressure Relief Procedure,
page 11.
2. Disconnect the pneumatic line to the motor.
3. See the figure on page 31. Remove four screws
(218). Remove the pneumatic valve (217) and gas-
ket (216*).
4. To repair the pneumatic valve, go to Disassemble
the Pneumatic Valve, page 19. To install a replace-
ment pneumatic valve (217), continue with step 5.
5. Align the new pneumatic valve gasket (216*) on
the manifold, then attach the pneumatic valve (217).
Torque screws (218) to 95-105 in-lb (11-12 N•m).
6. Reconnect the pneumatic line to the motor.
Replace Seals or Rebuild Pneumatic Valve
Inspect and replace seals and worn parts while disas-
sembling and reassembling the pneumatic valve on the
next following pages.
Use FIG. 12 and the following table to identify the kits
needed for replacements:
Disassemble the Pneumatic Valve
1. Perform steps 1-3 under Replace Complete Pneu-
matic Valve, page 19.
2. See FIG. 12. Use a 2 mm or 5/64 in. hex key to
remove two screws (309†). Remove the valve
plate (305), cup (312), and spring (311).
3. See FIG. 12. Remove the snap ring (310) from
each end. Use the piston to push the end caps
(307) out of the ends. Remove end cap o-rings
(306†).
4. Remove the piston (302). Remove the u-cup seals
(308†) from each end, and the detent assembly
(303) and detent cam (304) from the center.
Symbol Kit Description
† Pneumatic Valve Seal Kits. See page 34
Pneumatic Valve Repair Kits. See page 34.
Pneumatic Valve End Cap Kits. See
page 34.

Repair - Pneumatic Motor
20 3A6831A
FIG. 12
1
Apply lubricant.
 310
307
 307
†309
305
312 311
303
302
†308
†
308
301
304
310 ti16213a
†321
†321
313
314
1
1
1
1
1
1
1
1