Graco Z-Pump S1 Series Parts list manual

For pumping plural component materials. For professional use only.
Not for use in explosive atmospheres.
3500 psi (24 MPa, 241 bar) Maximum Working Pressure
See page 3 for model information, including maximum working pressure and approvals.
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment.
Save these instructions.
r_257891_3a0019_1h
Instructions-Parts
Z-Pump S1, S3, and
S4 Series 3A0019ZAC
EN

2 3A0019ZAC
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Important Isocyanate (ISO) Information. . . . . . . . . 7
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 7
Keep Components A and B Separate . . . . . . . . . 7
Material Self Ignition . . . . . . . . . . . . . . . . . . . . . . . . 7
Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 7
Keep Components A and B Separate. . . . . . . . . . . 8
Foam Resins with 245 fa Blowing Agents . . . . . . . 8
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component Identification . . . . . . . . . . . . . . . . . . . . 9
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 10
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Grease Cup Maintenance . . . . . . . . . . . . . . . . . 10
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inlet Housing Disassembly . . . . . . . . . . . . . . . . . 11
Inlet Housing Assembly . . . . . . . . . . . . . . . . . . . 13
Pump Disassembly. . . . . . . . . . . . . . . . . . . . . . . 14
Pump Rod Assembly . . . . . . . . . . . . . . . . . . . . . 16
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Complete Pump Assemblies for S1, S3, and S4 20
Various Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Seal Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Displacement Rod Kits. . . . . . . . . . . . . . . . . . . . 38
Check Valve Kits for S1 and S3 Pumps . . . . . . . 43
Check Valve Kits for S4 Pumps . . . . . . . . . . . . . 44
O-Ring Inlet Kit, All Pump Sizes . . . . . . . . . . . . . 45
Z-Pump Grease Cup Conversion Kits . . . . . . . . 46
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Outlet Housing Mounting Hole Layout. . . . . . . . 48
Technical Specifications . . . . . . . . . . . . . . . . . . . . 49
Graco Standard Warranty. . . . . . . . . . . . . . . . . . . . 50
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 50
Related Manuals
Manual in
English Description
313997 HFR, Setup - Operation
3A1961 HFR for NVH Foam - Modular, Setup -
Operation
3A6165 EFR, Instructions - parts

Models
3A0019ZAC 3
Models
* Due to a small seal cross-section, use unfilled
catalysts to achieve the best seal life results.
** S3 pump models are for NVH system use only.
Model Pump Size System Used On
*L005S1 5cc HFR
L010S1 10cc HFR
L015S1 15cc HFR
L020S1 20cc HFR
L025S1 25cc HFR
L030S1 30cc HFR
L035S1 35cc HFR
L040S1 40cc HFR
L045S1 45cc HFR
L050S1 50cc HFR
L060S1 60cc HFR
L065S1 65cc HFR
L070S1 70cc HFR
L075S1 75cc HFR
L080S1 80cc HFR
L086S1 86cc HFR
L090S1 90cc HFR
L100S1 100cc HFR
L105S1 105cc HFR
L120S1 120cc HFR
L140S1 140cc HFR
L150S1 150cc HFR
L160S1 160cc HFR
**L010S3 10cc NVH
**L020S3 20cc NVH
*L005S4 5cc EFR
L010S4 10cc EFR
L015S4 15cc EFR
L020S4 20cc EFR
L025S4 25cc EFR
L030S4 30cc EFR
L035S4 35cc EFR
L040S4 40cc EFR
L045S4 45cc EFR
L050S4 50cc EFR
L060S4 60cc EFR
L055S4 65cc EFR
L070S4 70cc EFR
L075S4 75cc EFR
L080S4 80cc EFR
L086S4 86cc EFR
L090S4 90cc EFR
L100S4 100cc EFR
L105S4 105cc EFR
L120S4 120cc EFR
L140S4 140cc EFR
L150S4 150cc EFR
L160S4 160cc EFR
Model Pump Size System Used On

Warnings
4 3A0019ZAC
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 symbol refers to procedure-specific risk.
Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this
manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or
solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:
• Use equipment only in well-ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static sparking).
• Ground all equipment in the work area.
• Never spray or flush solvent at high pressure.
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are anti-static or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment
until 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 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
3A0019ZAC 5
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
Specifications 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.
• Do not leave the work area while equipment is energized or under pressure.
• 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.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
WARNING

Warnings
6 3A0019ZAC
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 Sheets (SDSs) for handling instructions and to know the specific hazards of the
fluids you are using, including the effects of long-term exposure.
• When spraying, servicing equipment, or when in the work area, always keep work area
well-ventilated and always wear appropriate personal protective equipment. See Personal
Protective Equipment warnings in this manual.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Always wear appropriate personal protective equipment and cover all skin when spraying, servicing
equipment, or when in the work area. Protective equipment helps prevent serious injury, including
long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and
hearing loss. This protective equipment includes but is not limited to:
• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local
regulatory authority.
• Protective eyewear and hearing protection.
WARNING

Important Isocyanate (ISO) Information
3A0019ZAC 7
Important Isocyanate (ISO) Information
Isocyanate Conditions Keep Components A and B
Separate
Material Self Ignition
Moisture Sensitivity of
Isocyanates
Isocyanates (ISO) are catalysts used in two component
foam and polyurea coatings. ISO will react with
moisture (such as humidity) to form small, hard,
abrasive crystals, which become suspended in the
fluid. Eventually a film will form on the surface and the
ISO will begin to gel, increasing in viscosity. If used, this
partially cured ISO will reduce performance and the life
of all wetted parts.
The amount of film formation and rate of crystallization
varies depending on the blend of ISO, the humidity, and
the temperature.
Spraying or dispensing fluids that contain
isocyanates creates potentially harmful mists,
vapors, and atomized particulates.
• Read and understand the fluid manufacturer’s
warnings and Safety Data Sheets (SDSs) to know
specific hazards and precautions related to
isocyanates.
• Use of isocyanates involves potentially hazardous
procedures. Do not spray with this equipment
unless you are trained, qualified, and have read and
understood the information in this manual and in
the fluid manufacturer’s application instructions
and SDSs.
• Use of incorrectly maintained or mis-adjusted
equipment may result in improperly cured material.
Equipment must be carefully maintained and
adjusted according to instructions in the manual.
• To prevent inhalation of isocyanate mists, vapors,
and atomized particulates, everyone in the work
area must wear appropriate respiratory protection.
Always wear a properly fitting respirator, which
may include a supplied-air respirator. Ventilate the
work area according to instructions in the fluid
manufacturer’s SDSs.
• Avoid all skin contact with isocyanates. Everyone in
the work area must wear chemically impermeable
gloves, protective clothing and foot coverings as
recommended by the fluid manufacturer and local
regulatory authority. Follow all fluid manufacturer
recommendations, including those regarding
handling of contaminated clothing. After spraying,
wash hands and face before eating or drinking.
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or
damage equipment. To prevent cross-contamination:
• Never interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been
contaminated from the other side.
Some materials may become self-igniting if applied
too thickly.. Read material manufacture’s warnings
and material MSDS.

Keep Components A and B Separate
8 3A0019ZAC
To prevent exposing ISO to moisture:
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
• Keep the ISO lube pump reservoir (if installed) filled
with Graco Throat Seal Liquid (TSL™), Part 206995.
The lubricant creates a barrier between the ISO and
the atmosphere.
• Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system.
• Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
• Never use solvent on one side if it has been
contaminated from the other side.
• Always lubricate threaded parts with ISO pump oil
or grease when reassembling.
Keep Components A and
B Separate
Foam Resins with 245 fa
Blowing Agents
Some foam blowing agents will froth at temperatures
above 90°F (33°C) when not under pressure, especially
if agitated. To reduce frothing, minimize preheating in a
circulation system.
Changing Materials
• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after flushing.
• Check with your material manufacturer for chemical
compatibility.
• Most materials use ISO on the A side, but some use
ISO on the B side.
• Epoxies often have amines on the B (hardener)
side. Polyureas often have amines on the B (resin)
side.
To prevent cross-contamination of the equipment’s
wetted parts, never interchange component A
(isocyanate) and component B (resin) parts.

Component Identification
3A0019ZAC 9
Component Identification
Key:
A Displacement Rod (inside main cylinder)
B Throat Cartridge/Retainer
C Outlet Housing
D Main Cylinder
E Crossover Tube
F Tie Bolt
G Inlet Housing
H Inlet Cap
J Fluid Outlet
K Fluid Inlet (bottom of inlet housing)
L Pump Mounting Holes
M Pressure Transducer Port
N Linear Transducer Mounting Hole
P Identification Tag
R Rod Adapter (not on all models)
S Pump Coupler
T Coupler Cover
U Coupler Clamp
FIG. 1: Component Identification
40cc pump shown
Outlet Housing (C)
F
CD
E
A
H
J
G
K
L
M
N
P
R
S
B
T
U

Operation
10 3A0019ZAC
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Press the enable/disable key on the ADM to
disable the EFR/HFR, and verify it is inactive.
2. relieve pressure and shut off the supply systems.
See your appropriate supply system manual.
3. Turn the PRESSURE RELIEF/DISPENSE valves to
PRESSURE RELIEF/CIRCULATION. Route the fluid
to grounded waste containers or supply tanks.
4. For models with a dispense valve with a safety lock,
engage the dispense valve safety lock,
Flushing
• Flush out old fluid with new fluid, or flush out old
fluid with a compatible solvent before introducing
new fluid.
• Flush at the lowest pressure possible. Check
connectors for leaks and tighten as necessary.
• Flush with a fluid that is compatible with the fluid
being dispensed and the equipment wetted parts
Maintenance
NOTE: If the quick lube system is installed on the
Z-Pump, use one of the following operation manuals for
instructions: 313997, 3A1961, or 3A6165. If the quick
lube fittings are not installed then the Grease Cup
Maintenance procedures are used.
Grease Cup Maintenance
To manually grease the pump, the M5 grease fitting
(123) must be installed into the throat cartridge (119).
The M5 screw (124) is installed after the procedure is
done. These fittings are packaged separately, with the
pump
Frequency of greasing intervals is dependent on
material being pumped. As a basic schedule, lubricate
pump with grease after 250 gallons of material (five of
fifty five gallon drums) has been passed through the
pump.
If the grease has become hardened, remove the
materials or grease, and shorten the intervals between
greasing the pump.
If the grease remains clear and free of material, intervals
between greasing the pump can be increased.
To Grease the Pump
1. If previously installed, Remove the M5 screw (124)
to permit grease to circulate through the pump cor-
rectly.
2. Attach grease gun to the M5 grease fitting (123).
Pump new grease into the pump until fresh grease
is observed from grease relief hole (E).
3. Replace and re-tighten the M5 screw (124). See
FIG. 2.
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 spraying and before clean-
ing, 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 possible pressure.
Hot solvent may ignite. To avoid fire and explosion:
• Flush equipment only in a well-ventilated area
• Ensure main power is off and the heater is cool
before flushing
• Do not turn on heater until fluid lines are clear of
solvent
FIG. 2
123
E
124
119

Repair
3A0019ZAC 11
Repair
Required Tools
• Large vise
• Set of adjustable wrenches
• 1 in. wrench (S4 only)
• 1 1/4 in. Allen hex wrench.
• 3/8 in. Allen hex wrench (S4 only)
• 1 1/4 in. wrench (S4 only)
• 1 1/8 in. crowfoot wrench (S4 only)
• O-ring pick
• Rubber mallet
• Torque wrench
• 2 1/4 in. and 3 in. hex sockets
• Anti-seize lubricant
• Removable strength thread locker
• Grease (compatible with the material being
dispensed)
Inlet Housing Disassembly
Models S1 and S3 Pumps
S1 and S3 models can be identified by the hex head
(not square) on the inlet valve cap (113).
1. Relieve pressure and flush system. See Pressure
Relief Procedure and Flushing, page 10.
2. Remove inlet hose and drain inlet housing (106).
3. Remove inlet valve cap (113) from inlet housing
(116), and remove O-ring (108). See FIG. 3.
4. Remove upper ball cage housing (112), ball check
spring (111), SST ball (110), O-ring (108) and
carbide seat (109).
5. Press lower SST ball (110) off carbide seat (109)
from fluid inlet and drain the inlet housing (106).
6. Remove O-ring (108), lower ball cage housing (112),
ball check spring (111), SST ball (110), carbide seat
(109), and O-ring (108). See FIG. 4.
7. Clean all parts in a compatible solvent. Lay them in
order for easier reassembly. Inspect each ball and
seat for nicks or scratches; replace as required.
Model S4 Pumps
NOTE: S4 models can be identified by the square head
(not hex) on the inlet cap (136) being square.
1. Relieve pressure and flush system. See Pressure
Relief Procedure and Flushing, page 10.
FIG. 3
r_257891_3a0019_4h
113
108
106
FIG. 4
r_257891_3a0019_5h
111
110
108
109
112
112
111
110
109
108
106
108

Repair
12 3A0019ZAC
2. Remove inlet hose and drain inlet housing (106).
See FIG. 5.
3. Remove valve inlet cap (136) from inlet housing
(106), and remove O-ring (108).
4. Remove parts shown for the Upper Check (A). This
includes the spring retainer (137), ball cage housing
(138), ball check spring (139), HSG ball retainer
(140), silicone ball (141), ball seat (142), O-ring
(143), and check retainer (144).
5. Remove lower check (B), including the spring
retainer (137), ball cage housing (138), ball check
spring (139), HSG ball retainer (140), silicone ball
(141), ball seat (142), O-ring (143), and check
retainer (144). See FIG. 6.
6. Clean all parts in a compatible solvent. Lay them in
order for easier reassembly. Inspect each ball and
seat for nicks or scratches; replace as required.
7. It is recommended to replace both O-rings (108,
143) after cleaning.
FIG. 5
FIG. 6
136
106
108
138
139
140
142
137
137
138
143
144
142
141
108
141
143
108
139
140
144
108
Upper
Check (A)
Lower
Check (B)
136

Repair
3A0019ZAC 13
Inlet Housing Assembly
Model S1 Pumps
1. Apply anti-seize lubricant to the threads of inlet
valve cap (113) and install O-ring (108) into the
groove.
2. Assemble lower check assembly (DD). Install O-ring
(108) into inlet housing (106) followed by the
carbide seat (109).
3. Place the ball (110) onto the carbide seat (109)
followed by the ball check spring (111) and the ball
cage housing (112).
NOTE: Confirm the orientation of the ball cage prior to
installing. The end with the larger opening must face the
spring. See FIG. 7.
4. Assemble upper check assembly (CC). Repeat step
2 above after placing an O-ring (108) on top of the
lower check assembly (DD).
5. Install the valve inlet cap (113) compressing both
check assemblies together into the inlet housing.
Torque the valve inlet cap to 70 ft-lbs. (95 N•m).
Model S4 Pumps
1. When installing the inlet housing components:
a. Apply anti-seize lubricant to the ball cage
housing (138) and retainers (137 and 144).
b. Attach the ball cage housing (138) to the check
retainer (144) and torque to 50 ft-lbs (67.5 N•m)
after the ball seat (142) and check O-ring (143)
have been installed.
The radius of the ball seat (142) must face the silicone
ball (141).
c. Install the silicone ball (141), ball retainer (140)
and ball check spring (139) into the ball cage
housing (138).
d. Install the spring retainer (137) cup side down
into the ball cage housing (138) to trap the ball
check spring (139) until the spring retainer
bottoms out into the ball cage housing. Torque
to 30 ft-lbs (41 N•m).
e. Install the O-ring (108) into the inlet housing
(106).
f. Install lower check (B) assembly into the inlet
housing (106) in the orientation shown.
g. Install the O-ring (108) into the inlet housing
(106).
h. Install upper check (A) into the housing (106) in
the orientation shown.
2. Install O-ring (108) on inlet valve cap (113) and
apply anti-seize lubricant to inlet valve cap (113)
threads. Tighten inlet valve cap to 70 ft-lbs. (95
N•m).
FIG. 7
112
111
110
109
108
106

Repair
14 3A0019ZAC
Pump Disassembly
1. Relieve pressure and flush system. Follow
Pressure Relief Procedure and Flushing, page
10.
2. Remove inlet hose and drain inlet housing (106).
3. Using a bench vice, Horizontally clamp the pump
on outlet housing (107). Use a 1/2 in. hex bit socket
to loosen all four tie bolts (105) from inlet housing
(106).
4. For 20cc - 40cc pumps only: Use wrench to
remove rod adapter (121). See FIG. 8.
5. Remove pump assembly from vise and lay on a flat
surface with towels or in catch pan.
6. Completely remove the tie bolts (105). See FIG. 9.
7. Remove inlet housing (106) from pump cylinder
(103). Remove pump crossover tube (104) and
o-rings (102). See FIG. 10.
8. Pull pump cylinder (103) and displacement rod
(115) away from outlet housing (107).
9. Remove displacement rod (115) from pump
cylinder (103). See FIG. 11.
10. Remove two o-rings (101) from pump cylinder
(103). See FIG. 12.
11. Place outlet housing (107) in vise so throat cartridge
(118) is facing up.
FIG. 8
FIG. 9
107
106
clamp here clamp here
121
105
105
106
FIG. 10
Be careful not to scratch the displacement rod (115);
place it on a smooth working surface. Damage to the
displacement rod will shorten pump life.
FIG. 11
FIG. 12
104 102
103
115
106
102
107
103
115
101
103
101

Repair
3A0019ZAC 15
12. Remove Cartridge (118).
13. Use O-ring pick and remove O-ring (145)and two
throat seals (126) out of the throat cartridge (118).
see FIG. 13.
14. Remove throat retainer (119) and throat cartridge
O-rings (120) and (125). See FIG. 13.
15. Clamp flats on seal end of displacement rod (115)
in vise. Remove piston retainer (114), piston
retainer bearing (116), and two piston seals (117).
See FIG. 14, FIG. 15, and FIG. 16.
For 5cc, 10cc, and 15cc S1, S3, and S4 Pumps
For 20cc-50cc S1, S3, and S4 Pumps
For 60cc-160cc S1, S3, and S4 Pumps
16. If the displacement rod (115) shows damage or
wear on the surface below the piston seals (117) it
should be replaced to prevent damage to new
seals.
17. Thoroughly clean all metal parts in a compatible
solvent.
FIG. 13
FIG. 14
FIG. 15
118 145
126
119
120 107
125
116
114
117
115
116
114
117
115
FIG. 16
114
116
117
115

Repair
16 3A0019ZAC
Pump Rod Assembly
NOTE: Seal assembly tool is not needed for 10cc-30cc
pump sizes. Rod installation tool
1. Install piston seal installation tool (152) from pump
repair kit on displacement rod (115). Hand tighten.
2. Apply grease to seal and bearing surface of
displacement rod (115).
3. Install piston seal (117) and piston rod bearing
(116). Ensure piston seal springs face displacement
rod. Remove piston seal installation tool (152).
4. For 20cc-50cc pumps: Apply one stripe of
removable strength thread locker to displacement
rod (115) male threads and install piston retainer
(114). See FIG. 17.
5. For 5cc, 10cc, 15cc, and 60cc-160cc pumps: Apply
one stripe of removable strength thread locker to
piston retainer (114) threads and assemble. See
FIG. 18.
6. Clamp flats on seal end of displacement rod (115)
in vise. Torque piston retainer to displacement rod
using Piston Retainer (114) Torque
Specifications: page 17 for torque values
according to pump size.
NOTICE
To prevent cross-contamination of the equipment’s
wetted parts, never interchange component A
(isocyanate) and component B (resin) parts.
NOTICE
To prevent damage to seals always use seal
installation tool (152) and rod installation tool (153)
from repair kit when assembling the piston seals
and displacement rod.
NOTICE
Specification sheets and Graco testing indicate that
anaerobic sealant requires three days to fully cure.
Failure to allow three days for full cure may result in
parts coming loose during operation.
FIG. 17
116 114
117
115
152
Thread Locker
NOTICE
Specification sheets and Graco testing indicate that
anaerobic sealant requires three days to fully cure.
Failure to allow three days for full cure may result in
parts coming loose during operation.
FIG. 18
NOTICE
To prevent displacement rod damage, do not clamp
directly onto displacement rod surface.
114
116
117
115
152
60cc-160cc pumps
5cc, 10cc, and 15cc pumps
115 117
116
114
Thread Locker
Thread Locker

Repair
3A0019ZAC 17
Piston Retainer (114) Torque
Specifications:
7. Apply grease to the O-ring (145) and the two throat
seals (126). Install the O-ring into the upper most
groove of the throat cartridge (119). Slide O-ring
(101 or 125 depending on pump model) over the
boss end of the throat cartridge.
8. Place first throat seal (126) into the throat cartridge
(119) and ensure seal spring faces towards the
bottom of the throat cartridge. Using a suitable size
socket or dowel, press the throat seal to the bottom
of the throat cartridge.
9. Place the second throat seal (126) into the throat
cartridge (119) ensuring the spring side faces up
toward the throat retainer (118). Using a suitable
size socket or dowel, press the second throat seal
into the throat cartridge until it contacts the first
throat seal. See FIG. 19.
10. With the outlet housing (107) mounted securely in a
vice, Install the throat retainer O-ring (120) onto the
throat retainer (118). Place the retainer into the
outlet housing.
11. Apply anti-seize to the threads on the throat
retainer (119) and thread it into the outlet housing
(107). When fully threaded together torque the
throat retainer to 200 ft-lbs. (271 N•m). See FIG. 20.
12. Install cylinder O-rings (101) on pump cylinder (103)
and crossover tube O-rings (102) on crossover
pump tube (104). Lubricate o-rings with grease.
See FIG. 21 page 18.
Pump Size Torque
5cc 3.2 ft-lbs (4.3 N•m)
10cc 5.5 ft-lbs (7.4 N•m)
15cc 5.5 ft-lbs (7.4 N•m)
20cc 30 ft-lbs (40.8 N•m)
25cc 30 ft-lbs (40.8 N•m)
30cc 30 ft-lbs (40.8 N•m)
35cc 30 ft-lbs (40.8 N•m)
40cc 50 ft-lbs (67.5 N•m)
45cc 50 ft-lbs (67.5 N•m)
50cc 50 ft-lbs (67.5 N•m)
60cc 80 ft-lbs (108 N•m)
65cc 80 ft-lbs (108 N•m)
70cc 80 ft-lbs (108 N•m)
75cc 80 ft-lbs (108 N•m)
80cc 160 ft-lbs (216 N•m)
86cc 160 ft-lbs (216 N•m)
90cc 160 ft-lbs (216 N•m)
100cc 160 ft-lbs (216 N•m)
105cc 160 ft-lbs (216 N•m)
120cc 160 ft-lbs (216 N•m)
140cc 160 ft-lbs (216 N•m)
160cc 160 ft-lbs (216 N•m)
FIG. 19
FIG. 20
118
126
120
101/125
145
119
107
119

Repair
18 3A0019ZAC
13. Install pump cylinder (103) and pump crossover
tube (104) in outlet housing (107) with a rubber
mallet. See FIG. 22 page 18.
14. Lubricate piston seal (117), and piston bearing
retainer (116) with grease.
NOTE: For 60cc - 160cc pumps, place the cylinder
installation tool (150) over the end of the pump cylinder
(103) and lubricate with grease. This will help guide the
displacement rod (151) during installation. See FIG. 23.
15. Install displacement rod (151) in pump cylinder
(103) and into throat cartridge (118). Gently tap
displacement rod with a rubber mallet until the hex
surface of the piston retainer (114) is flush or below
the surface of the pump cylinder. See FIG. 24.
16. Gently place inlet housing (106) on pump cylinder
(103) and pump crossover tube (104). Ensure inlet
housing bores are aligned with pump cylinder and
pump crossover tube. Install with a rubber mallet.
17. Lubricate four tie bolts (105) threads with grease
and install.
FIG. 21
FIG. 22
104
102
101
103
102
101
107
104
103
FIG. 23
FIG. 24
NOTICE
To prevent damage to o-rings, ensure inlet housing
(106) is evenly seated on main cylinder (103) before
installing tie bolts (105).
150
103
116
115
117
103
118
114
150
151
Flush

Repair
3A0019ZAC 19
18. Torque tie bolts (105) in a star pattern to 10 ft-lbs
(13.5 N•m). Then torque again to 50 ft-lbs (67.5
N•m). Torque a final time to 200 ft-lbs (271 N•m)
19. After torquing the four tie bolts (105) ensure the
inlet housing (107) is evenly seated onto the pump
cylinder (103) and pump crossover tube (104).
20. For 20cc-40cc pumps only: Clean rod adapter (121)
threads with a wire brush and apply removable
strength thread locker to displacement rod (115)
threads. Install rod adapter (121) on displacement
rod (115). Torque Rod adapter and displacement
rod together to 45 ft-lbs (60.75 N•m). See FIG. 25
page 19.
21. For 10cc-50cc pumps only: Clean rod adapter (121)
threads with a wire brush and apply removable
strength thread locker to displacement rod (115)
threads. Install rod adapter on displacement rod .
See Rod Adapter Torque Specification Table for
rod adapter torque according to pump size.
Rod Adapter Torque Specification Table
FIG. 25
1
2
3
4
121
103
115
105
106
104
Pump Size Torque
5cc 38 in-lbs (3.2 ft-lbs) (4.3 N•m)
10cc 8.5 ft-lbs (11.5 N•m)
15cc 8.5 ft-lbs (11.5 N•m)
20cc 30 ft-lbs (40.6 N•m)
25cc 30 ft-lbs (40.6 N•m)
30cc 30 ft-lbs (40.6 N•m)
35cc 45 ft-lbs (60.75 N•m)
40cc 45 ft-lbs (60.75 N•m)
45cc 45 ft-lbs (60.75 N•m)
50cc 45 ft-lbs (60.75 N•m)

Parts
20 3A0019ZAC
Parts
Complete Pump Assemblies for S1, S3, and S4
5cc, 10cc, and 15cc Pumps
1. Lubricate seals, o-rings, lead-in’s and moving parts with
grease.
Apply one stripe of removable strength anaerobic sealant on
threads.
Torque to 50 ft-lbs (67.5 N•m).
Assemble and torque after displacement rod (151) is
assembled through throat retainer (118). Torque to 45 ft-lbs
(61.01 N•m).
Torque tie bolts (105) in star pattern to 10 ft-lbs (13.5 N•m).
Then torque again in star pattern to 50 ft-lbs (67.5 N•m).
Finally torque again in star pattern to 200 ft-lbs (271 N•m).
Torque to 200 ft-lbs. (271 N•m).
See Piston Retainer (114) Torque Specifications: on page
17 for torque specification.
Must be pressed straight into housing.
Apply anti-seize lubricant to threads.
Mount seals such that the non-spring end of one seal and the
non-spring end of the other seal is joined.
Ensure spring end of piston seal (117) faces displacement rod
(115).
Assemble piston rod bearing(116) and piston seal (117) onto
piston retainer (114).
Torque to 70 ft-lbs. (95 N•m).
Torque to 30 ft-lbs. (41 N•m).
The sharp corner of the outside diameter faces up towards the
ball cage housing (138).
NOTICE
Specification sheets and Graco testing indicate that
anaerobic sealant requires three days to fully cure. Failure
to allow three days for full cure may result in parts coming
loose during operation. if faster cure time is required,
warm components to 104°F (40°C for 6 hours).
2
3
4
5
6
7
8
9
10
11
12
13
14
15
r_257886_3a0019_1d
101
101
102
102
103
104
106
107
105
5
108
108
108
108
108
108
109
109
110
110
111
111
112
112
113 136
118
119
120
121
125
126
128/129
135 134
137
147
146
144
142
142
144
108
141
141
138
138
137
139
139
140
140
143
143
115
117
151
114
7
4
8
10
699
13
2
2
11 12
116
12
9
13
9
14
15
3
9
3
9
15
9
14
S1 and S3
Pumps S4 Pumps
FIG. 26
149
148
124
123