Graco 3A1494D Ld Oil Pump Repair Kits Manual Users

: Graco Graco-3A1494D-Ld-Oil-Pump-Repair-Kits-Manual-Users-Manual-686369 graco-3a1494d-ld-oil-pump-repair-kits-manual-users-manual-686369 graco pdf

Open the PDF directly: View PDF .
Page Count: 14

Repair Instructions

LD Oil Pump Repair

Kits 3A1494D

Instructions for repairing the LD Oil Pump.

Maximum Fluid Pressure - 750 psi (5.17 MPa, 51.7 bar)

Maximum Air Pressure - 150 psi (1.03 MPa, 10.3 bar)

Repair Kits:

24H853: Throat and Piston Seal Replacement Kit

24K293: O-Ring Replacement Kit for 3:1 pumps

24H855: O-Ring Replacement Kit for 5:1 pumps

24U230: Air Piston Replacement Kit

Important Safety Instructions

Read all warnings and instructions in this manual

and in your LD Series Oil or Grease Pump man-

ual. Save all instructions.

EN

Warnings

23A1494D

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, 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 dispense valve, 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 dispense valve at anyone or at any part of the body.

• Do not put your hand over the end of the dispense nozzle.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow Pressure Relief Procedure in this manual, when you stop spraying 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 ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical

reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or

property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or

fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier

for compatibility.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area

of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of

toxic fumes, and burns. This 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.

Instructions

3A1494D 3

Instructions

Always use all new parts included in your kit and dis-

pose of replaced parts according to all state and local

regulations for disposal of discarded components.

Inspect all parts when disassembling the pump. Replace

any and all worn and damaged parts.

Pressure Relief Procedure

1. Close the pump’s bleed-type master air valve.

2. Close the pump air regulator and disconnect the air

supply hose.

3. Open the dispensing valve and dispense fluid into a

waste bucket/container until pressure is fully

relieved.

If you suspect that the dispensing valve is clogged, or

that pressure has not been fully relieved after following

the steps above, very slowly loosen the dispensing

valve coupler or hose end coupling to relieve pressure

gradually, then loosen completely.

Disassembly

The following disassembly instructions describe the pro-

cedure for completely disassembling the LD oil pump.

Depending on the repair/maintenance procedure you

are performing on the pump, it may not be necessary to

entirely disassemble the pump or perform all steps in

this procedure.

The reference numbers used in the following instruc-

tions correspond to the reference numbers used in the

LD Series Oil and Grease Pump instruction manual.

1. Stop the pump. Follow Pressure Relief Procedure,

page 3.

2. Disconnect and remove the pump from its installed

location.

3. Clamp the pump (1) horizontally in a vise as shown

in Fig. 1.

The equipment stays pressurized until pressure is manually

relieved. To reduce the risk of serious injury from pressur-

ized fluid, fluid from the valve, or splashing fluid, follow the

procedure whenever you:

• are instructed to relieve pressure

• stop dispensing

• check, clean, or service any system equipment

• install or clean dispensing devices.

NOTICE

Take care to only use enough clamping force to hold

the pump in position. The pump cylinder is alumi-

num and could be damaged by using excessive

clamping force.

Fig. 1

1

Instructions

43A1494D

4. Secure a strap wrench around the fluid cylinder (32)

and a large adjustable wrench on the intake valve

housing (28). Turn the adjustable wrench counter

clockwise to loosen and remove the valve housing

(28) from the fluid cylinder (32) (Fig. 2).

NOTE: After a few turns, the valve housing should

be loose enough to finish loosening it with your

hand to remove this part.

5. Secure a strap wrench around the fluid cylinder

(32). Use the strap wrench to turn the fluid cylinder

counter-clockwise to loosen and remove it from the

flange (29) (Fig. 3).

NOTE: After a few turns, the fluid cylinder should be

loose enough to finish loosening it with your hand to

remove this part.

6. Using a 10 mm socket wrench, remove the 4 screws

(43) from the air valve (38) and completely remove

air valve assembly from air cylinder (27). Also

remove the two cover gaskets (25). If you are

replacing these parts, discard gaskets. (Fig. 4).

Repair and replacement instructions for the Air

Valve are included in a separate repair manual

included with the kit:

• Air Valve Replacement Kit - 24H848, 24H849,

24H850

• Air Valve Repair Kit - 24H798

• Air Motor Service Kit - 24J757, 24J758, 24J759

• Pilot Valve Kit - 24H749

• Air Valve Seal Kit - 24H851

• Air Valve End Cap Kit - 24H852

Fig. 2

Fig. 3

28

32

32

Fig. 4

43

38

27

25

Instructions

3A1494D 5

7. Using a 10 mm socket wrench, remove the 5 screws

(4) from the flange (29). Using your hand, firmly

grasp the end of the displacement rod (30) and

remove the entire assembly from the air cylinder

(27) (Fig. 5).

NOTE: Sliding the flat blade of a screw driver

between the flange (29) and air cylinder (27) will

help separate the two parts. Exercise caution, how-

ever, to not damage the o-ring (6).

8. Remove the air cylinder (27) from the vise.

9. Lay the flange assembly on a hard, clean work sur-

face. Use an adjustable wrench to hold the displace-

ment rod (30) securely in place. Use a 13 mm

wrench to loosen bolt (18). Remove bolt (18) and

washer (19) (Fig. 6 and Fig. 7).

NOTE: Do not use a hex wrench on the oil piston

(33) or ball holder (34) to loosen or tighten. Using a

hex wrench on this part could cause the pin (10)

(Fig. 7) to fail.

10. Pull the air piston (21) and o-ring (55) off the dis-

placement rod (30).

11. Pull the displacement rod (30) out of flange housing

(29).

Fig. 5

4

29

30

6

Fig. 6

Fig. 7

30

21

29 33

34

18

19

21

29

30

33

55

Instructions

63A1494D

12. Check displacement rod (30) for excessive wear or

damage. If displacement rod (30) is damaged,

replace the pump.

13. Using a 5 mm socket wrench remove the 3 screws

(3) from the bottom cover (26) (Fig. 8).

14. Separate the bottom cover (26) from the flange (29)

(Fig. 8).

If you are replacing the o-rings and seals installed in

the flange, bottom cover, and air piston continue

instructions with the Throat and Piston Seal

Replacement Kit 24H853 instructions beginning on

page 9 and then Step 1, page 6 of the Reassembly

instructions.

Pump Reassembly

NOTE: The following instructions describe the proce-

dure to follow to reassemble a completely disassembled

LD oil pump. Depending on the repair/maintenance pro-

cedure you are performing on the pump, it may not be

entirely disassembled. See the specific section(s)

related to your repair/replacement kit.

For all reassembly procedures:

• Clean all the parts carefully in a compatible solvent,

and inspect for wear or damage. Use all the repair

kit parts during reassembly, and replace other parts

as necessary.

• Check the polished surfaces for scratches or wear.

• Lubricate all parts with a light, water-resistant

grease.

1. Install new o-rings and seals in bottom cover (26)

and flange (29) as described in the Throat and Pis-

ton Seal Replacement Kit 24H853, page 9. Be sure

to apply a thin coat of water-resistant grease to all

o-rings and seals.

2. Apply a thin coat of grease round the top of the dis-

placement rod (30) and install the rod assembly in

the flange assembly as shown in Fig. 9.

3. Install bottom cover (26) over displacement rod

(30). Align pilot valve (20) installed in bottom cover

with opening (a) in flange (29) as shown in Fig. 10.

Compress the bottom cover (26) and flange (29)

together.

4. Install 3 screws (3) (Fig. 11). Tighten with a 5mm

socket wrench and torque to 60-70 in lbs (6.8 – 7.9

N.m).

Fig. 8

3

26

29

Fig. 9

Fig. 10

Fig. 11

29

26

Pin Hole

33

20

a

29

26

3

Instructions

3A1494D 7

5. Install o-ring (55) in groove on the end of the dis-

placement rod (30) (Fig. 12).

6. Push the air piston (21) over the end of the displace-

ment rod (30). Apply Loctite® 262 to the bolt (18)

shoulder. Install the washer (19) and bolt (18). Hold

the displacement rod (30) with an adjustable wrench

and use an 8mm hex wrench to tighten the bolt

securely. Torque bolt to 155 - 160 in. pounds (17.5 -

18.0 N.m) (Fig. 13).

NOTE: Loctite® is a registered trademark of the Loctite

Corporation.

7. Install new o-ring around air piston (21), and pump

piston (33) as described in the Throat and Piston

Seal Replacement Kit 24H853, page 9. Be sure to

apply a thin coat of water-resistant grease to all

o-rings and seals.

8. Slide air cylinder (27) over the bottom cover (26)

(Fig. 14).

9. Remove the assembly from the vise and place the

top of the air cylinder down on a clean hard surface.

Use the palms of your hands to press the bottom

cover (26) firmly into the air cylinder (27) as shown

in Fig. 15.

10. Secure assembly in vise as shown in Fig. 16. Install

5 screws (4) wrench tight only.

NOTE: If installing a new air cylinder (27) the mating

holes are not threaded by design. Use thread form-

ing screws (4) to form threads as they are being

installed. Torque to 95-105 in.-lbs (10.7 to 11.8 N.m)

to ensure full thread formation.

11. To ensure there is a proper seal between the air

valve and manifold, loosen all 5 screws (4) approxi-

mately 1/4 turn Fig. 16). These screws will be

torqued AFTER the air valve is installed (38) (Step

Fig. 12

Fig. 13

30

55

21

19

18

Fig. 14

Fig. 15

26

27

21

26

27

Instructions

83A1494D

15).

12. Perform any air valve repairs / maintenance

needed. Instructions for these procedures are

included in the separate repair manual included with

the Air Valve repair kit.

13. Be sure seals (25) are lightly greased and installed

on air valve (38). Install air valve on air cylinder (27)

(Fig. 17).

NOTE: The air valve (38) can be installed in any

configuration. There is not just one correct way to

install these parts.

14. Install screws (43). Torque to 60-70 in. lbs (6.8 - 7.9

N.m).

15. Torque bolts (4) installed in Step 10 to 60-70 in. lbs

(6.8 - 7.9 N.m).

Muffler (21) Installation (Fig. 17)

Depending on your installation, the air valve (38) can be

mounted with the muffler (21) on either side of the air

valve (38).

To change the installation location:

a. Remove the 4 screws (43).

b. Remove the air valve (38) from its current

mounted position on the air cylinder (27) and

rotate the air valve 180 degrees, which will

reposition the muffler to face the other side of

the pump.

16. Install new o-rings around pump piston (33) (Fig.

16) fluid cylinder (32) and intake valve housing (28)

(Fig. 18) as described in the O-Ring Replacement

Kit 24H855 or 24K293, page 11. Be sure to apply a

thin coat of water-resistant grease to all o-rings and

seals.

17. Install the fluid cylinder (32) over the displacement

rod (3), threaded end first. Hand tighten and then

torque to 20-25 ft. lbs (27-34 N.m) (Fig. 18).

NOTE: It is not necessary to torque the fluid cylinder

in this step. Everything will be torqued simultane-

ously in Step 16 with the intake housing (28).

18. Install the intake valve (28) housing on the end of

the fluid cylinder (32). Hand tighten and then torque

to 20-25 ft. lbs (27-34 N.m) (Fig. 18).

Fig. 16

Fig. 17

4

33

43

38

27

25

21

4

Fig. 18

32

28

Instructions

3A1494D 9

Repair Kits

All Repairs:

• Unless otherwise stated, entirely disassemble pump

as described in the pump disassembly instruction

section of this manual.

• Properly discard all replaced parts according to

local and state regulations for disposal of discarded

components.

• Always use all new parts included in the kit to

replace the identical part on the pump.

• Grease all parts prior to reassembly with a thin coat

of lightweight grease.

• Reassemble pump as described in the reassembly

instructions, page 6.

Throat and Piston Seal Replacement Kit -

24H853 (Fig. 19)

NOTE: When servicing the throat and piston seals, it is

recommended to also replace seals in the pump lower.

Order repair kit: 24K293 for 3:1 pumps or 24H855 for

5:1 pumps.

Replacement parts for o-ring (5) installed on air piston

(21), o-rings and u-cup seal (6, 7, 9, and 17) installed in

bottom cover (26), o-ring (8) installed on flange (29) and

gasket (25) used later in reassembly of the air valve

(38).

O-ring (55) is installed between the air piston (21) and

displacement rod (30).

1. Use a pick to remove the o-ring (5) installed around

the circumference of the air piston (21) (Fig. 20).

Grease the new o-ring included in the kit and install

it around the air piston.

2. Use a pick to remove o-rings (6, 7), bearing (22) and

u-cup seal (9) from the bottom cover. (Fig. 21).

Grease and replace the o-rings and u-cup seal with

the new parts included in the kit and install them in

the order shown in Fig. 21.

Ref. Description

Qty

.

5 O-RING, air piston 1

6O-RING 1

7O-RING 1

8 O-RING, wiper 1

9 SEAL, u-cup 1

10 PIN, spring 1

17 O-RING 3

25 GASKET, cover, small 2

55 O-RING 1

Fig. 19

Fig. 20

7

17

6

5

25

8

9

55

10

5

21

Instructions

10 3A1494D

NOTE:

• The bearing (22) is not included in the kit. This

part is reused. The bearing can be installed with

either side facing up. There is not just one way

to install this part.

• The bearing (22) is a transitional fit and in some

installations it may not be removed.

• Be sure u-cup seal (9) is installed with the lips

facing down as shown in Fig. 21.

3. Remove and discard the 3 small o-rings (17) in the

bottom cover (26) (Fig. 22). Grease the new o-rings

(17) included in the kit and install them in the bottom

cover housing.

4. Use a pick to remove o-rings (8) and (14) from the

flange (29). (Fig. 23). Grease and replace the

o-rings as shown in Fig. 23.

5. Reassemble the pump as described in the Reas-

sembly instructions, page 6.

Fig. 21

Fig. 22

26

6

9

7

22

Lips down

17

26

Fig. 23

8

29

14

29

Instructions

3A1494D 11

O-Ring Replacement Kit - 24K293 for 3:1

pumps; 24H855 for 5:1 pumps (Fig. 24)

NOTE: When replacing seals in the pump lower also

service the throat and piston seals. Order repair kit

24H853.

Replacement parts for o-ring (13) installed on pump pis-

ton (33), o-ring (14) installed on fluid cylinder (32) and

o-ring (15) installed in intake valve housing (28).

1. Use a pick to remove the o-ring (13) installed

around the circumference of the pump piston (33)

(Fig. 25). Grease the new o-ring included in the kit

and install it around the pump piston.

2. Use a pick to remove the o-ring (15) installed on the

intake valve housing (28) (Fig. 25). Grease the new

o-ring included in the kit and install it inside the

intake valve housing.

3. Reassemble the pump as described in the Reas-

sembly instructions, page 6.

Air Piston Replacement Kit - 24U230,

Series B

Ref. Description

Qty

.

13 O-RING 1

14 O-RING 1

15 O-RING 1

Fig. 24

Fig. 25

13

14

15

5

28

15

32

13

33

Ref. Part No. Description

Qty

.

5O-RING 1

18 BOLT 1

19 WASHER 1

21 AIR PISTON 1

25 15R001 GASKET, cover, small 2

27 AIR CYLINDER 1

55 O-RING 1

101 LABEL, Identification 1

102 LABEL, overlay, clear 1

Fig. 26

25

101/102

27

18

19

21

5

55

Instructions

12 3A1494D

Pump Disassembly,

Follow Pump Disassembly instructions Steps 1 - 10

only, pages 3 - 5.

Pump Reassembly

1. Install o-ring (55) in groove on the end of the dis-

placement rod (30) (Fig. 27).

2. To assemble the new air piston, push the air piston

(21) over the end of the displacement rod (30).

NOTE: The counter bored side of the piston (21)

mates with the displacement rod (30) as shown in

Fig. 28.

3. Apply Loctite® 262 to the bolt (18). Install the

washer (19) and bolt (18). Hold the displacement

rod (30) with an adjustable wrench and use a13 mm

wrench to tighten the bolt securely. Torque bolt to

155 - 160 in. pounds (17.5 - 18.0 N.m) (Fig. 29).

NOTE: Loctite® is a registered trademark of the Loctite

Corporation.

4. Remove pilot valve (20) from the old air cylinder

(27). Apply a light coat of grease to o-rings.

5. Install into new air cylinder (27) (Fig. 30). Torque to

95-105 in. lbs (10.7-11.9 N.m).

Fig. 27

Fig. 28

55

30

30 21

Fig. 29

Fig. 30

21

19

18

27

20

Instructions

3A1494D 13

6. Install new o-ring (5) around air piston (21), Install

new o-ring (6) into bottom cover (26). Be sure to

apply a thin coat of water-resistant grease to all

o-rings and seals.

7. Slide new air cylinder assembly (27) over the air pis-

ton (21) and bottom cover (26) (Fig. 31).

NOTE: The five screws (4) are thread forming

screws and as a result the mating holes in the air

cylinder (27) are not threaded by design.

8. Continue reassembly instructions Steps 9 - 18,

beginning on page 7.

9. Use a permanent marker to record the pump part

number, serial number and series code shown the

original label located on the old air cylinder, onto the

new label (101) included in the kit.

10. Apply label (101) to the new cylinder. Apply the

clear overlay (102) over the new label.

Fig. 31

26

27

21

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

Original instructions. This manual contains English. MM3A1494

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

Copyright 2011, Graco Inc. is registered to ISO 9001

www.graco.com

November 2014

Graco Information

For the latest information about Graco products, visit www.graco.com.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.

Phone: 612-623-6928 or Toll Free: 1-800-533-9655, Fax: 612-378-3590