Graco 3A1495C User Manual

Repair Instructions

LD Grease Pump Repair Kits

Instructions for repairing the LD Grease Pump.

Maximum Fluid Pressure - 7500 psi (51.7 MPa, 517 bar) Maximum Air Pressure - 150 psi (1.03 MPa, 10.3 bar)

Important Safety Instructions

Read all warnings and instructions in this manual and in your LD Series Oil or Grease Pump manual. Save all instructions.

3A1495C

Repair Kits:

24H854: Throat and Piston Seal Replacement Kit

24H856: O-Ring and Seal Replacement Kit

24U984: Air Piston Replacement Kit

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, 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.

2 3A1495C

Instructions

Always use all new parts included in your kit and dispose 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

The equipment stays pressurized until pressure is manually relieved. To reduce the risk of serious injury from pressurized 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.

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

2. Close the pump air regulator and disconnect the air supply hose.

Disassembly

The following disassembly instructions describe the procedure for completely disassembling the LD grease 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 instructions 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) upside down in a vise as shown in Fig. 1.

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.

NOTE: Take care to only use enough clamping force to hold the pump in position. The pump cylinder is aluminum and could be damaged by using excessive clamping force.

Fig. 1

If you are only servicing the air valve (40) and seals (18) or air piston (15), skip Steps 4 - 14.

3A1495C 3

Instructions

19, 35

4. Secure a strap wrench around the shovel cylinder (27). Use the strap wrench to turn the shovel cylinder counter-clockwise to loosen and remove it from the pump assembly (Fig. 2).

NOTE: After a few turns, the shovel cylinder should be loose enough to finish turning it with your hand to remove this part.

6. Use a wrench to loosen and remove the seal retainer (29) (Fig. 4).

Fig. 4

Fig. 2

5. Use an adjustable wrench to hold the priming rod (34) securely. Use a second adjustable wrench to loosen and remove the nut (19) and priming piston (35) (Fig. 3, Fig. 4).

Fig. 3

7. Tighten a strap wrench on the spacer cylinder (36) and use it to prevent this part from moving. Secure a strap wrench around the cylinder (26) and use it to turn the cylinder to loosen and remove it from the pump assembly. (Fig. 5). Remove the intake seal (28).

Fig. 5

4 3A1495C

Instructions

PULL

8. If the gasket (30) is still inside the spacer cylinder (36) use a pick to remove.

9. Secure a strap wrench around the spacer cylinder (36) and use it to turn the cylinder counter clockwise to loosen and remove it from the flange (22) (Fig. 6).

NOTE: After a few turns, the spacer cylinder should be loose enough to finish loosening it with your hand to remove this part.

13. Use a rubber hammer and small punch to drive out pin (8), holding together the priming rod (34) and piston rod (23). Turn the priming rod (34) counter clockwise to loosen and remove it from the piston rod (Fig. 7).

Fig. 7

Fig. 6

10. Use a pick to remove gasket (30) from inside the flange (22).

11. Use a rubber hammer and small punch to drive out pin (8), holding together the piston rod (23) and the connection rod (32). Turn the piston rod (23) counter clockwise to loosen and remove it from the connection rod. Remove the piston seal (24) from the piston rod (Fig. 8).

12. Remove the pump assembly from the vise and set it down on a clean, hard work surface.

NOTE: When removing the pin (8) in Steps 12 - 14, it is helpful to place a support such as a piece of wood, below the rods.

14. Use a rubber hammer and small punch to drive out pin (8), holding together the connection rod (32) and displacement rod (25). Turn the connection rod (32) counter clockwise to loosen and remove it from the displacement rod (Fig. 8).

Fig. 8

If you are only replacing or repairing the pump lower continue instructions beginning with Step 14, page 8 of the Reassembly instructions and the related O-Ring and Seal Replacement Kit 24H856, page 12.

15. Clamp the air cylinder (21) horizontally in a vise as shown in Fig. 9.

NOTE: Take care to only use enough clamping

3A1495C 5

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