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Thank you for selecting Ground Force Manufacturing, L.L.C. as your supplier of mining and construction support equipment.

Our business is based on providing quality equipment and the service to support it. Our Parts Department in Post Falls is stocked with the commonly used parts on your machinery and will be glad to assist you in any way to provide replacement parts when they are needed, as quickly as you need them. In addition, trained field mechanics are available to assist your in-house service personnel should the need arise.

If you have any questions or if we can be of assistance at any time, please don’t hesitate to call us at (208) 664-9291.

We look forward to a long and mutually rewarding association.

Sincerely,

Ground Force Manufacturing Documentation Department

Please refer to the following information when calling about service or parts: UNIT SERIAL NUMBERS: 145-04-001 / 145-04-002 Delivery Date: January 2005 Original Customer: Borusan Makina Kazakhstan

Operation, Service & Parts

Manual

FUEL / LUBE TRUCKS

Borusan Makina Kazakhstan - Serial # 145-04-001 / 145-04-002 © Copyright 2005, by Ground Force Mfg., L.L.C. All rights reserved. No part of this manual may be reproduced in any form or by any means (including electronic storage and retrieval or translation into a foreign language) without prior agreement and written consent from Ground Force Mfg. as governed by United States and International copyright laws.

Ground Force Mfg., L.L.C. E. 5650 Seltice Way Post Falls, Idaho 83854 (208) 664-9291

Printing History: First Edition - July, 2001 Second Edition - November, 2002 Third Edition – February, 2005

Contents

Part One: GENERAL

Part Two: OPERATION

Part Three: MAINTENANCE / TROUBLE SHOOTING

Part Four: HYDRAULICS / PNEUMATICS / ELECTRICAL

Part Five: PARTS

1. GENERAL

G3 General

INTRODUCTION Your lube truck was built to provide many years of operation. Durability, ease of operation and high speed product delivery have been the goals in the design of the unit. This booklet will give you the basic operating instructions in the use of your new truck. As with any piece of equipment, each unit will have its own individual operating characteristics which will become familiar to an operator with time. Should any questions arise while you become familiar with your unit please don't hesitate to call us at Ground Force Mfg. Our goal is satisfied customers and we will do all we can to assure we meet that goal. LW General

LIMITED WARRANTY A. Ground Force Mfg. warrants that the specialty

equipment it manufactures, including accessory equipment and parts manufactured by Ground Force Mfg., shall be free from: 1. Defects in material and workmanship

furnished by Ground Force Mfg. and used in the fabrication thereof;

2. Defects arising from the selection of materials or processes of manufacture;

3. Defects in the design thereof in view of the state of the art on the date hereof.

The foregoing warranty shall apply also to accessories, equipment and parts manufactured to Ground Force Mfg.’s detailed design and specifications and supplied to Ground Force Mfg. by other manufacturers. B. Ground Force Mfg. makes no warranty with

regard to component parts not manufactured or fabricated by it, but agrees to assign to the purchaser all of its rights under any original manufacturer's warranty covering such component parts, and agrees to assist the purchaser in making such contacts with the manufacturer of such component parts as may be necessary to protect its right under the warranty covering them.

C. In case of defects in materials or workmanship or defects arising from the selection of material or processes of manufacture, such defects must become apparent in the machine, accessory, equipment or part within six months or 1,000 hours of operations, whichever shall first expire after delivery of the machine to the original purchaser.

The extent of Ground Force Mfg.’s liability under this warranty as to defects in material or workmanship and

defects arising from the selection of materials or the processes of manufacture is limited to the repair of such defects or to the repair or replacement (with a similar item free from the defect in question) of any accessory, equipment, or part which is defective in any such respects. D. The extent of Ground Force Mfg.’s liability

under this warranty as to defects inherent in design is limited to the correction at its expense of all such defects becoming apparent in the machine, accessory, equipment or part purchased here within six months or 1,000 hours of use, whichever shall first expire.

E. The warranty of Ground Force Mfg. does not cover, and Ground Force Mfg. makes no warranty with respect to: 1. Defects not reported and defective items

not returned to Ground Force Mfg. within the warranty period;

2. Failure and damages due to misapplication, lack of proper maintenance, abuse, improper installation, or abnormal conditions of temperature, moisture, dirt or corrosive matter;

3. Failure due to operations, intentional or otherwise, in any improper manner;

4. Damage caused by components, or parts, or accessories built by others or which were not manufactured or installed by Ground Force Mfg.

5. Any item which has in any way been altered by anyone other than an authorized representative of Ground Force Mfg.

6. Any item damaged in shipment or otherwise without the fault of Ground Force Mfg.

Ground Force Mfg. shall in no way be liable for any expenses incurred by the purchaser in any attempt to repair, replace or rework any originally defective item of sale. Ground Force Mfg. shall in no way be liable for any losses, costs, forfeiture or damages (including loss of profits, liabilities of the purchaser, or its customers, or third persons, and all other consequential damages), whether direct or indirect, and whether or not resulting from or contributed to by the default or negligence of Ground Force Mfg., its agents, employees and subcontractors, which might be claimed as a result of the defect, use or failure of the item delivered. Except as stated, there is no warranty, express or implied, in connection with the design, manufacture, sale or use of the machinery, accessories, equipment and parts sold by Ground Force Mfg. Ground Force Mfg.’s liability on its warranty shall in no event exceed the cost of the item of sale.

2. OPERATION

PON1a Operation

IMPORTANT!!! PRE-OPERATION NOTE Because of strict regulations which govern the overseas shipment of equipment, any fluids or oils, which are not pertinent to or necessary for movement of this unit, have most likely been removed or drained. This process may have been performed either at Ground Force Mfg.'s facility or prior to loading for shipment. Any and all gate valves or ball valves pertaining to the hydraulic oil tank have been closed to help eliminate any interior contamination to the tank. Any and all valves MUST BE OPENED prior to operation of this unit or severe damage to hydraulic oil pump and hydraulic oil filters WILL occur. Gate valves must be turned fully CCW to open and ball valves are clearly marked on the handles as to which position is open or closed. All other fluids and oils must be checked for proper levels prior to operation. PSP1 Operation

IMPORTANT!!! POST-SHIPMENT PREPARATION This unit has been specially prepared to eliminate the detrimental effects, which occur to equipment in the environment of ocean transport. There are a few procedures that may need to be addressed prior to operation of this unit. ♦ Remove any shipping film that has been

applied to surfaces. This film is typically applied by means of a paint spray gun. This is meant to provide protection directly on non-painted, machined surfaces such as control valves, shafts, couplings, cylinder piston rods, etc. The film may be removed by simply wiping down the surface with a rag soaked with lacquer thinner or strong grade rubbing alcohol.

Because this film is very tacky and is not soluble with water or most oils, all surfaces must be cleaned thoroughly to prevent the malfunction of moving parts such as valve spools.

♦ Check all fluids pertaining to the operation of not only the truck chassis (if applicable), but also the on-board system tanks or reservoirs

such as hydraulic oil tanks, gear boxes, compressor crankcase oil or “Lubricoolant” tanks, etc. If the unit involves oil-pumping equipment (such as lubrication trucks or skids), a minimal amount of product oil must be loaded into each particular tank to immerse the suction stand pipe. This will guarantee that when the oil product pumps are initially started, there will be enough oil to prevent running the pump dry.

♦ Remove stretch-wrap or shrink film from

equipment or assemblies. Many times if a particular component needs protection during shipment against rough handling, abrasions, or overall abusive contact, it will be protected by means of a wrapping compound or film. This film, either by itself or accompanied by “bubble wrap,” cardboard or wood should be removed prior to operation, but not before the final stage of commissioning of the equipment.

NUB35 Operation

IMPORTANT!!! New Unit Break-In 1. Check hydraulic pump drive shaft set screws to

be sure shipping vibration has not loosened them.

2. Check pump and air compressor drive shaft

coupling set screws daily until they set and no longer loosen with operation.

3. Tighten any hydraulic fittings, which may

loosen. Fittings will commonly loosen and drip the first few weeks of operation.

4. Check oil level on compressor daily. POC15 Operation

PRE-OPERATION CHECK LIST 1. Check hydraulic oil level. 2. Check hydraulic oil tank outlet to be sure it is

open. 3. Check product oil tank outlets to be sure they

are open. 4. Check general condition of truck. 5. Check motor drive couplings.

6. Check charge on fire extinguishers. 7. Be sure all operating controls are "OFF"

before starting truck. 8. Check compressor crankcase oil level. POC15 Operation (Continued) 9. Check product levels in tanks - make certain

that there is enough oil or product in tank to immerse the pump suction if tank is not in use.

DO NOT RUN PRODUCT PUMPS DRY!!! HPU1a Operation

ENGAGING THE HYDRAULIC PUMP This unit is equipped with a variable volume hydraulic pump. There are two distinct methods which Ground Force Mfg. uses to mount and couple these pumps to the chassis or drive system. These two methods also determine the procedure to engage the pump. Direct Front Mount The first mounting method is pump installation ahead of radiator (front mount) between the chassis frame rails. The pump is then connected to the engine crankshaft dampener via a flexible u-joint driveline. This driveline also includes a slip-spline for any extreme movement of engine due to torque. Since the direct drive line connection means that the pump is turning continuously with the engine or power unit, a ball valve has been installed within the pump discharge line to disengage the pump. By closing this ball valve and stopping the flow of oil from the pump, the pump will remain in a "neutral state". When hydraulic pressure is needed to run systems, simply turn on the ball valve. IMPORTANT!!! Note: At no time should this vehicle be operated at higher than 1500 rpm with hydraulic pump engaged. The pump is designed to run with no load (disengaged) at speeds up to 2400 rpm without damage. The ball valve must be turned off while unit is being operated at these higher speeds. PTO or Direct-Couple PTO The second mounting method consists of a P.T.O. using either a drive line or a direct coupled configuration to drive the pump. Typically the pump is mounted separate from the P.T.O. on a heavy mount which is suspended from truck frame or main structure of carriage. To engage this system is simply to flip the P.T.O. switch to "Engage" position.

Both methods of mounting incorporate an operating speed of 1400-1800 rpm engine speed. Consult the "Operating Instructions" in section 2 of this manual for your particular application. ESO1c Operation

EMERGENCY SHUT-OFF PRODUCT PUMPS This unit is equipped with an emergency shut-off valve which enables the operator to disengage the low volume product oil product pumps (by pushing one valve knob) but ONLY in the case of an emergency. Such emergencies would include a low volume oil product delivery hose failing, or if equipment tank being filled was not monitored and allowed to overflow. In many cases, the emergency shut-off is easier and quicker to push than trying to figure out in a split second which product control to shut off. Keep in mind that the purpose of this valve IS NOT for daily operation and MUST not be used as (what some operators have, in the past, been considering) a main On/Off control.

WARNING!!!

This Emergency Valve has been installed ONLY for the above mentioned reason in an EMERGENCY situation. This valve does not turn Off all systems on the unit. If used as a main shut-off during daily operations, the potential for damage to other pumping systems is extremely high. This damage will NOT be covered under warranty.

This emergency shut-off system is operated with a single valve and needs simply to be pushed in to the "off" position IF NECESSARY. The valve is installed in the hose reel compartment and is clearly marked. Operators must familiarize themselves with not only this but all controls. IMPORTANT!!! Note: This valve does not effect the diesel delivery system or any high volume oil product delivery system. Each of these systems have their own separate on-off controls. OPW1 Operation

WARNING!!! Oil Product Pump The oil product pumps on this unit utilize a self contained hydraulic control system. This system will automatically control the hydraulic circuit that turns the pump/motor on and off. The system relies on a series of sensing lines and check valves to send proper signals which determine the demand of any one product delivery system.

The most danger to these systems occurs when the supply tanks are run low on product. Once the product pump looses its prime, the product line is not OPW1 Operation (Continued) allowed to build pressure and will not properly signal the hydraulic control system. Without signal, the pump will continue to run dry and will eventually be damaged. At NO time should these pumps be allowed to run dry. Damage due to dry-running is typically self-evident and is not covered by warranty. Operators must be aware of product levels in tanks to prevent this type of damage. In the case of a product tank being inadvertently run dry during oiling procedures, the “Emergency Pump Shut-Off” may be utilized to turn off the dry pump. Tank must be immediately refilled before engaging the “Emergency Pump Shut-Off” again and running the product pump. OI237 Operation

OPERATING INSTRUCTIONS Fuel/Lube Truck 1. Do pre-operation checklist. 2. Be sure all operating controls are in

"OFF" position before starting truck. 3. Start truck engine and allow to idle. Make

certain that parking brakes are set. 4. Engage the hydraulic pump. Engine must run

at approximately 1500 RPM. 5. If compressed air is needed, locate

compressor control, turn on compressor and allow it to charge tank(s) fully.

6. Product delivery functions may be

operated from rear compartment. 7. Reset product totalizer or meter. 8. Engage selected product by pulling

appropriate selector valve handle out to "ON" position.

Note: Low volume oil product pumps have no selector valve (see “Emergency Shut-Off Product Pumps” instructions). 9. All product delivery rates on this truck have

been preset to the maximum allowable, so no adjusting of pump speeds will be necessary.

10. If so equipped, using appropriate reel control

valve, pull out knob to "UNWIND" position and pull hose from appropriate reel. (See also "Ground Force Hose Reel Operating Instructions".)

11. Dispense required amount of product. 12. Return hoses to reel by pushing in on the knob

of the appropriate rewind control valve. 13. When dispensing of product is complete, turn

the appropriate pump control off. 14. When delivery processes are completed allow

truck engine to idle. Disengage hydraulic pump.

Oil Delivery System The oil pumping systems on your new lube truck utilize a self-contained hydraulic control system. This system automatically turns the pump hydraulics on and off as the truck operator opens the oil discharge nozzle. The truck operator is not required to manually turn the oil pump systems on. Once the discharge nozzle is attached to the receiving equipment, the operator simply needs to turn on the control valve at the end of the delivery hose. The oil pump delivery rates depend on whether the oil system is equipped for low volume, fixed delivery, or for high volume delivery. The high volume system has a variable output rate with which the truck operator can adjust from minimum flow to maximum flow (approx. 20-30 gpm). The delivery speed control is affected by moving the pump speed control lever CW to decrease flow, CCW to increase flow. The output rate of the low volume system is a fixed rate (not adjustable). Pump delivery can be throttled back however, by partially opening the hose-end delivery control valve. Grease Pumps Pull out the appropriate control valve for grease reel to engage either the high or low volume grease pumps. Grease hoses will be charged until the control valves are turned off (pushed in). Waste Oil Pump Pull out the appropriate control valve to engage the waste oil pump. If so equipped, a selector valve is included in the waste oil plumbing system to allow both on-loading and offloading. The selector valve is clearly marked for flow position.

Coolant Pump Pull out the appropriate control valve to engage the coolant pump. The coolant pump will run as long as the control valve is in the “ON” position. This coolant system will deliver new coolant. OI237 Operation (Continued)

Diesel Fuel Pump Pull out the appropriate control valve to engage the diesel pump. The pump will run as long as the control valve is in the “ON” position. DO NOT let this pump run continually!! Run the pump only as long as delivery is required. Damage to pump may occur if allowed to run indefinitely.

CAUTION!!!

Any time the pump control valves are pulled out, the product hoses will be pressurized. DO NOT open the discharge nozzle or valve unless you are ready to have product pumped out!!!

OI164 Operation

OPERATING INSTRUCTIONS Ground Force Hose Reels This unit is equipped with Ground Force hydraulically controlled product hose reels. Each hydraulic control for these reels consist of one single spool directional control valve and one hydraulic drive motor which also acts as the live center for the drum (sheave) of the reel. The control valve has three positions being: 1) unwind, 2) lock, and 3) rewind. Each of these three positions will determine the function of the reel. Note: The hydraulic systems on Ground Force equipment are typically of the load sensing type and in order for proper operation of the reel controls, one or more product delivery functions may need to be engaged. The easiest system to accomplish this is the diesel delivery. By engaging this system the main hydraulic system will maintain its maximum pressure and provide more control for hose reel circuits. 1. Unwind: this function is accomplished by

pulling out on the control valve handle. When engaged in this position the reel will be allowed to “float” or coast so that the operator may pull any desired amount of hose from the reel. Although having a slight tension, this function does not allow hose to be held in position by itself. Hose will continue to feed off of reel (by

gravity) until control valve is moved to another function position.

2. Lock: this function is accomplished by

“bumping” the control valve handle slightly from the unwind position to the “center” position. In this position, the valve will close off the flow of hydraulic fluid to the reel drive motor and create a “lock” in the hydraulic circuit, which will allow virtually no reel movement.

This position may also be used after rewinding by simply allowing control valve handle/spool to return to the center (lock) position. 3. Rewind: this function is accomplished by using

the control valve handle to the fully “in” position. This is a spring loaded valve position which when released will return to the “lock” position. In the “rewind” position, the hydraulic valve controls the powered rewind function of the reel. The hydraulic fluid which drives the reel motor is regulated both in pressure and flow. Even though this function is regulated, during this function the operator must maintain a moderate tension on the product hose (by physically holding the hose) to eliminate the “freewheeling” effect that will occur if hose is left unattended. “Freewheeling” can cause serious personal injury and/or equipment damage if not monitored. Damage encountered because of this freewheeling is considered misuse and is not covered by warranty.

When the rewinding procedure is completed, simply release the valve handle, allowing valve to return to the “lock” position. Hose Reels Each of the Ground Force hydraulic rewind reels includes the use of a specific size and type of hose, which has been installed to accommodate the type and flow requirements of that particular product delivery system. Many different fluid flow rates and working pressures may be present, so mixing of hoses from one reel to another may have detrimental affects. If servicing of reels or replacement of reel hoses is required, make certain that the hoses installed on reels are of original size and type. Hose Stops Each Ground Force reel is equipped with a hose stop to alleviate the problem of pulling the product hose through the reel fair lead during rewinding procedures. This hose stop should be occasionally checked for tightness and positioning, and should be replaced immediately if any damage shows evident. If

the hose stop is missing or damaged, extreme caution should be exercised during reel use, until hose stop can be replaced. Pressure and Flow Regulation The hydraulic circuits which control the functions of the Ground Force hose reels have incorporated relief OI164 Operation (Continued) valves and flow controls which have been factory set to accommodate the needs of this particular unit. These controls must not be tampered with.

CAUTION!!!

Severe damage to equipment and/or personal injury could result if relief valves and flow controls are readjusted by anyone other than a qualified Ground Force technician. This damage will not be covered as a part of the warranty.

OI87d Operation

OPERATING INSTRUCTIONS Air Compressor This truck is equipped with an on-board hydraulic-drive air compressor. This compressor develops an air supply which may be used to fill tires, drive air tools and remote pumps or motors, etc. Included with this air compressor is one or more receiver tanks, an “F.R.L.” package (explained later), and a supply of ½” or ¾” I.D. hose which is loaded on a hose reel. The loading of this compressed air supply is an “on-demand” system. Once the “compressor” switch (located either in truck cab or rear control panel) is turned on, the hydraulic system will drive the compressor which will run until a pre-set air pressure is reached, and then the system will shut down leaving the compressor in a “standby” mode. The compressor will then stay idle until additional air is needed to replenish the supply, or until the “compressor” switch is turned off. F.R.L. (Optional) Installed within the airline system is a “filter-regulator-lubricator” assembly. This assembly is used to filter and trap airline contaminants, regulate the airline pressure, and automatically lubricate the discharge line air. The filter must be cleaned and drained on a regular basis and the lubricator kept relatively full with a high quality, moisture repelling air system lubricant. Do not allow lubricator to run dry.

To Operate After initial warm-up procedures have been followed, the hydraulic pump must be engaged (see also “Engaging the Hydraulic Pump” section) and the “compressor” switch must be turned On. Note: Compressor switch is sometimes accompanied by an On indicator light. If compressor indicator light does not illuminate when switch is turned on, do not assume that the compressor is not functioning, check for faulty bulb. Allow the compressor to run long enough to fully charge the receiver tanks (until system shuts down to “standby” mode). Air system is now ready for use. Drain tank condensation with each use (see below). IMPORTANT!!!

SAFETY NOTE!!!

Do not assume that the compressor is turned off simply because it is not running. This system will intermittently start and stop without warning. Keep hands and loose clothing clear of all moving parts and make certain that all guards and shields are properly in place at all times.

After use of compressor is complete, turn off “compressor” switch (located either in truck cab or at control console). This system should never be left “on” while not in use. During any “Down-Time” of this truck (whether it be for a short period, shift change, or for prolonged service or maintenance) the air compressor as well as all system controls should be in the “Off” position. Any functions left in “On” position could cause potential dangers when hydraulic system or air system is re-engaged. Air Tank Drain Most air receiver tanks for these air systems are equipped with a drain valve for bleeding residual condensation. This valve should be opened daily and should be considered part of the normal maintenance for this unit.

3. MAINTENANCE / TROUBLE

SHOOTING

M16 Maintenance

INTRODUCTION Your lube truck was constructed with care and with quality materials. Simple routine maintenance will assure that it will continue to operate with minimal problems. This section of this manual will help you establish a routine maintenance schedule and will detail components which may need service at some time. Note: This section of the manual has the suggested schedule of maintenance operations for your new truck body. Some or all of the schedules will apply to your individual truck. These schedules are intended as a guideline only. As long as attention is paid to lubrication and maintenance a minimum of times as recommended, your own mine maintenance schedule can supersede the recommended schedule. SP1 Maintenance

SAFETY PROCEDURES 1. THINK!! 2. Use EXTREME CAUTION when working on or

servicing any machinery. 3. Before doing any work on equipment, follow

three easy steps:

A. Lock It Out

B. Tag It Out

C. Put The Keys In Your Pocket 4. Before starting equipment after servicing,

check to see that all personnel are clear. When you are positive all are clear, check again!

HS11 Maintenance

HYDRAULIC SYSTEM Inspection Inspect your truck daily for worn hoses or loose fittings. When hoses appear worn (especially if wire wrappings are showing through), replace the hose before a failure occurs. Tighten any loose fittings. Note: When equipment is new, leaks will frequently occur. This is normal and will cease after the unit has been in operation for a while when fittings are tightened and seated.

Hint: When re-sealing pipe thread fittings, use anaerobic hydraulic thread sealant (Felpro #51452). Do not use Teflon tape (its use voids some component manufacturers warranties). General Fitting Sizes: o 1/4" hose - JIC #4 (37o) o 3/8" hose - JIC #8 (37o) o 1/2" hose - JIC #10 (37o) o 3/4" hose - JIC #12 (37o) o 1" hose - JIC #16 (37o) Hydraulic Oil Your new truck has been shipped without hydraulic oil. Utilize preferably a premium grade AW46 hydraulic oil. Return Oil Filter These filters are the screw-on canister filters which are plumbed to the hydraulic oil tank in the return oil line. Ground Force replacement filters MUST be used to maintain the factory warranty. We recommend changing the hydraulic system return oil filters monthly if your truck is used frequently. A

$30 filter is an inexpensive preventative maintenance for a $6,000.00 hydraulic system. Suction Filter This filter is included to capture any large particles which may get into the oil reservoir. This filter is the screw-on canister filter which is plumbed to the hydraulic oil tank in the suction oil line.

CAUTION!!!

Your hydraulic reservoir is equipped with a pressure holding vent cap. This pressurizes the reservoir to approximately 3 psi to assure adequate oil feed to the hydraulic pump. DO NOT replace this cap with a non-pressurized model!!!

MS60 Maintenance

MAINTENANCE SCHEDULE DESCRIPTION DAILY WEEKLY MONTHLY ANNUALLY

Lubricate reel fair lead rollers X

Lubricate hydraulic valves and actuators X

Change hydraulic oil X

Change hydraulic oil filter X

Clean in-tank suction strainer (with oil change) X

Check hydraulic oil level X

Check chassis motor oil X

Check hydraulic control valves X

Check hydraulic hoses and fittings X

Check drive couplings and inserts X

Check body mounting bolts X

Check hydraulic pump driveshaft bolts/coupling set screws

X

Check hydraulic pump mount bolts X

Check compressor crankcase oil level X

Check compressor drive couplings X

Change compressor crankcase oil See Compressor “Maintenance Schedule”

Clean compressor air filter element See Compressor “Maintenance Schedule”

FRL package - drain condensation from filter/separator - add lubricant oil to lubricator as needed

X

Clean coolant suction strainer (if applicable) X

Replace diesel fuel filters (if applicable) X

Drain condensation from air receiver tanks X

TSG10 Trouble Shooting

INTRODUCTION Periodically some problem may occur with your lube truck. Most problems are minor and can be easily solved. This section of this manual is provided to help you in diagnosing and solving problems you may encounter. Note: Before replacing any major components, isolate the problem! As with any hydraulic or electrical

system, simple tests will narrow down potential problems. Test instruments which are needed to diagnose your truck are: o High pressure and flow test meter. o Digital electronic multi-meter (Must be digital

with 0-10 amp DC current range).

TS11a Trouble Shooting

TROUBLE SHOOTING GUIDE

PROBLEM

PROBABLE CAUSE

ITEMS TO CHECK Hydraulic system will not operate.

PTO not engaged or main pump ball valve not turned on.

Cable Shift PTO's: Check cable. Air Shift PTO's: Adequate air pressure to shift? Air Tank Emergency Valve: Valve functioning? Control valve working properly? Shift cylinder on PTO operating? Check position of ball valve on pump (direct mount only).

Hydraulic pump not running.

Check PTO-pump driveshaft. Check keyways in pump, PTO driveshaft. Check pump shaft. Check if pump is free or "frozen up."

Hydraulic pump turning, no apparent oil output.

Check oil level in hydraulic tank. Check pump driveshaft.

Hydraulic pump turning, oil output apparently O.K.

Check pressure build when a circuit is used. a. No/low Pressure: Check circuit or main

relief valve. b. High Pressure Relieving: Check to be

sure the operating system is not "frozen up."

(Pressure Compensated Pumps Only) Pump output pressure too low.

Check pressure compensator, reset to 1800 psi. Check relief valves.

TS11a Trouble Shooting

TROUBLE SHOOTING GUIDE (Continued)

PROBLEM

PROBABLE CAUSE

ITEMS TO CHECK

Product pump will not run.

Motor flow control closed.

Check inlet flow control to motor; closed, reset for desired output.

No hydraulic oil at drive motor or low oil pressure.

Check main hydraulic pump ball valve to be sure it is fully opened.

High pressure in system, pump will not turn.

Pump binding: Check oil flow to be sure pump turns with hydraulic motor uncoupled.

Motor turns, pump will not.

Check drive coupling.

Hydraulic motor bad.

Check motor.

Hose reel will not function.

PTO not engaged.

Check PTO.

No hydraulic oil or low pressure to control valve.

Check hydraulic pump.

Relief valve on valve block set too low.

Check system pressure, if OK and hose reel does not develop pressure when running, reset reel control valve relief.

Hydraulic motor getting oil, but not functioning.

Replace motor.

TS44 Trouble Shooting

HYDRAULIC LOAD SENSING SYSTEM TROUBLE SHOOTING GUIDE

PROBLEM

PROBABLE CAUSE

ITEMS TO CHECK

Hydraulic system will not return to a standby pressure of 300-500 psi after all circuits have been disengaged.

Plugged load sense bleed valve cartridge.

Remove cartridge, check for debris creating obstruction of orifice. Clean and reinstall.

Faulty pump compensator.

Replace compensator block.

Hydraulic circuit(s) not totally disengaged - load sense circuit still receiving signal pressure.

Perform single circuit diagnostics to determine which circuit remains open. Repair circuit components.

Hydraulic system will not develop high pressure (will not raise above typical 300-500 psi standby pressure).

Plugged signal port on pump compensator control block.

Remove load sense signal line from compensator block. Engage one circuit (such as “product delivery,” compressor, or down riggers). Signal hose should discharge a steady stream of oil. Remove compensator block and thoroughly clean (see pump service instructions).

Wrong sized orifice in load sense bleed valve cartridge. Pressure is not being allowed to build in load sense signal circuit.

Check for proper load sense bleed valve cartridge. If questionable, replace with 0.1 g.p.m. cartridge.

Leak in load sense signal line circuit.

Check for leaks, repair as needed.

Circuit control valve not being engaged properly.

Check for mechanical failure such as pneumatic pilot not actuating a hydraulic valve.

Faulty load sense check valve or possible plug.

Systematically run each separate circuit. Determine which circuit does not bring pump up to pressure. Replace or repair load sense check valve on that circuit.

Faulty pump compensator.

Replace compensator block.

Hydraulic system pressure will not increase even with all system and circuit relief valves set.

Too high of volume of load sense circuit signal pressure lost by bleed to tank or by line leaks.

Check for leaks, repair as needed. Check for proper load sense bleed valve cartridge. If questionable, replace with 0.1 g.p.m. cartridge.

4. HYDRAULICS / PNUEMATICS / ELECTRICAL

VVH5 Hydraulics

VARIABLE VOLUME HYDRAULIC PUMP ADJUSTMENT For Part #3286PM3XX, 3286PM4XX, 3286PM6XX, Series Pumps This Ground Force hydraulic system is designed to operate at less than 1800 psi hydraulic pressure. Therefore, it is important that the pressure compensator (which sets the maximum available hydraulic pressure of the hydraulic pumps) be set properly or damage to the hydraulic system could potentially occur. The pressure compensator is a cast housing which is attached to the main body of the hydraulic pump. This cast housing includes two adjustment screws. One being the load sense pressure adjustment, and the other being the load pressure limiter adjustment. The load pressure limiter should be the only adjustment immediately necessary. Some portions of Ground Force hydraulic systems are designed to "overdrive" the hydraulic pressure needed to operate the system, i.e. on air compressors. This means that when that function of the truck is engaged, the hydraulic pump will automatically deliver its maximum pressure rather than just the pressure needed to operate the system. This aids in adjusting the compensator. Follow the listed procedures to adjust the compensator. Bulk Explosive Trucks With Variable Volume Pump Engage the auger delivery circuit to bring the truck to maximum pressure. It will be O.K. to leave the product selector (ANFO or Blend) off and run the truck as though it is in a "clean out" mode; this will still bring the truck up to full operating pressure. When the system is turned on, adjust the pressure limiter adjusting screw on the pressure compensator control up to the desired 1800 psi, and set the lock nut. Service Trucks (Mechanics, Lube, etc.) The air compressor on all Ground Force service trucks is designed to overdrive the hydraulic system. Turn on the compressor controls, and while the air compressor is running adjust pressure to 1800 psi and set the lock nut. On All Units When replacing the main hydraulic pump or the compensator; be sure to back off the pressure compensator adjustment counter clockwise when first installing the part. Engage the hydraulics and bring the pressure up and set at 1800 psi. DO NOT start

out with the compensator/pump set at high pressure, or system damage could occur if the compensator setting is too high. For further information, see the adjustment procedures in the appropriate “Overhaul Manual.” HSP4 Hydraulics

HYDRAULIC SYSTEM Pressure Relief Adjustment Procedures (With Hydraulic Pump Series 3286 PM 3XX, 4XX, and 6XX/Without Spool Valve Relief) Reference Drawing No. 96019/B32 Prior to adjusting any relief valves, please verify which particular valves are involved with this procedure. Follow directions precisely and carefully. A = Main Hydraulic Pump - Flow and Pressure

Compensated B= Load Sense Adjustment Screw C= Pressure Compensator Adjustment

Screw D = Main System Relief Valve (only one)

E= Cap, Adjustment Screw Cover F= Adjustment Screw G= Cartridge, Relief Adjustment

Note: Do not start engine or engage hydraulic system(s) until called for!!! Adjustment Preparation 1. Locate "A" (Hydraulic Pump) and control

block which includes “B” (Load Sense Adjustment Screw) and “C” (Pressure Compensator Adjustment Screw).

2. Using a 1/2" wrench, loosen the jam nuts on

“B” and “C,” making sure that “B” and “C” do not turn in the process. A 5/32" Allen wrench may be used to hold “B” and “C” in place.

3. Using a 5/32" Allen wrench, turn “C” (Pressure

Compensator Adjustment Screw) CCW until spring pressure is no longer observed. Then turn the same “C” screw CW approximately 2 full turns. This will adjust the pump output to a fairly low pressure.

4. Locate "D" (Main System Relief Valve) and

associated components "E", "F", and "G".

HSP4 Hydraulics (Continued) 5. Use a 1" wrench to hold "G" (Relief Valve

Cartridge) in place while using a 15/16" wrench to loosen and remove "E" (Adjustment Screw Cap). Make certain that during this procedure the Relief Valve Cartridge "G" does not loosen from its seated position within the main block of the relief valve (assembly). Place "E" in a safe location (to be reinstalled later).

6. Make certain ALL controls are "OFF" or in

"NEUTRAL" position, including the "Product Delivery" control.

Adjustment Procedures Note: Do not attempt any adjustments without first following steps 1 through 6 of "Adjustment Preparation." 1. Start engine, engage hydraulic pump, raise to

approximately 1000 rpm. Note: Please keep in mind that even the slightest adjustments made must be monitored visually on the "Hydraulic System Pressure Gauge."

2. Making sure that ALL other operating controls

are "OFF" or in "NEUTRAL" position, turn "ON" one of the main hydraulic circuits:

u Stemming/ANFO Trucks =

Product Delivery

u Mechanic/Service/Lubrication Units = Air Compressor or Fuel Pump

3. Locate "C” (Pressure Compensator

Adjustment) on main pump control block. 4. Turn “C” (Adjustment Screw) CW while

monitoring the pressure gauge. Continue to turn until pressure reads 2000 psi or until "D" (Main System Relief Valve) starts to make a whistling or squealing sound, whichever comes first.

3. If 2000 psi cannot be obtained without the main

system relief valve making noise (which signifies that the oil is relieving), then "F" (Relief Valve Adjustment Screw) must be turned CW no more than ½ (one-half) turn at a time, along with continued CW adjustment of the "Pressure Compensator Adjustment Screw," until a 2000 psi pressure is reached.

Once the pressure gauge reads 2000 psi, locate "D" and turn "F" (Adjustment Screw) CCW until the valve begins to "squeal."

7. Turn "F" slowly CW until "squealing" stops. 8. Replace "E" (Cap). Do not over tighten, needs

only to be slightly more than hand tight. Main System Relief Valve is now set and should need no further adjustments.

9. Return to main pump and while monitoring the

pressure gauge, turn "Pump Compensator Pressure Adjustment Screw" CCW slowly until pressure gauge reads 1800 psi pressure.

10. While holding the adjustment screw with a

5/32" Allen wrench, tighten the jam nut with a ½" wrench.

11. Recheck pressure at gauge. If pressure has

changed, pump compensator must be readjusted.

12. Disengage the main hydraulic circuit which had

been engaged for pressure adjustments. 13. Locate “B” (Load Sense Pressure Adjustment).

While monitoring the system pressure gauge, use a 5/32" Allen wrench and adjust the “Standby” pressure to 400-500 psi.

CW = Increase Pressure CCW = Decrease Pressure

Note: After releasing all of the function circuits to “Neutral” on this system, the “Standby” pressure should drop to 400-500 psi within 30-45 seconds maximum. If the system does not react in this manner, see the “Load Sense Trouble Shooting” section in this manual. 14. Once the “Standby” pressure has been

adjusted and rechecked (by engaging and disengaging a hydraulic circuit) tighten the jam nut on “B” to secure in place.

15. Disengage the hydraulic pump. 16. Allow engine to idle for "cool down" period

and then stop engine.

HP22 Parts

HYDRAULIC SYSTEM PARTS UNIT SERIAL NUMBERS 145-04-001 & 145-04-002

REFERENCE HYDRAULIC DIAGRAM145-02-001_2/H

ITEM

PART #

DESCRIPTION

QTY

1

3286PM604

MAIN HYDRAULIC PUMP

1

2

1227HY301

MAIN RELIEF VALVE

1

3

9475FI010

SUCTION STRAINER, IN TANK

1

4

9475HY003

FILLER/BREATHER CAP - 3 PSI

1

5

9475FI011

FILTER HOUSING, RETURN OIL

1

6

9777FI004

FILTER ELEMENT DO NOT SUBSTITUTE

2

7

9400HY003

CARTRIDGE, LOAD SENSE BLEED VALVE

1

7A

9400HY004

BODY, FLOW CONTROL

1

8

3400VA008

GATE VALVE, 2-1/2" TANK SUCTION

1

9

3451VA054

CHECK VALVE, 3/4" BRONZE

1

10

1812HY001

SIGHT GLASS

2

11

9400HY031

BODY FLOW CONTROL

5

12

9400HY078

CARTRIDGE, FLOW CONTROL - 2.0 GPM

1

13

9400HY007

PRESSURE REDUCING VALVE

1

14

9414HY257

MOTOR, HYDRAULIC - REELS

8

14A

9414HY253

MOTOR, HYDRAULIC - REEL

2

15

9411HY001

VALVE, SINGLE SPOOL - REELS

10

16

6156GG001

PRESSURE GAUGE - 3000 PSI

1

17

2519HY351

VALVE, SELECTOR - 1/2"

3

18

9400HY070

CARTRIDGE, FLOW CONTROL

2

19

9400HY074

CARTRIDGE, RELIEF VALVE

2

20

9424HY001

CHECK VALVE, LOAD SENSE

3

21

9900HY131

MANIFOLD, COMPRESSOR CONTROL

1

22

9400HY083

SOLENOID CARTRIDGE

1

23

9400HY084

SOLENOID COIL - 12 VDC

1

24

9500HY063

CARTRIDGE, LOAD SENSE CHECK

1

25

9400HY052

CARTRIDGE, FLOW CONTROL - 25 GPM

1

HP22 Parts

HYDRAULIC SYSTEM PARTS

UNIT SERIAL NUMBERS 145-04-001 & 145-04-002 REFERENCE HYDRAULIC DIAGRAM

(Continued)

26

9414HY247

MOTOR, HYDRAULIC

1

27

9400HY078


1

28

9400HY078


1

29

9414HY272

MOTOR, HYDRAULIC - COMPRESSOR COOLING FAN

1

30

10082PM301

MOTOR, HYDRAULIC - GREASE PUMP

2

31

10082PM303

PUMP TUBE, GREASE - HIGH PRESSURE

1

32

10082PM302

PUMP TUBE, GREASE - HIGH VOLUME

1

33

9900HY130

MANIFOLD, PRODUCT PUMP - SEE ALSO DRAWING NO. 94080/B91

5

34

9400HY013


5

35

9424HY004

CHECK VALVE, PRODUCT OIL

5

36

2617PM303

PUMP/MOTOR COMBO - SEE ALSO DRAWING NO. 94080/B91

5

37

2519HY352

SELECTOR VAVLE, 3/4"

1

38

9400HY012


1

39

9400HY016

BODY, FLOW CONTROL

1

40

9414HY209

MOTOR, HYDRAULIC - WATER PUMP

1

5. PARTS

Parts

WARRANTY PARTS

When Ground Force manufactures machinery, we utilize parts and supplies made by many vendors. It is an unfortunate fact of life that a percentage of these parts that we purchase to assemble our machinery will be bad. Component parts all have their respective manufacturer's warranties. Since you've purchased Ground Force manufactured machinery, we will do everything in our power to assure you that your equipment stays in top operating condition and will back you in any warranty claims. Should any parts on your new unit prove to become defective, we can usually ship a replacement part from our stock overnight if you so desire. What we need to do at Ground Force to receive our warranty credit for parts proven to be defective is to have parts returned by you, the owner of the machine, to us, so that we may apply to parts suppliers for warranty credit. To do this, it is imperative that we receive the faulty part when you replace it with a new one. Our warranty procedure at Ground Force is that when we ship a replacement part for your unit, either on warranty or standard replacement, we will send an invoice with that part. When we receive the defective part back from you, we will submit that to our suppliers for a warranty credit. As soon as warranty credit is received for that part, we will issue a credit invoice for the amount charged on your replacement. (Freight charges are not covered under warranty). If you have any questions about Ground Force's warranty system, please contact Chad Wilson at (208) 664-9291.

Parts

TO PURCHASE PARTS:

Order ALL parts for the items shown in this book through Ground Force not the part manufacturer!!! Ground Force is a master distributor all the components used to build your equipment and can furnish them cheaper and faster than the component manufacturer. When ordering, use the Ground Force Part Number to assure receiving the right part quickly! Ground Force maintains an inventory of the common parts which are part of the normal maintenance and repair of your equipment.

DP4aDP4aDP4aDP4aDP4a

DOOR PARTSDOOR PARTSDOOR PARTSDOOR PARTSDOOR PARTS

GAS SPRINGGAS SPRINGGAS SPRINGGAS SPRINGGAS SPRINGSIDE COMPARTMENTSSIDE COMPARTMENTSSIDE COMPARTMENTSSIDE COMPARTMENTSSIDE COMPARTMENTS(LIFT-UP DOORS)(LIFT-UP DOORS)(LIFT-UP DOORS)(LIFT-UP DOORS)(LIFT-UP DOORS)PART # 15088HW125PART # 15088HW125PART # 15088HW125PART # 15088HW125PART # 15088HW1252 EACH PER DOOR2 EACH PER DOOR2 EACH PER DOOR2 EACH PER DOOR2 EACH PER DOOR

(SIDE-SWING DOORS)(SIDE-SWING DOORS)(SIDE-SWING DOORS)(SIDE-SWING DOORS)(SIDE-SWING DOORS)PART # 15088HW035PART # 15088HW035PART # 15088HW035PART # 15088HW035PART # 15088HW0351 EACH PER DOOR1 EACH PER DOOR1 EACH PER DOOR1 EACH PER DOOR1 EACH PER DOOR

CATCHCATCHCATCHCATCHCATCH

LATCH LEVERLATCH LEVERLATCH LEVERLATCH LEVERLATCH LEVERPART # 13500WH501PART # 13500WH501PART # 13500WH501PART # 13500WH501PART # 13500WH501(INCLUDES CATCH)(INCLUDES CATCH)(INCLUDES CATCH)(INCLUDES CATCH)(INCLUDES CATCH)

EDGE TRIMEDGE TRIMEDGE TRIMEDGE TRIMEDGE TRIMPART # 4200WH015 (PER FOOT)PART # 4200WH015 (PER FOOT)PART # 4200WH015 (PER FOOT)PART # 4200WH015 (PER FOOT)PART # 4200WH015 (PER FOOT)

"D" DOOR SEAL (SELF BONDING)"D" DOOR SEAL (SELF BONDING)"D" DOOR SEAL (SELF BONDING)"D" DOOR SEAL (SELF BONDING)"D" DOOR SEAL (SELF BONDING)PART # 10600WH939PART # 10600WH939PART # 10600WH939PART # 10600WH939PART # 10600WH939(ORDER PER FOOT)(ORDER PER FOOT)(ORDER PER FOOT)(ORDER PER FOOT)(ORDER PER FOOT)

NOTE : PART NUMBERS HIGHLIGHTED ARE APPLICABLE TO YOUR TRUCK.

22222

DIM �A�OUTSIDEDIAMETER

11111

11111

DRIVE COUPLING DRIVE COUPLING DRIVE COUPLING DRIVE COUPLING DRIVE COUPLINGSERIES 100, 300, 400 & 500.

DRAWING NUMBER : 92-01-25-B392-01-25-B392-01-25-B392-01-25-B392-01-25-B3Ground Force Mfg.Ground Force Mfg.Ground Force Mfg.Ground Force Mfg.Ground Force Mfg.

1266DC401 COUPLING HALF, 1-1/4� x 5/16�

4.0�

DIM�A�

ARESCOPART #

DESCRIPTION QTY


1266DC404 COUPLING HALF, 50 mm x 14 mm

1266DC405 COUPLING HALF, 1� x 1/4�


1266DC403 INSERT, HYTREL

4.8�












1266DC502 INSERT, NEOPRENE


1266DC304 COUPLING HALF, 3/4� x 3/16�










1266DC316 COUPLING HALF, 9/16 x 1/8�




1266DC109 COUPLING HALF, 16.5 mm x 5 mm



1266DC113

1266DC114 COUPLING HALF, 3/8� BORE


1266DC116 COUPLING HALF, 5/16� BORE

ITEM

1

2

1

2

3.45�

2.6�

1

1

2

1266DC317 COUPLING HALF, 7/8�13 TOOTH SPLINED


1266DC412 COUPLING HALF, 1-1/4�14 TOOTH SPLINED

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

AR

1266DC301 COUPLING HALF, 1� 6 TOOTH SPLINED

AR

1266DC310 COUPLING HALF, 38 mm x 10 mm AR

OV

2 1266DC104 INSERT, HYTREL AR

AR

COUPLING HALF, 1/2� x # 404WOODRUFF

1266DC513 COUPLING HALF, 2-1/4� X 3/8�

Derrick

Highlight

Derrick

Highlight

Derrick

Highlight

JB1

1 7813LT012 JUNCTION BOX/COMPLETE

JUNCTION BOX

ITEM PART# DESCRIPTION

L1

ITEM PART # DESCRIPTION

1 7813LT012 JUNCTION BOX

2 7813LT007 LAMP, CLEARANCE, AMBER

3 7813LT006 LAMP, CLEARANCE, RED

4 7813LT005 IDENTIFICATION BAR

5 7813LT009 LAMP, STOP, OR TURN

TRUCK LIGHTSTRUCK LIGHTSTRUCK LIGHTSTRUCK LIGHTSTRUCK LIGHTS

1

2

L2

TRUCK LIGHTS


7813LT009 LAMP, STOP OR TURN/COMPLETE

1 1156 BULB

2 7813LT025 LENS, REPLACEMENT - RED

L4

ICC LIGHTS


1 7813LT005 IDENTIFICATION BAR

2 7813LT001 LENS

3 T-67 BULB

L5b

FLOOD LIGHT ASSEMBLY


7813LT014 FLOOD LIGHT, AMBER/COMPLETE

7813LT008 FLOOD LIGHT, CLEAR/COMPLETE

7813LT013 FLOOD LIGHT, HALOGEN/COMPLETE

1 7813LT017 BULB, HALOGEN

2 7813LT018 BULB, CLEAR FLOOD

3 7813LT022 BULB, AMBER

L7aL7aL7aL7aL7a

CLEARANCE LIGHT ASSEMBLYCLEARANCE LIGHT ASSEMBLYCLEARANCE LIGHT ASSEMBLYCLEARANCE LIGHT ASSEMBLYCLEARANCE LIGHT ASSEMBLY

ITEM. PART # DESCRIPTION

1 7813LT006 LAMP,CLEARANCE RED/COMPLETE

2 7813LT007 LAMP, CLEARANCE AMBER/COMPLETE

3 7813LT002 LENS, AMBER

4 7813LT003 LENS, RED

5 56 GROMMET

6 T67 BULB

WIRING LOOM AND FITTINGS

90 ELBOW (3/8" - 635-053)(1/2" - 635-065)

3/8" TUBING - PT24006 1/2" TUBING - PT24008

STRAIGHT FITTING (3/8" - 600-053(1/2" - 600-063)

WIRING JUNCTION BOX (BOX - #4900EL125) (PANEL - #4900EL126)

PART # 6500-04-04PART # 6500-04-04PART # 6500-04-04PART # 6500-04-04PART # 6500-04-04


1615AP0021615AP0021615AP0021615AP0021615AP002

3936AP0063936AP0063936AP0063936AP0063936AP006

3936AP0073936AP0073936AP0073936AP0073936AP007








1615AP0011615AP0011615AP0011615AP0011615AP001


PART # 222P-4-4PART # 222P-4-4PART # 222P-4-4PART # 222P-4-4PART # 222P-4-4

PART # 222P-4-4PART # 222P-4-4PART # 222P-4-4PART # 222P-4-4PART # 222P-4-4

DRAWING NUMBER : 3 9 3 6 A P3 9 3 6 A P3 9 3 6 A P3 9 3 6 A P3 9 3 6 A PPLUMBING AIR VALVESPLUMBING AIR VALVESPLUMBING AIR VALVESPLUMBING AIR VALVESPLUMBING AIR VALVES(1615AP001, 1615AP002,3936AP006/007)

Ground Force Mfg.Ground Force Mfg.Ground Force Mfg.Ground Force Mfg.Ground Force Mfg.

ov

G5G5G5G5G5G3G3G3G3G3

1111122222

33333

44444

55555

66666

7777788888

99999

1010101010

44444

9483HY056 CLAMP 1-1/4� PIPE, G5 AR10 9483HY054 CLAMP 1� PIPE, G5 AR9 9483HY050 CLAMP WELD PLATE, G5 AR8 9483HY049 CLAMP BOLT, G5 AR7 9483HY048 STACKING BOLT, G5 AR6 9483HY040 CLAMP, RAIL WELD PLATE, G3 AR 9483HY039 CLAMP, 1� TUBING, G3 AR 9483HY038 CLAMP, 7/8� TUBING, G3 AR 9483HY037 CLAMP, 3/4� TUBING, G3 AR 9483HY035 CLAMP, 5/8� TUBING, G3 AR 9483HY033 CLAMP, 1/2� TUBING, G3 AR5 9483HY032 CLAMP, 1/4� TUBING, G3 AR4 9483HY031 CLAMP INSERT, G3 AR3 9483HY030 CLAMP WELD PLATE, G3 AR2 9483HY029 CLAMP BOLT, G3 AR1 9483HY028 STACKING BOLT, G3 AR

DRAWING NUMBER :

Ground Force Mfg.Ground Force Mfg.Ground Force Mfg.Ground Force Mfg.Ground Force Mfg.PARTSRIGID HYDR. TUBE MOUNTINGRIGID HYDR. TUBE MOUNTINGRIGID HYDR. TUBE MOUNTINGRIGID HYDR. TUBE MOUNTINGRIGID HYDR. TUBE MOUNTINGRIGID HYDR. TUBE MOUNTINGRIGID HYDR. TUBE MOUNTINGRIGID HYDR. TUBE MOUNTINGRIGID HYDR. TUBE MOUNTINGRIGID HYDR. TUBE MOUNTING

ITEMITEMITEMITEMITEM PART #PART #PART #PART #PART # DESCRIPTIONDESCRIPTIONDESCRIPTIONDESCRIPTIONDESCRIPTION QTYQTYQTYQTYQTY

92-01-24-B192-01-24-B192-01-24-B192-01-24-B192-01-24-B1

DRIVELINE - COMPLETEDL25dc

Highlighted Items Apply to This UnitNote: Quanity "A/R" = As Required

LENGTH USED IN INCHES

1 2 3 4 5

7 6 6 7

ITEM PART # DESCRIPTION QUANTITY

4 2-40-1701DS SPLINE STUB 1

2-40-1711DS SPLINE STUB 1

5 2-3-5221KX SLIP YOKE 1

3-3-1501KX SLIP YOKE 1

6 1-0153HD U-JOINT ASSEMBLY 2

2-0053 U-JOINT ASSEMBLY 2

5-280X U-JOINT ASSEMBLY 2

7 2-4-433 END YOKE, 3/4" X 3/16" KEY A/R

2-4-473 END YOKE, 1" X 1/4" KEY A/R

2-4-1741 END YOKE, SPLINED A/R

2-4-533 END YOKE, 1-1/4" X 5/16" KEY A/R

2-4-1233 END YOKE, 1-1-/2" X 3/8" KEY A/R

2-4-3331 END YOKE, 7/8" SPLINED A/R

8 50-2502 SET SCREW A/R

NOT SHOWN

1-0099 U-BOLT KIT FOR 2-0053 A/R

3-4-24 YOKE, TAPER A/R

6-4-7541X YOKE A/R

6-4-7561X YOKE A/R


1 2-2-329 FLANGE YOKE

2-2-479 FLANGE YOKE

3-2-119 FLANGE YOKE

2 2-28-1757 TUBE YOKE

3-28-47 TUBE YOKE

3 DOM 2 X .120 DRIVELINE TUBING

DOM 2-1/2 X .083 DRIVELINE TUBING

Instructions – Parts List

��

��

ALUMINUM AND STAINLESS STEEL

Husky� 1040 Air-OperatedDiaphragm PumpsAluminum Model Shown

120 psi (0.8 MPa, 8 bar) Maximum Fluid Working Pressure120 psi (0.8 MPa, 8 bar) Maximum Air Input Pressure

*Model No. D73____ Aluminum Pumps*Model No. D83____ Aluminum Pumps, Remote*Model No. D74____ Stainless Steel Pumps*Model No. D84____ Stainless Steel Pumps, Remote*Model No. D7C____ Aluminum BSPT Pumps*Model No. D8C____ Aluminum BSPT Pumps, Remote*Model No. D7D____ Stainless Steel BSPT Pumps*Model No. D8D____ Stainless Steel BSPT Pumps, Remote*Model No. DR4____ Stainless Steel Plus Pumps*Model No. DS4____ Stainless Steel Plus Pumps, Remote*Model No. DRD____ Stainless Steel BSPT Plus Pumps*Model No. DSD____ Stainless Steel BSPT Plus Pumps, RemoteModel No. 232501 Private–Label Aluminum 1040 Pump (See page 24.)

(not certified )Model No. 234124 Private–Label Aluminum 1040 Pump (See page 24.)

*NOTE: Refer to the Pump Matrix on page 24 to determine the Model No. of your pump.

NOTE: Plus models include stainless steel center sections.

US and Foreign Patents Pending

308479AD

Read warnings and instructions.See page 2 for table of contents

��

� ��

Table of ContentsSafety Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Symbols 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Matrix 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Kit Matrix 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensional Drawings 31. . . . . . . . . . . . . . . . . . . . . . . . . Technical Data and Performance Chart 32. . . . . . . . . . . Graco Standard Warranty 34. . . . . . . . . . . . . . . . . . . . . . Graco Information 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SymbolsWarning Symbol

WARNINGThis symbol alerts you to the possibility of seriousinjury or death if you do not follow the instructions.

Caution Symbol

CAUTIONThis symbol alerts you to the possibility of damage toor destruction of equipment if you do not follow theinstructions.

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

� This equipment is for professional use only.

� Read all instruction manuals, tags, and labels before operating the equipment.

� Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.

� Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

� Check equipment daily. Repair or replace worn or damaged parts immediately.

� Do not exceed the maximum working pressure of the lowest rated component in your system.This equipment has a 120 psi (0.8 MPa, 8 bar) maximum working pressure at 120 psi(0.8 MPa, 8 bar) maximum incoming air pressure.

� Use fluids and solvents which are compatible with the equipment wetted parts. Refer to theTechnical Data section of all equipment manuals. Read the fluid and solvent manufacturer’swarnings.

� Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents orfluids containing such solvents in pressurized aluminum equipment. Such use could result in achemical reaction, with the possibility of explosion.

� Do not use hoses to pull equipment.

� Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex-pose Graco hoses to temperatures above 82�C (180�F) or below –40�C (–40�F).

� Do not lift pressurized equipment.

� Comply with all applicable local, state, and national fire, electrical, and safety regulations.

WARNING

INSTRUCTIONS

��

TOXIC FLUID HAZARD

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on theskin, inhaled, or swallowed.

� Know the specific hazards of the fluid you are using.

� Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,state and national guidelines.

� Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluidand solvent manufacturer.

� Pipe and dispose of the exhaust air safely, away from people, animals, and food handling areas.If the diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation onpage 9.

FIRE AND EXPLOSION HAZARD

Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition andresult in a fire or explosion and serious injury.

� Ground the equipment. Refer to Grounding on page 4.

� If there is any static sparking or you feel an electric shock while using this equipment, stoppumping immediately. Do not use the equipment until you identify and correct the problem.

� Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluidbeing sprayed.

� Pipe and dispose of the exhaust air safely, away from all sources of ignition. If the diaphragmfails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 9.

� Keep the work area free of debris, including solvent, rags, and gasoline.

� Electrically disconnect all equipment in the work area.

� Extinguish all open flames or pilot lights in the work area.

� Do not smoke in the work area.

� Do not turn on or off any light switch in the work area while operating or if fumes are present.

� Do not operate a gasoline engine in the work area.

WARNING

� ��

InstallationGeneral Information

� The Typical Installations shown in Figs. 2–4 areonly guides for selecting and installing systemcomponents. Contact your Graco distributor forassistance in planning a system to suit your needs.

� Always use Genuine Graco Parts and Accessories.Refer to Product Data Sheet 305588.

� Reference numbers and letters in parentheses referto the callouts in the figures and the parts lists onpages 26–28.

� Aluminum Husky 1040 Pump Model No. 239823,with straight-thread manifolds, is available and canbe ordered separately.

TOXIC FLUID HAZARDHazardous fluid or toxic fumes cancause serious injury or death if splashedin the eyes or on the skin, inhaled, or

swallowed.

1. Read TOXIC FLUID HAZARD on page 3.

2. Use fluids and solvents which are compatiblewith the equipment wetted parts. Refer to theTechnical Data section of all equipment manu-als. Read the fluid and solvent manufacturer’swarnings.

WARNING

Tightening Screws Before First Use

After you unpack the pump, and before you use it forthe first time, check and retorque external fasteners.Retorque the fluid cover screws first, then the manifoldscrews. This keeps the manifolds from interfering withtightening the fluid covers. See the Service section fortorque specifications.

After the first day of operation, check and retorque thefasteners again. Although the recommended fre-quency for retorquing fasteners varies with pumpusage, a general guideline is to retorque fastenersevery two months.

Grounding

FIRE AND EXPLOSION HAZARDThis pump must be grounded. Beforeoperating the pump, ground the systemas explained below. Also, read the sec-tion FIRE AND EXPLOSION HAZARD,on page 3.

WARNING

To reduce the risk of static sparking, ground the pumpand all other equipment used or located in the pumpingarea. Check your local electrical code for detailedgrounding instructions for your area and type of equip-ment. Ground all of this equipment.

� Pump: Connect a ground wire and clamp as shownin Fig. 1. Loosen the grounding screw (W). Insertone end of a 12 ga (1.5 mm�) minimum ground wire(Y) behind the grounding screw and tighten thescrew securely. Connect the clamp end of theground wire to a true earth ground. Order PartNo. 222011 Ground Wire and Clamp.

Fig. 1

Y

W

��

� Air and fluid hoses: Use only grounded hoses witha maximum of 500 ft (150 m) combined hoselength to ensure grounding continuity.

� Air compressor: Follow the manufacturer’s recom-mendations.

� All solvent pails used when flushing: Follow thelocal code. Use only metal pails, which are conduc-tive. Do not place the pail on a non-conductivesurface, such as paper or cardboard, which inter-rupts the grounding continuity.

� Fluid supply container: Follow the local code.

��

InstallationMountings

CAUTIONThe pump exhaust air may contain contaminants.Ventilate to a remote area if the contaminantscould affect your fluid supply. See Air ExhaustVentilation on page 9.

� Be sure the mounting surface can support theweight of the pump, hoses, and accessories, aswell as the stress caused during operation.

� For all mountings, be sure the pump is bolteddirectly to the mounting surface.

� For ease of operation and service, mount the pumpso the air valve cover (2), air inlet, and fluid inletand outlet ports are easily accessible.

� Rubber Foot Mounting Kit 236452 is available toreduce noise and vibration during operation.

Air Line

WARNINGA bleed-type master air valve (B) is required inyour system to relieve air trapped between thisvalve and the pump. Trapped air can cause thepump to cycle unexpectedly, which could result inserious injury, including splashing in the eyes or onthe skin, injury from moving parts, or contaminationfrom hazardous fluids. See Fig. 3.

1. Install the air line accessories as shown in Figs.2–4 on pages 7 and 8. Mount these accessorieson the wall or on a bracket. Be sure the air linesupplying the accessories is grounded.

a. Install an air regulator (C) and gauge to controlthe fluid pressure. The fluid outlet pressure willbe the same as the setting of the air regulator.

b. Locate one bleed-type master air valve (B)close to the pump and use it to relieve trappedair. See the WARNING above. Locate theother master air valve (E) upstream from all airline accessories and use it to isolate themduring cleaning and repair.

c. The air line filter (F) removes harmful dirt andmoisture from the compressed air supply.

2. Install a grounded, flexible air hose (A) betweenthe accessories and the 1/2 npt(f) pump air inlet(N). See Fig. 5. Use a minimum 3/8” (9.5 mm) IDair hose. Screw an air line quick disconnect cou-pler (D) onto the end of the air hose (A), and screwthe mating fitting into the pump air inlet snugly. Donot connect the coupler (D) to the fitting until youare ready to operate the pump.

Installation of Remote Pilot Air Lines

1. Refer to Parts Drawings. Connect air line to pumpas in preceding steps.

2. Connect 1/4 in. O.D. tubing to push type connec-tors (14) on air motor of pump.

NOTE: by replacing the push type connectors, othersizes or types of fittings may be used. The new fittingswill require 1/8 in. npt threads.

3. Connect remaining ends of tubes to external airsignal, such as Graco’s Cycleflo (P/N 195264) orCycleflo II (P/N195265) controllers.

NOTE: the air pressure at the connectors must be atleast 30% of the air pressure to the air motor for thepump to operate.

Fluid Suction Line

1. Use grounded fluid hoses. The pump fluid inlet (R)is 1” npt(f). See Fig. 5. Screw the fluid fitting intothe pump inlet securely.

2. If the fluid inlet pressure to the pump is more than25% of the outlet working pressure, the ball checkvalves will not close fast enough, resulting ininefficient pump operation.

3. At inlet fluid pressures greater than 15 psi (0.1MPa, 1 bar), diaphragm life will be shortened.

4. See the Technical Data on page 32 for maximumsuction lift (wet and dry).

��

InstallationFluid Outlet Line

WARNINGA fluid drain valve (J) is required to relieve pres-sure in the hose if it is plugged. The drain valvereduces the risk of serious injury, including splash-ing in the eyes or on the skin, or contaminationfrom hazardous fluids when relieving pressure.Install the valve close to the pump fluid outlet. SeeFig. 3.

1. Use grounded fluid hoses (L). The pump fluidoutlet (S) is 1” npt(f). See Fig. 5. Screw the fluidfitting into the pump outlet securely.

2. Install a fluid drain valve (J) near the fluid outlet.See the WARNING above, and Figs. 2–4 onpages 7 and 8.

3. Install a shutoff valve (K) in the fluid outlet line.

��

Installation

��

KEY FOR FIG. 2

A Air supply lineB Bleed-type master air valve

(required for pump)C Air regulatorD Air line quick disconnectE Master air valve (for accessories)F Air line filterG Fluid suction lineH Bung adapterJ Fluid drain valve (required)K Fluid shutoff valveL Fluid lineY Ground wire (required; see page 4

for installation instructions)

Fig. 2

TYPICAL BUNG-MOUNT INSTALLATION

Y

J

F BE C

A

D

G

H

K L

��Fig. 3

TYPICAL FLOOR-MOUNT INSTALLATION

Y

J

F BE CA

D

KL

G

KEY FOR FIG. 3


(required for pump)C Air regulatorD Air line quick disconnectE Master air valve (for accessories)F Air line filterG Fluid suction lineJ Fluid drain valve (required)K Fluid shutoff valveL Fluid lineY Ground wire (required; see page 4


� ��

InstallationKEY FOR FIG. 4


(required for pump)C Air regulatorD Air line quick disconnectE Master air valve (for accessories)F Air line filterG Fluid suction lineJ Fluid drain valve (required)K Fluid shutoff valveL Fluid lineM Wall mounting bracketY Ground wire (required; see page 4


Fig. 4

TYPICAL WALL-MOUNT INSTALLATION

Y

J

F BE C

A

D

G

K L

M

��

Changing the Orientation of the Fluid Inletand Outlet Ports

On aluminum pumps, the fluid inlet and outlet man-ifolds have threaded ports on both ends. The pump isshipped with a plug installed in one end of each man-ifold, and the opposite end open. See Fig. 5. Tochange the orientation of the inlet and/or outlet port,remove the plug from one end of a manifold and installit in the opposite end.

On stainless steel pumps, the fluid inlet and outletmanifolds have threaded ports on one end only. Thepump is shipped with the ports facing the same direc-tion. To reverse the orientation of the ports:

1. Remove the screws and nuts holding the inletand/or outlet manifold to the covers.

2. Reverse the manifold and reattach. Install thescrews and torque to 120–150 in-lb (14–17 N.m).

��

KEY

N 1/2 npt(f) air inlet portP Muffler. Air exhaust port is 3/4 npt(f)R 1 npt(f) fluid inlet portS 1 npt(f) fluid outlet port106Manifold and cover screws3 Air valve screws

Fig. 5

�

Apply medium-strength(blue) Loctite� or equiv-alent to the threads, andtorque to 120–150 in-lb (14–17 N.m).

N

P

R

S

Torque to 50–60 in-lb (5.6–6.8 N�m).

3

106

�

106

��

InstallationAir Exhaust Ventilation

FIRE AND EXPLOSION HAZARDBe sure to read and follow the warningsand precautions regarding TOXICFLUID HAZARD, and FIRE OR EXPLO-SION HAZARD on page 3, before op-erating this pump.

Be sure the system is properly ventilated for yourtype of installation. You must vent the exhaust to asafe place, away from people, animals, food handl-ing areas, and all sources of ignition when pumpingflammable or hazardous fluids.

Diaphragm failure will cause the fluid beingpumped to exhaust with the air. Place an appropri-ate container at the end of the air exhaust line tocatch the fluid. See Fig. 6.

WARNING

The air exhaust port is 3/4 npt(f). Do not restrict the airexhaust port. Excessive exhaust restriction can causeerratic pump operation.

To provide a remote exhaust:

1. Remove the muffler (P) from the pump air exhaustport.

2. Install a grounded air exhaust hose (T) and con-nect the muffler (P) to the other end of the hose.The minimum size for the air exhaust hose is 3/4in. (19 mm) ID. If a hose longer than 15 ft (4.57 m)is required, use a larger diameter hose. Avoidsharp bends or kinks in the hose.

3. Place a container (U) at the end of the air exhaustline to catch fluid in case a diaphragm ruptures.See Fig. 6.

Fig. 6

KEY


(required for pump)C Air regulatorD Air line quick disconnectE Master air valve (for accessories)F Air line filterP MufflerT Grounded air exhaust hoseU Container for remote air exhaustF BE C

A

D

VENTING EXHAUST AIR

P

T

U

��

� ��

InstallationFluid Pressure Relief Kit

Pressure Relief Kit 235409 (V) is available for Aluminum Pumps, to prevent overpressurization and rupture ofthe pump or hose. See Fig. 7. The kit includes instructions.

Thermal expansion of fluid in the outlet line can cause overpressurization. This can occur when using long fluidlines exposed to sunlight or ambient heat, or when pumping from a cool to a warm area (for example, from anunderground tank).

Overpressurization can also occur if the Husky pump is being used to feed fluid to a piston pump, and theintake valve of the piston pump does not close, causing fluid to back up in the outlet line.

CAUTION

Fig. 7

� Connect fluid inlet line here.

KEY

R 1 npt(f) optional fluid inlet portS 1 npt(f) optional fluid outlet portV Pressure relief kit

R

S

Connect fluid outlet line here.

�

�

Install kit between fluid inlet and outlet manifolds.

V

�

��

��

OperationPressure Relief Procedure

PRESSURIZED EQUIPMENT HAZARDThe equipment stays pressurized until pressure ismanually relieved. To reduce the risk of seriousinjury from pressurized fluid, accidental spray fromthe gun or splashing fluid, follow this procedurewhenever you

� Are instructed to relieve pressure� Stop pumping� Check, clean or service any system equipment� Install or clean fluid nozzles

WARNING

1. Shut off the air to the pump.

2. Open the dispensing valve, if used.

3. Open the fluid drain valve to relieve fluid pressure,having a container ready to catch the drainage.

Flush the Pump Before First UseThe pump was tested in water. If the water couldcontaminate the fluid you are pumping, flush the pumpthoroughly with a compatible solvent. Follow the stepsunder Starting and Adjusting the Pump.

Starting and Adjusting the Pump

TOXIC FLUID HAZARDTo reduce the risk of serious injury,splashing in the eyes or on the skin, andtoxic fluid spills, never move or lift a

pump under pressure. If dropped, the fluid sectionmay rupture. Always follow the Pressure ReliefProcedure Warning above before lifting the pump.

WARNING

1. Be sure the pump is properly grounded. Refer toGrounding on page 4.

2. Check fittings to be sure they are tight. Use acompatible liquid thread sealant on male threads.Tighten fluid inlet and outlet fittings securely.

3. Place the suction tube (if used) in fluid to bepumped.

NOTE: If fluid inlet pressure to the pump is more than25% of outlet working pressure, the ball check valveswill not close fast enough, resulting in inefficient pumpoperation.

4. Place the end of fluid hose (L) into an appropriatecontainer.

5. Close the fluid drain valve (J).

6. Back out the air regulator (C) knob, and open allbleed-type master air valves (B, E).

7. If the fluid hose has a dispensing device, hold itopen while continuing with the following step.

8. Slowly increase air pressure with the air regulator(C) until the pump starts to cycle. Allow the pumpto cycle slowly until all air is pushed out of the linesand the pump is primed.

If you are flushing, run the pump long enough tothoroughly clean the pump and hoses. Close theair regulator. Remove the suction tube from thesolvent and place it in the fluid to be pumped.

Operation of Remote Piloted Pumps

1. Follow preceding steps 1 through 7 of Startingand Adjusting Pump.

2. Open air regulator (C).

WARNINGThe pump may cycle once before the external sig-nal is applied. Injury is possible. If pump cycles,wait until end before proceeding.

3. Pump will operate when air pressure is alternatelyapplied and relieved to push type connectors (14).

NOTE: Leaving air pressure applied to the air motor forextended periods when the pump is not running mayshorten the diaphragm life. Using a 3–way solenoidvalve to automatically relieve the pressure on the airmotor when the metering cycle is complete preventsthis from occurring.

Pump Shutdown

WARNINGTo reduce the risk of serious injury whenever youare instructed to relieve pressure, always follow thePressure Relief Procedure at left.

At the end of the work shift, relieve the pressure.

� ��

MaintenanceLubricationThe air valve is designed to operate unlubricated,however if lubrication is desired, every 500 hours ofoperation (or monthly) remove the hose from the pumpair inlet and add two drops of machine oil to the airinlet.

CAUTIONDo not over-lubricate the pump. Oil is exhaustedthrough the muffler, which could contaminate yourfluid supply or other equipment. Excessive lubrica-tion can also cause the pump to malfunction.

Flushing and Storage

WARNINGTo reduce the risk of serious injury whenever youare instructed to relieve pressure, always follow thePressure Relief Procedure on page 11.

Flush the pump often enough to prevent the fluid youare pumping from drying or freezing in the pump anddamaging it. Use a compatible solvent.

Always flush the pump and relieve the pressure beforestoring it for any length of time.

Tightening Threaded Connections

Before each use, check all hoses for wear or damage,and replace as necessary. Check to be sure allthreaded connections are tight and leak-free. Checkand retorque all threaded connections at least everytwo months. Retorque the fluid cover screws first,followed by the manifold screws.

The recommended frequency for retorquing of fasten-ers varies with pump usage; a general guideline is toretorque fasteners every two months.

Preventive Maintenance Schedule

Establish a preventive maintenance schedule, basedon the pump’s service history. This is especially impor-tant for prevention of spills or leakage due to dia-phragm failure.

��

Notes

� ��

Troubleshooting


� Relieve the pressure before checking or servicingthe equipment.

� Check all possible problems and causes beforedisassembling the pump.

PROBLEM CAUSE SOLUTION

Pump cycles at stall or fails to holdpressure at stall.

Worn check valve balls (301), seats(201) or o-rings (202).

Replace. See page 18.

Pump will not cycle, or cycles onceand stops.

Air valve is stuck or dirty. Disassemble and clean air valve.See page 16. Use filtered air.

Check valve ball (301) severelyworn and wedged in seat (201) ormanifold (102 or 103).

Replace ball and seat. See page18.

Check valve ball (301) is wedgedinto seat (201), due to overpressur-ization.

Install Pressure Relief Valve (see page 10).

Dispensing valve clogged. Relieve pressure and clear valve.

Pump operates erratically. Clogged suction line. Inspect; clear.

Sticky or leaking balls (301). Clean or replace. See page 18.

Diaphragm ruptured. Replace. See pages 19–21.

Restricted exhaust. Remove restriction.

Air bubbles in fluid. Suction line is loose. Tighten.

Diaphragm ruptured. Replace. See pages 19–21.

Loose inlet manifold (102), dam-aged seal between manifold andseat (201), damaged o-rings (202).

Tighten manifold bolts (106) or re-place seats (201) or o-rings (202).See page 18.

Loose diaphragm shaft bolt (107). Tighten or replace (pages 19–21).

Damaged o-ring (108). Replace. See pages 19–21.

��

TroubleshootingPROBLEM CAUSE SOLUTION

Fluid in exhaust air. Diaphragm ruptured. Replace. See pages 19–21.

Loose diaphragm shaft bolt (107). Tighten or replace (pages 19–21).

Damaged o-ring (108). Replace. See pages 19–21.

Pump exhausts excessive air atstall.

Worn air valve block (7), o-ring (6), plate (8), pilot block (18), u-cups(10), or pilot pin o-rings (17).

Repair or replace. See page 16.

Worn shaft seals (402). Replace. See pages 19–21.

Pump leaks air externally. Air valve cover (2) or air valve coverscrews (3) are loose.

Tighten screws. See page 16.

Air valve gasket (4) or air covergasket (22) is damaged.

Inspect; replace. See pages 16,22–23.

Air cover screws (25) are loose. Tighten screws. See pages 22–23.

Pump leaks fluid externally from ballcheck valves.

Loose manifolds (102, 103), dam-aged seal between manifold andseat (201), damaged o-rings (202).

Tighten manifold bolts (106) or re-place seats (201) or o-rings (202).See page 18.

��

ServiceRepairing the Air Valve

Tools Required

� Torque wrench

� Torx (T20) screwdriver or 7 mm (9/32”) socketwrench

� Needle-nose pliers

� O-ring pick

� Lithium base grease

NOTE: Air Valve Repair Kit 236273 is available. Referto page 25. Parts included in the kit are marked with asymbol, for example (4�). Use all the parts in the kit forthe best results.

Disassembly


1. Relieve the pressure.

2. With a Torx (T20) screwdriver or 7 mm (9/32”)socket wrench, remove the six screws (3), airvalve cover (2), and gasket (4). See Fig. 8.

3. Move the valve carriage (5) to the center positionand pull it out of the cavity. Remove the valveblock (7) and o-ring (6) from the carriage. Using aneedle-nose pliers, pull the pilot block (18) straightup and out of the cavity. See Fig. 9.

4. Pull the two actuator pistons (11) out of the bear-ings (12). Remove the u-cup packings (10) fromthe pistons. Pull the pilot pins (16) out of thebearings (15). Remove the o-rings (17) from thepush pins. See Fig. 10.

5. Inspect the valve plate (8) in place. If damaged,use a Torx (T20) screwdriver or 7 mm (9/32”)socket wrench to remove the three screws (3).Remove the valve plate (8) and seal (9). See Fig.11.

6. Inspect the bearings (12, 15) in place. See Fig. 10.The bearings are tapered and, if damaged, mustbe removed from the outside. This requires disas-sembly of the fluid section. See page 22.

7. Clean all parts and inspect for wear or damage.Replace as needed. Reassemble as explained onpage 16.

Reassembly

1. If you replaced the bearings (12, 15), reinstall asexplained on page 22. Reassemble the fluid sec-tion.

2. Install the valve plate seal (9�) into the groove atthe bottom of the valve cavity. The rounded side ofthe seal must face down into the groove. SeeFig. 11.

3. Install the valve plate (8) in the cavity. The plate isreversible, so either side can face up. Install thethree screws (3), using a Torx (T20) screwdriver or7 mm (9/32”) socket wrench. Tighten until thescrews bottom out on the housing. See Fig. 11.

4. Install an o-ring (17�) on each pilot pin (16).Grease the pins and o-rings. Insert the pins intothe bearings (15), narrow end first. See Fig. 10.

5. Install a u-cup packing (10�) on each actuatorpiston (11), so the lips of the packings face thenarrow end of the pistons. See Fig. 10.

6. Lubricate the u-cup packings (10�) and actuatorpistons (11). Insert the actuator pistons in thebearings (12), wide end first. Leave the narrowend of the pistons exposed. See Fig. 10.

7. Grease the lower face of the pilot block (18�) andinstall so its tabs snap into the grooves on theends of the pilot pins (16). See Fig. 9.

8. Grease the o-ring (6�) and install it in the valveblock (7�). Push the block onto the valve carriage(5). Grease the lower face of the valve block. SeeFig. 9.

9. Install the valve carriage (5) so its tabs slip into thegrooves on the narrow end of the actuator pistons(11). See Fig. 9.

10. Align the valve gasket (4�) and cover (2) with thesix holes in the center housing (1). Secure with sixscrews (3), using a Torx (T20) screwdriver or 7mm (9/32”) socket wrench. Torque to 50–60 in-lb(5.6–6.8 N.m). See Fig. 8.

��

ServiceTorque to 50–60 in-lb(5.6–6.8 N�m).

Fig. 8

3

2

4�

� �

02644B

18� 5

Fig. 9

�

See Detail at right.

Grease.

� Grease lower face.

�7

�6

5

�

�

02642

�

Detail

��

Fig. 10

17� 16

11

10�

12

15

�

Insert narrow end first.

Grease.

�Install with lips facing narrow end of piston (11).

� Insert wide end first.

�

�

�

�

��

�

8

�9

3Rounded side must face down.

Tighten screws untilthey bottom out onthe housing.

Fig. 11

�

� ��

ServiceBall Check Valve Repair

Tools Required

� Torque wrench

� 10 mm socket wrench

� O-ring pick

Disassembly

NOTE: A Fluid Section Repair Kit is available. Refer topage 25 to order the correct kit for your pump. Partsincluded in the kit are marked with an asterisk, forexample (201*). Use all the parts in the kit for the bestresults.

NOTE: To ensure proper seating of the balls (301),always replace the seats (201) when replacing theballs. Also, on some models, replace the o-rings (202).


1. Relieve the pressure. Disconnect all hoses.

2. Remove the pump from its mounting.

3. Using a 10 mm socket wrench, remove the fourbolts (106) and nuts (114, used on stainless steelpumps only) holding the outlet manifold (103) tothe fluid covers (101). See Fig. 12.

4. Remove the o-rings (202, not used on somemodels), seats (201), and balls (301) from themanifold (103).

5. Turn the pump over and remove the inlet manifold(102). Remove the o-rings (202, not used on somemodels), seats (201), and balls (301) from the fluidcovers (101).

Reassembly

1. Clean all parts and inspect for wear or damage.Replace parts as needed.

2. Reassemble in the reverse order, following allnotes in Fig. 12. Be sure the ball checks andmanifolds are assembled exactly as shown. Thearrows (A) on the fluid covers (101) must pointtoward the outlet manifold (103).

��

Fig. 12

�

�

Apply medium-strength (blue) Loctite� or equivalent to thethreads, and torque to 120–150 in-lb (14–17 N.m).

Beveled seating surface must face the ball (301).

Arrow (A) must point toward outlet manifold (103).

� Not used on some models.

106

103

101

A

201*

301*

106

102

201*

301*

�

202*

202*

�

�

�

�

Aluminum Model Shown

��

ServiceDiaphragm Repair

Tools Required

� Torque wrench


� 15 mm socket wrench (aluminum models) or 1” socket wrench (stainless steel models)


� O-ring pick

� Lithium-base grease

DisassemblyNOTE: A Fluid Section Repair Kit is available. Refer topage 25 to order the correct kit for your pump. Partsincluded in the kit are marked with an asterisk, forexample (401*). Use all the parts in the kit for the bestresults.



2. Remove the manifolds and disassemble the ballcheck valves as explained on page 18.

3. Using a 10 mm socket wrench, remove the screws(106) holding the fluid covers (101) to the aircovers (23). Pull the fluid covers (101) off thepump. See Fig. 13.

Fig. 13

�

23

101

106

A �

B

Arrow (A) must point toward air valve (B).

Apply medium-strength (blue) Loctite� or equivalent tothe threads, and torque to 120–150 in-lb (14–17 N.m).

��

��

Service4. Loosen but do not remove the diaphragm shaft

bolts (107), using a 15 mm socket wrench (1” onstainless steel models) on both bolts.

5. Unscrew one bolt from the diaphragm shaft (24)and remove the o-ring (108), fluid side diaphragmplate (105), Teflon� diaphragm (403, used onTeflon� models only), diaphragm (401), and airside diaphragm plate (104). See Fig. 14.

6. Pull the other diaphragm assembly and the dia-phragm shaft (24) out of the center housing (1).Hold the shaft flats with a 19 mm socket wrench,and remove the bolt (107) from the shaft. Disas-semble the remaining diaphragm assembly.

7. Inspect the diaphragm shaft (24) for wear orscratches. If it is damaged, inspect the bearings(19) in place. If the bearings are damaged, refer topage 22.

8. Reach into the center housing (1) with an o-ringpick and hook the u-cup packings (402), then pullthem out of the housing. This can be done with thebearings (19) in place.

9. Clean all parts and inspect for wear or damage.Replace parts as needed.

Reassembly1. Install the shaft u-cup packings (402*) so the lips

face out of the housing (1). Lubricate the pack-ings. See Fig. 14.

2. Install the diaphragm assembly on one end of theshaft (24) as follows:

a. Install the o-ring (108*) on the shaft bolt (107).

b. Install the fluid side diaphragm plate (105) onthe bolt so the rounded side faces the dia-phragm (401).

NOTE: On stainless steel pumps only, the fluid sidediaphragm plate (105) is stainless steel. This plate isnot stamped with its part number. Be sure to installthis plate on the fluid side of the diaphragm.

c. On Teflon� models only, install the Teflon�diaphragm (403*). Make certain the sidemarked AIR SIDE faces the center hous-ing (1).

d. Install the diaphragm (401*) on the bolt. Makecertain the side marked AIR SIDE faces thecenter housing (1).

e. Install the air side diaphragm plate (104) sothe rounded side faces the diaphragm (401).This plate is used on all models, and isstamped with its part number.

f. Apply medium-strength (blue) Loctite� orequivalent to the bolt (107) threads. Screw thebolt into the shaft (24) hand tight.

3. Grease the length and ends of the diaphragm shaft(24), and slide it through the housing (1).

4. Assemble the other diaphragm assembly to theshaft as explained in step 2.

5. Hold one shaft bolt (107) with a wrench and torquethe other bolt to 20–25 ft-lb (27–34 N.m) at 100rpm maximum.

6. Align the fluid covers (101) and the center housing(1) so the arrows (A) on the covers face the samedirection as the air valve (B). Apply medium-strength (blue) Loctite� or equivalent to thethreads of the screws (106). Secure the coverswith the screws handtight. See Fig. 13. Using a 10mm socket wrench, torque the screws oppositelyand evenly to 120–150 in-lb (14–17 N.m).

7. Reassemble the ball check valves and manifoldsas explained on page 18.

��

Service

Fig. 14

�

�

�

24

104

403*

401*

108*

10724

24 104 401*

403*

107

105

19 402*

Cutaway View, with Diaphragms in Place Cutaway View, with Diaphragms Removed

1

Lips face out of housing (1).

Rounded side faces diaphragm (401).

Air Side must face center housing (1).

1

Grease.

Apply medium-strength (blue) Loctite� orequivalent. Torque to 20–25 ft-lb (27–34 N-m) at 100rpm maximum.

Used on pumps with Teflon� diaphragms only.

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�

�

� �

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�

�

1

�

�

�

�

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105 �

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ServiceBearing and Air Gasket Removal

Tools Required� Torque wrench


� Bearing puller

� O-ring pick

� Press, or block and mallet

DisassemblyNOTE: Do not remove undamaged bearings.



2. Remove the manifolds and disassemble the ballcheck valves as explained on page 18.

3. Remove the fluid covers and diaphragm assem-blies as explained on page 19.

NOTE: If you are removing only the diaphragm shaftbearing (19), skip step 4.

4. Disassemble the air valve as explained on page16.

5. Using a 10 mm socket wrench, remove the screws(25) holding the air covers (23) to the centerhousing (1). See Fig. 15.

6. Remove the air cover gaskets (22). Always replacethe gaskets with new ones.

7. Use a bearing puller to remove the diaphragmshaft bearings (19), air valve bearings (12) or pilotpin bearings (15). Do not remove undamagedbearings.

8. If you removed the diaphragm shaft bearings (19)reach into the center housing (1) with an o-ringpick and hook the u-cup packings (402), then pullthem out of the housing. Inspect the packings. SeeFig. 14.

Reassembly1. If removed, install the shaft u-cup packings (402*)

so the lips face out of the housing (1).

2. The bearings (12, 15, and 19) are tapered and canonly be installed one way. Insert the bearings intothe center housing (1), tapered end first. Using apress or a block and rubber mallet, press-fit thebearing so it is flush with the surface of the centerhousing.

3. Reassemble the air valve as explained on page16.

4. Align the new air cover gasket (22) so the pilot pin(16) protruding from the center housing (1) fitsthrough the proper hole (H) in the gasket.

5. Align the air cover (23) so the pilot pin (16) fits inthe middle hole (M) of the three small holes nearthe center of the cover. Install the screws (25),handtight. Apply medium-strength (blue) Loctite�or equivalent to the threads of the screws (25).See Fig. 15. Using a 10 mm socket wrench, torquethe screws oppositely and evenly to 130–150 in-lb(15–17 N.m).

6. Install the diaphragm assemblies and fluid coversas explained on page 19.

7. Reassemble the ball check valves and manifoldsas explained on page 18.

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Service

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Fig. 15

�

�

25

23

22

1

19

15

12

16

HM

Insert bearings tapered end first.

Press-fit bearings flush with surface of center housing (1).

Apply medium-strength (blue) Loctite� or equivalent.Torque to 130–150 in-lb (15–17 N.m).

Detail of Air Valve Bearings

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Pump MatrixHusky 1040 Aluminum and Stainless Steel Pumps, Series AYour Model No. is marked on the pump’s serial plate. To determine the Model No. of your pump from the followingmatrix, select the six digits which describe your pump, working from left to right. The first digit is always D,designating Husky diaphragm pumps. The remaining five digits define the materials of construction. For example, apump with an aluminum air motor, aluminum fluid section, polypropylene seats, Teflon� balls, and Teflon�diaphragms is Model D 7 3 9 1 1. To order replacement parts, refer to the part lists on pages 26–28. The digits inthe matrix do not correspond to the ref. nos. in the parts drawing and lists.

DiaphragmPump Air Motor Fluid Section – Seats Balls Diaphragms

232501* aluminum aluminum – Hytrel� acetal Hytrel�

D (for all pumps) 7 Aluminum (Standard)

1 (not used) – 1 (not used) 1 (Teflon�) 1 (Teflon�)

234124* 8 Aluminum (Remote)

2 (not used) 2 (acetal) 2 (acetal) 2 (not used)

R sst (standard) 3 (aluminum) – 3 (316 sst) 3 (316 sst) 3 (not used)

S sst (remote) 4 (sst) – 4 (17–4 PH sst) 4 (440C sst) 4 (not used)

5 (not used) – 5 (Hytrel�) 5 (Hytrel�) 5 (Hytrel�)

C (aluminum BSPT)

6 (Santoprene�) 6 (Santoprene�) 6 (Santoprene�)

D (sst BSPT) – 7 (buna–N) 7 (buna-N) 7 (buna-N)

– 8 (Viton�) 8 (Viton�) 8 (Viton�)

– 9 (polypropylene) 9 (not used) 9 (not used)

– A (Kynar�) A (not used) A (not used)

– G (Geolast�) G (Geolast�) G (Geolast�)

* 232501, Aluminum 1040 Pump, Series A Model No. 232501 is a private-label aluminum 1040 pump. This pump is the same as Model No. D73525 except forthe label and:Reference #10 is 115666 Packing, U–cup, VitonReference #17 is 168518 O–ring, VitonUse 243492 as the Air Valve Repair Kit

* 234124, Aluminum 1040 Pump, Series A Model No. 234124 is a private-label aluminum 1040 pump. This pump is the same as Model No. D73GGG exceptfor the label and:Reference #10 is 115666 Packing, U–cup, VitonReference #17 is 168518 O–ring, VitonUse 243492 as the Air Valve Repair Kit

246450 Stainless Steel Air Motor Conversion KitUse kit 246450 and refer to manual 309643 (included in kit) to convert from aluminum air motor to stainless steel airmotor.

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Repair Kit MatrixFor Husky 1040 Aluminum and Stainless Steel Pumps, Series ARepair Kits may be ordered separately. To repair the air valve, order Part No. 236273 (see page 28). Parts includedin the Air Valve Repair Kit are marked with a symbol in the parts list, for example (4�).

To repair your pump, select the six digits which describe your pump from the following matrix, working from left toright. The first digit is always D, the second digit is always 0 (zero), and the third is always 7. The remaining threedigits define the materials of construction. Parts included in the kit are marked with an asterisk in the parts list, forexample (201*). For example, if your pump has polypropylene seats, Teflon� balls, and Teflon� diaphragms, orderRepair Kit D 0 7 9 1 1. If you only need to repair certain parts (for example, the diaphragms), use the 0 (null)digits for the seats and balls, and order Repair Kit D 0 7 0 0 1. The digits in the matrix do not correspond to theref. nos. in the parts drawing and lists on pages 26–28.

DiaphragmPump Null Shaft O-ring – Seats Balls Diaphragms

D (for all pumps) 0 (for all pumps) 7 (Teflon�) – 0 (null) 0 (null) 0 (null)

– 1 (not used) 1 (Teflon�) 1 (Teflon�)

– 2 (acetal) 2 (acetal) 2 (not used)

– 3 (316 sst) 3 (316 sst) 3 (not used)

– 4 (17–4 PH sst) 4 (440C sst) 4 (not used)

– 5 (Hytrel�) 5 (Hytrel�) 5 (Hytrel�)

– 6 (Santoprene�) 6 (Santoprene�) 6 (Santoprene�)

– 7 (buna–N) 7 (buna-N) 7 (buna-N)

– 8 (Viton�) 8 (Viton�) 8 (Viton�)

– 9 (polypropylene) 9 (not used) 9 (not used)

– A (Kynar�) A (not used) A (not used)

– G (Geolast�) G (Geolast�) G (Geolast�)

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PartsAir Motor Parts List (Matrix Column 2)

DigitRef.No. Part No. Description Qty

7 1 188838 HOUSING, center; alumi-num

1

2 188854 COVER, air valve; alum. 1

3 116344 SCREW, mach, hexflange hd; M5 x 0.8; 12 mm (0.47 in.)

9

4� 188618 GASKET, molded Santo-prene

1

5 188855 CARRIAGE; aluminum 1

6� 108730 O-RING; nitrile 1

7� 188616 BLOCK, air valve; acetal 1

8 188615 PLATE, air valve; sst 1

9� 188617 SEAL, valve plate;buna-N 1

10� 112181 PACKING, u-cup; nitrile 2

11 188612 PISTON, actuator; acetal 2

12 188613 BEARING, piston; acetal 2

13� 104765 PLUG, pipe; headless 2

14� 115671 FITTING, connector; male 2

15 188611 BEARING, pin; acetal 2

16 188610 PIN, pilot; stainless steel 2

17� 157628 O-RING; buna-N 2

18� 188614 BLOCK, pilot; acetal 1

19 188609 BEARING, shaft; acetal 2

20 116343 SCREW, grounding 1

22 188603 GASKET, air cover; foam 2

23 188839 COVER, air; aluminum 2

24 188608 SHAFT, diaphragm; sst 1

25 115643 SCREW; M8 x 1.25; 25 mm (1 in.)

12


8 Same as 7 with the following exceptions

1 195921 HOUSING, center; alumi-num, remote

1

23 195917 COVER, air; remote 2

R Same as 7 with the following exceptions

1 15A734 HOUSING, center; stainless steel

1

2 15A735 COVER, air valve; stainless steel

1

23 15A736 COVER, air; stainlesssteel

2

S Same as 7 with the following exceptions

1 15B835 HOUSING, center; remote, stainless steel

1

2 15A735 COVER, air valve; stainless steel

1

23 15B794 COVER, air; remote,stainless steel

2

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PartsFluid Section Parts List (Matrix Column 3)


3 101 188840 COVER, fluid; aluminum 2

102 188841 MANIFOLD, inlet; aluminum

1

103 188842 MANIFOLD, outlet; aluminum

1

104 188607 PLATE, air side; alum. 2

105 188607 PLATE, fluid side; aluminum

2

106 115643 SCREW; M8 x 1.25; 25 mm (1 in.)

24

107 189044 BOLT; M12 x 1.75; 35 mm (1.38 in.); sst

2

108* 104319 O-RING; Teflon� 2

110

188970 LABEL, warning 1

111 112182 MUFFLER 1

113 112183 PLUG: 1” npt; cst 4

114 None Not Used 0


4 101 188860 COVER, fluid; sst 2

102 188862 MANIFOLD, inlet; sst 1

103 188861 MANIFOLD, outlet; sst 1

104 188607 PLATE, air side; alum. 2

105 188960 PLATE, fluid side; sst 2

106 112178 SCREW; M8 x 1.25; 25 mm (1 in.)

24

107 189044 BOLT; M12 x 1.75; 35 mm (1.38 in.); sst

2

108* 104319 O-RING; Teflon� 2

110


111 112182 MUFFLER 1

113 None Not Used 0

114 112257 NUT, hex; M8 x 1.25; sst 8

continued

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Parts

Used on pumps with Teflon� diaphragms only.

* These parts are included in the Pump Repair Kit, which may be purchased separately. Refer to the Repair Kit Matrix on page 25 to determine the correct kit for your pump.

� These parts are included in Air Valve Repair Kit 236273, which may be purchased separately.

Replacement Danger and Warning labels, tags and cards are available at no cost.

� These parts are unique to remote piloted air motor, D8–––– and DS––––

� Not used on stainless steel pumps.

� Not used on aluminum pumps.

� Not used on all models.

Aluminum Model Shown

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1

2

3

4�

5

6�

7�

89�

10�11

12

15

1617�

�18

1920

22

23

2425

101

102

103

104

105

110

111

201*

202*

301*401**402

403*

3

16

�17

11 10�

106

106

*201

*301

202*

107108*

113

113

106

114

�

�

�

�

�

202* �

202* �

13�

14�

� 113

� 113

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PartsFluid Section Parts List (Matrix Column 3)(continued)


C 101 188840 COVER, fluid; aluminum 2

102 192070 MANIFOLD, inlet; aluminum; BSPT

1

103 192071 MANIFOLD, outlet; aluminum; BSPT

1

104 188607 PLATE, air side; aluminum

2

105 188607 PLATE, fluid side; aluminum

2

106 115643 SCREW; M8 x 1.25; 25 mm (1 in.)

24

107 189044 BOLT; M12 x 1.75; 35 mm (1.38 in.); sst

2

108* 104319 O-RING; Teflon� 2

110


111 112182 MUFFLER 1

113 113991 PLUG: 1” BSPT; cst 4

114 None Not Used 0

D 101 188860 COVER, fluid; sst 2

102 192068 MANIFOLD, inlet; sst;BSPT

1

103 192069 MANIFOLD, outlet; sst;BSPT

1

104 188607 PLATE, air side; aluminum

2

105 188960 PLATE, fluid side; sst 2

106 112178 SCREW; M8 x 1.25; 25 mm (1 in.)

24

107 189044 BOLT; M12 x 1.75; 35 mm (1.38 in.); sst

2

108* 104319 O-RING; Teflon� 2

110


111 112182 MUFFLER 1

113 None Not Used 0

114 112257 NUT, hex; M8 x 1.25; sst 8

Seat Parts List (Matrix Column 4)


2 201* 188604 SEAT; acetal 4

202* 109205 O-RING; Teflon� 8

3 201* 188707 SEAT; 316 stainless steel 4

202* 109205 O-RING; Teflon� 8

4 201* 188708 SEAT; 17-4 stainless steel 4

202* 109205 O-RING; Teflon� 8

5 201* 188711 SEAT; Hytrel� 4

202 None Not Used 0

6 201* 191595 SEAT; Santoprene 4

202* 109205 O-RING; Teflon� 8

7 201* 15B275 SEAT; Buna–N 4

202* None Not used 0

8 201* 15B633 SEAT; Viton 4

202 None Not Used 0

9 201* 189722 SEAT; polypropylene 4

202* 109205 O-RING; Teflon� 8

A 201* 189723 SEAT; Kynar 4

202* 109205 O-RING; Teflon� 8

G 201* 194211 SEAT; Geolast 4

202* 109205 O-RING; Teflon� 8

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PartsBall Parts List (Matrix Column 5)


1 301* 112088 BALL; Teflon� 4

2 301* 112254 BALL; acetal 4

3 301* 103869 BALL; 316 stainless steel 4

4 301* 102973 BALL; 440C stainlesssteel

4

5 301* 112089 BALL; Hytrel� 4

6 301* 112092 BALL; Santoprene 4

7 301* 15B488 BALL; buna-N 4

8 301* 15B487 BALL; Viton� 4

G 301* 114751 BALL; Geolast� 4

Diaphragm Parts List (Matrix Column 6)


1 401* 188606 DIAPHRAGM, backup;Hytrel�

2

402* 112181 PACKING, u-cup; nitrile 2

403* 188605 DIAPHRAGM; Teflon� 2

5 401* 188606 DIAPHRAGM; Hytrel� 2


6 401* 188857 DIAPHRAGM; Santo-prene

2


7 401* 15B499 DIAPHRAGM; buna-N 2


8 401* 15B500 DIAPHRAGM; Viton� 2


G 401* 194212 DIAPHRAGM; Geolast� 2


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Dimensional DrawingsFRONT VIEW

12.0 in.(305 mm)

1/2 npt(f)Air Inlet

3/4 npt(f)Air Exhaust(mufflerincluded)

1 npt(f)OptionalFluid Inlet

5.5 in.(139.5 mm)

1 npt(f)OptionalFluid Outlet

1.0 in.(25.5 mm)

9.1 in.(231.1 mm)

6.0 in.(152 mm)

SIDE VIEW

1 npt(f)Fluid Inlet

1 npt(f)FluidOutlet

5.0 in.(127 mm)

9.25 in.(235 mm)

3.95 in.(100 mm)

45°

PUMP MOUNTING HOLE PATTERN

Four 0.5 in.(12.5 mm) diameter holes

5.0 in.(127 mm)

5.5 in.(139.5 mm)

7437A

On aluminum pumps only.

A

B

C

12.58 in. (319.5 mm)

13.58 in. (345.0 mm)

14.48 in. (367.8 mm)

12.31 in. (312.7 mm)

13.31 in. (338.1 mm)

14.21 in. (360.9 mm)

Dim. Alum. Pumps SST Pumps

A B C

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Technical DataMaximum fluid working pressure 120 psi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(0.8 MPa, 8 bar)Air pressure operating range 20–120 psi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(0.14–0.8 MPa, 1.4–8 bar)Maximum air consumption 60 scfm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air consumption at 70 psi/20 gpm 20 scfm (see chart). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum free-flow delivery 42 gpm (159 l/min). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum pump speed 276 cpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gallons (Liters) per cycle 0.15 (0.57). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum suction lift 18 ft (5.48 m) wet or dry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum size pumpable solids 1/8 in. (3.2 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * Maximum Noise Level at 100 psi, full flow 89 dBa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * Sound Power Level 100 dBa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * Noise Level at 70 psi and 50 cpm 78 dBa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum operating temperature 150�F (65.5�C);. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200�F (93.3�C) for models with Teflon� diaphragmsAir inlet size 1/2 npt(f). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid inlet size 1” npt(f). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid outlet size 1” npt(f). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wetted parts Vary by Model. See pages 26–28.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-wetted external parts aluminum, 302, 316 stainless steel, polyester (labels). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weight

Aluminum pumps 18 lb (8.2 kg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stainless steel pumps with aluminum center section 33 lb (15.0 kg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stainless steel pumps with stainless steel center section 47 lb (22kg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Teflon�, Viton�, and Hytrel� are registered trademarks of the DuPont Co.

Geolast� and Santoprene� are registered trademarks of the Monsanto Co.

Kynar� is a registered trademark of Atochem North America, Inc.

Loctite� is a registered trademark of the Loctite Corporation.

* Noise levels measured with the pump mounted on the floor, using Rubber Foot Kit 236452. Sound power measured per ISO Standard 9614–1.

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Performance ChartTest Conditions: Pump tested in water with inlet submerged.

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(0.7, 7)

Fluid Pressure Curves

A at 120 psi (0.7 MPa, 7 bar) air pressure

B at 100 psi (0.7 MPa, 7 bar) air pressure

C at 70 psi (0.48 MPa, 4.8 bar) air pressure

D at 40 psi (0.28 MPa, 2.8 bar) air pressure

A

B

D

To find Fluid Outlet Pressure(psi/MPa/bar) at a specific fluid flow(gpm/lpm) and operating air pressure(psi/MPa/bar):

1. Locate fluid flow rate along bottom ofchart.

2. Follow vertical line up to intersectionwith selected fluid outlet pressure curve.

3. Follow left to scale to read fluid outletpressure. F

LU

ID O

UT

LE

T P

RE

SS

UR

E––

psi

(M

Pa,

bar

)

(0.55, 5.5)

(0.41, 4.1)

(0.28, 2.8)

(0.14, 1.4)

C

(0.84, 8.4)

FLUID FLOW--gpm (lpm)

(38) (133) (152)(76) (114)(95)(57)(19)

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FLUID FLOW--gpm (lpm)

AIR

CO

NS

UM

PT

ION

––sc

fm (

cub

ic m

eter

s/m

in)

To find Pump Air Consumption (scfm orm/min) at a specific fluid flow (gpm/lpm) andair pressure (psi/MPa/bar):

1. Locate fluid flow rate along bottom of chart.

2. Read vertical line up to intersection withselected air consumption curve.

3. Follow left to scale to read air consumption.

(38) (133)

(1.68)

(152)(76) (114)

(1.40)

(1.12)

(0.84)

(0.56)

Air Consumption Curves

A at 120 psi (0.7 MPa, 7 bar) air pressure

B at 100 psi (0.7 MPa, 7 bar) air pressure

C at 70 psi (0.48 MPa, 4.8 bar) air pressure

D at 40 psi (0.28 MPa, 2.8 bar) air pressure

B

C

A

D

(0.28)

(95)(57)(19)

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Graco WarrantiesGraco Standard Husky Pump WarrantyGraco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on thedate of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limitedwarranty published by Graco, Graco will, for a period of five years from the date of sale, repair or replace any part of the equipmentdetermined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accor-dance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused byfaulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub-stitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility ofGraco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor forverification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. Theequipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defectin material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, andtransportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUTNOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no otherremedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or anyother incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within six years of the dateof sale.

Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connectionwith accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufacturedby Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will providepurchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipmenthereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERSThe parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedingsentered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais-sent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciairesexécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.

Extended Product WarrantyGraco warrants all Husky 205, 307, 515, 716, 1040, 1590, 2150, and 3275 air valve center sections to be free from defects in materialand workmanship for a period of fifteen years from date installed in service by the original purchaser. Normal wear of items such aspackings or seals are not considered to be defects in material and workmanship.

Five years Graco will provide parts and labor.Six to Fifteen years Graco will replace defective parts only.

Graco InformationTO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:

1–800–367–4023 Toll Free612–623–6921

612–378–3505 Fax

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.

Sales Offices: Minneapolis, DetroitInternational Offices: Belgium, Korea, Hong Kong, Japan

www.graco.comPRINTED IN USA 308479 11/1994, Revised 05/2003

PneumaticParker Hannifin CorporationPneumatic DivisionRichland, Michiganwww.parker.com/pneumatic

14

Standard part numbers shown, for other models refer to ordering information below.‡ For polycarbonate bowl see Caution on page 2.§ SCFM = Standard cubic feet per minute at 90 PSIG inlet and 5 PSIG pressure drop.

Port NPT BSPPSize Twist Drain Automatic Float Drain Twist Drain Automatic Float Drain

Poly Bowl ‡ / Metal Guard

3/8" 07F22AC 07F26AC 07F22AC1 07F26AC1

1/2" 07F32AC 07F36AC 07F32AC1 07F36AC1

3/4" 07F42AC 07F46AC 07F42AC1 07F46AC1

Metal Bowl / Sight Gauge

3/8" 07F24AC 07F28AC 07F24AC1 07F28AC1

1/2" 07F34AC 07F38AC 07F34AC1 07F38AC1

3/4" 07F44AC 07F48AC 07F44AC1 07F48AC1

07F Filter Dimensions

A B C3.24 3.25 .70(82) (83) (18)

D D † E6.97 7.00 7.67(177) (178) (195)

E † F7.70 2.75(196) (70)

Inches (mm)† With Automatic Float Drain

Features• Excellent water removal efficiency.

• Unique deflector plate and shroud creates aswirling of the air stream ensuring maximumwater and dirt separation.

• Large filter element surface guarantees lowpressure drop and increased element life.

• Optional Push ‘N’ Drain requires only fingertiptouch to drain. Optional automatic float drainavailable.

• Shown with recommended metal bowl guard.

• High Flow: 3/8" – 100 SCFM §

1/2" – 130 SCFM §

3/4" – 145 SCFM §

07F Filters – Standard

Prep-Air® II, 07F Series3/8", 1/2", 3/4" – Basic 1/2" Body

Catalog 0600P-6/USA

Standard 07F Series

A

B

DE

C

Distance RequiredTo Remove All BowlsRegardless OfDrain Option

F

Ordering Information

AutomaticDrain

TwistDrain

Port Size2. 3/8 Inch3. 1/2 Inch4. 3/4 Inch

Elements

A. 40 MicronB. 5 MicronZ. Adsorber

Polycarbonate Bowl1. Twist Drain2. Metal Bowl Guard /

Twist Drain5. Auto Float Drain6. Metal Bowl Guard /

Auto Float DrainE. Push ‘N’ DrainF. Metal Bowl Guard /

Push ‘N’ DrainJ. Semi-Auto DrainK. Metal Bowl Guard /

Semi-Auto Drain

Metal Bowl3. Twist Drain4. Sight Gauge /

Twist Drain7. Auto Float Drain8. Sight Gauge /

Auto Float DrainG. Push ‘N’ DrainH. Sight Gauge /

Push ‘N’ DrainL. Semi-Auto Drain

M. Sight Gauge /Semi-Auto Drain

Bowl Options

07F 3 2 A C — —

Port Type

Blank. NPT1. BSPP2. BSPT

EngineeringLevel

C. Current

NOTE: BOLD OPTIONS ARE STANDARD.

Options

Blank. NoneP. Differential

PressureIndicator


15

X

0

7

1

2

3

4

5

6

0

.1

.2

.3

.4

Pre

ssu

re D

rop

- P

SIG

Pre

ssu

re D

rop

- b

ar

35 PSIG 90 PSIG 150 PSIGPrimary Pressure - PSIG

2.4 bar 6.2 bar 10.3 barPrimary Pressure - bar

Flow - SCFM

Flow - dm /s3n

600 20 40 80 100 120 140 160

0 10 20 30 40 50 60 70

180 200 220 240 260

80 90 100 110 120

Flow Characteristics07F42A

3/4 Inch Ports

Pre

ssu

re D

rop

- P

SIG

Pre

ssu

re D

rop

- b

ar



Flow - SCFM

Flow - dm /s3

n

00

20 40 60 80 100 120 140 160

0 10 20 30 40 50 60 70

7

1

2

3

4

5

6

0

.1

.2

.3

.4


3/8 Inch Ports

6000

20 40 80 100 120 140 160

0 10 20 30 40 50 60 70

7

1

2

3

4

5

6

0

.1

.2

.3

.4

180 200 220

80 90 100

Pre

ssu

re D

rop

- P

SIG

Pre

ssu

re D

rop

- b

ar



Flow - SCFM

Flow - dm /s3

n


1/2 Inch Ports

Prep-Air® II, 07F SeriesAir Line Filters

Catalog 0600P-6/USA

Technical Specifications – 07F

07F Filter Kits & AccessoriesBowl Guard Kit .................................................................. PS805PBowl Kits –

Poly Bowl – Automatic Float Drain ................................. PS822PSemi-Auto Drain ..........................................PS892PTwist Drain .................................................. PS832PPush ‘N’ Drain ............................................. PS804P

Metal Bowl –Automatic Float Drain ................................. PS826PSemi-Auto Drain ..........................................PS894PTwist Drain .................................................. PS834PPush ‘N’ Drain ............................................. PS825PSight Gauge / Automatic Drain ...................PS823PSight Gauge / Semi-Auto Drain ..................PS893PSight Gauge / Twist Drain ........................... PS835PSight Gauge / Push ‘N’ Drain ......................PS806P

DPI Replacement Kit ..........................................................PS781PDrain Kits – Automatic Float Drain ................................. PS506P

Semi-Auto Drain ..........................................PS511PTwist Drain .................................................. PS512PPush ‘N’ Drain ............................................. PS513P

Filter Element Kits –40 Micron .......................................... PS801P5 Micron ............................................ PS802PAdsorber ........................................... PS831P

Mounting Bracket Kit ........................................................ PS843PSight Gauge Kit ................................................................. PS814P

SpecificationsBowl Capacity .............................................................. 7.2 OuncesSump Capacity ............................................................ 2.8 Ounces

Port Threads ......................................................... 3/8, 1/2, 3/4 InchPressure & Temperature Ratings –Without Differential Pressure Indicator:

Polycarbonate Bowl – 0 to 150 PSIG (0 to 10.3 bar)32°F to 125°F (0°C to 52°C)

Metal Bowl – 0 to 250 PSIG (0 to 17.2 bar)32°F to 175°F (0°C to 80°C)

With Differential Pressure Indicator –0 to 150 PSIG (0 to 10.3 bar)32°F to 125°F (0°C to 52°C)

Automatic Float Drain – 10 to 250 PSIG (0.7 to 17.2 bar)at 125°F (52°C) or less

Weight ....................................................................... 2.2 lb. (1.0 kg)

Materials of ConstructionBody ........................................................................................... ZincBowls .................................................... Transparent Polycarbonate

Metal (Zinc) With or Without Sight GaugeBowl Guards ........................................................................... SteelCollar ....................................................................... Plastic or MetalDeflector, Shroud & Baffle ................................................. PlasticDrains – Twist Drain – Body & Nut ....................................... Plastic

Push ‘N’ Drain – Body .............................................. NitrileStem ............................................. Brass

Automatic Float Drain – Housing, Float ................. PlasticSeals ............................................. NitrileSprings, Push Rod ........ Stainless Steel

Filter Elements –40 Micron (Standard) ................................ Plastic5 Micron (Optional) ................................... PlasticAdsorber (Optional) .............. Activated Charcoal

Seals ........................................................................................ NitrileSight Gauge ................................................................... Polyamide

Technical Information


54

07R Regulators – Standard

Prep-Air® II, 07R Series3/8", 1/2", 3/4" – Basic 1/2" Body

Catalog 0600P-6/USA

Standard 07R Series

C

E

D

B

A

PU

SH TO LO

CK

Features• Secondary aspiration plus balanced poppet provides

quick response and accurate pressure regulation.

• Rolling diaphragm for extended life.

• Two high flow 1/4" gauge ports can be used asadditional outlets.

• Easily serviced.

• Removable non-rising knob for panel mountingand tamper resistance.


1/2" – 90 SCFM §

3/4" – 90 SCFM §

Standard part numbers shown, for other models refer to ordering information below.

NOTE: 2.00 Dia. (51mm) hole required for panel mounting.§ SCFM = Standard cubic feet per minute at 100 PSIG inlet,

90 PSIG no flow secondary setting and 10 PSIG pressure drop.

07R Regulator Dimensions

A B C3.24 2.74 4.79(82) (70) (122)

D E1.61 6.40(41) (163)

Inches (mm)

Port Size NPT BSPP

Without Gauge

3/8" 07R213AC 07R213AC1

1/2" 07R313AC 07R313AC1

3/4" 07R413AC 07R413AC1

With 160 PSI Gauge

3/8" 07R218AC 07R218AC1

1/2" 07R318AC 07R318AC1

3/4" 07R418AC 07R418AC1



07R 3 13 A C — — ---

Port Size

2. 3/8 Inch3. 1/2 Inch4. 3/4 Inch

Relief

A. RelievingL. Non-Relieving

Options

Blank. No OptionsL.† Preset

Non-Adjustable

P.† PresetAdjustable

R. Reverse Flow

† Inlet Pressure is 100 PSIG.For other pressures, contactfactory.

Port TypeEngineering

Level

C. Current Blank. NPT1. BSPP2. BSPT

Pressure Range

Without Gauge10. 30 PSIG11. 60 PSIG13. 125 PSIG15. 250 PSIG

With Gauge17. 30 PSIG16. 60 PSIG18. 125 PSIG21. 250 PSIG

* Available PresetRange, 10 to 90PSIG in 5 PSIGincrements. Forhigher pressures,contact factory.

(Example:

065 = 65 PSIG)

Preset

Blank. NoneXXX* Preset

Pressure

! WARNING

Product rupture can cause serious injury.Do not connect regulator to bottled gas.

Do not exceed maximum primary pressure rating.


55

X

Prep-Air® II, 07R SeriesAir Line Regulators

Catalog 0600P-6/USA

Technical Specifications – 07R


07R Regulator Kits & AccessoriesBonnet Assembly Kit ........................................................ PS715PControl Knob ................................................................... P04069B

Gauges – 60 PSIG (0 to 400 kPa) ..................................... P781641160 PSIG (0 to 1100 kPa) ................................. P781642300 PSIG (0 to 2000 kPa) ................................. P781643

Mounting Bracket Kit (Includes Panel Mount Nut) ........... PS807PPanel Mount Nut – Plastic ..................................................P04082

Metal ................................................. P04079B

Reverse Flow Service Conversion Kit –Relieving ................................................... PS808RPNon-Relieving ........................................... PS809RP

Service Kit – Relieving (Includes Poppet) ......................... PS808PNon-Relieving (Includes Poppet) ................. PS809P

Springs – 1-30 PSIG Range .................................................P016981-60 PSIG Range .................................................P040622-125 PSIG Range ...............................................P040635-250 PSIG Range ...............................................P04064

Tamperproof Kit .................................................................. PS737P

SpecificationsGauge Ports (2) .................................................................. 1/4 Inch

(Can be used as additional High Flow 1/4 Inch Outlet Ports)

Port Threads ......................................................... 3/8, 1/2, 3/4 InchPrimary Pressure Rating –

Maximum Primary Pressure ........................ 250 PSIG (1725 kPa)Secondary Pressure Ranges –

Standard Pressure ......................... 2 to 125 PSIG (14 to 863 kPa)Low Pressure .................................. 1 to 60 PSIG (6.9 to 414 kPa)High Pressure .............................. 5 to 250 PSIG (35 to 1725 kPa)

Temperature Rating ........................... 32°F to 175°F (0°C to 80°C)Weight ........................................................................ 2.5 lb. (1.1 kg)

Materials of ConstructionAdjusting Stem ....................................................................... Steel

Body .......................................................................................... ZincBonnet, Piston Stem, Valve Poppet & Cap ......................... PlasticCollar, Knob ........................................................................... Plastic

Diaphragm .............................................................................. NitrileSeals ........................................................................................ NitrileSprings – Poppet ............................................................... Stainless

Control ...................................................................... Steel

00

Relief And Flow Characteristics07R213A

10 30 50 70 900

20

60

80

40

100

1

2

3

4

5

6

10 110 130

0 5 45 555 15 25 35

Sec

on

dar

y P

ress

ure

- P

SIG

Sec

on

dar

y P

ress

ure

- b

ar

Rated Flow - SCFM

Flow - dm /s3

n

3/8 Inch Ports100 PSIG (6.9 bar) Primary Pressure

00


10 30 50 70 900

20

60

80

40

100

1

2

3

4

5

6

10 110 130

0 5 45 555 15 25 35

Sec

on

dar

y P

ress

ure

- P

SIG

Sec

on

dar

y P

ress

ure

- b

ar

Rated Flow - SCFM

Flow - dm /s3

n


00


10 30 50 70 900

20

60

80

40

100

1

2

3

4

5

6

10 110 130 150 170

0 5 45 55 65 755 15 25 35

Sec

on

dar

y P

ress

ure

- P

SIG

Sec

on

dar

y P

ress

ure

- b

ar

Rated Flow - SCFM

Flow - dm /s3

n



106

Prep-Air® II, 17L Series3/8", 1/2", 3/4" – Basic 1/2" Body

Catalog 0600P-6/USA

Standard 17L Series

17L Micro-Mist Lubricators – Standard

Features• Proportional oil delivery over a wide range of air flows.

• Generates oil particles of 5 micron or smallerdownstream to lubricate systems having complexpiping arrangements.

• Precision needle valve assures repeatable oil deliveryand provides simple adjustment of delivery rate.

• Ideal for low and high flow applications with changingair flow.

• Transparent sight dome for 360° visibility.

• Yellow fill cap identifies Micro-Mist Lubricator.


1/2" – 90 SCFM §

3/4" – 90 SCFM §

A

B

D

C

E

Distance RequiredTo Remove All BowlsRegardless OfDrain Option

F


Standard part numbers shown, for other models refer to ordering information below.‡ For polycarbonate bowl see Caution on page 2.§ SCFM = Standard cubic feet per minute at 90 PSIG inlet and 5 PSIG pressure drop.

Port NPT BSPPSize Twist Drain No Drain Twist Drain No Drain

Poly Bowl ‡ / Metal Guard

3/8" — 17L22BE — 17L22BE1

1/2" — 17L32BE — 17L32BE1

3/4" — 17L42BE — 17L42BE1

Metal Bowl / Sight Gauge

3/8" 17L24BE — 17L24BE1 —

1/2" 17L34BE — 17L34BE1 —

3/4" 17L44BE — 17L44BE1 —

17L Lubricator Dimensions

A B C3.24 3.25 2.41(82) (83) (61)

D D † E6.86 6.95 9.27(174) (177) (235)

E † F7.93 2.75(201) (70)

Inches (mm)† With Twist Drain

17L 2 2 B E —

Engineering PortPort Size Bowl Options Options Level Type

2. 3/8 Inch3. 1/2 Inch4. 3/4 Inch

Polycarbonate Bowl1. No Drain2. Metal Bowl Guard/

No Drain5. Pressure Fill6. Metal Bowl Guard/

Pressure FillJ. Auto Fill DeviceK. Metal Bowl Guard/

Auto Fill DeviceR. Twist DrainN. Metal Bowl Guard/

Twist Drain

B. With Fill PlugC. With Fill Plug/Nylon

Sight DomeF. With Body Pressure FillG. With Body Pressure Fill/

Nylon Sight Dome

Metal Bowl4. Sight Gauge/

Twist Drain8. Sight Gauge/

Pressure FillM. Sight Gauge/

Auto Fill Device

E. Current


Blank. NPT1. BSPP2. BSPT


107

X

0 5 10 15 20 25 30 35 40 45 50 55 60 7065

00

10 20 30 40

7

1

2

3

4

5

6

0

.1

.2

.3

.4

50 60 70 80 90 100 110 120 130 140 150

Flow Characteristics17L32B 1/2 Inch Ports

&17L42B 3/4 Inch Ports

Pre

ssu

re D

rop

- P

SIG

Pre

ssu

re D

rop

- b

ar



Flow - SCFM

Flow - dm /s3

n

0 5 10 15 20 25 30 35 40 45

00

10 20 30 40

7

1

2

3

4

5

6

0

.1

.2

.3

.4

50 60 70 80 90 100

Flow Characteristics17L22B 3/8 Inch Ports

Pre

ssu

re D

rop

- P

SIG

Pre

ssu

re D

rop

- b

ar



Flow - SCFM

Flow - dm /s3

n

Prep-Air® II, 17L SeriesAir Line Micro-Mist Lubricators

Catalog 0600P-6/USA

Technical Specifications – 17L


17L Micro-Mist Lubricator Kits &AccessoriesAdjustment Knob ............................................................... P04121

Bowl Guard Kit ..................................................................PS805PBowl Kits –

Poly Bowl – No Drain ......................................................PS846PTwist Drain .................................................. PS817PPressure Fill ................................................PS819PRemote Fill .................................................. PS828P

Metal Bowl –Sight Gauge / Twist Drain ........................... PS829PSight Gauge / Pressure Fill ........................PS820P

Drain Kit – Twist Drain ......................................................... PS512PFill Cap Kit ........................................................................... PS742P

Lubricator Service Kit ........................................................ PS748PMounting Bracket Kit ......................................................... PS843POil – 1 Gal. .......................................................................... F442002

12 Quart Case ............................................................F4420034 Gallon Case ............................................................F442005

Pressure Fill Adapter Kit ................................................... PS716PPressure Fill Button ........................................................... P11912Remote Auto-Fill Device ................................................. PS505CP

Sight Dome / Fill Cap Kit .................................................. PS739PSight Dome Kit ...................................................................PS740PNylon Sight Dome Kit ...................................................... PS740N

Sight Gauge Kit ..................................................................PS814P

SpecificationsBowl Capacity .............................................................. 4.9 OuncesMinimum Flow for Lubrication ................... 1 SCFM At 100 PSIGPort Threads ......................................................... 3/8, 1/2, 3/4 InchPressure & Temperature Rating –

Polycarbonate Bowl – 0 to 150 PSIG (0 to 10.3 bar)32°F to 125°F (0°C to 52°C)

Metal Bowl – 0 to 250 PSIG (0 to 17.2 bar)32°F to 175°F (0°C to 80°C)

Suggested Lubricant ......................................................... F442 OilPetroleum based oil of 100 to 200 SSU viscosityat 100°F and an aniline point greater than 200°F(DO NOT USE OILS WITH ADDITIVES,COMPOUNDED OILS CONTAINING SOLVENTS,GRAPHITE, DETERGENTS, OR SYNTHETIC OILS.)

Weight ......................................................................... 1.9 lb. (.9 kg)

Materials of ConstructionBody .......................................................................................... ZincBowls – Transparent .................................................. Polycarbonate

Metal (With Sight Gauge) ............................................ ZincBowl Guard ............................................................................. SteelCollar ....................................................................... Plastic or MetalDrain – Twist – Body & Nut .................................................... PlasticInjector Meter Block & Base Assembly ............................PlasticSeals ....................................................................................... NitrileSight Dome ............................................................... PolycarbonateSight Gauge ...................................................... Polyamide (Nylon)

DRAWING NUMBER

8

4

1663a21718

16 16 3

16

16

5

9 71

CONTROL VALVE& PLUMBING

SEE DWG.# 99063/B1998038/B1998041/B19

ROLLER KITDETAIL

1

1

22a

3

3a

9

2b

5

7

6

8

10

DRAWING NUMBER

308156Rev. K

First choice whenquality counts.�

06151B

INSTRUCTIONS-PARTS LIST

INSTRUCTIONS

This manual contains importantwarnings and information.READ AND KEEP FOR REFERENCE.

Dyna-Star� HYDRAULIC RECIPROCATOR AND PUMP1500 psi (10 MPa, 102 bar) Maximum Hydraulic Input Pressure7500 psi (51 MPa, 517 bar) Maximum Fluid Outlet Pressure

FOR LUBRICATING FLUIDS ONLY

5:1 Ratio Universal Pump and ReciprocatorModel 224912, Series C, 35 lb. pail sizeModel 224751, Series C, 120 lb. drum sizeModel 224752, Series C, 400 lb. drum sizeModel 239883, Series A, reciprocator onlyPatent No. 4,383,475Foreign Patents PendingPatent 1984 CanadaBrevete 1984

Table of ContentsWarnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Throat Seals 11. . . . . . . . . . . . . . . . . . . . . . Disconnecting the Reciprocator and Displacement Pump 12. . . . . . . . . . . . . . . . . . . . Reciprocator Repair 13. . . . . . . . . . . . . . . . . . . . . . . . . Displacement Pump Repair 17. . . . . . . . . . . . . . . . . . .

Parts 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displacement Pump 19. . . . . . . . . . . . . . . . . . . . . . . . . Reciprocator 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Parts 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions and Mounting Hole Layout 23. . . . . . . . . . . Graco Standard Warranty 24. . . . . . . . . . . . . . . . . . . . . . Graco Phone Number 24. . . . . . . . . . . . . . . . . . . . . . . . . .

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441�COPYRIGHT 1991, GRACO INC.

Graco Inc. is registered to I.S. EN ISO 9001

� ��

SymbolsWarning Symbol

WARNINGThis symbol alerts you to the possibility of seriousinjury or death if you do not follow the correspondinginstructions.

Caution Symbol

CAUTIONThis symbol alerts you to the possibility of damage toor destruction of equipment if you do not follow thecorresponding instructions.




� Read all instruction manuals, tags, and labels before operating the equipment.




� Do not exceed the maximum working pressure of the lowest rated component in your system.This equipment has a 1500 psi (10 MPa, 102 bar) maximum hydraulic input pressure and7500 psi (51 MPa, 517 bar) maximum fluid outlet pressure.

� Use fluids and solvents that are compatible with the equipment wetted parts. Refer to the Techni-cal Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

� Handle hoses carefully. Do not pull on hoses to move equipment.

� Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex-pose Graco hoses to temperatures above 82�C (180�F) or below –40�C (–40�F).



WARNINGWARNING

��

TOXIC FLUID HAZARD

Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on theskin, inhaled, or swallowed.

� Know the specific hazards of the fluid you are using.

� Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,state and national guidelines.

� Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluidand solvent manufacturer.

FLUID INJECTION HAZARD

Fluid from the dispensing valve, leaks or ruptured components can inject fluid into your body andcause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or onthe skin can also cause serious injury.

� Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediatemedical attention.

� Do not point the dispensing valve at anyone or at any part of the body.

� Do not put your hand or fingers over the end of the dispensing valve.

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

� Use only extensions and couplers that are designed for use with your dispensing valve.

� Do not use a low pressure flexible nozzle with this equipment.

� Follow the Pressure Relief Procedure on page 8 if the grease fitting coupler clogs and beforecleaning, checking or servicing the equipment.

� Tighten all fluid connections before operating the equipment.

� Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Donot repair high pressure couplings; you must replace the entire hose.

� Fluid hoses must have spring guards on both ends, to help protect them from rupture caused bykinks or bends near the couplings.

WARNINGWARNING

� ��

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers.

� Keep clear of all moving parts when starting or operating the pump.

� Before servicing the equipment, follow the Pressure Relief Procedure on page 8 to preventthe equipment from starting unexpectedly.

FIRE AND EXPLOSION HAZARD

Improper grounding, poor ventilation, open flames, or sparks can cause a hazardous condition andresult in a fire or explosion and serious injury.

� Ground the equipment and the object being dispensed to. Refer to Grounding on page 7.

� If there is any static sparking or you feel an electric shock while using this equipment, stopdispensing immediately. Do not use the equipment until you identify and correct the problem.

� Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluidbeing dispensed.

� Keep the dispense area free of debris, including solvent, rags, and gasoline.

� Do not smoke in the dispense area.

� Do not turn on or off any light switch in the dispense area while dispensing or while operating iffumes are present.

WARNINGWARNING

��

Installation

Fig. 1

KEY

A Follower plateB Weep tubeC Fluid outlet line (to gun)D Drain valve (required)E Ground wireF Hydraulic return line, minimum

3/4” I.D. (required)G Hydraulic outlet, 1/2 nptH Return line shut-off valve,

minimum 3/4” (required)

J Hydraulic inlet, 1/2 nptK Tee, 3/4 nptL* Supply line shut-off valveM* Pressure gaugeN* Pressure reducing valve

(required in systems over 1500 psi[10 MPa, 102 bar])

P Accumulator

Q* Flow control valve(required in systems over 3 gpm[11 lpm])

R Hydraulic supply lineS Check valveT Variable volume pressure

compensated pumpU Hydraulic power supplyW Drain line, accumulator

Typical Installation of a Suction Feed System

AB

CD

EF G H J K L M N

P

Q

R

ST

U

W

��

* Included in Hydraulic Fluid Control Kit 236864, which can be ordered separately.

Although the installation shown in Fig. 1 is only a guidefor selecting and installing system components andaccessories, some of the equipment is required, asnoted in the key. For assistance in designing a systemto suit your needs, contact your Graco distributor.

Mount the pump to suit the type of installation planned.

Maximum Working Pressure of AccessoriesTo reduce the risk of serious injury including fluidinjection and splashing in the eyes or on the skin,which may be caused if a component ruptures, allaccessories added to the reciprocator power sup-ply side must have at least a 1500 psi (10 MPa,102 bar) maximum working pressure.

All accessories added to the pump fluid outlet sidemust have at least a 7500 psi (51 MPa, 517 bar)maximum working pressure.

WARNING

Pump Accessories

� Follower plate (A) ensures a good prime.Place the plate on the grease and rotate whilepressing firmly to level the material.

� Pump outlet drain valve (D) helps relievefluid pressure in the pump when the pump isshut off. Install the valve close to the pumpfluid outlet. Order Part No. 111229, valve.

WARNINGPump Outlet Drain ValveA pump outlet drain valve (D) is required in yoursystem. This valve helps relieve pressure in thedisplacement pump and hose when shutting downthe system and in case of a clogged outlet hose.Install the valve close to the pump outlet.

� ��

Installation

WARNINGMount the pump securely so that it cannot movearound during operation. Failure to do so couldresult in personal injury or equipment damage.

NOTE: Refer to Fig. 1 to locate the parts mentionedbelow.

Keep the Hydraulic System Clean

The hydraulic supply system must be kept clean atall times to reduce the risk of damaging the recip-rocator hydraulic power supply. Blow out all hy-draulic lines with air, flush thoroughly with solvent,and then blow out with air again before connectingthe lines to the reciprocator.

Always plug the hydraulic inlets, outlets and lineswhen disconnecting them for any reason to avoidintroducing dirt and other contaminants into thesystem.

Carefully follow the manufacturer’s recommenda-tions on reservoir and filter cleaning, and periodicchanges of hydraulic fluid.

CAUTION

Hydraulic Power Supply

Limit Fluid Flow to ReciprocatorTo reduce the risk of overpressurizing the hydraulicreciprocator, which could cause a rupture andserious injury, including fluid injection, the hydraulicsystem must have a means to limit the incomingfluid flow to the reciprocator to a maximum of 3gpm (11 lpm) and 1500 psi (10 MPa, 102 bar). Seethe description below.

WARNING

The hydraulic power supply system (U) must have apressure reducing valve and a pressure-compensatedflow control. A flow control valve (Q) is required to limitthe incoming flow to the reciprocator to a maximum of3 gpm (11 lpm).

NOTE: A supply line shut-off valve (L), pressuregauge (M), pressure reducing valve (N), and a flowcontrol valve (Q) are included in the Hydraulic FluidControl Kit 236864, which can be ordered separately.

Hydraulic Lines

� Shut-off valves (H and L) are installed in thehydraulic supply and return lines. Order PartNo. 108537.

� Drain Line: Remove the plug (59) from thepump adapter and install a 1/8” diameter weeptube (B), ending in a waste container. Monitorthe weepage of hydraulic fluid. If it seemsexcessive or increases suddenly, thereciprocator/pump seals may need to bechanged. See Fig. 2.

Fig. 2

59

06146B

� Hoses: Use a minimum 1/2” supply line (R)and minimum 3/4” return line (F) on thereciprocator. Contact your Gracorepresentative for details of line sizing.

� A pressure reducing valve (N) circulatesexcess hydraulic fluid pressure back to thehydraulic power supply. Install this valve (N) inthe hydraulic supply line with a drain hose (W)teed into the hydraulic return line (F). Limitsupply pressure to a maximum of 1500 psi(10 MPa, 102 bar).

� An accumulator (P) reduces the hammeringeffect caused by the motor when it reversesdirection.

� A fluid-filled pressure gauge (M), Part No.112567, monitors hydraulic pressure to thereciprocator during startup. See Fig. 1. Usethe gauge for initial adjustment of thereciprocator. It can be removed afteradjustment is made.

��

InstallationGrounding

To reduce the risk of static sparking, ground the pump.Check your local electrical code for detailed groundinginstructions for your area and type of equipment.

� Pump: Use ground wire and clamp as shown inFig. 3. To order a Grounding Wire and Clamp Kit,order Part No. 222011.

� Hydraulic Hoses and Fluid Outlet Hoses: Use onlyelectrically conductive hoses.

� Hydraulic Power Supply: Follow manufacturer’srecommendations.

� Any pails used when flushing: Use only metal,grounded pails when flushing. Make firm metal tometal contact between the a metal part of thedispense valve and the pail. Use the lowestpossible pressure.

To ground the pump, remove the ground screw (Z)and insert through the eye of the ring terminal at end ofground wire (Y). Fasten the ground screw back ontothe pump and tighten securely. Connect the other endof the wire to a true earth ground.

Fig. 3

Y

Z

06147B

� ��


INJECTION HAZARDThe system pressure must be manuallyrelieved to prevent the system fromstarting or dispensing accidentally. Fluid

under high pressure can be injected through theskin and cause serious injury. To reduce the risk ofan injury from injection, splashing fluid, or movingparts, follow the Pressure Relief Procedurewhenever you

� Are instructed to relieve the pressure� Check or service any of the system equipment� Install or clean the nozzle

WARNING

1. Shut off the hydraulic power supply.

2. Close the supply line shut-off valve (L in Fig. 1).

3. Open the dispensing valve to relieve pressure.

4. Open the pump outlet drain valve, and have acontainer ready to catch the drainage.

5. Close the return line shut-off valve (H).

NOTE: Leave the drain valve open until you are readyto dispense again.

If you suspect that the nozzle or hose is completelyclogged, or that pressure has not been fully relievedafter following the steps above, very slowly loosen thehose end coupling to relieve pressure, then clear theobstruction.

Before You Start the Pump

1. Check the hydraulic fluid level in the hydraulicpower supply before each use, and add fluid asnecessary to fill the lines.

CAUTIONAlways use Graco approved hydraulic oil or equiv-alent, Part Numbers 169236 (5 gallon) or 207428(1 gallon). Do not substitute lower grade oil.

2. Flush the pump before using it for the first time toremove the light oil that was left in after factorytesting to protect the pump from corrosion. Be surethe solvent used is compatible with the fluid to bepumped and the pump wetted parts. SeeTechnical Data, page 23. Flush until clean solventcomes from the outlet hose.

To start the pump

1. Turn on the hydraulic power supply.

2. Open the return line shut-off valve (H) first andslowly open the hydraulic supply shut-off valve (L).

3. Adjust the flow control valve (Q) to limit thehydraulic flow to no more than 3 gpm (11 lpm),which is approximately 60 cycles per minute.

NOTE: If Graco Part No. 236864 hydraulic fluidcontrol is used, no adjustment is necessary.

4. By adjusting the pressure reducing valve (N),increase the hydraulic inlet pressure from 50 to1500 psi (0.34 to 10 MPa, 3.4 to 103 bar).Increasing the inlet pressure increases the outletpressure. Decreasing the inlet pressuredecreases the outlet pressure.

5. Open the drain valve while priming the pump;close it when the pump is primed.

6. Always use the lowest pressure possible to obtainthe desired results. This reduces pump wear.

Never allow a pump to run dry of the fluid beingpumped. A dry pump quickly speeds up and candamage itself. If it speeds up, shut off the powersupply to the reciprocator immediately. Refill thesupply container, and prime the pump to eliminateair.

CAUTION

CAUTIONMaximum Working TemperatureDo not exceed 130� F (54� C) hydraulic oil tem-perature. The reciprocator seals will wear fasterand leakage may occur if the pump is operated athigher oil temperatures.

��

Operation

MAXIMUM WORKING PRESSURES

To reduce the risk of serious injury, includingfluid injection and splashing in the eyes or on theskin, which may be caused if a componentruptures:

Never exceed 1500 psi (10 MPa, 102 bar) Maxi-mum Hydraulic Pressure to the reciprocator.

Never exceed 7500 psi (51 MPa, 517 bar) Maxi-mum Outlet Pressure from the displacement pump.

Be sure all accessories added to the reciprocatorpower supply side have at least a 1500 psi(10 MPa, 102 bar) Maximum Working Pressure.Accessories added to the pump fluid outlet sideshould have at least a 7500 psi (51 MPa, 517 bar)Maximum Working Pressure.

The working pressure of the displacement pumphas a 5:1 ratio to the pressure at which the recipro-cator is operated. Therefore, if the fluid supplied tothe reciprocator is 1000 psi (7 MPa, 69 bar), thepump fluid outlet pressure will be 5 times the hy-draulic pressure, or 5000 psi (34 MPa, 345 bar).

WARNING If the Pump Leaks at the Fluid Fittings

Tighten the fittings (1, 5, 58), which are self-sealingand have replaceable o-rings. If leaking persists,change the o-rings.

Fig. 4 ��

self-sealingfitting (1,5,58)

o-ring(1a,5a,58a)

reciprocator

Shutdown

Relieve the pressure whenever you shut down.


��

Troubleshooting

Problem Cause Solution

Pump does not run. Closed dispense valve. Pump only runs with valve open.

Pressure too low. Increase supply pressure using apressure adjusting valve.

Insufficient hydraulic fluid supply. Check hydraulic supply. Adjust to amaximum of 3 gpm (11 lpm) flow.

Clogged fluid outlet line, intake valve,dispense valve, suction line.

Relieve pressure. Check; clear obstructions.

Reciprocator damaged. Repair. See page 13.

Pump speeds up or runs erratically. Pump piston and/or intakevalve worn.

Relieve pressure. Check and repair.See pages 17 and 18.

Empty supply container. Refill and reprime. Do not allow pumpto run dry. Monitor closely or use alow-level cutoff valve.

Pump runs, but output low on up and/or down stroke.

Pump piston and/or intake valveworn.

Relieve pressure. Check and repair.See page 17 and 18.

Pump runs but output low on bothstrokes.

Insufficient hydraulic fluid supply. Check hydraulic supply. Adjust tomaximum 3 gpm (11 lpm) flow.

Pressure too low. Increase supply pressure using apressure adjusting valve.

Clogged fluid outlet line, intake valve,dispense valve, suction line.

Relieve pressure. Check; clearobstructions.

Excessive weepage from weeptube (B).

Worn throat packings. Repair. See page 11.

Hydraulic oil leaks from fittings in theupper or lower reciprocator blocks(31,32).

Fittings (1,5,58) are loose, or theiro-rings are worn or damaged.

Tighten the self-sealing fittings. Ifleaking persists, change the o-rings.

��

ServiceReplacing the Throat Seals

See Fig. 5.

NOTE: Replace these seals if fluid leaks excessivelythrough the weep tube (B). This procedure can bedone without disassembling the entire reciprocator.



2. Disconnect the reciprocator from the pump. Seethe procedure on page 12.

3. Remove the four capscrews (46) from the bottomof the adapter (43). Tap the adapter to loosen itand pull it off the bottom cap (32).

4. Remove the seals (16*,44*) and guide (19) fromthe top of the adapter (43).

NOTE: Items 16 and 44 are included in theReciprocator Repair Kit, 223426.

5. Lubricate the guide (19) and install the seals andguide in the adapter (43), one at a time in the order shown in Fig. 5.

6. Reassemble. Torque the capscrews (46) to 28 to32 ft-lb (38 to 43 N-m). Install the displacementpump. Follow Step 24, page 16.

Fig. 501660

32

33

46

43

44*

� Torque to 28 to 32 ft-lb (38 to 43 N-m).

�

�16*

16*

19

�

�

�

�

�

Lips face up.

Lips face down.

Lubricate.

��

ServiceDisconnecting the Reciprocator and Displacement Pump

See Fig. 6.

NOTE: When displacement pump 224914 ispurchased separately, it comes with the priming piston(112) and priming cylinder (111) unassembled.Connect the displacement pump to the hydraulicreciprocator before assembling the priming piston andcylinder. Torque the priming piston to 35 ft-lb (47 N-m).

Fig. 6

06151B

01682

43

36,37

33

32

46 (hidden from view)

35

202*

203*101

103

204

3

CAUTIONKeep The Hydraulic System CleanIt is essential to keep the hydraulic oil system cleanand free of contaminants to reduce the risk of dam-aging the hydraulic reciprocator. Always install aplug in each tube fitting and on each hose endwhenever fluid lines are disconnected to preventcontamination.

1. Flush the pump if possible and stop it with thedisplacement rod in the lowest position.



3. Disconnect the outlet hose from the displacementpump.

4. Slowly loosen the hydraulic supply (58) and return(5) fittings to relieve any pressure, and thenremove the hoses. Install plugs on the tube fittingsand in the hose ends. Check the o-rings (5a, 58a)on the fittings and replace them if they are worn ordamaged. See Fig. 4 and the Parts Drawing.

5. Using a strap wrench on the displacement cylinder(108), screw it out of the pump adapter (43), andslide it down as far is it will go.

6. Pull the connecting rod (35) down as far as it willgo. Remove the cotter pin (204).

NOTE: For the 35 lb. length pump, the primingcylinder (111) and the priming piston (112) must becompletely removed before you can pull down thedisplacement cylinder (108) far enough to remove thecotter pin (204).

7. Unscrew the piston coupling (103) to remove thepump.

��

Reciprocator RepairReciprocator RepairNOTES

� Clean and inspect all parts for wear or damage.Replace parts as needed. For the best results,always replace all the o-rings and seals when youdisassemble the pump. Repair Kit 223426 isavailable. Parts included in the kit are marked withone asterisk, for example (23*), in the text anddrawings. Always replace the seals (23*,24*) andthe seals (16*, 44*) together.

� Assembly Tool 189305 is required forreassembling the reciprocator.

� Loctite� 242 thread sealant and Loctite� Primer Tor Perma-Loc� 115 thread sealant andPerma-Bond� Surface Conditioner I are required.Be sure their shelf life is within the manufacturer’srecommendations.

Before you begin, drain the oil out of the reciprocatoras follows: Place the reciprocator in a drain pan, pushthe piston all the way up/in, then all the way down/out.

1. Place the adapter (43) in a vise. Remove the fourcapscrews (46) and the base (33). Pull the bottomcap (32) off of the adapter (43). See Fig. 7. Ifneeded, replace the seals as described onpage 11.

2. Loosen both nuts on the fluid tube (45). Use awrench to rotate the tube fittings (1,58) to the side,and then remove the tube (45). Check the o-rings(1a,58a) on the fittings and replace them if theyare worn or damaged. Install plugs in the fittings toprevent contamination. See Fig. 4 and the PartsDrawing.

3. Remove the capscrew (3), nuts (36) andlockwashers (37) on top of the reciprocator. SeeFig. 7.

Fig. 7

43

36,37

33

32

3,39,2

46 hidden from view

06146B

See Fig. 9 for Steps 4 to 20, except where noted.

4. Tap on the bottom of the displacement rod (34)with a plastic mallet to loosen the cylinder (25).

5. Grasp the valve spool (31) and pull it off thecylinder and tie rods (38). Pull the cylinder andpiston off the bottom cap (32). It is not necessaryto remove the tie rods from the bottom cap.

6. Lay the assembly on its side. Place a clean ragaround the yoke (9) to prevent losing the detentballs. Slide the yoke (9) sideways off the valvesleeve (29) while holding the balls (7) and spring(6) in place.

7. Slide the cylinder (25) off the displacement rod(34). Hold the hex end of the displacement rod in avise and use a spanner wrench in the pin holes ofthe piston (22) to screw it off the rod.

CAUTIONBe careful not to scratch the outside of the dis-placement rod or the inside of the cylinder.

8. Visually inspect the spring (21). If there is wear ordamage, remove the nut (18), spring (21) andretainers (20) from the trip rod (12). Reassemblewith a retainer (20) on each end of the new spring(21). You must thread the nut onto the rod until itruns out of thread, so that it bottoms out on theshoulder of the rod. See Fig. 8.

20

21

20

Fig. 8 0166418

12

��

Reciprocator Repair

Fig. 9 06153

12

38

36,37

31

29

32

22

20

21

18

51

17

*13

6,7

9

17

25

34

SeeFig. 8

20

13*

*24

23*,49*

3,39,2

30

�

�

� Torque to 42 to 45 in-lb (4.7 to 5.1 N-m)

�

Torque to 30 to 40 ft-lb (41 to 54 N-m)

26

NOTE: If you are re-using or reassembling any parts,use a surface cleaner such as chlorinated solvent onthe threads, and blow with compressed air. A 1/4–28UNF–2A tap can be used to remove adhesive from theinternal threads of the yoke (9).

NOTE: Thread sealant and primer are required. Seethe third bulleted note on page 13 for specifications.

9. Apply fresh thread sealant to the first two or threeinternal threads of the yoke (9). Apply primer to theexternal thread of the rod (12). Let dry for three orfour minutes. Assemble, torquing the screw to 54to 56 in-lb (6.1 to 6.3 N-m). Remove excesssealant. Allow 24 hours to cure before operatingthe reciprocator.

10. Clean all sealant from the threads of any part youare reusing, and apply thread sealant to the firsttwo or three internal threads of the valve assembly(31). If you removed the capscrew (51), applythread sealant to the first two or three internalthreads of the valve stop (26). Apply primer to theexternal threads of the valve sleeve (29). Let dryfor three or four minutes, assemble, and removeexcess sealant. Allow 24 hours to cure beforeoperating the reciprocator.

11. Remove the o-ring (13*) from the bottom of thespool valve (31) and replace it with a new o-ring.

12. Use a spanner wrench to screw the piston (22)onto the displacement rod (34). Torque to 30 to 40ft-lb (41 to 54 N-m).

CAUTIONWhen inserting the piston into the cylinder, care-fully guide the piston seal (23*) and bearing (24*)to prevent damaging these parts.

13. Lay Assembly A and Assembly B on theworkbench.

14. Slide Assembly B into the center of the tool (D),Part No. 189305. Align the upper detent holes (C)of the yoke (9) with the center line of the tool (D).See Fig. 10.

��

Reciprocator Repair

06148Fig. 10

31

ASSEMBLY B

26

6

7

9

29

12

ASSEMBLY A

C

D

15. Insert the spring (6) and one ball (7) into the valvestop (26) of Assembly A. Tilt the valve stop andstart guiding it into the tool (D), making sure theball is sliding into the rounded slot in the tool (D).Place the other ball at the other end of the springand push it in with your thumb while rotating thevalve stop (26) until the spring is horizontal and theballs are in place. Continue holding this assemblytogether. See Fig. 10.

16. Slide the valve stop assembly down into the tool.Make sure the balls (7) snap into the upper set ofholes (C) in the yoke (9), and the curved ends ofthe guide clamp have engaged the valve sleeve(29) groove. See Fig. 10. Slide the tool (D) backover the rod (12) to remove it.

Refer to Fig. 11 for Steps 17 to 24.

17. Place the adapter (43) in a vise, and install theseals as described on page 11. Install the cylindercap (32).

18. If the tie rods (38) were removed, reinstall themwith the short threaded end up. The other endshould be screwed about 9/16” into the bottomcylinder cap (32).

NOTE: When reinstalling the cylinder (25) (Step 19),be sure the “P” port in the valve spool (31) and the portin the bottom cylinder cap (32) are in line with eachother. Be sure the o-rings (13*) are in place in thevalve spool and cylinder cap.

19. Place the cylinder (25) on the cylinder cap (32).Install the piston (22) and valve assembly (31).

20. Install the o-ring (49*) in the deep lower groove ofthe piston (22) and install the seal (23*) over theo-ring. Install the piston bearing (24*) around theupper groove of the piston. Holding the pistonbearing in place to avoid damage, slide thecylinder over the piston and press it down.

��

Reciprocator Repair21. Install the capscrew (3), o-ring (39) and washer

(2). Install the lockwashers (37) and nuts (36).Torque the nuts to 28 to 32 ft-lb (36 to 43 N-m).

CAUTIONNever install the fluid tube (45) before torquing thetie rods. Doing so could cause misalignment anddamage the reciprocator when it is operated.

22. Reinstall the fluid tube (45) and fittings (1). Torquethe fittings to 25 to 35 ft-lb (34 to 48 N-m). See theParts Drawing on page 20.

23. Pull the displacement rod (34) in and out to besure it moves easily with only a little resistancefrom the rod seal.

24. To reconnect the reciprocator and pump, install theo-ring (17). Screw the connecting rod (35) into thedisplacement rod (34). Install the cotter pin (204).Install a new copper gasket (202*). Make sure theseal (203*) in the bottom of the adapter (43) is ingood condition. Push the cylinder up into theadapter and engage the threads. Screw in thepump, using a strap wrench for the final tightening.See Fig. 12.

25. Connect the hydraulic supply and return hoses tothe fittings (5, 60).

WARNINGTo reduce the risk of static sparking be sure to re-connect the ground wire before operating thepump.

36,37

31

32

*13

25

13*

3,39,2

43

38

Fig. 11 06153

35

�

�

Torque to 28 to 32 ft-lb (36 to 43 N-m)

Fig. 12 01682

*202204

118

103203*

43

35

� Torque to 150 to 160 ft-lb (205 to 220 N-m)

�

��

Displacement Pump RepairDisassembly


1. If possible, flush the pump. Relieve the pressure.

2. Follow Disconnecting the Reciprocator andDisplacement Pump procedure on page 12.

3. Place the pump in a vise. Unscrew the primingcylinder (111).

4. Push the priming piston (112) into the pump untilthe hex of the piston coupling (103) is exposed.

5. Hold the piston coupling (103), and unscrew thepiston rod (119).

6. Unscrew the packing housing (110) and remove allparts.

7. Pull the piston (107) and the priming tube (108)assembly out of the pump housing.

8. Unscrew the priming tube (108), and remove allparts.

9. Unscrew the piston (107), and remove all parts.

10. Clean all parts thoroughly with a compatiblesolvent. Inspect the parts for wear, and replace asneeded. Scoring or irregular surfaces on thepriming tube (108), or inside the cylinder (118)causes premature packing wear and leaking.

Insert 1/4” dia. rod through hole to hold primingtube (108) when removing or installing partsconnected to it.

Fig. 13

�

01684A

116102

115

104*

105*

106

102

115

101

103

107

117

116

108

119

111

112

109

114*

113*

118

110

�

� Only used on Models 223513 and 223514.

�

��

Displacement Pump RepairReassembly

NOTE: Repair Kit 223427 is available. Referencenumbers marked with an asterisk are included in thekit.

NOTE: The balls (116) cannot be reseated on thehardened seats (102). However, the seats can bereversed and used a second time.

NOTE: Lubricate all parts with a light, waterproofgrease.

1. Insert the pin (101) into the piston coupling (103),and insert the pin (117) into the pump piston (107).

2. Put the pump piston (107) in a vise, and stack thespacer (106), seal (105*), packing (104*), gasket(115), seat (102), and ball (116) on it in the ordershown in Fig. 14. Thread the piston coupling (103)onto the pump piston (107), and torque it to 60 ft-lb(80 N-m).

3. Turn the pump piston (107) over in the vise, andinsert the ball (116), seat (102), and gasket (115).

4. Assemble the seal (113), packing (114) andbearing (109) on the packing housing (110). Screwthe packing housing into the cylinder (118), andtorque to 60 ft-lb (80 N-m).

5. Slide the assembly into the cylinder from the top.Use your finger to guide the assembly through thelower seals.

6. Models 223513, 223514 only: Screw the pistonrod (119) onto the priming tube (108). Torque to 35ft-lb (47 N-m).

7. Place the gasket (202*) in the base of thereciprocator. Place the o-ring (203*) into thegroove of the pump adapter (43). Screw thecylinder into the pump adapter.

8. Firmly screw the priming piston (112) onto thepiston rod (119). Torque to 35 ft-lb (47 N-m).

9. Firmly screw the priming cylinder (111) onto the cylinder (118).

10. Reconnect the ground wire to the reciprocator if itis disconnected.

Fig. 14 01684A

�

116102

115

104*

105*

106

102

115

101

103

107

117

116

108

119

111

112

109

114*

113*

118

110

�

�

� �

�

�

�

�

�

Torque to 60 ft-lb (80 N-m).

Torque to 35 ft-lb (47 N-m).

Only used on Models 223513 and 223514.

Insert 1/4” dia. rod through hole to hold primingtube (108) when removing or installing partsconnected to it.

�

��

Displacement Pump PartsModel 223513, Series A, 120 lb.Includes items 101 to 119

Model 223514, Series A, 400 lb.Includes items 101 to 119

Model 224914, Series A, 35 lb.Includes items 101 to 118

Ref.No. Part No. Description Qty.

101 108992 PIN, spring 1102 162559 SEAT, valve 2103 183670 COUPLING, piston 1104* 108990 PACKING, block 1105* 108989 SEAL, backup 1106 183669 SPACER, piston 1107 183676 PISTON, pump 1108 183677 TUBE, priming 1109 183668 BEARING, priming 1110 183675 HOUSING, packing 1111 CYLINDER, priming 1

183673 Model 223513185999 Model 223514187312 Model 224914

112 183672 PISTON, priming 1113* 108988 SEAL, backup 1114* 108987 PACKING, block 1115 150451 GASKET, copper 2116 100170 BALL 2117 108991 PIN, spring 1118 183678 CYLINDER, pump 1119 ROD, piston 1

186002 Model 223513185998 Model 223514None Model 224914

* These parts and items 202, 203 on page 22, areincluded in Repair Kit 223427, which may bepurchased separately.

Fig. 1501685

101

118

112

111

109

*114

*113

110

116102115

108

116102115

105*

106

117

103

107

119

104*

��

Reciprocator PartsModel 239883, Series AIncludes items 1 to 60

7

33

49*

38

4652

43

16*

44*

19

16*

32

18

20

21

20

22

*13

*13

24*

23*

25

17

NOTE: See pages 11 to 18 for impor-tant assembly proceduresand torque values.

34

59

40Label

14

17

35

9

26

29

31

37

36

*4

51

5

45

58

7

6

1

5a58a

1a 12

3

39

2

30

��

46

60

��

Reciprocator PartsModel 239883, Series AIncludes items 1 to 60



1 106470 ELBOW, straight thread,3/4–16 unf–2a x 3/4–16 unf–2a, 37� flare includes item 1a 1

1a 110987 .O-RING 12 178179 WASHER, sealing 13 106276 CAPSCREW, hex hd,

3/8–24 x 5/8” 14 104093 O-RING 15 112568 ADAPTER, pipe,3/4 unf(m)

1/2 npt(f), steelincludes item 5a 1

5a 110987 .O-RING 16 108437 SPRING, compression, steel 17 100069 BALL, 1/4” dia. steel 29 189077 YOKE, valve 112 192657 ROD, stop, cs 113* 106274 O-RING, buna–N 214 116343 SCREW, grounding 116* 108952 PACKING, v-block 217 105765 O-RING 218 114231 LOCKNUT, hex, 1/4–28 unf–3b

steel and nylon 119 183531 GUIDE, rod, bronze 120 192655 RETAINER, spring, cs 221 178189 SPRING, compression, steel 122 192656 PISTON, CS 123* 178226 SEAL, piston

glass-filled Teflon 124* 178207 BEARING, piston

bronze-filled Teflon 125 178229 CYLINDER, motor, cs 126 192654 STOP, valve, cs 129 189072 SLEEVE, valve, steel 1

30 178181 PLATE, cap 131 239874 SPOOL, valve assembly

3/4–16 unf –2b(f) 132 186225 CAP, cylinder, bottom, cs 133 183833 BASE, aluminum 134 188078 ROD, displacement, cs 135 183671 CONNECTING ROD 136 100307 NUT, full, hex; 3/8–16 unc–2b 437 100133 LOCKWASHER, 3/8” 438 187405 ROD, tie, 8.5” shoulder to

shoulder, 3/8–16 unc–2a,cs 439 155685 O-RING 140� 179885 LABEL, Warning 143 183533 ADAPTER, pump, cs 144* 108951 SEAL, polyester elastomer 145 217221 TUBE, inlet 146 108986 CAPSCREW, sch, 3/18–16

unc–2a x 4.5” 449* 108014 O-RING, buna–N 151 104092 CAPSCREW, sch; 10–24

unrc–3a x 5/8” 252 106115 LOCKWASHER, spring; 3/8” 458 107197 TEE includes item 58a 158a 110987 .O-RING 159 110064 PLUG, pipe, vented, 1/8–27 nptf 160 112569 UNION, swivel; steel 1

* These parts and items 202, 203 on page 22 areincluded in Repair Kit 223426, which may bepurchased separately.

� Replacement Danger and Warning labels, tags andcards are available at no cost.

Assembly Tool 189305 required for repairing thereciprocator.

��

Pump PartsModel 224752, Series C400 pound drum size


201 239883 RECIPROCATOR, see page 21 1202* 183715 GASKET, copper 1203* 108993 O-RING 1204 108992 PIN 1205 223514 DISPLACEMENT PUMP

see page 19 1206 183741 LABEL, identification 1

Model 224751, Series C120 pound drum size



see page 19 1206 183741 LABEL 1

Model 224912, Series C35 pound drum size



see page 19 1206 183741 LABEL 1

* These parts are included in Repair Kits 223426 and223427, which may be purchased separately.

201

202

203*

204

205

206label

06155B

��

Technical DataMax. grease output pressure 7500 psi (51 MPa, 517 bar). . . . . . . . . . . . . . . . . . . . . . Max. hydraulic fluid input pressure 1500 psi (10 MPa, 102 bar). . . . . . . . . . . . . . . . . . Max. hydraulic fluid input volume 3 gpm (11.7 lpm), 60 cpm. . . . . . . . . . . . . . . . . . . . Hydraulic fluid consumption rate 6.5 ounces (0.195 liter) per cycle . . . . . . . . . . . . . .

or 1 gallon per 19.5 cyclesMaximum fluid temperature 130� F (55� C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Effective piston area 1.48 sq in. (9.55 cm2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston rod diameter 1 3/8 in. (34.9 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output per cycle with No. 2 grease at 60 cpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

free flow: 5 lb/min (2.25 kg/min)at 3000 psi (21 MPa, 207 bar): 4 lb/min (1.8 kg/min)

Stroke 4 in. (101.6 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thrust at 1000 psi (7 MPa, 69 bar) 1480 lb (673 kg). . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum suction lift 13 feet (4 m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displacement pump wetted parts steel, copper, polyurethane,. . . . . . . . . . . . . . . . . . .

buna–N, polyester elastomerWeight Model 224752: 42 lb (18.9 kg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model 224751: 37.5 lb (16.9 kg)Model 224912: 32.5 (17.7 kg)

Sound pressure* 77 dB(A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * Sound pressure reading taken with pump operating at 66 cycles per minute.

Sound pressure measured per CAGI-PNEUROP, 1971.

Loctite� is a registered trademark of Loctite Corporation.

Dimensions and Mounting Hole Layout

33.75 in.(857 mm)Model 223514

14.75 in.(375 mm)ReciprocatorModel 239883

48.5 in.(1232 mm)Model 224752

3.536 in.(90.424 mm)

3 in (76.2 mm)minimum diameter clearance hole

clearance for, ortap 5/16–18,typical 4 places

NOTE:Pump body orientation is squarewith mounting holes.

3.536 in.(90.424 mm)

26.75 in.(679 mm)Model 223513

3/4 npt Hydraulic Outlet3/8 npt Hydraulic Inlet

41.5 in.(1054 mm)Model 224751

1/2 npt(f)fluidoutlet

29.75 in.(756 mm)Model 224912

15 in.(381 mm)Model 224914

06151

��

Graco Standard WarrantyGraco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on thedate of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limitedwarranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipmentdetermined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained inaccordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused byfaulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, orsubstitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility ofGraco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.



Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no otherremedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or anyother incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of thedate of sale.



FOR GRACO CANADA CUSTOMERSThe parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedingsentered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les partiesreconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procéduresjudiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.

Graco Phone NumbersTO PLACE AN ORDER, contact your Graco distributor, or call one of the following numbers

to identify the distributor closest to you:1–800–533–9655 Toll Free

612–623–6928612–378–3590 Fax

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.


GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441www.graco.com

PRINTED IN U.S.A. 308156 December 1991, Revised August 2001

308642Rev. L

First choice whenquality counts.�

INSTRUCTIONS–PARTS LIST

INSTRUCTIONS

This manual contains importantwarnings and information.READ AND KEEP FOR REFERENCE.

WITH OR WITHOUT ELECTRONIC METERS

V5� V12� EM6� and EM12�Dispense Valves1500 psi (10 MPa, 102 bar) Maximum Working Pressure

These dispense valves are designed to dispensepetroleum-based lubricants only.

CAUTION

Notes� See the list on page 3 for Model Numbers and

configurations.

� See manual 307965 for information on electronicmeters 244075 and 244076.

Table of ContentsModels 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warnings 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts — EM12 and V12 Dispense Valves 12. . . . . . . . . Parts — EM6 Dispense Valves 13. . . . . . . . . . . . . . . . . . Parts — V5 Dispense Valves 14. . . . . . . . . . . . . . . . . . . . Technical Data 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Graco Standard Warranty 16. . . . . . . . . . . . . . . . . . . . . . Graco Phone Number 16. . . . . . . . . . . . . . . . . . . . . . . . . .

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441�COPYRIGHT 1997, GRACO INC.

Graco Inc. is registered to I.S. EN ISO 9001

V12Model 238644

EM12Model 238641

06292A

06294A

Bare ValveModel 238646

8537A

TI0407

EM6Model 243599

� ��

Notes

��

ModelsNon-Metered Valves

V12 – with trigger lock

With Extension

238644 3/4” swivel, rigid extension

238645 3/4” swivel, flex extension



V5 – with trigger lock

With Extension

222411, Series C, 1/2” swivel, oil nozzle/extension

222412, Series C, 1/2” swivel, gear lube extension

222413, Series C, 1/2” swivel, ATF nozzle/extension

Bare Valves

238646 3/4” swivel, no extension, with trigger lock

238647 1/2” swivel, no extension, with trigger lock

243992 1/2” swivel, no extension, without trigger lock

Metered ValvesEM12 – with trigger lockEnglish Meter





Metric Meter





EM6 – without trigger lockEnglish Meter


243600 1/2” swivel, gear lube


Metric Meter


243603 1/2” swivel, gear lube


� ��

WarningsWarning Symbol

WARNINGThis symbol alerts you to the possibility of seriousinjury or death if you do not follow the instructions.

Caution Symbol

CAUTIONThis symbol alerts you to the possibility of damage toor destruction of equipment if you do not follow theinstructions.




� Read all instruction manuals, tags, and labels before you operate this equipment.




� Do not exceed the maximum working pressure of the lowest rated system component. Refer tothe Technical Data on page 15 for the maximum working pressure of this component.

� Use fluids and solvents which are compatible with the equipment wetted parts. Refer to theTechnical Data section of all equipment manuals. Read the fluid and solvent manufacturer’swarnings.

� Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents orfluids that contain such solvents in pressurized aluminum equipment. Such use could result in achemical reaction, with the possibility of explosion.

� Do not use hoses to pull equipment.

� Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do notexpose Graco hoses to temperatures above 180� F (82� C) or below –40� F (–40� C).



WARNINGWARNING

INSTRUCTIONS

��

INJECTION HAZARD

Fluid from the dispensing valve, leaks, or ruptured components can inject fluid into your body andcause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or onthe skin can also cause serious injury.

� Fluid injected into the skin may look like just a cut, but it is a serious injury. Get immediatemedical attention.

� Do not point the dispensing valve at anyone or at any part of the body.

� Do not put your hand or fingers over the end of the dispensing valve.

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

� Use only extensions and nozzles that are designed for use with your dispensing valve.

� Do not use a low-pressure flexible extension with this equipment.

� Follow the Pressure Relief Procedure on page 9 before you clean, check, or service theequipment.

� Tighten all fluid connections before you operate the equipment.

� Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Donot repair high pressure couplings; you must replace the entire hose.

WARNINGWARNING

� ��

InstallationSee manual 307965 for electronic meters installation, operation, parts, and cautions and warnings.

NOTE: Numbers in parenthesis, for example (7), and in the Parts Drawings are reference numbers in the Parts List on page12.

Typical Installation

Fig. 1 shows a typical installation. Additionally, thesedispense valves can be installed on a console.

Do not use this electronic metered dispensevalve on non-Graco consoles. Such use couldresult in the trigger becoming inadvertentlypressed while the dispense valve is stowed.

CAUTION

Fig. 1

L

M

K

N

J

��

H

KEY DESCRIPTION

H Thermal relief kit (required) Part No. 237904Install downstream from pump.

J Fluid shut-off valve

K Hose

L Hose reel fluid inlet hose

M Hose reel

N Metered dispense valve

The installation shown in Fig. 1 is only a guide. Thecomponents shown are typical; however, it is not acomplete system design. Contact your Graco distribu-tor for assistance in designing a system to suit yourparticular needs.

To prevent line contamination, which can causeequipment malfunction or damage, flush the linesbefore you install the equipment in the system.

CAUTION

FIRE AND EXPLOSION HAZARDThe movement of fluids through thedispensing system generates staticelectricity. The static electricity can

cause volatile fumes to ignite, resulting in explosionand fire. The dispensing system must always begrounded. See Grounding on page 8.

WARNING

��

InstallationPre-Installation Procedure



2. Close the fluid shut-off valve (item J in Fig. 1).

3. Ground the hose and reel or console. SeeGrounding on page 8. Do not use Teflon� tapeon the pipe joints; it may cause a loss of groundacross the pipe joint.

Installation Procedure

CAUTIONIf this is a new installation, or if the oil in thelines is contaminated, flush the lines before youinstall the dispensing valve.

New Installation1. Relieve the pressure.

WARNINGTo reduce the risk of serious injury, whenever youare instructed to relieve pressure, always follow thePressure Relief Procedure on page 9.

Steps 2 to 6 are the Flushing Procedure.

2. Close the fluid shut-off valve (J) at each dispenseposition.

3. Make sure the main fluid outlet valve at the pumpis closed, the air pressure to the pump motor isadjusted, and the air valve is open. Slowly openmain fluid valve.

4. Place the hose end (with no dispense valve con-nected) into a container for waste oil. Secure thehose in the container so it will not come out duringflushing. If you have multiple dispense positions,first flush the dispense position farthest from thepump, and work your way toward the pump.

5. Slowly open the shut-off valve (J) at the dispenseposition. Flush out a sufficient amount of oil toensure that the entire system is clean, and closethe valve.

6. Repeat step 5 at all other dispense positions.

Existing Installation


WARNINGTo reduce the risk of serious injury, whenever youare instructed to relieve pressure, always follow thePressure Relief Procedure on page 9.

2. Loosen and disconnect the hose from the olddispense valve (the one that you are replacing).

For steps 3 to 5, see Fig. 2.

3. Thread the extension (26a) into the outlet of thedispense valve, and tighten firmly.

NOTE: Do not over tighten the extension tubeassembly by using the nozzle adapter to hand turn thenozzel. For rigid extensions, thread the extensionin at least three full turns, position the extensionfor proper alignment, and tighten the sealingnut (7). The Teflon� seal on the sealing nut mustface the valve housing.

4. Apply thread sealant to the male threads of thehose fitting, thread the hose fitting into the swivel(20), and tighten firmly.

5. Thread the new nozzle (8) or nozzle adapter ontothe extension, and tighten firmly.

6. Open all dispense position shut-off valves, andstart the pump to pressurize the system. See theOperation section for proper operation.

7. For metered dispense valves, to ensure dispens-ing accuracy, purge all air from the fluid lines anddispense valves before you use them.

20

Model shown is a V12 witha 75� bend rigid extension.

Fig. 2

26a

7

8

06292A

� ��

InstallationGrounding

Proper grounding is an essential part of maintaining asafe system.

To reduce the risk of static sparking, ground all systemcomponents per local and national electrical codes.Refer to the user manuals for the pump and othersystem components to ground the following:

� Pump: Follow manufacturer’s recommendations.

� Air and Fluid hoses: Use only grounded hoses.

� Air compressor: Follow manufacturer’s recommen-dations.

� Fluid supply container: Follow your local code.

� To maintain grounding continuity when flushing orrelieving pressure, always hold a metal part of thevalve firmly to the side of a grounded metal pail,then trigger the valve.

��


PRESSURIZED EQUIPMENT HAZARDThe equipment stays pressurized untilpressure is manually relieved. Toreduce the risk of serious injury from

pressurized fluid, accidental spray from thedispenser or splashing fluid, follow the PressureRelief Procedure whenever you

� Are instructed to relieve pressure� Check, clean, or service any system equipment� Install or clean fluid nozzles

WARNING

1. Turn off the power supply to the pump.

2. Trigger the valve into a waste container to relievepressure.

3. Open any bleed-type master air valves and fluiddrain valves in the system.

4. Leave the drain valve open until you are ready topressurize the system.

If you suspect that the dispensing valve, extension, ornozzle is clogged or that pressure has not been fullyrelieved after following the steps above, very slowlyloosen a fitting on the fluid line to relieve pressuregradually, then loosen it completely, then clear theclog.

WARNINGTo reduce the risk of a serious bodily injury, includ-ing fluid injection, never exceed the maximumworking pressure of the valve you are using or ofthe lowest rated component in your system.

Dispensing Procedure

See instruction manual 307965 for electronic meteroperation.

NOTE: Before you begin, make sure you understandhow to unlock the trigger. Model EM6 does not havea trigger lock.

1. Pull the trigger toward the valve body to open thevalve and begin dispensing.

2. Lock the valve open by keeping the triggersqueezed and depressing the trigger lock button(25 in the Parts Drawing). Then release thetrigger, releasing your forefinger from the triggerlock last.

3. Pull the trigger toward the valve body to releasethe trigger lock. The trigger lock disengages.

4. Release the trigger to stop dispensing.

� ��

TroubleshootingRelieve the pressure before you check or repair thedispensing valve. Be sure all other valves and controlsand the pump are operating properly.


Problem Cause Solution

Display does not activate or isshowing unintelligentcharacters.

Electronic control is malfunctioning. Replace the electronic control.See instruction manual 307965.

Slow or no fluid flow Filter is clogged, or

Pump pressure is low, or

Shutoff valve is not fully open, or

Foreign material is jammed in themetering element.


2. Clean or replace the filter (10).See Filter Replacement onpage 11.

3. If the problem remains, contactyour Graco distributor for repairor replacement.

Oil leaks from swivel. Swivel is loose. Torque the swivel (20) to 15 to 20ft-lb (20 to 27 N-m).

If the problem remains, contact yourGraco distributor for repair orreplacement.

O-ring is worn or damaged. Replace the o-ring (6), and torque theswivel (20) to 15 to 20 ft-lb (20 to 27N-m).

If the problem remains, contact yourGraco distributor for repair orreplacement.

Oil drips from nozzle. * Nozzle is damaged or obstructed. Inspect the nozzle for damage orobstructions, and replace if damaged.

Valve leaks. O-rings or valve seat are worn ordamaged.

Replace the o-rings (15) and/or thevalve seat (29).See Valve Handle Repair onpage 11.

* Some fluid weepage is possible in applications where thermal expansion of fluid is possible.

��

ServiceNOTE: See instruction manual 307965 for electronic meter service instructions.

Valve Handle RepairSee Fig. 3.

NOTE: The large end of the pushrod (30) fits into anotch in the cam (21), which is part of the triggerassembly. It is important that you know this before youremove or install parts.


WARNINGTo reduce the risk of serious injury, when you areinstructed to relieve pressure, always follow thePressure Relief Procedure on page 9.

2. If you are replacing the o-rings (15), or the cam(21), or the push rod (30), remove the swivel (20),and remove the internal pieces. You mustremove the cam in order to get the push rodout of the outlet end of the valve handle.

3. Remove the screws (14) and washers (28), andremove the trigger (24). Push the cam (21) out ofthe valve handle (18). Replace the o-rings (15)and/or the cam.

4. Replace any worn or broken parts.

5. Reassemble the internal pieces. The push rod(30) must be inserted through the outlet end ofthe valve handle before the cam (21) isinstalled.

6. Lubricate the cam, and slide it into the valvehandle, making sure the notch is oriented asshown in Fig. 3. Ensure that the large end of thepushrod is resting in the notch of the cam.

7. Replace the screws (14) and washers (28), andtorque the screws to 15 to 25 in-lb (1.7 to2.8 N-m).

8. Replace the swivel (20), and torque to 15 to 20ft-lb (20 to 27 N-m).

Filter ReplacementSee Fig. 3.


WARNINGTo reduce the risk of serious injury, when you areinstructed to relieve pressure, always follow thePressure Relief Procedure on page 9.

2. Unscrew the hose fitting from the swivel (20).

3. Remove and replace the filter (10), which is insidethe valve handle (18). Make sure the filter isoriented as shown in Fig. 3.

4. Thread the hose fitting into the swivel (20), andtighten. Make sure the swivel (20) is torqued to15 to 20 ft-lb (20 to 27 N-m).

Fig. 3

14

14

15

20

21

24

18

2830

notch

15

28

10

NOTE: For torque specifications and lubrication instructions, see the service notes in the Parts Drawings on pages 12, 13 and 14. EM6 models do nothave trigger lock parts 11, 25, and 27.

��

2711

25

� ��

Parts — EM12 and V12 Dispense Valves

12

6

�

20

10

EM12 Models: 238636 to 238643 – with trigger lock(with electronic meter and extension)

V12 Models: 238644, 238645, 238651,and 238652 – with trigger lock(no meter, includes extension)

Bare Valves: 238646 and 238647 – with trigger lock(no meter, no extension)

Includes items 6, 10–25, and 27–30

14

14

15

1518

21

24

25

2829

30

726a

26b

8

8

35

36

�

�

�

Apply lubricant to threads when reassembling.

Apply lubricant to packings and sealing surfaces when reassembling.

Apply thread sealant when reassembling.

�

�

�

�

�

Torque to 15 to 20 ft-lb (20 to 27 N-m).

Torque to 15 to 25 in-lb (1.7 to 2.8 N-m).

06293C

27

11

28

16

Ref No. Part No. Description Qty6 111137 O–RING, valve/swivel

For Models 238636 to 238645,238651, and 238652 2For Models 238646 and 238647 1

7 112841 NUT, seal; 1/2–14 nptFor Models 238636, 238638, 238640, 238642, 238644, and238651 1

8 238400 NOZZLE, oilFor Models 238636 to 238645,238651, and 238652 1

10 185416 FILTER 111 113924 SPRING, compression 112 113493 SPRING, compression 114 110637 SCREW, machine 215 113574 SEAL, o-ring 216 113627 WASHER, plain 118 191074 HANDLE, valve 120 238398 SWIVEL; 3/4–14 npt

For Models 238636 to 238639and 238644 to 238646 1

238399 SWIVEL; 1/2–14 nptFor Models 238640 to 238643, 238647, 238651 and 238652 1

Ref No. Part No. Description Qty

21 191315 CAM 124 191320 TRIGGER 125 191321 TRIGGER LOCK 126a 191403 TUBE, 75� bend; 1/2 npt

For Models 238636, 238638, 238640, 238642, 238644, and238651 1

26b 238401 HOSE, flexible; 1/2 nptFor Models 238637, 238639,238641, 238643, 238645, and 238652 1

27 192106 GUIDE, spring 128 191552 WASHER, flat 229 191313 SEAT, valve 130 192501 ROD, push 135 158491 NIPPLE

For Models 238636 to 238643 136 244075 METER, electronic; English

For Models 238636, 238637,238640, and 238641 1

244076 METER, electronic; metricFor Models 238638, 238639,238642, and 238643 1

��

Parts — EM6 Dispense Valves

TI0408

EM6 Models: 243599 to 243604 – without trigger lock(with electronic meter and extension)

Bare Valve: 243992 bare valve – without trigger lock(no meter, no extension)

Includes items 6, 10–23, and 25–27

�

�

�



Apply thread sealant when reassembling.



18

6 �

10

1126

17

25

13 27

32

33

23

14 2014

25

13

30a

29b

28b

15

�

�

�

�

�

7 28a

28c

29c

29a

30b


6 111137 O–RING, valve/swivelFor Models 243599 to 243604, 2For Model 243992 1

7 112841 NUT, seal; 1/2–14 nptFor Models 243599 to 243604, 1

10 185416 FILTER 111 113493 SPRING, compression 113 110637 SCREW, machine 214 113574 SEAL, quad ring 215 113627 WASHER, plain 117 191074 HANDLE, valve 118 238399 SWIVEL; 1/2–14 npt 120 191315 CAM 123 191320 TRIGGER 128 203265 NOZZLE, rigid extension

For Models 243599, and 243602Includes items 28a–28c 1

28a 100081 . BUSHING; 1/2 npt(m) x 3/8 npt(f) 128b 159246 . TUBE, nozzle 128c 203655 . NOZZLE, non–drip 1

Ref No. Part No. Description Qty29 201701 NOZZLE, gear lube

For Models 243600 and 243603Includes items 29a–29c 1

29a 100206 . BUSHING; 1/2 npt(m) x 1/4 npt(f) 129b 187046 . TUBE, nozzle 129c 201540 . NOZZLE, non–drip30 203687 NOZZLE, flexible extension

For Models 243601 and 243604Includes items 30a–30b 1

30a 109160 . HOSE, coupled; 1 ft (0.3 m);1/2–14 npt(m) x 1/4–18 npt(f) 1

30b 203655 . NOZZLE, non–drip 125 191552 WASHER, flat 126 191313 SEAT, valve 127 192501 ROD, push 132 158491 NIPPLE

For Models 243599 to 243604 133 244075 METER, electronic; English

For Models 243599, 243600,and 243601 1

244076 METER, electronic; metricFor Models 243602, 243603,and 243604 1

� ��

Parts — V5 Dispense Valves

2

3

4

1

��

Model 238647 –– Bare ValveRef No. Part No. Description Qty1* 238647 VALVE 1

Model 222411, Series C –– For OilRef No. Part No. Description Qty1* 238647 VALVE 12 203265 NOZZLE, oil 1

See parts list on page 13.

Model 222412, Series C –– For Gear LubeRef No. Part No. Description Qty1* 238647 VALVE 13 201701 NOZZLE, gear lube 1

See parts list on page 13.

Model 222413, Series C –– For A.T.F.Ref No. Part No. Description Qty1* 238647 VALVE 14 203687 NOZZLE, A.T.F. 1

See parts list on page 13.* See parts below.

14

20

18

15

2829

10


6 111137 O-RING, valve/swivel 110 185416 FILTER 111 113924 SPRING, compression 112 113493 SPRING, compression 114 110637 SCREW, machine 215 113574 SEAL, o-ring 216 113627 WASHER, plain 118 191074 HANDLE, valve 120 238399 SWIVEL; 1/2–14 npt 121 191315 CAM 124 191320 TRIGGER 125 191321 TRIGGER LOCK 127 192106 GUIDE, spring 128 191552 WASHER, flat 229 191313 SEAT, valve 130 192501 ROD, push 1

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6

16

12

25

2711

Model 238647 –– Bare Valve, with trigger lock

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�





�

�

�

30

15 �

21

24

14 �

28

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Technical DataNOTE: See instruction manual 307965 for electronic meter Technical Data.

Recommended maximum flow rate*V5 dispense valves 5.0 gpm (18.9 lpm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EM6 dispense valves 6.0 gpm (23.0 lpm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V12 and EM12 dispense valves 12.0 gpm (45.4 lpm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum operating pressure 1500 psi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(10 MPa, 102 bar)Weight (without meter) 0.4 lb (0.18 kg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating temperature range –40� to 180� F (–40� to 82� C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inlet sizes 1/2 npt and 3/4 npt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See page 3 for model numbers and configurations.Outlet size 1/2 npt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wetted parts aluminum, stainless steel,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

carbon steel, acetal, nitrile rubber, Geolast�

* Under normal operating conditions

Teflon� is a registered trademark of the DuPont Company.

Geolast� is a trademark of Advanced Elastomer Systems.

� ��

Graco Standard WarrantyGraco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on thedate of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limitedwarranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipmentdetermined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accor-dance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused byfaulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub-stitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility ofGraco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.



Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no otherremedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or anyother incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of thedate of sale.



FOR GRACO CANADA CUSTOMERSThe parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedingsentered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais-sent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciairesexécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.

Graco Phone NumbersTO PLACE AN ORDER, contact your Graco distributor, or call one of the following numbers

to identify the distributor closest to you:1–800–533–9655 Toll Free

612–623–6928612–378–3590 Fax

All written and visual data contained in this document reflect the latest product information available at the time of publication.Graco reserves the right to make changes at any time without notice.


GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441www.graco.com

PRINTED IN USA 308642 February 1997, Revised September 2001

Automotive

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