Graco Inc 800-345, 308-522, 4040 Pump Service, Servicing the Plungers, Valves, Pumping Section

PUMP SERVICE

						Servicing the Plungers
	To	reducetherisk	Of serious	bodily injury,		NOTE Plunger repairkit, P/N 803-510 is availableto
	includingfluid injection, splashinginthe eyes or					replace retainers,O-rings,washersand
	on the skin, orinjury from moving				parts, always	backup rings for threecylinders.
	follow the PressureRelief ProcedureWarning
	beforeproceeding.WARN'NG
II1I 1. Loosentheplungerretainingscrew five to sixtums,
						usingan M10 wrench. Push theplunger towards the
NOTE:		The following metricwrenchesareneeded:				crankcase to separatetheplunger and retaining
								. .	-
		M10,M13 a n i M30ReDair.		kits are available.		screw.
		Refer to the individual repair sectionsand the				2.Removethescrewfromtheplunger			and examine
		pump partspagefor moredetails. Forthe best
						the O-ring,backup ringand copper bearindgasket
		results, useall parts in the kits.
						washer. Replacethese parts,ifnecessary,usingkit
NOTE Thereare two different tool kits to aidin						803-510.
		servicing the pump. P/N 800-298 is used to				3.Removethe	plunger and flinger from theplunger
		easeinstallation of packings.P/N 800-271				shaftClean,examineand.		replace partsas
		includesthe itemsin800-298 andtools to aid				necessary.
		in the removalof packing retainers.				4. Inspecttheplunger shaftfor oil leakage fromthe
Valves						crankcase.Ifleaking		is obvious,replacethe oil
NOTE		For a set of six valves, order P/N 801 -472.				seals. Otherwise,DO NOT remove these seals as
						they cannotbe reused.An oil seal kit is availableto
1.	Remove the hex .plug- from the manifold using an					replace the seals.
	M30 wrench.					5. Lightly grease the oil seal, if it is being replaced,
2.	Examine the O-ring under the hexplug and replace					and the flinger and replace them on the plunger
						shaft. Theninstallthe plunger.
	it if	itis cut or distorted.
3.	Remove the valve assembly from the cavity; the					6. Lightly grease the retaining screwandthe outer end
						of the plunger. Place the washer, Oand-ringbackup
	assembly maycome apart.
						ring around the screwand installthe			screw through
4. lnslallthe newvalve. Installthe O-ring and hexplug;						the plunger. Torqueto 14.4 ft-lb(19.5 Nm).
									-
	torque to 75 ft-lb (103 Nm).
						NOTE: If vou plan to replacethePackinas. refer to
NOTE Retorque theplug after 5 hours of operation.						Sitvicing the V-backings. '
Pumping Section						7. Lubricatetheoutside of each plunger. Slide the
						manifold onto the crankcase, being careful not to
1. Remove the eight capscrews and lockwashers from
						damage the seals.
	the manifold using an M13 wrench.					8. Installthecapscrews		and washersfinger-tight.
2.	Carefully separatethemanifoldfrom the crankcase.
						Torque the	screwsto 21.7 ft-lb ( 2 9 Nm) followingthe
NOTE:		Itmay be necessaryto tap themanifoldlightly				tighteningpattem (Figure4).Uneven			tightening
						may cause the manifoldto bind or jam.
		with a soft mallei to loosen.
	Keep the manifold properly aligned withthe					I			I
	ceramicplungers		whenremoving		to avoid
	damage to the plungeror seals.

3.Carefully examine each plunger for any scoring or cracking and replaceas necessary.

Figure 4

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