Graco Inc 800-901, 800-900, 308-535 Pump Service, Servicing the Plungers, Valves, Pumping Section

PUMP SERVICE

		WARNING					Servicing the Plungers
	To reduce the risk of		serious bodily			injury,	NOTE		Plunger repair kit, P/N 801-474is available to
	including fluid injection,		splashingin the			eyes or			replace retainers, O-rings, washers and
	on the skin, or injury from moving parts, always								backup ringsfor three cylinders.
	follow the Pressure Relief Procedure Warnlng
	before	proceeding.					. Loosen the plunger retaining screw fiveto six tums,
								using anMI0wrench. Push the plunger towardsthe
NOTE:		The following metric		wrenches are needed:				crankcase to separate the plunger and retaining
					1
		M10, Mi3 and M30. Repairkits are available.						screw.
		Referto the individual repair sections and the					2. Remove the screw from the plungerand examine
		pump parts page formore detailsFor. thebest
								the O-ring, backup ringand copper bearindgasket
		results, useall parts in the kits.
								washer. Replace these parts,ifnecessary, usingkit
NOTE There are two different tool kits to aid in								801-474.
		servicing the pump. P/N 800-298is used to					3.	Remove the plungerand flinger from the plunger
		ease installation of packings. P/N 800-271						shafl. Clean, examine and replace parts as
		includes the itemsin800-298 andtoolsto aid						necessary.
		in the removal of packing retainers.					4. Inspect the plunger shaft foroil leakage from the
Valves
								crankcase. if leaking is obvious, replace the oil
NOTE:		For aset of six valves, orderP/N 801-472.						seals. Otherwise,DO NOT remove these seals as.
								they cannotbe reused. An oil seal kit is available to
1. Remove the hexplug from the manifold using an								replace		the seals.
	M30wench.						5.	Lightly		grease the flinger andoil seal, ifit is being
2. Examine the O-ring under the hexplugand replace								replaced and replace themon the plunger snafl.
								Then installthe plunger.
	it if it is cut or distorted.
3. Remove the valve assembly from the cavity; the							6. Lightly grease the retaining screw and the outer end
								of the plungerPlace. thewasher, O-ring and backup
	assembly may come apart.
								ringaround the screw and instailthe screw through
4.	Install the new valveinstail.the O-ringand hex plug;							the plunger. Torqueto 14.4 fl-lb (19.5 Nrn).
	torque to 75 fl-lb(103 Nm).						NOTE:		if	you pianto replace the packings, referto
NOTE Retorque theplug afler 5 hours of operation.									Servicing the V-Packings.
Pumping Section							7. Lubricate the outside of each plunger. Slide the
								manifold onto the crankcase, being careful notto
1. Remove the eight capscrews and lockwashers from								damage the seals.
	the manifold usingan Mi3 wrench.						8. Install the capscrews and washers finger-tight.
	Carefully separate the manifold from the crankcase.
2.								Torque the screwsto21.7 fl-lb (29Nm) followingthe
NOTE:		it maybenecessaryto tap the manifoldlightly						tightening pattern (Figure 4). Uneven tightening
								may cause the manifoldto bindor jam.
		with asofl mallet to loosen.

CAUTION

Keep the manifold properly aligned with the ceramic plungers when removing to avoid damage to the plunger or seals.

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

I1

3 2 6 I

Figure 4

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