Graco LD 24U984 Setup guide

Repair Instructions

LD Grease Pump

Repair Kits 3A1495C

Instructions for repairing the LD Grease Pump.

Maximum Fluid Pressure - 7500 psi (51.7 MPa, 517 bar)

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

Repair Kits:

24H854: Throat and Piston Seal Replacement Kit

24H856: O-Ring and Seal Replacement Kit

24U984: Air Piston Replacement Kit

Important Safety Instructions

Read all warnings and instructions in this manual and

in your LD Series Oil or Grease Pump manual. Save

all instructions.

Warnings

23A1495C

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-

tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When

these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and

warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

SKIN INJECTION HAZARD

High-pressure fluid from dispense valve, hose leaks, or ruptured components will pierce skin. This may

look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

treatment.

• Do not point dispense valve at anyone or at any part of the body.

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

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

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,

checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

PRESSURIZED ALUMINUM PARTS HAZARD

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

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

property damage.

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

fluids containing such solvents.

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

for compatibility.

PERSONAL PROTECTIVE EQUIPMENT

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

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

toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

Instructions

3A1495C 3

Instructions

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

pose of replaced parts according to all state and local

regulations for disposal of discarded components.

Inspect all parts when disassembling the pump. Replace

any and all worn and damaged parts.

Pressure Relief Procedure

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

2. Close the pump air regulator and disconnect the air

supply hose.

3. Open the dispensing valve and dispense fluid into a

waste bucket/container until pressure is fully

relieved.

If you suspect that the dispensing valve is clogged, or

that pressure has not been fully relieved after following

the steps above, very slowly loosen the dispensing

valve coupler or hose end coupling to relieve pressure

gradually, then loosen completely.

Disassembly

The following disassembly instructions describe the pro-

cedure for completely disassembling the LD grease

pump. Depending on the repair/maintenance procedure

you are performing on the pump, it may not be neces-

sary to entirely disassemble the pump or perform all

steps in this procedure.

The reference numbers used in the following instruc-

tions correspond to the reference numbers used in the

LD Series Oil and Grease Pump instruction manual.

1. Stop the pump. Follow Pressure Relief Procedure,

page 3.

2. Disconnect and remove the pump from its installed

location.

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

in Fig. 1.

NOTE: Take care to only use enough clamping

force to hold the pump in position. The pump cylin-

der is aluminum and could be damaged by using

excessive clamping force.

If you are only servicing the air valve (40) and seals

(18) or air piston (15), skip Steps 4 - 14.

The equipment stays pressurized until pressure is manually

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

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

procedure whenever you:

• are instructed to relieve pressure

• stop dispensing

• check, clean, or service any system equipment

• install or clean dispensing devices.

Fig. 1

Instructions

43A1495C

4. Secure a strap wrench around the shovel cylinder

(27). Use the strap wrench to turn the shovel cylin-

der counter-clockwise to loosen and remove it from

the pump assembly (Fig. 2).

NOTE: After a few turns, the shovel cylinder should

be loose enough to finish turning it with your hand to

remove this part.

5. Use an adjustable wrench to hold the priming rod

(34) securely. Use a second adjustable wrench to

loosen and remove the nut (19) and priming piston

(35) (Fig. 3, Fig. 4).

6. Use a wrench to loosen and remove the seal

retainer (29) (Fig. 4).

7. Tighten a strap wrench on the spacer cylinder (36)

and use it to prevent this part from moving. Secure a

strap wrench around the cylinder (26) and use it to

turn the cylinder to loosen and remove it from the

pump assembly. (Fig. 5). Remove the intake seal

(28).

Fig. 2

Fig. 3

19, 35

Fig. 4

Fig. 5

Instructions

3A1495C 5

8. If the gasket (30) is still inside the spacer cylinder

(36) use a pick to remove.

9. Secure a strap wrench around the spacer cylinder

(36) and use it to turn the cylinder counter clockwise

to loosen and remove it from the flange (22) (Fig. 6).

NOTE: After a few turns, the spacer cylinder should

be loose enough to finish loosening it with your

hand to remove this part.

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

flange (22).

11. Use a rubber hammer and small punch to drive out

pin (8), holding together the piston rod (23) and the

connection rod (32). Turn the piston rod (23)

counter clockwise to loosen and remove it from the

connection rod. Remove the piston seal (24) from

the piston rod (Fig. 8).

12. Remove the pump assembly from the vise and set it

down on a clean, hard work surface.

NOTE: When removing the pin (8) in Steps 12 - 14,

it is helpful to place a support such as a piece of

wood, below the rods.

13. Use a rubber hammer and small punch to drive out

pin (8), holding together the priming rod (34) and

piston rod (23). Turn the priming rod (34) counter

clockwise to loosen and remove it from the piston

rod (Fig. 7).

14. Use a rubber hammer and small punch to drive out

pin (8), holding together the connection rod (32) and

displacement rod (25). Turn the connection rod (32)

counter clockwise to loosen and remove it from the

displacement rod (Fig. 8).

If you are only replacing or repairing the pump lower

continue instructions beginning with Step 14, page

8 of the Reassembly instructions and the related

O-Ring and Seal Replacement Kit 24H856, page 12.

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

shown in Fig. 9.

NOTE: Take care to only use enough clamping

Fig. 6

PULL

830

Fig. 7

Fig. 8

Instructions

63A1495C

force to hold the pump in position. The pump cylin-

der is aluminum and could be damaged by using

excessive clamping force.

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

(43) from the air valve (40) and completely remove

air valve assembly from air cylinder (21). Also

remove the two cover gaskets 18). If you are replac-

ing these parts, discard gaskets. (Fig. 9).

Repair and replacement instructions for the Air

Valve are included in a separate repair manual

included with the kit:

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

24H850

• Air Valve Repair Kit - 24H798

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

• Pilot Valve Kit - 24H749

• Air Valve Seal Kit - 24H851

• Air Valve End Cap Kit - 24H852

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

(4) from the flange (22).

18. Using your hand, firmly grasp the flange (22) and

remove the entire assembly from inside the air cylin-

der (21).

NOTE: Sliding the flat blade of a screw driver between

the flange (22) and air cylinder (21) will help separate

the two parts. Be careful not to damage the o-ring (6)

(Fig. 10).

19. Pull the flange assembly off the displacement rod

(25). Set the displacement rod aside. You will not

need it until you reassemble the pump.

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

(3) from the bottom cover (14) (Fig. 11).

21. Separate the bottom cover (14) from the flange (22)

(Fig. 11).

NOTE: Insert the flat blade of a screwdriver

between the flange and bottom cover to help loosen

the seal between these two pieces and pull them

apart more easily.

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

the flange, bottom cover, and air piston continue

instructions with Step 1, page 7 of the Reassembly

instructions and the Throat and Piston Seal

Replacement Kit 24H854 instructions beginning on

page 11.

Fig. 9

Fig. 10

Fig. 11

Instructions

3A1495C 7

Pump Reassembly

NOTE: The following instructions describe the proce-

dure to follow to reassemble a completely disassembled

LD grease pump. Depending on the repair/maintenance

procedure you are performing on the pump, it may not

be entirely disassembled. See the specific section(s)

related to your repair/replacement kit.

For all reassembly procedures:

• Clean all the parts carefully in a compatible solvent,

and inspect for wear or damage. Use all the repair

kit parts during reassembly, and replace other parts

as necessary.

• Check the all polished surfaces for scratches or

wear.

• Lubricate all parts with a light, water-resistant

grease.

1. Install new o-rings and seals in bottom cover (14)

and flange (22) as described in the Throat and Pis-

ton Seal Replacement Kit 24H854, page 11. Be

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

all o-rings and seals.

2. Align pilot valve (20) installed in bottom cover with

opening (a) in flange (22) as shown in Fig. 12. Com-

press the bottom cover (14) and flange (22)

together.

3. Install 3 screws (3) (Fig. 13). Tighten with a 5 mm

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

N.m).

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

placement rod (50). Push the displacement rod

through the opening in the bottom cover and into the

flange assembly as shown in Fig. 14.

5. Install the air cylinder (21) over the bottom cover

(14). Place the top of the air cylinder down on a

clean hard surface. Use the palms of your hands to

press the bottom cover firmly into the air cylinder

(Fig. 15).

Fig. 12

20 a

Fig. 13

Fig. 14

Fig. 15

Instructions

83A1495C

6. Install the 5 screws (4) wrench tight only.

NOTE: If installing a new air cylinder (27), the mat-

ing holes are not threaded by design. Use thread

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

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

to ensure full thread formation.

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

valve and manifold, loosen all 5 screws (Fig. 16)

approximately 1/8 to 1/4 turn. These screws will be

torqued in Step 12, AFTER the air valve (40) is

installed.

8. Secure pump assembly in a vise as shown in Fig.

17.

9. Perform any air valve repairs / maintenance

needed. See separate instruction manual included

with the related air valve repair kit.

10. Be sure seals (18) are lightly greased and installed

on air valve (40). Install air valve on air cylinder (21).

NOTE: The air valve (40) can be installed in any

configuration. There is not just one correct way to

install these parts.

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

N.m).

12. Torque screws (4) installed in Step 6 to 60-70 in. lbs

(6.8 - 7.9 N.m).

Muffler (17) Installation (Fig. 17)

13. Depending on your installation, the air valve (40)

can be mounted with the muffler (17) on either side

of the air valve.

To change the installation location:

a. Remove the 4 screws (43).

b. Remove the air valve (40) from its current

mounted position on the air cylinder (21) and

rotate the air valve 180 degrees, which will

reposition the muffler to face the other side of

the pump.

NOTE: When installing the pin (8) in Steps 14 - 20, it is

helpful to place a support, such as a piece of wood,

below the rods.

14. Screw the connecting rod (32) and the displacement

rod (25) together, aligning the pin hole in both

pieces to allow the pin to be pushed through (Fig.

18).

15. Replace the pin (8). Use a rubber hammer to tap the

pin into place, being careful to make sure the sides

of the pin are flush with the outside surface of the

connecting rod (Fig. 18).

16. Install piston seal (24) over the end of the piston rod

(23). Note the correct orientation of the piston seal

on the piston rod as shown in Fig. 19.

Fig. 16

Fig. 17

Fig. 18

Instructions

3A1495C 9

17. Screw the piston rod (23) and the connecting rod

(32) together aligning the pin hole in both pieces to

allow the pin to be pushed through (Fig. 19).

18. Replace the pin (8). Use a rubber hammer to tap the

pin into place, being careful to make sure the sides

of the pin are flush with the outside surface of the

connecting rod (Fig. 19).

19. Screw the piston rod (23) and priming rod (34)

together aligning the pin hole in both pieces to allow

the pin to be pushed through (Fig. 20).

20. Replace the pin (8). Use a rubber hammer to tap the

pin into place, being careful to make sure the sides

of the pin are flush with the outside surface of the

piston rod (Fig. 20)

21. Check to make sure there is end play at all pinned

connections.

NOTE: When there is end play at the pinned connec-

tion, you should be able to slightly move from

side-to-side, the displacement rod (25) pinned to the

connecting rod (32) and the connecting rod (32) pinned

to the piston rod (23) and piston rod (23) pinned to the

priming rod (34).

22. If these connections seem too rigid remove the pin

and adjust hole alignment by 1/2 turn in the direction

that aligns the through holes as close as possible,

axis-to-axis (Fig. 21).

23. Install spacer cylinder (36) over rod assembly. Use

a strap wrench to tighten spacer cylinder securely.

24. Install cylinder (26) and seal (30). Torque to 45 - 55

ft. lbs (61 - 75 N.m).

25. Install the intake seal (28) over the end of the prim-

ing rod (34). Note the correct orientation of the

Fig. 19

Fig. 20

NOTICE

Improper alignment will take the self-aligning feature

out of the design which could result in damage to the

pump.

Fig. 21

Correct Alignment

Permits end play

Fig 3 - Correct

Fig 1 - 1/2 Turn Too Shallow

Incorrect Alignment

Fig 2 - 1/2 Turn Too Deep

Does not permit

end play

ti10469a

ti10468a

Does not permit

end play

ti10479a

Instructions

10 3A1495C

intake seal on the priming rod as shown in Fig. 20.

26. Install seal retainer (29) over priming rod (34) (Fig.

22).

27. Use an adjustable wrench to tighten seal retainer

securely, then torque to 45 - 55 ft lbs (61 - 75 N.m).

28. Install the priming piston (35 and nut (19) (Fig. 3,

Fig. 4) on priming rod (34) Use an adjustable

wrench to hold the priming rod (34) securely. Use a

second adjustable wrench to tighten nut. Then

torque nut to 70 - 80 in. lbs (7.9 - 9.0 N.m) (Fig. 22

and Fig. 23).

29. Install shovel cylinder (27) over priming rod (34)

(Fig. 24). Use a strap wrench to tighten shovel cylin-

der securely then torque to 45 - 55 ft. lbs (61 - 75

N.m).

Repair Kits

All Repairs:

• Unless otherwise stated, entirely disassemble pump

as described in the pump disassembly instruction

section of this manual.

• Properly discard all replaced parts according to

local and state regulations for disposal of discarded

components.

• Always use all new parts included in the kit to

replace the identical part on the pump.

• Grease all parts prior to reassembly with a thin coat

of lightweight grease.

• Reassemble pump as described in the reassembly

instruction section of this manual.

Fig. 22

Fig. 23

19, 35

Fig. 24

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