Graco Modu-Flo AL-5M User manual

332042D

Instructions

Modu-Flo® Pumps

For dispensing a specific volume of lubricant. For use with Graco Modu-Flo manifold

packages. For professional use only.

Part No.:

Pneumatic - 563304, 563306, 563308, 563347, 563348, 563351, 563353, 563354

Hydraulic - 563305, 563307, 563345

See page 2 for model information, including maximum working pressure.

Important Safety Instructions

Read all warnings and instructions in this

manual before using the equipment. Save all

instructions.

ti20035

ti20044

Hydraulic Pump Pneumatic Pump

Models

2 332042D

Models

*Refers to motor action, not lube piston action: all lube

pistons are single-acting

**Do not exceed 10 cpm with grease (3 seconds on, 3

seconds off)

***Pneumatic or hydraulic cylinder displacement volume

at maximum output setting

General Information

• AL or models may be single or double acting.

• ALJ and HLJ refer to double acting motors.

- Double acting air motors require 4-way air

valve.

- All hydraulic models are double acting.

• All models have single acting lube piston.

• All models are designed to mount directly to either

a pump-to-reservoir manifold or a pump-to-wall

manifold.

- See manual 313830 for information on

manifolds.

Part No. Model Actuation Pump

Ratio

Air or

Hydraulic

Motor

Action*

Output

Displacement

Range cu.in. (cm³)

per stroke

Max.

Cycles

per

Minute**

Approx.

Weight,

lb (kg)

Input

Operating

Volume

per Full

stroke/cycle

cu.in. (cm³)***

Input Air/

Hydraulic

Pressure

PSI (bar)

Max.

Fluid

Output

Pressure

PSI (bar)

Min. Max.

563304 AL-5M Pneumatic 30:1 Single 0.010 to 0.030

(0.164 to 0.492)

30 3.75

(1.7)

1.06 (17.4) 40 (2.76) 150

(10.3)

3000

(206.8)

Double 60 2.09 (34.3)

563306 AL-25M Pneumatic 30:1 Single 0.030 to 0.120

(0.492 to 1.966)

30 4.75

(2.15)

4.20 (68.8) 40 (2.76) 150

(10.3)

3000

(206.8)

Double 60 8.28 (135.7)

563308 AL-50M Pneumatic 30:1 Single 0.060 to 0.240

(0.983 to 3.933)

30 6.5

(2.9)

8.40 (137.6) 40 (2.76) 150

(10.3)

3000

(206.8)

Double 60 16.56 (271.4)

563305 HLJ-5M Hydraulic 5.5:1 Double 0.010 to 0.030

(0.164 to 0.492) 100 3.375

(1.53) 0.35 (5.7) 200

(13.8)

2000

(138)

3000

(206.8)

563307 HLJ-25M Hydraulic 5.5:1 Double 0.030 to 0.120

(0.492 to 1.966) 50 5.5

(2.49) 1.38 (22.6) 200

(13.8)

2000

(138)

3000

(206.8)

563345 HLJ-5X Hydraulic 2.2:1 Double 0.030 to 0.092

(0.492 to 1.51) 50 3.375

(1.53) 0.28 (4.7) 200

(13.8)

3000

(207)

3000

(206.8)

563351 ALJ-5M Pneumatic 30:1 Double 0.010 to 0.030

(0.164 to 0.492) 60 3.75

(1.7) 2.09 (34.4) 40 (2.76) 150

(10.3)

3000

(206.8)

563348 ALJ-25M Pneumatic 30:1 Double 0.030 to 0.120

(0.492 to 1.966) 60 4.75

(2.15) 4.2 (68.8) 40 (2.76) 150

(10.3)

3000

(206.8)

563347 ALJ-50M Pneumatic 30:1 Double 0.060 to 0.240

(0.983 to 3.933) 60 6.5

(2.9) 16.56 (271.4) 40 (2.76) 150

(10.3)

3000

(206.8)

563353

AL-5M

Fixed

Output

Pneumatic 30:1

Single Fixed at 0.030

(0.492)

30 3.75

(1.7)

1.06 (17.4)

40 (2.76) 150

(10.3)

3000

(206.8)

Double 60 2.09 (34.3)

563354

AL-25M

Fixed

Output

Pneumatic 30:1

Single Fixed at 0.120

(0.492)

30 4.75

(2.15)

4.2 (68.8)

40 (2.76) 150

(10.3)

3000

(206.8)

Double 60 8.28 (135.7)

Warnings

332042D 3

Warnings

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

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

When these symbols appear in the body of this manual or on warning labels, 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 dispensing device, 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 surgi-

cal treatment.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

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

• Follow the Pressure Relief Procedure when you stop dispensing 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.

Warnings

4 332042D

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Notes in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Notes in all equip-

ment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about

your material, request Safety Data Sheets (SDSs) from distributor or retailer.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine

manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and

create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, includ-

ing eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is

not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufac-

turer.

WARNING

Installation

332042D 5

Installation

Component Identification

Key:

A Single Acting (S.A.) Port

B Double Acting (D.A.) Port

C Mounting Holes

D Lube Inlet Port

E Lube Outlet Port

F Adjustment Cover

G Bleed Screw

FIG. 1

EGti20035

Installation

6 332042D

Installation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever

you see this symbol.

1. Disable the pump’s pneumatic or hydraulic supply.

2. Slowly loosen output connection fitting.

Bleeding Air

After assembly, disassembly and reassembly, it may be

necessary to bleed air from the pump. Follow the

procedure below:

1. After reinstalling the pump, cycle the pump a few

times. This should bleed out the air.

2. If cycling the pump does not bleed out the air,

loosen the bleed screw (29). Cycle the pump a few

times.

NOTE: Do not remove the ball (28) or bleed screw (29).

3. Re-tighten the bleed screw (29).

4. Operate the pump as usual.

Output Adjustment Procedure

Reference numbers used in the following procedure

refer to the Parts table, page 8.

1. Follow the Pressure Relief Procedure, page 6.

2. Remove adjustment screw cap (12) and gasket (8)

from adjustment screw (11), holding jam nut (9) with

a wrench if necessary (FIG. 2).

3. Place the adjustment screw cap (12) against the

jam nut (9) and use the stamped numbers on the

cap (cu. in. per stroke) to determine how much

adjustment is needed.

4. Loosen jam nut (9) and use a flat screwdriver to turn

adjustment screw (11). Turn adjustment screw in for

less output and turn out for more output (FIG. 3).

5. Tighten jam nut (9) and install gasket (8) and adjust-

ment screw cap (12) over the adjustment screw

(11).

This equipment stays pressurized until pressure is

manually relieved. To help prevent serious injury from

pressurized fluid, such as skin injection, splashing

fluid and moving parts, follow the Pressure Relief

Procedure when you stop dispensing and before

cleaning, checking, or servicing the equipment.

FIG. 2

FIG. 3 AL-5 model shown

ti20036

ti20037

Troubleshooting

332042D 7

Troubleshooting

1. Follow Pressure Relief Procedure, page 6, before

checking or repairing gun.

Reference numbers used in the following procedure

refer to the Parts table, pages 8, 10, or 11.

Problem Cause Solution

Inconsistent Pump Output Air and/or lubricant leak between

the pump and the manifold

1. Check four socket head screws

(7) to make sure they are tight.

Torque to 60 to 70 in.lbs. (6.77 to

7.90 N•m).

Loose screws could allow air

and/or lubricant to leak between

the pump and the manifold.

1. Check for leakage past gasket

(8). Replace gasket if required.

Jam nut is loose Check jam nut (9) to make sure it is

tight against adjustment screw body

(10).

If the jam nut is loose, the

adjustment screw (11) could rotate

and cause the pump output to

change. This condition could also

result in either lubricant leakage or

air infiltrating the lubricant.

Irregular Lubricant Flow Air trapped in pump/system 1. Cycle the pump a few times.

This should bleed out the air.

2. If cycling the pump does not

bleed out the air, loosen the

bleed screw (29). Cycle the

pump a few times.

NOTE: Do not remove the ball (28) or

bleed screw (29).

3. Re-tighten the bleed screw (29).

Parts

8 332042D

Parts

Pneumatic Pump

Part No./Description

20 26

Ref. Part Description Qty.

563304 PUMP ASSEMBLY, AL-5M

563306 PUMP ASSEMBLY, AL-25M

563308 PUMP ASSEMBLY, AL-50M

1❄BODY, pump 1

2✿★◆ SPRING, check valve 1

3✿★◆ SEAT, check valve 1

4✿★◆ O-RING 1

5✿★◆ PIN, 1/8” dia x 1/4 lg 1

6 557617 SCREW, check valve enclosure 1

7 103345 SCREW, socket-head, 1/4-20 x

1-1/4

8✿★◆ GASKET 1

9✿NUT, jam, hexagon, 5/16-24 1

★NUT, jam, hexagon, 7/16-20 1

◆NUT, jam, hexagon, 1/2-20 1

10 560741 BODY, adjustment screw, AL-5M 1

15R127 BODY, adjustment screw, AL-25M 1

557592 BODY, adjustment screw, AL-50M 1

11 557589 SCREW, adjustment, AL-5M 1

15R126 SCREW, adjustment, AL-25M 1

560740 SCREW, adjustment, AL-50M 1

12 560737 CAP, adjustment screw, AL-5M 1

560738 CAP, adjustment screw, AL-25M 1

560739 CAP, adjustment screw, AL-50M 1

13 15M726 RETAINER, air cylinder 1

14 ✿★◆ SPRING, piston return 1

15 557563 PISTON, air, AL-5M 1

557567 PISTON, air, AL-25M 1

557570 PISTON, air, AL-50M 1

16 557562 CAP, cylinder, AL-5M 1

557566 CAP, cylinder, AL-25M 1

557569 CAP, cylinder, AL-50M 1

17 560728 RETAINER, spring, AL-5M 1

560727 RETAINER, spring, AL-25M 1

560721 RETAINER, spring, AL-50M 1

18❄PISTON, lube 1

Ref. Part Description Qty.

Parts

332042D 9

✿ Parts included in Kit 563902 (purchase separately)

★ Parts included in Kit 563903 (purchase separately)

◆ Parts included in Kit 563904 (purchase separately)

❄ Not available as replacement part

19 560708 CYLINDER, air, AL-5M 1

557565 CYLINDER, air, AL-25M 1

560723 CYLINDER, air, AL-50M 1

20❄LABEL, name serial 1

21 ✿★◆ O-RING 1

22 ✿★◆ O-RING 1

23 ✿★◆ O-RING 1

24 ✿★◆ O-RING 5

25 ✿★◆ O-RING 1

26 ✿★◆ O-RING 1

27 ✿★◆ O-RING 1

28 ✿★◆ BALL, sst 1/8” dia 2

29 ✿★◆ SCREW, bleed, 10-32” x 1/4” 1

30 ✿★◆ RING, retainer 1

31 ✿★◆ RING, retainer 1

33 ✿★◆ BALL, check, chrome stl, 3/16”

dia

34 ✿SEAL, washer, 5/16-24 thd 2

★SEAL, washer, 7/16-20 thd 2

◆SEAL, washer, 1/2-20 thd 2

35 ✿★◆ RING, retainer 1

✿563902 REPAIR KIT, AL-5M, includes 2 -

5, 8, 9, 14, 21 - 31, 33 - 35

★563903 REPAIR KIT, AL-25M, includes 2 -

5, 8, 9, 14, 21 - 31, 33 - 35

◆563904 REPAIR KIT, AL-50M, includes 2 -

5, 8, 9, 14, 21 - 31, 33 - 35

Ref. Part Description Qty.

Parts

10 332042D

Hydraulic Pump (HLJ-5M and HLJ-5X)

Part No./Description

❖Parts included in Kit 563905 (purchase separately).

✿Parts included in Kit 563925 (purchase separately).

❄ Not available as replacement parts

26 27

18 17

HL-5 model

HL-5X model

28 29

ti20046

Ref. Part Description Qty.

563305 PUMP ASSEMBLY, HLJ-5M

563345 PUMP ASSEMBLY, HLJ-5X

1❄LABEL, name serial 1

2❖✿ SPRING, check valve modu-flo 1

3❄BODY, pump 1

4 560711 PLUG, end 1

5❄PISTON, hydraulic 1

6❖✿ SEAT, check valve 1

7 103345 SCREW, cap sch 4

8❖✿ GASKET, copper 1

9 556379 NUT, 5/16-24 heavy hex hd 1

10 560741 BODY, adjustment 1

11 557589 SCREW, adjustment 1

12 560737 CAP, adjustment screw, HLJ-5M 1

560756 CAP, adjustment screw, HLJ-5X 1

13 ❖✿ SCREW, check valve enclosure 1

14 ✿O-RING 1

15 ❖O-RING 1

16 ❖✿ O-RING 1

17 ❖✿ O-RING 3

18 ❖✿ O-RING 1

19 ❖O-RING 1

20 ❖✿ O-RING 1

21 ❖✿ O-RING 1

22 ❖✿ SEAL, washer, 5/16-24 2

23 ❖✿ BALL, check, chrome stl 3/16” dia 1

24 ❖PIN, 1/8” dia grv type 1

25 ✿O-RING 1

26 ✿RING, back up 2

27 ✿RING, back up 2

28 ❖✿ BALL, sst 1/8” dia 1

29 ❖✿ SCREW, bleed, 10-32” x 1/4” 1

30 PISTON, lube 1

Ref. Part Description Qty.

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