Graco Heat Pump 222839 Series A User Manual

Instructions–Parts List

STAINLESS STEEL

Check–Mate 200 Pumpst

WITH PRIMING PISTON, AND

SEVERE-DUTY ROD AND CYLINDER

308200D

Model 222839, Series A

23:1 Ratio Monarkr Pump

180 psi (1.2 MPa, 12 bar) Maximum Air Input Pressure

4140 psi (29 MPa, 285 bar) Maximum Fluid Working Pressure

Model 222907, Series A

46:1 Ratio Presidentr Pump

100 psi (0.7 MPa, 7 bar) Maximum Air Input Pressure

4600 psi (32 MPa, 317 bar) Maximum Fluid Working Pressure

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

Table of Contents

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Model 222907 Shown

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Service

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Disconnecting the Displacement Pump . . . . . . . . 12

Reconnecting the Displacement Pump . . . . . . . . 13

Displacement Pump Service . . . . . . . . . . . . . . . . . 14

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Graco Phone Numbers . . . . . . . . . . . . . . . . . . . . . . . . . 30

01057

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WARNING

SKIN INJECTION HAZARD

Spray from the spray gun/dispense valve, hose leaks or ruptured components can inject fluid into your

body and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes

or on the skin can also cause serious injury.

D Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate

surgical treatment.

D Do not point the gun/valve at anyone or at any part of the body.

D Do not put your hand or fingers over the spray tip/nozzle.

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

D Do not “blow back” fluid; this is not an air spray system.

D Always have the tip guard and the trigger guard on the spray gun when spraying.

D Check the gun diffuser operation weekly. Refer to the gun manual.

D Be sure the gun/valve trigger safety operates before spraying/dispensing.

D Lock the gun/valve trigger safety when you stop spraying/dispensing.

D Follow the Pressure Relief Procedure on page 8 whenever you: are instructed to relieve pres-

sure; stop spraying/dispensing; clean, check, or service the equipment; and install or clean the

spray tip/nozzle.

D Tighten all fluid connections before operating the equipment.

D Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.

Permanently coupled hoses cannot be repaired; replace the entire hose.

D Use only Graco approved hoses. Do not remove any spring guard that is used to help protect the

hose from rupture caused by kinks or bends near the couplings.

MOVING PARTS HAZARD

Moving parts, such as the priming piston, can pinch or amputate your fingers.

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

D Keep hands and fingers away from the priming piston during operation and whenever the pump is

charged with air.

D Before servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the

equipment from starting unexpectedly.

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WARNING

FIRE AND EXPLOSION HAZARD

Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and

result in a fire or explosion and serious injury.

D Ground the equipment and the object being sprayed. Refer to Grounding on page 6.

D If there is any static sparking or you feel an electric shock while using this equipment, stop spray-

ing/dispensing immediately. Do not use the equipment until you identify and correct the problem.

D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid

being sprayed/dispensed.

D Keep the spray/dispense area free of debris, including solvent, rags, and gasoline.

D Electrically disconnect all equipment in the spray/dispense area.

D Extinguish all open flames or pilot lights in the spray/dispense area.

D Do not smoke in the spray/dispense area.

D Do not turn on or off any light switch in the spray/dispense area while operating or if fumes are

present.

D Do not operate a gasoline engine in the spray/dispense area.

TOXIC FLUID HAZARD

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,

inhaled, or swallowed.

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

D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,

state and national guidelines.

D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and

solvent manufacturer.

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Installation

The Typical Installation on page 7 shows the pump

General Information

(A) mounted on a pneumatic elevator cart (B). The

pump may also be mounted on a 19 liter (5 gal.) pail

ram. In either case, it is used with a wiper plate (C).

Refer to the separate manuals for the cart, ram, and

wiper plate for further information.

NOTE: Reference numbers and letters in parentheses

in the text refer to the callouts in the figures and the

parts drawings.

NOTE: If you supply your own accessories, be sure

they are adequately sized and pressure–rated to meet

the system’s requirements.

Kits 223881 and 224829 are available to mount the

pump on a 200 liter (55 gallon) ram. Refer to the

separate manuals included with the kits for further

information.

Fig. 2 is only a guide for selecting and installing sys-

tem components and accessories. Contact your Graco

distributor for assistance in designing a system to suit

your particular needs.

Air Line Accessories

Install the following accessories as shown in Fig. 2,

using adapters as necessary:

System Accessories

D A pump runaway valve (G) senses when the

pump is running too fast and automatically shuts off

the air to the motor. A pump which runs too fast can

be seriously damaged. Install closest to the pump

air inlet.

WARNING

Two accessories are required in your system: a

bleed–type master air valve (J) and a fluid drain

valve (N). These accessories help reduce the risk

of serious bodily injury including fluid injection,

splashing in the eyes or on the skin, and injury from

moving parts if you are adjusting or repairing the

pump.

D An air line lubricator (H) provides automatic air

motor lubrication.

D A bleed-type master air valve (J) is required in

your system to relieve air trapped between it and

the air motor when the valve is closed (see the

WARNING at left). Be sure the bleed valve is easily

accessible from the pump, and is located down-

stream from the air regulator.

The bleed–type master air valve relieves air

trapped between this valve and the pump after the

air is shut off. Trapped air can cause the pump to

cycle unexpectedly. Locate the valve close to the

pump.

D An air regulator (K) controls pump speed and

outlet pressure by adjusting the air pressure to the

pump. Locate the regulator close to the pump, but

upstream from the bleed-type master air valve.

The fluid drain valve assists in relieving fluid pres-

sure in the displacement pump, hose, and gun.

Triggering the gun to relieve pressure may not be

sufficient.

D An air line filter (L) removes harmful dirt and

moisture from the compressed air supply.

Air and Fluid Hoses

Be sure all air and fluid hoses are properly sized and

pressure-rated for your system. Use only grounded air

and fluid hoses. Fluid hoses must have a braided

stainless steel cover (or have spring guards on both

ends).

D A second bleed-type air valve (M) isolates the air

line accessories for servicing. Locate upstream

from all other air line accessories.

D An air line quick disconnect coupler (F) is

required for pumps mounted on the pneumatic

elevator cart. The female coupler attaches to the

end of the air hose (D), and the male coupler

screws into the air manifold (E). See the separate

cart manual for further information.

Mounting Accessories

Mount the pump (A) to suit the type of installation

planned. The pump dimensions and mounting hole

layouts are shown on pages 28 and 29.

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Installation

Fluid Line Accessories

Install the following accessories in the positions shown

in Fig. 2, using adapters as necessary:

D A fluid drain valve (N) is required in your system

to relieve fluid pressure in the hose and gun (see

the WARNING at left). Screw the drain valve into

the open branch of a tee mounted in the fluid line.

Install the drain valve pointing down, but so the

handle points up when opened.

0864

Fig. 1

D A fluid regulator (P) controls fluid pressure to the

gun/valve, and dampens pressure surges.

D A gun or valve (S) dispenses the fluid. The gun

shown in the Typical Installation is a dispensing gun

for highly viscous fluids.

2. Air and fluid hoses: use only electrically conductive

hoses.

3. Air compressor: follow manufacturer’s recommen-

D A gun swivel (T) allows freer gun movement.

dations.

4. Spray gun/dispense valve: ground through connec-

Grounding

tion to a properly grounded fluid hose and pump.

5. Fluid supply container: follow your local code.

6. Object being sprayed: follow your local code.

WARNING

FIRE AND EXPLOSION HAZARD

Before operating the pump, ground the

system as explained below. Also read

the section FIRE AND EXPLOSION

HAZARD on page 4.

7. All solvent pails used when flushing: follow your

local code. Use only metal pails, which are con-

ductive, placed on a grounded surface. Do not

place the pail on a nonconductive surface, such as

paper or cardboard, which interrupts the grounding

continuity.

1. Pump: use a ground wire and clamp. See Fig. 1.

Loosen the grounding lug locknut (W) and washer

(X). Insert one end of a 1.5 mm@ (12 ga) minimum

ground wire (Y) into the slot in lug (Z) and tighten

the locknut securely. Connect the other end of the

wire to a true earth ground. Order Part No. 237569

Ground Wire and Clamp.

8. To maintain grounding continuity when flushing or

relieving pressure, always hold a metal part of the

gun/valve firmly to the side of a grounded metal

pail, then trigger the gun/valve.

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Installation

KEY

Pump

Pneumatic Elevator Cart

Wiper Plate

MAIN AIR LINE

Air Hose

Air Manifold

Air Line Quick Disconnect Coupler

Pump Runaway Valve

Air Line Lubricator

Bleed-Type Master Air Valve (required, for pump)

Air Regulator

Air Line Filter

Bleed-Type Master Air Valve (for accessories)

Fluid Drain Valve (required)

Fluid Pressure Regulator

Fluid Hose

Gun or Dispensing Valve

Gun/Valve Swivel

Ground Wire (required)

19 LITER (5 GAL.) PAIL

01058

Fig. 2

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Operation

Pressure Relief Procedure

Packing Nut/Wet-Cup

Before starting, fill the packing nut (2) 1/3 full with

Graco Throat Seal Liquid (TSL) or compatible solvent.

See Fig. 3. Adjust the packing nut weekly so it is just

snug; do not overtighten.

WARNING

SKIN INJECTION HAZARD

The system pressure must be manually

relieved to prevent the system from

starting or dispensing accidentally. Fluid

under high pressure can be injected through the

skin and cause serious injury. To reduce the risk of

an injury from injection, splashing fluid, or moving

parts, follow the Pressure Relief Procedure

whenever you:

WARNING

To reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure at left.

D are instructed to relieve the pressure,

D stop spraying/dispensing,

D check or service any of the system equipment,

D or install or clean the spray tip/nozzle.

1. Lock the gun/valve trigger safety.

Air Motor Plate

2. Close the pump’s bleed-type air valve (required in

your system).

3. Shut off the master air bleed valve (required in

your system).

4. Unlock the gun/valve trigger safety.

5. Hold a metal part of the gun/valve firmly to the side

of a grounded metal pail, and trigger the gun/valve

to relieve pressure.

6. Lock the gun/valve trigger safety.

7. Open the drain valve (required in your system),

having a container ready to catch the drainage.

8. Leave the drain valve open until you are ready to

spray/dispense again.

If you suspect that the spray tip/nozzle or hose is

completely clogged, or that pressure has not been fully

relieved after following the steps above, very slowly

loosen the tip guard retaining nut or hose end coupling

and relieve pressure gradually, then loosen completely.

Now clear the tip/nozzle or hose.

01057

Fig. 3

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Operation

NOTE: When changing fluid containers with the hose

Flush the Pump Before First Use

and gun already primed, be sure to open the bleeder

valve (33), to assist in priming the pump and venting

air before it enters the hose. Close the valve when all

air has been eliminated.

The pump is tested with lightweight oil, which is left in

to protect the pump parts. If the fluid you are using

may be contaminated by the oil, flush it out with a

compatible solvent. See Flushing on page 10.

Starting and Adjusting the Pump

WARNING

SKIN INJECTION HAZARD

WARNING

MOVING PARTS HAZARD

See Fig. 3. The priming piston (23) and

the air motor piston (located behind the

air motor plates) move during operation.

To reduce the risk of fluid injection, do not use

your hand or fingers to cover the bleed hole on the

underside of the bleeder valve body when priming

the pump. Use a crescent wrench to open and

close the bleeder plug. Keep your hands away from

the bleed hole.

Keep hands and fingers away from the priming

piston (23) during operation and whenever the

pump is charged with air. The priming piston ex-

tends beyond the intake cylinder (20) to pull materi-

al into the pump and can amputate a hand or finger

caught between it and the intake cylinder. Follow

the Pressure Relief Procedure on page 8,

before checking, clearing, or cleaning the priming

piston to prevent the pump from starting acciden-

tally.

With the pump and lines primed, and with adequate air

pressure and volume supplied, the pump will start and

stop as the spray gun/dispensing valve is opened and

closed.

Use the air regulator (K) to control the pump speed and

the fluid pressure. Always use the lowest air pressure

necessary to get the desired results. Higher pressures

cause premature tip/nozzle and pump wear.

Never operate the pump with the air motor plates

removed.

WARNING

See the Installation on page 7. If you are using a

pneumatic elevator cart or 19 liter (5 gallon) ram with

the pump, refer to the separate instructions for those

components for set-up and operation instructions.

To reduce the risk of overpressurizing the system,

which could result in component rupture and cause

serious injury, NEVER exceed the specified maxi-

mum incoming air pressure to the pump (see the

Technical Data on pages 24–27).

Lower the pump into a fluid container. Be sure the air

regulator (K) and bleed-type master air valve (J) are

closed. Then open the bleed valve (J). Hold a metal

part of the spray gun/dispensing valve (S) firmly to the

side of a grounded metal pail and hold the trigger

open. Now slowly open the air regulator until the pump

starts.

CAUTION

Do not allow the pump to run dry. It will quickly

accelerate to a high speed, causing damage. A

pump runaway valve (G), which shuts off the air

supply to the pump if the pump accelerates beyond

the pre-set speed, is available. See the Typical

Installation in Fig. 2. If your pump accelerates

quickly, or is running too fast, stop it immediately and

check the fluid supply. If the supply container is

empty and air has been pumped into the lines, refill

the container and prime the pump and the lines with

fluid, or flush and leave it filled with a compatible

solvent. Be sure to eliminate all air from the fluid

system.

Cycle the pump slowly until all the air is pushed out

and the pump and hoses are fully primed. Release the

spray gun/dispensing valve trigger and engage the

safety latch. The pump should stall against pressure

when the trigger is released.

If the pump fails to prime properly, open the bleeder

valve (33) slightly. See Fig. 7 on page 16. Use the

bleeder hole (on the underside of the valve housing) as

a priming valve until the fluid appears at the hole.

Close the bleeder valve.

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Operation

Shutdown and Care of the Pump

WARNING

To reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 8.

For overnight shutdown, stop the pump at the bottom

of the stroke to prevent fluid from drying on the ex-

posed displacement rod and damaging the throat

packings. Relieve the pressure.

Always flush the pump before the fluid dries on the

displacement rod. Refer to Flushing below.

1. Relieve the pressure.

Flushing

2. Remove the spray tip/nozzle from the gun/valve.

WARNING

3. Hold a metal part of the gun/valve firmly to the side

of a grounded metal pail.

FIRE AND EXPLOSION HAZARD

Before operating the pump, read the

section FIRE AND EXPLOSION HAZ-

ARD on page 4. Be sure the entire

system and flushing pails are properly

grounded. Refer to Grounding on page

4. Start the pump. Always use the lowest possible

fluid pressure when flushing.

5. Trigger the gun/valve.

Flush with a fluid that is compatible with the fluid you

are pumping and with the wetted parts in your system.

Check with your fluid manufacturer or supplier for

recommended flushing fluids and flushing frequency.

Always flush the pump before fluid dries on the dis-

placement rod.

6. Flush the system until clear solvent flows from the

gun/valve.

7. Relieve the pressure.

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Troubleshooting

1. Relieve the pressure.

WARNING

To reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 8.

2. Check all possible problems and causes before

disassembling the pump.

PROBLEM

CAUSE

SOLUTION

Pump fails to operate. Restricted line or inadequate air supply Clear*; see Technical Data on pages 24–27.

Obstructed fluid hose or gun/valve;

fluid hose ID is too small.

Clear*; use a hose with a larger ID.

Fluid dried on the displacement rod.

Dirty or worn air motor parts.

Clean; see Service on pages 12–19.

Clean or repair; see separate air motor manual.

Pump operates, but Restricted line or inadequate air supply. Clear*; see Technical Data on pages 24–27.

output is low on both

strokes.

Obstructed fluid hose or gun/valve;

fluid hose ID is too small.

Clear*; use a hose with a larger ID.

Close.

Bleeder valve is open.

Air is leaking into the supply container. Check wiper plate seal.

Fluid is too heavy for pump priming. Use bleeder valve (see page 9); use wiper plate

with ram or pneumatic elevator cart.

Worn packings in displacement pump. Replace packings.

Pump operates, but Fluid too heavy for pump priming.

output is low on down-

stroke.

Use bleeder valve (see page 9); use wiper plate

with ram or pneumatic elevator cart.

Held open or worn intake valve or seals. Clear valve; replace seals.

Pump operates, but Held open or worn piston valve or seals. Clear valve; replace seals.

output is low on up-

stroke.

Erratic or accelerated Exhausted fluid supply.

pump speed.

Refill and prime.

Fluid is too heavy for pump priming.

Use the bleeder valve (see page 9); use wiper

plate with ram or pneumatic elevator cart.

Held open or worn piston valve or seals. Clear valve; replace seals.

Held open or worn priming piston. Clear; service.

Worn packings in displacement pump. Replace packings.

* To determine if the fluid hose or gun is obstructed, follow the Pressure Relief Procedure on page 8. Disconnect

the fluid hose and place a container at the pump fluid outlet to catch any fluid. Turn on the air just enough to start

the pump (about 20–40 psi [0.14–0.3 MPa, 1.4–2.8 bar]). If the pump starts when the air is turned on, the obstruc-

tion is in the fluid hose or gun.

NOTE: If you experience air motor icing, contact your Graco distributor for assistance.

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Service

2. Relieve the pressure.

Required Tools

D Torque wrench

D Bench vise, with soft jaws

D Rubber mallet

D Hammer

D Razor or other sharp tool

D 8 mm (5/16 in.) dia. brass rod

3. Disconnect the air hose. Hold the fluid outlet fitting

(7) with an adjustable wrench to keep it from being

loosened while you disconnect the fluid hose.

Remove the pump from its mounting. Note the

relative position of the pump’s fluid outlet to the air

inlet.

D 8 mm, 11 mm, 15 mm, 25 mm, 3/4 in., and 7/8 in.

4. Using an adjustable wrench, unscrew the coupling

nut (104) from the connecting rod (103). Remove

the coupling collars (105). Take care not to lose or

drop them. See Fig. 4.

open–end wrenches

D 17 mm box or socket wrench

D 22 mm crow’s–foot wrench

D Adjustable wrenches

5. Hold the tie rod flats with an 11 mm wrench to

keep them from turning. Use the wrench (113)

provided with the pump (or a 17 mm box or socket

wrench) to unscrew the locknuts (106) from the tie

rods (102). Carefully pull the displacement pump

(107) off the air motor (101).

D 24 in. adjustable wrench

D Thread lubricant

D Anaerobic thread sealant

Disconnecting the Displacement Pump

1. Flush the pump, if possible. Stop the pump at the

bottom of its stroke.

6. Refer to page 14 for displacement pump service.

To service the air motor, refer to the separate air

motor manual, supplied.

WARNING

To reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 8.

Keep hands and fingers away from the priming

piston during operation and whenever the pump is

charged with air. On the pump downstroke the

priming piston extends beyond the intake cylinder

to pull the material into the pump. The priming

piston works under extreme force. During operation

and whenever the pump is charged with air, the

priming piston can severely injure or amputate a

hand or finger, or break a tool, caught between it

and the intake cylinder.

The air motor piston (located behind the air motor

plates) also moves when air is supplied to the

motor. NEVER operate the pump with the air motor

plates removed.

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Service

Reconnecting the Displacement Pump

WARNING

To reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 8.

101

1. Orient the pump’s fluid outlet to the air motor’s air

inlet as was noted in step 3 under Disconnecting

the Displacement Pump. Position the displace-

ment pump (107) on the tie rods (102). See Fig. 4.

108

103

102

105

NOTE: If you removed the tie rods (102) from the air

motor (101) or air motor adapter plate, reinstall them

using an 11 mm wrench. Torque the rods to 20-25 N.m

(15-18 ft-lb) on Model 222907, and 34-41 N.m (25-30

ft-lb) on Model 222839.

104

2. Screw the locknuts (106) onto the tie rods (102)

and torque to 34-41 N.m (25-30 ft-lb), using the

wrench (113) provided (or a 17 mm box or socket

wrench).

106

3. Place the coupling nut (104) on the displacement

rod (1), then place the collars (105) in the nut.

Screw the nut onto the connecting rod (103)

loosely. Hold the connecting rod flats with an

adjustable wrench to keep it from turning. Using an

adjustable wrench, torque the nut to 41-48 N.m

(30-35 ft-lb).

113

107

4. Using a torque wrench in the square hole of the

supplied wrench (113), torque the packing nut (2)

to 27-34 N.m (20-25 ft-lb).

Torque to 30–35 ft–lb (41–48 NSm).

Torque to 15–18 ft–lb (20–25 NSm) on model 222907; 25–30

ft–lb (34–41 NSm) on model 222839.

Torque to 20–25 ft–lb (27–34 NSm).

Torque to 25–30 ft–lb (34–41 NSm).

5. Mount the pump and reconnect all hoses. Recon-

nect the ground wire if it was disconnected during

repair. Turn on the air and run the pump slowly.

01059

Fig. 4

6. Fill the packing nut/wet-cup 1/3 full of Graco

Throat Seal Liquid or compatible solvent.

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Service

7. Inspect the rod guide (17) while in place in the

Disassembly

housing (16). Remove the rod guide only if it is

visibly damaged. Using a hammer and brass rod,

gently tap around the outer edge of the guide to

loosen it.

When disassembling the pump, lay out all removed

parts in sequence, to ease reassembly. Refer to Fig. 7.

NOTE: Repair Kit 222784 is available separately to

replace the piston and intake valve seals. For the best

results, use all the new parts in the kit. Kit parts are

marked with one asterisk, for example (8*). See Dis-

placement Pump Parts on page 23.

8. Push the displacement rod (1) down as far as

possible, then pull it and the priming piston rod

(21) out of the outlet housing (9) and cylinder (11).

Repair Kit 222785 is available to replace the throat

packings. For the best results, use all the new parts in

the kit. Kit parts are marked with a check mark, for

example (3n).

9. Remove the packing nut (2) and throat packings

from the outlet housing (9). Do not remove the

fluid outlet nipple (7) and o-ring (8) unless dam-

aged.

1. Disconnect the displacement pump from the air

motor as explained on page 12.

10. Unscrew the plug (AA) of the bleeder valve (33)

completely from the valve housing (BB). Do not

unscrew the valve housing from the outlet housing

(9), because the threads may gall. Clean the valve

threads and the bleed hole on the underside of the

valve housing.

2. Place the pump in a vise, with the jaws on the

outlet housing (9).

3. Hold the flats of the priming piston rod (21) with an

8 mm wrench. Using a 3/4 in. wrench, unscrew the

priming piston nut (22) from the rod. Slide the

priming piston (23) and priming piston guide (24)

off the rod. Inspect the surfaces of the guide (24)

and piston (23) for scoring, wear, or other damage.

11. Use a 24 in. adjustable wrench on the pump

cylinder (11) flats to unscrew it from the housing

(9). Remove the o-rings (10). Inspect the inside of

the cylinder for damage by holding it up to the light

at an angle or running a finger over the surface.

4. Loosen the packing nut (2) using the packing nut

wrench (113, supplied), or a hammer and brass

rod.

12. Inspect the surface of the displacement rod (1)

and priming piston rod (21) for wear, scoring or

other damage by running a finger over the surface.

5. Remove the intake cylinder (20), using a 24 in.

adjustable wrench. Remove the seal (19) and seat

(18) from the intake valve housing (16); always

replace the seal with a new one.

13. Use a vise with soft jaws to hold the displacement

rod (1) by its flats. Place a 15 mm wrench on the

piston flats and unscrew the piston (13) and prim-

ing piston rod (21) from the displacement rod (1).

Remove the piston guide assembly (V) from the

piston (13), and set aside for disassembly later.

6. Unscrew the intake valve housing (16) from the

cylinder (11), using a 24 in. adjustable wrench. Pull

the housing off the pump. The intake check valve

assembly (U) should slide down the priming piston

rod (21) as you remove the housing; if it does not

slide easily, loosen it by firmly tapping the top of

the housing (16) with a rubber mallet. Take care

not to drop the assembly (U) as it comes free. Set

the check valve assembly aside for disassembly

later.

14. It is not necessary to remove the priming piston

rod (21) from the piston (13) unless you see scor-

ing, wear, or other damage to either part. To

disassemble, place the piston flats in a vise. Using

an 8 mm wrench on the rod flats, unscrew the rod.

308200

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Service

15. To disassemble the piston guide assembly (V),

16. To disassemble the intake check valve assembly

(U), place the nut (27) in a vise and unscrew the

intake valve body (25) from the nut, using a 25 mm

wrench. See Fig. 6. Remove the seal (30) from the

nut (27) and the other seal (26) from the valve

body; always replace them with new ones. Inspect

the mating surfaces of the intake valve body (25)

and seat (18) for wear, scoring, or other damage.

place the flats of the piston seat (15) in a vise.

Close the jaws just tight enough to hold the part; it

can be damaged by squeezing it too tightly. Using

an 8 mm (5/16 in.) dia. brass rod, unscrew the

piston guide (12) from the piston seat (15). See

Fig. 5. Remove the piston seal (14); always re-

place with a new one. Inspect the mating surfaces

of the piston (13) and piston seat (15) for nicks,

scoring or wear.

Brass

Rod

0206

Fig. 6

NOTE: The seal (30) is press-fit in the nut (27), and

may require cutting with a razor to ease removal.

0205

Fig. 5

17. Inspect all parts and threads, and clean with a

compatible solvent. To reassemble, see page 17.

308200 15

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Service

DETAIL OF THROAT PACKINGS

AA 1

DETAIL OF

PISTON CHECK VALVE

11 (REF)

V (See detail at left.)

16 (REF)

U (See detail below.)

DETAIL OF

INTAKE CHECK VALVE

17 (REF)

Remove.

Leave installed; clean bleed hole on underside.

Remove only if damaged.

308200

Fig. 7

01060

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Service

4. Place the outlet housing (9) in a vise. If the bleeder

Reassembly

Refer to Fig. 8 for reassembly.

valve housing (BB) was removed, apply PTFE

tape to the threads and reinstall it in the outlet

housing (9), making sure the bleed hole faces

toward the bottom of the outlet housing. Then

screw the valve plug (AA) fully into the valve

housing (BB).

1. Place an 8 mm (5/16 in.) dia. brass rod lengthwise

in a vise. Install a new piston seal (14*) on the

piston seat (15). Apply thread lubricant to the

threads of the piston guide (12). Place the piston

guide (12) securely on the brass rod. Using a 22

mm crow’s-foot, screw the piston seat (15) into the

piston guide. Torque to 35–41 N.m (26–30 ft-lb).

NOTE: The bleeder valve plug (AA) has two sets of

threads. When reassembling, be sure the plug is fully

screwed into the valve housing (BB).

2. If it was necessary to remove the priming piston

rod (21) from the piston (13), apply thread lubricant

to the female threads of the piston. Place the flats

of the piston (13) in a vise. Hold the flats of the rod

with an 8 mm wrench, and screw the rod into the

piston. Torque to 35-41 N.m (26-30 ft-lb). Be

NOTE: It is not ordinarily necessary to remove the

outlet nipple (7) and o-ring (8*). However, if they were

replaced because of damage, lubricate the o-ring (8*)

and place it on the nipple (7). Screw the nipple into the

outlet housing (9). Torque to 60-84 N.m (44–62 ft-lb).

careful not to create burrs on the flats of the rod.

3. Use a vise with soft jaws to hold the flats of the

displacement rod (1). Install the assembled piston

guide/seat on the piston (13). Apply thread lubri-

cant to the female threads of the piston, and screw

the piston assembly onto the rod, using a 15 mm

wrench on the piston flats. Torque to 35-41 N.m

(26-30 ft-lb). There will be a small gap between the

top of the piston (13) and the shoulder of the rod

(1).

308200 17

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Service

5. Lubricate the o-rings (10*) and install them on the

11. Lubricate a new intake valve seal (26*) and slide it

onto the rod, being careful not to damage the seal

when passing over the flats of the rod. Slide the

seal up until it reaches the packing nut (27). Apply

thread lubricant to the female threads of the intake

valve body (25), and slide it onto the rod until it

reaches the nut (27).

cylinder (11). Apply thread lubricant to the top

threads of the cylinder. Using a 24 in. adjustable

wrench on the flats of the cylinder, screw it into the

outlet housing (9). Torque to 159–221 N.m

(117–163 ft-lb).

6. Lubricate the throat packings and glands, and

install them in the outlet housing (9) one at a time

in the following order, with the lips of the v-pack-

ings facing down: male gland (6n), UHMWPE

v-packing (5n), PTFE v-packing (3n), UHMWPE

(5n), PTFE (3n), UHMWPE (5n), and female

gland (4n). Apply thread lubricant to the packing

nut (2) and install it loosely in the outlet housing.

12. Place a 7/8 in. wrench on the hex of the packing

nut (27) and a 25 mm wrench on the flats of the

valve body (25). Screw the nut into the body,

making certain they remain in position above the

flats of the rod (21). Torque to 35–41 N.m (26–30

ft-lb). Slide the assembled intake check valve (U)

up the priming piston rod and into the rod guide

(17) as far as possible; this may be difficult due to

high friction between the seal (26*) and rod (21).

7. Carefully insert the displacement rod (1) into the

bottom of the cylinder (11). Push the rod up into

the cylinder and through the outlet housing (9),

until it protrudes from the packing nut (2). Be

careful not to damage the piston seal (14*) while

performing this step.

13. Position the intake valve seat (18) so its large

beveled side faces down toward the pump intake.

Slide the seat (18) onto the priming piston rod (21)

and into the intake valve housing (16) until it seats

on the rod guide (17) . Lubricate a new seal (19*)

and push it up into the beveled gap around the

bottom outer edge of the seat (18). Be sure the

seal is fully and uniformly positioned in the gap.

8. Apply thread lubricant to the bottom threads of the

cylinder (11). Be sure the o-ring (10*) is in place on

the cylinder. Guide the intake valve housing (16)

up onto the priming piston rod (21). Screw the

valve housing onto the cylinder, using a 24 in.

adjustable wrench. Torque to 159–221 N.m

(117–163 ft-lb).

14. Apply thread lubricant to the threads of the intake

cylinder (20) and screw the cylinder into the intake

valve housing (16), using a 24 in. adjustable

wrench. Torque to 159–221 N.m (117–163 ft-lb).

Installation of the intake cylinder (20) will seat the

parts of the intake valve assembly (U) securely in

the proper position.

9. If the rod guide (17) was removed from the intake

valve housing (16), reinstall it with the open end

facing down toward the pump intake.

15. Slide the priming piston guide (24) onto the rod

(21) until it stops. Then install the priming piston

(23), with the flat side facing up toward the pump.

Apply thread lubricant to the female threads of the

priming piston nut (22). Hold the rod (21) steady

with an 8 mm wrench on the flats, and screw the

priming piston nut (22) onto the rod with a 3/4 in.

wrench. Torque to 35-41 N.m (26-30 ft-lb).

10. With the beveled side facing up, press the seal

(30*) into the recess of the intake packing nut (27)

until it snaps into place. The nose of the seal

should be flush with or slightly recessed into the

face of the packing nut. With the threads facing

down toward the pump intake, slide the nut up

onto the priming piston rod (21) until it clears the

flats of the rod.

16. Reconnect the displacement pump to the air motor

as explained on page 13.

308200

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Service

DETAIL OF THROAT PACKINGS

Torque to 35–41 NSm (26–30 ft-lb).

If removed, apply PTFE tape to threads.

Bleed hole must face toward bottom of

outlet housing (9).

Torque to 159–221 NSm (117–163 ft-lb).

Flat side must face up.

Apply thread lubricant and torque to

35-41 NSm (26-30 ft-lb).

Lips of V–packings must face down.

Remove only if damaged. Torque to

60–84 NSm (44–62 ft-lb).

Apply lubricant to female threads.

Apply lubricant to threads.

10*

DETAIL OF

PISTON CHECK VALVE

Large bevel must face down.

1 (REF)

11 (REF)

V (See detail at left.)

14*

U (See detail below.)

DETAIL OF

INTAKE CHECK VALVE

10*

*30

16 (REF)

17 (REF)

1 27

*26

*19

308200 19

01060

Fig. 8

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Parts

Model 222839, Series A

23:1 Ratio Monark Pump

(includes items 101–113)

Ref.

No.

101

Part No. Description

Qty.

101

222791

AIR MOTOR, Monark

(see 307043 for parts)

102

103

104

105

106

24B190

184162

184100

184131

109209

KIT, tie rod

ROD, adapter

NUT, coupling

COLLAR, coupling

NUT, hex, self-locking; with

nylon insert; M10 x 1.5

PUMP, displacement

(see pages 23–22 for parts)

PIN, cotter

SCREW, cap, socket hd;

3/8–16 unc–3a x 0.75” (19 mm)

PLATE, adapter

108

110

107

222814

108

109

101946

109212

109

110

113

184077

184119

WRENCH, packing nut

105

104

103

102

113

106

107

308200

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Parts

Model 222907, Series A

46:1 Ratio President Pump

(includes items 101–113)

Ref.

No.

101

Part No. Description

Qty.

101

222772

AIR MOTOR, President

(see 306982 for parts)

102

103

104

105

106

24B190

184160

184100

184131

109209

KIT, tie rod

ROD, adapter

NUT, coupling

COLLAR, coupling

NUT, hex, self-locking; with

nylon insert; M10 x 1.5

PUMP, displacement

(see pages 23–22 for parts)

PIN, cotter

108

103

107

222814

108

113

101946

184119

WRENCH, packing nut

102

105

104

106

113

107

01059

308200 21

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Displacement Pump Parts

Model 222814, Series A

Displacement Pump

(includes items 1–33)

30}l

4{n

3{n

26*l

25l

n{6

14}

l*19

10*

21 (REF)

*10

1 (REF)

01062B

308200

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Displacement Pump Parts

Model 222814, Series A Displacement Pump

(includes items 1–42)

Ref.

No.

Ref.

No.

Part No. Description

Qty.

Part No. Description

184438 GUIDE, priming piston; sst

Qty.

184101

184423

ROD, displacement; sst

NUT, packing; sst

25l 184433

26*l 184114

VALVE BODY, intake; sst

SEAL, intake valve; PTFE

NUT, packing, intake valve; sst

SEAL, valve; PTFE

3{n 109301

4{n 184171

6{n 184221

V–PACKING, PTFE

GLAND, female; sst

V–PACKING, UHMWPE

GLAND, male; sst

184432

109251

30}l 184553

184392

190293

HOUSING, valve; sst; 3/8–18 npt 1

x 1/2–20 unf–2b

PLUG, valve; sst; 1/2–20 unf–2a

184424

FITTING, outlet; M27 x 1.5(m);

1/2 npt(m); sst

109450

184422

109451

184106

15K690

184426

184554

184428

184430

184431

184435

O–RING; PTFE

HOUSING, outlet; sst

O–RING, PTFE

CYLINDER, pump; sst

GUIDE, piston; sst

PISTON; sst

SEAL, piston; PTFE

SEAT, piston; sst

HOUSING, intake valve; sst

GUIDE, rod; sst

SEAT, intake valve; sst

SEAL; acetal

CYLINDER, intake; sst

ROD, priming piston; sst

NUT, priming piston; sst

PISTON, priming; sst

These parts are included in Seal Repair Kit 222784,

which may be purchased separately.

10*

14}

{ These parts are included in Throat Packing Conver-

sion Kit 222786, which may be purchased sepa-

rately.

n These parts are included in Throat Packing Repair

Kit 222785, which may be purchased separately.

19*l 184296

l These parts are included in Intake Valve Repair Kit

184437

184117

184440

184439

222908, which may be purchased separately.

} Keep these spare parts on hand to reduce down

time.

308200 23

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Technical Data (222839 Monark)

WARNING

Be sure that all fluids and solvents used are chemically compatible with the

Wetted Parts listed below. Always read the manufacturer’s literature before

using fluid or solvent in this pump.