Repair Instructions
LD Grease Pump
Repair Kits
3A1495C
EN
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)
Important Safety Instructions
Read all warnings and instructions in this manual and
in your LD Series Oil or Grease Pump manual. Save
all instructions.
Repair Kits:
24H854: Throat and Piston Seal Replacement Kit
24H856: O-Ring and Seal Replacement Kit
24U984: Air Piston Replacement Kit
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Instructions
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.
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.
Inspect all parts when disassembling the pump. Replace
any and all worn and damaged parts.
Pressure Relief 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.
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.
1. Stop the pump. Follow Pressure Relief Procedure,
2. Disconnect and remove the pump from its installed
location.
1. Close the pump’s bleed-type master air valve.
3. Clamp the pump (1) upside down in a vise as shown
2. Close the pump air regulator and disconnect the air
supply hose.
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.
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.
1
Fig. 1
If you are only servicing the air valve (40) and seals
3A1495C
3
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Instructions
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
6. Use a wrench to loosen and remove the seal
retainer (29) (Fig. 4).
19
NOTE: After a few turns, the shovel cylinder should
be loose enough to finish turning it with your hand to
remove this part.
35
29
27
34
34
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
(28).
Fig. 2
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
26
19, 35
30
34
28
Fig. 3
36
Fig. 5
4
3A1495C
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Instructions
8. If the gasket (30) is still inside the spacer cylinder
(36) use a pick to remove.
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
9. Secure a strap wrench around the spacer cylinder
(36) and use it to turn the cylinder counter clockwise
NOTE: After a few turns, the spacer cylinder should
be loose enough to finish loosening it with your
hand to remove this part.
8
24
23
36
32
34
PULL
30
8
22
8
28
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).
25
Fig. 6
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).
23
34
32
24
12. Remove the pump assembly from the vise and set it
down on a clean, hard work surface.
28
Fig. 8
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.
If you are only replacing or repairing the pump lower
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
NOTE: Take care to only use enough clamping
3A1495C
5
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Instructions
force to hold the pump in position. The pump cylin-
der is aluminum and could be damaged by using
excessive clamping force.
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).
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-
21
40
43
6
18
21
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
21
Fig. 9
14
Repair and replacement instructions for the Air
Valve are included in a separate repair manual
included with the kit:
3
•
Air Valve Replacement Kit - 24H848, 24H849,
24H850
•
•
•
•
•
Air Valve Repair Kit - 24H798
Air Motor Service Kit - 24J757, 24J758, 24J759
Pilot Valve Kit - 24H749
22
Fig. 11
21. Separate the bottom cover (14) from the flange (22)
Air Valve Seal Kit - 24H851
Air Valve End Cap Kit - 24H852
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.
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).
If you are replacing the o-rings and seals installed in
the flange, bottom cover, and air piston continue
instructions and the Throat and Piston Seal
Replacement Kit 24H854 instructions beginning on
page 11.
6
3A1495C
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Instructions
socket wrench and torque to 60-70 in lbs (6.8 – 7.9
N.m).
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.
3
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.
Fig. 13
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.
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.
22
50
2. Align pilot valve (20) installed in bottom cover with
press the bottom cover (14) and flange (22)
together.
14
a
20
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
14
22
Fig. 12
21
Fig. 15
3A1495C
7
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Instructions
6. Install the 5 screws (4) wrench tight only.
11. Install screws (43). Torque to 60-70 in. lbs (6.8 - 7.9
N.m).
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.
(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.
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
installed.
To change the installation location:
a. Remove the 4 screws (43).
14
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.
4
helpful to place a support, such as a piece of wood,
below the rods.
Fig. 16
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).
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).
8
NOTE: The air valve (40) can be installed in any
configuration. There is not just one correct way to
install these parts.
32
40
43
25
Fig. 18
17
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
16. Install piston seal (24) over the end of the piston rod
(23). Note the correct orientation of the piston seal
21
Fig. 17
8
3A1495C
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Instructions
17. Screw the piston rod (23) and the connecting rod
(32) together aligning the pin hole in both pieces to
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).
24
8
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,
32
23
NOTICE
Improper alignment will take the self-aligning feature
out of the design which could result in damage to the
pump.
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
Fig 1 - 1/2 Turn Too Shallow
Does not permit
end play
19. Screw the piston rod (23) and priming rod (34)
together aligning the pin hole in both pieces to allow
ti10469a
Incorrect Alignment
Fig 2 - 1/2 Turn Too Deep
28
23
ti10479a
Does not permit
end play
34
Fig 3 - Correct
Permits end play
ti10468a
Fig. 20
Correct Alignment
Fig. 21
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
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).
21. Check to make sure there is end play at all pinned
connections.
25. Install the intake seal (28) over the end of the prim-
ing rod (34). Note the correct orientation of the
3A1495C
9
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Instructions
der securely then torque to 45 - 55 ft. lbs (61 - 75
N.m).
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).
27
19
35
29
34
34
Fig. 24
Fig. 22
Repair Kits
All Repairs:
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
•
•
Unless otherwise stated, entirely disassemble pump
as described in the pump disassembly instruction
section of this manual.
19, 35
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.
34
Grease all parts prior to reassembly with a thin coat
of lightweight grease.
Fig. 23
Reassemble pump as described in the reassembly
instruction section of this manual.
29. Install shovel cylinder (27) over priming rod (34)
10
3A1495C
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Instructions
2. Use a pick to remove the o-ring (5) installed around
the circumference of the air piston (15) (Fig. 26).
Grease the new o-ring included in the kit and install
it around the air piston.
Throat and Piston Seal Replacement Kit -
24H854 (Fig. 25)
Replacement parts for o-ring (5) installed on air piston
(15), o-rings (6 and 12) installed in bottom cover (14),
o-ring (7), u-cup seal (11) and gasket (30) installed on
flange (22), pin (8) used to reassemble rod sections,
and gasket (18) used later in reassembly of the air valve
(40). A replacement part for the retainer nut (37) is also
included in this kit.
5
Qty
Ref. Description
.
5
6
7
8
11
12
18
30
37
O-RING, air piston
O-RING
O-RING
PIN, slotted, straight
SEAL, u-cup
O-RING
GASKET, cover, small
GASKET
1
1
1
3
1
3
2
1
1
15
Fig. 26
3. Use a pick to remove o-ring (7) and gasket (30) from
replace the o-ring and gasket in flange.
NUT, retainer
18
11
7
6
7
8
12
22
37
5
30
22
30
Fig. 25
1. Disassemble the pump following Disassembly
Fig. 27
3A1495C
11
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Instructions
the new o-rings (12) and o-ring (6) included in the kit
and install them in the bottom cover housing.
22
12
25
6
37
14
Fig. 28
Fig. 30
8. Reassemble the pump as described in the Reas-
5. Remove u-cup seal (11) from flange (22) (Fig. 29).
Grease and replace the u-cup seal with the new part
included in the kit and install them in the order
shown in Fig. 29.
O-Ring and Seal Replacement Kit - 24H856
NOTE:
Replacement parts for gasket (30) installed in the flange
and around the circumference of the cylinder (26), o-ring
(10) installed around the seal retainer (29), pin (8) used
to reassemble rod sections, and replacement seals (24
and 28) installed on the displacement rod assembly.
•
The bearing (31) is not included in the kit. This
part is reused. The bearing can be installed with
either side facing up. There is not just one way
to install this part.
•
•
The bearing (31) is a transition fit and in some
installations it may not be removed.
Qty
Ref. Description
.
Be sure u-cup seal (11) is installed with the lips
facing down as shown in Fig. 29.
8
PIN, slotted, straight
O-RING
3
1
1
1
2
10
24
28
30
SEAL, piston
SEAL, intake
GASKET
Lips down
11
30
24
22
8
31
37
28
Fig. 29
6. Install displacement rod (25) through flange assem-
bly (22) (Fig. 30).
10
7. Remove and discard the 3 small o-rings (12) and
o-ring (6) in the bottom cover (14) (Fig. 30). Grease
Fig. 31
12
3A1495C
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Instructions
1. Disassemble the pump following Disassembly
Air Piston Replacement Kit - 24U984 (Fig. 35)
Qty
Ref. Description
.
2. Use a pick to remove the gasket (30) installed
Grease the new gasket included in the kit and install
it inside the flange.
5
8
O-RING
1
1
1
1
2
1
1
1
1
1
1
1
PIN, straight, slotted, 2.5 x 16
GASKET, 32 OD
PISTON, air, plastic
GASKET, cover small
NUT, hex
CYLINDER, air, machined
ROD, displacement, 50:1
GASKET
13
15
18
19
21
25
30
38
22
30
36
WASHER, 32 OD
101 LABEL, identification
102 LABEL, overlay, clear
18
18
Fig. 32
101/102
3. Use a pick to remove the other gasket (30) installed
Grease the new gasket included in the kit and install
it around the cylinder.
21
13
19
15
5
30
38
30
36
26
25
Fig. 33
4. Use a pick to remove the o-ring (10) installed
Grease the new o-ring included in the kit and install
it over the seal retainer.
8
Fig. 35
Pump Disassembly,
10
beginning on page 3.
2. 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.
36).
29
Fig. 34
NOTE: After a few turns, the spacer cylinder should
be loose enough to finish loosening it with your
hand to remove this part.
5. Reassemble the pump as described in the Reas-
sembly instructions, page 7.
3A1495C
13
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Instructions
3. Pull spacer cylinder (36) away from pump to access
Pump Reassembly
Always use all new parts included in the kit for reas-
sembly.
36
1. Apply a thin coat of grease around the threaded end
of the new displacement rod (25).
2. Assemble washer (38), air piston (15), gasket (13),
o-ring (5) and hex nut (19) to displacement rod (25)
as shown in Fig. 37. Be sure the male boss on gas-
ket (13) mates with the counter bore in air piston
(15). Tighten and torque nut (19) to 155 - 165 in.
pounds (17.5 - 18.6 N.m).
PULL
8
25
30
22
19
13
Fig. 36
38
15
5
4. Use a rubber hammer and small punch to drive the
pin (8) out.
25
5. Unscrew the pump lower from displacement rod
(25). Set aside pump lower for reassembly.
19
6. Use a pick to remove gasket (30) from inside the
flange (22).
13
15
8. Discard pin (8), air piston (15) and displacement rod
(25) according to all applicable safety regulations for
disposal of these parts.
38
25
Fig. 37
3. Apply a thin coat of grease around the chamfered
end of the displacement rod assembly (25). Push
the displacement rod through the opening in the bot-
tom cover and into the flange assembly as shown in
14
3A1495C
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Instructions
14
22
21
25
14
Fig. 40
7. Install the 5 screws (4) wrench tight only.
Fig. 38
NOTE: If installing a new air cylinder (27) the mating
holes are not threaded by design. Use thread form-
ing 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.
4. Remove pilot valve (20) from the old air cylinder
(21). Apply a light coat of grease to o-rings.
5. Install pilot valve (20) into new air cylinder included
(10.7-11.9 N.m).
8. To ensure there is a proper seal between the air
valve and manifold, loosen all 5 screws (4) approxi-
torqued AFTER the air valve (40) is installed.
20
14
4
21
Fig. 41
Fig. 39
beginning on page 8.
6. Apply a thin coat of grease to o-rings (5) and o-ring
on bottom cover (14). Install the air cylinder (21)
over the bottom cover (14) / air piston (15) assem-
bly. Place the top of the air cylinder down on a clean
hard surface. Use the palms of your hands to press
11. Screw the connecting rod (32) and the displacement
rod (25) together, aligning the pin hole in both
3A1495C
15
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pieces to allow the pin to be pushed through (Fig.
42).
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).
8
14. 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,
32
NOTICE
Improper alignment will take the self-aligning feature
out of the design which could result in damage to the
pump.
25
14
30
Fig. 42
15. Slide spacer cylinder (36) into bottom cover (14).
12. 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
16. Using a strap wrench, tighten and torque spacer cyl-
inder (36) to 45 - 55 ft. lbs (61.0 - 74.5 N.m).
17. Use a permanent marker to record the pump part
number, serial number and series code shown the
original label located on the old air cylinder, onto the
new label (101) included in the kit.
13. Check to make sure there is end play at all pinned
connections.
18. Apply label (101) to the new cylinder. Apply the
clear overlay (102) over the new label.
Graco Information
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6928 or Toll Free: 1-800-533-9655, Fax: 612-378-3590
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM3A1495
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2011, Graco Inc. is registered to ISO 9001
June 2011, revised November 2014
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