Thank you for selecting Ground Force manufacturing L.L.C.

as your
supplier of mining and construction support equipment.

Our business is based on providing quality equipment and the

service to support it. Our Parts Department in Post Falls is stocked with
the commonly used parts on your machinery and will be glad to assist you
in any way to provide replacement parts when they are needed, as quickly
as you need them. In addition, trained field mechanics are available to
assist your in-house service personnel should the need arise.

If you have any questions, or if we can be of assistance at any

time, please dont hesitate to call us at (208) 664-9291.

We look forward to a long and mutually rewarding association.

Sincerely,

Ground Force Manufacturing

Please refer tot he following information when calling about service or

parts:

UNIT SERIAL NUMBER: 165901

DELIVERY DATE: August 2010

ORIGINAL CUSTOMER: Finining Canada

 Operation,
Service & Parts
Manual
GF40EFLT CAT 740
FUEL/LUBE TRUCK
Unit Serial No. 165901

Copyright 2009, by Ground Force Mfg. L.L.C. All rights reserved. No

part of this manual may be reproduced in any form or by any means
(including electronic storage and retrieval or translation into a foreign
language) without prior agreement and written consent from Ground Force as
governed by the United States and International Copyright Laws.

Ground Forge Mfg. L.L.C.

E. 5650 Seltice Way
Post Falls, Idaho 83854
(208) 664-9291

Printing History: First Edition June, 2009

 Contents
Section One: OVERVIEW

Section Two: OPERATION

Section Three: MAINTENANCE

Section Four: SCHEMATICS

Section Five: PARTS

Section Six: MANUFACTURER MANUALS

1. OVERVIEW
G3 General
INTRODUCTION
Your lube truck was built to provide many years of
operation. Durability, ease of operation and high
speed product delivery have been the goals in the
design of the unit.
This booklet will give you the basic operating
instructions in the use of your new truck. As with
any piece of equipment, each unit will have its own
individual operating characteristics which will
become familiar to an operator with time.
Should any questions arise while you become
familiar with your unit please don't hesitate to call us
at Ground Force Mfg. Our goal is satisfied
customers and we will do all we can to assure we
meet that goal.
LW General
LIMITED WARRANTY
A. Ground Force warrants that the specialty
equipment it manufactures, including
accessory equipment and parts manufactured
by Ground Force, shall be free from:
1. Defects in material and workmanship
furnished by Ground Force and used in
the fabrication thereof;
2. Defects arising from the selection of
materials or processes of manufacture;
3. Defects in the design thereof in view of
the state of the art on the date hereof.
The foregoing warranty shall apply also to
accessories, equipment and parts manufactured to
Ground Forces detailed design and specifications
and supplied to Ground Force by other
manufacturers.
B. Ground Force makes no warranty with regard
to component parts not manufactured or
fabricated by it, but agrees to assign to the
purchaser all of its rights under any original
manufacturer's warranty covering such
component parts, and agrees to assist the
purchaser in making such contacts with the
manufacturer of such component parts as may
be necessary to protect its right under the
warranty covering them.
C. In case of defects in materials or workmanship
or defects arising from the selection of
material or processes of manufacture, such
defects must become apparent in the machine,
accessory, equipment or part within six
months or 1,000 hours of operations,
whichever shall first expire after delivery of
the machine to the original purchaser.
The extent of Ground Forces liability under this
warranty as to defects in material or workmanship
and defects arising from the selection of materials or
the processes of manufacture is limited to the repair
of such defects or to the repair or replacement (with a
similar item free from the defect in question) of any
accessory, equipment, or part which is defective in
any such respects.
D. The extent of Ground Forces liability under
this warranty as to defects inherent in design is
limited to the correction at its expense of all
such defects becoming apparent in the
machine, accessory, equipment or part
purchased here within six months or 1,000
hours of use, whichever shall first expire.
E. The warranty of Ground Force does not cover,
and Ground Force makes no warranty with
respect to:
1. Defects not reported and defective
items not returned to Ground Force
within the warranty period;
2. Failure and damages due to
misapplication, lack of proper
maintenance, abuse, improper
installation, or abnormal conditions of
temperature, moisture, dirt or corrosive
matter;
3. Failure due to operations, intentional or
otherwise, in any improper manner;
4. Damage caused by components, or
parts, or accessories built by others or
which were not manufactured or
installed by Ground Force.
5. Any item which has in any way been
altered by anyone other than an
authorized representative of Ground
Force.
6. Any item damaged in shipment or
otherwise without the fault of Ground
Force.
Ground Force shall in no way be liable for any
expenses incurred by the purchaser in any attempt to
repair, replace or rework any originally defective
item of sale. Ground Force shall in no way be liable
for any losses, costs, forfeiture or damages (including
loss of profits, liabilities of the purchaser, or its
customers, or third persons, and all other
consequential damages), whether direct or indirect,
and whether or not resulting from or contributed to
by the default or negligence of Ground Force, its
agents, employees and subcontractors, which might
be claimed as a result of the defect, use or failure of
the item delivered.
Except as stated, there is no warranty, express or
implied, in connection with the design, manufacture,
sale or use of the machinery, accessories, equipment
and parts sold by Ground Force. Ground Forces
liability on its warranty shall in no event exceed the
cost of the item of sale.
2. OPERATION
IMPORTANT!!!

New Unit Break-In

1. Grease Diesel pumps daily with a single pump of grease!!

2. Product pumps and Hose reel bearings on a monthly basis!!

3. Check pump drive shaft coupling set screws daily until they set and no longer
loosen with operation.

4. Check hydraulic pump drive shaft set screws to be sure shipping vibration has not
loosened them.

5. Tighten any hydraulic fittings that may loosen. Fittings will commonly loosen and
drip the first few weeks of operation.

6. Check oil level on compressor daily.

7. Check body mount and Pins for tightness on a daily basis!

PRE-OPERATION CHECK LIST

1. Check hydraulic oil level.

2. Check body mount bolts and pins. Make sure they are tight!!

3. Check hydraulic oil tank outlet to be sure it is open.

4. Check product oil tank outlets to be sure they are open.

5. Check general condition of truck.

6. Check motor drive couplings.

7. Check charge on fire extinguishers.

8. Be sure all operating controls are Off before starting truck.

9. Check product levels in tanks make certain that there is enough oil or product in
tank to immerse the pump suction if tank is not in use.

DO NOT RUN PRODUCT PUMPS DRY!!!

 Operating instructions General
Overview
The following system operating
instructions are for use with the delivery
and control systems installed by Ground
Force Mfg. These systems are as follows
(If Applicable):
1) Fuel Delivery System.
2) New Oil Delivery Systems
3) A High Pressure (Zerk) Grease
System
4) A High Volume Grease System
5) A Compressed Air System
6) A Coolant Delivery System
7) A Used oil Recovery System
a) This system is equipped with a
Filter Drawer Drain Valve.
8) A Jump Start System
9) Hydraulically operated access doors
(front and rear).
Each delivery system is equipped with a
hose reel, delivery hose, and dispensing
valve (except for the air delivery hose,
which is capped from the factory).
Meters:
The new oil systems are equipped with
panel-mount meters or hose end meters
at the operators station. The coolant
hose is equipped with a panel mounted
or hose end meter. The meters for the
fuel delivery systems are also located at
the operators station.
Filters:
Refer to the MAINTENANCE section
for information on filter inspection and
replacement requirements for the
filters/strainers listed below.
The fuel filters are mounted in the curb-
side compartment, along with the fuel
pumps. Inlet and outlet pressure gages
are installed. A difference of 20 PSI or
greater indicates a clogged filter.
The fuel pumps are equipped with a
suction strainer mounted directly on the
pump inlet.
The new oil delivery systems are
equipped with in-line filtration. These 25
micron filters are physically located by
the Product tanks or by the hose reels.
The coolant meter is equipped with an
inlet strainer. This strainer is internal to
the meters inlet housing.
The used oil system is equipped with a
Y strainer mounted on the four-way
directional control valve. This control
valve is mounted at the operators station
or by the rear door.
Remote Fill Connections:
All new product tanks are equipped with
remote fill connections accessible from
the ground. The fuel tank filling station
is located on the forward side of the
drivers side compartment, below the
fuel tank. All other products are filled
from the remote filling station located in
a compartment at the drivers-side rear
of the body. Level alarm and indicating
systems are provided for the various
tanks. Refer to Fuel Tank Filling or
Product Tank Filling instructions for
more information.
Auxiliary Heating System
An auxiliary heating system has been
installed. It is designed to heat selected
new oil tanks, the grease bin, and the
reel compartment.
This heating system uses the chassis
engine cooling system as a heat source
or there will be a Webasto system
installed on the front head of the diesel
tank.
The heat exchangers installed in the reel
compartment, for compartment heating,
are equipped with electric-drive air
circulating fans. These fans are
controlled by a switch located at the
operators station or by the rear door.
Electrical System:
All systems installed are controlled
electrically from one of two locations.
All components installed on the body by
Ground Force Mfg. are powered through
a fuse panel. This fuse panel is supplied
from the battery through a heavy-duty
main relay.
The fuse panel and main relay are in an
enclosure located in the reel
compartment. Additional relays are also
installed in this electrical enclosure for
control of the various electrical systems.
The main relay is controlled by the
ignition key. The ignition key must be
on for any Ground Force Mfg.
electrical system to function.
In-Cab Controls:
Along with control power for the main
relay, the following in-cab controls are
supplied by the chassis ignition circuit:
1) Main hydraulic system control
switch- energizes the hoist control
valve RAISE solenoid coil to send
hydraulic oil to the body. This switch
works in conjunction with the
emergency stop button located at the
operators station and also the
chassis parking break. Both
switches must be on before the
hydraulic system will engage.
2) This pump switch also engages the
high idle
3) Floodlight Control Switch-
Energizes the two rear-facing
floodlights mounted on the cab
handrails (directly) and the eight
body-mounted floodlights (via a
heavy-duty relay).
Each time that the engine is started,
the pump switch must be cycled to
on twice before the high idle will
engage. Once the high idle has been
engaged successfully the first time,
this switch only needs to be turned to
on once for any subsequent uses
unless the engine is turned off.
The engines high idle circuit must
be engaged if the floodlights are to
be used for more than a few minutes.
It should also be used to provide an
additional volume of hydraulic oil if
necessary (e.g. operating the air
compressor and a fuel pump, or both
fuel pumps, at the same time).
Operators Station:
All components and systems installed by
Ground Force Mfg. are electrically
controlled unless otherwise noted. All
components and systems are controlled
from the operators station at the rear of
the body.
Jump-Start System (If Applicable):
The jumper cables are installed on a
manually rewound cable reel. This cable
reel is mounted to the front access door
for the drivers side compartment, under
the fuel tank.

All of the control switches are two-
position rotary switches. All switches
must be turned clockwise (to the right)
for on and counterclockwise (to the
left) for off.
The jumper cables are equipped with a
modular connector for connection to
Caterpillar equipment. An adapter has
been provided for connection to other 24
volt equipment.

Electrical power for all body-mounted Operating Instructions:

systems is supplied from the fuse panel
in the relay enclosure. This enclosure is The following operating instructions are
physically located in the reel broken down by system for convenience.
compartment, and also contains the
component control switches.

Bumper:

The bumper on this body is designed as

a holding tank. All drainage from the
operators station drip tray is routed to
the bumper. The bumper is not equipped
with a sight gage and must be drained
daily to prevent overfilling.

Hydraulically Operated Doors (If

Applicable):

There are two hydraulically operated

access doors installed. One is at the
operators station at the rear of the body.

The other access door is at the front of

the fuel tank. This door is for access to
the Grease System components, and also
the air compressor and receiver.
 Hydraulic System Description

If the hoist pump on the chassis was
originally a positive displacement pump,
it has been replaced. The hydraulic
system on the lube body uses a pressure-
compensated, load-sensing, variable
displacement pump to provide the
motive force for all hydraulic
components. The discharge oil from this
pump is routed through the original hoist
control valve and provides the oil
necessary for any hoist system auxiliary
functions (e.g. Brake Cooling).
When the hydraulic system control
switch is placed in the on position the
hoist control valve is shifted to the
raise position to route oil to the lube
body. It is important that the hydraulic
system control switch be turned to off
prior to driving the unit. This will ensure
that the hoist system auxiliary functions
are supplied with oil.
The return oil from the various functions
is collected in the return manifold. From
the manifold, the oil is routed through an
oil cooler. The fan for this cooler is
thermostatically controlled, and starts
automatically when the oil flowing
through it reaches the setpoint listed on
the provided hydraulic schematic. (See
SCHEMATICS)
From the oil cooler, the oil is routed
either back to the hoist control valve, or
directly back to the chassis hydraulic
tank.
Use the following procedures to engage
and disengage the hydraulic system.

If the hoist lever position sensor

provides inputs to the transmission
ECM, these inputs have not been
bypassed. The operator must position the
lever as would be required with a dump
bed installed in order to start and drive
the truck. (Refer to the Chassis
Operators Manual.)

When the hydraulic system is engaged,

oil is routed from the hoist valve to a
distribution manifold installed on the
body. Oil is then distributed to the
various hydraulic functions.
 Hydraulic System Operation in the hydraulic schematic. (See
SCHEMATICS)
DANGER:
Follow all Local Safety procedures
and Chassis Manufacturers WARNING:
instructions for securing the truck The hydraulic system MUST be
prior to exiting the cab with the disengaged in order to ensure that
engine running. Failure to do so hydraulic oil is available for hoist system
could lead to equipment damage, auxiliary functions. Failure to disengage
personnel injury, or even death. the hydraulic system prior to driving the
truck could lead to chassis component
failure.
Engaging the hydraulic system:
Disengaging the hydraulic
1) Park the truck in a safe location and
system:
secure it in preparation for exiting
the cab.
1) Verify that all hydraulic controls are
2) Engage the parking brake switch.
in off, or neutral, and the hydraulic
Then engage the hydraulic system by
system pressure is at its standby
turning the control switch to on.
setting.
3) Engage the engines high-idle system
2) Secure the operators station in
(if required).
preparation for moving the truck.
4) Ensure that it is safe to exit the cab,
3) Enter the cab and disengage the
and proceed to the operators station.
engines high-idle system (if
5) Verify that the hydraulic system is
required).
engaged by observing the system
4) Disengage the hydraulic system by
pressure gage. If no pressure is
turning the system control switch to
indicated, check that the emergency
off.
stop button is pulled out. If there is
The truck may now be driven to the next
still no pressure indicated, refer to
location. Refer to the Chassis
the troubleshooting guide for further
Manufacturers Operators Manual for
instructions.
instructions.
6) The lube body is now ready to
deliver product as required.
a) During operation, the hydraulic
system pressure indicated will
vary. It will indicate the
standby pressure of
approximately 500 PSI unless a
demand is placed on the system.
b) When a hydraulic function is
engaged (except for hydraulic-
rewind hose reels) the system
pressure will rise to the
compensated pressure specified
 Hydraulic Doors
DANGER:
It is impossible to guard all pinch
points on these access doors.
Operators should be especially
vigilant to ensure that all equipment
and personnel are clear of the travel
paths during operation of the
hydraulically operated access doors.
To use the auxiliary pump, open the Ball
valve that is located on the door control
lever next to the hand pump. Then shift
the door control lever in the proper
position to raise or lower the door. Now
the hand pump can be used to move the
door. When the hand pump is not used
close the ball valve on the door control
valve so that the reservoir will not be
over pressured by the main hydraulic
system.

The access door for the operators

station at the rear of the lube body is
hydraulically operated. The hydraulic
system must be engaged for normal door
operations (See Hydraulic System).

The door is controlled by a manually

actuated control valve mounted at the
right rear of the body. The control lever
extends through the body wall to allow
operator access. Raising the lever up will
open the door. The door is closed by
pushing the lever down.

Safety pins have been provided for the

rear access door. These pins are
designed to block the track for the door
guides. These pins are intended to hold
the rear access door open in the event of
a hydraulic component failure. These
safety pins should be installed any time
the rear access door is opened.

A hydraulic hand pump has also been

installed. This auxiliary hydraulic pump
is to be used to open the rear access door
in the event that the main hydraulic
system should become unavailable for
any reason. The auxiliary hydraulic
pump is located on the driver side of the
rear compartment. Open the driver side
door to access this feature.
 Hose Reel Operations
Ground Force Mfg. uses different styles
of hose reels, depending on customer
preference and the specific application.
The three most common types are:
1) Spring rewind These reels are
identified by their lack of external
controls, and their characteristic
clicking sound as the ratchet and
pawl work together.
2) Hydraulic rewind These hose
reels are identified by external
control knobs mounted in a control
panel. These knobs are identified as
to which hose reel they control.
3) Electric rewind These reels are
identified by external control
pushbuttons mounted in a control
panel. These pushbuttons are
identified as to which hose they
control. Electric rewind reels may be
further identified by the electric
motor mounted on the side of the
hose reel frame.
If Applicable, the Manufacturers
Operating Instructions (refer to the
MAINTENANCE section) should be
used in conjunction with the following
for hose reel operations.
Spring Rewind Hose Reels
These hose reels are identified by their
lack of external controls and by their
characteristic clicking sound as the
ratchet works with the pawl. Observe the
CAUTIONARY NOTES and operate the
hose reels using the following as
guidelines.
Cautionary Notes
Be sure that the hose is under control
at all times.
1) Prior to releasing all tension on
the hose; one of the following
conditions MUST exist:
a) The ratchet is seated against
the pawl, locking the hose reel
in place.
b) The ball stop on the hose is in
contact with the fairlead
rollers.
2) DO NOT hand-over-hand a
hose, or allow it to freewheel
back onto a hose reel.
3) Always walk a hose back onto
a spring rewind hose reel.
Positive control of the hose must
be maintained at all times.
Failure to observe the above cautions
may result in component damage,
personnel injury, or even death.
1) Hose is removed from the hose reel
by simply pulling it off. Maintain
positive control of the hose at all
times during hose removal.
2) The hose reel is locked in place by
latching the ratchet into the pawl.
Positive control of the hose should
be maintained until it is verified that
the ratchet is latched.
3) The hose reel is rewound by pulling
on the hose, releasing the ratchet
latch, and slowly allowing spring
tension to rewind the hose. Maintain
positive control of the hose until the
ball stop contacts the fairlead roller.
 Hydraulic Rewind Hose Reels
These hose reels are identified by the
individual control knobs installed in a
control panel at the operators station.
The control knobs are identified as to
which hose reel they control.
The hydraulic controls for these reels are
supplied through a pressure regulating
valve. This regulating valve has been
preset to ensure that the hose reel will
stall should the hose become entangled.
The hydraulic controls themselves are of
the dead-man type. Releasing the knob
will stop the rewinding process at any
time.
It is good practice to maintain a slight
tension on the hose during the rewind
process. This will cause the hose to
rewind more neatly on the reel,
minimizing the chances of the hose
reels binding.
The hydraulic system must be engaged
(see Hydraulic System Operations)
before the hose reels may be used as
follows:
1) To remove hose from a hydraulic
rewind hose reel, pull out on the
appropriate control knob. Hose can
then be removed from the reel as
required with no need to lock the
reel.
2) Rewind the hose by pushing in on
the appropriate control knob.
Maintain a slight tension on the hose
during the rewinding process. If the
hose should become entangled or
bound, release the hose reel control
knob. Pull out on the knob and free
the bind before continuing to rewind.
3) Once the hose is fully rewound,
release the hose reel control knob
and the hose reel will lock in place.
Electric Rewind Hose Reels
These reels are identified by the
individual rewind pushbuttons located at
the operators station. These pushbuttons
are identified as to which hose reel they
control.
These electric rewind hose reels are
equipped with a band-brake to lock the
hose reel in place. This brake must be
loosened to allow the hose to be
removed from the reel, and then
tightened to lock the hose reel after use.
These hose reels rewind the hose very
rapidly. The controls are designed to
allow for repeated bumping of the
rewind pushbutton. This intermittent
engagement of the hose reel motor
allows for a more controlled rewinding
process.
The hose should be continually
monitored during the rewind process. If
the hose should become entangled,
release the rewind pushbutton and free
the hose before continuing to rewind.
1) To remove hose from an electric
rewind hose reel, loosen the band-
brake. The desired amount of hose
can then be removed from the reel.
2) Rewind the hose by momentarily
pushing the rewind pushbutton.
Repeat the momentary use of this
button as necessary.
3) After the hose has been fully
rewound, tighten the band-brake to
lock the hose reel in place.
 Fuel Delivery System Operations

Description: 6) Two hose reels, each equipped with

a delivery hose and nozzle.
Your fuel system consists of the a) The High Volume hoses are
following: equipped with a fast-fill nozzle
for servicing large equipment.
1) One bulk fuel tank equipped with a b) The Low Volume hose is
manual emergency shutoff valve. equipped with an automotive-
a) The actuator for this valve is style nozzle for servicing smaller
mounted on the forward outside equipment.
of the drivers-side compartment. 7) The fuel delivery system controls
This valve must be open for all and meter displays are located at the
fuel system operations. operators station.
2) An electronic bar graph to indicate
fuel tank level. This bar graph is
located near the fuel tank filling
connection.
a) This bar graph and its associated
alarms are discussed later under
Fuel Tank Filling.
3) One hydraulically driven fuel pump.
a) These fuel pumps are equipped
with a small recirculation line.
The purpose of this recirculation
line is to allow for a small
amount of flow through the
pumps at all times. The isolation
valves for these recirculation
lines (located on the fuel pumps
discharge fittings) must be open
during all delivery operations.
4) One fuel filter.
a) One fuel filter is installed for
each fuel pump.
b) The filters are equipped with
inlet and outlet pressure gages.
The filter elements should be
replaced when the pressure drop
across the filters reach 20 PSI.
Refer to the MAINTENANCE
section for further information.
5) One fuel meters. (One for each
pump.)
Fuel Delivery:
Once the hydraulic system has been
engaged (see Hydraulic System
Operations), perform the following to
deliver fuel.
WARNING:
The emergency shutoff valve and the fuel
pump recirculation valve must be open
for all fuel system operations
1) Verify that the fuel tank emergency
shutoff valve and the fuel pump
recirculation valves are open. Also
reset the fuel meters to zero if
necessary.
2) Refer to Hose Reel Operations,
and remove the desired amount of
hose from the selected reel.
3) Pre-select the pump speed based on
the nozzle selected.
a) If using the Low Volume hose,
speeds greater than turn
Clockwise will cause excessive
foaming with no increase in the
delivery rate.
b) If using a High Volume hose, the
speed control valve should be
fully opened clockwise.
4) If using a High Volume hose, the
nozzle should be connected and the
delivery valve opened prior to
starting the pump.
5) Start the selected fuel pump by
turning its control switch to on.
6) While dispensing fuel, observe the
following.
a) The fuel meter should be
monitored occasionally to verify
that fuel is flowing.
b) The fuel filter inlet and outlet
pressure gages should be checked
during full flow operations. A
pressure drop of 20 PSI or
greater indicates a clogged filter.
(Refer to the
MAINTENANCE section for
further instructions.)
c) While using the High Volume
nozzle, if the tank being filled is
not adequately vented the fast-fill
nozzle will shut prematurely. If
this occurs, the pump speed
should be slowed by turning the
appropriate speed control valve
clockwise. Operator experience
will determine how fast each
piece of equipment can be filled
without premature shut-off.
WARNING:
Extended Operations with no flow through
a delivery nozzle will result in fuel pump
overheating and subsequent damage. The
fuel pump should be turned off as soon as
possible once the delivery nozzles are shut
off to avoid fuel pump damage.
7) When the tank being filled is full,
use the fuel pump control switch to
turn the fuel pump off as soon as
possible.
8) Disconnect the nozzle from the tank
being filled (if required).
9) Refer to Hose Reel Operations and
rewind the hose onto the reel.
10) Record the amount of fuel pumped
as required by local procedures, and
reset the meters.
Fuel Tank Filling:
CAUTION:
Follow all local safety procedures
and applicable guidelines while
filling the bulk fuel tank.
The bulk fuel tank is filled through a fill
connection located on forward side of
the drivers side compartment, below the
fuel tank. The fuel tank level indicator is
located near this connecting point. To
fill the fuel tank, follow all local safety
procedures and applicable guidelines,
and perform the following.
WARNING:
The fuel tank Emergency Shutoff
valve must be open while filling the
fuel tank.
1) Verify that the Emergency Shutoff
valve is open by checking that the
actuating lever (mounted on the
outside front of the drivers-side
compartment) is latched in the
open position.
WARNING:
As with all other electrical systems
installed by Ground Force Mfg., the
Diesel Tank Level Indication and
Alarm System will not function
unless the ignition key is on.
2) Examine the fuel tank level indicator
to verify that the tank needs to be
filled. If the level indicator reads 0%,
verify that the ignition key is turned
on.
WARNING:
An initial reading of either zero or
100% may also indicate component
failure, and should not be trusted
until actual level is verified.
Verification is done visually through
the access hatch in the tank manhole
cover.
WARNING:
The Diesel Tank Level Alarms are
not enabled unless the Whisker
Switch mounted near the fill
connection is actuated. Be sure that
the whisker is displaced by the fill
nozzle when connecting to the fill
connection.
3) When level has been verified,
connect the fill nozzle to the fill
connection. BE SURE THAT THE
WHISKER SWITCH IS
ACTUATED.
4) Open the fill connection isolation
valve and commence filling the fuel
tank according to applicable local
procedures. Observe the tank level
indicator to verify that the tank is
filling.
5) Continually monitor tank level
displayed on the level indicator.
6) The tank level indicator also controls
various alarm functions. These alarm
 functions are enabled only when the
whisker switch at the fill connection
is actuated. A description of the
alarms and warnings associated with
this level indicator follows.
a) As the indicated level passes
through 85%, the display will
change from flashing to solid. At
the same time, the yellow beacon
at the fill station and yellow
warning light in the cab will 7) Stop filling IMMEDIATELY when
illuminate. the tank level reaches 95%. If the
b) When the tank level reaches tank is overfilled, pump some fuel
95%, the display will start out to ensure adequate expansion
flashing again. At the same time, volume prior to leaving the truck
the red beacon at the fill station, idle.
the red alarm light in the cab, and 8) Shut the fill connection isolation
the audible alarms at both places valve, and remove the fill nozzle to
will be energized. complete the filling operation.
c) The alarms and warnings will 9) Shut down the filling station
remain energized until the nozzle according to applicable local
is disconnected, and the whisker procedures.
switch is no longer actuated. 10) Record the amount of fuel on-loaded
d) As tank level drops during as required by local procedures.
delivery operations, the display
will change from flashing to
solid, and then back to flashing
again as the different setpoints
are reached.

CAUTION:

The fuel tank is continually vented

through the access hatch in the
manhole cover. As a result, the fast
fill nozzle will not shut automatically.
Tank level must be continually
monitored. Filling must be manually
 Oil Delivery Systems
Description:
This Lube Truck is equipped with
multiple oil delivery systems. The
delivery systems are all similar, and
consist of the following:
1) A bulk tank for storage during
transport.
2) A hydraulically driven delivery
pump.
a) Each pump is equipped with a
pressure switch in the pump
discharge block to turn the pump
off when not in use.
3) A product filter may be installed.
Refer to the MAINTENANCE
section for further information.
4) A meter may be installed. Refer to
the MAINTENANCE section for
further information.
a) If a meter is installed, it is either
on the end of the delivery hose or
in a panel at the operators
station.
5) A hose reel equipped with a delivery
hose and dispensing valve.
6) On/Off controls at the operators
station.
a) These controls may be one
switch for all oil pumps or one
switch for each oil pump.
b) One common switch will simply
be labeled OIL PUMPS.
c) Individual control switches will
be identified by a product
number or product type (OIL 1,
OIL 2, etc., or 10 WT, 30 WT,
HYDRAULIC OIL, GEAR OIL,
etc.)
Product Delivery:
After the hydraulic system is engaged
(see Hydraulic System Operations),
perform the following to deliver oil
product:
1) Refer to Hose Reel Operations and
remove the desired amount of hose
from the selected reel.
2) Reset the appropriate meter (if
applicable).
3) Connect the fill coupling to the
equipment being serviced (if
applicable).
WARNING:
It is important to note that the oil
product pumps are designed to
operate as an on demand system.
When a common control switch is
used, ALL pumps are enabled when
the pump controls are turned to on.
At this point, any pumping system
with an open dispensing valve will
start pumping. Be sure that ALL oil
dispensing valves are SHUT prior to
turning the common OIL PUMPS
control switch to on.
4) Verify that all oil delivery valves are
shut, and turn the OIL PUMPS
control switch to on (if applicable).
If individual control switches are
provided, turn the appropriate
control switch to on.
 a) It is common for the hydraulic
system pressure to spike when
an oil pump is turned on. This is
due to the oil delivery pumps
response to a depressurized
delivery hose
b) Any pressure spike observed
should be momentary, and the
hydraulic system pressure should
rapidly return to standby pressure
once all oil delivery hoses are
charged.
c) Any time that an oil delivery
system is turned on, the hydraulic
system pressure should rapidly
return to its standby pressure
when the delivery valve is shut.
If this does not occur, a problem
with the pumps automatic
controls is indicated (see NOTE
at right).
5) Open the delivery valve for the
selected product to start dispensing
oil. Observe the meter (if applicable)
to verify flow.
6) When the desired amount of product
has been dispensed, shut the delivery
valve to stop delivery.
7) Disconnect the fill coupling from the
equipment being serviced (if
applicable).
8) Refer to Hose Reel Operations and
rewind the delivery hose onto the
hose reel.
9) Observe the hydraulic system
pressure gage to verify that the oil
delivery system is off (See NOTE at
right).
10) Turn the appropriate control switch
to off.
11) Record the amount of product(s)
pumped as required by local
procedures and reset the meter(s) (if
applicable).
NOTE:
The hydraulic system pressure gage
should be observed prior to turning
any oil pump control switch to off.
This is to verify that the pumps
automatic controls are functioning
properly.
The hydraulic system should be at, or
at least nearing, its standby pressure
by the time that a delivery hose has
been rewound.
If the hydraulic system pressure
remains at operating pressure, a
problem with the oil pumps pressure
switch is indicated. Operations may
continue for the rest of the shift while
arrangements are made for
troubleshooting and repair.
Short-term operations with a pressure
switch out of adjustment will not
cause damage as long as the
procedure to the left is followed, and
the hydraulic system does return to its
standby pressure after the oil product
pumps control switch is turned off.
If the hydraulic system fails to return
to its standby pressure after the oil
pumps control switch is turned off,
the problem is more pressing and
continued operations should be
avoided until after repairs have been
performed.
Refer to Hydraulic System
Operations and the
MAINTENANCE section for
further information.
 Grease Delivery System(s)
Description:
There are two different types of delivery
systems available; High Pressure (Zerk),
and High Volume (Bulk). The grease
delivery systems are similar, and consist
of the following:
1) A grease container of some sort.
a) Ground Force Mfg. Grease bins
are designed to accommodate
one Zerk grease pump and one
bulk grease pump.
b) Other containers may be used,
depending on the options
ordered.
2) A grease pump.
a) Zerk grease pumps are identified
by their small size and the
pump discharge hose.
b) Bulk grease pumps are identified
by their large size and the 1
pump discharge hose.
3) A hose reel equipped with a delivery
hose and dispensing valve.
a) Zerk Grease systems are
equipped with a grease gun at the
end of the delivery hose.
b) Bulk Grease systems are
equipped with a ball valve and
short length of hose at the end of
the delivery hose.
4) The hydraulic controls for the two
pumps are similar.
a) All grease pump hydraulic
controls are equipped with a
pressure regulating valve. This
valve is preset to limit the
pumps hydraulic supply
pressure to 1500 PSI. This is the
maximum pressure allowed for
these hydraulic motors. Do not
adjust this pressure regulating
valve.
b) Also installed in the hydraulic
control block for each motor is a
flow limiter. This is to limit the
grease pump speed to a
maximum of 60 strokes per
minute.
c) All Grease pumps installed are
individually controlled using a
selector switch at the operators
station. There are no automatic
controls installed. The grease
pumps must be turned off
manually when not in use.
Operation:
All grease systems are operated the same
way. To dispense grease, select the
product to be delivered and proceed as
follows:
1) Engage the hydraulic system if not
already done (see Hydraulic System
Operations).
2) Refer to Hose Reel operations and
remove the required amount of hose
from the reel.
3) Start the selected grease pump by
turning the associated control switch
to on.
4) Dispense grease as necessary.
5) When dispensing operations are
complete, stop the grease pump by
turning the pumps control switch to
off.
6) Refer to Hose Reel Operations and
rewind the hose onto the hose reel.
7) Disengage the hydraulic system
unless needed for another function
(see Hydraulic System
Operations).
 Compressor Operations
Description:
This Lube truck is equipped with a
compressed air system that consists of
the following components:
pneumatic components) installed are
supplied after the FRL assembly.
The FRL is normally set at 80 PSI at
the factory, but may be turned up to
100 PSI if desired.
Operation:

1) One hydraulically driven air WARNING:

compressor, equipped with automatic
controls. Once the hydraulic system is
a) When the air compressor manual engaged, the air compressor may be
control switch is turned on, the turned on and left on. The air
compressor will cycle compressor manual control switch
automatically to maintain 100- MUST be turned to OFF prior
125 PSI in the receiver. leaving the operators station and
b) Compressor oil level should be returning to the cab. This is to
checked according to the prevent damage to the hydraulic
schedule in the system when it is next engaged.
MAINTENANCE section.
2) An air receiver for storage and initial
moisture separation.
After the hydraulic system is engaged
a) This receiver is equipped with a
(see Hydraulic System Operations),
manual drain valve, and should
the air compressor may be turned on.
be drained at least once per shift.
Refer to the Manufacturers operating
b) It is good practice to leave this
instructions and turn the air compressor
drain valve open if the
manual control switch to on. The
compressed air system will be
installed pressure switch will cycle the
idle for extended periods (greater
hydraulic controls automatically to
than one shift).
maintain 100-125 PSI in the air receiver.
3) A filter-regulator-lubricator (FRL)
assembly for air treatment.
Air compressor operations are required
a) This FRL assembly may be
for any operations involving diaphragm
equipped with a desiccant air
pumps or other pneumatic components
dryer.
installed on the truck body. Any of the
b) Refer to the MAINTENANCE
chassis pneumatic components are
section for more information.
supplied by the chassis compressed air
4) A hose reel equipped with a delivery
system.
hose.
a) This hose reel is supplied with
To prevent damage to the hydraulic
filtered, unregulated air. If an air
system, the air compressor manual
dryer is installed, the hose reel is
control switch must be turned off prior
supplied with filtered, dried,
to returning to the cab. It is good
unregulated air.
practice to leave the air compressor
5) The pneumatic controls for the
controls off when the system is not in
diaphragm pumps (and any other
use.
 Coolant System
Description:
The coolant delivery system on this
truck consists of the following
components:
1) A storage tank equipped with a sight
gage with isolation valves for level
indication.
a) This tank may also be equipped
with remote level indication. If
so it will activate warning lights
and alarms at the remote filling
station, located at the rear of the
truck. See Product Tank Filling
for more information.
2) A pneumatically driven diaphragm
pump.
3) A meter may be installed to monitor
fluid delivery (refer to the
MAINTENANCE section for
further information).
a) If installed, this meter will be
located either on the end of the
delivery hose (with the
dispensing valve), or mounted in
a panel at the operators station.
4) A hose reel equipped with a delivery
hose and dispensing valve.
3) Connect the delivery hose to the fill
connection on the equipment being
filled, (if applicable).
4) Reset the coolant meter (if installed).
5) Start the coolant pump by turning its
control switch to on.
6) Open the dispensing valve to start
the flow of fluid.
7) Monitor the coolant meter (if
installed) to verify fluid flow.
8) When the desired amount of fluid
has been delivered, shut the
dispensing valve to stop flow.
9) Stop the coolant pump by turning its
control switch to off.
10) Refer to Air compressor operations
and stop the air compressor unless
needed for another function.
11) Refer to Hose Reel Operations and
rewind the coolant delivery hose
onto the reel.
12) Record the amount of fluid delivered
as required by local procedures (if
applicable).

Operation:

Compressed air is required for coolant

delivery. Coolant delivery is achieved as
follows:

1) Refer to Air Compressor

Operations and start the air
compressor.
2) Refer to Hose Reel Operations and
remove the required amount of hose
from the reel.
 Used Oil System
Description:
The used oil system is provided for
recovery, transport, and disposal of oil
removed from equipment in the field. It
consists of the following:
1) A tank for storage during transport.
a) This storage tank is equipped
with a sight gage with isolation
valves for level indication.
b) This tank may also be equipped
with a remote level alarm system
located at the operators station,
near the used oil pump controls.
c) This tank is equipped with a tank
inlet/outlet isolation valve. This
valve must be open for all used
oil system operations.
2) A pneumatically driven diaphragm
pump.
3) A four-way directional control valve.
a) This valve allows the use of the
same pumping system for both
on-loading and off-loading
operations.
Warning:
Opening the Filter Drawer Isolation
Valve inappropriately may result in
filling the filter drawer with used oil.
This isolation valve should only be
opened after ensuring that the used
oil pump is running, and the four-way
directional control valve is in the
FILL TANK position. The Filter
Drawer Isolation Valve should be
shut at all other times.
b) This valve may be equipped with
a Filter Drawer Drain Valve
attached to the HOSE port on the
four-way valve.
4) A hose reel equipped with a
suction/delivery hose and a hose end
isolation valve.
5) Pump on/off controls located at the
operators station
Filter Drawer Evacuation:
If a used filter drawer is installed, it may
be evacuated two ways:
1) Follow the On-loading procedure
below, but route the suction/delivery
hose to the filter drawer rather than a
drain valve.
Warning:
Opening the Filter Drawer Isolation
Valve inappropriately may result in
filling the filter drawer with used oil.
This isolation valve should only be
opened after ensuring that the used
oil pump is running, and the four-way
directional control valve is in the
FILL TANK position. The Filter
Drawer Isolation Valve should be
shut at all other times.
2) If a Filter Drawer Drain Valve has
been installed, it will be attached to
the HOSE port on the four-way
directional control valve. Use the
On-loading procedure below as a
guide while using this feature but
operate the Filter Drawer Drain
Valve rather than the hose end
isolation valve. BE SURE TO SHUT
THIS VALVE when the filter drawer
is empty.
On-loading operations:
When it is desired to on-load used oil,
proceed as follows:
1) Ensure that there is enough room in
the used oil tank. Verify that the
tanks inlet/outlet isolation valve is
open.
2) Refer to Air Compressor
Operations and start the air
compressor.
3) Refer to Hose Reel Operations and
remove the desired amount of hose
from the reel.
4) Connect the used oil hose to the
appropriate evacuation fitting on the
equipment being serviced (if
applicable), or route the end of the
hose to the drain pan.
Warning:
Opening the Filter Drawer Isolation
Valve inappropriately may result in
filling the filter drawer with used oil.
This isolation valve should only be
opened after ensuring that the used
oil pump is running, and the four-way
directional control valve is in the
FILL TANK position. The Filter
Drawer Isolation Valve should be
shut at all other times.
5) Verify that the Filter Drawer Drain
Valve is shut (if applicable).
6) Verify that the four-way directional
control valve is in the FILL TANK
position.
7) Start the used oil pump by turning its
control switch to on.
8) Open the hose end isolation valve to
start oil flow.
9) Monitor the used oil tank level by
observing the sight gage. Stop on-
loading if the tank should become
full.
10) If the tank is equipped with a remote
level indication system, warning
lights and alarms will be mounted at
the operators station, near the used
oil pump controls.
a) The yellow 50% light (if
installed) will be lit any time that
the used oil tank level is greater
than 50% and the ignition key is
on.
b) If a high level alarm is installed,
a red alarm light will illuminate,
and an audible alarm will sound,
when used oil tank level reaches
95%. Depressing the Alarm
Acknowledge pushbutton will
silence the alarm, but the red
light will remain lit until tank
level drops below 95%.
c) The audible alarm will reset itself
any time that the key is turned
off. If the used oil tank level is
greater than 95% when the
ignition key is turned on, the
Alarm Acknowledge
pushbutton must be depressed to
silence the audible alarm.
11) When on-loading is complete, or the
used oil tank becomes full
(whichever occurs first), shut the
hose end isolation valve.
12) Stop the used oil pump by turning its
control switch to off.
13) Refer to Air Compressor
Operations and stop the air
compressor unless needed for
another function.
14) Refer to Hose Reel Operations and
rewind the suction/delivery hose
onto the reel.
Used Oil Off-loading:
NOTE:
Be sure to comply with all local
guidelines and procedures at the used
oil receiving facility while
performing this procedure.
When the used oil tank is full, it is
emptied by performing the following:
1) Verify that there is sufficient room in
the receiving facilitys receiving
tank.
2) Verify that the used oil tank
inlet/outlet isolation valve is open.
3) Refer to Air Compressor
Operations and start the air
compressor.
4) Refer to Hose Reel Operations and
remove the required amount of
suction/delivery hose from the reel.
5) Connect the suction/delivery hose to
the receiving facilitys filling
connection (if required). Perform all
other steps to prepare the facility for
receiving used oil.
Warning:
Opening the Filter Drawer Isolation
Valve inappropriately may result in
filling the filter drawer with used oil.
This isolation valve should only be
opened after ensuring that the used
oil pump is running, and the four-way
directional control valve is in the
FILL TANK position. The Filter
Drawer Isolation Valve should be
shut at all other times.
6) Verify that the Filter Drawer Drain
Valve (if installed) is shut, and shift
the four-way directional control
valve to EMPTY TANK.
7) Start the used oil pump to by turning
its control switch to on.
8) Open the hose end isolation valve to
start off-loading used oil.
9) Monitor the receiving tanks level
according to local procedures, and
stop filling if the receiving tank
should become full.
10) Monitor the trucks used oil tank
level. The remote level indicating
lights (if installed) should go out as
the used oil tank level drops below
the setpoints.
11) When the used oil tank is empty, or
the receiving tank is full (whichever
occurs first), shut the hose end
isolation valve.
12) Return the four-way directional
control valve to FILL TANK.
13) Stop the used oil pump by turning its
control switch to off.
14) Refer to Air Compressor
Operations and turn off the air
compressor, unless needed for
another function.
15) Perform all steps required by the
receiving facilitys operating
procedures prior to disconnecting the
suction/delivery hose.
16) Disconnect the suction/delivery hose.
17) Refer to Hose Reel Operations and
rewind the hose onto the hose reel.
 Product Tank Filling
Description:
This Lube truck is equipped with a
ground-level filling station for all new
oils and coolant. If equipped, the grease
tote may also be filled from this location.
All fill connections installed at this
location are equipped with an isolation
valve as well as provisions for
installation of customer-supplied quick-
couplers. The isolation valve is provided
to allow for the replacement of the
quick-couplers in the event of their
failure. An isolation valve is also
installed on the tank inlet for each
product tank filled from this location.
Both the tank inlet and fill connection
isolation valves should be open for tank
filling from this location.
All new oil and coolant product tanks
are equipped with sight gages for direct
indication of tank level. The grease tote
level is monitored visually through the
access hatch in the totes manhole cover.
NOTE:
As with all other electrical
systems installed by Ground
Force Mfg, the Product Tank
Level Indicating and Alarm
system will not function unless
the ignition key is on.
This truck may also be equipped with
various warning and alarm lights at the
ground-level filling station:
1) 50% level indication.
a) If so equipped, a yellow
indicating light will be
illuminated as long as the
associated tank level is greater
than 50%.
b) Grease totes are not equipped
with this feature.
2) 95% level alarm.
a) If so equipped, a red alarm light
will illuminate whenever the
associated tank level rises above
95%.
b) An audible alarm is activated
whenever one of these red alarm
lights illuminates. Pushing the
associated Alarm
Acknowledge pushbutton will
silence the audible alarm. The
red alarm light will remain
illuminated, however, until the
tank level drops below 95%.
c) The grease totes may be
equipped with a similar high
level alarm.
3) On most units, an oil tank overflow
recovery system has been installed.
In the event that a new oil product
tank is overfilled, the overflow is
routed to the used oil tank through a
flow switch.
a) If so equipped, this flow switch
will activate a red warning light,
and audible alarm at the ground-
level filling station. This alarm
will reset itself after flow through
the switch is stopped.
4) Any alarms and indicating lights
installed at this ground-level filling
station are enabled only when the
access door is opened. Each time that
this door is opened, all 95% level
alarms must be acknowledged to
silence the audible alarm. This
should be done prior to commencing
any filling operations.
Product Tank Filling:
WARNING:
Follow all local procedures and
guidelines during product tank filling.
Proceed as follows to fill a product tank
from the ground-level filling station. Be
sure to comply with all applicable local
guidelines and procedures during this
process.
1) Visually check the level in the
tank(s) to be filled. Verify that the
tank inlet isolation valves are open.
2) Open the ground-level filling station
access door and silence any existing
high level alarms by pushing the
appropriate alarm acknowledge
pushbuttons.
3) Follow local procedures and
guidelines to connect the product
supply to the appropriate fill
connection.
4) Open the selected fill connection
isolation valves and commence
filling.
5) The selected tanks actual level
should be periodically checked
visually during filling. These checks
should become more frequent as the
level nears full.
6) Observe that the selected product
tanks 50% light (if so equipped)
illuminates as the actual tank level
rises above 50%.
7) If so equipped, the selected tanks
high level alarms will activate as the
actual tank level reaches 95%
a) Stop filling the appropriate tank
immediately when this occurs.
b) Once filling of the selected tank
is stopped, silence the audible
alarm by pushing in on the
appropriate alarm acknowledge
pushbutton. The red light will
remain illuminated as long as the
actual tank level is greater than
95%.
8) Some units are equipped with an oil
product tank overflow alarm. If so
equipped, an alarm is activated at the
ground-level filling station to warn
the operator that there is flow
through the overflow recovery line.
Stop ALL filling operations
immediately if this alarm sounds.
a) The alarm will clear itself once
the flow through the overflow
recovery line stops.
b) Filling operations should not be
resumed until it is determined
which tank is overflowing.
c) The overflow recovery system is
for oil products ONLY and
should not be relied upon as` a
backup for any coolant tank level
indicators.
9) As the selected tanks become full,
stop filling them according to local
procedures and guidelines.
10) Shut the fill connection isolation
valves and disconnect the fill
connections.
11) Once all filling operations are
complete, shut the ground-level
filling station access door. This will
disable the Product Tank Level
Warning and Alarm System (if
installed). All existing high level
alarms should be acknowledged prior
to filling any tanks when this door is
subsequently opened.
 Tank and Compartment Heaters
Description:
The heating system installed circulates
heated coolant through various
components.
1) The oil product tanks.
2) The grease tote installed.
3) Various compartment heaters.
The diesel-fired heater is supplied with
fuel from an independent fuel tank
installed in the drivers-side
compartment below the bulk fuel tank.
Level in this tank should be monitored
during heater operations, and filled as
necessary using the trucks Low Volume
Fuel Delivery System.
Electrical power for this heater is
supplied from the distribution panel
installed by Ground Force Mfg. As with
all other functions supplied from this
panel, the ignition key must be on for
heater operations.
Once the heater control switch is turned
on, the heater will start and cycle
automatically. Refer to the
Manufacturers Operations Manual for
further instructions.
An expansion tank for this heating
system is located against the front wall
of the product tank enclosure. There are
two bulls-eye sight gages installed in
this tank for monitoring tank level.
Expansion tank level should be
periodically monitored. Initial level in a
cold system should be halfway up the
lower sight gage. Once the system is
warm, any level above this point is
acceptable. Refer to the
MAINTENANCE section for further
instructions.
Component Heaters:
Heat loops are installed in the selected
product tanks. Compartment heaters are
also installed in various locations.
Depending on the number of individual
components used, there may be one or
more individual heat circuits installed.
All components in each individual
circuit are connected in series, the
product needing the most heat coming
first. Each circuit is then connected in
parallel with any other circuits, via
supply and return manifolds, if required.
The compartment heaters (if installed)
are equipped with electric-motor-driven
air circulation fans. These fans are
manually controlled using an on/off
switch installed below the
compartments internal lighting control
switch. The fans may also be equipped
with thermostatic controls (refer to the
MAINTENANCE section)
 Jumper Cable Reel

WARNING:

Read and understand any equipment-

specific instructions, along with all
local safety and operating procedures,
prior to jump starting any piece of
equipment.

The jumper cables are installed on a reel

in the drivers-side compartment, below
the bodys fuel tank. The reel is mounted
on the forward access door for this
compartment for operator convenience.

The jumper cables are equipped with a

modular cable connector to mate with
Caterpillar equipment. An adapter cable
with regular jumper cable clamps is also
provided to allow connection with other
24 volt equipment.

There is an isolation switch mounted on

the jumper cable reel. This switch looks
similar to a battery disconnect switch,
and breaks the power to the positive
cable. Once the jumper cables are
connected to the equipment being
serviced, this switch must be turned on
before any power is available to the
jumper cables.

Power for the jumper cables is taken

directly from the chassis batteries
through a circuit breaker located in the
battery compartment.

The reel for jumper cable storage is

manually rewound using the provided
hand crank. A holster for storage of
this crank is installed on the front of the
jumper cable reel.
3. MAINTENANCE /
TROUBLE-
SHOOTING
M16 Maintenance
INTRODUCTION
Your lube truck was constructed with care and with
quality materials. Simple routine maintenance will
assure that it will continue to operate with minimal
problems. This section of the manual will help you
establish a routine maintenance schedule and will
detail components which may need service at some
time. In some cases the body utlizes the chassis'
system hydraulic tank and we recommend to use the
Mfg recomendations on oils and filters maintenance.
Note: This section of the manual has the suggested
schedule of maintenance operations for your new
truck body. Some or all of the schedules will apply
to your individual truck. These schedules are
intended as a guideline only. As long as attention is
paid to lubrication and maintenance a minimum of
times as recommended, your own mine maintenance
schedule can supersede the recommended schedule.
SP1 Maintenance
SAFETY PROCEDURES
1. THINK!!
2. Use EXTREME CAUTION when working
on or servicing any machinery.
3. Before doing any work on your equipment
follow three easy steps:
A. Lock It Out
B. Tag It Out
C. Put The Keys In Your Pocket
4. Before starting equipment after servicing,
check to see that all personnel are clear. When
you are positive all are clear, check again!
HS10 Hydraulics
HYDRAULIC SYSTEM
Inspection
Inspect your truck daily for worn hoses or loose
fittings. When hoses appear worn (especially if wire
wrappings are showing through), replace the hose
before a failure occurs. Tighten any loose fittings.
Note: When equipment is new, leaks will frequently
occur. This is normal and will cease after the unit has
been in operation for a while when fittings are
tightened and seated.
Hint: When re-sealing pipe thread fittings, use
anaerobic hydraulic thread sealant (Felpro #51452).
Do not use Teflon tape (its use voids some
component manufacturers warranties).
General Fitting Sizes:
o 1/4" hose - ORS - 4
o 3/8" hose - ORS - 6
o 1/2" hose - ORS - 8
o 3/4" hose - ORS - 12
o 1" hose - ORS - 16
Hydraulic Oil
Your new truck has been shipped without hydraulic
oil. Utilize preferably ATF (Dexron II) or a premium
grade AW46 hydraulic oil. ATF is compatible with
all hydraulic components on your system and has the
least amount of control speed variation with oil
temperature change.
Note: If ATF is not available, the same Hydraulic
fluid could be used that is put into the Chassis hoist
system or Grade that is on site.
Return Oil Filters
These filters are in tank filters mounted on top of the
system hydraulic tank. These filters can also be
remote mounted if space above the hydraulic tank is
to close to remove filter from top of tank.
We recommend changing the hydraulic system return
oil filters monthly if your unit is used frequently. A
$30 filter is cheap preventative maintenance for a
$6,000.00 hydraulic system.
CAUTION!!!
Your hydraulic reservoir is equipped with a
pressure holding vent cap. This pressurizes the
reservoir to approximately 3 psi to assure adequate
oil feed to the hydraulic pump. Do not replace this
cap with a non-pressurized model!!!
LU7 Maintenance
LUBRICATION
Proper lubrication will be the single most important
item affecting the life of your Fuel/Lube Truck. In
the harsh environment the equipment is used in,
regular and proper lubrication will ensure that
moving parts do not seize.
Use clean lubricants. Clean off grease fittings and
the grease gun before using. If using an air-operated
grease gun, be sure the pressures developed will not
damage seals.
Basic Components to Lubricate
Hinges, Latches, Bearings and Reels
Lubricate regularly (preferably every two weeks) or
following a washdown. Use a nickel based (not
copper based) anti-seize compound such as:
a. Loctite Nickel Anti-Seize (Part #77164).
b. Felpro Nickel-Ease (Part #51119).
c. Felpro Nickel-Ease (Part #51286) 1-lb. aerosol
can.
 PREVENTATIVE MAINTENANCE SCHEDULE
DESCRIPTION DAILY WEEKLY MONTHLY ANNUALLY
Lubricate Reel Rollers X
Lubricate Reels X
Grease/Lube - Pumps and Motors (If Applicable) X
Change Hydraulic Oil X
Change Hydraulic Filter X
Clean In-Tank Suction Strainer (If Applicable) X
Change High Pressure Filters (If Applicable) X
Change Product Tank Breathers (If Applicable) X
Clean Used Oil Strainer (If Applicable) X
Change Diesel Filter (If Applicable) X
Clean Diesel Strainer (If Applicable) X
Check Hydraulic Fluid Level X
Check Hydraulic Control Valves X
Check Hydraulic Hoses and Fittings X
Check Drive Couplings and Inserts (If Applicable)
*Hydraulic System X
*Diesel System X
*Product systems X
*Water System X
Check Body Mounts (If Applicable)
*Spring Body Mounts X
*Rigid Body Mounts X
*Rear Body Pins X
Check Pump Mounting Bolts (If Applicable)
*Hydraulic System X
*Diesel System X
*Product systems X
*Water System X
Check Fuses in Fuse Panel X

**See Manufacturer Manuals for Specific Maintenance Details**

Maintenance Schedule Page 1

 PREVENTATIVE MAINTENANCE SCHEDULE

Daily Log
DESCRIPTION Date
Check Hydraulic Fluid Level
Check Hydraulic Control Valves
Check Hydraulic Hoses and Fittings
Check Drive Couplings and Inserts (If Applicable)
*Hydraulic System
*Diesel System
*Product systems
*Water System
Check Body Mounts (If Applicable)
*Spring Body Mounts
*Rigid Body Mounts
*Rear Body Pins
Check Pump Mounting Bolts (If Applicable)
*Hydraulic System
*Diesel System
*Product systems
*Water System
Check Fuses in Fuse Panel

**See Manufacturer Manuals for Specific Maintenance Details**

Weekly Log
DESCRIPTION Week
Lubricate Reel Rollers
Lubricate Reels
Grease/Lube - Pumps and Motors (If Applicable)

**See Manufacturer Manuals for Specific Maintenance Details**

Maintenance Log Page 1

 Monthly Log
DESCRIPTION Month
Change Hydraulic Filter
Change High Pressure Filters (If Applicable)
Change Product Tank Breathers (If Applicable)
Change Diesel Filter (If Applicable)
Clean Used Oil Strainer (If Applicable)

**See Manufacturer Manuals for Specific Maintenance Details**

Annual Log
DESCRIPTION Year
Change Hydraulic Oil
Clean In-Tank Suction Strainer (If Applicable)
Clean Diesel Strainer (If Applicable)

**See Manufacturer Manuals for Specific Maintenance Details**

Maintenance Log Page 2

TS26a
TROUBLE SHOOTING GUIDE
PROBLEM PROBABLE CAUSE
Hydraulic system will Hydraulic pump not running.
not operate.
Hydraulic pump turning, no
apparent oil output.
Hydraulic pump turning, oil
output apparently O.K.
(Pressure Compensated
Pumps Only) Pump output
pressure too low.
Product pump will Solenoid valve is closed.
not run.
No hydraulic oil at drive motor or
low oil pressure.
High pressure in system, pump
will not turn.
Motor runs, pump will not.
Hydraulic motor bad.
Hose reel will not PTO not engaged.
function.
No hydraulic oil or low pressure
to control valve.
Regulating valve on valve block
set too low.
Hydraulic motor getting oil, but
no functioning.
Trouble Shooting
ITEMS TO CHECK
Check PTO-pump driveshaft.
Check keyways in pump, PTO driveshaft.
Check pump shaft.
Check if pump is free or frozen up
Check oil level in hydraulic tank.
Check pump driveshaft.
Check pressure build when a circuit is
used:
a. No/low Pressure: Check circuit or
main relief valve.
b. High Pressure Relieving: Check to
be sure the operating system is not
frozen up.
Check pressure compensator, reset
pressure to what is required by hydraulic
schematic.
Check relief valves.
Check power to coil. Also check
cartridge for debris.
Check main hydraulic pump ball valve to
be sure it is fully opened.
Pump binding: Check oil flow to be sure
pump turns with hydraulic motor
uncoupled.
Check drive coupling.
Check motor.
Check PTO.
Check hydraulic pump.
Check system pressure, Verify with
Hydraulic schematic.
Replace motor.
TS44b
HYDRAULIC LOAD SENSING SYSTEM
TROUBLE SHOOTING GUIDE
PROBLEM
Hydraulic system will not
return to a standby
pressure of 300-500 psi
after all circuits have been
disengaged.
Hydraulic system will not
develop high pressure (will
not raise above typical
300-500 psi standby
pressure).
Hydraulic system pressure
will not increase even with
all system and circuit relief
valves set.
PROBABLE CAUSE
Plugged load sense bleed valve
cartridge. (Verify That bleeder
exists with hydraulic schematic)
Faulty pump compensator.
Hydraulic circuit(s) not totally
disengaged - load sense circuit still
receiving signal pressure.
Plugged signal port on pump
compensator control block.
Wrong sized orifice in load sense
bleed valve cartridge. Pressure is
not being allowed to build in load
sense signal circuit.
Leak in load sense signal line
circuit.
Circuit control valve not being
engaged properly.
Faulty load sense check valve.
Faulty pump compensator.
Too high of volume of load sense
circuit signal pressure lost by
bleed to tank or by line leaks.
Trouble Shooting
ITEMS TO CHECK
Remove cartridge, check for debris
creating obstruction of orifice.
Clean and reinstall.
Replace compensator block.
Perform single circuit diagnostics to
determine which circuit remains
open.
Repair circuit components.
Remove load sense signal line from
compensator block. Engage one
circuit (such as product delivery,
compressor, or down riggers).
Signal hose should discharge a
steady stream of oil.
Remove compensator block and
thoroughly clean (see pump service
instructions).
Check for proper load sense bleed
valve cartridge. If questionable,
replace with 0.1 gpm cartridge.
Check for leaks, repair as needed.
Check for mechanical failure such
as pneumatic pilot not actuating a
hydraulic valve.
Systematically run each separate
circuit. Determine which circuit
does bring pump up to pressure.
Replace or repair load sense check
valve on that circuit.
Replace compensator block.
Check for leaks, repair as needed.
Check for proper load sense bleed
valve cartridge. If questionable,
replace with 0.1 gpm cartridge.
4. SCHEMATICS
Customer: Ground Force Deutsch 12-pin connectors
Project: Diesel Pump V1.0 Plug: DTM06-12SA (Grey)

Wedgelock: WM12S
Socket: 0462-201-20141 (qty 12 ea)
Blank: 0413-204-2005 (AR)
MC12-10 Node 3
Pin # Pin Type Description Wire # Wire Color
C1-P1 Power Ground - Negative Battery Terminal
C1-P2 Power Supply + Power Supply + Battery Terminal
C1-P3 CAN + CAN Hi
C1-P4 CAN - CAN Lo
C1-P5 AIN/CAN Shield Pot #1
C1-P6 +5VDC Snsr Pwr to Pots
C1-P7 - Snsr Gnd to Pots
C1-P8 DIN/AIN/freqIN Enbl Sw #1
C1-P9 DIN/AIN/freqIN Enbl Sw #2
C1-P10 DIN/AIN/freqIN Pot #2
C1-P11 PWMOUT/DOUT/PVGOUT Valve Solenoid #1
C1-P12 PWMOUT/DOUT/PVGOUT Valve Solenoid #2

MC12-10 Diesel Pump Pin.xls rev-6/8/2009 1 of 2

Customer: Ground Force
Project: Diesel Pump V1.0

MC12-10 Node 3
Pin # Pin Type Pin Var Pin Config
C1-P1 Power Ground -
C1-P2 Power Supply +
C1-P3 CAN +
C1-P4 CAN -
C1-P5 AIN/CAN Shield
C1-P6 +5VDC Snsr Pwr
C1-P7 - Snsr Gnd
C1-P8 DIN/AIN/freqIN
C1-P9 DIN/AIN/freqIN
C1-P10 DIN/AIN/freqIN
C1-P11 PWMOUT/DOUT/PVGOUT
C1-P12 PWMOUT/DOUT/PVGOUT

MC12-10 Diesel Pump Pin.xls rev-6/8/2009 2 of 2

 Compact Switch
Features
Pressure Series 96201, 96211, 96221
Compact size
Low & high pressures including vacuum
Extremely versatile
Optional DIN and conduit connectors
NEMA 1 & 4; IP65
Single pole double throw snap action switching
Factory preset or field adjustable

Applications
Pump & compressor monitoring
Air proving in HVAC systems
Engine monitoring
Machine tools
Hydraulic power units
Mobile hydraulics
Medical equipment
Irrigation systems
General industrial applications

General Specifications*
Accuracy: 2% of full range Temperature Range:
Switch: Series 96201: -40 to +165F (-40 to +74C)
Type: SPDT snap action; single circuit Series 96211: -20 to +165F (-29 to +74C)
Series 96221: 0 to +165F (-18 to +74C)
Rating: 5 Amp @ 125/250 VAC (Class BB Adjustment Capability: Models L96201, L96211 and
microswitch - standard) L96221 are factory set and
10 Amp @ 125/250 VAC (Class CC permanently locked.
microswitch) Models 96201, 96211, and 96221
5 Amp @ 30 VDC (Class BB and CC are field adjustable via an external
microswitches) adjustment sleeve.
Wetted Parts: Pressure Setpoint
Process Fitting: Brass (standard); 416 stainless steel Adjustment: Secure hex body with open-end
(optional) wrench; hand turn adjustment
sleeve:
O-Ring Seals & Buna-N (standard)
Diaphragms: Clockwise (counterclockwise for
vacuum models) to increase.
Piston (96201 models): Stainless steel; Teflon back-up ring
Electrical Connection: 12 free leads, #18 AWG Counterclockwise (clockwise for
vacuum models) to decrease set
Enclosure Ratings: NEMA 1 (plastic - standard) point.
NEMA 4 (when ordered with -T4
or -T5 options) Shipping Weight: Approximate 0.95 lbs.
IP65 (when ordered with T2 DIN
connection option
Pressure Connection: 1/4 NPT male (standard) Wiring Code
Approvals:
UL: UL recognized component (UR); PRESSURE VACUUM
With optional conduit connector (-T4 LEAD COLOR PIN COLOR PIN
or -T5 option) becomes UL listed. UL NORMALLY CLOSED BLUE 2 RED 3
File No. E42816.
COMMON PURPLE 1 PURPLE 1
CSA: CSA #LR22354 NORMALLY OPEN RED 3 BLUE 2
* See product configurator for additional options.

1
Compact Switch Series 96201, 96211, 96221
Technical Drawings
Dimensions in inches (mm)

!002/8
&2%% &2%%,%!$3

,%!$3 ./ 
4!-0%2 (%8
 # .# 2%3)34!.4
3%43#2%7 

 4!-0%2 @4/04)/./.,9
%6)$%.43%!, #/..%#4).'
,/#+%$!.$ @,OPTIONONLY #!",%',!.$
0%2-!.%.4,9  /$ 
3%!,%$  
@,OPTIONONLY  
 

  


"ARKSDALE)NC "ARKSDALE)NC 
"ARKSDALE)NC ,OS!NGELES#!
,OS!NGELES#!  "ARKSDALE)NC
,OS!NGELES#!
 ,OS!NGELES#ALIFORNIA
5, 5,

 7!2.).' 53%).34!,,!.$-!).  7!2.).' 53%).34!,,!.$-!).

 (%8 7!2.).' 53%).34!,,!.$-!).

7!2.).' 53%).34!,,!.$-!).


 490
.04-!,% 
02%3352%0/24
4-/$)&)#!4)/.
34!.$!2$-/$%, 4-/$)&)#!4)/. 4-/$)&)#!4)/.
&2%%
,%!$3

Product Configurator Example: 96211-BB3 SS -T5 -V (%8



Prefix 
L Factory set and permanently locked (optional)

T Tamper resistant setscrew (optional) 
"ARKSDALE)NC
,OS!NGELES#ALIFORNIA

5, 5,
7!2.).' 53%).34!,,!.$-!).

Base Model
Adjustable Range Approx. Deadband Proof
Decreasing - psi (bar) Increasing - psi (bar) (Actuation Value) Pressure
4-/$)&)#!4)/.
Min. Max. Min. Max. psi (bar) psi (bar)
96221-BB1 1 Hg 28 Hg 6 Hg 30 Hg .5 - 8 Hg 30 (2) Hg Vacuum
Options
96211-BB1 2.5 (.2) 12.8 (.9) 3 (.2) 15 (1) .3 - 3 (.02 - .21) 1000 (68)
Low Pressure

SJO cable, #18 AWG

Diaphragms

96211-BB2 5 (.3) 31 (2) 6 (.4) 35 (2.4) .5 - 6 (.03 - .41) 1000 (68) -JXXX
(XXX = inches)
96211-BB3 8.5 (.6) 44 (3) 10 (.6) 50 (3.4) .5 - 8 (.03 - .55) 1000 (68)
-Z1 Cleaned for oxygen service
96211-BB4 22.5 (1.5) 112 (8) 25 (1.8) 125 (8.5) 1 - 15 (.07 - 1.03) 1000 (68)
Gold contact limit swtich,
96211-BB5 70 (5) 220 (15) 80 (5.5) 250 (17) 5 - 40 (.34 - 2.76) 1000 (68) -Z12
1 A, 125 VAC
96211-BB6 110 (7) 440 (30) 130 (9) 500 (34) 10 - 75 (.69 - 5.17) 1000 (68)
DIN 43650 base only
-Z17
96201-BB1 190 (13) 450 (31) 250 (17) 600 (41) 30-150 ( 2.07 -10.35) 7000 (476) (no mating plug)
High Pressure
Diaphragms

96201-BB2 360 (24) 1450 (105) 430 (29) 1700 (116) 40-400 (2.76 - 27.59) 7000 (476) Unshielded cable,
-Z24
#18 AWG PVC
96201-BB3 1450 (105) 3900 (265) 1650 (112) 4400 (300) 100-750 (6.90 - 51.72) 7000 (476)
96201-BB4 3650 (248) 6700 (456) 4000 (272) 7500 (510) 200-1000 (13.79-68.96) 12000 (816) 7/16-20 SAE pressure
-P1
Fitting with O-ring
96201-BB5 300 (20) 2500 (170) 380 (26) 3000 (200) 80-500 (5.52-34.48) 7000 (476)
1
-CC 10A @ 125/250VAC Limit Switch (replace -BB with -CC) -WXXX Extra wire length (XXX = inches)
2
-SXXX Factory preset (consult factory)

Fitting Option
Blank Brass (Standard) Electrical Connectors Diaphragm/O-ring Material
Stainless steel (not available Blank 12 free leads (standard) Blank Buna-N (standard)
SS
with vacuum models) -E Ethylene propylene (EPR)
-T1 1/4 male spade terminals
-T2 DIN Connector, 43650 type -N Neoprene
1/2 NPT male conduit -V Viton
-T4
connector with free leads

NOTES: -T5 1/2 NPT female conduit

1 Not available with DIN connector (-T2 option) connector with free leads
2 No charge for factory set (L- option) models

3211 Fruitland Avenue Los Angeles, CA 90058  800-835-1060 Fax: 323-589-3463 www.barksdale.com
2
See Barksdales Standard Conditions of Sale Specifications are subject to modification at any time Bulletin #S0073-E 09/07 2007 Printed in the U.S.A.
5. PARTS
 WARRANTY PARTS

Ground Force Mfg., LLC utilizes parts made by many vendors.

All vendor component parts have their respective manufacturers
warranties. Ground Force Mfg., LLC. agrees to assign to the
purchaser all of its rights under any original manufacturers warranty
covering such component parts, and agrees to assist the purchaser in
making such contacts with the manufacturer of such component parts
as may be necessary to protect its right under the warranty covering
them. We will endeavor to do everything possible to assure that your
Ground Force Mfg., LLC equipment stays in top operating condition
and will provide you with warranty claim support.

How to File a Claim

1) Locate the Ground Force serial number (six numerals)

2) Have a PO ready to charge the shipping method of your choice
to, as well as the cost of the replacement part.
3) Call Ground Force Mfg., LLC (208) 664-9291 with the serial
number of your Ground Force Mfg., LLC equipment and a part
number/part description and ask for the Warranty Department.
4) Ground Force Mfg., LLC will ship the part out to you along with
a Return Goods Authorization (RGA).
5) Replace the part in question and return the part in question
along with the RGA to Ground Force Mfg., LLC.
6) Upon arrival, Ground Force Mfg., LLC will route the part to the
appropriate vendor for warranty consideration.
7) The vendor will report their findings to Ground Force Mfg., LLC
and either deny the claim or issue a credit.
8) Ground Force Mfg., LLC will forward the vendors findings to
you the customer. If a credit is issued it will be placed against
the PO used to purchase and ship the part to you.
PartsWarranty.Doc
Revised1/15/2008
 8 7 6 5 4 3 2 1
ITEM QTY. STOCK/DESCRIPTION PART NUMBER Material WEIGHT PcMRP 6 6 6
3 2 FLOOR DRAIN - 4" 91081913153 37.38 REF# 913153
5 5 5

4 1 250 GAL COOLANT TANK 91081913145 SS 664.19 REF# 913145

170 GALLON GREASE BIN -

5 1 91081913089 678.46 REF# 913089
1100#
250 GAL. NEW OIL 4
6 5 91081913143 MS 3937.1 REF# 913143
PRODUCT TANK
250 GAL USED OIL 1
7 1 91081913144 MS 676.07 REF# 913144
D PRODUCT TANK D
22 1 DOOR LATCH, VAN BODY 4200SM026 13.28

23 3 HINGE, SS TRAILER FLAT 13400SM001 HDWR 3.27

ALL PRODUCT TANKS ARE STAINLESS STEEL, EXCEPT THE GREASE STATION 3
2

22 23
1 3

C C

3
2

6
5
5 6
1 7 5
1
TOP VIEW

B B

1
1

DRIVERSIDE VIEW

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES

TOLERANCES:
DRAWN JLW 1/26/2010 GROUND FORCE MFG.
FRACTIONAL 1/16 CHECKED TITLE:
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES.
A 2. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED.
ANGULAR: MACH/BEND .25
ENG APPR. A
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED.
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
PRODUCT TANK
MFG APPR.
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. LAYOUT
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH
*ULTRA 70 (CORE WIRE) UNLESS OTHERWISE SPECIFIED. INTERPRET GEOMETRIC Q.A.
6. WHEN "ORB TYPE FITTINGS ARE REQUIRED, WELD FLANGES WILL PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE. MATERIAL
THE INFORMATION CONTAINED IN THIS
SIZE DWG. NO. REV

B 914130
7. ALL BOLTS USED IN THE ASSEMBLY PROCESS TO BE TIGHTENED DRAWING IS THE SOLE PROPERTY OF
PER TORQUE SPECIFICATIONS SHOWN ON DRAWING. GROUND FORCE MFG., LLC . ANY
8. ALL THREADED COUPLINGS ON WATER TANKS REQUIRE USING TEFLON REPRODUCTION IN PART OR AS A WHOLE FINISH
PIPE THREAD TAPE (ONLY) FOR SEALING PURPOSES. WITHOUT THE WRITTEN PERMISSION OF
9. PRIOR TO WELDING ON ANY CHASSIS IT IS REQUIRED TO DISCONNECT GROUND FORCE MFG., LLC. IS
THE BATTERY SOURCE TO PREVENT DAMAGE TO THE ELECTRONICS. PROHIBITED. DO NOT SCALE DRAWING SCALE: 1:30 WEIGHT: 14651.07 SHEET 3 OF 3
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
Defau
ITEM STOCK/DESCRIPTION PART NUMBER Material WEIGHT PcMRP
lt
PRODUCT TANK FEET
6 2 91081913059 0 REF# 913059
ASSEMBLY
SIGHT GAUGE ASSEMBLY,
7 1 91081913061 0 REF# 913061
60" TANK
J-HOOK ASSEMBLY, 60 IN
8 2 TANK 91081913057 0 REF# 913057

FLOAT SWITCH ASSEMBLY -

9 1 91081912844 0 REF# 912844
95% WARNING

10 1 3" TOP FILL 91081913063 0 REF# 913063

D D
11 1 TIE IN MOUNTS- RIGHT SIDE 91081913067 0 REF# 913067

12 1 TIE IN MOUNTS- LEFT SIDE 91081913066 0 REF# 913066

13 1 FILTER ASSEMBLY 91081913064 0 REF# 913064

VENT, 6PSI PRESSURE
16 1 15300SD006 6061 Alloy 0
ALUMINUM

TOP VIEW

C C

16 8
1 2

8
11
2
1

10
1

13
1

B B
12
1

6
9 2
1 SIDE VIEW FRONT VIEW

*NOTE: 1 ASSEMBLIES REQUIRED

*NOTE: SEE SUB-ASSEMBLY UNLESS OTHERWISE SPECIFIED: NAME DATE
DRAWING FOR DETAILS
DIMENSIONS ARE IN INCHES
TOLERANCES:
DRAWN JMD 2/27/2009 GROUND FORCE MFG.
FRACTIONAL 1/16 CHECKED TITLE:
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES.
A 2. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED.
ANGULAR: MACH/BEND .25
ENG APPR. A
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED.
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
250 GAL PRODUCT
MFG APPR.
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. TANK- COOLANT
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH
*ULTRA 70 (CORE WIRE) UNLESS OTHERWISE SPECIFIED. INTERPRET GEOMETRIC Q.A.
6. WHEN "ORB TYPE FITTINGS ARE REQUIRED, WELD FLANGES WILL PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE. MATERIAL
THE INFORMATION CONTAINED IN THIS
SIZE DWG. NO. REV
ISOMETRIC VIEW SS

B 913145
7. ALL BOLTS USED IN THE ASSEMBLY PROCESS TO BE TIGHTENED DRAWING IS THE SOLE PROPERTY OF
PER TORQUE SPECIFICATIONS SHOWN ON DRAWING. 6 GROUND FORCE MFG., LLC . ANY
8. ALL THREADED COUPLINGS ON WATER TANKS REQUIRE USING TEFLON
2 REPRODUCTION IN PART OR AS A WHOLE FINISH
PIPE THREAD TAPE (ONLY) FOR SEALING PURPOSES. WITHOUT THE WRITTEN PERMISSION OF
9. PRIOR TO WELDING ON ANY CHASSIS IT IS REQUIRED TO DISCONNECT GROUND FORCE MFG., LLC. IS
THE BATTERY SOURCE TO PREVENT DAMAGE TO THE ELECTRONICS. PROHIBITED. DO NOT SCALE DRAWING SCALE: 1:24 WEIGHT: 664.19 SHEET 2 OF 2
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
Defau
ITEM STOCK/DESCRIPTION PART NUMBER Material WEIGHT PcMRP
lt
SIGHT GAUGE ASSEMBLY,
7 1 91081913061 0 REF# 913061
60" TANK
J-HOOK ASSEMBLY, 60 IN
8 2 91081913057 0 REF# 913057
TANK

9 1 3" TOP FILL 91081913063 0 REF# 913063

10 1 TIE IN MOUNTS- RIGHT SIDE 91081913067 0 REF# 913067

11 1 TIE IN MOUNTS- LEFT SIDE 91081913066 0 REF# 913066

D D
12 1 FILTER ASSEMBLY 91081913064 0 REF# 913064 *TO BE MADE STAINLESS
OVERFLOW ASSEMBLY-
13 1 91081913077 0 REF# 913077
USED OIL

14 1 HEAT LOOP ASSEMBLY 91081910840 0 REF# 910840

VENT, 6PSI PRESSURE
18 1 15300SD006 6061 Alloy 0
ALUMINUM

TOP VIEW

C C

13
1 8
18 2
8 1 10
2
1

9
1

12
1

B B
11
1

6
2

FRONT VIEW
7
1 SIDE VIEW
*NOTE: 1 ASSEMBLIES REQUIRED
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES

TOLERANCES:
DRAWN JMD 2/27/2009 GROUND FORCE MFG.
14 FRACTIONAL 1/16 CHECKED TITLE:
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES.
A 2. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED. 1 ANGULAR: MACH/BEND .25
ENG APPR. A
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED.
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
250 GAL PRODUCT
MFG APPR.
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. TANK- USED OIL
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH
*ULTRA 70 (CORE WIRE) UNLESS OTHERWISE SPECIFIED. INTERPRET GEOMETRIC Q.A.
6. WHEN "ORB TYPE FITTINGS ARE REQUIRED, WELD FLANGES WILL PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE. MATERIAL
THE INFORMATION CONTAINED IN THIS
SIZE DWG. NO. REV
ISOMETRIC VIEW MS

B 913144
7. ALL BOLTS USED IN THE ASSEMBLY PROCESS TO BE TIGHTENED DRAWING IS THE SOLE PROPERTY OF
PER TORQUE SPECIFICATIONS SHOWN ON DRAWING. GROUND FORCE MFG., LLC . ANY
8. ALL THREADED COUPLINGS ON WATER TANKS REQUIRE USING TEFLON 6 REPRODUCTION IN PART OR AS A WHOLE FINISH
PIPE THREAD TAPE (ONLY) FOR SEALING PURPOSES. WITHOUT THE WRITTEN PERMISSION OF
9. PRIOR TO WELDING ON ANY CHASSIS IT IS REQUIRED TO DISCONNECT 2 GROUND FORCE MFG., LLC. IS
THE BATTERY SOURCE TO PREVENT DAMAGE TO THE ELECTRONICS. PROHIBITED. DO NOT SCALE DRAWING SCALE: 1:24 WEIGHT: 676.07 SHEET 2 OF 2
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
Defau
ITEM STOCK/DESCRIPTION PART NUMBER Material WEIGHT PcMRP
lt
PRODUCT TANK FEET
6 2 91081913059 0 REF# 913059
ASSEMBLY
SIGHT GAUGE ASSEMBLY,
7 1 91081913061 0 REF# 913061
60" TANK
J-HOOK ASSEMBLY, 60 IN
8 2 TANK 91081913057 0 REF# 913057

FLOAT SWITCH ASSEMBLY -

9 1 91081912844 0 REF# 912844
95% WARNING

10 1 3" TOP FILL 91081913063 0 REF# 913063

D D
11 1 TIE IN MOUNTS- RIGHT SIDE 91081913067 0 REF# 913067

12 1 TIE IN MOUNTS- LEFT SIDE 91081913066 0 REF# 913066

*TO BE MADE STAINLESS

13 1 FILTER ASSEMBLY 91081913064 0 REF# 913064

14 1 OVERFLOW ASSEMBLY 91081913065 0 REF# 913065

15 1 HEAT LOOP ASSEMBLY 91081910840 0 REF# 910840

ASSEMBLY, SUCTION PIPE

17 1 & BRACKET 91081914199 0 REF# 914199
TOP VIEW
PUMP, STANDARD COMBO
18 1 91081911792 0 REF# 911792
PUMP LAYOUT

C C
14
1
17
1
8
8 18 2
1 11
2
1

10
1

13
1

B B
12
1

9
1

6
2

FRONT VIEW
7
1
SIDE VIEW
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES

TOLERANCES:
DRAWN JMD 2/27/2009 GROUND FORCE MFG.
15 FRACTIONAL 1/16 CHECKED TITLE:
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES.
A 2. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED. 1 ANGULAR: MACH/BEND .25
ENG APPR. A
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED.
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
250 GAL PRODUCT
MFG APPR.
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY.
15
TANK- OIL
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH
*ULTRA 70 (CORE WIRE) UNLESS OTHERWISE SPECIFIED. INTERPRET GEOMETRIC Q.A.
1 PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
6. WHEN "ORB TYPE FITTINGS ARE REQUIRED, WELD FLANGES WILL COMMENTS:
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE. MATERIAL
THE INFORMATION CONTAINED IN THIS
SIZE DWG. NO. REV
ISOMETRIC VIEW MS

B 913143
7. ALL BOLTS USED IN THE ASSEMBLY PROCESS TO BE TIGHTENED DRAWING IS THE SOLE PROPERTY OF
PER TORQUE SPECIFICATIONS SHOWN ON DRAWING. GROUND FORCE MFG., LLC . ANY
8. ALL THREADED COUPLINGS ON WATER TANKS REQUIRE USING TEFLON 6 REPRODUCTION IN PART OR AS A WHOLE FINISH
PIPE THREAD TAPE (ONLY) FOR SEALING PURPOSES. WITHOUT THE WRITTEN PERMISSION OF
9. PRIOR TO WELDING ON ANY CHASSIS IT IS REQUIRED TO DISCONNECT 2 GROUND FORCE MFG., LLC. IS
THE BATTERY SOURCE TO PREVENT DAMAGE TO THE ELECTRONICS. PROHIBITED. DO NOT SCALE DRAWING SCALE: 1:24 WEIGHT: 787.42 SHEET 2 OF 2
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
ITEM QTY. STOCK/DESCRIPTION PART NUMBER Material WEIGHT PcMRP
8 1 16" MANWAY ASSEMBLY 91081913080 27.3 REF# 913080 18
18 1 VENT, 6PSI PRESSURE
ALUMINUM 15300SD006 6061 Alloy 0.33 8 1
19 1 FILTER ASSEMBLY 91081913078 5.5 REF# 913078 1
21 1 GREASE BIN LEVEL SENSOR 91081913079 31.81 REF# 913079

19
1
D D
D D

21
TOP VIEW 1

8 18
21 1 1
C C
1
19
1

B B

SECTION D-D

REAR VIEW
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES

TOLERANCES:
DRAWN JMD 03.17.2009 GROUND FORCE MFG.
FRACTIONAL 1/16 CHECKED TITLE:
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES.
A 2. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED.
ANGULAR: MACH/BEND .25
ENG APPR. A
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED.
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
GREASE BIN, 1100#
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. MFG APPR.
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH
*ULTRA 70 (CORE WIRE) UNLESS OTHERWISE SPECIFIED. INTERPRET GEOMETRIC Q.A.
6. WHEN "ORB TYPE FITTINGS ARE REQUIRED, WELD FLANGES WILL PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE. MATERIAL
THE INFORMATION CONTAINED IN THIS
SIZE DWG. NO. REV

B 913089 0
7. ALL BOLTS USED IN THE ASSEMBLY PROCESS TO BE TIGHTENED DRAWING IS THE SOLE PROPERTY OF
PER TORQUE SPECIFICATIONS SHOWN ON DRAWING. GROUND FORCE MFG., LLC . ANY
8. ALL THREADED COUPLINGS ON WATER TANKS REQUIRE USING TEFLON REPRODUCTION IN PART OR AS A WHOLE FINISH
PIPE THREAD TAPE (ONLY) FOR SEALING PURPOSES. WITHOUT THE WRITTEN PERMISSION OF PAINTED
9. PRIOR TO WELDING ON ANY CHASSIS IT IS REQUIRED TO DISCONNECT GROUND FORCE MFG., LLC. IS
THE BATTERY SOURCE TO PREVENT DAMAGE TO THE ELECTRONICS. PROHIBITED. DO NOT SCALE DRAWING SCALE: 1:15 WEIGHT: 678.46 SHEET 2 OF 2
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
ITEM STOCK/DESCRIPTION PART NUMBER Material WEIGHT PcMRP

19" REEL FAIRLEAD

1 1 91081914136-1 0 -
ASSEMBLY
FAIRLEAD PLATE & ROLLER
2 3 9600RL002 0
, 6"
ASSEMBLY, 6" HYD REWIND
3 3 9900RL060 0
HOSE REEL
FAIRLEAD PLATE & ROLLER,
4 8 9600RL001 0
4"
HOSE REEL,
5 8 9900RL040 0
D 4"ASSY.HYD.DRIVE 23" D
ASSEMBLY, 19" HYD
6 1 91081914136 HDWR 0 -
REWIND HOSE REEL
K K
WHEN ORDERING REELS - LET PARTS DEPARTMENT KNOW WHICH REEL IS
BEING REPLACED. THIS ENSURES THAT THE CORRECT MANIFOLD IS PUT ON
FOR THE REEL DESIGNATION.

OIL 3

OIL 2

C OIL 4 C
OIL 5

5
3 8 OIL 1 HP GREASE
3
COOLANT

AIR

HV GREASE 4
8
LV DIESEL
6 HV DIESEL
3
1
3

USED OIL

B B

2 1
3 1

2
3

SECTION K-K
SCALE 1 : 30

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES

TOLERANCES:
DRAWN 5/14/2009 GROUND FORCE MFG.
FRACTIONAL 1/16 CHECKED TITLE:
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES.
A 2. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED.
ANGULAR: MACH/BEND .25
ENG APPR. A
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED.
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
HOSE REEL ASSEMBLY -
MFG APPR.
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. 165901 CHANGES
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH
*ULTRA 70 (CORE WIRE) UNLESS OTHERWISE SPECIFIED. INTERPRET GEOMETRIC Q.A.
6. WHEN "ORB TYPE FITTINGS ARE REQUIRED, WELD FLANGES WILL PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE. MATERIAL
THE INFORMATION CONTAINED IN THIS
SIZE DWG. NO. REV

B 914125
7. ALL BOLTS USED IN THE ASSEMBLY PROCESS TO BE TIGHTENED DRAWING IS THE SOLE PROPERTY OF
PER TORQUE SPECIFICATIONS SHOWN ON DRAWING. GROUND FORCE MFG., LLC . ANY
8. ALL THREADED COUPLINGS ON WATER TANKS REQUIRE USING TEFLON REPRODUCTION IN PART OR AS A WHOLE FINISH
PIPE THREAD TAPE (ONLY) FOR SEALING PURPOSES. WITHOUT THE WRITTEN PERMISSION OF
9. PRIOR TO WELDING ON ANY CHASSIS IT IS REQUIRED TO DISCONNECT GROUND FORCE MFG., LLC. IS
THE BATTERY SOURCE TO PREVENT DAMAGE TO THE ELECTRONICS. PROHIBITED. DO NOT SCALE DRAWING SCALE: 1:48 WEIGHT: 4583.58 SHEET 2 OF 2
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
ITEM QTY. STOCK/DESCRIPTION PART NUMBER Material WEIGHT PcMRP
11 7 14 15 11 2 11
1 1 PL3/16X15 5/8X13 PL3/16X48 Plain Carbon Steel 22.41 9900SM616 2 1 2 1 2 1 2 14 5 3
2 1 1
2 1 PL3/16X14 3/4X21 1/8 PL3/16X48 Plain Carbon Steel 14.41 90181111024

MS PL 3/16 X 11.70 OD X
3 1 PL3/16X48 Plain Carbon Steel 5.37 9900SM605
2.75 ID 15
HOSE REEL DRIVE HUB, 1 9
4 1 9900RL002 Plain Carbon Steel 2.32 9900RL002
TAPERED
SPOUTING, S12X10GA X 16 1
5 1 S12X10GA Plain Carbon Steel 9.62 90181111021
D 19" L D
1 6
6 1 PL3/16X11 1/16X11 11/16 PL3/16X48 Plain Carbon Steel 5.42 90181111025
1
7 1 PL3/16X12 1/4X23 1/14 PL3/16X48 Plain Carbon Steel 13.64 90181111023

BEARING, 2 7/16" FLANGE

8 1 UCF212-39 Plain Carbon Steel 16.29 10
4-BOLT

9 1 MOTOR, HYDRAULIC 9414HY253 Plain Carbon Steel 18.52 9414HY253 3

11..3CID HOSE REEL

10 3 MS PL 10GA X1"X3" SH10GAX48 Plain Carbon Steel 0.18 90181110356

11 2 PL3/16X29X29 PL3/16X60 Plain Carbon Steel 57.6 90181111022

12
1
12 1 2SCH40, L=4 2SCH40 Plain Carbon Steel 1.21 ND 90181111026
THIS END IS
13 1 2SCH40, L=1/2 2SCH40 Plain Carbon Steel 0.15 ND 90181111027 CENTERED
OVER PIPE CUT COUPLER INHALF AND WELD TO PLUMBING
14 2 ELBOW, 2" 90DEG SR WELD 4800SM070 Plain Carbon Steel 1.92 CENTER
15 1 COUPLER, 1-1/2" BIP 1-1/2XCPL Plain Carbon Steel 1.46
TOP VIEW
16 1 NIPPLE, 2" PN2000 Plain Carbon Steel 0.44

C C
11 15 13
11 11
2 1 1 2
2 2
12 1
1
16 8
1 1 4
1
ISOMETRIC VIEW
16 9 1
1 1 1
10
3 2
1

7
1
B B
1
3
1
1

11
2

5
1
LEFT SIDE
RIGHT SIDE
FRONT VIEW

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES

TOLERANCES:
DRAWN JLW 1/29/2010 GROUND FORCE MFG.
FRACTIONAL 1/16 CHECKED TITLE:
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES.
A 2. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED.
ANGULAR: MACH/BEND .25
ENG APPR. A
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED.
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
ASSEMBLY, 19" HYD
MFG APPR.
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. REWIND HOSE REEL
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH
*ULTRA 70 (CORE WIRE) UNLESS OTHERWISE SPECIFIED. INTERPRET GEOMETRIC Q.A.
6. WHEN "ORB TYPE FITTINGS ARE REQUIRED, WELD FLANGES WILL PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE. MATERIAL
THE INFORMATION CONTAINED IN THIS
SIZE DWG. NO. REV

B 914136
7. ALL BOLTS USED IN THE ASSEMBLY PROCESS TO BE TIGHTENED DRAWING IS THE SOLE PROPERTY OF
PER TORQUE SPECIFICATIONS SHOWN ON DRAWING. GROUND FORCE MFG., LLC . ANY
8. ALL THREADED COUPLINGS ON WATER TANKS REQUIRE USING TEFLON REPRODUCTION IN PART OR AS A WHOLE FINISH
PIPE THREAD TAPE (ONLY) FOR SEALING PURPOSES. WITHOUT THE WRITTEN PERMISSION OF
9. PRIOR TO WELDING ON ANY CHASSIS IT IS REQUIRED TO DISCONNECT GROUND FORCE MFG., LLC. IS
THE BATTERY SOURCE TO PREVENT DAMAGE TO THE ELECTRONICS. PROHIBITED. DO NOT SCALE DRAWING SCALE: 1:10 WEIGHT: 170.22 SHEET 1 OF 2
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
ITEM QTY. STOCK/DESCRIPTION PART NUMBER Material WEIGHT PcMRP REVISIONS
NOTE: BOLT TORQUE SPECS
1 1 PL3/8X8X8-1/2 PL3/8X48 Plain Carbon Steel 7.19 ND 90181101140 7/16-14NC HEX NUT............70 FT LBS REV. ECN. DESCRIPTION DATE SIGNATURE APPROVED
7/16-14NC NYLOC NUT......54 FT LBS
2 1 8" FLAT HINGE 4200SM004 0 1/2-13NC HEX NUT..............110 FT LBS 1 05-053 CORRECT FLAT PATTERN DIMENSION IN BOM 4.18.2005 KRC
1/4-20NC HEX BOLT............TO TIGHT
3 - NOT USED 0 2 06- CHANGED MATERIAL CALLOUT AND DIMENSION ITEM 4 10.17.2006 DMc
BELT ADJUSTMENT SPECIFICATION:
4 1 PL3/16"X8"X12" PL3/16"X48 Plain Carbon Steel 4.36 90181102166 TO MAXIMIZE BELT LIFE AND 3 07-053 REVISE TO CORRECT FORMAT, MATERIAL AND CALLOUT 1.30.2007 KRC
MINIMIZE BELT SLIPPAGE, ADJUST
5 1 PERF. ALUM. .063 H14 X AP1/4.063X48 ALUM. 1.5 ND 90181101772 BELT(S) TENSION TO MAXIMUM 4 09-032 REPLACED ITEM 3 WITH ITEMS 35 & 36 5/12/2009 HLP JLW
D 15"X35" D
1/4" X 3/4" NC GR8 BOLT, 3/8" DEFLECTION.
6 14 0801025007520 0
PLATED
NOTE: UNLESS OTHERWISE NOTED, ALL WELDS TO BE FILLET WELDS.
7 14 1/4" FLAT WASHER L-9 0945.025.0.20 0

8 1 PL1/2"X16"X35" PL1/2"X48 Plain Carbon Steel 78.65 90181101773

1/2" X 2" NC GR8 BOLT,

9 8 0801050020020 0 35 36 30
PLATED

10 - NOT USED 0 1 1 1

11 4 7/16"-14 NC GR8 NUT, 0105.043.01.20 0

NOTE: REMOVE ALL
PLATED SHARP EDGES
12 4 7/16" FLAT WASHER L-9 0945.043.0.20 0
FROM EXPANDED
ALUMINUM MESH.
BUSHING, 7/8" BORE 1/4"
13 1 8300DC078 0
KEY

14 1 PULLY 7.5" 2 GROOVE 8300DC075 1.5

MOTOR, HYDRAULIC, 7/8" 5 4 20
15 1 3200HY115 Cast Alloy Steel 0
SHAFT
ELBOW, 3/4" TUBE 3/4' MPT
1 1 1
16 1 90 DEG. 2501-12-12 0

ELBOW,1"ORFD 3/4"ORB 90
17 2 DEG ADJUSTA FF6801-16-20 0 27
C 1 C
18 2 TR3"X2"X1/4"X35" TR3"X2"X1/4" Plain Carbon Steel 41.14 90181101850

19 2 L2"X2"X3/16"X2" L2"X2"X3/16" Plain Carbon Steel 0.78 90181101781

20 1 SH10GAX12"X15 1/8" SH10GAX48 Plain Carbon Steel 4.17 90181101779 8

1
21 4 7/16" NYLOC NUT 0120.043.01.20 0

22 2 1/2" HEX NUT 0105.050.01.20 0

1/2" X 3-1/2" GR8 BOLT,

23 2 0801050035020 0
PLATED

24 2 1/2" HEX COUPLER NUT AC1/2-13 0 014305006212520 15

1
25 - NOT USED 0

26 - NOT USED 0 18
PERF. ALUM. .063 H14 X
2
27 1 AP1/4.063X48 ALUM. 1.77 ND 90181106077
18"X35"
1/4" LOCK WASHER
34 17
28 14 1103.025.0.20 0
PLATED 1 2
29 2 V-BELT, 74" OD B71 0
B 22 23 24 33 B
AIR COMPRESSOR, 7.5-
30 1 SL707 300
10HP 46CFM 2 2 2 2
31 4 1/2" LOCK WASHER 1103.050.0.20 0

32 4 1/2" FLAT WASHER 0945.050.0.20 0

(THESE TWO ITEMS ARE NOT SHOWN.)
33 2 1/2" FIN. JAM NUTS 0103.050.01.20 0 19
2
ADAPTER,1"FORFD
34 1 FF2407-16-12 0
3/4"MORFS STRAIGH 1
35 1 SH11GAX4 13/16"X72" SH11GAX48 Plain Carbon Steel 11.48 90181110294 1
2
36 1 SH11GAX32 7/8"X4 13/16" SH11GAX48 Plain Carbon Steel 5.33 90181110295
1 3D VIEW

(THIS ITEM IS NOT SHOWN.)

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES

TOLERANCES:
DRAWN KRC 5/11/2009 GROUND FORCE MFG.
FRACTIONAL 1/16 CHECKED TITLE:
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES.
A 2. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED.
ANGULAR: MACH/BEND .25
ENG APPR. A
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED.
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
STD. SAYLORBEALL 707
MFG APPR.
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. MOUNT BRACKET
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH
*ULTRA 70 (CORE WIRE) UNLESS OTHERWISE SPECIFIED. INTERPRET GEOMETRIC Q.A. ASSEMBLY
6. WHEN "ORB TYPE FITTINGS ARE REQUIRED, WELD FLANGES WILL PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE. MATERIAL
THE INFORMATION CONTAINED IN THIS
SIZE DWG. NO. REV

B 910292 4
7. ALL BOLTS USED IN THE ASSEMBLY PROCESS TO BE TIGHTENED DRAWING IS THE SOLE PROPERTY OF
PER TORQUE SPECIFICATIONS SHOWN ON DRAWING. GROUND FORCE MFG., LLC . ANY
8. ALL THREADED COUPLINGS ON WATER TANKS REQUIRE USING TEFLON REPRODUCTION IN PART OR AS A WHOLE FINISH
PIPE THREAD TAPE (ONLY) FOR SEALING PURPOSES. WITHOUT THE WRITTEN PERMISSION OF
9. PRIOR TO WELDING ON ANY CHASSIS IT IS REQUIRED TO DISCONNECT GROUND FORCE MFG., LLC. IS
THE BATTERY SOURCE TO PREVENT DAMAGE TO THE ELECTRONICS. DO NOT SCALE DRAWING SCALE: 1:8 WEIGHT: 837.31 SHEET 1 OF 2
PROHIBITED.

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1

14 13 29
1 1 2

3
4" 30
1
D D

32 31 9 11 12 21 (THESE ITEMS ARE NOT SHOWN.)

4 4 4 TOP VIEW 4 4 4
(THESE ITEMS ARE NOT SHOWN.)
C C

28 7 6 16 (THIS ITEM IS NOT SHOWN.)

3 14 14 14 1
4"

3
88"
TYP
1/8 1-4

B B

WELD NUT
16" 4 - PLACES 13
8 16 "
1 CENTER OF HOLE
19 2 "
END VIEW 13
16 16 " SHAFT TO SHAFT
35"

SIDE VIEW UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES

TOLERANCES:
DRAWN KRC 5/11/2009 GROUND FORCE MFG.
FRACTIONAL 1/16 CHECKED TITLE:
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES.
A 2. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED.
ANGULAR: MACH/BEND .25
ENG APPR. A
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED.
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
STD. SAYLORBEALL 707
MFG APPR.
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. MOUNT BRACKET
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH
*ULTRA 70 (CORE WIRE) UNLESS OTHERWISE SPECIFIED. INTERPRET GEOMETRIC Q.A. ASSEMBLY
6. WHEN "ORB TYPE FITTINGS ARE REQUIRED, WELD FLANGES WILL PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE. MATERIAL
THE INFORMATION CONTAINED IN THIS
SIZE DWG. NO. REV

B 910292 4
7. ALL BOLTS USED IN THE ASSEMBLY PROCESS TO BE TIGHTENED DRAWING IS THE SOLE PROPERTY OF
PER TORQUE SPECIFICATIONS SHOWN ON DRAWING. GROUND FORCE MFG., LLC . ANY
8. ALL THREADED COUPLINGS ON WATER TANKS REQUIRE USING TEFLON REPRODUCTION IN PART OR AS A WHOLE FINISH
PIPE THREAD TAPE (ONLY) FOR SEALING PURPOSES. WITHOUT THE WRITTEN PERMISSION OF
9. PRIOR TO WELDING ON ANY CHASSIS IT IS REQUIRED TO DISCONNECT GROUND FORCE MFG., LLC. IS
THE BATTERY SOURCE TO PREVENT DAMAGE TO THE ELECTRONICS. DO NOT SCALE DRAWING SCALE: 1:8 WEIGHT: 837.31 SHEET 2 OF 2
PROHIBITED.

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
ITEM QTY. STOCK/DESCRIPTION PART NUMBER Material WEIGHT PcMRP

1 1 LAMP, CLEARANCE RED 7813LT006 ABS 0.11

LENS KIT, LED, RED 24V
2 1 7813LT047 PP Copolymer 0.07
7813LT006

D D

1
1

2
1 1
1

C C

GASKET
2
1
HOUSING

RED LED LENS KIT

1
1

B B

2
1

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES

TOLERANCES:
DRAWN JLW 4/17/2009 GROUND FORCE MFG.
FRACTIONAL 1/16 CHECKED TITLE:
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES.
A 2. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED.
ANGULAR: MACH/BEND .25
ENG APPR. A
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED.
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
LAMP, CLEARANCE
MFG APPR.
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. RED - 24V LED
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH
*ULTRA 70 (CORE WIRE) UNLESS OTHERWISE SPECIFIED. INTERPRET GEOMETRIC Q.A.
6. WHEN "ORB TYPE FITTINGS ARE REQUIRED, WELD FLANGES WILL PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE. MATERIAL
THE INFORMATION CONTAINED IN THIS
SIZE DWG. NO. REV

B
7. ALL BOLTS USED IN THE ASSEMBLY PROCESS TO BE TIGHTENED DRAWING IS THE SOLE PROPERTY OF

8.
PER TORQUE SPECIFICATIONS SHOWN ON DRAWING.
ALL THREADED COUPLINGS ON WATER TANKS REQUIRE USING TEFLON
GROUND FORCE MFG., LLC . ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
7813LT006 - 24V LED
PIPE THREAD TAPE (ONLY) FOR SEALING PURPOSES. WITHOUT THE WRITTEN PERMISSION OF
9. PRIOR TO WELDING ON ANY CHASSIS IT IS REQUIRED TO DISCONNECT GROUND FORCE MFG., LLC. IS
THE BATTERY SOURCE TO PREVENT DAMAGE TO THE ELECTRONICS. DO NOT SCALE DRAWING SCALE: 1:2 WEIGHT: 0.20 SHEET 1 OF 1
PROHIBITED.

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
ITEM QTY. STOCK/DESCRIPTION PART NUMBER Material WEIGHT PcMRP

1 1 LAMP, CLEARANCE AMBER 7813LT007 ABS 0.11

LENS KIT, LED, AMBER 24V
2 1 7813LT048 PP Copolymer 0.07
7813LT007

D D

1
1

2
1 1
1

C C

GASKET
2
1
HOUSING

AMBER LED LENS KIT

1
1

B B

2
1

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES

TOLERANCES:
DRAWN JLW 4/17/2009 GROUND FORCE MFG.
FRACTIONAL 1/16 CHECKED TITLE:
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES.
A 2. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED.
ANGULAR: MACH/BEND .25
ENG APPR. A
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED.
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
LAMP, CLEARANCE
MFG APPR.
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. AMBER - 24V LED
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH
*ULTRA 70 (CORE WIRE) UNLESS OTHERWISE SPECIFIED. INTERPRET GEOMETRIC Q.A.
6. WHEN "ORB TYPE FITTINGS ARE REQUIRED, WELD FLANGES WILL PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE. MATERIAL
THE INFORMATION CONTAINED IN THIS
SIZE DWG. NO. REV

B
7. ALL BOLTS USED IN THE ASSEMBLY PROCESS TO BE TIGHTENED DRAWING IS THE SOLE PROPERTY OF

8.
PER TORQUE SPECIFICATIONS SHOWN ON DRAWING.
ALL THREADED COUPLINGS ON WATER TANKS REQUIRE USING TEFLON
GROUND FORCE MFG., LLC . ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
7813LT007 - 24V LED
PIPE THREAD TAPE (ONLY) FOR SEALING PURPOSES. WITHOUT THE WRITTEN PERMISSION OF
9. PRIOR TO WELDING ON ANY CHASSIS IT IS REQUIRED TO DISCONNECT GROUND FORCE MFG., LLC. IS
THE BATTERY SOURCE TO PREVENT DAMAGE TO THE ELECTRONICS. DO NOT SCALE DRAWING SCALE: 1:2 WEIGHT: 0.20 SHEET 1 OF 1
PROHIBITED.

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
ITEM QTY. STOCK/DESCRIPTION PART NUMBER Material WEIGHT PcMRP
LAMP,RIGHT
1 1 7813LT033 6061 Alloy 1.33 7813LT033
TURN/STOP/TAIL DUAL
LED LENS KIT, RED 24V FOR
2 2 7813LT043 1.58
7813LT032/0

1
1
D 2 D
2 1
1

HOUSING

2
2

GASKET
C C

LAMP HOUSING

24V LED LENS

B B

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES

TOLERANCES:
DRAWN JLW 5/19/2009 GROUND FORCE MFG.
FRACTIONAL 1/16 CHECKED TITLE:
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES.
A 2. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED.
ANGULAR: MACH/BEND .25
ENG APPR. A
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED.
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
LAMP, TURN/STOP/TAIL
MFG APPR.
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. DUAL RH - 24V LED
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH
*ULTRA 70 (CORE WIRE) UNLESS OTHERWISE SPECIFIED. INTERPRET GEOMETRIC Q.A. CONVERSION
6. WHEN "ORB TYPE FITTINGS ARE REQUIRED, WELD FLANGES WILL PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE. MATERIAL
THE INFORMATION CONTAINED IN THIS
SIZE DWG. NO. REV

B
7. ALL BOLTS USED IN THE ASSEMBLY PROCESS TO BE TIGHTENED DRAWING IS THE SOLE PROPERTY OF

8.
PER TORQUE SPECIFICATIONS SHOWN ON DRAWING.
ALL THREADED COUPLINGS ON WATER TANKS REQUIRE USING TEFLON
GROUND FORCE MFG., LLC . ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
7813LT033 - 24V LED
PIPE THREAD TAPE (ONLY) FOR SEALING PURPOSES. WITHOUT THE WRITTEN PERMISSION OF
9. PRIOR TO WELDING ON ANY CHASSIS IT IS REQUIRED TO DISCONNECT GROUND FORCE MFG., LLC. IS
THE BATTERY SOURCE TO PREVENT DAMAGE TO THE ELECTRONICS. DO NOT SCALE DRAWING SCALE: 1:5 WEIGHT: 2.90 SHEET 1 OF 1
PROHIBITED.

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
ITEM QTY. STOCK/DESCRIPTION PART NUMBER Material WEIGHT PcMRP
LAMP,LEFT TURN/STOP/TAIL
1 1 7813LT032 6061 Alloy 1.33 7813LT032
DUAL

2 2 LED LENS KIT, RED 24V FOR 7813LT043 1.58 1

7813LT032/0
1

D D
2
2

1
1

2
C 2 C

HOUSING

GASKET

LAMP HOUSING

24V LED

B B

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES

TOLERANCES:
DRAWN JLW 5/19/2009 GROUND FORCE MFG.
FRACTIONAL 1/16 CHECKED TITLE:
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES.
A 2. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED.
ANGULAR: MACH/BEND .25
ENG APPR. A
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED.
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
LAMP, TURN/STOP/TAIL
MFG APPR.
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. DUAL LH - 24V LED
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH
*ULTRA 70 (CORE WIRE) UNLESS OTHERWISE SPECIFIED. INTERPRET GEOMETRIC Q.A. CONVERSION
6. WHEN "ORB TYPE FITTINGS ARE REQUIRED, WELD FLANGES WILL PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE. MATERIAL
THE INFORMATION CONTAINED IN THIS
SIZE DWG. NO. REV

B
7. ALL BOLTS USED IN THE ASSEMBLY PROCESS TO BE TIGHTENED DRAWING IS THE SOLE PROPERTY OF

8.
PER TORQUE SPECIFICATIONS SHOWN ON DRAWING.
ALL THREADED COUPLINGS ON WATER TANKS REQUIRE USING TEFLON
GROUND FORCE MFG., LLC . ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
7813LT032 - 24V LED
PIPE THREAD TAPE (ONLY) FOR SEALING PURPOSES. WITHOUT THE WRITTEN PERMISSION OF
9. PRIOR TO WELDING ON ANY CHASSIS IT IS REQUIRED TO DISCONNECT GROUND FORCE MFG., LLC. IS
THE BATTERY SOURCE TO PREVENT DAMAGE TO THE ELECTRONICS. DO NOT SCALE DRAWING SCALE: 1:4 WEIGHT: 2.90 SHEET 1 OF 1
PROHIBITED.

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
ITEM QTY. STOCK/DESCRIPTION PART NUMBER Material WEIGHT PcMRP
1 1 JUNCTION BOX, 90 DEGREE 1.25"D X 1.375"W X 4" L 4900EL127 Plain Carbon Steel 0.47
2 1 PANEL FOR 4900EL127 4900EL128 Galvanized Steel 0.18
3 1 SWITCH LIQUID LEVEL 12300EL025 ABS 0.25
4 1 FITTING, 1/2"TUBE 1/2"MPT POLY 600-066 PP Copolymer 0.03

5 1 SWITCH, 2 - TERM PUSHBUTTON W/BOOT 7700EL003 0

6 1 RELAY, 24V, 40/60AMP 60BU5084V24 0
7 1 GASKET FOR 4900EL127 4900EL129 0
D D

**NOTE THIS ASSEMBLY TO BE USED FOR HIGH LEVEL WARNING WITH

ACKNOWLEDGEMENT CIRCUIT. ITEM 5 AND 6 TO BE IN CONTROL
PANEL BY QUICKFILL

2 7 1
1 1 1
FLOAT SWITCH CAN NOT BE PLACED ANY 3
CLOSER THEN 5" FROM OBSTRUCTIONS 1
INSIDE THE TANK. THIS IS DUE TO THE FLOAT
C SWITCH MAY BREAK OFF DURING INSTALL. 3 C
1

5" 5"

ISOMETRIC VIEW

FLOAT PUT INTO EXISTING 1" PHX ON TANK

THIS SWITCH IS TO BE USED AS THE HIGH LEVEL
WARNING ONLY. THIS IS DUE TO THE
B 4 ACKNOWLEDGEMENT CIRCUIT. USE ASSEMBLY
912842 FOR ALL OTHER FLOAT NEEDS. B
1 REAR VIEW 4
1

SIDE VIEW

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES

TOLERANCES:
DRAWN JLW 10/1/2008 GROUND FORCE MFG.
FRACTIONAL 1/16 CHECKED TITLE:
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES.
A 2. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED.
ANGULAR: MACH/BEND .25
ENG APPR. A
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED.
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
FLOAT SWITCH
MFG APPR.
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. ASSEMBLY - 95%
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH
*ULTRA 70 (CORE WIRE) UNLESS OTHERWISE SPECIFIED. INTERPRET GEOMETRIC Q.A. WARNING
6. WHEN "ORB TYPE FITTINGS ARE REQUIRED, WELD FLANGES WILL PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE. THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

B 912844
7. ALL BOLTS USED IN THE ASSEMBLY PROCESS TO BE TIGHTENED DRAWING IS THE SOLE PROPERTY OF
PER TORQUE SPECIFICATIONS SHOWN ON DRAWING. GROUND FORCE MFG., LLC . ANY
8. ALL THREADED COUPLINGS ON WATER TANKS REQUIRE USING TEFLON REPRODUCTION IN PART OR AS A WHOLE FINISH
PIPE THREAD TAPE (ONLY) FOR SEALING PURPOSES. WITHOUT THE WRITTEN PERMISSION OF
9. PRIOR TO WELDING ON ANY CHASSIS IT IS REQUIRED TO DISCONNECT GROUND FORCE MFG., LLC. IS
THE BATTERY SOURCE TO PREVENT DAMAGE TO THE ELECTRONICS. PROHIBITED. DO NOT SCALE DRAWING SCALE: 1:4 WEIGHT: 0.93 SHEET 1 OF 1
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
ITEM QTY. STOCK/DESCRIPTION PART NUMBER Material WEIGHT PcMRP
1 1 USED FILTER BOX - TALL 91081910696 105.6 REF# 910696
2 1 TOOL DRAWER STD, ASSEMBLY 91081911788 21.56 REF# 911788
3 2 SH10GAX20 11/16X29 3/8 SH10GAX48 Plain Carbon Steel 45.7 90181102246
4 2 L4X3X1/4, L=20" L4X3X1/4 Plain Carbon Steel 19.06 ND 90181102275
5 6 DRAWER SLIDE,18" 200# LOAD PER PAIR 26100818 0 12 13 14 15
6 2 GRAB HANDLE, 7" CHROME 4200SM039 0
6 6 6 6

D 7 3 LATCH, SELF LOCKING W/COVER 13700WH710 0 D

8 50 HUCK 3/16", TRUSS HEAD FASTENER MGPT-R6-10-G 0
9 50 HUCK COLLAR, 3/16" MGC-R6 0
10 8 RIVET,1/4" FLUSH HEAD HUCK MGP90-R8-10-G 0
11 20 HUCK, COLLAR 1/4" MGCR8-U 0
12 6 3/8"-16 NC GR8 NUT, PLATED 0105.037.01.20 0
13 6 3/8" X 1" NC GR8 BOLT, PLATED 0801037010020 0
14 6 3/8" FLAT WASHER L-9 0945.037.0.20 0
15 6 3/8" LOCK WASHER PLATED 1103.037.0.20 0
16 12 HUCK 1/4", TRUSS HEAD FASTENER MGPT-R8-10-G 0

TOP VIEW
6 10 11
2 2 8 20 5 8 9
C 1 6 50 50 C
7 16 11
3 12 20

11 16 7
20 12 3
7 16 11
3 12 20

1
1
ISOMETRIC VIEW

5 8 9
6 50 50
3
2 5 8 9
6 50 50
B B

4
2
SIDE VIEW
FRONT VIEW

UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES

TOLERANCES:
DRAWN JLW 12/15/2008 GROUND FORCE MFG.
FRACTIONAL 1/16 CHECKED TITLE:
NOTES: 1. REMOVE ALL BURRS AND SHARP EDGES.
A 2. ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SPECIFIED.
ANGULAR: MACH/BEND .25
ENG APPR. A
3. DO NOT SCALE DRAWINGS UNLESS OTHERWISE SPECIFIED.
TWO PLACE DECIMAL .010
THREE PLACE DECIMAL .003
USED FILTER AND
MFG APPR.
4. DATUM LINES ARE FOR DIMENSIONING REFERENCE ONLY. STORAGE BOX - TALL
5. ALL MATERIAL THICKNESS 3/16" AND UP TO BE WELDED WITH
*ULTRA 70 (CORE WIRE) UNLESS OTHERWISE SPECIFIED. INTERPRET GEOMETRIC Q.A.
6. WHEN "ORB TYPE FITTINGS ARE REQUIRED, WELD FLANGES WILL PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
BE WELDED WITH ER70 HARD-WIRE UNLESS SPECIFIED OTHERWISE. MATERIAL
THE INFORMATION CONTAINED IN THIS
SIZE DWG. NO. REV

B 910695
7. ALL BOLTS USED IN THE ASSEMBLY PROCESS TO BE TIGHTENED DRAWING IS THE SOLE PROPERTY OF
PER TORQUE SPECIFICATIONS SHOWN ON DRAWING. GROUND FORCE MFG., LLC . ANY
8. ALL THREADED COUPLINGS ON WATER TANKS REQUIRE USING TEFLON REPRODUCTION IN PART OR AS A WHOLE FINISH
PIPE THREAD TAPE (ONLY) FOR SEALING PURPOSES. WITHOUT THE WRITTEN PERMISSION OF
9. PRIOR TO WELDING ON ANY CHASSIS IT IS REQUIRED TO DISCONNECT GROUND FORCE MFG., LLC. IS
THE BATTERY SOURCE TO PREVENT DAMAGE TO THE ELECTRONICS. PROHIBITED. DO NOT SCALE DRAWING SCALE: 1:10 WEIGHT: 195.13 SHEET 2 OF 2
8 7 6 5 4 3 2 1
 GFMFG - MASTER PARTS LIST
165901 - ENCLOSED FUEL AND LUBE TRUCK
PART NUMBER DESCRIPTION QTY. MODEL NUMBER
0688-12-12 HOSE END, 3/4"BARB X 3/4" 10 0688-12-12
0705.AB6-6ACLD RIVET 3/16" DIA ALUM CLOS 2000 0705.AB6-6ACLD
0932.38-22LP PIN, PTO WITH LOOP LOCK 2 0932.38-22LP
1/2XCAP CAP, 1/2" BIP 1 1/2CAP
100101077 FERRULE, 1/4" 8
10082PM204 GREASE VALVE 1 81495
10082PM205 GREASE SWIVEL 1 81729
10082PM206 GREASE COUPLER 1 5845
10082VA816 VALVE, 4-WAY REVERSING, 1 1 120581
101010003 WELD STUD, 1/4"-20 X 3/4" 8 101-010-003
10143-2-4 HOSE END, 1/4"HOSE1/8"MPT 2 10143-2-4
10200DL165901 DRIVE LINE ASSEMBLY, 60" 1
10600WH015 EDGE TRIM, 1/4" 12 T-100B3X1/4
10600WH939 SEAL, D-DOOR WITH BONDING 240 939HATS-500
10643-10-12 HOSE END, 3/4"HOSE5/8"TUB 2 10643-10-12
1100SM002 FLANGE, 10"STANDARD 8HOLE 1 3/8"X5/8"SLOT 11-/12"BC
1113R CLAMP, 1/2" STAINLESS OET 14 1113R
11600AP047 SOLENOID VALVE, 24VDC 3-W 2 4HN47
11600EL021 SWITCH, SELECTOR, 22MM NE 14 6HK59
11600EL030 SWITCH, SNAP ACTION 20AMP 1 3XG30
11600FI100 STRAINER, 1" FPT Y-STYLE 1 1RNC8
11600FI613 DESICCANT DRYER, 25CFM 1 5VC91
11600SD200 VALVE, SAFETY 200PSI 1 5A715
11600SD750 VALVE, CHECK 3/4" NPT IN 1 6X209
11743-16-16 HOSE END, 1"HOSE 1"CODE 6 11 11743-16-16
12300EL025 SWITCH, LIQUID LEVEL, HOR 6 46235K25
12300EL031 SWITCH, PUSH/PULL 1 6749K92
12700GA146 O-RING FOR 12700WH146 7 AS337
12700SD402 VENT, 1-1/2" NPT MUSHROOM 1 0401-01-1500
12700WH146 PLUG, 3" NPT TANK TRUCK, 10 0147-01-3000
12TF-S FLANGE, #12 ORB BIP WELD 2
13400SM002 HINGE, SS TRAILER 22 H-1021
13400WH001 BUMPER, FLAT TOP 2 CCN-91004
13500WH501 LATCH, LEVER HANDLE, YELL 1 A2-10-501-22
13500WH902 LATCH, ADJUSTABLE DRAW, B 1 A1-11-902-31
13700WH710 LATCH, SELF LOCKING W/COV 3 709-S-1-ZN E-DIM.
1410125360010 1-1/4" X 3' NC GR8 ALLTHR 4 1410.125.3600.10
1422 DRAIN COCK, 3/8" MPT 3/8" 27 1422
14408GG521-L METER, 76-760LPM DIESEL 3 1 TS30AV04AL
145WHD DRAIN COCK, 1/4" NPT 5 145WHD
1469X6 ELBOW,3/8"TUBE 1/4"MPT AB 1 1469-6
14900LT761 STROBE LIGHT, AMBER LED, 2 7612A
14900LT772 STROBE LIGHT, RED RECEIVE 1 TS7710R-R
14900LT773 STROBE LIGHT, AMBER RECEI 1 TS7710R-A
14900SD241 BACK UP ALARM, 12-24 VDC 1 240C
15300SD006 VENT, 5 PSI PRESSURE ALUM 14 3338ALV
17000RL008 SWIVEL, 1/2" GREASE 1 001-13010-MT
1703151 LAMP, HID, CLEAR FLOOD, 3 8 1703151

MASTER PARTS LIST Page 1

 GFMFG - MASTER PARTS LIST
165901 - ENCLOSED FUEL AND LUBE TRUCK
PART NUMBER DESCRIPTION QTY. MODEL NUMBER
1812HY016 FLANGE, 1-1/4"FPT 4-BOLT 1 W44-20-20U
1812HY017 FLANGE, 2-1/2"FPT SPLIT 3 1 SFK-40
1913GA001 GASKET, 3" CORK/BUNA 1 RGA301CB
1913GA013 GASKET, 3" SUMP CORK/BUNA 1 G15181CB
1913SD158 FUSIBLE LINK 158 DEGREE 2 7490
1913SM007 SUMP, 3" STEEL W/WELDED S 1 SU25388MS
1913SM013 HATCH WELD RING, 16" 1 3057MS
1913SM017 MANHOLE, 16"ROUND 10"FILL 1 VPS8016SXB
1913SM019 WELD RING, 20" 1 3176MS
1913SM027 MANHOLE, 20" OFFSET MS 1 PPVL720BXB
1972SM001 FLANGE, 3"TTMA FLUED MS 2 20056-A
1972VA003 VALVE, 3" EMERGENCY MILD 1 EV46671ALB
1N5406 DIODE, 3 AMP 1 1N5406
201002 SENSOR, FUEL LEVEL, CONTI 1 201002/UCL-200-24.5'
2013EL104 COUPLING, .125-.375 ALUM 6 T&B 2920AL
2013EL105 COUPLING, .310-.560 ALUM 9 T&B 2921AL
2013EL107 NUT, 1" CONDUIT 5 1LN
20169020 VALVE, 2" BUTTERFLY, 150# 4 B5-RLO2S
2068EL009 ENCLOSURE, 6X6X4 PVC 4 664PJ
2068EL018 ENCLOSURE, 12X10X5 14GA S 2 A1210SC
2068EL034 ENCLOSURE, 2.5X2.5X12 WIR 1 F22T12HC
2068EL101 PANEL 2 A12P10
2070EL003 PRESSURE SWITCH, 20-300PS 1 836T-T254J
2-1/2X2B BUSHING, 2-1/2" X 2" BIP 1 21/2-2BU
2100BR039 BEARING, 2-7/16" FLANGE 4 1 UCF 212-39
210X3 HOSE,3"WATER DISCHARGE BL 4 3 #210
2400UP050 UHMW, 1 1-3/4"
3/4 ROUND STOCK 1 2400UP050
2444RO012 BALL STUD, STAINLESS STEE 8 BALL STUD
2444RO012 BALL STUD, STAINLESS STEE 8 BALL STUD
2500NP001 DECAL, GFMFG LOGO WHITE L 2 2500NP001
2500NP001 DECAL, GFMFG LOGO WHITE L 2 2500NP001
2500NP002 PIN STRIPE, WARM RED 1" X 2 2500NP002
2500NP002 PIN STRIPE, WARM RED 1" X 3 2500NP002
2500NP040 DECAL, GF40EFLT WHITE LET 2
255-0-24 HEAT EXCHANGER, 30000 BTU 2 R-255-0-24P
26100560112 DOOR HOLDER, WITH KEEPER, 1 5601 1/2ZN
26100818 DRAWER SLIDE,18" 200# LOA 3 8800-18
26100818 DRAWER SLIDE,18" 200# LOA 3 8800-18
3/8TYGON HOSE, 3/8"ID 1/2"OD CLEAR 36 3/8URETHANE
3000WH104 SPRING, VIBRATOR/TANK 28 LHL-1250D-2
302-6B-50 HOSE, 3/8" 100R2AT 50' 1 302-01-06-6-8-6-600
3200HY012 MANIFOLD, PUMP/MOTOR CONT 5 BFP-GF-PERMCO-12SAE
3200HY025 CHECK VALVE, LOAD SENSE 9 CP104-1-B-0-025
3200HY030 VALVE, FLOW CONTROL 3.0GP 1 CP301-1-B-0-3.0
3200HY060 VALVE, FLOW CONTROL 6.0GP 5 CP301-1-B-0-6.0
3200HY090 VALVE, PROPORTIONAL 1 PFC16-RC-90-00-00-B-00
3200HY1038 VALVE BODY, #10 3-WAY #8 1 CP10-3-8S
3200HY115 MOTOR, HYDRAULIC, 7/8"SHA 1 RPMC115-5B-5

MASTER PARTS LIST Page 2

 GFMFG - MASTER PARTS LIST
165901 - ENCLOSED FUEL AND LUBE TRUCK
PART NUMBER DESCRIPTION QTY. MODEL NUMBER
3200HY210 VALVE, SOLENOID, NC 8 CP500-3-B-0-000
3200HY211 VALVE, SOLENOID 1 CP502-3-B-0-000
3200HY230 VALVE, PRESSURE REDUCING 3 CP230-3-B-0-F-C-1500
3200HY612 VALVE, NEEDLE, ADJUSTABLE 1 CP612-2-B-0-E
3200HY962 PRESSURE SWITCH 5 T-96201-BB2-P1
32100.75X6 SKIRTBOARD, 3/4" X 6" X 1 2 3/4" X 6" X 120' LONG
3260EL1424 SOLENOID COIL, 24VDC 30WA 1 D14E-30W-24D-H
3260HY005 CHECK VALVE, LOAD SENSE 3 CP102-1-B-0-005
3260HY488 MOTOR, 4.88CID 1-1/4" X 5 2 151F2316
3286EL001 CONNECTOR, DIN, W/O GASKE 12 932106-100
3286EL024 SOLENOID COIL, 24VDC 6 D10-16-24D-H
3286EL100 AMPLIFIER BOARD 1 PC100
3286GA001 GASKET, DIN CONNECTOR 12 731531-002
3290PM304 PUMP/MOTOR COMBO P30-M30 5 M3000AAXLNDE10/P3000
3299HY002 MANIFOLD, AIR COMPRESSOR 1 BFP-GF-AIR2-MANIFOLD
3299HY004 MANIFOLD, 4 STATION LOAD 1 BFP-GF-LS-BLOCK-4
3299HY006 MANIFOLD, GREASE PUMP CON 2 BFP-GF-GREASE
3299HY013 MANIFOLD, PUMP/MOTOR CONT 6 BFP-GF-PERMCO3-12SAE
3400VA011 BALL VALVE, 3/8" GRIP 1 MV609-6
3400WH250 HOSE, 2" X 50' FUEL 1
3451VA004 BALL VALVE, 3/4" BRASS 2 XV500P-12
3451VA005 BALL VALVE, 1" BRASS 23 XV500P-16
3451VA006 BALL VALVE, 1-1/4" BRASS 9 XV500P-20
3451VA016 BALL VALVE, 1/2" 3000PSI 1 72-103-01
4001-20216 CHAIN, 1/8" 4.5 0310424
40095000100 PUMP, MAIN HYDRAULIC SET 1 MA10VO100DFR/31R-PSC62N
4200SM004 HINGE, 33-1/2"OPEN
1/2 OPEN WIDTH 1 1 A478
4200SM026 DOOR LATCH, VAN BODY CAM 7 5654 ZN
4200SM039 GRAB HANDLE, 7" CHROME 2 TH555 CH
4200WH009 TURNBUCKLE, 3/8"JAW & JAW 2 CROSBY 1032536
4200WH009 TURNBUCKLE, 3/8"JAW & JAW 4 2500-1010
4200WH013 DOOR HOLDER, EYE/HOOK 4.5 1 2445-C
4200WH015 EDGE TRIM 9 SD-1250
424604 INSULATION, 1-1/2" X 4" F 1
4300GA010 GASKET, 1/8"THICK 48"WIDE 3.5 4300GA010
4400HW101 BALL INSERT 7 .875"PP GR2 POLISHED
4400RL055 MANIFOLD, 1/2"GREASE HOSE 1 4400RL055
4400SM101 TANK FILTER MOUNT 1"-12 8 1-1/2"0D 7-3/4"LONG
451TC-16B-50 HOSE, 1" 100R17 50' 2 451TC01-06-16-16-16-600
451TC-8B-50 HOSE, 1/2" 100R17 50' 7 451TC-01-06-8-10-8-600
4600EL008 POTENTIOMETER, 0-1K OHMS 1 501-0005
4600EL009 KNOB, POTENTIOMETER, HIGH 1 41012-2B 1/4
4601-16-16 ELBOW, 1" ORB 1" 4
4645EL001 TERMINAL BLOCK, 6 CONTACT 1 TB200-06-B
4645EL002 TERMINAL BLOCK, 8 CONTACT 11 TB200-08
4645EL003 TERMINAL JUMPERS, J TYPE 33 601-J
4645EL005 TERMINAL BLOCK,5 CONTACT 1 TB200-05
465-1 TAPE, REFLECTIVE 2" WIDE 20 V825549

MASTER PARTS LIST Page 3

 GFMFG - MASTER PARTS LIST
165901 - ENCLOSED FUEL AND LUBE TRUCK
PART NUMBER DESCRIPTION QTY. MODEL NUMBER
4900EL125 JUNCTION BOX, 2.5D 2.875W 9 E9801
4900EL126 PANEL FOR 4900EL125 W/GA& 9 5173-0
4900EL127 JUNCTION BOX, 90 DEG 1.25 7 APPLB50A
4900EL128 PANEL FOR 4900EL127 7 APPK50A
4900EL129 GASKET FOR 4900EL127 7 APPGK50N
4900WH005 SHRINK TUBE, 3/4" BLACK 0.5 B2-3/4-BLK-200
5000 GREASE ZERK,1/8"PTF M STR 5 5000
5000-4-4 COUPLING, 1/4" FPT 1 000050005000
5000-8-8 COUPLING, 1/2" FPT 1 000150005000
5012 CLAMP, 3/4" HOSE 40 5012IDE
5404-8-6 NIPPLE, 1/2"MPT 3/8"MPT 1 000210005404
5404-8-8 NIPPLE, 1/2"MPT 3 000150005404
5405-2-4 ADAPTER, 1/8"MPT 1/4"FPT 2 C3209-4-2
5406-16P PLUG, 1"MPT HEX HEAD 1 001310005406
5700WH100 SWIVEL, 1" FUEL NOZZLE MP 1 36S-5090
5707DC250 MOUNT KIT, SAE A TO 2"-2. 1 891458
5707DC300 MOUNT KIT, SAE A TO 3"-4" 1 895140
5707FI300 STRAINER, 3" FLANGE 1 STR300
5707PM201 PUMP, 2 " WASTE OIL 1 XLW2F-ISAC
5707PM300 PUMP, 3" PETROLEUM 1 TXD300
60000100944 PIN KIT, MICRO CONTROLLER 1 10100944
60000103773 MICRO CONTROLLER, DIESEL 1 P308MN2AK0407R0D00 LHX
60000CCB070 CIRCUIT BREAKER, 70A MANU 1 CCB70
60000CCB100 CIRCUIT BREAKER, 100A MAN 1 CCB100
600-053 CONNECTOR, 3/8"TUBE 1/4"M 72 P6MC4
600-055 CONNECTOR, 3/8"TUBE 3/8"M 3 P6MC6
600 065
600-065 CONNECTOR, 1/2 1/2"TUBE
TUBE 3/8
3/8"M
M 52 P8MC6
600-066 CONNECTOR, 1/2"TUBE 1/2"M 2 P8MC8
6007524V5MB LED, 30V BLUE WITH BEZEL 4
6007524V5MG LED, 30V GREEN WITH BEZEL 10
6007524V5MR LED, 30V RED WITH BEZEL 8
6007524V5MY LED, 30V YELLOW WITH BEZE 20
60BU5084V24 RELAY, 24V, 40/60AMP 4 BU5084V24
6156GG001 GAUGE , 3000 PSI PANEL MO 1 SPG-063-03000-5-P-N04-U
66192120 FILTER HOUSING, 120 GPM 1 2 40187
6700WH001 CABLE, 1/4" AIRCRAFT 6.5 100-00070
6700WH002 THIMBLE, 1/4" 2 10-37292
6700WH003 CLIP, 1/4" WIRE ROPE 4 86290
6700WH010 CABLE, 1/8" AIRCRAFT 15 719-1/8GI
6700WH011 THIMBLE, 1/8" 4 2400-00160
6700WH012 FERRULE, 1/8" DUPLEX 12 2900-00540
6700WH021 CABLE, 3/8" AIRCRAFT 36 100-0090
6700WH023 CLIP, 3/8" WIRE ROPE 6 1900-00240
6700WH024 THIMBLE, 3/8" 2 2400-00030
6800WH002 LADDER EXTENSION, 3/4"OD 4 6100-05050
6816 CLAMP, 1" HOSE 8 6816
7300WH008 QUICKLINK,1/8" 2 4500-300
75000107021 DECAL, DO NOT PUSH OR PUL 1 WHITE REFLECTIVE LETTER

MASTER PARTS LIST Page 4

 GFMFG - MASTER PARTS LIST
165901 - ENCLOSED FUEL AND LUBE TRUCK
PART NUMBER DESCRIPTION QTY. MODEL NUMBER
7700EL010 SWITCH, TOGGLE 6TERM.DPDT 1 55054
7700EL015 BUS BAR, 3-HOLE 1 86126-6/CUT IN HALF
7700EL020 SEAL, TOGGLE SWITCH 2 81255
7700EL025 PILOT LIGHT, AMBER 1 PL-118-AC-001
7700EL030 SOCKET, 7-POLE TRAILER 1 12063
7700EL041 SOLENOID, 24VDC NORMALLY 1 24063-08
7700EL041 SOLENOID, 24VDC NORMALLY 1 24063-08
7700EL710 FUSE PANEL, 25AMP 10POS C 1 46377-10
7700EL776 FUSE PANEL, 25AMP 6POS CI 1 46377-6
7700EL905 FUSE, 5AMP BLADE 4 782-2015
7700EL910 FUSE, 10AMP BLADE 1 782-2017
7700EL915 FUSE, 15AMP BLADE 1 782-2018
7813LT006 LAMP, RED CLEARANCE 2 500012
7813LT007 LAMP, AMBER CLEARANCE 2 500013
7813LT012 JUNCTION BOX W/3/8"NPT HO 1 M47A-01-0693/470062
7813LT032 LAMP, TURN/STOP/TAIL DUAL 1 410013
7813LT033 LAMP, TURN/STOP/TAIL DUAL 1 410015
7813LT043 LENS KIT, LED, RED 24V 7 4 710005
7813LT047 LENS KIT, LED, RED 24V 78 2 510047
7813LT048 LENS KIT, LED, AMBER 24V 2 510048
7900NP005 NAMEPLATE, SERIAL NUMBER 1 NP3417
801-8 HOSE, 1/2" PUSH-LOC 18 1/2PUSHLOK
8300DC075 PULLEY, 7.5"PD 2-GROOVE 1 2B74SK
8300DC078 BUSHING, 7/8" BORE 1/4" K 1 SK-7/8
85601582011 FUEL TANK, 20 GAL ABOVE D 1 1582011
85601582014 FUEL TANK HOLD DOWN KIT 1 1582014
881 16B 50
881-16B-50 HOSE, 1
1" 100R4 50'
50 1 881-01-06-16-16-16-600
881 01 06 16 16 16 600
900729-16 CLAMP, 2.88" DIA. 3 900729-16
90181100317 SPLIT RING, RETAINER 1
90181101201 D400 REAR DECK MOUNT PIN 4
90181104873 D400 REAR DECK MOUNT PIN 2 104873
920469 HEATER, 104K BTU 24VOLT W 1 920469
9400RL008 MANIFOLD, 1/2" HOSE REEL 6 C7189
9400RL016 HOSE REEL MANIFOLD, 1" 3 SPEN27
9411HY001 VALVE, 1-SPOOL HYDRAULIC 12 30931-CEL
9411WH002 ADAPTER,9411WH001-12300WH 12 1/2"-13 X 2" ROD
9411WH002 ADAPTER, 9411WH001-12300W 12 1/2"-13 X 2" ROD
9411WH004 KNOB EXTENSION, 5MM PIN 12 9411WH004/AD
9411WH005 TENSION PIN, 3/16" X 3/4" 12 0930.018.0075.10
9414HY253 MOTOR, HYDRAULIC 11.3 CID 4 9414HY253
9414HY257 MOTOR, HYDRAULIC 7.3CID H 8 9414HY257
9437AP001 AIR LINE REQULATOR, 125 P 1 07R313A
9437AP002 AIR LINE FILTER, 40 MICRO 1 07F32A
9437AP003 AIR LINE LUBRICATOR 1 17L32B
9437GG004 GAUGE, 160PSI 2" FACE 1 12-30DSB-0-160X
9475FI0231 FILTER HOUSING & ELEMENT 5 HP3000-N16-000-025-N
9600RL008 HOSE BUMPER, 1/2" or 3/8" 8 2-HR1004-3
9600RL016 HOSE BUMPER, 1" HOSE 1.39 3 4-HR1005

MASTER PARTS LIST Page 5

 GFMFG - MASTER PARTS LIST
165901 - ENCLOSED FUEL AND LUBE TRUCK
PART NUMBER DESCRIPTION QTY. MODEL NUMBER
9700GA495 O-RING, 9700PM902 1 109495
9700GG643 METER & VALVE, 45LPM 1/2" 5 238643
9700GG803 METER & VALVE, 5GPM/19LPM 1 255803
9700PM752 PUMP, GREASE 5:1 3GPM 1 224752
9700PM902 PUMP, GREASE 2.4:1, 12GPM 1 222902
9700PM939 PUMP, DIAPHRAGM 16GPM 3/4 1 241906
9777FI008 FILTER ELEMENT, 25 MICRON 8 70135 GFMFG LOGO
9777FI015 FILTER ELEMENT, 30MICRON 2 30037
99007032447 RADIATOR CAP, 16PSI VENT 1 703-2447
9900GG105 GAUGE, 160PSI 2"FACE 1/8" 4 20D-B-160
9900HY126 MANIFOLD, PARALLEL-INLET 2 B5234
9900HY127 MANIFOLD, PARALLEL-CENTER 2 B5235
9900HY128 MAINFOLD, PARALLEL-OUTLE 2 B5236
9900RL002 HOSE REEL DRIVE HUB, TAPE 12 910-0000-100
9900RL022 HOSE REEL SIDE PLATE 23"L 12 9900RL022
9900RL023 HOSE REEL SIDE PLATE 23"W 10 9900RL023
9900SM002 TANK MOUNT BRACKET 40 9900SM002/MOUNT
9900SM213 CATCH, TANK HOLD DOWN ROD 12
9900SM613-1 HOSE REEL FAIRLEAD STANDO 2 910-0000-212
9900SM613-2 HOSE REEL FAIRLEAD ST-OFF 2 910-0000-212
9X-1439 LIGHT, SUSPENDED FLOOD 8 9X-1439
B71 V-BELT, 74"OD 2 B71
BG18-3-P7-15/30 INDICATOR, BAR GRAPH 24-6 1 BG18-3-P7-15/30
C-1-1/4 COUPLER,1-1/4"HOSEBARB 1- 1 11/4C-AL
DM6 HOSE MENDER, 3/4"HOSE X 2 DM6
FP-10 FENDER FLARE, RUBBER 30 FP-10
H30F AIR TANK, 30 GALLON 200 P 1 4377K52
H521-2 NOZZLE, 1" FULL FLOW 1 173310-03
HK0709 CLAMP, 3/8" DIA 35 HK0709
HK0913 CLAMP, 1/2" DIA 43 HK0913
HK1313 CLAMP, 3/4" DIA 17 HK1313
HK1713 CLAMP, 1" DIA 7 HK1713
HK2117 CLAMP, 1-1/4" DIA 3 HK2117
HK2517 CLAMP, 1-1/2" DIA. 7 HK2517
HTM175 CLAMP, 1-3/4" HOSE 10 HTM175
HTM200 CLAMP, 2" HOSE 10 HTM200
IRGF1-1/2 INSULATION, 1.5" X 4' X 8 8
IRGF2 INSULATION, 2" X 4' X 8' 4
J206 CLAMP,1-3/4"X5/8" .030 SS 2 J206
J844X1/4 HOSE, 1/4"OD SYNFLEX 10 1120-4A-BLK-1000
JV125L JET SENSOR, LONG 1 JV125L
OAD1124VBP1.5C1 OIL COOLER, 24VDC FAN 1 OAD-11-24V-BP1.5C120
RTSRB12 RECIEVER TUBE,12" FOR 2"S 1 318600
SL707 AIR COMPRESSOR, 7.5-10HP 1 707
SPC18 COVER,SPLASH PROOF,1/8"DI 1 SPC18
TAGS165901 TAGS, COMPLETE LIST 16590 1
TBC188 CLAMP, T-BOLT STAINLESS 5 300100188
TBC200 CLAMP, 2" T-BOLT 4 300100200

MASTER PARTS LIST Page 6

 GFMFG - MASTER PARTS LIST
165901 - ENCLOSED FUEL AND LUBE TRUCK
PART NUMBER DESCRIPTION QTY. MODEL NUMBER
TBC238 CLAMP, 2-3/8" T-BOLT 32 300100238
TBC250 CLAMP, 2-1/2" T-BOLT 3 C410N-75-250S
TBC288 CLAMP, T-BOLT 8 C410N-75-288S
TBC350 CLAMP, 3-1/2" T-BOLT 8 300100350
VIC2N GASKET, 2" VICTAULIC NITR 1 2GSKVIC
VR300-5 ADAPTER, NOZZLE 1 VR300-5
VR301 NOZZLE, DIESEL FUELING 1 VR301
VR304-18 GASKET, RECEIVER FLANGE 1 VR304-18
VR325 RECEIVER, FUELING 1 VR325
W.21204 COUPLING, 1/4"FPT BULK- 1 W21204
WIL1765 VISE, 6.5" JAW 6.5"OPENIN 1 1765
ZS250 SWIVEL, 2.5" FUEL NOZZLE 1 ZS250
ZV10NFB VENT, FUELING 1 ZV10NFB

MASTER PARTS LIST Page 7

 GFMFG - RECOMMENDED SPARE PARTS LIST
165901 - FUEL AND LUBE TRUCK
PART NUMBER DESCRIPTION QTY.
10082PM204 GREASE VALVE 1
10082PM205 GREASE SWIVEL 1
10200DL165901 DRIVE LINE ASSEMBLY, 60" 1
11600AP047 SOLENOID VALVE, 24VDC 3-W 2
11600EL021 SWITCH, SELECTOR, 2POS 22 6
11600FI100 STRAINER, 1" FPT Y-STYLE 1
11600FI613 DESICCANT DRYER, 25CFM 1
12300EL025 SWITCH, LIQUID LEVEL, HOR 2
12300EL031 SWITCH, PUSH/PULL 1
13400SM002 HINGE, SS TRAILER 3
13500WH501 LATCH, LEVER HANDLE, YELL 1
13500WH902 LATCH, ADJUSTABLE DRAW, B 1
13700WH710 LATCH, SELF LOCKING W/COV 1
14408GG521-L METER, 76-760LPM DIESEL 3 1
14900LT761 STROBE LIGHT, AMBER LED, 2
14900LT772 STROBE LIGHT, RED RECEIVE 1
14900LT773 STROBE LIGHT, AMBER RECEI 1
14900SD241 BACK UP ALARM, 12-24 VDC 1
17000RL008 SWIVEL, 1/2" GREASE 1
1703151 LAMP, HID, CLEAR FLOOD, 3 2
201002 SENSOR, FUEL LEVEL, CONTI 1
2100BR039 BEARING, 2-7/16" FLANGE 4 1
255-0-24 HEAT EXCHANGER, 30000 BTU 2
3200HY025 CHECK VALVE, LOAD SENSE 4
3200HY090 VALVE, PROPORTIONAL 1
3200HY115 MOTOR, HYDRAULIC, 7/8"SHA 1
3200HY210 VALVE, SOLENOID, NC 2
3200HY211 VALVE, SOLENOID 1
3200HY230 VALVE, PRESSURE REDUCING 3
3200HY612 VALVE, NEEDLE, ADJUSTABLE 1
3200HY962 PRESSURE SWITCH 2
3260EL1424 SOLENOID COIL, 24VDC 30WA 1
3260HY005 CHECK VALVE, LOAD SENSE 2
3260HY488 MOTOR, 4.88CID 1-1/4" X 5 1
3286EL024 SOLENOID COIL, 24VDC 2
3286EL100 AMPLIFIER BOARD 1
3290PM304 PUMP/MOTOR COMBO P30-M30 2
40095000100 PUMP, MAIN HYDRAULIC SET @ 2000PSI 1
4200SM026 DOOR LATCH, VAN BODY CAM 1
4600EL008 POTENTIOMETER, 0-1K OHMS 1
4600EL009 KNOB, POTENTIOMETER, HIGH 1
5707FI300 STRAINER, 3" FLANGE 1
5707PM201 PUMP, 2 " WASTE OIL 1
5707PM300 PUMP, 3" PETROLEUM 1
60000103773 MICRO CONTROLLER, DIESEL 1
60000CCB070 CIRCUIT BREAKER, 70A MANU 1
60000CCB100 CIRCUIT BREAKER, 100A MAN 1
6007524V5MB LED, 30V BLUE WITH BEZEL 30

RECOMMENDED SPARE PARTS

 GFMFG - RECOMMENDED SPARE PARTS LIST
165901 - FUEL AND LUBE TRUCK
PART NUMBER DESCRIPTION QTY.
6007524V5MY LED, 30V YELLOW WITH BEZE 30
60BU5084V24 RELAY, 24V, 40/60AMP 4
6156GG004 GAUGE, 5000PSI 1/4"MPT B- 1
7700EL010 SWITCH, TOGGLE 6TERM.DPDT 1
7700EL025 PILOT LIGHT, AMBER 1
7700EL030 SOCKET, 7-POLE TRAILER 1
7700EL041 SOLENOID, 24VDC NORMALLY 2
7813LT043 LENS KIT, LED, RED 24V 7 4
7813LT047 LENS KIT, LED, RED 24V 78 2
7813LT048 LENS KIT, LED, AMBER 24V 2
8300DC075 PULLEY, 7.5"PD 2-GROOVE 1
8300DC078 BUSHING, 7/8" BORE 1/4" K 1
920469 HEATER, 104K BTU 24VOLT W 1
9411HY001 VALVE, 1-SPOOL HYDRAULIC 1
9411WH002 ADAPTER,9411WH001-12300WH 1
9414HY253 MOTOR, HYDRAULIC 11.3 CID 1
9414HY257 MOTOR, HYDRAULIC 7.3CID H 1
9437AP001 AIR LINE REQULATOR, 125 P 1
9437AP002 AIR LINE FILTER, 40 MICRO 1
9437AP003 AIR LINE LUBRICATOR 1
9475FI0231 FILTER HOUSING & ELEMENT 60
9700GG643 METER & VALVE, 45LPM 1/2" 2
9700GG803 METER & VALVE, 5GPM/19LPM 1
9700PM752 PUMP, GREASE 5:1 3GPM 1
9700PM902 PUMP, GREASE 2.4:1, 12GPM 1
9700PM939 PUMP, DIAPHRAGM 16GPM 3/4"NPT INLET 1
9777FI008 FILTER ELEMENT, 25 MICRON 96
9777FI015 FILTER ELEMENT, 30MICRON 24
9X-1439 LAMP, HALOGEN FLOOD, SUSP 2
B71 V-BELT, 74"OD 6
BG18-3-P7-15/30 INDICATOR, BAR GRAPH 24-6 1
JV125L JET SENSOR, LONG 1
OAD1124VBP1.5C1 OIL COOLER, 24VDC FAN 1
RTSRB12 RECIEVER TUBE,12" FOR 2"S 1
SL707 AIR COMPRESSOR, 7.5-10HP 1
VR300-5 ADAPTER, NOZZLE 1
VR301 NOZZLE, DIESEL FUELING 1
VR304-18 GASKET, RECEIVER FLANGE 1
VR325 RECEIVER, FUELING 1
WIL1765 VISE, 6.5" JAW 6.5"OPENIN 1
ZS250 SWIVEL, 2.5" FUEL NOZZLE 1
ZV10NFB VENT, FUELING 1

RECOMMENDED SPARE PARTS

6. MANUFACTURER
MANUALS
 WARRANTY PARTS

Ground Force Mfg., LLC utilizes parts made by many vendors.

All vendor component parts have their respective manufacturers
warranties. Ground Force Mfg., LLC. agrees to assign to the
purchaser all of its rights under any original manufacturers warranty
covering such component parts, and agrees to assist the purchaser in
making such contacts with the manufacturer of such component parts
as may be necessary to protect its right under the warranty covering
them. We will endeavor to do everything possible to assure that your
Ground Force Mfg., LLC equipment stays in top operating condition
and will provide you with warranty claim support.

How to File a Claim

1) Locate the Ground Force serial number (six numerals)

2) Have a PO ready to charge the shipping method of your choice
to, as well as the cost of the replacement part.
3) Call Ground Force Mfg., LLC (208) 664-9291 with the serial
number of your Ground Force Mfg., LLC equipment and a part
number/part description and ask for the Warranty Department.
4) Ground Force Mfg., LLC will ship the part out to you along with
a Return Goods Authorization (RGA).
5) Replace the part in question and return the part in question
along with the RGA to Ground Force Mfg., LLC.
6) Upon arrival, Ground Force Mfg., LLC will route the part to the
appropriate vendor for warranty consideration.
7) The vendor will report their findings to Ground Force Mfg., LLC
and either deny the claim or issue a credit.
8) Ground Force Mfg., LLC will forward the vendors findings to
you the customer. If a credit is issued it will be placed against
the PO used to purchase and ship the part to you.
PartsWarranty.Doc
Revised1/15/2008
 BLACKMER TRUCK PUMPS 960280
INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS INSTRUCTIONS NO. 201-A00
Page 1 of 12
MODELS: TX, TXS, TXD, TXSD 1.5, 2A, 2.5A, 3E, 4A Section 200
TXV 2.5B, 3B Effective March 2003
Replaces June 2001
and Discontinued TX(S) 2, 21/2, 3; TXV 2(A)(B), 21/2(A), 3(A) Models

SAFETY DATA

This is a SAFETY ALERT SYMBOL.

When you see this symbol on the product, or in the manual, look for
one of the following signal words and be alert to the potential for
personal injury, death or major proper ty damage.

Warns of hazards that WILL cause serious personal injury,

death or major proper ty damage.
TABLE OF CONTENTS Page

SAFETY DATA .................................................................1-2 Warns of hazards that CAN cause serious personal injury,
PUMP DATA .........................................................................2 death or major property damage.
Technical Data.......................................................2
Initial Start Up Information .....................................2
Warns of hazards that CAN cause personal injury
INSTALLATION ...............................................................2-3 or property damage.
Pre-Installation Cleaning .......................................2
Location and Piping...............................................2 NOTICE:
Truck Mounting......................................................3 Indicates special instructions which are very
Pump Drive............................................................3 impor tant and must be followed.
Pump Rotation.......................................................3
To Change Pump Rotation ....................................3

OPERATION .....................................................................4-5
Pre-Start Up Check List.........................................4
Start Up Procedures ..............................................4
Pump Speed..........................................................4
Reverse Rotation...................................................4
Flushing the Pump ................................................4
Relief Valve ...........................................................4
Relief Valve Setting and Adjustment .....................5
MAINTENANCE ...............................................................5-8
Lubrication.............................................................5
Vane Replacement ................................................5
Pump Disassembly................................................6
Pump Assembly ....................................................6
GENERAL PUMP TROUBLESHOOTING .................9-10
NOTE: Numbers in parentheses following individual
parts indicate reference numbers on the
corresponding Blackmer Parts Lists.
NOTICE:
Blackmer truck pumps MUST only be installed in
systems which have been designed by qualified
engineering personnel. The system MUST conform to
all applicable local and national regulations and safety
standards.
This manual is intended to assist in the installation
and operation of the Blackmer truck pumps, and
MUST be kept with the pump.
Blackmer truck pump service shall be performed by
qualified technicians ONLY. Service shall conform to
all applicable local and national regulations and safety
standards.
Thoroughly review this manual, all instructions and
hazard warnings, BEFORE performing any work on
the Blackmer truck pumps.
Maintain ALL system and Blackmer truck pump
operation and hazard warning decals.
 SAFETY DATA
FAILURE TO SET THE VEHICLE DISCONNECTING FLUID OR
EMERGENCY BRAKE AND CHOCK PRESSURE CONTAINMENT
WHEELS BEFORE PERFORMING COMPONENTS DURING PUMP
SERVICE CAN CAUSE SEVERE OPERATION CAN CAUSE SERIOUS
Hazardous machinery PERSONAL INJURY, DEATH OR MAJOR
can cause severe PERSONAL INJURY OR PROPERTY Hazardous pressure
can cause
personal injury or personal injury or PROPERTY DAMAGE.
property damage. DAMAGE. property damage.

FAILURE TO RELIEVE SYSTEM IF PUMPING HAZARDOUS FLUIDS

PRESSURE PRIOR TO PERFORMING SYSTEM MUST BE FLUSHED PRIOR
PUMP SERVICE OR MAINTENANCE TO PERFORMING SERVICE.
CAN CAUSE PERSONAL INJURY OR
Hazardous pressure
can cause PROPERTY DAMAGE. Hazardous or toxic
personal injury or fluids can cause
property damage. serious injury.

PUMP DATA
TECHNICAL DATA INITIAL START UP INFORMATION
TX(S)(D) TXV
Models Models Model No.
Maximum Temperature* 300oF (149oC) 375oF (190oC)
Serial No.
Maximum Pump Speed 640 RPM1

Maximum Viscosity* 50,000 SSU (10,800 cSt) Date of Installation:

Maximum Differential Pressure 125 psi (8.6 bar)
Pressure Gauge Reading:
Maximum Working Pressure 175 psi (12.1 bar)
(Inlet Pressure + Differential Pressure)
Vacuum Gauge Reading:
* Optional materials of construction may be required to meet the
operating limits listed above. Refer to Blackmer Material Specs Flow Rate:
201/91-92 for TX(S)(D) models or 202/91-92 for TXV models.
1 780 RPM maximum pump speed for TX(S)(D)1.5, 2 and 2.5 models.
500 RPM maximum pump speed for TX4A pump models.

INSTALLATION
NOTICE: PRE-INSTALLATION CLEANING
BLACKMER TRUCK PUMPS MUST ONLY BE Foreign matter entering the pump WILL cause extensive
INSTALLED IN SYSTEMS DESIGNED BY QUALIFIED damage. The supply tank and intake piping MUST be cleaned
ENGINEERING PERSONNEL. SYSTEM DESIGN MUST and flushed prior to pump installation and operation.
CONFORM WITH ALL APPLICABLE REGULATIONS
AND CODES AND PROVIDE WARNING OF ALL LOCATION AND PIPING
SYSTEM HAZARDS. An improperly designed piping system or unit installation WILL
significantly reduce pump performance and life. Blackmer
recommends the following piping system layout and unit
FAILURE TO SET THE VEHICLE installation.
EMERGENCY BRAKE AND CHOCK 1. To minimize intake losses, locate the pump as close as
WHEELS BEFORE PERFORMING possible to the source of supply.
SERVICE CAN CAUSE SEVERE 2. Piping MUST be properly supported to prevent any piping
Hazardous machinery
PERSONAL INJURY OR PROPERTY loads from being placed on the pump.
can cause severe
personal injury or
property damage. DAMAGE. 3. Intake piping and fittings MUST be at least as large in
diameter as the pump intake connection.
2
 INSTALLATION
4. Minimize the number of intake line fittings (valves, elbows,
etc.) and piping turns or bends.
5. Temporarily install vacuum and pressure gauges in the 1/4"
NPT intake and discharge ports located on the pump
cylinder to check pump performance at start-up.
6. Install a strainer in the inlet line to protect the pump from
foreign matter. Placement of intake strainers should
facilitate frequent cleaning.
7. Intake and discharge piping MUST be free of all leaks.
TRUCK MOUNTING
The pump will operate satisfactorily in any position. Consult
Blackmer factory for vertical shaft mounts. The pump can be
bolted to the truck frame or on a saddle hung below the frame,
and MUST be adequately supported. Mounting the pump with
the cylinder feet down, or with the intake port up, is
recommended for thorough draining of the pump.
PUMP DRIVE
The pump may be driven by a power take-off through universal
joints. When using universal joints, a splined slip joint,
properly lubricated, must be used on the connecting jack shaft
to prevent end thrust on the pump shaft.
It is very important to install a proper drive line to avoid
excessive wear, vibration and noise (see Fig. 1 and Table 1).
(Yokes must be in phase)
Figure 1 - Pump Drive
Angle of Drive Shaft
1o through 5o 6o through 10o 11o through 15o
Very Good Good Fair
Table 1
General guidelines to follow for proper pump drive:
1. Do not use square slip joints.
2. Use the least number of jack shafts as is practical.
3. Use an even number of universal joints.
4. The pump shaft and power take-off shaft should be parallel
in all respects. Use an angular level measuring device to
ensure the PTO and pump shaft are parallel to each other.
If necessary, the pump can be shimmed to correct any
misalignment. The PTO shaft coming off at the
transmission does not need to be perfectly horizontal as
3
long as the pump is shimmed to have its shaft parallel in all
respects to the PTO shaft.
5. The yokes of the universals at both ends of the jack shaft
must be parallel and in phase.
6. The maximum recommended angle between the jack shaft
and the pump shaft is 15 degrees. Refer to Table 1.
Failure to follow any of these guidelines may result in a gallop
or uneven turning of the pump rotor, which will in turn cause a
surging vibration to the liquid stream and piping system.
Contact the supplier of the drive line components for specific
design assistance.
Hydraulic Drive
The pump may also be driven hydraulically. Hydraulic motors
must be well supported with their shafts parallel to the pump
shaft in all respects. Blackmer provides an optional close-
coupled hydraulic motor adapter. The adapter provides for
straight alignment of a hydraulic motor drive through a solid
coupling connected to a straight key pump shaft. This
coupling connection requires grease lubrication every three
months at minimum. Refer to the "Lubrication" section of this
manual.
PUMP ROTATION
NOTICE:
CONFIRM CORRECT PUMP ROTATION BY CHECKING
THE PUMP ROTATION ARROWS RESPECTIVE TO PUMP
DRIVER ROTATION.
TO CHANGE PUMP ROTATION
TX(S)D and TXV Models
The TX(S)D and TXV pump models are equipped with a
double ended rotor and shaft, enabling them to be driven from
either shaft end. To change rotation, rotate the pump 180
degrees so that the opposite shaft becomes the driven shaft.
On TX(S)D pump models, the shaft protector (186) MUST be
mounted over the non-driven shaft end. On TXV pump
models, the outboard bearing cover (27) MUST be mounted
over the non-driven shaft end.
OPERATION WITHOUT SHAFT
PROTECTOR CAN CAUSE SERIOUS
PERSONAL INJURY, MAJOR
PROPERTY DAMAGE, OR DEATH.
Do not operate
without guard
in place.
TX1.5, TX4 Models and Discontinued TX(S) Models
To reverse the pump rotation, remove the bearing covers,
locknuts/lockwashers or lock collars (if equipped), from both
inboard and outboard heads. Remove the inboard head
assembly and reverse the rotor and shaft, so that the driven
end of the shaft protrudes from the outboard head. Remove
and replace the vanes so that the relief grooves face in the
direction of pump rotation. Refer to the "Maintenance" Section
of this manual for pump disassembly and assembly.
 OPERATION
PRE-START UP CHECK LIST
1. Check the alignment of the pipes to the pump. Pipes must
be supported so that they do not spring away or drop down
when the pump flanges or union joints are disconnected.
2. Temporarily install vacuum and pressure gauges in the 1/4"
NPT ports located on the pump cylinder. These can be
used to check the actual suction and discharge conditions
after pump start-up.
3. Inspect complete piping system to ensure that no piping
loads are being placed on the pump.
4. Secure appropriate hose connections.
START UP PROCEDURES
PUMP OPERATING AGAINST A
CLOSED VALVE CAN CAUSE
SYSTEM COMPONENT FAILURE,
PERSONAL INJURY AND PROPERTY
Hazardous pressure
can cause DAMAGE.
personal injury or
property damage.
NOTICE:
CONSULT THE "GENERAL PUMP TROUBLESHOOTING"
SECTION OF THIS MANUAL IF DIFFICULTIES DURING
START UP ARE EXPERIENCED.
1. Start the pump. Priming should occur within one minute.
2. Check the vacuum and pressure gauges to ensure the
system is operating within expected parameters. Record
the gauge readings in the "Initial Start Up Information"
section of this manual for future reference.
3. Inspect piping, fittings, and associated system equipment
for leaks, noise, vibration and overheating.
4. Check the flow rate to ensure the pump is operating within
the expected parameters.
5. Check the pressure setting of the relief valve by
momentarily closing a valve in the discharge line and
reading the pressure gauge. This pressure should be 15 -
20 psi (1.0 - 1.4 bar) higher than the maximum system
operating pressure, or the external bypass valve setting (if
equipped). DO NOT operate the pump against a closed
discharge valve for more than 15 seconds. If
adjustments need to be made, refer to the "Relief Valve
Setting and Adjustment" section of this manual.
PUMP SPEED
PTO and hydraulically driven units MUST contain speed
control devices to prevent pump speeds above the maximum
RPM specifications, regardless of the truck engine unloading
speeds. Should fluid delivery be appreciably less than
expected, see the "General Pump Troubleshooting" section.
4
REVERSE ROTATION
NOTICE:
PUMPS OPERATED IN REVERSE MUST HAVE A
SEPARATE PRESSURE RELIEF VALVE INSTALLED TO
PROTECT THE PUMP FROM EXCESSIVE PRESSURE.
It may be desirable to run the pump in reverse rotation for
system maintenance. The pump will operate satisfactorily in
reverse rotation to strip lines, at a reduced performance level.
When operating the pump in reverse, a separate bypass valve
MUST be installed to protect the pump from excessive
pressure.
FLUSHING THE PUMP
NOTICE:
IF FLUSHING FLUID IS TO BE LEFT IN THE PUMP FOR
AN EXTENDED TIME, IT MUST BE A LUBRICATING,
NON-CORROSIVE FLUID. IF A CORROSIVE, NON-
LUBRICATING FLUID IS USED, IT MUST BE FLUSHED
FROM THE PUMP IMMEDIATELY.
To flush the pump, use the following procedure:
1. Allow the pump to evacuate as much fluid as possible.
2. Run cleaning fluid through the pump intake. The cleaning
fluid must be compatible with the pump O-rings and vane
material. When handling "sticky" fluids that solidify within
the pump (i.e., waxes, adhesives, resins, asphalts, etc.),
use a fluid that will prevent solidification of the fluid being
transferred and facilitate flushing.
3. Operate the pump against a closed discharge for 15
seconds to allow the cleaning fluid to recirculate through
the internal relief valve.
RELIEF VALVE
NOTICE:
THE PUMP INTERNAL RELIEF VALVE IS DESIGNED TO
PROTECT THE PUMP FROM EXCESSIVE PRESSURE
AND MUST NOT BE USED AS A SYSTEM PRESSURE
CONTROL VALVE.
Pumping volatile liquids under suction lift may cause
cavitation. Partial closing of the discharge valve WILL result in
internal relief valve chatter and must not be done. For these
applications, install an external bypass valve, and any
necessary piping, back to the storage tank. This bypass
system must be used when operating for extended periods
(more than 1 minute) against a closed discharge valve.
RELIEF VALVE SETTING AND ADJUSTMENT
The relief valve pressure setting is marked on a metal tag
attached to the valve cover. Generally, the relief valve should
be set at least 15 - 20 psi (1.0 - 1.4 bar) higher than the
operating pressure, or the external bypass valve setting (if
equipped).
 OPERATION
Relief Valve Adjustment Procedure: NOTICE:
1. To INCREASE the pressure setting , remove the relief WHERE REGULATIONS REQUIRE, HOLES IN R/V CAP (1) AND
valve cap, loosen the locknut, and turn the adjusting screw CAPSCREW W / HOLE (5C) ARE USED BY THE WEIGHTS AND
inward, or clockwise. Replace the valve cap. MEASURES OFFICIAL (S) TO APPLY A SECURITY SEAL OR TAG.
2. To DECREASE the pressure setting, remove the relief
valve cap, loosen the locknut, and turn the adjusting screw
outward, or counterclockwise. Replace the valve cap. INCORRECT SETTINGS OF THE
PRESSURE RELIEF VALVE CAN
Refer to the individual Blackmer pump parts lists for various
spring pressure ranges. The pumps are supplied from the CAUSE SYSTEM COMPONENT
factory with the relief valve adjusted to the mid-point of the FAILURE, PERSONAL INJURY AND
spring range. If the pump is equipped with a Blackmer air Hazardous pressure
PROPERTY DAMAGE.
can cause
valve, refer to setting and adjustment procedures covered in personal injury or
property damage.
Blackmer Air Valve Instructions and Parts List No. 201-F00,
286/F or 201-B00.

MAINTENANCE
NOTICE: LUBRICATION
MAINTENANCE SHALL BE PERFORMED BY QUALIFIED Ball bearings and hydraulic motor couplings (if equipped) must
TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE be lubricated every three months at a minimum. More frequent
PROCEDURES AND WARNINGS AS PRESENTED IN lubrication may be required, depending on the application and
the operating conditions. TXV pump model bearings MUST
THIS MANUAL.
be replaced after each 1000 hours of service if fluid
temperature is greater than 250oF (120oC).
FAILURE TO SET THE VEHICLE
Recommended Grease:
EMERGENCY BRAKE AND CHOCK
WHEELS BEFORE PERFORMING TX(S)(D) Models - Exxon (Esso) - Ronex MP or Mobile -
Mobilith AW-2, or equivalent Lithium grease.
SERVICE CAN CAUSE SEVERE
Hazardous machinery TXV Models - Exxon (Esso) - Polyres or Mobile - Mobile Poly
PERSONAL INJURY OR PROPERTY
can cause severe 372, or equivalent Polyurea grease.
personal injury or
property damage. DAMAGE.
Greasing Procedure:
1. Remove the grease relief fittings (76A) from the bearing
FAILURE TO RELIEVE SYSTEM covers (27 and 27A) or hydraulic motor adapter (135).
PRESSURE PRIOR TO PERFORMING 2. SLOWLY apply grease with a hand gun until grease begins
PUMP SERVICE OR MAINTENANCE to escape from the grease relief fitting port. Discard
excess grease in accordance with the proper codes and
CAN CAUSE PERSONAL INJURY OR
regulations.
Hazardous pressure PROPERTY DAMAGE.
can cause 3. Replace the grease relief fittings (76A).
personal injury or
property damage.
DO NOT overgrease pump bearings. While it is normal for
some grease to escape from the grease tell-tale hole after
DISCONNECTING FLUID OR lubrication, excessive grease on pumps equipped with
PRESSURE CONTAINMENT mechanical seals can cause seal failure.

COMPONENTS DURING PUMP

OPERATION CAN CAUSE SERIOUS VANE REPLACEMENT
PERSONAL INJURY, DEATH OR MAJOR
Hazardous pressure
can cause
NOTICE:
personal injury or PROPERTY DAMAGE. MAINTENANCE SHALL BE PERFORMED BY QUALIFIED
property damage.
TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE
PROCEDURES AND WARNINGS AS PRESENTED IN
IF PUMPING HAZARDOUS FLUIDS THIS MANUAL.

SYSTEM MUST BE FLUSHED PRIOR 1. Remove the head assembly from the outboard (non-
driven) side of the pump according to steps 2 - 6 in the
TO PERFORMING SERVICE.
"Pump Disassembly" section of this manual.
2. Turn the shaft by hand until a vane comes to the top (12
Hazardous or toxic
fluids can cause o'clock) position of the rotor. Remove the vane.
serious injury.
3. Install a new vane, ensuring that the rounded edge is UP,

5
 MAINTENANCE
and the relief grooves are facing towards the direction of
rotation. See Figures 2 and 3.
4. Repeat steps 2 and 3 until all vanes have been replaced.
5. Reassemble the pump according to steps 2 - 7 and 12 - 17
of the "Pump Assembly." section of this manual.
Figure 2 - Vane Installation - TX(S)(D) Models*
*NOTE: 1.5 and 2-inch pump models have four (4) vanes.
Figure 3 - Vane Installation - TXV Models*
*NOTE: 2-inch pump models have four (4) vanes.
PUMP DISASSEMBLY
NOTICE:
FOLLOW ALL HAZARD WARNINGS AND
INSTRUCTIONS PROVIDED IN THE "MAINTENANCE"
SECTION OF THIS MANUAL.
1. Starting on the inboard (driven) end of the pump, clean the
pump shaft thoroughly, making sure the shaft is free of
nicks and burrs. This will prevent damage to the
mechanical seal or lip seal when the inboard head
assembly is removed.
2. Remove the inboard bearing cover capscrews (28) and
slide the inboard bearing cover (27A) and gasket (26) off
the shaft. Discard the bearing cover gasket. On the 1.5, 2,
2.5, and 3-inch pump models, the dirt shield (123A) will
come off with the bearing cover.
3. Remove the outboard bearing cover capscrews (28) and
slide the outboard bearing cover (27) and gasket (26) off
the shaft. Discard the bearing cover gasket.
4. If equipped with locknuts and lockwashers (24A and 24B):
6
a. Bend up the engaged lockwasher tang and rotate the
locknut counterclockwise to remove it from the shaft
b. Slide the lockwasher off the shaft. Inspect the
lockwasher for damage and replace as required.
c. Repeat steps a and b on the opposite shaft end.
5. The TX(S)4-inch pump model is equipped with bearing lock
collars (24A). To remove:
a. Remove the jam nuts (24C) and loosen the two set
screws (24B).
b. Slide the lock collar off the shaft.
c. Repeat steps a and b on the opposite shaft end.
6. Remove the head capscrews (21) and carefully pry the
head (20) away from the cylinder (12).
7. Slide the head off the shaft. The head O-ring (72), bearing
(24), and mechanical seal (153) or lip seal (152) will come
off with the head assembly. Remove and discard the head
O-ring.
a. Pull the bearing (24) from the housing in the head (20).
b.To remove the mechanical seal (153), use two screw
drivers to gently push the backside of the seal jacket to
push the seal from the head (see Figure 4). Use care
when placing the screw drivers to prevent damage to
the seal faces. Remove and discard mechanical seal
O-rings.
Figure 4 - Mechanical Seal Removal
c. To remove the lip seal assembly (152), use a thin pry
bar against the lip seal retaining ring to gently push the
housing (152B) out of the head (20). Use care not to
damage the lip seal (152A). To remove the lip seal
(152A), remove the retaining ring (152D) from the
housing, and gently pry the lip seal from the housing.
Remove and discard the housing O-ring(s) (152C and
152E).
8. Pull the rotor and shaft (13) from the cylinder (12). While
one hand is pulling the shaft, the other hand should be
cupped underneath the rotor to prevent the vanes (14) and
push rods (77) from falling out. Carefully set the rotor and
shaft aside for future vane replacement and reassembly.
9. Remove the remaining components from the outboard side
of the pump, as instructed in steps 6 and 7 above.
PUMP ASSEMBLY
Before reassembling the pump, inspect all component
parts for wear or damage, and replace as required. Wash
out the bearing /seal recess of the head and remove any
burrs or nicks from the rotor and shaft.
 MAINTENANCE
e. Install new housing O-ring(s) (152C and 152E) in the
1. Reassemble the OUTBOARD side of the pump first:
groove(s) of the housing. Lightly grease the housing O-
a. For a CLOCKWISE rotation pump, position the pump ring(s) and push the lip seal and housing assembly into
cylinder with the INTAKE port to the left. the head recess with the lip seal inward. The lips of the
lip seal will face the rotor when the housing is installed.
b. For a COUNTERCLOCKWISE rotation pump, position
Make sure the housing is bottomed out in the back of
the pump cylinder with the INTAKE port to the right.
the head (20).
2. Install a new head O-ring (72) in the groove on the inside
face of the head (20). Lay the O-ring flat and start in on
one side of the groove, stretching ahead with the fingers,
as shown in Figure 5.

Figure 6 - Lip Seal - TXV B Models

Figure 5 - Head O-ring Installation

3. Install the head (20) on the outboard side of the cylinder

(12). Install and uniformly tighten four head capscrews
(21) 90o apart, torquing to 25 lbs ft (34 Nm).

4. MECHANICAL SEAL (If equipped)

Apply a small amount of motor oil in the head recess. Push
the mechanical seal assembly (153) into the recess of the
head with seal jacket drive tangs inward. The pin in the
stationary seat must be between the lugs in the back of the
head recess.

5. LIP SEAL ASSEMBLY (if equipped) Figure 7 - Lip Seal - Discontinued TXV A Models
The lip seal assembly (152) consists of a metal housing
with elastomer(s) around its outer diameter(s), and a teflon
6. Hand pack the ball bearing (24) with grease. Refer to the
lip seal in its inner diameter. TXV A model pumps are
"Lubrication" section for the recommended grease.
equipped with spacer washers. Refer to Figures 6 and 7.
7. Install the bearing (24) into the head recess. The bearing
a. Apply a small amount of light motor oil on the inner
balls must face outward, with the grease shield inward.
diameter of the lip seal housing (152B) to facilitate lip
Ensure the bearing is fully and squarely seated against the
seal (152A) installation.
lip seal housing (152B) or mechanical seal (153). On TXV
Note: When installing the lip seal, be careful not to pump models, install two 3/8" (10 mm) washers and two
damage the lip seal O-ring. bearing cover capscrews (28) to clamp the bearing and
b. On TXV B model pumps, push the lip seal (152A) compress the lip seal housing inner O-ring (152E) for
squarely into the housing (152B) with the pin in the lip proper bearing locknut adjustment (see Figure 8). The
seal aligned with the hole in the back of the housing. washers and capscrews will be removed after the locknuts
The lip seal should seat flush or slightly recessed in the are adjusted.
housing, around its entire diameter.
c. On TXV A model pumps, insert the spacer washers
(152F) into the housing, then push the lip seal (152A)
squarely into the housing (152B) with flat side of the lip
seal against the spacer washers. The lip seal should
seat flush or slightly recessed in the housing, around its
entire diameter. Note: If necessary, the spacer
washers can also be located after the lip seal, as shown
in Figure 7, to re-position the lip seal on the pump shaft.
d. Insert the retaining ring (152D) into the groove in the
housing. Figure 8 - Clamping the Bearing

7
 MAINTENANCE
8. Turn the pump cylinder (12) around and begin assembly on
the opposite, inboard end.
9. Remove the vanes (14) and push rods (77) from the rotor
and shaft assembly (13). Inspect for wear and damage,
and replace as follows:
a. Partially install the non-driven end of the rotor and shaft
(13) into the open side of the pump cylinder (12).
b. Leave part of the rotor outside of the cylinder so that the
bottom vanes (14) can be installed and held in place as
the push rods (77) are installed in the push rod holes of
the rotor. Insert the new vanes into the rotor slots with
the rounded edges outward, and the vane relief
grooves facing TOWARDS the direction of rotation.
Refer to Figures 2 and 3.
c. After the bottom vanes (14) and push rods (77) are
installed, insert the rotor and shaft (13) fully into the
cylinder (12).
d. Install the remaining vanes (14) into the top positions of
the rotor. If equipped with a mechanical seal (153),
rotate the shaft by hand to engage the drive tangs
of the seal jacket in the rotor slots.
10. Install the inboard head (20), mechanical seal (153) or lip
seal (152), and bearing (24) as instructed in steps 2
through 7. Apply a thin coating of motor oil on the inboard
shaft to aid installation.
11. Rotate the shaft by hand to engage the mechanical seal
drive tangs (if equipped), and to test for binding or tight
spots. If the rotor does not turn freely, lightly tap the rims of
the heads (20) with a soft faced mallet until the correct
position is found. Install all of the remaining head
capscrews (21) for each head (20) and uniformly torque to
25 lbs ft (34 Nm).
12. LOCKNUT INSTALLATION (if equipped)
It is important that the bearing locknuts (24A) and
lockwashers (24B) be installed and adjusted properly.
Overtightening locknuts can cause bearing (24) failure or a
broken lockwasher tang. Loose locknuts will allow the rotor
(13) to shift against the heads, causing wear. See Figure 9.
Figure 9 - Locknut Adjustment
a. On both ends of the pump shaft, Install a lockwasher
(24B) with the tangs facing outward, followed by a
locknut (24A) with the tapered end inward. Ensure the
inner tang "A" of the lockwasher is located in the slot in
the shaft threads, bending it slightly, if necessary.
b. Tighten both locknuts (24A) to ensure that the bearings
(24) are bottomed in the head recess. DO NOT
overtighten and bend or shear the lockwasher inner
tang.
8
c. Loosen both locknuts (24A) one complete turn.
d. Tighten one locknut (24A) until a slight rotor drag is felt
when turning the shaft by hand.
e. Back off the nut the width of one lockwasher tang "B".
Secure the nut by bending the closest aligned
lockwasher tang into the slot in the locknut. The pump
should turn freely when rotated by hand.
f. Tighten the opposite locknut (24A) by hand until it is
snug against the bearing (24). Then, using a spanner
wrench, tighten the nut the width of one lockwasher
tang. Tighten just past the desired tang, then back off
the nut to align the tang with the locknut slot. Secure
the nut by bending the aligned lockwasher tang into the
slot in the locknut. The pump should continue to turn
freely when rotated by hand.
g. To check adjustment, grasp the nut and washer with
fingers and rotate back and forth. If this cannot be
done, one or both locknuts (24A) are too tight and
should be alternately loosened one stop at a time
(.001") (25 microns). Begin by loosening the locknut
adjusted last.
h. On TXV pumps, after adjustment is complete, remove
the bearing cover capscrews (28) and 3/8" washers from
both ends of the pump.
13. LOCK COLLAR INSTALLATION - TX(S)4 Pump Models
a. Slide the lock collar (24A) over the shaft and against the
bearing (24), with the counterbored side towards the
bearing.
b. Push the collar (24A) forcibly against the bearing (24)
by hand, while tightening the two setscrews (24B).
Install and tighten the two jam nuts (24C) against the
collar.
c. Repeat this procedure on the opposite pump end. After
installing both lock collars, verify the shaft turns freely
when rotated by hand.
14. Inspect the grease seal (104) for wear or damage and
replace as required. Grease the outside diameter of the
grease seal and push it into the bearing cover (27 or 27A)
with the lip of the seal inward. The lip will face outward
when the bearing cover is installed on the head.
15. Attach a new bearing cover gasket (26) and the bearing
cover (27 or 27A) to the head (20). Install and torque the
bearing cover capscrews (28) to 15 lbs ft (20 Nm).
16. Follow steps 14 and 15 to install the grease seal (104) and
bearing cover (27 or 27A ) on the opposite side of the
pump. On TXV pump models, the outboard bearing cover
(27) is also a shaft protector and must be installed on the
non-driven shaft end.
17. On 1.5, 2 and 2.5-inch pump models, push the dirt shield
(123A) over the inboard shaft and firmly against the
bearing cover (27).
18. On TX(S)D pump models, attach the shaft protector (186)
on the non-driven shaft end.
OPERATION WITHOUT SHAFT
PROTECTOR CAN CAUSE SERIOUS
PERSONAL INJURY, MAJOR
PROPERTY DAMAGE, OR DEATH.
Do not operate
without guard
in place.
 GENERAL PUMP TROUBLESHOOTING

NOTICE:
MAINTENANCE SHALL BE PERFORMED BY QUALIFIED TECHNICIANS
ONLY, FOLLOWING THE APPROPRIATE PROCEDURES AND
WARNINGS AS PRESENTED IN THIS MANUAL.

SYMPTOM PROBABLE CAUSE

Pump Not Priming 1. Pump not wetted.

2. Worn vanes.
3. Suction valve closed.
4. Leaks in the suction line.
5. Strainer clogged.
6. Suction line or valves clogged or too restrictive.
7. Broken drive train.
8. Pump vapor-locked.
9. Pump speed too low for priming.
10. Relief valve partially open, worn or not seating properly.

Reduced Capacity 1. Pump speed too low.

2. Suction valves not fully open.
3. Leaks in the suction line.
4. Excessive restriction in the suction line (i.e.: undersized piping, too many elbows
& fittings, clogged strainer, etc.).
5. Damaged or worn parts.
6. Excessive restriction in discharge line causing partial flow through the relief valve.
7. Relief Valve worn, set too low, or not seating properly.
8. Vanes installed incorrectly (see "Vane Replacement").

Noise 1. Excessive vacuum on the pump due to:

a. Undersized or restricted fittings in the suction line.
b. Pump speed too fast for the viscosity or volatility of the liquid.
c. Pump too far from fluid source.
2. Running the pump with a closed discharge line.
3. Pump not securely mounted.
4. Improper drive line (see "Pump Drive").
5. Bearings worn or damaged.
6. Vibration from improperly anchored piping.
7. Bent shaft, or drive coupling misaligned.
8. Excessively worn rotor.
9. Malfunctioning valve in the system.
10. Relief valve setting too low.
11. Damaged vanes (see following category).

Damaged Vanes 1. Foreign objects entering the pump.

2. Running the pump dry.
3. Cavitation.
4. Viscosity too high for the vanes and /or the pump speed.
5. Incompatibility with the liquids pumped.
6. Excessive heat.
7. Worn or bent push rods, or worn push rod holes.
8. Settled or solidified material in the pump at start-up.
9. Hydraulic hammer - pressure spikes.
10. Vanes installed incorrectly (see"Vane Replacement").

Troubleshooting continued on page 10.

9
 GENERAL PUMP TROUBLESHOOTING

SYMPTOM PROBABLE CAUSE

Broken Shaft 1. Foreign objects entering the pump.
2. Viscosity too high for the pump speed.
3. Relief valve not opening.
4. Hydraulic hammer - pressure spikes.
5. Pump/driver misalignment.
6. Excessively worn vanes or vane slots.
7. Settled or solidified material in the pump at start-up.

Lip Seal / Mechanical Seal Leakage 1. O-rings not compatible with the liquids pumped.
2. O-rings nicked, cut or twisted.
3. Shaft at seal area damaged, worn or dirty.
4. Ball bearings overgreased.
5. Excessive cavitation.
6. Lip seal not seated properly.
7. Corrosion on lip seal housing.
8. Mechanical seal faces cracked, scratched, pitted or dirty.

10
 1809 Century Avenue, Grand Rapids, Michigan 49509-1595, U.S.A.
Telephone: (616) 241-1611 Fax: (616) 241-3752
E-mail: blackmer@blackmer.com Internet Address: www.blackmer.com Litho in U.S.A Copyright 2003
 961815 PARTS LIST
BLACKMER PARTS LIST Page 1 of 2 201-A04
PUMP MODELS: TXD3E, TXSD3E (Double Ended Shafts) Section 201
TX3E, TXS3E (Single Ended Shafts) Effective Sept 2007
See Instructions 201-A00 for Installation, Operation and Maintenance Replaces Jan 2007

LOCKNUT TOOL

Parts Parts
Ref. Ref.
Description Per Part No. Description Per Part No.
No. No.
Pump Pump
1 Cap Relief Valve (R/V) 1 413957 27A Bearing Cover 1-2 041815
2 Adjusting Screw R/V 1 431808 Bearing Cover - Outboard 01 041817
3 Locknut Adjusting Screw 1 922923 28 Capscrews Bearing Cover 12 920285
1
4 Cover R/V 1 411807 35 Key Shaft 1 909178
5 Capscrew R/V Cover 3 920331 Flange 3" NPT 651803
42 1-2
5A Capscrew w / Hole R/V Cover 1 920330 Flange 3" Weld 655102
1
7 Spring Guide R/V 1 421805 42A Gasket Flange 2 381816
8 Spring R/V (51-110 psi)(Std.) 1 471806 Capscrew NPT Flange 920532
42B 4-8
Spring R/V (111-125 psi) 471809 Capscrew Weld Flange 920510
1
9 Valve - R/V (Std. TXD) 1 451807 O-Ring - Head (Buna-N) (Std. TXD) 701944
Valve - R/V (Nickel Plated) (Std. TXSD) 451808 72 O-Ring - Head (FKM) (Std. TXSD) 2 711938
1
10 Gasket R/V Cover 1 531803 O-Ring Head (PTFE) 702233
12 Cylinder 1 021805 73 Gage Plug 2 908198
13A Rotor & Shaft Asy. - Double Ended 2 1 261837 76 Grease Fitting 2 317815
Rotor & Shaft Asy. - Single Ended 2 261839 76A Grease Relief Fitting 2 701992
1 1
14 Vane Duravane 6 091819 77 Push Rod 3 121807
1
20 Head 2 031815 88 Gasket - R/V Cap 1 533908
21 Capscrews Head 20 920369 104 Grease Seal 1 - 2 1 331908
1
24 Ball Bearing 2 903172 186 Shaft Protector 0-1 341801
24A Locknut Bearing 2 903523 Air Valve Kit 891798
1
24B Lockwasher - Bearing 2 903524 Tool - Locknut 903091
1
26 Gasket Bearing Cover 2 381817 Kit Maintenance (TXD3E only) 898952
1 2
Included in Maintenance Kit Includes ref. Nos. 24A & 24B
Keep this parts list with Installation, Operation and Maintenance Instructions.
MECHANICAL SEALS
PARTS
REF. PART
PART NAME PER
NO. NO.
PUMP
Mechanical Seal Complete - Std. TXD
1
Cast Iron Stationary Seat, Carbon Seal 331880
Face, Buna-N O-Rings. (INCN)
Mechanical Seal Complete - Std. TXSD
153 Cast Iron Stationary Seat, FKM O-Rings, 2 331883
Carbon Seal Face. (IVCV)
Mechanical Seal Complete - Cast Iron
Stationary Seat, PTFE O-Ring, Carbon 331873
Seal Face w/ PTFE Seal Ring. (IACT)
O-Ring - Stationary (Buna-N) 701936
153D O-Ring - Stationary (FKM) 2 711931
O-Ring - Stationary (PTFE) 702080
O-Ring - Rotating (Buna-N) 711912
153L O-Ring - Rotating (FKM) 2 701962
Seal Ring - Rotating (PTFE) **
1
Included in Maintenance Kit
* * PTFE Rotating Seal Ring is not available as a separate part.

OPTIONAL HYDRAULIC MOTOR ADAPTER PARTS

REF. PART NAME PARTS PART
NO. PER NO.
PUMP
Hydraulic Motor Adapter Kit * 895140
26A Gasket Hydraulic Motor Adapter 1 381817
28A Capscrew 6 920369
Hydraulic Motor Adapter / Head
34 Coupling w/ Setscrew 1 906967
for 1.25 straight key hydraulic motor
35 Key Coupling 1 909184
76 Grease Fitting 1 317815
76A Grease Relief Fitting 1 701992
135 Hydraulic Motor Adapter 1 041831
SAE A Flange
135A Capscrew Adapter / Motor 2 920510
* Hydraulic Motor Adapter Kits shipped after Spring 2002 were of a
two piece design refer to page 206-B00.

1809 Century Avenue, Grand Rapids, Michigan 49503-1530, U.S.A.

Telephone: (616) 241-1611 / Fax: (616) 241-3752 Parts List 201-A04
E-Mail: blackmer@blackmer.com / Internet: www.blackmer.com Page 2 of 2
 960326 PARTS LIST
BLACKMER PARTS LIST Page 1 of 2 201-B00
With Installation and Maintenance Instructions Section 201
T-TYPE TRUCK PUMP STRAINERS Effective July 2001
FOR PUMP SIZES: 2", 2.5", 3" Replaces 286/C1 Nov97

Part No. Part No Part No

Ref. No. Description Qty.
2" Size 2.5" Size 3" Size
1 Strainer Assembly 1 740053 740056 740061
2 Strainer Basket 1 621608 621612 621801
42 Body Flange - Plain2 0-1 651411 651611 651803
42A Inlet Flange - Plain 1 651603 651611 651803
42C Strainer Cover 1 611431 611633 611831
43 Gasket - Inlet Flange, Strainer Cover 2 381650 381650 381816
43A Gasket - Body Flange 1 381421 381650 381816
44 Capscrew - Strainer Body1 0-4 920331 920471 920491
Capscrew - 2" Inlet Flange 920471 920471
44A Capscrew 2 1/2" Inlet Flange 4 920532
Capscrew - 3" Inlet Flange 920532
44C Capscrew - Strainer Cover 4 920471 920471 920491
44D Mounting Bolt - Body Flange2 0-4 920381 920547 920547
44E Nut - Mounting Bolt2 0-4 922841 922850 922850
1
For direct pump mounting use Ref. Nos. 43A and 44.
2
For intake line mounting use Ref. Nos. 42, 43A, 44D and 44E.
 INSTALLATION
SAFETY DATA
NOTICE:
Blackmer truck pumps MUST only be installed in
systems which have been designed by qualified
engineering personnel. The system MUST conform to
all applicable local and national regulations and safety
standards.
These instructions are intended to assist in the
installation of Blackmer T-Type strainers, and MUST be
kept with the pump.
Blackmer truck pump service shall be performed by
qualified technicians ONLY. Service shall conform to
all applicable local and national regulations and safety
standards.
Thoroughly review the pump manual, all instructions
and hazard warnings, BEFORE performing any work on
Blackmer truck pumps.
Maintain ALL system and Blackmer truck pump
operation and hazard warning decals.
STRAINER MOUNTING
Blackmer T-Type strainers are designed for direct mounting on
Blackmer truck pumps, or as line strainers for use with
Blackmer truck pumps or other makes of pumps. T-Type
strainers are available in 2, 2.5 and 3-inch sizes.
For direct mounting on Blackmer 2, 2.5 and 3-inch truck pump
models, the strainer takes the place of the intake pipe flange
and bolts directly to the INTAKE port of the pump. To mount
the strainer directly on the Blackmer pump, use four (4) strainer
capscrews (Ref. No. 44) and flange gasket (Ref. No. 43A). See
Figure 1.
When using the Blackmer T-Type strainer as a line strainer, 2,
21/2 and 3-inch NPT tapped pipe flanges are available to adapt
the strainer for use in the intake line. To mount the strainer in
the intake line, use the strainer body flange (Ref. No. 42),
flange gasket (Ref. No. 43A), and four (4) mounting bolts and
nuts (44D & 44E). See Figure 2.

FAILURE TO SET THE VEHICLE

EMERGENCY BRAKE AND CHOCK
WHEELS BEFORE PERFORMING
SERVICE CAN CAUSE SEVERE
PERSONAL INJURY OR PROPERTY
DAMAGE.

FAILURE TO RELIEVE SYSTEM

PRESSURE PRIOR TO PERFORMING
PUMP SERVICE OR MAINTENANCE CAN
CAUSE PERSONAL INJURY OR
PROPERTY DAMAGE.

NOTICE:
THE APPROPRIATE BLACKMER PUMP MANUAL CAN
BE OBTAINED BY CONTACTING BLACKMER
CUSTOMER SERVICE AT THE ADDRESS OR
TELEPHONE NUMBER PROVIDED.

PUMP INSTRUCTION SHEET AND PARTS LISTS

PUMP PUMP PARTS
PUMP MODEL INSTRUCTION LIST
SHEET
TX(S)(D)2 285/C 285/C1
TX(S)(D)2.5 285/C 285/C3
TX(S)(D)3 285/C 285/C5

1809 Century Avenue, Grand Rapids, Michigan 49509-1595, U.S.A.

Telephone: (616) 241-1611 / Fax: (616) 241-3752 Parts List 201-B00
E-Mail: blackmer@blackmer.com / Internet: www.blackmer.com Page 2 of 2
 963907
BLACKMER POWER PUMPS INSTRUCTIONS NO. 105-B00
Section 105
INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS Effective Apr 2005
Replaces June 2003
MODELS: XLW2F, XLW3F
DISCONTINUED MODELS: XLW2E-N, XLW3E-N

SAFETY DATA

This is a SAFETY ALERT SYMBOL.

When you see this symbol on the product, or in the
manual, look for one of the following signal words and be
alert to the potential for personal injury, death or major
property damage

Warns of hazards that WILL cause serious personal injury,

death or major property damage.
TABLE OF CONTENTS Page
PUMP DATA
Technical Data 2
Initial Pump Start Up Information 2 Warns of hazards that CAN cause serious personal injury,
INSTALLATION death or major property damage.
Pre-Installation Cleaning 3
Location and Piping 3
Mounting 3
Warns of hazards that CAN cause personal injury
Coupling Alignment 4
or property damage.
Pump Rotation 4
To Change Pump Rotation 4 NOTICE:
Check Valves 4 Indicates special instructions which are very
OPERATION important and must be followed.
Pre-Start Up Check List 4
Start Up Procedures 5
Running the Pump in Reverse Rotation 5
Flushing the Pump 5 NOTICE:
Pump Relief Valve 5
Relief Valve Setting and Adjustment 6 Blackmer Pumps MUST only be installed in systems,
MAINTENANCE which have been designed by qualified engineering
Lubrication 6 personnel. The system MUST conform to all applicable
Strainers 7 local and national regulations and safety standards.
Vane Replacement 7
Pump Disassembly 7 This manual is intended to assist in the installation and
Parts Replacement 7 operation of the Blackmer XLW Series pumps, and MUST
Pump Assembly 8 be kept with the pump.
TROUBLE SHOOTING 10
Pump service shall be performed by qualified technicians
NOTE: ONLY. Service shall conform to all applicable local and
Numbers in parentheses following individual parts national regulations and safety standards.
indicate reference numbers on Blackmer Parts List No.
105-A01. Thoroughly review this manual, all instructions and hazard
warnings, BEFORE performing any work on the pump.
Blackmer pump manuals and parts lists may be obtained
from Blackmer's website (www.blackmer.com) or by
Maintain ALL system and pump operation and hazard
contacting Blackmer Customer Service.
warning decals.
 SAFETY DATA

FAILURE TO DISCONNECT AND FAILURE TO DISCONNECT AND

LOCKOUT ELECTRICAL POWER OR LOCKOUT ELECTRICAL POWER
ENGINE DRIVE BEFORE ATTEMPTING BEFORE ATTEMPTING MAINTENANCE
MAINTENANCE CAN CAUSE SEVERE CAN CAUSE SHOCK, BURNS OR
Hazardous PERSONAL INJURY OR DEATH Hazardous voltage. DEATH
machinery can
Can shock, burn or
cause serious
cause death.
personal injury.

IF PUMPING HAZARDOUS OR TOXIC DISCONNECTING FLUID OR PRESSURE

FLUIDS, SYSTEM MUST BE FLUSHED CONTAINMENT COMPONENTS DURING
AND DECONTAMINATED, INSIDE AND PUMP OPERATION CAN CAUSE
OUT, PRIOR TO PERFORMING SERVICE SERIOUS PERSONAL INJURY, DEATH
Hazardous or toxic
OR MAINTENANCE Hazardous pressure OR MAJOR PROPERTY DAMAGE
can cause personal
fluids can cause
injury or property
serious injury. damage

FAILURE TO RELIEVE SYSTEM

OPERATION WITHOUT GUARDS IN
PRESSURE PRIOR TO PERFORMING
PLACE CAN CAUSE SERIOUS
PUMP SERVICE OR MAINTENANCE
PERSONAL INJURY, MAJOR
CAN CAUSE PERSONAL INJURY OR
PROPERTY DAMAGE, OR DEATH.
Do not operate Hazardous pressure PROPERTY DAMAGE.
without guard can cause personal
injury or property
in place damage

PUMP DATA
PUMP IDENTIFICATION
A pump Identification tag, containing the pump serial number, I.D. number, and model designation, is attached to each pump. It is
recommended that the data from this tag be recorded and filed for future reference. If replacement parts are needed, or if
information pertaining to the pump is required, this data must be furnished to a Blackmer representative.

TECHNICAL DATA INITIAL PUMP START UP INFORMATION

Maximum Pump Speed 350 RPM Model No.: ____________________________________

Maximum Operating Temperature 300F (149C) Serial No.: ____________________________________

Maximum Viscosity 75,000 SSU (15,750 cP) ID No.: _______________________________________

Maximum Differential Pressure 150 psi (10.3 Bar) Date of Installation: ____________________________

Maximum Working Pressure 350 psi (24.1 Bar) Inlet Gauge Reading: ___________________________

* Technical Data is for standard materials of construction. Discharge Gauge Reading: ______________________
Consult Blackmer Material Specs for optional materials of
construction. Flow Rate: ____________________________________

105-B00 page 2/12

 INSTALLATION
NOTICE:
BLACKMER PUMPS MUST ONLY BE INSTALLED IN
SYSTEMS DESIGNED BY QUALIFIED ENGINEERING
PERSONNEL. SYSTEM DESIGN MUST CONFORM WITH
ALL APPLICABLE REGULATIONS AND CODES AND
PROVIDE WARNING OF ALL SYSTEM HAZARDS.
8. Check alignment of pipes to pump to avoid strains which
might later cause misalignment. See Figure 1. Unbolt
flanges or break union joints. Pipes should not spring
away or drop down. After pump has been in operation for
a week or two, completely recheck alignment.

Install, ground and wire to local and

National Electrical Code requirements.
Install an all-leg disconnect switch near
the unit motor.
Disconnect and lockout electrical power
before installation or service
Hazardous voltage.
Can shock, burn or Electrical supply MUST match motor Figure 1
cause death. nameplate specifications.
9. When pumping liquids at elevated temperature,
Motors equipped with thermal protection automatically
provisions should be made to compensate for expansion
disconnect motor electrical circuit when overload exists.
Motor can start unexpectedly and without warning.
and contraction of the pipes, especially when long pipe
lines are necessary. Steel pipe expands approximately
3/4 (1.9 cm) per 100 feet (30.49 m) per 100F (37.8C)
rise in temperature.
PRE-INSTALLATION CLEANING
NOTICE:
NEW PUMPS CONTAIN RESIDUAL TEST FLUID AND
RUST INHIBITOR. IF NECESSARY, FLUSH PUMP
PUMP MOUNTING
A solid foundation reduces noise and vibration, and will
PRIOR TO USE.
improve pump performance. On permanent installations it is
Foreign matter entering the pump WILL cause extensive recommended the pumping unit be secured by anchor bolts
damage. The supply tank and intake piping MUST be as shown in Figure 2. This arrangement allows for slight
cleaned and flushed prior to pump installation and operation. shifting of position to accommodate alignment with the
mounting holes in the base plate.

LOCATION AND PIPING

Pump life and performance can be significantly reduced
when installed in an improperly designed system. Before
starting the layout and installation of the piping system,
review the following:
1. Locate the pump as near as possible to the source of
supply to avoid excessive inlet pipe friction.
2. The inlet line MUST be at least as large as the intake
port on the pump. It should slope downward to the
pump, and should not contain any upward loops.
Eliminate restrictions such as sharp bends; globe
valves, unnecessary elbows, and undersized strainers.
3. It is recommended a strainer be installed in the inlet line
to protect the pump from foreign matter. The strainer
should be located at least 24" (0.6m) from the pump, Figure 2 - Pipe Type Anchor Bolt Box
and have a net open area of at least four times the area
of the intake piping. Strainers must be cleaned regularly For new foundations, it is suggested that the anchor bolts be
to avoid pump starvation. set in concrete. When pumps are to be located on existing
4. The intake system must be free of air leaks. concrete floors, holes should be drilled into the concrete to
hold the anchor bolts.
5. Expansion joints, placed at least 36" (0.9m) from the
pump, will compensate for expansion and contraction of When installing units built on channel or structural steel type
the pipes. Contact the flexible connector/hose bases, use care to avoid twisting the base out of shape when
manufacturer for required maintenance/care and design anchor bolts are tightened. Shims should be used under the
assistance in their use. edges of the base prior to tightening of the anchor bolts to
prevent distortion.
6. Install pressure gauges in the NPT ports provided in the
pump casing to check pump at start up.
7. ALL piping and fittings MUST be properly supported to
prevent any piping loads from being placed on the
pump.

105-B00 page 3/12

COUPLING ALIGNMENT
The pump must be directly coupled to a gear and/or driver
with a flexible coupling. Both angular and parallel coupling
alignment MUST be maintained between the pump, gear,
motor, etc. in accordance with manufacturers instructions.
See Figure 3.
1. Parallel alignment: The use of a laser alignment tool or
dial indicator is preferred. If a laser alignment tool or
dial indicator is not available, use a straightedge. Turn
both shafts by hand, checking the reading through one
complete revolution. Maximum offset should be less
than .005" (.127 mm).
2. Angular alignment: Insert a feeler gauge between the
coupling halves. Check the spacing at 90 increments
around the coupling (four checkpoints). Maximum
variation should not exceed .005" (.127 mm). Some
laser alignment tools will check angular alignment as
well.
3. Replace the coupling guards after setting alignment.
PUMP ROTATION
A right-hand pump rotates clockwise with the intake on the
right side, when viewed from the driven end.
A left-hand pump rotates counterclockwise with the intake on
the left side, when viewed from the driven end.
TO REVERSE PUMP ROTATION
To reverse rotation, the pump must be disassembled then
reassembled with the shaft on the opposite side of the pump.
See the Maintenance section for instructions.
CHECK VALVES
The use of check valves or foot valves in the supply tank is
not recommended with self-priming, positive displacement
pumps.
If the possibility of liquid backflow exists when the pump is off,
a check valve in the pump discharge piping is recommended
because the pump can motor in the reverse rotation and
create undue stress on all attached components. Never start
a pump when it is rotating in the reverse rotation as the added
starting torque can damage the pump and related equipment.

Figure 3 Alignment Check

OPERATION

OPERATION WITHOUT GUARDS IN PUMPS OPERATING AGAINST A

PLACE CAN CAUSE SERIOUS CLOSED VALVE CAN CAUSE SYSTEM
PERSONAL INJURY, MAJOR FAILURE, PERSONAL INJURY AND
PROPERTY DAMAGE, OR DEATH. PROPERTY DAMAGE
Do not operate Hazardous pressure
without guard can cause personal
in place injury or property
damage

PRE-START UP CHECK LIST

DISCONNECTING FLUID OR PRESSURE 1. Check the alignment of the pipes to the pump. Pipes
CONTAINMENT COMPONENTS DURING should be supported so that they do not spring away or
PUMP OPERATION CAN CAUSE drop down when pump flanges or union joints are
SERIOUS PERSONAL INJURY, DEATH disconnected.
Hazardous pressure OR MAJOR PROPERTY DAMAGE 2. Blackmer helical gear reducers (if supplied) are shipped
can cause personal
injury or property from the factory without oil in the gearcase. Fill with the
damage
grade of oil indicated on the reducer tag. For more
specific instructions on Blackmer gear reducers, refer to
the appropriate Gear reducer Installation, Operation and
FAILURE TO RELIEVE SYSTEM Instruction Manual.
PRESSURE PRIOR TO PERFORMING 3. Check the entire pumping system to verify that the
PUMP SERVICE OR MAINTENANCE proper inlet and discharge valves are fully open, and
CAN CAUSE PERSONAL INJURY OR that the drain valves and other auxiliary valves are
Hazardous pressure PROPERTY DAMAGE. closed.
can cause personal
injury or property 4. Install vacuum and pressure gauges on the pump in the
damage
1/4 NPT connections provided to check suction and
discharge conditions after pump start-up.
5. Check the wiring of the motor, and briefly turn on the
power to make sure that the pump rotates in the
direction of the rotation arrow.

105-B00 Page 4/12

START UP PROCEDURES
NOTICE:
CONSULT THE "GENERAL PUMP TROUBLESHOOTING"
SECTION OF THIS MANUAL IF DIFFICULTIES DURING
START UP ARE EXPERIENCED.
1. Start the motor. Priming should occur within one minute.
2. Check the suction and discharge pressure to see if the
pump is operating within the expected conditions. Record
pressures in the Initial Start Up Information section.
3. Check for leakage from the piping and equipment.
4. Check for overheating, excessive noise or vibration of the
pump, reducer, and motor.
5. Check the flow rate to ensure the pump is operating
within the expected parameters. Record flow rate in the
Initial Start Up Information section.
6. Check the pressure setting of the relief valve by briefly
closing a valve in the discharge line and reading the
pressure gauge. This pressure should be 20 psi (1.4 bar)
higher than the maximum operating pressure.
Do not run the pump for more than 10-15 seconds
with the discharge valve completely closed.
If adjustments need to be made, refer to "Relief Valve
Setting & Adjustment."
INCORRECT SETTINGS OF THE
PRESSURE RELIEF VALVE CAN
CAUSE PUMP COMPONENT FAILURE,
PERSONAL INJURY, AND PROPERTY
Hazardous pressure DAMAGE.
can cause personal
injury or property
damage
RUNNING THE PUMP IN REVERSE
ROTATION
NOTICE:
PUMP SHOULD BE OPERATED IN REVERSE ROTATION
FOR NO MORE THAN 10 MINUTES AND ONLY WHEN A
SEPARATE PRESSURE RELIEF VALVE IS INSTALLED TO
PROTECT THE PUMP FROM EXCESSIVE PRESSURE.
It may be desirable to run the pump in reverse rotation for
system maintenance. The pump will operate satisfactorily in
reverse rotation for a LIMITED time, at a reduced
performance level.
105-B00
FLUSHING THE PUMP
NOTICE:
IF FLUSHING FLUID IS TO BE LEFT IN THE PUMP FOR
AN EXTENDED TIME, IT MUST BE A LUBRICATING,
NON-CORROSIVE FLUID. IF A CORROSIVE OR NON-
LUBRICATING FLUID IS USED, IT MUST BE FLUSHED
FROM THE PUMP IMMEDIATELY.
1. To flush the pump, run the pump with the discharge
valve open and the intake valve closed. Bleed air into
the pump through the intake gauge plug hole or through
a larger auxiliary fitting in the intake piping. Pump air
for 30 second intervals to clean out most of the
pumpage.
2. Run a system compatible flushing fluid through the
pump for one minute to clear out the remainder of the
original pumpage. The valve in the discharge line
should be restricted to build up 10 psi (0.7 bar) to force
flushing liquid through the bearing seal chamber.
3. To remove the flushing fluid, follow step 1 above.
NOTICE:
AFTER FLUSHING THE PUMP SOME RESIDUAL FLUID
WILL REMAIN IN THE PUMP AND PIPING.
NOTICE:
PROPERLY DISPOSE OF ALL WASTE FLUIDS IN
ACCORDANCE WITH THE APPROPRIATE CODES AND
REGULATIONS.
PUMP RELIEF VALVE
NOTICE:
THE PUMP INTERNAL RELIEF VALVE IS DESIGNED TO
PROTECT THE PUMP FROM EXCESSIVE PRESSURE
AND MUST NOT BE USED AS A SYSTEM PRESSURE
CONTROL VALVE.
XLW series pumps are fitted with an internal pressure relief
valve that bypasses back to the suction side of the pump.
Pumping volatile liquids under suction lift may cause
cavitation. Partial closing of the discharge valve WILL result
in internal relief valve chatter and is NOT recommended. For
these applications, install an external system pressure
control valve, and any necessary bypass piping, back to the
storage tank.
A system pressure control valve is also recommended when
operating for extended periods (more than 15 seconds)
against a closed discharge valve.
Page 5/12
RELIEF VALVE SETTING AND ADJUSTMENT
The relief valve pressure setting is marked on a metal tag
attached to the valve cover. Generally, the relief valve should INCORRECT SETTINGS OF THE
be set at least 15 - 20 psi (1.0 - 1.4 Bar) higher than the PRESSURE RELIEF VALVE CAN
operating pressure, or the external bypass valve setting (if CAUSE PUMP COMPONENT FAILURE,
equipped). PERSONAL INJURY, AND PROPERTY
Hazardous pressure DAMAGE.
DO NOT remove the R /V Cap OR adjust the relief valve can cause personal
injury or property
pressure setting while the pump is in operation. damage
1. To INCREASE the pressure setting, remove the relief
valve cap, loosen the locknut, and turn the adjusting screw
inward, or clockwise. Replace the valve cap.
2. To DECREASE the pressure setting, remove the relief RELIEF VALVE CAP IS EXPOSED TO
valve cap, loosen the locknut, and turn the adjusting screw PUMPAGE AND WILL CONTAIN SOME
outward, or counterclockwise. Replace the valve cap. FLUID
Refer to the individual Blackmer pump parts lists for various
Hazardous or toxic
spring pressure ranges. Unless specified otherwise, pumps fluids can cause
are supplied from the factory with the relief valve adjusted to serious injury.

the mid-point of the spring range.

MAINTENANCE:

FAILURE TO DISCONNNECT AND

IF PUMPING HAZARDOUS OR TOXIC
LOCKOUT ELECTRICAL POWER OR
FLUIDS, SYSTEM MUST BE FLUSHED
ENGINE DRIVE BEFORE
AND DECONTAMINATED, INSIDE AND
ATTEMPTING MAINTENANCE CAN
OUT, PRIOR TO PERFORMING
CAUSE SEVERE PERSONAL INJURY
Hazardous SERVICE OR MAINTENANCE
machinery can OR DEATH Hazardous or toxic
cause serious fluids can cause
personal injury. serious injury.

NOTICE:
MAINTENANCE SHALL BE PERFORMED BY QUALIFIED
FAILURE TO DISCONNECT AND TECHNICIANS ONLY. FOLLOWING THE APPROPRIATE
LOCKOUT ELECTRICAL POWER PROCEDURES AND WARNINGS AS PRESENTED IN THIS
BEFORE ATTEMPTING MANUAL.
MAINTENANCE CAN CAUSE SHOCK,
Hazardous voltage.
BURNS OR DEATH SCHEDULED MAINTENANCE
Can shock, burn or
cause death. LUBRICATION
NOTICE:
TO AVOID POSSIBLE ENTANGLEMENT IN MOVING
FAILURE TO RELIEVE SYSTEM PARTS DO NOT LUBRICATE PUMP BEARINGS, GEAR
PRESSURE PRIOR TO PERFORMING REDUCER OR ANY OTHER PARTS WHILE THE PUMP IS
PUMP SERVICE OR MAINTENANCE RUNNING.
CAN CAUSE PERSONAL INJURY OR Pump bearings should be lubricated every one to twelve
Hazardous pressure PROPERTY DAMAGE. weeks (AT MINIMUM), depending on the application, and
can cause personal
injury or property operating conditions.
damage
Recommended Grease:
Exxon - RONNEX MP Grease,
Mobile - MOBILITH AW-2 (64353-6) Grease, or
DISCONNECTING FLUID OR
equivalent.
PRESSURE CONTAINMENT
COMPONENTS DURING PUMP Greasing Procedure:
OPERATION CAN CAUSE SERIOUS 1. Remove the grease relief fittings (76A) from the bearing
PERSONAL INJURY, DEATH OR covers (27A).
Hazardous pressure
can cause personal MAJOR PROPERTY DAMAGE 2. SLOWLY apply grease with a hand gun until grease
injury or property begins to escape from the grease relief fitting port. (76)
damage
3. Replace the grease relief fittings (76A).
DO NOT overgrease pump bearings. While it is normal for
some grease to escape from the grease tell-tale hole after
OPERATION WITHOUT GUARDS IN lubrication, excessive grease on pumps equipped with
PLACE CAN CAUSE SERIOUS mechanical seals can cause seal failure.
PERSONAL INJURY, MAJOR If equipped: Blackmer gear reducers are shipped from the
PROPERTY DAMAGE, OR DEATH. factory without oil in the gearcase. Fill with the grade of oil
Do not operate indicated on the reducer tag. The oil should be changed after
without guard
in place the first 48 hours of use and approximately every 500 hours
of use thereafter.
105-B00 Page 6/12
STRAINERS
Strainers must be cleaned regularly to avoid pump starvation.
Schedule will depend upon the application and conditions.
VANE REPLACEMENT
NOTICE:
MAINTENANCE SHALL BE PERFORMED BY QUALIFIED
TECHNICIANS ONLY. FOLLOWING THE APPROPRIATE
PROCEDURES AND WARNINGS AS PRESENTED IN
MANUAL.
1. Flush the pump per instructions in this manual. Drain and
relieve pressure from the pump and system as required.
2. Remove the head assembly from the outboard
(nondriven) side of the pump according to steps 4 - 8 in
the "Pump Disassembly" section of this manual.
3. Turn the shaft by hand until a vane comes to the top (12
o'clock) position of the rotor. Remove the vane.
4. Install a new vane, ensuring that the rounded edge is UP,
and the relief grooves are facing towards the direction of
rotation. See Figure 4.
5. Repeat steps 3 and 4 until all vanes have been replaced.
This method of vane installation ensures the push rods do
not fall out of their rotor slots.
6. Reassemble the pump according to the "Pump
Assembly." section of this manual.
Figure 4 Vane Replacement
PUMP DISASSEMBLY
NOTICE:
FOLLOW ALL HAZARD WARNINGS AND INSTRUCTIONS
PROVIDED IN THE MAINTENANCE SECTION OF THIS
MANUAL.
NOTE: The numbers in parentheses following individual parts
indicate reference numbers on the Pump Parts List.
1. Flush the pump per instructions in this manual. Drain and
relieve pressure from the pump and system as required.
2. Starting on the inboard (driven) end of the pump, clean
the pump shaft thoroughly, making sure the shaft is free
of nicks and burrs. This will prevent damage to the
mechanical seal when the inboard head assembly is
removed.
105-B00
3. Remove the inboard bearing cover capscrews (28) and
slide the inboard bearing cover (27A) and gasket (26) off
the shaft. Discard the bearing cover gasket. On 2-inch
pump models, the dirt shield will slide off with the bearing
cover.
4. Remove the outboard bearing cover capscrews (28) and
slide the outboard bearing cover (27) and gasket (26) off
the shaft. Discard the bearing cover gasket.
5. To remove locknuts and lockwashers (24A and 24B):
a. Bend up the engaged lockwasher tang and rotate the
locknut counterclockwise to remove it from the shaft.
b. Slide the lockwasher off the shaft. Inspect the
lockwasher for damage and replace as required.
c. Repeat steps a and b on the opposite shaft end.
6. Remove the head capscrews (21). Gently pry the head
away from the casing using two large screwdrivers. The
head O-ring should come off with the head assembly.
7. Slide the head and O-ring off the shaft. The bearing (24),
mechanical seal stationary seat and stationary O-ring
(153A & 153D) will come off with the head assembly.
a. Pull the bearing (24) from the housing in the head.
b. To remove the mechanical seal stationary seat
(153A), use the blunt end of a screw driver to gently
push the backside of the stationary seat from the
head. Place a cloth under the seal to avoid damage.
Be careful not to contact the polished face of the seal
during removal. Remove and discard mechanical seal
stationary O-ring.
8. Carefully pull the rotating seal assembly, including seal
jacket (153C), rotating seal face and rotating O-ring
(153B & 153E) from the shaft. Remove and discard the
rotating O-ring. Remove the disc (71).
9. Pull the rotor and shaft (13) from the casing. While one
hand is pulling the shaft, the other hand should be
cupped underneath the rotor to prevent the vanes (14)
and pushrods (77) from falling out. Carefully set the rotor
and shaft aside for future vane replacement and
reassembly.
10. Lay the pump flat with the remaining head facing upward
to remove the outboard head assembly, mechanical seal
and disc from the outboard side of the pump, as
instructed in steps 6 - 8.
11. If necessary, remove the liner (41) by tapping around the
outside diameter of the liner with a hard wood drift and a
hammer until it is driven from the casing.
PARTS REPLACEMENT
1. If any of the O-rings have been removed or disturbed
during disassembly, they be replaced with new O-rings.
NOTE: PTFE O-rings should be heated in hot water to
aid installation.
2. Excessive or continuous leakage from the tell-tale hole in
the bearing cover may be an indication of a damaged
mechanical seal. If a mechanical seal has been leaking, it
is recommended the entire seal be replaced. Refer to
"General Pump Troubleshooting" for possible causes of
seal leakage.
Page 7/12
PUMP ASSEMBLY
Before reassembling the pump, inspect all component
parts for wear or damage, and replace as required. Wash
out the bearing/seal recess of the head and remove any
burrs or nicks from the rotor and shaft.
6. DISC
Install the disc (71) on the inboard side of the pump with
the seal cavity facing outward and the disc relief hole
located as shown in Figure 6.

Reassemble the OUTBOARD side of the pump first:

For a CLOCKWISE rotation pump, position the pump
cylinder with the INTAKE port to the left.
For a COUNTERCLOCKWISE rotation pump, position the
pump cylinder with the INTAKE port to the right.
1. Install the liner key (74) in the slot located in the top of the
liner. Align the key with the notch in the top of the pump
casing and start the liner into the casing.
The word INTAKE cast on the liner must face the intake
port of the pump casing. Uniformly tap the outer edge of
the liner with a rubber mallet to fully insert into the casing.
2. Place the disc (71) against the liner with the seal cavity
outward.
3. Without installing the head O-ring or mechanical seal
components, temporarily attach the outboard head and
bearing to the casing. Install and hand-tighten two head
capscrews, 180 degrees apart. This head will be used to
hold and align the rotor and shaft while the inboard side of
the pump is assembled.
4. Turn the pump around to begin assembly on the inboard
side. Before installing the rotor & shaft assembly, the
direction of pump rotation must be determined as
indicated under the Pump Rotation section of this
manual.
Figure 6 Disc Relief Hole Location
7. MECHANICAL SEAL
Rotating Assembly
a. Apply a small amount of motor oil on the shaft
between the shaft threads and the rotor.
b. Slide the seal jacket assembly (153C) over the shaft
and into the disc cavity with the drive tangs of the
jacket towards the rotor. Rotate the jacket assembly
to engage the drive tangs in the rotor slots.
c. Install a new rotating O-ring (153E) in the rotating seal
face (153B). Align and insert the rotating assembly
into the the seal jacket with the polished face outward.
Clean the polished face with a clean tissue and
alcohol.
Stationary Seat
a. Apply a small amount of motor oil in the seal access
of the head.
b. Install a new stationary O-ring (153D) in the stationary
seat (153A). Clean the polished face with a clean
tissue and alcohol. Align the pin in the stationary seat
with the slot in the head recess and push the seat fully
into the seal recess with the polished face outward.
8. Install a new head O-ring (72) in the groove on the inside
face of the head. Lay the O-ring flat and start in on one
side of the groove, stretching ahead with the fingers, as
shown in Figure 7.

Figure 5 Pushrod Installation

5. Remove the vanes (14) and push rods (77) from the rotor
and shaft assembly. Inspect for wear and damage, and
replace as follows:
a. Insert the vanes into the bottom three rotor slots with
the relief grooves facing in the direction of pump
rotation, and with the rounded edges outward. See
Figure 4.
Figure 7 Head O-Ring Installation
b. Hold the three bottom vanes in place while inserting
the three push rods (77). See Figure 5.
9. Carefully install the head assembly (20) over the shaft.
c. After the bottom vanes and push rods are installed, Do not contact the end of the shaft with the mechanical
carefully insert the non-driven end of rotor and shaft seal. Position the head with the small weep hole towards
into the casing. the bottom of the pump. Install and partially tighten four
d. Install the remaining vanes into the top positions of head capscrews (21) 90 apart. The remaining
the rotor. capscrews will be installed in step 18.

105-B00 Page 8/12

10. Hand pack the ball bearing (24) with grease. Refer to the
"Lubrication" section for the recommended grease.
11. Install the bearing into the head recess. The bearing balls
should face outward, with the grease shield inward. The
bearing must be fully and squarely seated in the head.
12. Turn the pump casing around and remove the outboard
head and disc previously installed.
13. Install the mechanical seal and disc in the outboard head
as instructed in steps 7 through 8.
14. Finish assembling the outboard side of the pump as
instructed in steps 10 through 13.
15. Rotate the shaft by hand to engage the mechanical seal
drive tangs, and to test for binding or tight spots. If the
rotor does not turn freely, lightly tap the rims of the heads
with a soft faced mallet until the correct position is found.
16. Install and partially tighten the remaining head capscrews
17. Uniformly torque the head capscrews to 30 lbs ft (40.7 Nm),
alternating between one side of the head and the other.
Frequently check that the shaft still turns freely. If tight,
loosen the capscrews and repeat the procedure. If the
shaft continues to bind, check for grease or dirt on the
mechanical seal faces.
Figure 8 Locknut Assembly
18. LOCKNUT ADJUSTMENT
It is important that the bearing locknuts (24A) and
lockwashers (24B) be installed and adjusted properly.
Overtightening locknuts can cause bearing failure or a
broken lockwasher tang. Loose locknuts will allow the
rotor to shift against the discs, causing wear. See Figure
8.
a. On both ends of the pump shaft, install a lockwasher
(24B) with the tangs facing outward, followed by a
locknut (24A) with the tapered end inward. Ensure the
inner tang "A" of the lockwasher is located in the slot
in the shaft threads, bending it slightly, if necessary.
b. Tighten both locknuts to ensure that the bearings are
bottomed in the head recess. DO NOT overtighten
and bend or shear the lockwasher inner tang.
c. Loosen both locknuts one complete turn.
d. Tighten one locknut until a slight rotor drag is felt
when turning the shaft by hand.
e. Back off the nut the width of one lockwasher tang "B".
Secure the nut by bending the closest aligned
lockwasher tang into the slot in the locknut. The pump
should turn freely when rotated by hand.
105-B00
f. Tighten the opposite locknut by hand until it is snug
against the bearing. Then, using a spanner wrench,
tighten the nut the width of one lockwasher tang B.
Tighten just past the desired tang, then back off the
nut to align the tang with the locknut slot. Secure the
nut by bending the aligned lockwasher tang into the
slot in the locknut. The pump should continue to turn
freely when rotated by hand.
g. To check adjustment, grasp the nut and washer with
fingers and rotate back and forth. If this cannot be
done, one or both locknuts are too tight and should be
alternately loosened one stop at a time 0.001"
(0.025mm). Begin by loosening the locknut adjusted
last.
19. Inspect the grease seal (104) for wear or damage and
replace as required. Grease the outside diameter of the
grease seal and push it into the inboard bearing cover
(27A) with the lip of the seal inward (towards the pump).
20. Attach a new bearing cover gasket (26) and the inboard
bearing cover (27A) to the inboard head. Install the
outboard bearing cover (27) and a new gasket to the
outboard head. Make sure the grease fittings (76) on the
bearing covers are accessible. Install and torque the
bearing cover capscrews (28) to 30 lbs ft (40.7 Nm).
21. RELIEF VALVE ASSEMBLY
a. Insert the valve (9) into the relief valve bore of the
casing with the fluted end inward.
b. Install the relief valve spring (8) and spring guide (7)
against the valve.
c. Attach a new relief valve O-ring (10) and the valve
cover (4) on the cylinder.
d. Screw the relief valve adjusting screw (2) with locknut
(3) into the valve cover (4) until it makes contact with
the spring guide (7).
e. After the relief valve has been adjusted, tighten the
Locknut (3) and install the relief valve cap (1) and O-
ring (88)
NOTICE:
The relief valve setting MUST be tested and adjusted
more precisely before putting the pump into service.
Refer to "Relief Valve Setting and Adjustment"
OPERATION WITHOUT GUARDS IN
PLACE CAN CAUSE SERIOUS
PERSONAL INJURY, MAJOR
PROPERTY DAMAGE, OR DEATH.
Do not operate
without guard in
place.
22. Reinstall coupling, shaft key, and coupling guards.
23. Refer to Pre-Start Up Check List and Start Up
Procedures sections of this manual prior to restarting
pump operation.
Page 9/12
 PUMP TROUBLESHOOTING
NOTICE:
MAINTENANCE SHALL BE PERFORMED BY QUALIFIED TECHNICIANS ONLY, FOLLOWING THE APPROPRIATE
PROCEDURES AND WARNINGS AS PRESENTED IN THIS MANUAL.
LEAKAGE
Location Probable Cause/Corrective Action
Between the head & casing Damaged head O-ring: Inspect and replace if necessary.
Burrs/dirt in head O-ring groove or cylinder: File and clean as necessary.
Around the shaft New Mechanical Seals: New seals may leak slightly at start up, but
should seal up shortly thereafter.
Damaged mechanical seals: Check for damaged O-rings or cracked,
scratched or worn seal faces

SHAFT BINDING
Probable Cause
Burrs, dirt or foreign particles on the heads or discs.
Improper locknut adjustment.
Contaminated mechanical seal faces.
OTHER POSSIBLE CAUSES OF SHAFT BINDING:
Foreign particles on rotor, liner or vanes.
Damaged vanes or rotor.
Corrective Action
During assembly, both heads and discs must be clean and smooth. File
any burrs or rough spots, and wipe the discs with a clean cloth and
alcohol to remove any dirt or foreign particles.
Locknuts must be adjusted properly to center the rotor and shaft between
the heads. Refer to "Locknut Installation" on Page 10.
Any trace of grease or dirt on the seal faces will prevent the faces from
mating properly, causing the rotor and shaft to bind or turn hard. Use a
tissue paper & alcohol to clean the seal faces. NOTE: Apply a light oil or
suitable lubricant to bronze seal faces only.
Bent push rods.
Liquids that "set up" when inactive.

OVERHEATING
Probable Cause
Continual, full bypassing of the liquid.
OTHER POSSIBLE CAUSES OF OVERHEATING:
Improper relief valve adjustment
(See "Relief Valve" on Page 3).
LOW DELIVERY RATE
Probable Cause
Relief valve setting too low, causing the liquid to
bypass.
OTHER POSSIBLE CAUSES OF A LOW DELIVERY RATE:
Restriction in the suction line.
Suction valve not fully open.
Resistance in the discharge line.
Air leaks in the suction line.
Damaged or worn pump parts.
Pump speed too low or too high.
Corrective Action
The relief valve should be adjusted such that the pump will not bypass
during normal operation. WARNING: Internal bypassing of liquid
elevates the liquid temperature. The internal bypass valve should
only be used for brief periods and at differential pressures below
125 psi.
For extended periods of higher pressures, the internal bypass port
must be plugged and the liquid returned back to the source.
Plugged discharge line.
Closed valve.
Corrective Action
The relief valve setting should be 20 psi (1.4 bar) higher than the
differential pressure.
Relief valve leaking.
Relief valve sticking open, or not properly seating.
Dirty strainer.
Liner installed backwards
Vanes install incorrectly
Excessive restriction in discharge line causing RV to open.

105-B00 Page 10/12

 PUMP TROUBLESHOOTING
EXCESSIVE NOISE AND VIBRATION
Probable Cause Corrective Action
Cavitation or vaporization of the liquid resulting from Check for:
excessive vacuum on the pump due to starved Inlet piping too long or too small in diameter.
suction. Strainer plugged or dirty.
Undersized or restrictive fittings, such as globe valves or partially
closed valves.
Excessive amount of elbows.
Suction lift too great.
Pump speed too high for the viscosity of the liquid being pumped.
Entrained air or vapors in the pump. Check pipe joints for leakage of air. Sometimes when recirculating liquid
in a tank, the returning liquid falling through the air carries air down
into the tank, which eventually gets back into the pump.
Pump speeds exceed the recommended maximum. Check the recommended RPM for your specific application.
Liner Installed Backwards The word INTAKE, which is cast on the liner MUST be towards the
intake side of the pump
Continual or long term bypassing of liquid through Check for restriction in the discharge line, or an improper relief valve
relief valve. adjustment (See "Relief Valve" on Page 6).
OTHER POSSIBLE CAUSES OF NOISE AND VIBRATION:
Excessively worn vanes, discs or rotor. Misalignment of pump and driver or bent shaft.
Bearing Worn or Damaged. Pump base not properly mounted.
Loose or improperly installed piping. Insufficient Oil in the Gear Reducer

POOR OR NO PRIMING
Probable Cause
Air leaks in the suction line. Worn vanes.
Valve partially closed or other restriction in the Suction Valve Closed.
suction line. Incorrect pump rotation
Damaged or worn pump parts. Relief Valve partially open, valve not seating properly.
Too much lift for the vapor pressure of the fluid. Pump speed too low for priming
A dirty or clogged strainer.

DAMAGED VANES
Probable Cause
Foreign objects entering the pump. Excessive heat.
Running the pump dry for extended periods of Worn or bent push rods, or worn push rod holes.
time. Settled or solidified material in the pump at start-up.
Cavitation. Hydraulic hammer - pressure spikes.
Viscosity too high for the vanes and /or the pump Vanes installed incorrectly (see"Vane Replacement").
speed.
Incompatibility with the liquids pumped.

BROKEN SHAFT
Probable Cause
Foreign objects entering the pump. Pump/driver, driveline/drive shaft misalignment.
Viscosity too high for the pump speed. Excessively worn vanes or vane slots.
Relief valve not opening. Settled or solidified material in the pump at start-up.
Hydraulic hammer - pressure spikes. Overtightened V-belts, if used.

SEAL LEAKAGE
Probable Cause
O-rings not compatible with the liquids pumped. Excessive cavitation.
O-rings nicked, cut or twisted. Mechanical seal faces cracked, scratched, pitted or dirty.
Shaft at seal area damaged, worn or dirty. Ball bearings overgreased.

MOTOR OVERLOAD
Probable Cause
Horsepower of motor not sufficient for application
Excessive viscosity, pressure or speed.
Improper wire size / wiring and/or voltage to motor.
Faulty or worn bearings.
Misalignment in pump drive system.
Rotor rubbing against head or liner.
Bearing locknuts adjusted improperly.
Dirty mechanical seal faces.

105-B00 Page 11/12

 Sliding Vane Pumps: 5 to 2200 GPM System One Centrifugal Pumps
Refined Fuels, Liquefied Gases, Process, 10 to 7500 GPM
Transport, Marine Process, Marine

C-Series Eccentric Disc Pumps Abaque Peristaltic Hose Pumps

1 to 150 GPM 0.5 to 220 GPM
Shear Sensitive, Food, Process High Lift, Solids, Abrasives

Rotary Vane and Screw Compressors Reciprocating Gas Compressors

Dry Bulk Unloading Liquefied Gas Transfer, Boosting, Vapor Recovery

Hydraulic Coolers Magnetic Drive Pumps

Complete Packages Iron and Stainless, 14 to 333 GPM

Hand Operated Pumps Accessories

Dispensing, Transfer, In-line Gear Reducers, Bypass Valves, Strainers
Visit www.blackmer.com for complete information on all Blackmer products

1809 Century Avenue, Grand Rapids, Michigan 49503-1530 U.S.A.

Telephone: (616) 241-1611 Fax: (616) 241-3752
E-mail: blackmer@blackmer.com Internet Address: www .blackmer.com
 963908 PARTS LIST
BLACKMER PARTS LIST Page 1 of 2 105-B01
PUMP MODELS: XLW2F, XLW3F Section 105
DISCONTINUED MODELS: XLW2E-N, XLW3E-N Effective Mar 2005
NOTE: F model suffix indicates FKM replaces Buna-N as the standard elastomer. Replaces Oct 2004
(See Instructions 105-B00 Installation, Operation and Maintenance)

LOCKNUT TOOL

Parts Parts
Ref. Size 2 Size 3 Ref. Size 2 Size 3
Description per Description per
No. Part No. Part No. No. Part No. Part No.
Pump Pump
1
1 Cap Relief Valve (R/V) 1 414402 414402 26 Gasket Bearing Cover 2 383940 1 385125
2 Adjusting Screw R/V 1 433905 435109 27 Bearing Cover Outboard 1 041433 041817
3 Locknut Adjusting Screw 1 922923 922923 27A Bearing Cover Inboard 1 041431 041815
4 Cover R/V 1 414408 415109 28 Capscrews Bearing Cover 8-12 920285 920285
1
5 Capscrew R/V Cover 6 920316 920331 35 Key Shaft 1 909130 1 909130
2
7 Spring Guide R/V 1 424401 425109 41 Liner 1 183913 2 185116
Spring R/V (35-50 psi) 471420 471608 Flange NPT 654401 655112
42 4 2
Spring R/V (51-75 psi) (Std.) 471425 471612 Flange Weld 654405 655102
8 1 1
Spring R/V (76-110 psi) 471428 471621 O-Ring Flange (FKM) (Std.) 702086 1 711931
42A 2
Spring R/V (111-150 psi) 471430 475109 O-Ring Flange (PTFE) 702078 702080
Valve R/V (std) 454405 455109 Capscrew NPT Flange 920384 920547
9 1 42B 8
Valve R/V (Nickel Plated) 454406 3 455100 Capscrew Weld, ANSI, DIN 920351 920510
1 1 2
O-Ring R/V Cover (FKM) (Std.) 711929 701924 71 Disc 2 063900 2 065114
10 1 1
O-Ring R/V Cover (PTFE) 702077 702079 O-Ring Head (FKM) (Std.) 702045 1 711938
72 2
12 Casing 1 014405 015127 O-Ring Head (PTFE) 702081 702082
2
EC Rotor & Shaft Asy.(-.045) (Std) 263927 2 265143 73 Gage Plug 2 908195 908195
1 2
13 FS Rotor & Shaft Asy. 263923 265204 74 Key Liner 1 183991 2 185191
(Both Include Ref. 24A & 24B) 76 Grease Fitting 2 317815 317815
1
14 Vane EC Hardened Iron (Std.) 6 093931 1 095129 76A Grease Relief Fitting 2 701992 701992
1
Vane Laminate 091427 095109 77 Push Rod 3 123905 1 125105
1
Vane EC Laminate 091429 095107 O-Ring R/V Cap (FKM) (Std.) 701979 1 701979
88 1
20 Head 2 034416 035128 O-Ring R/V Cap (PTFE) 702075 702075
1
21 Capscrews Head 32-40 920351 920369 104 Grease Seal 1 331918 1 331908
1
24 Ball Bearing 2 903156 1 903172 Tool - Locknut 903091 903091
24A Locknut Bearing 2 903521 903523 Kit - Maintenance 898974 898975
1
24B Lockwasher Bearing 2 903522 1 903524 Kit - Rebuild 899074 899075
1 2
Included in Maintenance Kit and Rebuild Kit Included in Rebuild Kit EC = Extra Clearance FS = Full Size
3
The XLW3 Nickel Plated Relief Valve p/n455100 is not suitable for 111-150 psi spring range. 4 See more flanges on backside.
Keep this parts list with Installation, Operation and Maintenance Instructions.
MECHANICAL SEALS
Parts
Ref. Size 2 Size 3
Part Name Per
No. Part No. Part No.
Pump
Mechanical Seal Complete (Std.)
Silicon Carbide Stationary Seat, 1 1
333919 335147
Hardened Steel Seal Face, FKM O-
Rings. (LVSV)
Mechanical Seal Complete Silicon
Carbide Stationary Seat, Hardened
333922 335150
Steel Seal Face, PTFE O-Rings.
(LAST)
153 2
Mechanical Seal Complete Silicon
Carbide Stationary Seat, Silicon
333921 335149
Carbide Seal Face, FKM O-Rings.
(LVLV)
Mechanical Seal Complete Silicon
Carbide Stationary Seat, Silicon
333925 335161
Carbide Seal Face, PTFE O-Rings.
(LALT)
153A # Stationary Seat (Silicon Carbide) 2 334422 335141
Rotating Seal Face (Hardened Steel) 333917 335144
153B # 2
Rotating Seal Face (Silicon Carbide) 333916 335198
153C # Jacket Assembly 2 331651 335128
O-Ring Stationary (FKM) 701970 702015
153D 2
O-Ring Stationary (PTFE) 702084 711999
O-Ring Rotating (FKM) 701980 701962
153E 2
Seal Ring Rotating (PTFE) 711963 701963
1
Included in Maintenance Kit and Rebuild Kit
# These components are included in the complete mechanical seal assemblies
(Ref. No. 153), and are NOT available as replacement parts. Consult factory.

FLANGE OPTIONS
Parts
Ref. Size 2 Size 3
Part Name Per
No. Part No. Part No.
Pump
Flange ANSI 2 150 lb. R.F. 651417 ---
Flange ANSI 3 150 lb. R.F. --- 651817
42 1-2
Flange DIN3 50 PN10 651418 ---
Flange DIN3 80 PN10 --- 651818

1809 Century Avenue, Grand Rapids, Michigan 49503-1530, U.S.A.

Telephone: (616) 241-1611 / Fax: (616) 241-3752 Parts List 105-B01
E-Mail: blackmer@blackmer.com / Internet: www.blackmer.com Page 2 of 2
Parts INSTRUCTIONS-PARTS LIST 308156
This manual contains important
Rev. K
warnings and information.
First choice when
READ AND KEEP FOR REFERENCE. quality counts.t
INSTRUCTIONS

Dyna-Start
HYDRAULIC RECIPROCATOR AND PUMP
1500 psi (10 MPa, 102 bar) Maximum Hydraulic Input Pressure
7500 psi (51 MPa, 517 bar) Maximum Fluid Outlet Pressure

FOR LUBRICATING FLUIDS ONLY

5:1 Ratio Universal Pump and Reciprocator

Model 224912, Series C, 35 lb. pail size
Model 224751, Series C, 120 lb. drum size
Model 224752, Series C, 400 lb. drum size
Model 239883, Series A, reciprocator only
Patent No. 4,383,475
Foreign Patents Pending
Patent 1984 Canada
Brevete 1984

Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Replacing Throat Seals . . . . . . . . . . . . . . . . . . . . . . 11
Disconnecting the Reciprocator
and Displacement Pump . . . . . . . . . . . . . . . . . . . . 12
Reciprocator Repair . . . . . . . . . . . . . . . . . . . . . . . . . 13
Displacement Pump Repair . . . . . . . . . . . . . . . . . . . 17
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . 19
Reciprocator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pump Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Dimensions and Mounting Hole Layout . . . . . . . . . . . 23
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . 24 06151B

Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . . 24

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 554401441

ECOPYRIGHT 1991, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
 Symbols
Warning Symbol Caution Symbol

WARNING CAUTION
This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to
injury or death if you do not follow the corresponding or destruction of equipment if you do not follow the
instructions. corresponding instructions.

WARNING
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
D This equipment is for professional use only.

D Read all instruction manuals, tags, and labels before operating the equipment.

D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.

D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

D Check equipment daily. Repair or replace worn or damaged parts immediately.

D Do not exceed the maximum working pressure of the lowest rated component in your system.
This equipment has a 1500 psi (10 MPa, 102 bar) maximum hydraulic input pressure and
7500 psi (51 MPa, 517 bar) maximum fluid outlet pressure.

D Use fluids and solvents that are compatible with the equipment wetted parts. Refer to the Techni-
cal Data section of all equipment manuals. Read the fluid and solvent manufacturers warnings.

D Handle hoses carefully. Do not pull on hoses to move equipment.

D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex-
pose Graco hoses to temperatures above 82_C (180_F) or below 40_C (40_F).

D Do not lift pressurized equipment.

D Comply with all applicable local, state, and national fire, electrical, and safety regulations.

2 308156
 WARNING
WARNING
FLUID INJECTION HAZARD
Fluid from the dispensing valve, 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
medical attention.

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

D Do not put your hand or fingers over the end of the dispensing valve.

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

D Use only extensions and couplers that are designed for use with your dispensing valve.

D Do not use a low pressure flexible nozzle with this equipment.

D Follow the Pressure Relief Procedure on page 8 if the grease fitting coupler clogs and before
cleaning, checking or servicing the equipment.

D Tighten all fluid connections before operating the equipment.

D Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do
not repair high pressure couplings; you must replace the entire hose.

D Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.

TOXIC FLUID HAZARD

Hazardous fluids 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.

308156 3
 WARNING
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 dispensed to. Refer to Grounding on page 7.

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

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

D Do not smoke in the dispense area.

D Do not turn on or off any light switch in the dispense area while dispensing or while operating if
fumes are present.

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers.
D Keep clear of all moving parts when starting or operating the pump.

D Before servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent
the equipment from starting unexpectedly.

4 308156
 Installation
Typical Installation of a L M N
Suction Feed System J K
F G H P
E
D Q
C
B
A
R U
T
S

KEY
A Follower plate J Hydraulic inlet, 1/2 npt Q* Flow control valve
B Weep tube K Tee, 3/4 npt (required in systems over 3 gpm
C Fluid outlet line (to gun) L* Supply line shut-off valve [11 lpm])
D Drain valve (required) M* Pressure gauge R Hydraulic supply line
E Ground wire N* Pressure reducing valve S Check valve
F Hydraulic return line, minimum (required in systems over 1500 psi T Variable volume pressure
3/4 I.D. (required) [10 MPa, 102 bar]) compensated pump
G Hydraulic outlet, 1/2 npt P Accumulator U Hydraulic power supply
H Return line shut-off valve, W Drain line, accumulator
minimum 3/4 (required)
* Included in Hydraulic Fluid Control Kit 236864, which can be ordered separately.
Fig. 1 04477A

Although the installation shown in Fig. 1 is only a guide Pump Accessories

for selecting and installing system components and
accessories, some of the equipment is required, as D Follower plate (A) ensures a good prime.
noted in the key. For assistance in designing a system Place the plate on the grease and rotate while
to suit your needs, contact your Graco distributor. pressing firmly to level the material.

Mount the pump to suit the type of installation planned.
WARNING
Maximum Working Pressure of Accessories
To reduce the risk of serious injury including fluid
injection and splashing in the eyes or on the skin,
which may be caused if a component ruptures, all
accessories added to the reciprocator power sup-
ply side must have at least a 1500 psi (10 MPa,
102 bar) maximum working pressure.
All accessories added to the pump fluid outlet side
must have at least a 7500 psi (51 MPa, 517 bar)
maximum working pressure.
D Pump outlet drain valve (D) helps relieve
fluid pressure in the pump when the pump is
shut off. Install the valve close to the pump
fluid outlet. Order Part No. 111229, valve.
WARNING
Pump Outlet Drain Valve
A pump outlet drain valve (D) is required in your
system. This valve helps relieve pressure in the
displacement pump and hose when shutting down
the system and in case of a clogged outlet hose.
Install the valve close to the pump outlet.

308156 5
 Installation
WARNING
Mount the pump securely so that it cannot move
around during operation. Failure to do so could
result in personal injury or equipment damage.
NOTE: Refer to Fig. 1 to locate the parts mentioned
below.
CAUTION
Keep the Hydraulic System Clean
The hydraulic supply system must be kept clean at
all times to reduce the risk of damaging the recip-
rocator hydraulic power supply. Blow out all hy-
draulic lines with air, flush thoroughly with solvent,
and then blow out with air again before connecting
the lines to the reciprocator.
Always plug the hydraulic inlets, outlets and lines
when disconnecting them for any reason to avoid
introducing dirt and other contaminants into the
system.
Carefully follow the manufacturers recommenda-
tions on reservoir and filter cleaning, and periodic
changes of hydraulic fluid.
Hydraulic Power Supply
WARNING
Limit Fluid Flow to Reciprocator
To reduce the risk of overpressurizing the hydraulic
reciprocator, which could cause a rupture and
serious injury, including fluid injection, the hydraulic
system must have a means to limit the incoming
fluid flow to the reciprocator to a maximum of 3
gpm (11 lpm) and 1500 psi (10 MPa, 102 bar). See
the description below.
The hydraulic power supply system (U) must have a
pressure reducing valve and a pressure-compensated
flow control. A flow control valve (Q) is required to limit
the incoming flow to the reciprocator to a maximum of
3 gpm (11 lpm).
NOTE: A supply line shut-off valve (L), pressure
gauge (M), pressure reducing valve (N), and a flow
control valve (Q) are included in the Hydraulic Fluid
Control Kit 236864, which can be ordered separately.
6 308156
Hydraulic Lines
D Shut-off valves (H and L) are installed in the
hydraulic supply and return lines. Order Part
No. 108537.
D Drain Line: Remove the plug (59) from the
pump adapter and install a 1/8 diameter weep
tube (B), ending in a waste container. Monitor
the weepage of hydraulic fluid. If it seems
excessive or increases suddenly, the
reciprocator/pump seals may need to be
changed. See Fig. 2.
59
Fig. 2
06146B
D Hoses: Use a minimum 1/2 supply line (R)
and minimum 3/4 return line (F) on the
reciprocator. Contact your Graco
representative for details of line sizing.
D A pressure reducing valve (N) circulates
excess hydraulic fluid pressure back to the
hydraulic power supply. Install this valve (N) in
the hydraulic supply line with a drain hose (W)
teed into the hydraulic return line (F). Limit
supply pressure to a maximum of 1500 psi
(10 MPa, 102 bar).
D An accumulator (P) reduces the hammering
effect caused by the motor when it reverses
direction.
D A fluid-filled pressure gauge (M), Part No.
112567, monitors hydraulic pressure to the
reciprocator during startup. See Fig. 1. Use
the gauge for initial adjustment of the
reciprocator. It can be removed after
adjustment is made.
 Installation
Grounding
To reduce the risk of static sparking, ground the pump. To ground the pump, remove the ground screw (Z)
Check your local electrical code for detailed grounding and insert through the eye of the ring terminal at end of
instructions for your area and type of equipment. ground wire (Y). Fasten the ground screw back onto
the pump and tighten securely. Connect the other end
D Pump: Use ground wire and clamp as shown in of the wire to a true earth ground.
Fig. 3. To order a Grounding Wire and Clamp Kit,
order Part No. 222011.

D Hydraulic Hoses and Fluid Outlet Hoses: Use only

electrically conductive hoses.
Z
D Hydraulic Power Supply: Follow manufacturers
recommendations.

D Any pails used when flushing: Use only metal,

grounded pails when flushing. Make firm metal to
metal contact between the a metal part of the
dispense valve and the pail. Use the lowest
possible pressure. Y

06147B
Fig. 3

308156 7
 Operation
Pressure Relief Procedure
WARNING
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
D Are instructed to relieve the pressure
D Check or service any of the system equipment
D Install or clean the nozzle
1. Shut off the hydraulic power supply.
2. Close the supply line shut-off valve (L in Fig. 1).
To start the pump
1. Turn on the hydraulic power supply.
2. Open the return line shut-off valve (H) first and
slowly open the hydraulic supply shut-off valve (L).
3. Adjust the flow control valve (Q) to limit the
hydraulic flow to no more than 3 gpm (11 lpm),
which is approximately 60 cycles per minute.
NOTE: If Graco Part No. 236864 hydraulic fluid
control is used, no adjustment is necessary.
4. By adjusting the pressure reducing valve (N),
increase the hydraulic inlet pressure from 50 to
1500 psi (0.34 to 10 MPa, 3.4 to 103 bar).
Increasing the inlet pressure increases the outlet
pressure. Decreasing the inlet pressure
decreases the outlet pressure.
5. Open the drain valve while priming the pump;
close it when the pump is primed.

3. Open the dispensing valve to relieve pressure.
4. Open the pump outlet drain valve, and have a
container ready to catch the drainage.
5. Close the return line shut-off valve (H).
NOTE: Leave the drain valve open until you are ready
to dispense again.
If you suspect that the nozzle or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, very slowly loosen the
hose end coupling to relieve pressure, then clear the
obstruction.
Before You Start the Pump
1. Check the hydraulic fluid level in the hydraulic
power supply before each use, and add fluid as
necessary to fill the lines.
6. Always use the lowest pressure possible to obtain
the desired results. This reduces pump wear.
CAUTION
Never allow a pump to run dry of the fluid being
pumped. A dry pump quickly speeds up and can
damage itself. If it speeds up, shut off the power
supply to the reciprocator immediately. Refill the
supply container, and prime the pump to eliminate
air.
CAUTION
Maximum Working Temperature
Do not exceed 130_ F (54_ C) hydraulic oil tem-
perature. The reciprocator seals will wear faster
and leakage may occur if the pump is operated at
higher oil temperatures.

CAUTION
Always use Graco approved hydraulic oil or equiv-
alent, Part Numbers 169236 (5 gallon) or 207428
(1 gallon). Do not substitute lower grade oil.

2. Flush the pump before using it for the first time to

remove the light oil that was left in after factory
testing to protect the pump from corrosion. Be sure
the solvent used is compatible with the fluid to be
pumped and the pump wetted parts. See
Technical Data, page 23. Flush until clean solvent
comes from the outlet hose.

8 308156
 Operation
If the Pump Leaks at the Fluid Fittings
WARNING
Tighten the fittings (1, 5, 58), which are self-sealing
MAXIMUM WORKING PRESSURES and have replaceable o-rings. If leaking persists,
change the o-rings.
To reduce the risk of serious injury, including
fluid injection and splashing in the eyes or on the
skin, which may be caused if a component self-sealing
ruptures: fitting (1,5,58)
Never exceed 1500 psi (10 MPa, 102 bar) Maxi-
mum Hydraulic Pressure to the reciprocator. reciprocator

Never exceed 7500 psi (51 MPa, 517 bar) Maxi-

mum Outlet Pressure from the displacement pump.
Be sure all accessories added to the reciprocator
power supply side have at least a 1500 psi o-ring
(10 MPa, 102 bar) Maximum Working Pressure. (1a,5a,58a)
Accessories added to the pump fluid outlet side 04478
should have at least a 7500 psi (51 MPa, 517 bar) Fig. 4
Maximum Working Pressure.
The working pressure of the displacement pump Shutdown
has a 5:1 ratio to the pressure at which the recipro-
cator is operated. Therefore, if the fluid supplied to Relieve the pressure whenever you shut down.
the reciprocator is 1000 psi (7 MPa, 69 bar), the
pump fluid outlet pressure will be 5 times the hy-
draulic pressure, or 5000 psi (34 MPa, 345 bar).
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.

308156 9
 Troubleshooting
Problem Cause Solution
Pump does not run. Closed dispense valve. Pump only runs with valve open.
Pressure too low. Increase supply pressure using a
pressure adjusting valve.
Insufficient hydraulic fluid supply. Check hydraulic supply. Adjust to a
maximum of 3 gpm (11 lpm) flow.
Clogged fluid outlet line, intake valve, Relieve pressure. Check; clear
dispense valve, suction line. obstructions.
Reciprocator damaged. Repair. See page 13.
Pump speeds up or runs erratically. Pump piston and/or intake Relieve pressure. Check and repair.
valve worn. See pages 17 and 18.
Empty supply container. Refill and reprime. Do not allow pump
to run dry. Monitor closely or use a
low-level cutoff valve.
Pump runs, but output low on up Pump piston and/or intake valve Relieve pressure. Check and repair.
and/or down stroke. worn. See page 17 and 18.
Pump runs but output low on both Insufficient hydraulic fluid supply. Check hydraulic supply. Adjust to
strokes. maximum 3 gpm (11 lpm) flow.
Pressure too low. Increase supply pressure using a
pressure adjusting valve.
Clogged fluid outlet line, intake valve, Relieve pressure. Check; clear
dispense valve, suction line. obstructions.
Excessive weepage from weep Worn throat packings. Repair. See page 11.
tube (B).
Hydraulic oil leaks from fittings in the Fittings (1,5,58) are loose, or their Tighten the self-sealing fittings. If
upper or lower reciprocator blocks o-rings are worn or damaged. leaking persists, change the o-rings.
(31,32).

10 308156
 Service
Replacing the Throat Seals
See Fig. 5. 32
16* 2
NOTE: Replace these seals if fluid leaks excessively
through the weep tube (B). This procedure can be
19 4
done without disassembling the entire reciprocator.

44*
WARNING
To reduce the risk of serious injury whenever you 16* 3
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
43
1. Relieve the pressure.
1 46
2. Disconnect the reciprocator from the pump. See
the procedure on page 12.

3. Remove the four capscrews (46) from the bottom 33

of the adapter (43). Tap the adapter to loosen it
and pull it off the bottom cap (32).

4. Remove the seals (16*,44*) and guide (19) from

the top of the adapter (43).

NOTE: Items 16 and 44 are included in the 1 Torque to 28 to 32 ft-lb (38 to 43 N-m).
Reciprocator Repair Kit, 223426. 2 Lips face up.
3 Lips face down.
5. Lubricate the guide (19) and install the seals and
guide in the adapter (43), one at a time in the 4 Lubricate.
order shown in Fig. 5.
01660

6. Reassemble. Torque the capscrews (46) to 28 to Fig. 5

32 ft-lb (38 to 43 N-m). Install the displacement
pump. Follow Step 24, page 16.

308156 11
 Service
Disconnecting the Reciprocator and
Displacement Pump
See Fig. 6.
NOTE: When displacement pump 224914 is
purchased separately, it comes with the priming piston
(112) and priming cylinder (111) unassembled.
Connect the displacement pump to the hydraulic
reciprocator before assembling the priming piston and
cylinder. Torque the priming piston to 35 ft-lb (47 N-m).
CAUTION
Keep The Hydraulic System Clean
It is essential to keep the hydraulic oil system clean
and free of contaminants to reduce the risk of dam-
aging the hydraulic reciprocator. Always install a
plug in each tube fitting and on each hose end
whenever fluid lines are disconnected to prevent
contamination.

3 1. Flush the pump if possible and stop it with the

displacement rod in the lowest position.
36,37

WARNING
32 To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
43
Pressure Relief Procedure on page 8.
46 (hidden from view)

2. Relieve the pressure.

3. Disconnect the outlet hose from the displacement

33 pump.

4. Slowly loosen the hydraulic supply (58) and return

(5) fittings to relieve any pressure, and then
35 remove the hoses. Install plugs on the tube fittings
204 and in the hose ends. Check the o-rings (5a, 58a)
202*
on the fittings and replace them if they are worn or
101 203* damaged. See Fig. 4 and the Parts Drawing.
103
5. Using a strap wrench on the displacement cylinder
(108), screw it out of the pump adapter (43), and
01682 slide it down as far is it will go.
06151B
6. Pull the connecting rod (35) down as far as it will
Fig. 6 go. Remove the cotter pin (204).

NOTE: For the 35 lb. length pump, the priming

cylinder (111) and the priming piston (112) must be
completely removed before you can pull down the
displacement cylinder (108) far enough to remove the
cotter pin (204).
7. Unscrew the piston coupling (103) to remove the
pump.

12 308156
 Reciprocator Repair
Reciprocator Repair
NOTES
D Clean and inspect all parts for wear or damage.
Replace parts as needed. For the best results,
always replace all the o-rings and seals when you
disassemble the pump. Repair Kit 223426 is
available. Parts included in the kit are marked with
one asterisk, for example (23*), in the text and
drawings. Always replace the seals (23*,24*) and
the seals (16*, 44*) together.
D Assembly Tool 189305 is required for
reassembling the reciprocator.
D Loctiter 242 thread sealant and Loctiter Primer T
or Perma-Locr 115 thread sealant and
Perma-Bondr Surface Conditioner I are required.
Be sure their shelf life is within the manufacturers
recommendations.
Before you begin, drain the oil out of the reciprocator
as follows: Place the reciprocator in a drain pan, push
the piston all the way up/in, then all the way down/out.
1. Place the adapter (43) in a vise. Remove the four
capscrews (46) and the base (33). Pull the bottom
cap (32) off of the adapter (43). See Fig. 7. If
needed, replace the seals as described on
page 11.
2. Loosen both nuts on the fluid tube (45). Use a
wrench to rotate the tube fittings (1,58) to the side,
and then remove the tube (45). Check the o-rings
(1a,58a) on the fittings and replace them if they
are worn or damaged. Install plugs in the fittings to
prevent contamination. See Fig. 4 and the Parts
Drawing.
3. Remove the capscrew (3), nuts (36) and
lockwashers (37) on top of the reciprocator. See
Fig. 7.
See Fig. 9 for Steps 4 to 20, except where noted.
4. Tap on the bottom of the displacement rod (34)
with a plastic mallet to loosen the cylinder (25).
5. Grasp the valve spool (31) and pull it off the
cylinder and tie rods (38). Pull the cylinder and
piston off the bottom cap (32). It is not necessary
to remove the tie rods from the bottom cap.
6. Lay the assembly on its side. Place a clean rag
around the yoke (9) to prevent losing the detent
balls. Slide the yoke (9) sideways off the valve
sleeve (29) while holding the balls (7) and spring
(6) in place.
7. Slide the cylinder (25) off the displacement rod
(34). Hold the hex end of the displacement rod in a
vise and use a spanner wrench in the pin holes of
the piston (22) to screw it off the rod.
CAUTION
Be careful not to scratch the outside of the dis-
placement rod or the inside of the cylinder.
8. Visually inspect the spring (21). If there is wear or
damage, remove the nut (18), spring (21) and
retainers (20) from the trip rod (12). Reassemble
with a retainer (20) on each end of the new spring
(21). You must thread the nut onto the rod until it
runs out of thread, so that it bottoms out on the
shoulder of the rod. See Fig. 8.
12
20

3,39,2
21
36,37

20

Fig. 8 18 01664

32
43

46
hidden from view

33
06146B
Fig. 7

308156 13
 Reciprocator Repair
NOTE: If you are re-using or reassembling any parts,
3,39,2 use a surface cleaner such as chlorinated solvent on
36,37
the threads, and blow with compressed air. A 1/428
UNF2A tap can be used to remove adhesive from the
30 internal threads of the yoke (9).
31 NOTE: Thread sealant and primer are required. See
the third bulleted note on page 13 for specifications.
*13
9. Apply fresh thread sealant to the first two or three
internal threads of the yoke (9). Apply primer to the
external thread of the rod (12). Let dry for three or
four minutes. Assemble, torquing the screw to 54
29 to 56 in-lb (6.1 to 6.3 N-m). Remove excess
sealant. Allow 24 hours to cure before operating
the reciprocator.
26
6,7
10. Clean all sealant from the threads of any part you
are reusing, and apply thread sealant to the first
9 51 2 two or three internal threads of the valve assembly
(31). If you removed the capscrew (51), apply
1 22
thread sealant to the first two or three internal
12 threads of the valve stop (26). Apply primer to the
external threads of the valve sleeve (29). Let dry
25 for three or four minutes, assemble, and remove
*24 excess sealant. Allow 24 hours to cure before
operating the reciprocator.
23*,49*
11. Remove the o-ring (13*) from the bottom of the
17 spool valve (31) and replace it with a new o-ring.
20
38 12. Use a spanner wrench to screw the piston (22)
21 onto the displacement rod (34). Torque to 30 to 40
ft-lb (41 to 54 N-m).
32 34
CAUTION
13* When inserting the piston into the cylinder, care-
See
Fig. 8
fully guide the piston seal (23*) and bearing (24*)
to prevent damaging these parts.
20

18 13. Lay Assembly A and Assembly B on the

workbench.

14. Slide Assembly B into the center of the tool (D),

Part No. 189305. Align the upper detent holes (C)
of the yoke (9) with the center line of the tool (D).
See Fig. 10.

17

1 Torque to 30 to 40 ft-lb (41 to 54 N-m)

2 Torque to 42 to 45 in-lb (4.7 to 5.1 N-m)
06153
Fig. 9

14 308156
 Reciprocator Repair
31
ASSEMBLY A
C ASSEMBLY B
Fig. 10
15. Insert the spring (6) and one ball (7) into the valve
stop (26) of Assembly A. Tilt the valve stop and
start guiding it into the tool (D), making sure the
ball is sliding into the rounded slot in the tool (D).
Place the other ball at the other end of the spring
and push it in with your thumb while rotating the
valve stop (26) until the spring is horizontal and the
balls are in place. Continue holding this assembly
together. See Fig. 10.
16. Slide the valve stop assembly down into the tool.
Make sure the balls (7) snap into the upper set of
holes (C) in the yoke (9), and the curved ends of
the guide clamp have engaged the valve sleeve
(29) groove. See Fig. 10. Slide the tool (D) back
over the rod (12) to remove it.
Refer to Fig. 11 for Steps 17 to 24.
17. Place the adapter (43) in a vise, and install the
seals as described on page 11. Install the cylinder
cap (32).
29
26
6
7
12
06148
18. If the tie rods (38) were removed, reinstall them
with the short threaded end up. The other end
should be screwed about 9/16 into the bottom
cylinder cap (32).
NOTE: When reinstalling the cylinder (25) (Step 19),
be sure the P port in the valve spool (31) and the port
in the bottom cylinder cap (32) are in line with each
other. Be sure the o-rings (13*) are in place in the
valve spool and cylinder cap.
19. Place the cylinder (25) on the cylinder cap (32).
Install the piston (22) and valve assembly (31).
20. Install the o-ring (49*) in the deep lower groove of
the piston (22) and install the seal (23*) over the
o-ring. Install the piston bearing (24*) around the
upper groove of the piston. Holding the piston
bearing in place to avoid damage, slide the
cylinder over the piston and press it down.
308156 15
 Reciprocator Repair
21. Install the capscrew (3), o-ring (39) and washer
(2). Install the lockwashers (37) and nuts (36). 3,39,2
Torque the nuts to 28 to 32 ft-lb (36 to 43 N-m).
1 36,37

CAUTION 31
Never install the fluid tube (45) before torquing the
tie rods. Doing so could cause misalignment and
damage the reciprocator when it is operated. *13

22. Reinstall the fluid tube (45) and fittings (1). Torque
the fittings to 25 to 35 ft-lb (34 to 48 N-m). See the
Parts Drawing on page 20.
25
23. Pull the displacement rod (34) in and out to be
sure it moves easily with only a little resistance
from the rod seal.
38
24. To reconnect the reciprocator and pump, install the
o-ring (17). Screw the connecting rod (35) into the
displacement rod (34). Install the cotter pin (204).
Install a new copper gasket (202*). Make sure the
seal (203*) in the bottom of the adapter (43) is in
good condition. Push the cylinder up into the 32
adapter and engage the threads. Screw in the
pump, using a strap wrench for the final tightening.
13*
See Fig. 12.
43
25. Connect the hydraulic supply and return hoses to
the fittings (5, 60).

WARNING
To reduce the risk of static sparking be sure to re-
connect the ground wire before operating the
pump.
35

1 Torque to 28 to 32 ft-lb (36 to 43 N-m)

06153
Fig. 11

*202 35
204 43
203*
103

118 1

1 Torque to 150 to 160 ft-lb (205 to 220 N-m) 01682

Fig. 12

16 308156
 Displacement Pump Repair
Disassembly

WARNING
116
To reduce the risk of serious injury whenever you 101 102
are instructed to relieve pressure, always follow the
103 115
Pressure Relief Procedure on page 8.
104*

1. If possible, flush the pump. Relieve the pressure. 107 105*

2. Follow Disconnecting the Reciprocator and 117

106
Displacement Pump procedure on page 12.
102
3. Place the pump in a vise. Unscrew the priming 115
cylinder (111). 116

4. Push the priming piston (112) into the pump until 118 109
the hex of the piston coupling (103) is exposed. 114*
108
5. Hold the piston coupling (103), and unscrew the
piston rod (119).
110 113*
6. Unscrew the packing housing (110) and remove all 1 119
parts.
2
7. Pull the piston (107) and the priming tube (108)
assembly out of the pump housing.

8. Unscrew the priming tube (108), and remove all

parts. 111

9. Unscrew the piston (107), and remove all parts. 112

10. Clean all parts thoroughly with a compatible
solvent. Inspect the parts for wear, and replace as
needed. Scoring or irregular surfaces on the
priming tube (108), or inside the cylinder (118)
causes premature packing wear and leaking.

1 Only used on Models 223513 and 223514.

2 Insert 1/4 dia. rod through hole to hold priming

tube (108) when removing or installing parts
connected to it.
01684A
Fig. 13

308156 17
 Displacement Pump Repair
Reassembly
NOTE: Repair Kit 223427 is available. Reference
numbers marked with an asterisk are included in the
116
kit. 101 102
NOTE: The balls (116) cannot be reseated on the 103 115
hardened seats (102). However, the seats can be
104*
reversed and used a second time.
1 107 105*
NOTE: Lubricate all parts with a light, waterproof
grease. 117
106
1. Insert the pin (101) into the piston coupling (103), 102
and insert the pin (117) into the pump piston (107).
115
2. Put the pump piston (107) in a vise, and stack the 116
spacer (106), seal (105*), packing (104*), gasket
(115), seat (102), and ball (116) on it in the order 118 109
shown in Fig. 14. Thread the piston coupling (103) 1 108 114*
onto the pump piston (107), and torque it to 60 ft-lb
(80 N-m).
1 110 113*
3. Turn the pump piston (107) over in the vise, and
insert the ball (116), seat (102), and gasket (115). 2 3 119

4. Assemble the seal (113), packing (114) and 4

bearing (109) on the packing housing (110). Screw
the packing housing into the cylinder (118), and
torque to 60 ft-lb (80 N-m).

5. Slide the assembly into the cylinder from the top. 111
Use your finger to guide the assembly through the
lower seals. 2 112

6. Models 223513, 223514 only: Screw the piston

rod (119) onto the priming tube (108). Torque to 35
ft-lb (47 N-m).

7. Place the gasket (202*) in the base of the

reciprocator. Place the o-ring (203*) into the
groove of the pump adapter (43). Screw the
cylinder into the pump adapter. 1 Torque to 60 ft-lb (80 N-m).

8. Firmly screw the priming piston (112) onto the
piston rod (119). Torque to 35 ft-lb (47 N-m).
9. Firmly screw the priming cylinder (111) onto the
cylinder (118).
Fig. 14
10. Reconnect the ground wire to the reciprocator if it
is disconnected.
2 Torque to 35 ft-lb (47 N-m).
3 Only used on Models 223513 and 223514.
4 Insert 1/4 dia. rod through hole to hold priming
tube (108) when removing or installing parts
connected to it.
01684A

18 308156
 Displacement Pump Parts
Model 223513, Series A, 120 lb.
Includes items 101 to 119
103 109
Model 223514, Series A, 400 lb. 101 116 *114
Includes items 101 to 119 102 *113
115
Model 224914, Series A, 35 lb. 104*
Includes items 101 to 118 105* 110
106
Ref.
No. Part No. Description Qty.

101 108992 PIN, spring 1 107

102 162559 SEAT, valve 2
116 119
103 183670 COUPLING, piston 1 117
104* 108990 PACKING, block 1 102
105* 108989 SEAL, backup 1 115
106 183669 SPACER, piston 1
107 183676 PISTON, pump 1
108 183677 TUBE, priming 1 108
109 183668 BEARING, priming 1
110 183675 HOUSING, packing 1 112
111 CYLINDER, priming 1
183673 Model 223513
185999 Model 223514
111
187312 Model 224914
112 183672 PISTON, priming 1 118
113* 108988 SEAL, backup 1
114* 108987 PACKING, block 1
115 150451 GASKET, copper 2
116 100170 BALL 2
117 108991 PIN, spring 1
118 183678 CYLINDER, pump 1
119 ROD, piston 1
186002 Model 223513
185998 Model 223514
None Model 224914

* These parts and items 202, 203 on page 22, are

included in Repair Kit 223427, which may be
purchased separately.
01685
Fig. 15

308156 19
 Reciprocator Parts
Model 239883, Series A
Includes items 1 to 60

3
NOTE: See pages 11 to 18 for impor-
39 tant assembly procedures
2 and torque values.
36
37 24*

30 22
5
49*
23*
16*
*4
31 17
58a 5a 20 19

58
29 21
44*
9 20
7 18 16*

6
60
7
26
45 59
51 34

46 43
1a 12
1
17
*13
38
25 35
14
33
40 52
Label 46

32

*13

06154B

20 308156
 Reciprocator Parts
Model 239883, Series A
Includes items 1 to 60

Ref. Ref.
No. Part No. Description Qty. No. Part No. Description Qty.

1 106470 ELBOW, straight thread, 30 178181 PLATE, cap 1

3/416 unf2a x 31 239874 SPOOL, valve assembly
3/416 unf2a, 37_ flare 3/416 unf 2b(f) 1
includes item 1a 1 32 186225 CAP, cylinder, bottom, cs 1
1a 110987 .O-RING 1 33 183833 BASE, aluminum 1
2 178179 WASHER, sealing 1 34 188078 ROD, displacement, cs 1
3 106276 CAPSCREW, hex hd, 35 183671 CONNECTING ROD 1
3/824 x 5/8 1 36 100307 NUT, full, hex; 3/816 unc2b 4
4 104093 O-RING 1 37 100133 LOCKWASHER, 3/8 4
5 112568 ADAPTER, pipe,3/4 unf(m) 38 187405 ROD, tie, 8.5 shoulder to
1/2 npt(f), steel shoulder, 3/816 unc2a,cs 4
includes item 5a 1 39 155685 O-RING 1
5a 110987 .O-RING 1 40Y 179885 LABEL, Warning 1
6 108437 SPRING, compression, steel 1 43 183533 ADAPTER, pump, cs 1
7 100069 BALL, 1/4 dia. steel 2 44* 108951 SEAL, polyester elastomer 1
9 189077 YOKE, valve 1 45 217221 TUBE, inlet 1
12 192657 ROD, stop, cs 1 46 108986 CAPSCREW, sch, 3/1816
13* 106274 O-RING, bunaN 2 unc2a x 4.5 4
14 116343 SCREW, grounding 1 49* 108014 O-RING, bunaN 1
16* 108952 PACKING, v-block 2 51 104092 CAPSCREW, sch; 1024
17 105765 O-RING 2 unrc3a x 5/8 2
18 114231 LOCKNUT, hex, 1/428 unf3b 52 106115 LOCKWASHER, spring; 3/8 4
steel and nylon 1 58 107197 TEE includes item 58a 1
19 183531 GUIDE, rod, bronze 1 58a 110987 .O-RING 1
20 192655 RETAINER, spring, cs 2 59 110064 PLUG, pipe, vented, 1/827 nptf 1
21 178189 SPRING, compression, steel 1 60 112569 UNION, swivel; steel 1
22 192656 PISTON, CS 1
23* 178226 SEAL, piston * These parts and items 202, 203 on page 22 are
glass-filled Teflon 1 included in Repair Kit 223426, which may be
24* 178207 BEARING, piston purchased separately.
bronze-filled Teflon 1
25 178229 CYLINDER, motor, cs 1 Y Replacement Danger and Warning labels, tags and
26 192654 STOP, valve, cs 1 cards are available at no cost.
29 189072 SLEEVE, valve, steel 1
Assembly Tool 189305 required for repairing the
reciprocator.

308156 21
 Pump Parts
Model 224752, Series C
400 pound drum size
201
Ref.
No. Part No. Description Qty.
201 239883 RECIPROCATOR, see page 21 1
202* 183715 GASKET, copper 1
203* 108993 O-RING 1
204 108992 PIN 1 206
label
205 223514 DISPLACEMENT PUMP
see page 19 1 202
206 183741 LABEL, identification 1
203*
Model 224751, Series C 204
120 pound drum size
Ref.
No. Part No. Description Qty.
205
201 239883 RECIPROCATOR, see page 21 1
202* 183715 GASKET, copper 1
203* 108993 O-RING 1
204 108992 PIN 1
205 223513 DISPLACEMENT PUMP
see page 19 1
206 183741 LABEL 1

Model 224912, Series C

35 pound drum size
Ref.
No. Part No. Description Qty.
201 239883 RECIPROCATOR, see page 21 1
06155B
202* 183715 GASKET, copper 1
203* 108993 O-RING 1
204 108992 PIN 1
205 224914 DISPLACEMENT PUMP
see page 19 1
206 183741 LABEL 1

* These parts are included in Repair Kits 223426 and

223427, which may be purchased separately.

22 308156
 Technical Data
Max. grease output pressure . . . . . . . . . . . . . . . . . . . . . . 7500 psi (51 MPa, 517 bar)
Max. hydraulic fluid input pressure . . . . . . . . . . . . . . . . . . 1500 psi (10 MPa, 102 bar)
Max. hydraulic fluid input volume . . . . . . . . . . . . . . . . . . . . 3 gpm (11.7 lpm), 60 cpm
Hydraulic fluid consumption rate . . . . . . . . . . . . . . 6.5 ounces (0.195 liter) per cycle
or 1 gallon per 19.5 cycles
Maximum fluid temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130_ F (55_ C)
Effective piston area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.48 sq in. (9.55 cm2)
Piston rod diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3/8 in. (34.9 mm)
Output per cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with No. 2 grease at 60 cpm
free flow: 5 lb/min (2.25 kg/min)
at 3000 psi (21 MPa, 207 bar): 4 lb/min (1.8 kg/min)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 in. (101.6 mm)
Thrust at 1000 psi (7 MPa, 69 bar) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1480 lb (673 kg)
Maximum suction lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 feet (4 m)
Displacement pump wetted parts . . . . . . . . . . . . . . . . . . . steel, copper, polyurethane,
bunaN, polyester elastomer
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model 224752: 42 lb (18.9 kg)
Model 224751: 37.5 lb (16.9 kg)
Model 224912: 32.5 (17.7 kg)
Sound pressure* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 dB(A)
* Sound pressure reading taken with pump operating at 66 cycles per minute.
Sound pressure measured per CAGI-PNEUROP, 1971.
LoctiteR is a registered trademark of Loctite Corporation.

Dimensions and Mounting Hole Layout

3/8 npt Hydraulic Inlet 3 in (76.2 mm)
3/4 npt Hydraulic Outlet
minimum diameter
clearance hole

14.75 in.
(375 mm)
Reciprocator
Model 239883
3.536 in.
(90.424 mm)
29.75 in.
(756 mm)
Model 224912

41.5 in.
(1054 mm) 3.536 in.
(90.424 mm) clearance for, or
Model 224751
tap 5/1618,
typical 4 places
48.5 in.
1/2 npt(f) (1232 mm)
fluid Model 224752 NOTE: Pump body orientation is square
outlet with mounting holes.
15 in.
(381 mm)
Model 224914
26.75 in.
(679 mm)
Model 223513

33.75 in.
(857 mm)
Model 223514

06151

308156 23
 Graco Standard Warranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the
date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limited
warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment
determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in
accordance with Gracos written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or
substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Gracos sole obligation and buyers sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.

Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide
purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties
reconnaissent avoir convenu que la rdaction du prsente document sera en Anglais, ainsi que tous documents, avis et procdures
judiciaires excuts, donns ou intents la suite de ou en rapport, directement ou indirectement, avec les procedures concernes.

Graco Phone Numbers

TO PLACE AN ORDER, contact your Graco distributor, or call one of the following numbers
to identify the distributor closest to you:
18005339655 Toll Free
6126236928
6123783590 Fax

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.

Sales Offices: Minneapolis, Detroit

International Offices: Belgium, Korea, Hong Kong, Japan

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 554401441

www.graco.com
PRINTED IN U.S.A. 308156 December 1991, Revised August 2001
24 308156
 Instructions Parts List
Parts

CARBON STEEL

CheckMatet2100 Pumps 308149P

With Priming Piston, and SevereDuty Rod and Cylinder
Part No. 222828 Pump, Series A
Part No. 246935 Pump, Series A
12:1 Ratio, with Bulldogr Air Motor
8.3 MPa, 83 bar (1200 psi) Maximum Fluid Working Pressure
0.7 MPa, 7 bar (100 psi) Maximum Air Input Pressure

Part No. 222829 Pump, Series A

12:1 Ratio, with Quiet Bulldogr Air Motor
8.3 MPa, 83 bar (1200 psi) Maximum Fluid Working Pressure
0.7 MPa, 7 bar (100 psi) Maximum Air Input Pressure

Part No. 222835 Pump, Series A

Part No. 246936 Pump, Series A
24:1 Ratio, with Kingt Air Motor
16.6 MPa, 166 bar (2400 psi) Maximum Fluid Working Pressure
0.7 MPa, 7 bar (100 psi) Maximum Air Input Pressure

Part No. 222901 Pump, Series B

24:1 Ratio, with Quiet Kingt Air Motor
16.6 MPa, 166 bar (2400 psi) Maximum Fluid Working Pressure
0.7 MPa, 7 bar (100 psi) Maximum Air Input Pressure

Part No. 222940 Pump, Series A

39:1 Ratio, with Premiert Air Motor
26.9 MPa, 269 bar (3900 psi) Maximum Fluid Working Pressure
0.7 MPa, 7 bar (100 psi) Maximum Air Input Pressure

Part No. 222902 Pump, Series B

Part No. 246937 Pump, Series A
with Viscountr Hydraulic Motor
15.9 MPa, 159 bar (2300 psi) Maximum Fluid Working Pressure
10 MPa, 103 bar (1500 psi) Maximum Hydraulic Input Pressure

Important Safety Instructions

Part No.
Read all warnings and instructions in this manual.
222835
Save these instructions. Shown
See page 2 for Table of Contents.

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 554401441

Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
 Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disconnecting the Displacement Pump . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Reconnecting the Displacement Pump . . . . . . . . 18
Installation (Air-Powered Pumps) . . . . . . . . . . . . . . . . . 8 Displacement Pump Service . . . . . . . . . . . . . . . . . 19
Installation (Hydraulic-Powered Pumps) . . . . . . . . . . 10 Parts Drawings and Lists
Operation/Maintenance Pump Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 25
All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . 28
Air-Powered Models . . . . . . . . . . . . . . . . . . . . . . . . 12 Technical Data and Performance Charts . . . . . . . . . . 30
Hydraulic-Powered Models . . . . . . . . . . . . . . . . . . 14 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Service Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . 15 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . 38
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2 308149
 Symbols
Warning Symbol Caution Symbol

WARNING CAUTION
This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to
injury or death if you do not follow the instructions. or destruction of equipment if you do not follow the
instructions.

WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS

This equipment is for professional use only.

Read all instruction manuals, tags, and labels before operating the equipment.

Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.

Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

Check equipment daily. Repair or replace worn or damaged parts immediately.

Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on pages 3035 for the maximum working pressure of this equipment.

Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturers warnings.

Do not kink or overbend hoses or use hoses to pull equipment.

Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82C (180F) or below 40C (40F).

Wear hearing protection when operating this equipment.

Do not lift pressurized equipment.

Comply with all applicable local, state, and national fire, electrical, and safety regulations.

308149 3
 WARNING
SKIN INJECTION HAZARD
Spray from the gun/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.

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

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

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

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

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

Always have the tip guard and the trigger guard on the gun/valve when spraying.

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

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

Follow the Pressure Relief Procedure on page 12 whenever you: are instructed to relieve pres-
sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip/
nozzle.

Tighten all fluid connections before operating the equipment.

Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.

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 air motor piston, can pinch or amputate your fingers.

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

Before servicing the equipment, follow the Pressure Relief Procedure on page 12 to prevent the
equipment from starting unexpectedly.

4 308149
 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.

Ground the equipment and the object being sprayed. Refer to Grounding on page 7.

If there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing immediately. Do not use the equipment until you identify and correct the problem.

Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.

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

Electrically disconnect all equipment in the spray area.

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

Do not smoke in the spray area.

Do not turn on or off any light switch in the spray area while operating or if fumes are present.

Do not operate a gasoline engine in the spray area.

Keep a fire extinguisher in the work 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.

Know the specific hazards of the fluid you are using.

Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.

Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

308149 5
 Notes

6 308149
 Installation
Grounding 7. Object being sprayed: according to your local
code.

WARNING 8. All solvent pails used when flushing, according to

FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE AND EXPLOSION
HAZARD on page 5.
your local code. Use only metal pails, which are
conductive, 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. King Pumps: use a ground wire and clamp. See 9. To maintain grounding continuity when flushing or
Fig. 1. Remove the ground screw (Z) and insert relieving pressure, always hold a metal part of the
through eye of ring terminal at the end of ground spray gun/dispensing valve firmly to the side of a
wire (Y). Fasten ground screw back onto pump grounded metal pail, then trigger the gun/valve.
and tighten securely. Connect the other end of the
wire to a true earth ground. Order Part No. 222011
Ground Wire and Clamp.

All Other Pumps: use a ground wire and clamp.

See Fig. 2. Loosen the grounding lug locknut (W) Z Y
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.
TI1052
2. Air and hydraulic hoses: use only electrically Fig. 1
conductive hoses.

3. Fluid hoses: use only electrically conductive fluid W

hoses.
X
4. Air compressor or hydraulic power supply: follow Y
manufacturers recommendations.
Z
5. Spray gun/dispensing valve: grounding is obtained
through connection to a properly grounded fluid
hose and pump.

6. Fluid supply container: according to your local

Fig. 2 0864
code.

308149 7
 Installation
(AIR-POWERED PUMPS)

NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawings.
Accessories are available from your Graco distributor.
If you supply your own accessories, be sure they are
adequately sized and pressure-rated to meet the
systems requirements.
The Typical Installation shown in Fig. 3 is only a guide
for selecting and installing system components and
accessories. Contact your Graco distributor for assis-
tance in designing a system to suit your particular
needs.

KEY
A Pump K Bleed-Type Master Air Valve (for accessories)
B 200 Liter (55 Gallon) Air-Powered Ram L Fluid Regulator
C Pump Runaway Valve M Fluid Drain Valve (required)
D Air Line Lubricator N Electrically Conductive Fluid Supply Hose
E Bleed-Type Master Air Valve P Fluid Shutoff Valve
(required, for pump) R Gun/Valve Swivel
F Pump Air Regulator S Airless Spray Gun or Dispensing Valve
G Air Manifold T Ram Air Regulator
H Electrically Conductive Air Supply Hose Y Ground Wire (required, see page 7 for
J Air Line Filter installation instructions)

FLUID HEADER PIPE

(3 in. Diameter)
J K MAIN AIR LINE

Y D

B L P L P
E
T
F
A C

G
S R M M

N N
M
S R

01177A

Fig. 3

8 308149
 Installation
(AIR-POWERED PUMPS)
SYSTEM ACCESSORIES
WARNING
A bleed-type master air valve (E) and a fluid drain
valve (M) are required in your system. These
accessories help reduce the risk of serious injury,
including fluid injection and splashing of fluid in the
eyes or on the skin, and injury from moving parts if
you are adjusting or repairing the pump.
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.
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.
Air and Fluid Hoses
Be sure all air hoses (H) and fluid hoses (N) are prop-
erly sized and pressure-rated for your system. Use
only electrically conductive hoses. Fluid hoses must
have spring guards on both ends.
Mounting Accessories
WARNING
For Model 222940 Premier Pump, do not lift the
pump by the lift ring when the total weight exceeds
550 lb (250 kg).
Mount the pump (A) to suit the type of installation
planned. Fig. 3 on page 8 illustrates a ram-mounted
pump in a multi-gun header system. Pump dimensions
and the mounting hole layout are shown on pages 36
and 37.
If you are mounting the pump on a ram, refer to the
separate ram manual for installation and operation
instructions.
Air Line Accessories
Install the following accessories in the order shown in
Fig. 3, using adapters as necessary:

An air line lubricator (D) provides automatic air
motor lubrication.

A bleed-type master air valve (E) is required in
your system to relieve air trapped between it and
the air motor when the valve is closed (see the
WARNING above). Be sure the bleed valve is
easily accessible from the pump, and is located
downstream from the air regulator.

An air regulator (F) 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.

A pump runaway valve (C) 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.

An air manifold (G) has a swivel air inlet. It
mounts to a ram, and has ports for connecting lines
to air accessories, such as the ram air regulator
(T).

An air line filter (J) removes harmful dirt and
moisture from the compressed air supply.

A second bleed-type air valve (K) isolates the air
line accessories for servicing. Locate upstream
from all other air line accessories.
Fluid Line Accessories
Install the following accessories in the positions shown
in Fig. 3, using adapters as necessary:

Install a fluid shutoff valve (P) at each gun drop,
to isolate the gun and fluid accessories for servic-
ing.

Install a fluid drain valve (M) near the pump fluid
outlet, and at each gun station. The drain valves
are required in your system to relieve fluid pressure
in the displacement pump, hose and gun (see the
WARNING at left). Drain valves at the gun stations
may be mounted in the base of a fluid regulator
(L), using an adapter.

A fluid regulator (L) controls fluid pressure to the
gun/valve, and dampens pressure surges.

A gun or valve (S) dispenses the fluid. The gun
shown in Fig. 3 is a high pressure dispensing gun
for highly viscous fluids.

A gun swivel (R) allows freer gun movement.
308149 9
 Installation
(HYDRAULIC-POWERED PUMPS)
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
Accessories are available from your Graco . If you
supply your own accessories, be sure they are ade-
quately sized and pressure-rated to meet the systems
requirements.
The Typical Installation shown in Fig. 4 is only a guide
for selecting and installing system components and
accessories. Contact your Graco distributor for assis-
tance in designing a system to suit your particular
needs.
CAUTION
It is very important to keep the hydraulic supply
system clean at all times. Be sure that all hydraulic
fluid lines are absolutely clean. Blow out the lines
with air and flush thoroughly with solvent before
connecting to the hydraulic motor, to avoid introduc-
ing harmful contaminants into the motor. Plug the
hydraulic lines immediately when they are discon-
nected.
Do not exceed 37.8 liter/min (10 gpm) hydraulic oil
volume to the motor, to avoid pump stalling.

For optimum pump performance, keep the tempera-

ture of the hydraulic oil below 54 C (130 F)

KEY
A Pump U Hydraulic Supply Line Shutoff Valve
B 200 Liter (55 Gallon) Air-Powered Ram V Hydraulic Return Line Shutoff Valve
C Hydraulic Supply Line Y Ground Wire (required, see page 7 for
D Hydraulic Return Line installation instructions)
E Drain Line (from pressure reducing valve) AA Hydraulic Return Line Filter
F Pressure Gauge
G Flow Control Valve
AIR FILTER FOR RAM AIR SHUTOFF VALVE FOR RAM
H Pressure Reducing Valve
J Accumulator FLUID HEADER PIPE
MAIN AIR LINE
K Drain Line (from motor drip pan)
(3 in. Diameter)
L Fluid Regulator
M Fluid Drain Valve (required) F U V
N Electrically Conductive Fluid
Supply Hose H
P Fluid Shutoff Valve A
R Gun/Valve Swivel J
S Airless Spray Gun B
or Dispensing Valve Y L P L P
T Ram Air Regulator

G
T
C
HYDRAULIC
D
POWER SUPPLY

E
S R M M
N N

S R
M

AA

DRAINAGE
K 01178
CONTAINER
Fig. 4

10 308149
 Installation
(HYDRAULIC-POWERED PUMPS)
SYSTEM ACCESSORIES
WARNING
A fluid drain valve (M) is required in your system to
help reduce the risk of serious injury, including fluid
injection and splashing of fluid in the eyes or on the
skin if you are adjusting or repairing the pump.
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.
Mounting Accessories
Mount the pump (A) to suit the type of installation
planned. Fig. 4 on page 10 illustrates a ram-mounted
pump in a multi-gun header system. Pump dimensions
and the mounting hole layout are shown on pages 36
and 37.
If you are mounting the pump on a air-powered ram,
refer to the separate ram manual for installation and
operation instructions, and recommended air accesso-
ries.
Filters
Be sure your hydraulic power supply is equipped with a
suction filter to the hydraulic pump and a system return
line filter (AA) of 10 micron size.
Carefully follow the manufacturers recommendations
on reservoir and filter cleaning, and periodic changes
of hydraulic fluid. Use only Graco-approved hydraulic
oil. Order Part No. 169236, 5 gal. (19 liter) or 207428,
1 gal. (3.8 liter). Do not substitute a lower grade oil or
one with a lower flash point.
Hydraulic Lines
The motor has a 3/4 npt(f) hydraulic oil supply fitting,
and a 1 npt(f) hydraulic oil return fitting. Use a mini-
mum 13 mm (1/2 in.) ID hydraulic supply line, and a
minimum 16 mm (5/8 in.) ID return line.
On the hydraulic supply line (C), install the following
accessories in the order shown in Fig. 4, using adapt-
ers as necessary:

A shutoff valve (U) to isolate the pump for servic-
ing.

A fluid pressure gauge (F) to monitor hydraulic oil
pressure to the motor and to avoid overpressurizing
the motor or displacement pump, and a pressure-
and temperature-compensated flow control
valve (G) to prevent the motor from running too
fast and possibly damaging itself.

A pressure reducing valve (H), with a drain line
(E) running into the hydraulic return line (D).

An accumulator (J) to reduce the hammering
effect caused by the motor reversing direction.
On the hydraulic return line (D), install the following
accessories in the order shown in Fig. 4, using adapt-
ers as necessary:

A shutoff valve (V) to isolate the pump for servic-
ing.

A filter (AA) of 10 micron size.
Hydraulic Motor Drip Pan
The hydraulic motor has a drip pan to collect any
leakage that may occur. Connect a 6 mm (1/4 in.) ID
drain line (K) to the barbed hose fitting on the drip pan,
and place the free end in a suitable container to re-
ceive the drainage.
Fluid Supply Hoses
Be sure the fluid supply hose (N) is properly sized and
pressure-rated for your system. Use only electrically
conductive hoses. Fluid hoses must have spring
guards on both ends.
Fluid Line Accessories
Install the following accessories in the positions shown
in Fig. 4, using adapters as necessary:

Install a fluid shutoff valve (P) at each gun drop,
to isolate the gun and fluid accessories for servic-
ing.

Install a fluid drain valve (M) near the pump fluid
outlet, and at each gun station. The drain valves
are required in your system to relieve fluid pressure
in the displacement pump, hose and gun (see the
WARNING at left). Drain valves at the gun stations
may be mounted in the base of a fluid regulator
(L), using an adapter.

A fluid regulator (L) controls fluid pressure to the
gun/valve, and dampens pressure surges.

A gun or valve (S) dispenses the fluid. The gun
shown in Fig. 4 is a high pressure dispensing gun
for highly viscous fluids.

A gun swivel (R) allows freer gun movement.
308149 11
 Operation
(ALL MODELS)
Pressure Relief Procedure
WARNING
SKIN INJECTION HAZARD
Fluid under high pressure can be in-
jected 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:

are instructed to relieve the pressure,

stop spraying/dispensing,

check or service any of the system equipment,

or install or clean the spray tip/nozzle.
1. Engage the gun/valve trigger safety.
2. Shut off the air or hydraulic supply to the pump.
3. In air-powered systems, close the bleed-type
master air valve (required in your system). In
hydraulic-powered systems, close the hydraulic
supply line valve first, then the return line valve.
4. Unlock the gun/valve safety latch.
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 safety latch.
7. Open the drain valve (required in your system)
and/or the pump bleeder valve, 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, nozzle, or hose end
coupling and relieve pressure gradually, then loosen
completely. Now clear the tip/nozzle or hose.
Packing Nut/Wet-Cup
Fill the packing nut/wet-cup (2) 1/3 full with Graco
Throat Seal Liquid (TSL) or compatible solvent. See
Fig. 5. Using the supplied wrench (104), adjust the
packing nut weekly so it is just snug; do not overtigh-
ten. Follow the Pressure Relief Procedure above
before adjusting the packing nut.
12 308149
Flushing the Pump
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 before using the pump.
WARNING
Before operating the pump, ground the system as
explained under FIRE AND EXPLOSION HAZARD
and Grounding on page 5.
(AIR-POWERED MODELS)
Starting and Adjusting the Pump
Supply fluid to the pump, per the requirements of your
system.
Refer to Fig. 3 on page 8. Be sure the air regulator
(F) is closed. Then open the pumps bleed-type master
air valve (E). Hold a metal part of the spray gun/dis-
pensing 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.
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 plug (35) slightly. Use the bleed hole, on the
underside of the valve body (34), as a priming valve
until the fluid appears at the hole. See Fig. 5. Close the
plug (35).
NOTE: When changing fluid containers with the hose
and gun already primed, open the bleeder valve plug
(35), to assist in priming the pump and venting air
before it enters the hose. Close the bleeder valve
when all air has been eliminated.
WARNING
To reduce the risk of fluid injection, do not use your
hand or fingers to cover the bleed hole when
priming the pump.
 Operation
(AIR-POWERED MODELS)
With the pump and lines primed, and with adequate air Always flush the pump before the fluid dries on the
pressure and volume supplied, the pump will start and displacement rod. Never leave water or water-based
stop as the gun/valve is opened and closed. In a fluid in the pump overnight. First, flush with water or a
circulating system, the pump will speed up or slow compatible solvent, then with mineral spirits. Relieve
down on demand, until the air supply is shut off. the pressure, but leave the mineral spirits in the pump
to protect the parts from corrosion.
Use the air regulator (F) to control the pump speed
and the fluid pressure. Always use the lowest air Model 222835 Shown
pressure necessary to get the desired results. Higher
pressures cause premature tip/nozzle and pump wear.

Bleed hole must

WARNING 1 face down.

To reduce the risk of overpressurizing your 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 3035)

Never allow the pump to run dry of the fluid being

pumped. A dry pump will quickly accelerate to a high
speed, possibly damaging itself. A pump runaway
valve (C), which shuts off the air supply to the pump if
the pump accelerates beyond the pre-set speed, is 2
available. See Fig. 3 on page 8. If your pump acceler-
ates quickly, or is running too fast, stop it immediately
and check the fluid supply. If the supply container is
34, 35 1
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.
104
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 12.

For overnight shutdown, relieve the pressure. Stop

the pump at the bottom of the stroke to prevent fluid
0913A
from drying on the exposed displacement rod and
damaging the throat packings. Fig. 5

308149 13
 Operation
(HYDRAULIC-POWERED MODELS)
Starting and Adjusting the Pump
Supply fluid to the pump, per the requirements of your
system.
Refer to Fig. 4 on page 10. Check the hydraulic fluid
level before each use, and add fluid as necessary.
Make certain that the supply line shutoff valve (U) and
the return line shutoff valve (V) are closed, then start
the hydraulic power supply.
Hold a metal part of the gun/valve (S) firmly to the side
of a grounded metal pail and hold the trigger open.
Open the return line shutoff valve (V) first, then slowly
open the supply line shutoff valve (U).
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
trigger safety. The pump should stall against pressure
when the trigger is released.
If the pump fails to prime properly, open the bleeder
valve (35) slightly. Use the bleed hole on the underside
of the valve body (34) as a priming valve until the fluid
appears at the hole. See Fig. 10. Close the plug (35).
NOTE: When changing fluid containers with the hose
and gun already primed, open the bleeder valve plug
(35), to assist in priming the pump and venting air
before it enters the hose. Close the bleeder valve
when all air has been eliminated.
WARNING
To reduce the risk of fluid injection, do not use your
hand or fingers to cover the bleed hole when
priming the pump.
With the pump and lines primed, and with adequate
hydraulic volume supplied, the pump will start and stop
as the gun/valve is opened and closed. In a circulating
system, the pump will speed up or slow down on
demand, until the hydraulic power supply is shut off.
Use the fluid pressure gauge (F) and flow control valve
(G) to control the pump speed and the fluid outlet
pressure. Always use the lowest hydraulic flow and
pressure necessary to get the desired results. Higher
pressures cause premature tip/nozzle and pump wear.
14 308149
WARNING
To reduce the risk of overpressurizing your system,
which could result in component rupture and cause
serious injury, never exceed 10 MPa, 103 bar
(1500 psi) Maximum Hydraulic Input Pressure to
the pump or 15.9 MPa, 159 bar (2300 psi) Maxi-
mum Fluid Working Pressure (see the Technical
Data on page 35).
To prevent overpressurizing the hydraulic motor or
its seals, always shut off the supply line valve (U)
first, then shut off the return line valve (V).
CAUTION
Do not allow the hydraulic oil temperature to exceed
54 C (130 F). The pump seals will wear faster and
leakage may occur if the pump is operated at higher
oil temperatures.
Never allow the pump to run dry of the fluid being
pumped. A dry pump will quickly accelerate to a high
speed, possibly damaging itself. If your pump acceler-
ates 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.
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 12.
For overnight shutdown, relieve the pressure. Stop
the pump at the bottom of the stroke to prevent fluid
from drying on the exposed displacement rod and
damaging the throat packings.
Always flush the pump before the fluid dries on the
displacement rod. Never leave water or water-based
fluid in the pump overnight. First, flush with water or a
compatible solvent, then with mineral spirits. Relieve
the pressure, but leave the mineral spirits in the pump
to protect the parts from corrosion.
 Troubleshooting
1. Relieve the pressure.
WARNING
2. Check all possible causes and problems before
To reduce the risk of serious injury whenever you disassembling the pump.
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.

PROBLEM CAUSE SOLUTION

Pump fails to operate Restricted line or inadequate air/hydraulic Clear; increase air/hydraulic supply.
supply; closed or clogged valves
Obstructed fluid hose or gun/valve;
fluid hose ID is too small
Fluid dried on the displacement rod
Dirty, worn, or damaged motor parts
Pump operates, but out- Restricted line or inadequate air/hydraulic Clear; increase air/hydraulic supply.
put low on both strokes supply; closed or clogged valves
Obstructed fluid hose or gun/valve;
fluid hose ID is too small
Bleeder valve open
Air leaking into supply container
Fluid too heavy for pump priming
Worn packings in displacement pump
Pump operates, but out- Fluid too heavy for pump priming
put low on downstroke
Held open or worn intake valve or seals
Pump operates, but out- Held open or worn piston valve or seals
put low on upstroke
Erratic or accelerated Exhausted fluid supply
pump speed
Fluid too heavy for pump priming
Held open or worn piston valve or seals
Held open or worn priming piston
Worn packings in displacement pump
Check that valves are open.
Open, clear*; use hose with larger ID.
Clean; always stop pump at bottom of stroke;
keep wet-cup 1/3 filled with compatible solvent.
Clean or repair; see separate motor manual.
Check that valves are open.
Open, clear*; use hose with larger ID.
Close.
Check ram plate seal.
Use bleeder valve (see pages 12 and 14); use ram.
Replace packings.
Use bleeder valve (see pages 12 and 14); use ram.
Clear valve; replace seals.
Clear valve; replace seals.
Refill and prime.
Use bleeder valve (see pages 12 and 14); use ram.
Clear valve; replace seals.
Clear; service.
Replace packings.

* To determine if the fluid hose or gun is obstructed, relieve the pressure. Disconnect the fluid hose and place a container at
the pump fluid outlet to catch any fluid. Turn on the air/hydraulic power just enough to start the pump. If the pump starts when
the air/hydraulic power is turned on, the obstruction is in the fluid hose or gun.

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

308149 15
 Service
1. Flush the pump, if possible. Stop the pump at the
WARNING bottom of its stroke. Relieve the pressure.

To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 12.
Required Tools

Torque wrench

Bench vise, with soft jaws

Rubber mallet

Hammer

O-ring pick

13 mm (1/2 in.) dia. brass rod

Set of socket wrenches

Set of adjustable wrenches

24 in. adjustable wrench

Thread lubricant

Thread sealant

Loctite 2760 or equivalent
NOTE: Service Tool 109508 is available as an acces-
sory. The tool fits over the top of the displacement rod,
making it easier to apply a 24 inch adjustable wrench
or 3/4 in. drive socket when connecting or disconnect-
ing the rod from the piston assembly.
Disconnecting the Displacement Pump
WARNING
Keep hands and fingers away from the priming
piston during operation and whenever the pump is
charged with air/hydraulic fluid to reduce the risk of
injury! On the pump downstroke the priming piston
extends beyond the intake housing to pull the
material into the pump. The priming piston works
under extreme force. During operation and when-
ever the pump is charged with air/hydraulic fluid,
the priming piston can severely injury or amputate
a hand or finger, or break a tool, caught between it
and the intake housing. Always relieve the pres-
sure before checking, clearing, cleaning, flushing,
or servicing any part of the pump.
2. Disconnect the air or hydraulic hose. Plug all
hydraulic hoses immediately, to prevent contami-
nation of the hydraulic system. Hold the fluid outlet
fitting (20) with a wrench to keep it from being
loosened while you disconnect the fluid hose.
3. Disconnect the displacement pump (105) from the
motor (101) as follows. Be sure to note the relative
position of the pumps fluid outlet to the air or
hydraulic inlet of the motor. If the motor does not
require servicing, leave it attached to its mounting.
CAUTION
Be sure to use at least two people when lifting,
moving, or disconnecting the pump. This pump is too
heavy for one person. If you are disconnecting the
displacement pump from a motor which is still
mounted (for example, on a ram), be sure to support
the displacement pump while it is being discon-
nected, to prevent it from falling and causing injury or
property damage. Do this by securely bracing the
pump, or by having at least two people hold it while
another disconnects it.
4. Using an adjustable wrench, unscrew the coupling
nut (103). Remove the coupling collars (108). Take
care not to lose or drop them. See Fig. 6.
5. Hold the tie rod flats with a wrench to keep the
rods from turning. Unscrew the nuts (106) from the
tie rods (107). Carefully remove the displacement
pump (105) from the motor (101).
6. Refer to page 19 for displacement pump service.
To service the air or hydraulic motor, refer to the
separate motor manual, supplied.

On King and Bulldog air-powered pumps, the air

motor piston (located behind the air motor shield)
moves when air is supplied to the motor. Never
operate the pump with the air motor shield re-
moved.

On Premier air-powered pumps, the rocker arms

(located beneath the rocker arm covers) move
when air is supplied to the motor. Never operate
the pump with the rocker arm covers removed.

Before servicing the pump, relieve the pressure to

prevent the pump from starting accidentally.
16 308149
 Service
King, Bulldog, and Premier Pumps
Viscount Pumps (Model 222940
(Model 222835 Shown)
Shown)

101

101

7 7

1 107 102 2 102 6

108 5 107
103 2 109 6

2 3

105 108

103 6

2 3
4 104
105
1 106 20

4 104

0914A 5 106 20

1 Torque to 129142 N.m (95105 ftlb). 5 Torque to 129142 N.m (95105 ftlb).

2 Torque to 196210 N.m (145155 ftlb). 6 Torque to 312340 N.m (230250 ftlb).

3 Torque to 135169 N.m (100125 ftlb). 7 Apply Loctite 2760 (or equivalent) to threads.
01403B
4 Square hole is for use with torque wrench.

Fig. 6

308149 17
 Service
Reconnecting the Displacement Pump
CAUTION
Be sure to use at least two people when lifting,
moving, or disconnecting the pump. This pump is too
heavy for one person. If you are disconnecting the
displacement pump from a motor which is still
mounted (for example, on a ram), be sure to support
the displacement pump while it is being discon-
nected, to prevent it from falling and causing injury or
property damage. Do this by securely bracing the
pump, or by having at least two people hold it while
another disconnects it.
NOTE: On Premier models, ensure that the rod adapt-
er (102) has not loosened during maintenance. Proper
torque is necessary to prevent the rod adapter from
loosening during the pump operation.
If the rod adapter (102) has loosened during mainte-
nance, remove the adapter and apply Loctite 2760
(or equivalent) to the rod adapter and air motor piston
threads, and then torque as specified in Fig. 6.
1. Use at least two people to hold the displacement
pump while another reconnects it to the motor (see
the CAUTION above). Orient the pumps fluid
outlet to the air or hydraulic inlet as was noted in
step 3 under Disconnecting the Displacement
Pump. Position the displacement pump (105) on
the tie rods (107). See Fig. 6.
18 308149
2. Screw the nuts (106) onto the tie rods (107) and
torque as noted in Fig. 6.
3. Place the coupling nut (103) on the displacement
rod (1), then place the coupling collars (108) into
the nut. Loosely screw the coupling nut onto the
connecting rod adapter (102) or connecting rod
(109, Model 222940 only). Hold the adapter or
connecting rod flats with a wrench to keep it from
turning. Use an adjustable wrench to tighten the
coupling nut. Torque as noted in Fig. 6.
4. Torque the packing nut (2) to 135169 N.m
(100125 ftlb).
5. Reconnect all hoses. Reconnect the ground wire if
it was disconnected. Fill the wet-cup (2) 1/3 full of
Graco Throat Seal Liquid or compatible solvent.
6. Turn on the air or hydraulic power supply. On
hydraulic pumps, open the hydraulic return line
valve first, then the supply line valve. Run the
pump slowly to ensure that it is operating properly.
 Service
Displacement Pump Disassembly
When disassembling the pump, lay out all the removed
parts in sequence, to ease reassembly. Clean all parts
with a compatible solvent and inspect them for wear or
damage. Refer to Fig. 10.
8. Place the flats of the displacement rod (1) in a
vise. Using a 13 mm (1/2 in.) diameter brass rod,
pry the intake check valve assembly away from
the rod guide (18) far enough to apply wrenches to
the valve assembly. See Fig. 7.

NOTE: Repair Kit 222860 is available to replace the

INTAKE CHECK VALVE
packings and seals. Parts included are denoted with
an asterisk, for example (7*). Repair Kit 222974 is
available to repair the intake valve. Parts included are 12
denoted with a symbol, for example (10). For the best 10
9
results, use all the new parts in the kits. Conversion Kit
222861 is available to convert the pump to all PTFE 18
v-packings, and Conversion Kit 222862 is available to
convert to leather v-packings. See page 29.

1. Remove the displacement pump from the air motor

as explained on page 16.

2. Hold the flats of the priming piston rod (12) with an 1

adjustable wrench, and use a second wrench to
unscrew the priming piston nut (14) from the rod. 1 13 mm (1/2 in.) Diameter Brass Rod.
Slide the priming piston (15) and guide (13) off the 6
01171
rod. Inspect the outer surface of the guide (13) and Fig. 7
the inner and outer surfaces of the piston (15) for
scoring, wear, or other damage.
9. Hold the valve body (10) steady with a wrench on
3. Stand the pump upright in a vise. Loosen the
the flats. Using an adjustable wrench, loosen the
packing nut (2) using the packing nut wrench (104)
intake packing nut (9) to decrease tension on the
supplied, or a hammer and brass rod. Using a
priming piston rod (12). Now slide the intake valve
socket wrench, remove the six capscrews (32).
assembly off the rod and set it aside. See Fig. 8.
4. Tap the underside of the outlet housing (19) with a
rubber mallet to loosen the housing from the
cylinder (4). Lift the outlet housing off the pump 12
2 3
and set it aside. Be careful not to scratch the
1 3
displacement rod (1) while removing the housing.
Remove the seal (39) from the top of the cylinder.

5. Lift the cylinder (4) up off the intake housing (17).

The displacement rod (1), piston assembly, intake
valve assembly, and priming piston rod (12) will
come with the cylinder.

6. Place the cylinder (4) sideways in a vise with soft

Hold valve body (10)
jaws. Using a rubber mallet on the end of the 1
steady.
priming piston rod (12), drive the displacement rod Loosen intake
2
(1) and piston assembly out the top of the cylinder. packing nut (9).
Continue to pull the rod out of the cylinder until the When reassembling
priming piston rod (12) comes free. 3
items 9 and 10,
torque to 97106 N.m
7. Remove the seal (39) from the bottom of the (7178 ftlb).
See page 22.
cylinder (4). Hold the cylinder up to the light at an 01172

angle to examine the inside surface for scoring or Fig. 8

damage.

308149 19
 Service
10. Pull the seal (39) and seat (11) out the top of the
intake housing (17). See Fig. 10. If the seat is
difficult to remove, turn the housing upside down
and drive the seat out using a hammer and brass
rod.
11. Examine the mating surfaces of the seat (11) and
the intake valve body (10) for damage.
12. Slide the rod guide (18) off the priming piston rod
(12). Unscrew the priming piston rod from the
piston (6). Run a finger over the surface of the rod
to check for scratches or scoring.
NOTE: Service Tool 109508 is available as an acces-
sory. The tool fits over the top of the displacement rod
(1), making it easier to apply a 24 inch adjustable
wrench or 3/4 in. drive socket when disconnecting the
rod from the piston (6).
13. Place the flats of the piston (6) in a vise. Unscrew
the displacement rod (1) from the piston (6). Lift
the piston seat and guide assembly off the piston.
Inspect the mating surfaces of the piston (6) and
piston seat (8) for damage. See the Detail in Fig.
10.
14. Remove the displacement rod (1) from the vise
and inspect it for scratches and scoring by running
a finger over the surface.
15. Place the piston seat and guide assembly in the
vise and close the jaws on the flats of the seat (8)
just tight enough to hold the part. Slide a brass rod
through the openings in the piston guide (5) and
unscrew it from the seat as shown in Fig. 9. Re-
move the piston seal (7).
20 308149
5
8
1 13 mm (1/2 in.) Diameter Brass Rod.
2 When reassembling items 5 and 8, ap-
ply thread sealant and torque to approx.
125137 N.m (92101 ftlb).
01173
Fig. 9
16. Take the intake valve assembly removed in step 9
and unscrew the packing nut (9) from the valve
body (10). Using an o-ring pick, remove the glands
(16, 41) and v-packings (40 and 42) from the valve
body. Remove the seal (43) from the packing nut.
See the Detail in Fig. 10.
NOTE: The seal (43) is press-fit in the packing nut and
may require cutting to ease removal.
17. Unscrew the bleeder valve plug (35) completely
from the valve housing (34). Clean the valve
threads and the bleed hole in the valve housing. It
is not necessary to remove the valve housing from
the outlet housing (19).
18. Remove the packing nut (2) from the outlet hous-
ing (19). Remove the throat packings (22, 24) and
glands (21, 23) from the outlet housing (19). Do
not remove the fluid outlet nipple (20) and o-ring
(25) from the outlet housing unless they need
replacement.
19. Inspect all parts for damage. Clean all parts and
threads with a compatible solvent. Reassemble as
explained on page 22.
 Service
THROAT PACKING DETAIL

1
DETAIL OF
21 PISTON CHECK VALVE

24
22 1
2
5
23 4

19 32
34 5 8
25
35 4
7
3 20
6

6
39
4 12
01120
1

DETAIL OF
INTAKE CHECK VALVE

2
16
42
40
42
Piston check valve 40 12
1 (see detail at right) 12
41
Intake check valve
2 (see detail at right)
39
3 Remove only if damaged.
4 Remove and clean plug. 17
5 Torque to 3038 Nm (2228 ft-lb) 9
6 Inspect mating surfaces.
18 43
13
0920A 17
15
39
14
11 10 6
01166A

Fig.
10

308149 21
 Service
Reassembly
Refer to Fig. 11 for reassembly.
1. Install the intake valve seat (11) in the intake
housing (17), with the large bevel of the seat
facing the bottom of the housing. Lubricate the
seal (39*) and install it in the housing. Set the
intake housing aside.
2. Install the piston seal (7*) on the piston seat (8).
Place the seat in a vise and close the jaws tight
enough to hold it securely, without placing too
much stress on the part. Apply thread sealant to
the threads of the seat and the piston guide (5).
Screw the guide onto the seat (8). Tighten using a
brass rod until the guide is securely seated,
approximately 125137 N.m (92101 ftlb). See
Figs. 9 and 11.
3. Place the flats of the piston (6) in a vise. Apply
thread sealant to the threads of the rod (1) and the
top threads of the piston. Set the piston seat/guide
assembly onto the piston.
NOTE: Service Tool 109508 is available as an acces-
sory. The tool fits over the top of the displacement rod
(1), making it easier to apply a 24 inch adjustable
wrench or 3/4 in. drive socket when connecting the rod
to the piston (6).
4. Screw the rod (1) into the piston (6) hand tight.
Torque the rod to 459481 N.m (338354 ftlb).
There will be a small gap between the top of the
piston (6) and the shoulder of the rod (1).
5. Apply thread sealant to the bottom threads of the
piston and the top threads of the priming piston rod
(12). Using an adjustable wrench on the flats of the
rod, screw the rod into the piston. Torque to
125137 N.m (92101 ftlb). Be careful not to
create burrs on the flats of the rod.
6. Slide the rod guide (18) onto the priming piston rod
(12), making certain that the end nearest the valve
stop (VS) goes on the rod first. See the Detail in
Fig. 11.
7. With the beveled side facing up, press the seal
(43*) into the recess of the intake packing nut (9)
until it snaps into place. The nose of the seal
should be flush with or slightly recessed into the
face of the packing nut.
22 308149
8. Lubricate the intake valve packings and the inner
diameter of the valve body (10). Install the pack-
ings one at a time in the following order, with the
lips of the v-packings facing up: the female
gland (41*), one PTFE v-packing (40*), one
UHMWPE v-packing (42*), PTFE(40*), UHMWPE
(42*), and the male gland (16*). Screw the intake
packing nut (9) into the valve body (10) handtight.
See the Detail in Fig. 11.
9. Slide the assembled intake valve onto the priming
piston rod (12), making certain that the packing nut
(9) goes on the rod first. Push the valve assembly
up the rod, stopping before it reaches the rod
guide (18).
10. Hold the valve body (10) steady with a wrench
while using an adjustable wrench to tighten the
packing nut (9). See Fig. 8. Torque to 97106 N.m
(7178 ftlb). Use a hammer and brass rod to
carefully drive the valve assembly further up the
rod until it reaches the stop (VS).
11. Remove the displacement rod (1) from the vise.
Place the cylinder (4) sideways in the vise with soft
jaws.
12. Lubricate the seal (39*) and place it on the bottom
of the cylinder (4). (The cylinder is symmetrical, so
either end can be the bottom.) See Fig. 11.
13. Slide the displacement rod (1), piston assembly,
intake valve assembly, and priming piston rod (12)
into the cylinder (4) from the bottom, until the
mating surfaces of the rod guide (18) and cylinder
(4) meet.
14. Put the intake housing (17) upright in a vise,
making sure it is off-center so there is sufficient
clearance for the priming piston rod (12) to be
lowered through the housing. Take the rod and
cylinder assembly and lower it into the intake
housing until the rod guide (18) bottoms on the
intake seat (11) and the priming piston rod (12)
protrudes from the bottom of the intake housing
(17).
15. Screw the bleeder valve plug (35) into the valve
housing. The plug has two sets of threads. When
reassembling, be sure to screw the plug fully into
the valve housing.
NOTE: It is not ordinarily necessary to remove the
outlet nipple (20) and o-ring (25*). However, if they
were replaced because of damage, lubricate the o-ring
(25*) and place it on the nipple (20). Screw the nipple
into the outlet housing (19). Torque to 156171 N.m
(115126 ftlb).
 Service
THROAT PACKING DETAIL

1 DETAIL OF
PISTON CHECK VALVE
*21
10 15 1
24* 5
2 14
*22 5
4
*23

8
19
34 16
*25 10 13 7*

3 20 6

10 13

*39 12
01120
4 32 12

Piston check valve

1 (see detail at right) DETAIL OF
Intake check valve INTAKE CHECK VALVE
2 (see detail at right) 39*
16*
Remove only if damaged.
3 Torque to 156171 N.m 2 42*
(115126 ftlb). 40*
42* 6
Screw plug completely
4 into valve housing. 12 40* 12
41* VS
Lips of v-packings must
5 face down.
6 Lips of v-packings must face up. 17 39*
7 Large bevel must face down.
8 Apply lubricant to inner diameter. 13
9 Flat side must face up.
9
10 Apply thread sealant.
15 9 18
11 Torque to 97106 N.m (7178 ftlb).
12 Torque to 244264 N.m (180195 ftlb). 43*
14 10 11 17
13 Torque to 125137 N.m (92101 ftlb).
14 Torque to 135169 N.m (100125 ftlb). *39
15 Torque to 459481 N.m (338354 ftlb).
0920A 7 11 8 10 01166A
16 Torque to 3038 N.m (2228 ft-lb).

Fig. 11
308149 23
 Service
16. Lubricate the throat packings and glands, and 12
install them in the outlet housing (19) one at a time
in the following order, with the lips of the v-pack-
ings facing down: the male gland (23*), one
UHMWPE v-packing (22*), one PTFE v-packing
(24*), UHMWPE (22*), PTFE(24*), UHMWPE
(22*), and the female gland (21*). Apply thread
lubricant to the packing nut (2) and install it loosely
in the outlet housing.

17. Lubricate the seal (39*) and place it on the top 13

edge of the cylinder (4). Set the outlet housing (19)
on top of the cylinder.

18. Install the six long capscrews (32) through the

outlet housing (19) and into the intake housing 1 15 14 2 3
(17). Using a socket wrench, torque the screws
oppositely and evenly to 244264 N.m (180195 1 Flat side must face up.
ftlb). Remove the pump from the vise and place it 2 Apply thread sealant.
on its side. 3 Torque to 97106 N.m (7178 ftlb).

19. Check that the flats of the priming piston rod (12) 01165

are accessible below the intake housing (17). If Fig. 12

not, tap on the top of the displacement rod (1) with
a rubber mallet, until the flats are exposed.

20. Slide the priming piston guide (13) onto the rod
(12) until it stops. Then install the priming piston
(15), with the flat side facing up toward the pump. 21. Reconnect the displacement pump to the air motor
Apply thread sealant to the threads of the priming as explained on page 18.
piston nut (14). Hold the rod (12) steady with an
adjustable wrench on the flats, and screw the nut
(14) onto the rod with another wrench. Torque to 22. Allow 2 hours for the thread sealant to cure before
97106 N.m (7178 ftlb). See Fig. 12. returning the pump to service.

24 308149
 Parts
Model 222828 Pump, Series A Model 222829 Pump, Series A
Model 246935 Pump, Series A 12:1 Ratio, with Quiet Bulldog Air Motor
12:1 Ratio, with Bulldog Air Motor

101 101

102
107
102 107

108 108

103 103

106 106

105 105

104 104

0917A 0918A

Ref Part
No. No. Description Qty
Ref Part
101 208356 AIR MOTOR, Bulldog No. No. Description Qty
See 307049 for parts 1
102 184451 ADAPTER, connecting rod 1 101 215255 AIR MOTOR, Bulldog, quiet
103 184096 NUT, coupling 1 See 307304 for parts 1
104 184278 WRENCH, packing nut 1 102 184451 ADAPTER, connecting rod 1
105 222810 PUMP, displacement (222828 only) 103 184096 NUT, coupling 1
See pages 2829 for parts 1 104 184278 WRENCH, packing nut 1
105 246934 PUMP, displacement (246935 only) 105 222810 PUMP, displacement
See pages 2829 for parts 1 See pages 2829 for parts 1
106 106166 NUT, hex; M16 x 2.0 3 106 106166 NUT, hex; M16 x 2.0 3
107 184452 ROD, tie; 265 mm (10.43) 107 184452 ROD, tie; 265 mm (10.43)
shoulder to shoulder 3 shoulder to shoulder 3
108 184130 COLLAR, coupling 2 108 184130 COLLAR, coupling 2

 These parts are included in Connection Kit 235414, which  These parts are included in Connection Kit 235414, which
may be purchased separately. may be purchased separately.
308149 25
 Parts
Model 222835 Pump, Series B Model 222901 Pump, Series B
Model 246936 Pump, Series A 24:1 Ratio, with Quiet King Air Motor
24:1 Ratio, with King Air Motor

101
101

102
107 102
107

108
108

103
103

106
106

105
105

104
104

0914A 0915A

Ref Part
No. No. Description Qty
Ref Part
101 245111 AIR MOTOR, King No. No. Description Qty
See 309347 for parts 1
102 184451 ADAPTER, connecting rod 1 101 220106 AIR MOTOR, King, quiet
103 184096 NUT, coupling 1 See 309348 for parts 1
104 184278 WRENCH, packing nut 1 102 184451 ADAPTER, connecting rod 1
105 222810 PUMP, displacement (222835 only) 103 184096 NUT, coupling 1
See pages 2829 for parts 1 104 184278 WRENCH, packing nut 1
105 246934 PUMP, displacement (246936 only) 105 222810 PUMP, displacement
See pages 2829 for parts 1 See pages 2829 for parts 1
106 106166 NUT, hex; M16 x 2.0 3 106 106166 NUT, hex; M16 x 2.0 3
107 184452 ROD, tie; 265 mm (10.43) 107 184452 ROD, tie; 265 mm (10.43)
shoulder to shoulder 3 shoulder to shoulder 3
108 184130 COLLAR, coupling 2 108 184130 COLLAR, coupling 2

 These parts are included in Connection Kit 235414, which  These parts are included in Connection Kit 235414, which
may be purchased separately. may be purchased separately.
26 308149
 Parts
Model 222940 Pump, Series A Model 222902 Pump, Series B
39:1 Ratio, with Premier Air Motor Model 246937 Pump, Series A
with Viscount Hydraulic Motor

101
101

107 102
102
109 107

108

103
108

103 106

106 105

105

104

0916A

104 01403B

Ref Part
Ref Part No. No. Description Qty
No. No. Description Qty
101 235345 HYDRAULIC MOTOR, Viscount
101 222800 AIR MOTOR, Premier See 307158 for parts 1
See 308213 for parts 1 102 184595 ADAPTER, connecting rod 1
102 184582 ADAPTER, connecting rod 1 103 184096 NUT, coupling 1
103 184096 NUT, coupling 1 104 184278 WRENCH, packing nut 1
104 184278 WRENCH, packing nut 1 105 222810 PUMP, displacement (222902 only)
105 222810 PUMP, displacement See pages 2829 for parts 1
See pages 2829 for parts 1 105 246934 PUMP, displacement (246937 only)
106 106166 NUT, hex; M16 x 2.0 3 See pages 2829 for parts 1
107 184381 ROD, tie; 560 mm (22.06) 106 106166 NUT, hex; M16 x 2.0 3
shoulder to shoulder 3 107 184596 ROD, tie; 315 mm (12.40)
108 184130 COLLAR, coupling 2 shoulder to shoulder 3
109 184556 ROD, connecting 1 108 184130 COLLAR, coupling 2

 These parts are included in Connection Kit 235421, which  These parts are included in Connection Kit 222976, which
may be purchased separately. may be purchased separately.
308149 27
 Parts
Model 222810, Series B
Model 246934, Series A
Displacement Pump

2 12
1
32

*21 43*
*22 24* 9
*23 *16

*42 40*
19 34 5 41*
10
*25 7*
39*
20
8 11
35

*39 6
17

4
18

13
*39
15
14
0919A

28 308149
 Parts
Model 222810, Series B * These parts are included in Repair Kit 222860, which may
be purchased separately.
Model 246934, Series A
Displacement Pump  These parts are included in Intake Valve Repair Kit
Ref Part 222974, which may be purchased separately. (The kit
No. No. Description Qty includes one seal, item 39.)
1 184002 ROD, displacement; sst 1 Replacement Danger and Warning labels, tags and cards
2 184006 PACKING NUT/WET-CUP; are available at no cost.
carbon steel (222810 only) 1
2 246965 PACKING NUT/WET-CUP;  These parts are included in Repair Kit 234419, which may
carbon steel (246934 only) 1 be purchased separately.
4 184393 CYLINDER, pump; sst 1
5 184394 GUIDE, piston; sst 1
6 184441 PISTON; sst 1
PTFE Packing Conversion Kit 222861
7* 184395 SEAL, piston; UHMWPE 1 Use to convert the pump to all PTFE throat and intake
8 184444 SEAT, piston; sst 1 packings. Must be purchased separately. Includes instruc-
9 189727 NUT, packing, intake valve; tions.
carbon steel 1
10 184496 VALVE BODY, intake; carbon steel 1
11 184495 SEAT, intake valve; carbon steel 1
Leather Packing Conversion Kit 222862
12 184400 ROD, priming piston; sst 1 Use to convert the pump to leather throat and intake pack-
13 189988 GUIDE, priming piston; sst 1 ings, with a PTFE backup. Must be purchased separately.
14 112733 NUT, priming piston; carbon steel 1 Includes instructions.
15 190276 PISTON, priming; carbon steel 1
16* 184221 GLAND, intake valve, male; sst 1
17 184413 HOUSING, intake; ductile iron 1
Ink Pump Conversion Kit 249032
18 184415 GUIDE, rod; sst 1 Use to convert the pump from 222810 style to 246934 style.
19 222920 HOUSING, outlet; ductile iron 1
20 184279 FITTING, outlet; 11/2 npt(m) x
M42 x 20; carbon steel 1
21* 184185 GLAND, throat, female; sst 1
22* 109265 V-PACKING, throat; UHMWPE 3
23* 184235 GLAND, throat, male; sst 1
24* 109315 V-PACKING, throat; PTFE
(222810 only) 2
24 109317 V-PACKING, throat; PTFE
(246934 only) 2
25* 109213 O-RING; PTFE 1
32 109203 SCREW, cap, hex hd; 5/811 unc2A x
12 (305 mm) 6
34 165702 BODY, bleeder valve; 3/818 npt x
1/220 unf-2b 1
35 190128 PLUG, valve; 1/220 unf-2a 1
39* 184072 SEAL; Acetal 3
40* 109301 V-PACKING, intake valve; PTFE 2
41* 184171 GLAND, intake valve, female; sst 1
42* 109251 V-PACKING, intake valve; UHMWPE 2
43* 189724 SEAL; UHMWPE 1
44 184090 PLATE, warning (not shown) 1
45 184293 PLATE, warning (not shown) 1
46 172477 TAG, warning (not shown) 1
47 172479 TAG, warning (not shown) 1

308149 29
 Technical Data
(Model 222828 and 246935 Bulldog Pump)
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12:1 (Standard Bulldog Air Motor)
Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 MPa, 83 bar (1200 psi)
Maximum air input pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 MPa, 7 bar (100 psi)
Pump cycles per 3.8 liters (1 gal.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Recommended pump speed for continuous operation . . . . . . . . . . . . . . . . . . 60 cycles per min
Maximum flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.5 liters/min (7.5 gpm) at 60 cycles/min
Air motor piston effective area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 cm (38.5 in.)
Stroke length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 mm (4.75 in.)
Displacement pump effective area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 cm (3.255 in.)
Maximum pump operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.5C (150F)
Air inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm(f)
Fluid outlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/2 npt(m)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 65 kg (142 lb)
Displacement Pump Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 37 kg (81 lb)
Wetted parts . . . . . . . . . . . . . . . . Carbon Steel; Chrome, Zinc, and Electroless Nickel Plating;
304 and 174 PH Grades of Stainless Steel; E52100 Alloy Steel;
Ductile Iron; Acetal; PTFE; Ultra-High Molecular Weight Polyethylene

KEY: Fluid Outlet Pressure Black Curves A 0.7 MPa, 7 bar (100 psi) Air Pressure
Air Consumption Gray Curves B 0.49 MPa, 4.9 bar (70 psi) Air Pressure
C 0.28 MPa, 2.8 bar (40 psi) Air Pressure
NOTE: Recommended pump speed for continuous operation
(to shaded area): 60 cpm

psi psi
bar cycles/min bar cycles/min
MPa 16 32 48 60 64 80 MPa 8 16 24 32 40
1200 scfm 1200 scfm
84 m
/min 84 m
/min
8.4 8.4
A
200 200
1000 1000 A
70 5.60 70 5.60
7.0 7.0
160 160
800 800
56 4.48 56 4.48
B A
5.6 5.6 B
600 120 600 120
3.36 3.36
42 B 42
4.2 4.2
400 C 80 400 80
C
28 2.24 28 A 2.24
2.8 C 2.8
200 40 200 B 40
14 1.12 14 1.12
1.4 1.4
C
0 0
gpm 0 2 4 6 8 10 gpm 0 1 2 3 4 5
liters/min 7.6 15.2 22.8 30.4 38.0 liters/min 3.8 7.6 11.4 15.2 19.0

FLUID FLOW FLUID FLOW

(TEST FLUID: 100,000 CENTIPOISE SEALANT) (TEST FLUID: 4,000,000 CENTIPOISE SILICON)

To find Fluid Outlet Pressure (MPa/bar/psi) at a specific fluid flow To find Pump Air Consumption (m
/min or scfm) at a specific fluid
(lpm/gpm) and operating air pressure (MPa/bar/psi): flow (lpm/gpm) and air pressure (MPa/bar/psi):
1. Locate desired flow along bottom of chart.
1. Locate desired flow along bottom of chart.
2. Follow vertical line up to intersection with selected fluid outlet
pressure curve (black). Follow left to scale to read fluid outlet 2. Read vertical line up to intersection with selected air consumption
pressure. curve (gray). Follow right to scale to read air consumption.

30 308149
 Technical Data
(Model 222829 Quiet Bulldog Pump)
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12:1 (Quiet Bulldog Air Motor)
Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 MPa, 83 bar (1200 psi)
Maximum air input pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 MPa, 7 bar (100 psi)
Pump cycles per 3.8 liters (1 gal.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Recommended pump speed for continuous operation . . . . . . . . . . . . . . . . . . 60 cycles per min
Maximum flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.5 liters/min (7.5 gpm) at 60 cycles/min
Air motor piston effective area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 cm (38.5 in.)
Stroke length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 mm (4.75 in.)
Displacement pump effective area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 cm (3.255 in.)
Maximum pump operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.5C (150F)
Air inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm(f)
Fluid outlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/2 npt(m)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 65 kg (142 lb)
Displacement Pump Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 37 kg (81 lb)
Wetted parts . . . . . . . . . . . . . . . . Carbon Steel; Chrome, Zinc, and Electroless Nickel Plating;
304 and 174 PH Grades of Stainless Steel; E52100 Alloy Steel;
Ductile Iron; Acetal; PTFE; Ultra-High Molecular Weight Polyethylene

KEY: Fluid Outlet Pressure Black Curves A 0.7 MPa, 7 bar (100 psi) Air Pressure
Air Consumption Gray Curves B 0.49 MPa, 4.9 bar (70 psi) Air Pressure
C 0.28 MPa, 2.8 bar (40 psi) Air Pressure
NOTE: Recommended pump speed for continuous operation
(to shaded area): 60 cpm
psi psi
bar cycles/min bar cycles/min
MPa 16 32 48 60 64 80 MPa 8 16 24 32 40
1200 scfm 1200 scfm
84 m
/min 84 m
/min
8.4 8.4
A 200 200
1000 1000
70 5.60 70 A 5.60
7.0 7.0
160 160
800 800
56 4.48 56 4.48
5.6
B A
5.6 B
600 120 600 120
42 3.36 42 3.36
B
4.2 4.2
400 C 80 400 80
28 2.24 28
C 2.24
2.8
C 2.8 A
B
200 40 200 40
14 1.12 14 1.12
1.4 1.4
C
0 0
gpm 0 2 4 6 8 10 gpm 0 1 2 3 4 5
liters/min 7.6 15.2 22.8 30.4 38.0 liters/min 3.8 7.6 11.4 15.2 19.0

FLUID FLOW FLUID FLOW

(TEST FLUID: 100,000 CENTIPOISE SEALANT) (TEST FLUID: 4,000,000 CENTIPOISE SILICON)

To find Fluid Outlet Pressure (MPa/bar/psi) at a specific fluid flow To find Pump Air Consumption (m
/min or scfm) at a specific fluid
(lpm/gpm) and operating air pressure (MPa/bar/psi): flow (lpm/gpm) and air pressure (MPa/bar/psi):
1. Locate desired flow along bottom of chart.
1. Locate desired flow along bottom of chart.
2. Follow vertical line up to intersection with selected fluid outlet
pressure curve (black). Follow left to scale to read fluid outlet 2. Read vertical line up to intersection with selected air consumption
pressure. curve (gray). Follow right to scale to read air consumption.

308149 31
 Technical Data
(Model 222835 and 246936 King Pump)
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24:1 (Standard King Air Motor)
Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6 MPa, 166 bar (2400 psi)
Maximum air input pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 MPa, 7 bar (100 psi)
Pump cycles per 3.8 liters (1 gal.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Recommended pump speed for continuous operation . . . . . . . . . . . . . . . . . . 50 cycles per min
Maximum flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.75 liters/min (6.25 gpm) at 50 cycles/min
Air motor piston effective area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506 cm (78.5 in.)
Stroke length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 mm (4.75 in.)
Displacement pump effective area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 cm (3.255 in.)
Maximum pump operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.5C (150F)
Air inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm(f)
Fluid outlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/2 npt(m)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 73 kg (160 lb)
Displacement Pump Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 37 kg (81 lb)
Wetted parts . . . . . . . . . . . . . . . . Carbon Steel; Chrome, Zinc, and Electroless Nickel Plating;
304 and 174 PH Grades of Stainless Steel; E52100 Alloy Steel;
Ductile Iron; Acetal; PTFE; Ultra-High Molecular Weight Polyethylene

KEY: Fluid Outlet Pressure Black Curves A 0.63 MPa, 6.3 bar (90 psi) Air Pressure
Air Consumption Gray Curves B 0.49 MPa, 4.9 bar (70 psi) Air Pressure
C 0.28 MPa, 2.8 bar (40 psi) Air Pressure
NOTE: Recommended pump speed for continuous operation
(to shaded area): 50 cpm

psi psi
bar cycles/min scfm bar cycles/min scfm
MPa 16 32 48 50 64 80 m
/min MPa 8 16 24 32 40 m
/min
2000 300 2000 300
140 A 8.40 140 8.40
14.0 14.0 A
1600 A 240 1600 240
112 6.72 112 6.72
11.2
B 11.2 B
1200 180 1200 180
84
B 5.04 5.04
84
8.4 8.4

800 C 120 800 C

120
C 3.36 3.36
56 56 A
5.6 5.6 B

400 60 400 60
28 1.68 28 C 1.68
2.8 2.8

0 0
gpm 0 2 4 6 8 10 gpm 0 1 2 3 4 5
liters/min 7.6 15.2 22.8 30.4 38.0 liters/min 3.8 7.6 11.4 15.2 19.0

FLUID FLOW FLUID FLOW

(TEST FLUID: 100,000 CENTIPOISE SEALANT) (TEST FLUID: 4,000,000 CENTIPOISE SILICON)

To find Fluid Outlet Pressure (MPa/bar/psi) at a specific fluid flow To find Pump Air Consumption (m
/min or scfm) at a specific fluid
(lpm/gpm) and operating air pressure (MPa/bar/psi): flow (lpm/gpm) and air pressure (MPa/bar/psi):
1. Locate desired flow along bottom of chart.
1. Locate desired flow along bottom of chart.
2. Follow vertical line up to intersection with selected fluid outlet
pressure curve (black). Follow left to scale to read fluid outlet 2. Read vertical line up to intersection with selected air consumption
pressure. curve (gray). Follow right to scale to read air consumption.

32 308149
 Technical Data
(Model 222901 Quiet King Pump)
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24:1 (Quiet King Air Motor)
Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6 MPa, 166 bar (2400 psi)
Maximum air input pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 MPa, 7 bar (100 psi)
Pump cycles per 3.8 liters (1 gal.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Recommended pump speed for continuous operation . . . . . . . . . . . . . . . . . . 50 cycles per min
Maximum flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.75 liters/min (7.5 gpm) at 50 cycles/min
Air motor piston effective area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506 cm (78.5 in.)
Stroke length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 mm (4.75 in.)
Displacement pump effective area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 cm (3.255 in.)
Maximum pump operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.5C (150F)
Air inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm(f)
Fluid outlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/2 npt(m)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 73 kg (160 lb)
Displacement Pump Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 37 kg (81 lb)
Wetted parts . . . . . . . . . . . . . . . . Carbon Steel; Chrome, Zinc, and Electroless Nickel Plating;
304 and 174 PH Grades of Stainless Steel; E52100 Alloy Steel;
Ductile Iron; Acetal; PTFE; Ultra-High Molecular Weight Polyethylene

KEY: Fluid Outlet Pressure Black Curves A 0.63 MPa, 6.3 bar (90 psi) Air Pressure
Air Consumption Gray Curves B 0.49 MPa, 4.9 bar (70 psi) Air Pressure
C 0.28 MPa, 2.8 bar (40 psi) Air Pressure
NOTE: Recommended pump speed for continuous operation
(to shaded area): 50 cpm

psi psi
bar cycles/min scfm bar cycles/min scfm
MPa MPa
16 32 48 50 64 80 m
/min 8 16 24 32 40 m
/min
2000 300 2000 300
140 A 8.40 140 8.40
14.0 14.0
A
1600 A 240 1600 240
112 6.72 112 6.72
11.2 B 11.2
B
1200 180 1200 180
84 5.04 84 5.04
B
8.4 8.4

120 120
800 C 800 C
3.36 3.36
56 C 56 A
5.6 5.6 B

400 60 400 60
28 1.68 28 C 1.68
2.8 2.8

0 0
gpm 0 2 4 6 8 10 gpm 0 1 2 3 4 5
liters/min 7.6 15.2 22.8 30.4 38.0 liters/min 3.8 7.6 11.4 15.2 19.0

FLUID FLOW FLUID FLOW

(TEST FLUID: 100,000 CENTIPOISE SEALANT) (TEST FLUID: 4,000,000 CENTIPOISE SILICON)

To find Fluid Outlet Pressure (MPa/bar/psi) at a specific fluid flow To find Pump Air Consumption (m
/min or scfm) at a specific fluid
(lpm/gpm) and operating air pressure (MPa/bar/psi): flow (lpm/gpm) and air pressure (MPa/bar/psi):
1. Locate desired flow along bottom of chart.
1. Locate desired flow along bottom of chart.
2. Follow vertical line up to intersection with selected fluid outlet
pressure curve (black). Follow left to scale to read fluid outlet 2. Read vertical line up to intersection with selected air consumption
pressure. curve (gray). Follow right to scale to read air consumption.

308149 33
 Technical Data
(Model 222940 Premier Pump)
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39:1 (Premier Air Motor)
Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 26.9 MPa, 269 bar (3900 psi)
Maximum air input pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 MPa, 7 bar (100 psi)
Pump cycles per 3.8 liters (1 gal.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Recommended pump speed for continuous operation . . . . . . . . . . . . . . . . . . 50 cycles per min
Maximum flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.75 liters/min (6.25 gpm) at 50 cycles/min
Air motor piston effective area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 cm (38.5 in.)
Stroke length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 mm (4.75 in.)
Displacement pump effective area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 cm (3.255 in.)
Maximum pump operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.5C (150F)
Air inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm(f)
Fluid outlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/2 npt(m)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 113 kg (248 lb)
Displacement Pump Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 37 kg (81 lb)
Wetted parts . . . . . . . . . . . . . . . . Carbon Steel; Chrome, Zinc, and Electroless Nickel Plating;
304 and 174 PH Grades of Stainless Steel; E52100 Alloy Steel;
Ductile Iron; Acetal; PTFE; Ultra-High Molecular Weight Polyethylene

KEY: Fluid Outlet Pressure Black Curves A 0.7 MPa, 7 bar (100 psi) Air Pressure
Air Consumption Gray Curves B 0.49 MPa, 4.9 bar (70 psi) Air Pressure
NOTE: Recommended pump speed for continuous operation C 0.28 MPa, 2.8 bar (40 psi) Air Pressure
(to shaded area): 50 cpm

psi psi
bar cycles/min bar cycles/min
MPa 16 32 48 50 64 80 MPa 8 16 24 32 40
4000 4000
280 280
28.0 scfm 28.0 scfm
3500 m
/min 3500 m
/min
245 245
24.5 A 24.5 A
3000 300 3000 300
210 8.40 210 8.40
21.0 A 21.0
2500 250 2500 250
175 7.00 175 7.00
17.5 B 17.5 B
2000 200 2000 200
140
B 5.60 140 5.60
14.0 14.0
1500 150 1500 150
105 4.20 105 4.20
10.5 C 10.5 C A
C 100 100
1000 1000
70 2.80 70 B 2.80
7.0 7.0
500 50 500 50
35 1.40 35 C 1.40
3.5 3.5
0 0
gpm 0 2 4 6 8 10 gpm 0 1 2 3 4 5
liters/min 7.6 15.2 22.8 30.4 38.0 liters/min 3.8 7.6 11.4 15.2 19.0

FLUID FLOW FLUID FLOW

(TEST FLUID: 100,000 CENTIPOISE SEALANT) (TEST FLUID: 4,000,000 CENTIPOISE SILICON)

To find Fluid Outlet Pressure (MPa/bar/psi) at a specific fluid flow To find Pump Air Consumption (m
/min or scfm) at a specific fluid
(lpm/gpm) and operating air pressure (MPa/bar/psi): flow (lpm/gpm) and air pressure (MPa/bar/psi):
1. Locate desired flow along bottom of chart.
1. Locate desired flow along bottom of chart.
2. Follow vertical line up to intersection with selected fluid outlet
pressure curve (black). Follow left to scale to read fluid outlet 2. Read vertical line up to intersection with selected air consumption
pressure. curve (gray). Follow right to scale to read air consumption.

34 308149
 Technical Data
(Model 222902 and 246937 Viscount Pump)
Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 15.9 MPa, 159 bar (2300 psi)
Maximum hydraulic oil input pressure . . . . . . . . . . . . . . . . . . . . . . 10.5 MPa, 105 bar (1500 psi)
Pump cycles per 3.8 liters (1 gal.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Recommended pump speed for continuous operation . . . . . . . . . . . . . . . . . . 60 cycles per min
Maximum flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.5 liters/min (7.5 gpm) at 60 cycles/min
Hydraulic motor piston effective area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.6 cm (4.9 in.)
Stroke length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 mm (4.75 in.)
Displacement pump effective area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 cm (3.255 in.)
Maximum pump operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.5C (150F)
Hydraulic oil inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt(f)
Fluid outlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/2 npt(m)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 89 kg (196 lb)
Displacement Pump Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 37 kg (81 lb)
Wetted parts . . . . . . . . . . . . . . . . Carbon Steel; Chrome, Zinc, and Electroless Nickel Plating;
304 and 174 PH Grades of Stainless Steel; E52100 Alloy Steel;
Ductile Iron; Acetal; PTFE; Ultra-High Molecular Weight Polyethylene

KEY: Fluid Outlet Pressure Black Curves A 10.5 MPa, 105 bar (1500 psi) Hydraulic Oil Pressure
Hydraulic Oil Consumption Gray Curves B 7.4 MPa, 74 bar (1050 psi) Hydraulic Oil Pressure
C 4.2 MPa, 42 bar (600 psi) Hydraulic Oil Pressure
NOTE: Recommended pump speed for continuous operation
(to shaded area): 60 cpm

psi psi
bar cycles/min bar cycles/min
MPa MPa
16 32 48 60 64 80 gpm 8 16 24 32 40 gpm
2400 lpm 2400 lpm
168 (hyd. 168 (hyd.
16.8 oil) 16.8 oil)
A
2000 20 2000 20
140 76.0 140 76.0
14.0 14.0
1600 16 1600 A 16
112 60.8 112 60.8
11.2 B 11.2
1200 12 1200
B 12
84 45.6 84 45.6
hydraulic oil
8.4 8.4
consumption
8 8
800 C 800
56 30.4 56 C 30.4
5.6 5.6

400 4 400 hydraulic oil 4

28 15.2 28 consumption 15.2
2.8 2.8

0 0
gpm 0 2 4 6 8 10 gpm 0 1 2 3 4 5
liters/min 7.6 15.2 22.8 30.4 38.0 liters/min 3.8 7.6 11.4 15.2 19.0

FLUID FLOW FLUID FLOW

(TEST FLUID: 100,000 CENTIPOISE SEALANT) (TEST FLUID: 4,000,000 CENTIPOISE SILICON)

To find Fluid Outlet Pressure (MPa/bar/psi) at a specific fluid flow
(lpm/gpm) and operating hydraulic oil pressure (MPa/bar/psi):
1. Locate desired flow along bottom of chart.
2. Follow vertical line up to intersection with selected fluid outlet
pressure curve (black). Follow left to scale to read fluid outlet
pressure.
To find Pump Hydraulic Oil Consumption (lpm or gpm) at a specific
fluid flow (lpm/gpm) and hydraulic oil pressure (MPa/bar/psi):
1. Locate desired flow along bottom of chart.
2. Read vertical line up to intersection with oil consumption curve
(gray). Follow right to scale to read oil consumption.

308149 35
 Dimensions

Model 222835 Shown

E
C
D

0913

Pump Model A B C D E
222828, 1333.6 mm 540.5 mm 793.1 mm 664.7 mm 256.8 mm
246935 (52.5 in.) (21.28 in.) (31.22 in.) (26.17 in.) (10.11 in.)
222829 1349.1 mm 556 mm 793.1 mm 664.7 mm 256.8 mm
(53.11 in.) (21.89 in.) (31.22 in.) (26.17 in.) (10.11 in.)
222835, 1376.1 mm 583 mm 793.1 mm 664.7 mm 256.8 mm
246936 (54.18 in.) (22.95 in.) (31.22 in.) (26.17 in.) (10.11 in.)
222901 1385.6 mm 592.5 mm 793.1 mm 664.7 mm 256.8 mm
(54.55 in.) (23.33 in.) (31.22 in.) (26.17 in.) (10.11 in.)
222940 1530.7 mm 428.8 mm 1101.9 mm 969.5 mm 565.1 mm
(60.31 in.) (16.89 in.) (43.41 in.) (38.20 in.) (22.26 in.)
222902, 1415.3 mm 622.2 mm 793.1 mm 664.7 mm 256.8 mm
246937 (55.72 in.) (24.5 in.) (31.22 in.) (26.17 in.) (10.11 in.)

36 308149
 Mounting Hole Layouts
Bulldog, King, and Viscount Pumps
94.28 mm
(3.712)

101.6 mm 94.28 mm
(4.0) (3.712)

50.8 mm
(2.0)

11.1 mm
(0.437)
DIA (4)

Three M16 x 2.0

Holes 88 mm
(3.464)

0653

Premier Pumps

135.0 mm 67.5 mm
(5.3 in.) (2.7 in.)

116.9 mm
(4.6 in.)

87.9 mm
(3.5 in.)

Three M16 x 2.0 Holes

Three 3/816 Mounting Studs

101.5 mm 50.7 mm
(4.0 in.) (2.0 in.) 06555

308149 37
 Graco Standard Warranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the
date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco,
Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be
defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Gracos written
recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub-
stitution of nonGraco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Gracos sole obligation and buyers sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.

Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide
purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais-
sent avoir convenu que la rdaction du prsente document sera en Anglais, ainsi que tous documents, avis et procdures judiciaires
excuts, donns ou intents la suite de ou en rapport, directement ou indirectement, avec les procedures concernes.

Graco Information
TO PLACE AN ORDER, contact your Graco distributor, or call one of the following numbers
to identify the distributor closest to you:
18003280211 Toll Free
6126236921
6123783505 Fax

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.

MM 308149

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 554401441

www.graco.com
PRINTED IN U.S.A. 308149 05/1992, Revised 4/2006
38 308149
 R

HYDRAULIC GEAR PUMPS AND MOTORS

'RPMC' Series
SINGLE MOTOR
SINGLE REVERSIBLE PUMP

Performance
Data
DISPLACEMENT/REVOLUTION IN-LB TORQUE HP/OUT
MODEL (THEORETICAL) @ 2400 RPM & @ 2400 MAX.
SIZE
U.S. CUBIC CUBIC RPM 2500 PSI RPM & PRESSURE
GALLONS INCHES CENT. MIN. MAX. START RUN 2500 PSI PSI BAR
RPMC45 .0038 0.88 14.4 600 3600 241 301 11 3500 241
RPMC65 .0055 1.27 20.8 600 3600 347 434 16 3500 241
RPMC85 .0072 1.66 27.2 600 3400 455 569 22 3500 241
RPMC100 .0085 1.96 32.1 600 3300 535 669 25 3500 241
RPMC115 .0097 2.24 36.7 600 3100 615 769 29 3000 207
RPMC150 .0127 2.93 48.1 600 2800 802 1003 38 2500 172
RPMC180 .0152 3.51 57.5 600 2500 962 1203 46 2500* 172
RPMC200 .0169 3.90 63.9 600 2200 1069 1337 51 2500* 172
* CONSULT FACTORY WITH TYPE APPLICATION
PRESSURES MAY BE LIMITED TO SHAFT TYPE

CAST IRON THROUGHOUT VARIOUS SHAFT, FLANGE AND PORT OPTIONS

PRESSURES TO 3500 PSI
FLOWS TO 37 GPM
HEAVY DUTY SLEEVE TYPE BEARINGS
DOUBLE VITON R SHAFT SEALS STANDARD
PRESSURE COMPENSATED THRUST PLATES
DESIGNED FOR HEAVY DUTY APPLICATIONS
SINGLE AND MULTI-STAGE CONFIGURATIONS
PRECISION GEARS MACHINED FROM SOLID BAR STOCK
COMPATIBLE WITH MOST FIRE RESISTANT FLUIDS
CONTAMINANT RESISTANT
COMPUTER DESIGNED AND MANUFACTURED
QUALITY CERTIFIED
FLEXIBLE DESIGN FOR NEW OR OEM REPLACEMENTS
SERVICE SUPPORTED BY DEDICATION AND INVENTORY

P. O. BOX 2160, 1506 FULTON DR.

CORINTH, MISSISSIPPI 38835
Phone: 662/286-2252 Fax: 662/287-6580 E-mail: haisales@geartek.com Http: www.geartek.com
 SHAFTS AVAILABLE
1 5/8"-9 TOOTH SPLINE 2 7/8"-13 TOOTH SPLINE
AVAILABLE ON 45 THRU 100 SIZES ONLY TORQUE LIMIT 184 FT.-LBS.
TORQUE LIMIT 52 FT.-LBS. FLAT ROOT SIDE FIT
FLAT ROOT SIDE FIT DIAMETRAL PITCH 16/32
DIAMETRAL PITCH 16/32 PRESSURE ANGLE 30
PRESSURE ANGLE 30 NO. OF TEETH 13
NO. OF TEETH 9 MINOR DIA. .722-.733
MINOR DIA. .465-.475
DIA.

1.20

DIA.
.75 FULL SPLINE FULL SPLINE
1.17

.8585
.8535
.608
.603

1.25 FLG. MTG.

SURFACE 1.62 FLG. MTG.
SURFACE

5 7/8" STRAIGHT 6 3/4" STRAIGHT

TORQUE LIMIT 184 FT.-LBS. AVAILABLE ON 45 THRU 115 SIZES ONLY
TORQUE LIMIT 105 FT.-LBS.
1/4"x1/4"x1 3/4" KEY 3/16"x3/16"x1 1/4" KEY
DIA.

DIA.
.875
.874

.749
.748
.25 1.50 1.62
FLG. MTG. FLG. MTG.
2.45 1.94
SURFACE SURFACE

PORTS AVAILABLE
1 REAR PORTED SAE STRAIGHT THREAD 3 SAE 4-BOLT CONNECTOR
5.60
2.70
1.35
.82

CASE DRAIN SAE NO. 6

O-RING BOSS
9/16-18UNF

5 SIDE PORTED SAE STRAIGHT THREAD PORT SIZES

FOR CODE 1 & 5 PORTS FOR CODE 3 PORTS
BOTH SIDES BOTH SIDES
SIZE SAE STRAIGHT THREAD SAE 4-BOLT
O-RING BOSS CODE 61
RPMC45 NO. 12 1 1/16-12UN-2B 3/4"
RPMC65 NO. 16 1 5/16-12UN-2B 1"
RPMC85 NO. 16 1 5/16-12UN-2B 1"
RPMC100 NO. 16 1 5/16-12UN-2B 1"
RPMC115 NO. 20 1 5/8-12UN-2B 1 1/4"
RPMC150 NO. 20 1 5/8-12UN-2B 1 1/4"
RPMC180 NO. 20 1 5/8-12UN-2B 1 1/4"
RPMC200 NO. 20 1 5/8-12UN-2B 1 1/4"

UNLESS OTHERWISE SPECIFIED, ALL LINEAR DIMENSIONS ARE IN INCHES.

 FLANGES AVAILABLE
A SAE 2 BOLT 'A' FLANGE B SAE 'B' FLANGE
R. 1.75 5.750

PILOT DIA.
2.875 R. 1.75
1.65

1.768

IA T
D ILO
1.65
3.250
3.248

.
P
3.536

99 0
3. .00

2.25
8
4
7/16" DIA. .50
2.094 2 HOLES
.25 9/16" DIA.
4.188 HOLES 1.768
3.536
R 4 BOLT ROUND FLANGE
PILOT DIA.

MOUNTING DIMENSIONS
SIZE A B
RPMC45 1.06 2.98
RPMC65 1.06 3.20
RPMC85 1.06 3.41
2.623
2.625

RPMC100 1.06 3.57

1.40

RPMC115 1.25 3.73

RPMC150 1.25 4.10
7/16" DIA. RPMC180 1.25 4.42
.813 2 HOLES RPMC200 1.25 4.64
1.625 .50
2.437 .187 FOR METRIC DIMENSIONS
3.250 MULTIPLY 25.4 X IN. = mm
DIMENSIONAL DATA
B
5.60
A .42
2.80
OPTIONAL:
SEE SHAFTS

UNLESS HIGH
3.50

PRESSURE SEAL IS
USED - TAIL DRAIN
3.25

5.35
MUST BE USED IF
BACK PRESSURE
EXCEEDS 100 PSI
ON MOTOR
9/16-18UNF-2B ON
.82

REAR CENTERLINE
NO. 6 PORT

.38 .50
MODEL EXAMPLE
2.24 RPMC X 45 - 2 B - 5
FLANGE LG.
OPTIONAL: A,B&R
SEE FLANGES SERIES PORTS
OPTIONAL: SPECIFY FLANGE
CODE 'H' THIS AREA FOR SHAFT
OTHER PORT TYPES AVAILABLE HIGH PRESSURE SEAL
CONSULT FACTORY OTHERWISE: LEAVE BLANK SIZE

X THE OPTIONAL HIGH PRESSURE SEAL MAY BE USED WHEN DRAIN LINES ARE NOT PRACTICAL.
FOR SYSTEMS TOLERATING A DRAIN LINE, ELIMINATE THE 'H' FROM THE MODEL CODE.

REVISED: APRIL 22, 2003 UNLESS OTHERWISE SPECIFIED, ALL LINEAR DIMENSIONS ARE IN INCHES.
 GEARTEK MC45 MOTOR PERFORMANCE
SAE 10W oil @ 150 degrees F
(Typical)
12.00 500 PSI
10.00 1000 PSI
INPUT FLOW, GPM

8.00 1500 PSI

6.00 2000 PSI

4.00 2500 PSI

2.00 3000 PSI

0.00 3500 PSI

300 600 900 1200 1500 1800 2100 2400
RPM

18.00
500 PSI
16.00
HORSEPOWER, OUT

14.00 1000 PSI

12.00 1500 PSI
10.00
2000 PSI
8.00
6.00 2500 PSI
4.00 3000 PSI
2.00
0.00 3500 PSI
300 600 900 1200 1500 1800 2100 2400
RPM

450
500 PSI
400
TORQUE OUT, IN-LB.

350 1000 PSI

300 1500 PSI
250
2000 PSI
200
150 2500 PSI
100
3000 PSI
50
0 3500 PSI
0 300 600 900 1200 1500 1800 2100 2400
RPM
 GEARTEK MC65 MOTOR PERFORMANCE
SAE 10W oil @ 150 degrees F
(Typical)
16.00 500 PSI
14.00
1000 PSI
INPUT FLOW, GPM

12.00
10.00 1500 PSI

8.00 2000 PSI

6.00 2500 PSI
4.00
3000 PSI
2.00
0.00 3500 PSI
300 600 900 1200 1500 1800 2100 2400
RPM

25.00 500 PSI

HORSEPOWER, OUT

20.00 1000 PSI

1500 PSI
15.00
2000 PSI
10.00
2500 PSI

5.00 3000 PSI

3500 PSI
0.00
300 600 900 1200 1500 1800 2100 2400
RPM

700 500 PSI

600
TORQUE OUT, IN-LB.

1000 PSI
500
1500 PSI
400
2000 PSI
300
2500 PSI
200
3000 PSI
100
0 3500 PSI
0 300 600 900 1200 1500 1800 2100 2400
RPM
 GEARTEK MC85 MOTOR PERFORMANCE
SAE 10W oil @ 150degrees F
(Typical)
20.00
18.00 500 PSI
16.00
INPUT FLOW, GPM

1000 PSI
14.00
12.00 1500 PSI
10.00 2000 PSI
8.00 2500 PSI
6.00
3000 PSI
4.00
2.00 3500 PSI
0.00
300 600 900 1200 1500 1800 2100 2400
RPM

35.00
500 PSI
30.00
HORSEPOWER, OUT

1000 PSI
25.00
1500 PSI
20.00
2000 PSI
15.00
2500 PSI
10.00
3000 PSI
5.00
0.00 3500 PSI
300 600 900 1200 1500 1800 2100 2400
RPM

900 500 PSI

800
TORQUE OUT, IN-LB.

700 1000 PSI

600 1500 PSI
500
2000 PSI
400
300 2500 PSI
200 3000 PSI
100
3500 PSI
0
0 300 600 900 1200 1500 1800 2100 2400
RPM
 GEARTEK MC100 MOTOR PERFORMANCE
SAE 10W oil @ 150degrees F (Typical)
25.00
500 PSI

20.00 1000 PSI

INPUT FLOW, GPM

1500 PSI
15.00
2000 PSI
10.00
2500 PSI
5.00 3000 PSI

0.00 3500 PSI

300 600 900 1200 1500 1800 2100 2400
RPM

40.00
500 PSI
35.00
HORSEPOWER, OUT

1000 PSI
30.00
25.00 1500 PSI

20.00 2000 PSI

15.00 2500 PSI
10.00
3000 PSI
5.00
3500 PSI
0.00
300 600 900 1200 1500 1800 2100 2400
RPM

1200
500 PSI
1000
TORQUE OUT, IN-LB.

1000 PSI
800 1500 PSI

600 2000 PSI

400 2500 PSI

200 3000 PSI

0 3500 PSI
0 300 600 900 1200 1500 1800 2100 2400
RPM
 GEARTEK MC115 MOTOR PERFORMANCE
SAE 10W oil @ 150 degrees F
(Typical)
30.00 500 PSI
25.00 1000 PSI
FLOW INPUT, GPM

20.00 1500 PSI

15.00 2000 PSI

10.00 2500 PSI

5.00 3000 PSI

0.00 3500 PSI

300 600 900 1200 1500 1800 2100 2400
RPM

45.00
500 PSI
40.00
HORSEPOWER, OUT

35.00 1000 PSI

30.00 1500 PSI
25.00
2000 PSI
20.00
15.00 2500 PSI
10.00 3000 PSI
5.00
3500 PSI
0.00
300 600 900 1200 1500 1800 2100 2400
RPM

1200
500 PSI
1000
TORQUE OUT, IN-LB.

1000 PSI
800 1500 PSI

600 2000 PSI

400 2500 PSI

200 3000 PSI

3500 PSI
0
0 300 600 900 1200 1500 1800 2100 2400
RPM
 GEARTEK MC150 MOTOR PERFORMANCE
SAE 10W oil @ 150 degrees F
(Typical)
35.00 500 PSI
30.00
1000 PSI
FLOW INPUT, GPM

25.00
1500 PSI
20.00
2000 PSI
15.00
2500 PSI
10.00
3000 PSI
5.00
0.00 3500 PSI
300 600 900 1200 1500 1800 2100 2400
RPM

60.00
500 PSI
50.00
HORSEPOWER, OUT

1000 PSI
40.00 1500 PSI
30.00 2000 PSI

20.00 2500 PSI

3000 PSI
10.00
3500 PSI
0.00
300 600 900 1200 1500 1800 2100 2400
RPM

1600
500 PSI
1400
TORQUE OUT, IN-LB.

1000 PSI
1200
1000 1500 PSI

800 2000 PSI

600
2500 PSI
400
3000 PSI
200
0 3500 PSI
0 300 600 900 1200 1500 1800 2100 2400
RPM
 GEARTEK MC180 MOTOR PERFORMANCE
SAE 10W oil @ 150 degrees F
(Typical)
45.00
500 PSI
40.00
INPUT FLOW, GPM

35.00 1000 PSI

30.00
25.00 1500 PSI
20.00 2000 PSI
15.00
10.00 2500 PSI
5.00
3000 PSI
0.00
300 600 900 1200 1500 1800 2100 2400
RPM

60.00
500 PSI
50.00
HORSEPOWER, OUT

1000 PSI
40.00
1500 PSI
30.00
2000 PSI
20.00
2500 PSI
10.00
3000 PSI
0.00
300 600 900 1200 1500 1800 2100 2400
RPM

1600
500 PSI
1400
TORQUE OUT, IN-LB.

1200 1000 PSI

1000
1500 PSI
800
600 2000 PSI

400 2500 PSI

200
3000 PSI
0
0 300 600 900 1200 1500 1800 2100 2400
RPM
 GEARTEK MC200 MOTOR PERFORMANCE
SAE 10W oil @ 150 degrees F
(Typical)
45.00
500 PSI
40.00
INPUT FLOW, GPM

35.00 1000 PSI

30.00
25.00 1500 PSI
20.00
2000 PSI
15.00
10.00 2500 PSI
5.00
3000 PSI
0.00
300 600 900 1200 1500 1800 2100 2400
RPM

70.00
500 PSI
60.00
HORSEPOWER, OUT

1000 PSI
50.00

40.00 1500 PSI

30.00 2000 PSI

20.00
2500 PSI
10.00
3000 PSI
0.00
300 600 900 1200 1500 1800 2100 2400
RPM

1800
500 PSI
1600
TORQUE OUT, IN-LB.

1400 1000 PSI

1200
1000 1500 PSI

800 2000 PSI

600
400 2500 PSI
200
3000 PSI
0
0 300 600 900 1200 1500 1800 2100 2400
RPM
Catalog 0600P-6/USA Prep-Air II, 07F Series
Standard 07F Series 3/8", 1/2", 3/4" Basic 1/2" Body

07F Filters Standard

A
Twist Automatic Features
Drain Drain
Excellent water removal efficiency.
B
Unique deflector plate and shroud creates a
swirling of the air stream ensuring maximum
water and dirt separation.
C
Large filter element surface guarantees low
pressure drop and increased element life.
Optional Push N Drain requires only fingertip E
touch to drain. Optional automatic float drain D
available.
Shown with recommended metal bowl guard.
High Flow: 3/8" 100 SCFM
Distance Required
1/2" 130 SCFM
F To Remove All Bowls
3/4" 145 SCFM Regardless Of
Drain Option

Port NPT BSPP 07F Filter Dimensions

Size Twist Drain Automatic Float Drain Twist Drain Automatic Float Drain A B C
Poly Bowl / Metal Guard 3.24 3.25 .70
(82) (83) (18)
3/8" 07F22AC 07F26AC 07F22AC1 07F26AC1
D D E
1/2" 07F32AC 07F36AC 07F32AC1 07F36AC1 6.97 7.00 7.67
3/4" 07F42AC 07F46AC 07F42AC1 07F46AC1 (177) (178) (195)
E F
Metal Bowl / Sight Gauge
7.70 2.75
3/8" 07F24AC 07F28AC 07F24AC1 07F28AC1 (196) (70)
1/2" 07F34AC 07F38AC 07F34AC1 07F38AC1 Inches (mm)

With Automatic Float Drain
3/4" 07F44AC 07F48AC 07F44AC1 07F48AC1
Standard part numbers shown, for other models refer to ordering information below.
For polycarbonate bowl see Caution on page 2.
SCFM = Standard cubic feet per minute at 90 PSIG inlet and 5 PSIG pressure drop.

Ordering Information
07F 3 2 A C

Engineering
Port Size Bowl Options Elements Level Options Port Type
2. 3/8 Inch Polycarbonate Bowl Metal Bowl A. 40 Micron C. Current Blank. None Blank. NPT
3. 1/2 Inch 1. Twist Drain 3. Twist Drain B. 5 Micron P. Differential 1. BSPP
4. 3/4 Inch 2. Metal Bowl Guard / 4. Sight Gauge / Z. Adsorber Pressure 2. BSPT
Twist Drain Twist Drain Indicator
5. Auto Float Drain 7. Auto Float Drain
6. Metal Bowl Guard / 8. Sight Gauge /
Auto Float Drain Auto Float Drain
E. Push N Drain G. Push N Drain
F. Metal Bowl Guard / H. Sight Gauge /
Push N Drain Push N Drain
J. Semi-Auto Drain L. Semi-Auto Drain
K. Metal Bowl Guard / M. Sight Gauge /
Semi-Auto Drain Semi-Auto Drain

NOTE: BOLD OPTIONS ARE STANDARD.

14 Parker Hannifin Corporation

Pneumatic Division
Pneumatic Richland, Michigan
www.parker.com/pneumatic
Catalog 0600P-6/USA Prep-Air II, 07F Series
Technical Specifications 07F Air Line Filters

Technical Information
Primary Pressure - bar Primary Pressure - bar
2.4 bar 6.2 bar 10.3 bar 2.4 bar 6.2 bar 10.3 bar
Primary Pressure - PSIG Primary Pressure - PSIG
35 PSIG 90 PSIG 150 PSIG 35 PSIG 90 PSIG 150 PSIG
7 7

.4 6 6
.4
Pressure Drop - PSIG

Pressure Drop - PSIG

Pressure Drop - bar

Pressure Drop - bar

5 5
.3 .3
4 4

.2 3 .2 3

2 2
.1 .1
1 Flow Characteristics 1 Flow Characteristics
07F22A 07F32A
3/8 Inch Ports 1/2 Inch Ports
0 0 0 0
0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 160 180 200 220
Flow - SCFM Flow - SCFM
0 10 20 30 40 50 60 70 0 10 20 30 40 50 60 70 80 90 100
3 3
Flow - dm /s Flow - dm /s
n n
Primary Pressure - bar
2.4 bar 6.2 bar 10.3 bar
Primary Pressure - PSIG
35 PSIG 90 PSIG 150 PSIG
7

.4 6
Pressure Drop - PSIG
Pressure Drop - bar

5
.3
4

.2 3

2
.1
1 Flow Characteristics
07F42A
3/4 Inch Ports
0 0
0 20 40 60 80 100 120 140 160 180 200 220 240 260
Flow - SCFM

0 10 20 30 40 50 60 70 80 90 100 110 120

Flow - dm3 /s
n

07F Filter Kits & Accessories Port Threads ......................................................... 3/8, 1/2, 3/4 Inch
Pressure & Temperature Ratings
Bowl Guard Kit .................................................................. PS805P
Without Differential Pressure Indicator:
Bowl Kits Polycarbonate Bowl 0 to 150 PSIG (0 to 10.3 bar)
Poly Bowl Automatic Float Drain ................................. PS822P
32F to 125F (0C to 52C)
Semi-Auto Drain .......................................... PS892P
Metal Bowl 0 to 250 PSIG (0 to 17.2 bar)
Twist Drain .................................................. PS832P
Push N Drain ............................................. PS804P 32F to 175F (0C to 80C)
Metal Bowl Automatic Float Drain ................................. PS826P With Differential Pressure Indicator 0 to 150 PSIG (0 to 10.3 bar)
Semi-Auto Drain .......................................... PS894P 32F to 125F (0C to 52C)
Twist Drain .................................................. PS834P Automatic Float Drain 10 to 250 PSIG (0.7 to 17.2 bar)
Push N Drain ............................................. PS825P at 125F (52C) or less
Sight Gauge / Automatic Drain ................... PS823P Weight ....................................................................... 2.2 lb. (1.0 kg)
Sight Gauge / Semi-Auto Drain .................. PS893P
Sight Gauge / Twist Drain ........................... PS835P Materials of Construction
Sight Gauge / Push N Drain ...................... PS806P
Body ........................................................................................... Zinc
DPI Replacement Kit .......................................................... PS781P Bowls .................................................... Transparent Polycarbonate
Drain Kits Automatic Float Drain ................................. PS506P Metal (Zinc) With or Without Sight Gauge
Semi-Auto Drain .......................................... PS511P Bowl Guards ........................................................................... Steel
Twist Drain .................................................. PS512P
Push N Drain ............................................. PS513P
Collar ....................................................................... Plastic or Metal
Deflector, Shroud & Baffle ................................................. Plastic
Drains Twist Drain Body & Nut ....................................... Plastic
X
Filter Element Kits 40 Micron .......................................... PS801P
5 Micron ............................................ PS802P Push N Drain Body .............................................. Nitrile
Adsorber ........................................... PS831P Stem ............................................. Brass
Mounting Bracket Kit ........................................................ PS843P Automatic Float Drain Housing, Float ................. Plastic
Sight Gauge Kit ................................................................. PS814P Seals ............................................. Nitrile
Springs, Push Rod ........ Stainless Steel
Filter Elements 40 Micron (Standard) ................................ Plastic
Specifications 5 Micron (Optional) ................................... Plastic
Bowl Capacity .............................................................. 7.2 Ounces Adsorber (Optional) .............. Activated Charcoal
Sump Capacity ............................................................ 2.8 Ounces Seals ........................................................................................ Nitrile
Sight Gauge ................................................................... Polyamide

15 Parker Hannifin Corporation

Pneumatic Division
Pneumatic Richland, Michigan
www.parker.com/pneumatic
Catalog 0600P-6/USA Prep-Air II, 07R Series
Standard 07R Series 3/8", 1/2", 3/4" Basic 1/2" Body

07R Regulators Standard

A

Features
Secondary aspiration plus balanced poppet provides B

PUS

CK
H

O
quick response and accurate pressure regulation. TO L

Rolling diaphragm for extended life.

Two high flow 1/4" gauge ports can be used as
additional outlets.
Easily serviced.
C
Removable non-rising knob for panel mounting E
and tamper resistance.
High Flow: 3/8" 70 SCFM
1/2" 90 SCFM D
3/4" 90 SCFM

Port Size NPT BSPP 07R Regulator Dimensions

Without Gauge A B C
3.24 2.74 4.79
3/8" 07R213AC 07R213AC1 (82) (70) (122)
1/2" 07R313AC 07R313AC1 D E
3/4" 07R413AC 07R413AC1 1.61 6.40
(41) (163)
With 160 PSI Gauge Inches (mm)
3/8" 07R218AC 07R218AC1
1/2" 07R318AC 07R318AC1
3/4" 07R418AC 07R418AC1
Standard part numbers shown, for other models refer to ordering information below.
NOTE: 2.00 Dia. (51mm) hole required for panel mounting.

! WARNING
SCFM = Standard cubic feet per minute at 100 PSIG inlet,
90 PSIG no flow secondary setting and 10 PSIG pressure drop. Product rupture can cause serious injury.
Do not connect regulator to bottled gas.
Do not exceed maximum primary pressure rating.

Ordering Information

07R 3 13 A C ---

Engineering
Port Size Pressure Range Relief Level Port Type Options Preset
2. 3/8 Inch Without Gauge A. Relieving C. Current Blank. NPT Blank. No Options Blank. None
3. 1/2 Inch 10. 30 PSIG L. Non-Relieving 1. BSPP L. Preset XXX* Preset
4. 3/4 Inch 11. 60 PSIG 2. BSPT Non-Adjustable Pressure
13. 125 PSIG P. Preset * Available Preset
15. 250 PSIG Adjustable Range, 10 to 90
PSIG in 5 PSIG
With Gauge R. Reverse Flow increments. For
17. 30 PSIG Inlet Pressure is 100 PSIG. higher pressures,
For other pressures, contact contact factory.
16. 60 PSIG (Example:
18. 125 PSIG factory.
065 = 65 PSIG)
21. 250 PSIG

NOTE: BOLD OPTIONS ARE STANDARD.

54 Parker Hannifin Corporation

Pneumatic Division
Pneumatic Richland, Michigan
www.parker.com/pneumatic
Catalog 0600P-6/USA Prep-Air II, 07R Series
Technical Specifications 07R Air Line Regulators

Technical Information
Relief And Flow Characteristics Relief And Flow Characteristics
07R213A 07R313A
100 100
Secondary Pressure - PSIG

Secondary Pressure - PSIG

6
Secondary Pressure - bar

Secondary Pressure - bar

80 80
5 5

4 60 60
4

3 3
40 40

2 2
20 20
1 3/8 Inch Ports 1 1/2 Inch Ports
100 PSIG (6.9 bar) Primary Pressure 100 PSIG (6.9 bar) Primary Pressure
0 0 0 0
10 0 10 30 50 70 90 110 130 10 0 10 30 50 70 90 110 130
Rated Flow - SCFM Rated Flow - SCFM
5 0 5 15 25 35 45 55 5 0 5 15 25 35 45 55
3 3
Flow - dm /s Flow - dm /s
n n

Relief And Flow Characteristics

07R413A
100
Secondary Pressure - PSIG

6
Secondary Pressure - bar

80
5

4 60

3
40

2
20
1 3/4 Inch Ports
100 PSIG (6.9 bar) Primary Pressure
0 0
10 0 10 30 50 70 90 110 130 150 170
Rated Flow - SCFM
5 0 5 15 25 35 45 55 65 75
3
Flow - dm /s
n

07R Regulator Kits & Accessories Specifications

Bonnet Assembly Kit ........................................................ PS715P Gauge Ports (2) .................................................................. 1/4 Inch
Control Knob ................................................................... P04069B (Can be used as additional High Flow 1/4 Inch Outlet Ports)
Gauges 60 PSIG (0 to 400 kPa) ..................................... P781641 Port Threads ......................................................... 3/8, 1/2, 3/4 Inch
160 PSIG (0 to 1100 kPa) ................................. P781642 Primary Pressure Rating
300 PSIG (0 to 2000 kPa) ................................. P781643 Maximum Primary Pressure ........................ 250 PSIG (1725 kPa)
Mounting Bracket Kit (Includes Panel Mount Nut) ........... PS807P Secondary Pressure Ranges
Panel Mount Nut Plastic .................................................. P04082 Standard Pressure ......................... 2 to 125 PSIG (14 to 863 kPa)
Metal ................................................. P04079B Low Pressure .................................. 1 to 60 PSIG (6.9 to 414 kPa)
High Pressure .............................. 5 to 250 PSIG (35 to 1725 kPa)
Reverse Flow Service Conversion Kit
Relieving ................................................... PS808RP
Non-Relieving ........................................... PS809RP
Temperature Rating ........................... 32F to 175F (0C to 80C)
Weight ........................................................................ 2.5 lb. (1.1 kg) X
Service Kit Relieving (Includes Poppet) ......................... PS808P Materials of Construction
Non-Relieving (Includes Poppet) ................. PS809P
Adjusting Stem ....................................................................... Steel
Springs 1-30 PSIG Range ................................................. P01698
1-60 PSIG Range ................................................. P04062 Body .......................................................................................... Zinc
2-125 PSIG Range ............................................... P04063 Bonnet, Piston Stem, Valve Poppet & Cap ......................... Plastic
5-250 PSIG Range ............................................... P04064 Collar, Knob ........................................................................... Plastic
Tamperproof Kit .................................................................. PS737P Diaphragm .............................................................................. Nitrile
Seals ........................................................................................ Nitrile
Springs Poppet ............................................................... Stainless
Control ...................................................................... Steel

55 Parker Hannifin Corporation

Pneumatic Division
Pneumatic Richland, Michigan
www.parker.com/pneumatic
Catalog 0600P-6/USA Prep-Air II, 17L Series
Standard 17L Series 3/8", 1/2", 3/4" Basic 1/2" Body

17L Micro-Mist Lubricators Standard

Features A

Proportional oil delivery over a wide range of air flows.

B
Generates oil particles of 5 micron or smaller
downstream to lubricate systems having complex
piping arrangements.
C
Precision needle valve assures repeatable oil delivery
and provides simple adjustment of delivery rate.
Ideal for low and high flow applications with changing
E
air flow.
D
Transparent sight dome for 360 visibility.
Yellow fill cap identifies Micro-Mist Lubricator.
High Flow: 3/8" 60 SCFM
Distance Required
1/2" 90 SCFM F To Remove All Bowls
3/4" 90 SCFM Regardless Of
Drain Option

Port NPT BSPP 17L Lubricator Dimensions

Size Twist Drain No Drain Twist Drain No Drain A B C
Poly Bowl / Metal Guard 3.24 3.25 2.41
(82) (83) (61)
3/8" 17L22BE 17L22BE1
D D E
1/2" 17L32BE 17L32BE1 6.86 6.95 9.27
3/4" 17L42BE 17L42BE1 (174) (177) (235)
E F
Metal Bowl / Sight Gauge
7.93 2.75
3/8" 17L24BE 17L24BE1 (201) (70)
1/2" 17L34BE 17L34BE1 Inches (mm)

With Twist Drain
3/4" 17L44BE 17L44BE1
Standard part numbers shown, for other models refer to ordering information below.
For polycarbonate bowl see Caution on page 2.
SCFM = Standard cubic feet per minute at 90 PSIG inlet and 5 PSIG pressure drop.

Ordering Information
17L 2 2 B E

Engineering Port
Port Size Bowl Options Options Level Type
2. 3/8 Inch Polycarbonate Bowl Metal Bowl B. With Fill Plug E. Current Blank. NPT
3. 1/2 Inch 1. No Drain 4. Sight Gauge/ C. With Fill Plug/Nylon 1. BSPP
4. 3/4 Inch 2. Metal Bowl Guard/ Twist Drain Sight Dome 2. BSPT
No Drain 8. Sight Gauge/ F. With Body Pressure Fill
5. Pressure Fill Pressure Fill G. With Body Pressure Fill/
6. Metal Bowl Guard/ M. Sight Gauge/ Nylon Sight Dome
Pressure Fill Auto Fill Device
J. Auto Fill Device
K. Metal Bowl Guard/
Auto Fill Device
R. Twist Drain
N. Metal Bowl Guard/
Twist Drain
NOTE: BOLD OPTIONS ARE STANDARD.

106 Parker Hannifin Corporation

Pneumatic Division
Pneumatic Richland, Michigan
www.parker.com/pneumatic
Catalog 0600P-6/USA Prep-Air II, 17L Series
Technical Specifications 17L Air Line Micro-Mist Lubricators

Technical Information Primary Pressure - bar

2.4 bar 6.2 bar 10.3 bar
Primary Pressure - PSIG
35 PSIG 90 PSIG 150 PSIG
7

.4 6

Pressure Drop - PSIG

Pressure Drop - bar
5
.3
4

.2 3

2
.1
1
Flow Characteristics
17L22B 3/8 Inch Ports
0 0
0 10 20 30 40 50 60 70 80 90 100
Flow - SCFM
0 5 10 15 20 25 30 35 40 45
3
Flow - dm /s
n

Primary Pressure - bar

2.4 bar 6.2 bar 10.3 bar
Primary Pressure - PSIG
35 PSIG 90 PSIG 150 PSIG
7

.4 6
Pressure Drop - PSIG
Pressure Drop - bar

5
.3
4

.2 3

2
.1 Flow Characteristics
17L32B 1/2 Inch Ports
1 &
17L42B 3/4 Inch Ports
0 0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Flow - SCFM
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
3
Flow - dm /s
n

17L Micro-Mist Lubricator Kits & Specifications

Accessories Bowl Capacity .............................................................. 4.9 Ounces
Adjustment Knob ............................................................... P04121 Minimum Flow for Lubrication ................... 1 SCFM At 100 PSIG
Bowl Guard Kit .................................................................. PS805P Port Threads ......................................................... 3/8, 1/2, 3/4 Inch
Bowl Kits Pressure & Temperature Rating
Polycarbonate Bowl 0 to 150 PSIG (0 to 10.3 bar)
Poly Bowl No Drain ...................................................... PS846P 32F to 125F (0C to 52C)
Twist Drain .................................................. PS817P
Metal Bowl 0 to 250 PSIG (0 to 17.2 bar)
Pressure Fill ................................................ PS819P
32F to 175F (0C to 80C)
Remote Fill .................................................. PS828P
Suggested Lubricant ......................................................... F442 Oil
Metal Bowl Sight Gauge / Twist Drain ........................... PS829P
Petroleum based oil of 100 to 200 SSU viscosity
Sight Gauge / Pressure Fill ........................ PS820P
at 100F and an aniline point greater than 200F
Drain Kit Twist Drain ......................................................... PS512P
(DO NOT USE OILS WITH ADDITIVES,
Fill Cap Kit ........................................................................... PS742P COMPOUNDED OILS CONTAINING SOLVENTS,
Lubricator Service Kit ........................................................ PS748P GRAPHITE, DETERGENTS, OR SYNTHETIC OILS.)
Mounting Bracket Kit ......................................................... PS843P Weight ......................................................................... 1.9 lb. (.9 kg)
Oil 1 Gal. .......................................................................... F442002
12 Quart Case ............................................................ F442003 Materials of Construction
Body .......................................................................................... Zinc
X
4 Gallon Case ............................................................ F442005
Pressure Fill Adapter Kit ................................................... PS716P Bowls Transparent .................................................. Polycarbonate
Metal (With Sight Gauge) ............................................ Zinc
Pressure Fill Button ........................................................... P11912
Bowl Guard ............................................................................. Steel
Remote Auto-Fill Device ................................................. PS505CP
Collar ....................................................................... Plastic or Metal
Sight Dome / Fill Cap Kit .................................................. PS739P
Drain Twist Body & Nut .................................................... Plastic
Sight Dome Kit ................................................................... PS740P
Injector Meter Block & Base Assembly ............................ Plastic
Nylon Sight Dome Kit ...................................................... PS740N Seals ....................................................................................... Nitrile
Sight Gauge Kit .................................................................. PS814P Sight Dome ............................................................... Polycarbonate
Sight Gauge ...................................................... Polyamide (Nylon)

107 Parker Hannifin Corporation

Pneumatic Division
Pneumatic Richland, Michigan
www.parker.com/pneumatic
INSTRUCTIONSPARTS LIST 308642
Rev. L
This manual contains important
warnings and information. First choice when
READ AND KEEP FOR REFERENCE. quality counts.t
INSTRUCTIONS

WITH OR WITHOUT ELECTRONIC METERS

V5t V12t EM6t and EM12t
Dispense Valves
1500 psi (10 MPa, 102 bar) Maximum Working Pressure

CAUTION EM12
These dispense valves are designed to dispense Model 238641
petroleum-based lubricants only.

Notes
D See the list on page 3 for Model Numbers and 06294A

configurations.
D See manual 307965 for information on electronic
meters 244075 and 244076. V12
Model 238644

Table of Contents 06292A

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Bare Valve
Model 238646
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Parts EM12 and V12 Dispense Valves . . . . . . . . . 12 8537A
Parts EM6 Dispense Valves . . . . . . . . . . . . . . . . . . 13
Parts V5 Dispense Valves . . . . . . . . . . . . . . . . . . . . 14
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . 16
Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . . 16 EM6
Model 243599

TI0407

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 554401441

ECOPYRIGHT 1997, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
 Notes

2 308642
 Models
Non-Metered Valves
V12 with trigger lock
With Extension
238644 3/4 swivel, rigid extension
238645 3/4 swivel, flex extension
238651 1/2 swivel, rigid extension
238652 1/2 swivel, flex extension
V5 with trigger lock
With Extension
222411, Series C, 1/2 swivel, oil nozzle/extension
222412, Series C, 1/2 swivel, gear lube extension
222413, Series C, 1/2 swivel, ATF nozzle/extension
Bare Valves
238646 3/4 swivel, no extension, with trigger lock
238647 1/2 swivel, no extension, with trigger lock
243992 1/2 swivel, no extension, without trigger lock
Metered Valves
EM12 with trigger lock
English Meter
238636 3/4 swivel, rigid extension
238637 3/4 swivel, flex extension
238640 1/2 swivel, rigid extension
238641 1/2 swivel, flex extension
Metric Meter
238638 3/4 swivel, rigid extension
238639 3/4 swivel, flex extension
238642 1/2 swivel, rigid extension
238643 1/2 swivel, flex extension
EM6 without trigger lock
English Meter
243599 1/2 swivel, rigid extension
243600 1/2 swivel, gear lube
243601 1/2 swivel, flex extension
Metric Meter
243602 1/2 swivel, rigid extension
243603 1/2 swivel, gear lube
243604 1/2 swivel, flex extension
308642 3
 Warnings
Warning Symbol Caution Symbol

WARNING CAUTION
This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to
injury or death if you do not follow the instructions. or destruction of equipment if you do not follow the
instructions.

WARNING
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS

D This equipment is for professional use only.

D Read all instruction manuals, tags, and labels before you operate this equipment.

D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.

D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

D Check equipment daily. Repair or replace worn or damaged parts immediately.

D Do not exceed the maximum working pressure of the lowest rated system component. Refer to
the Technical Data on page 15 for the maximum working pressure of this component.

D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturers
warnings.

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

fluids that contain such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.

D Do not use hoses to pull equipment.

D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180_ F (82_ C) or below 40_ F (40_ C).

D Do not lift pressurized equipment.

D Comply with all applicable local, state, and national fire, electrical, and safety regulations.

4 308642
 WARNING
WARNING
INJECTION HAZARD
Fluid from the dispensing valve, 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 may look like just a cut, but it is a serious injury. Get immediate
medical attention.

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

D Do not put your hand or fingers over the end of the dispensing valve.

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

D Use only extensions and nozzles that are designed for use with your dispensing valve.

D Do not use a low-pressure flexible extension with this equipment.

D Follow the Pressure Relief Procedure on page 9 before you clean, check, or service the
equipment.

D Tighten all fluid connections before you operate the equipment.

D Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do
not repair high pressure couplings; you must replace the entire hose.

308642 5
 Installation
See manual 307965 for electronic meters installation, operation, parts, and cautions and warnings.

NOTE: Numbers in parenthesis, for example (7), and in the Parts Drawings are reference numbers
in the Parts List on page12.

Typical Installation
Fig. 1 shows a typical installation. Additionally, these KEY DESCRIPTION
dispense valves can be installed on a console.
H Thermal relief kit (required) Part No. 237904
Install downstream from pump.
CAUTION J Fluid shut-off valve
Do not use this electronic metered dispense K Hose
valve on non-Graco consoles. Such use could L Hose reel fluid inlet hose
result in the trigger becoming inadvertently
pressed while the dispense valve is stowed. M Hose reel
N Metered dispense valve

The installation shown in Fig. 1 is only a guide. The

J components shown are typical; however, it is not a
complete system design. Contact your Graco distribu-
L tor for assistance in designing a system to suit your
H
particular needs.

M
CAUTION
To prevent line contamination, which can cause
equipment malfunction or damage, flush the lines
before you install the equipment in the system.
K

WARNING
FIRE AND EXPLOSION HAZARD
N
The movement of fluids through the
dispensing system generates static
electricity. The static electricity can
cause volatile fumes to ignite, resulting in explosion
and fire. The dispensing system must always be
grounded. See Grounding on page 8.
04472A
Fig. 1

6 308642
 Installation
Pre-Installation Procedure
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 9.
2. Close the fluid shut-off valve (item J in Fig. 1).
3. Ground the hose and reel or console. See
Grounding on page 8. Do not use TeflonR tape
on the pipe joints; it may cause a loss of ground
across the pipe joint.
Installation Procedure
CAUTION
If this is a new installation, or if the oil in the
lines is contaminated, flush the lines before you
install the dispensing valve.
New Installation
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 9.
Steps 2 to 6 are the Flushing Procedure.
2. Close the fluid shut-off valve (J) at each dispense
position.
3. Make sure the main fluid outlet valve at the pump
is closed, the air pressure to the pump motor is
adjusted, and the air valve is open. Slowly open
main fluid valve.
4. Place the hose end (with no dispense valve con-
nected) into a container for waste oil. Secure the
hose in the container so it will not come out during
flushing. If you have multiple dispense positions,
first flush the dispense position farthest from the
pump, and work your way toward the pump.
5. Slowly open the shut-off valve (J) at the dispense
position. Flush out a sufficient amount of oil to
ensure that the entire system is clean, and close
the valve.
6. Repeat step 5 at all other dispense positions.
Existing Installation
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 9.
2. Loosen and disconnect the hose from the old
dispense valve (the one that you are replacing).
For steps 3 to 5, see Fig. 2.
3. Thread the extension (26a) into the outlet of the
dispense valve, and tighten firmly.
NOTE: Do not over tighten the extension tube
assembly by using the nozzle adapter to hand turn the
nozzel. For rigid extensions, thread the extension
in at least three full turns, position the extension
for proper alignment, and tighten the sealing
nut (7). The TeflonR seal on the sealing nut must
face the valve housing.
4. Apply thread sealant to the male threads of the
hose fitting, thread the hose fitting into the swivel
(20), and tighten firmly.
5. Thread the new nozzle (8) or nozzle adapter onto
the extension, and tighten firmly.
6. Open all dispense position shut-off valves, and
start the pump to pressurize the system. See the
Operation section for proper operation.
7. For metered dispense valves, to ensure dispens-
ing accuracy, purge all air from the fluid lines and
dispense valves before you use them.
Model shown is a V12 with
a 75_ bend rigid extension.
7
26a
8
20
06292A
Fig. 2
308642 7
 Installation
Grounding
Proper grounding is an essential part of maintaining a
safe system.
To reduce the risk of static sparking, ground all system
components per local and national electrical codes.
Refer to the user manuals for the pump and other
system components to ground the following:
8 308642
D Pump: Follow manufacturers recommendations.
D Air and Fluid hoses: Use only grounded hoses.
D Air compressor: Follow manufacturers recommen-
dations.
D Fluid supply container: Follow your local code.
D To maintain grounding continuity when flushing or
relieving pressure, always hold a metal part of the
valve firmly to the side of a grounded metal pail,
then trigger the valve.
 Operation
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The equipment stays pressurized until
pressure is manually relieved. To
reduce the risk of serious injury from
pressurized fluid, accidental spray from the
dispenser or splashing fluid, follow the Pressure
Relief Procedure whenever you
D Are instructed to relieve pressure
D Check, clean, or service any system equipment
D Install or clean fluid nozzles
1. Turn off the power supply to the pump.
2. Trigger the valve into a waste container to relieve
pressure.
3. Open any bleed-type master air valves and fluid
drain valves in the system.
4. Leave the drain valve open until you are ready to
pressurize the system.
If you suspect that the dispensing valve, extension, or
nozzle is clogged or that pressure has not been fully
relieved after following the steps above, very slowly
loosen a fitting on the fluid line to relieve pressure
gradually, then loosen it completely, then clear the
clog.
WARNING
To reduce the risk of a serious bodily injury, includ-
ing fluid injection, never exceed the maximum
working pressure of the valve you are using or of
the lowest rated component in your system.
Dispensing Procedure
See instruction manual 307965 for electronic meter
operation.
NOTE: Before you begin, make sure you understand
how to unlock the trigger. Model EM6 does not have
a trigger lock.
1. Pull the trigger toward the valve body to open the
valve and begin dispensing.
2. Lock the valve open by keeping the trigger
squeezed and depressing the trigger lock button
(25 in the Parts Drawing). Then release the
trigger, releasing your forefinger from the trigger
lock last.
3. Pull the trigger toward the valve body to release
the trigger lock. The trigger lock disengages.
4. Release the trigger to stop dispensing.
308642 9

Relieve the pressure before you check or repair the
dispensing valve. Be sure all other valves and controls
and the pump are operating properly.
Problem
Display does not activate or is
showing unintelligent
characters.
Slow or no fluid flow
Oil leaks from swivel.
Oil drips from nozzle. *
Valve leaks.
* Some fluid weepage is possible in applications where thermal expansion of fluid is possible.
10 308642
Troubleshooting
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
Cause
Electronic control is malfunctioning.
Filter is clogged, or
Pump pressure is low, or
Shutoff valve is not fully open, or
Foreign material is jammed in the
metering element.
Swivel is loose.
O-ring is worn or damaged.
Nozzle is damaged or obstructed.
O-rings or valve seat are worn or
damaged.
WARNING
Solution
Replace the electronic control.
See instruction manual 307965.
1. Relieve the pressure.
2. Clean or replace the filter (10).
See Filter Replacement on
page 11.
3. If the problem remains, contact
your Graco distributor for repair
or replacement.
Torque the swivel (20) to 15 to 20
ft-lb (20 to 27 N-m).
If the problem remains, contact your
Graco distributor for repair or
replacement.
Replace the o-ring (6), and torque the
swivel (20) to 15 to 20 ft-lb (20 to 27
N-m).
If the problem remains, contact your
Graco distributor for repair or
replacement.
Inspect the nozzle for damage or
obstructions, and replace if damaged.
Replace the o-rings (15) and/or the
valve seat (29).
See Valve Handle Repair on
page 11.
 Service
NOTE: See instruction manual 307965 for electronic meter service instructions.

Valve Handle Repair
See Fig. 3.
NOTE: The large end of the pushrod (30) fits into a
notch in the cam (21), which is part of the trigger
assembly. It is important that you know this before you
remove or install parts.
1. Relieve the pressure.
WARNING
To reduce the risk of serious injury, when you are
instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
6. Lubricate the cam, and slide it into the valve
handle, making sure the notch is oriented as
shown in Fig. 3. Ensure that the large end of the
pushrod is resting in the notch of the cam.
7. Replace the screws (14) and washers (28), and
torque the screws to 15 to 25 in-lb (1.7 to
2.8 N-m).
8. Replace the swivel (20), and torque to 15 to 20
ft-lb (20 to 27 N-m).
Filter Replacement
See Fig. 3.
1. Relieve the pressure.

2. If you are replacing the o-rings (15), or the cam

(21), or the push rod (30), remove the swivel (20), WARNING
and remove the internal pieces. You must To reduce the risk of serious injury, when you are
remove the cam in order to get the push rod instructed to relieve pressure, always follow the
out of the outlet end of the valve handle. Pressure Relief Procedure on page 9.

3. Remove the screws (14) and washers (28), and 2. Unscrew the hose fitting from the swivel (20).
remove the trigger (24). Push the cam (21) out of
the valve handle (18). Replace the o-rings (15) 3. Remove and replace the filter (10), which is inside
and/or the cam. the valve handle (18). Make sure the filter is
oriented as shown in Fig. 3.
4. Replace any worn or broken parts.
4. Thread the hose fitting into the swivel (20), and
5. Reassemble the internal pieces. The push rod tighten. Make sure the swivel (20) is torqued to
(30) must be inserted through the outlet end of 15 to 20 ft-lb (20 to 27 N-m).
the valve handle before the cam (21) is
installed.
14
30
28
NOTE: For torque specifications and lubrication
instructions, see the service notes in the Parts 15
Drawings on pages 12, 13 and 14. EM6 models do not
have trigger lock parts 11, 25, and 27. 15
27
11 notch 28

18 25 14

21
10

20

24
308642 11
7854B
Fig. 3
 Parts EM12 and V12 Dispense Valves
EM12 Models: 238636 to 238643 with trigger lock
(with electronic meter and extension)
V12 Models: 238644, 238645, 238651, 7
26a
and 238652 with trigger lock
(no meter, includes extension)
36
Bare Valves: 238646 and 238647 with trigger lock
(no meter, no extension)
Includes items 6, 1025, and 2730 8 1

5 35 26b
2 14 30
28 15 4
18
21
15 4
29
8 1
12 27 28
16 11 14 2 06293C
10 25
1 Torque to 15 to 20 ft-lb (20 to 27 N-m).

2 Torque to 15 to 25 in-lb (1.7 to 2.8 N-m).

3 Apply lubricant to threads when reassembling.

6 4
4 Apply lubricant to packings and sealing
20 1 3 24 surfaces when reassembling.
5 Apply thread sealant when reassembling.

Ref Ref
No. Part No. Description Qty No. Part No. Description Qty
6 111137 ORING, valve/swivel 21 191315 CAM 1
For Models 238636 to 238645, 24 191320 TRIGGER 1
238651, and 238652 2 25 191321 TRIGGER LOCK 1
For Models 238646 and 238647 1 26a 191403 TUBE, 75_ bend; 1/2 npt
7 112841 NUT, seal; 1/214 npt For Models 238636, 238638,
For Models 238636, 238638, 238640, 238642, 238644, and
238640, 238642, 238644, and 238651 1
238651 1 26b 238401 HOSE, flexible; 1/2 npt
8 238400 NOZZLE, oil For Models 238637, 238639,
For Models 238636 to 238645, 238641, 238643, 238645,
238651, and 238652 1 and 238652 1
10 185416 FILTER 1 27 192106 GUIDE, spring 1
11 113924 SPRING, compression 1 28 191552 WASHER, flat 2
12 113493 SPRING, compression 1 29 191313 SEAT, valve 1
14 110637 SCREW, machine 2 30 192501 ROD, push 1
15 113574 SEAL, o-ring 2 35 158491 NIPPLE
16 113627 WASHER, plain 1 For Models 238636 to 238643 1
18 191074 HANDLE, valve 1 36 244075 METER, electronic; English
20 238398 SWIVEL; 3/414 npt For Models 238636, 238637,
For Models 238636 to 238639 238640, and 238641 1
and 238644 to 238646 1 244076 METER, electronic; metric
238399 SWIVEL; 1/214 npt For Models 238638, 238639,
For Models 238640 to 238643, 238642, and 238643 1
238647, 238651 and 238652 1

12 308642
 Parts EM6 Dispense Valves
EM6 Models: 243599 to 243604 without trigger lock
(with electronic meter and extension)
28c
Bare Valve: 243992 bare valve without trigger lock 28b
(no meter, no extension)
Includes items 6, 1023, and 2527 7 28a

29c
33

29b
5 32
29a
2 13 27

25 14 4
20
17 14 4 30a
25 30b
26
11 2 TI0408
13
15
10
1 Torque to 15 to 20 ft-lb (20 to 27 N-m).

2 Torque to 15 to 25 in-lb (1.7 to 2.8 N-m).

3 Apply lubricant to threads when reassembling.

4 Apply lubricant to packings and sealing

6 4 23 surfaces when reassembling.
5 Apply thread sealant when reassembling.
18 1 3

Ref Ref
No. Part No. Description Qty No. Part No. Description Qty
6 111137 ORING, valve/swivel 29 201701 NOZZLE, gear lube
For Models 243599 to 243604, 2 For Models 243600 and 243603
For Model 243992 1 Includes items 29a29c 1
7 112841 NUT, seal; 1/214 npt 29a 100206 . BUSHING; 1/2 npt(m) x 1/4 npt(f) 1
For Models 243599 to 243604, 1 29b 187046 . TUBE, nozzle 1
10 185416 FILTER 1 29c 201540 . NOZZLE, nondrip
11 113493 SPRING, compression 1 30 203687 NOZZLE, flexible extension
13 110637 SCREW, machine 2 For Models 243601 and 243604
14 113574 SEAL, quad ring 2 Includes items 30a30b 1
15 113627 WASHER, plain 1 30a 109160 . HOSE, coupled; 1 ft (0.3 m);
17 191074 HANDLE, valve 1 1/214 npt(m) x 1/418 npt(f) 1
18 238399 SWIVEL; 1/214 npt 1 30b 203655 . NOZZLE, nondrip 1
20 191315 CAM 1 25 191552 WASHER, flat 1
23 191320 TRIGGER 1 26 191313 SEAT, valve 1
28 203265 NOZZLE, rigid extension 27 192501 ROD, push 1
For Models 243599, and 243602 32 158491 NIPPLE
Includes items 28a28c 1 For Models 243599 to 243604 1
28a 100081 . BUSHING; 1/2 npt(m) x 3/8 npt(f) 1 33 244075 METER, electronic; English
28b 159246 . TUBE, nozzle 1 For Models 243599, 243600,
28c 203655 . NOZZLE, nondrip 1 and 243601 1
244076 METER, electronic; metric
For Models 243602, 243603,
and 243604 1
308642 13
 Parts V5 Dispense Valves

2 Model 238647 Bare Valve

Ref
No. Part No. Description Qty
1* 238647 VALVE 1
Model 222411, Series C For Oil
3 Ref
No. Part No. Description Qty
1* 238647 VALVE 1
2 203265 NOZZLE, oil 1
1 See parts list on page 13.
4 Model 222412, Series C For Gear Lube
Ref
No. Part No. Description Qty
1* 238647 VALVE 1
3 201701 NOZZLE, gear lube 1
See parts list on page 13.
Model 222413, Series C For A.T.F.
7853A
Ref
No. Part No. Description Qty
1* 238647 VALVE 1
4 203687 NOZZLE, A.T.F. 1
See parts list on page 13.
* See parts below.

Model 238647 Bare Valve, with trigger lock

Ref
No. Part No. Description Qty 1 Torque to 15 to 20 ft-lb (20 to 27 N-m).
6 111137 O-RING, valve/swivel 1
2 Torque to 15 to 25 in-lb (1.7 to 2.8 N-m).
10 185416 FILTER 1
11 113924 SPRING, compression 1 3 Apply lubricant to threads when reassembling.
12 113493 SPRING, compression 1
14 110637 SCREW, machine 2 4 Apply lubricant to packings and sealing
surfaces when reassembling.
15 113574 SEAL, o-ring 2
16 113627 WASHER, plain 1
18 191074 HANDLE, valve 1 14 2
20 238399 SWIVEL; 1/214 npt 1 30
21 191315 CAM 1 28
24 191320 TRIGGER 1
25 191321 TRIGGER LOCK 1
27 192106 GUIDE, spring 1 15 4
28 191552 WASHER, flat 2
29 191313 SEAT, valve 1 21
30 192501 ROD, push 1 15 4

29 27 28
12 11

16 25
18 14 2
10

20 1 3
24

7854B
6 4

14 308642
 Technical Data
NOTE: See instruction manual 307965 for electronic meter Technical Data.

Recommended maximum flow rate*

V5 dispense valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 gpm (18.9 lpm)
EM6 dispense valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 gpm (23.0 lpm)
V12 and EM12 dispense valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.0 gpm (45.4 lpm)
Maximum operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 psi
(10 MPa, 102 bar)
Weight (without meter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 lb (0.18 kg)
Operating temperature range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40_ to 180_ F (40_ to 82_ C)
Inlet sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 npt and 3/4 npt
See page 3 for model numbers and configurations.
Outlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 npt
Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . aluminum, stainless steel,
carbon steel, acetal, nitrile rubber, Geolastt
* Under normal operating conditions
Teflonr is a registered trademark of the DuPont Company.
Geolastt is a trademark of Advanced Elastomer Systems.

308642 15
 Graco Standard Warranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the
date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limited
warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment
determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accor-
dance with Gracos written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub-
stitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Gracos sole obligation and buyers sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.

Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide
purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais-
sent avoir convenu que la rdaction du prsente document sera en Anglais, ainsi que tous documents, avis et procdures judiciaires
excuts, donns ou intents la suite de ou en rapport, directement ou indirectement, avec les procedures concernes.

Graco Phone Numbers

TO PLACE AN ORDER, contact your Graco distributor, or call one of the following numbers
to identify the distributor closest to you:
18005339655 Toll Free
6126236928
6123783590 Fax

All written and visual data contained in this document reflect the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.

Sales Offices: Minneapolis, Detroit

International Offices: Belgium, Korea, Hong Kong, Japan

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 554401441

www.graco.com
PRINTED IN USA 308642 February 1997, Revised September 2001
16 308642
INSTRUCTIONS

SDM5 & SDM15 (Manual);

SDP5 & SDP15 (Preset)
Meters 312865F
- For metered dispense of oils and 50:50 antifreeze/water mix fluids -

Maximum Working Pressure: 1500 psi (10 MPa, 103 bar)

Maximum Working Pressure (50:50 antifreeze/water mix): 900 psi (6.2 MPa, 62 bar)
Maximum Flow Rate:14 gpm (53 lpm)

List of Models page 2

Preset Meter shown
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.

NOTICE
This dispense valve is designed to dispense
petroleum-based lubricants and antifreeze only.
Do not dispense windshield washer solvent with
this dispense valve.

ti11821
Models

Models

SDM5 Manual Dispense Electronic Meters

Model
Number Swivel Extension Description Nozzle Fluid Type

255348 1/2 npt(f) Flexible Extension Automatic, non-drip, quick close Oil

255349 1/2 npt(f) Gear Lube Extension None-drip, quick close Gear Lube

255350 1/2 npt(f) Rigid Extension Automatic, non-drip, quick close Oil

255802 1/2 npt(f) Rigid Extension Automatic, non-drip, quick close Anti-freeze

255803 1/2 npt(f) Flexible Extension Automatic, non-drip, quick close Anti-freeze

SDM15 Manual Dispense Electronic Meters

Model
Number Swivel Extension Description Nozzle Fluid Type

255800 3/4 npt(f) Rigid Extension Automatic, non-drip, quick close Oil

255801 3/4 npt(f) Flexible Extension Automatic, non-drip, quick close Oil

255836 1/2 npt(f) Rigid Extension Automatic, non-drip, quick close Oil

255837 1/2 npt(f) Flexible Extension Automatic, non-drip, quick close Oil

SDP5 Preset Dispense Electronic Meters

Model
Number Swivel Extension Description Nozzle Fluid Type

255200 1/2 npt(f) Rigid Extension Automatic, non-drip, quick close Oil

255351 1/2 npt(f) Flexible Extension Automatic, Non-drip, quick close Oil

255352 1/2 npt(f) Gear Lube Extension Non-drip, quick close Gear Lube

255355 1/2 npt(f) Rigid Extension Automatic, non-drip, quick close Anti-freeze

255356 1/2 npt(f) Flexible Extension Automatic, non-drip, quick close Anti-freeze

2 312865F
 Models

SDP15 Preset Dispense Electronic Meters

Model
Number Swivel Extension Description Nozzle Fluid Type

255353 3/4 npt(f) Rigid Extension Automatic, non-drip, quick close Oil

255354 3/4 npt(f) Flexible Extension Automatic, non-drip, quick close Oil

256838 1/2 npt(f) Rigid Extension Automatic, non-drip, quick close OIl

256839 1/2 npt(f) Flexible Extension Automatic, non-drip, quick close Oil

312865F 3
Warnings

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 symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found 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.

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 Technical Data in all equipment manuals.
Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturers warnings. For complete information
about your material, request MSDS forms from distributor or retailer.
Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturers replacement parts only.
Do not alter or modify equipment.
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.

BATTERY SAFETY
The battery may leak, explode, cause burns, or cause an explosion if mishandled:
You must use the battery type specified for use with the equipment.
Sparking can occur when changing batteries. Only replace the battery in a non-hazardous location,
away from flammable fluids or fumes.
Handle and dispose of battery properly - do not short circuit, charge, force over discharge, disas-
semble, crush, penetrate, incinerate, or heat the battery to a temperature exceeding 185 F (85 C).

4 312865F
 Warnings

WARNING
FIRE AND EXPLOSION HAZARD
When flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be
aware that flammable fumes can ignite or explode. To help prevent fire and explosion:
Use equipment only in well ventilated area.
Eliminate all ignition sources, such as cigarettes and portable electric lamps.
Keep work area free of debris, including rags and spilled or open containers of solvent and gasoline.
Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
Ground all equipment in the work area.
Use only grounded hoses.
If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
Keep a working fire extinguisher in the work area.

312865F 5
Installation

Installation
Typical Installations (FIG. 1) Mounting Bracket (FIG. 2)
The typical installation shown in FIG. 1 is only a guide. It Mounting Bracket Kit 249440 is available for resting the
is not a complete system design. Contact your Graco dispense valve on a console.
distributor for assistance in designing a system to suit
your needs.

NOTICE
The dispense valve is not designed for in-line
installation. Do not install with a shutoff valve on the
outlet side of the meter. Such installation could result in
damage to the meter housing cover.

B
D

E
ti11822
FIG. 2

Drum Mount Bracket (FIG. 3)

Mounting Bracket 15B750 is available for resting the
dispense valve on a drum.
C

ti11010a

FIG. 1

ITEM DESCRIPTION
A Electronic metered dispense valve
B Fluid shut-off valve
C Hose
D Hose reel fluid inlet hose
ti11823
E Hose reel
A Thermal Relief Kit (not shown) is required. The kit FIG. 3
required will vary by pump selected. See Parts, page 40 for
a list of available kits.

6 312865F

Pressure Relief Procedure
This equipment will stay pressurized until the pressure
has been manually relieved. To reduce the risk of
serious injury from pressurized fluid, accidental spray
from the dispense valve or splashing fluid, follow this
Pressure Relief Procedure when ever you:
Are instructed to relieve pressure.
Check, clean or service any system equipment.
Install or clean fluid nozzles or filter.
1. Turn off power supply to the pump or close
upstream ball valve.
2. Trigger the dispense valve into a waste container to
relieve pressure.
3. Open any bleed-type master air valves and fluid
drain valves in the system.
4. Leave the drain valve open until you are ready to
pressurize the system.
Grounding
FIRE HAZARD: Conductive metal surfaces on the
meter must not make contact with any positively
charged metal surface, including (but not limited to),
the starter solenoid terminal, alternator terminal or
battery terminal. Such contact could cause electrical
arcing and a fire.
The equipment must be grounded. Grounding reduces
the risk of static and electric shock by providing an
escape wire for the electrical current due to static build
up or in the event of a short circuit.
Pump: Follow manufacturers recommendations.
Air and fluid hoses: Only use electrically conductive
hoses. Check electrical resistance of hoses. If total
resistance to ground exceeds 29 megohms, replace
hose immediately.
312865F
Installation
Air compressor: Follow manufacturers
recommendations.
Fluid supply container: Follow local code.
To maintain grounding continuity when flushing or
relieving pressure: hold a metal part of the dispense
valve firmly to the side of a grounded metal pail, then
trigger the valve.
Pre-Installation Procedure
1. Relieve pressure, page 7.
2. Close the shut-off valve (B, FIG. 1).
3. Ground the hose and reel or console, page 7. Leave
at least two threads bare when using PTFE tape.
The bare threads ensure a ground is maintained.
Installation Procedure
NOTICE
If this is a new installation or if the fluid lines are
contaminated, flush the lines before you install the
metered valve. Contaminated lines could cause the
valve to leak.
Never dispense compressed air with meter. Doing
so will damage meter.
Flushing
If this is an existing installation, go to Installing Meter
section, page 8. The following procedure, Steps 1-5 are
the Flushing Procedure.
1. Close the fluid shut-off valve (B, FIG. 1, page 6) at
each dispense position.
2. Make sure:
main fluid outlet valve at the pump is closed,
air pressure to the pump motor is adjusted,
and
air valve is open.
7
Installation

3. Slowly open the main fluid valve. Installing Tube Extension (FIG. 5)
a. Place the hose end (with no dispense valve
connected) into a container for waste oil.
b
b. Secure the hose in the container so it will not
come out during flushing. 20
c. If you have multiple dispense positions, first
flush the dispense position farthest from the a
pump and work your way toward the pump.

4. Slowly open the shut-off valve (B) at the dispense

position. Flush out a sufficient amount of oil to
ensure that the entire system is clean; then close c
the valve.
ti10615A
5. Repeat Step 4 at all other positions.
FIG. 5

NOTICE
Installing Meter (FIG. 4
)
Do not use PTFE tape or thread sealant on threads of
extension tube (20). This could cause the fitting to
leak.

1.
1. Relieve pressure, page 7. a. Loosen nut (a) until it is completely off tube
threads.
a 32
b. Thread extension (20) into housing (b) until it
bottoms out.
31
c. Align extension (20) with meter housing and
handle (c).
d. Firmly tighten nut (a).

ti10983a

FIG. 4

2. Slide the swivel boot (32) back, over the hose, small
end first, to access the swivel fitting (a).

3. Apply thread sealant to the male threads of the hose

fitting. Thread the hose fitting into the meter swivel
(31). Use two wrenches to tighten securely (FIG. 4).

Make sure you let the sealant cure to the manufac-

turers recommendations before circulating fluid
through the system.

8 312865F
 Installation

Installing Nozzle (FIG. 6)

33

20

ti10615A

FIG. 6

1.
a. Thread new nozzle (33) onto extension (20).
b. With an open-end adjustable wrench on flats of
nozzle bushing, tighten firmly.

Only tighten nozzle with wrench on flats of the

nozzle bushing.

Do not disassemble the bushing from

nozzle. Disassembly will affect performance of
the nozzle.

2. Open automatic twist lock nozzle and all fluid

shut-off valves. Start pump to pressurize system.
See Operation Screens, Dispensing in either the
Manual or Preset Mode instructions beginning on
page 19 for complete meter operation information.

3. To ensure dispensing accuracy, purge all air from

the fluid lines and dispense valve before you use it.

4. Set the system flow to the desired flow rate.

NOTICE
Do not trigger meter when nozzle is closed. Fluid
will build up behind the nozzle, leak from the nozzle,
and unexpectedly be expelled when the nozzle is
opened. If you do accidentally trigger the meter with
the nozzle closed, point the nozzle into a waste
bucket and open the nozzle to relieve pressure and
expel the built up fluid.

312865F 9
Meter Overview

Meter Overview

Navigation and Modes Meter Display

Adjusting Screen Contrast using ARROWS

On the Setup Home Screen (page 11), use the LEFT
and RIGHT ARROWS to adjust the screen contrast.

Darken the Screen: Press the RIGHT ARROW

multiple times.
Brighten the Screen: Press the LEFT ARROW
multiple times.

Asleep/Awake Mode
Asleep: Battery-saving mode. The display goes
blank after 2 minutes of inactivity during normal
operation. Unit continues to keep track of amount
dispensed while the display is asleep.
Awake: Display comes awake from sleep mode
when you press any ARROW or the ENTER button
or when you squeeze the trigger to dispense fluid.

Locking and Unlocking Trigger

The Preset Meters only, include a locking trigger feature
that allows the user to lock the trigger in the dispense
ti11824
5-Way Menu position as shown in FIG. 8. To release the lock, firmly
Navigation Button squeeze the trigger to the handle.
FIG. 7
Preset Meters Only

5-Way Menu Navigation Button (FIG. 7)

Includes 4 direction ARROWS (UP, DOWN, LEFT,
RIGHT) and a center, ENTER button.

Pressing the direction ARROWS allows user to

easily scroll through menus. To select/store your
selection, you must press the center, ENTER
button. Unlocked
Pressing and holding a direction ARROW down
allows user to scroll through menus quickly.

Locked

FIG. 8

10 312865F
 Setup Mode Screens

Setup Mode Screens

If you are in Operation Mode you must be on the Home Screen shown in FIG. 10, to access the Setup Mode Screens.
(A complete description of the Home Screen is provided on page 18).

To display the Home Screen:

1. Wake up the meter by pressing any button on the key pad.

2. When an operation mode screen displays (such as

the one shown in FIG. 9):
MOBIL1 5W-20
a. Use the RIGHT ARROW to move the curser
over the House icon (a).

10.56 QTS
b. Press center, ENTER button to display the
Home Screen (FIG. 10).

ti12179a
FIG. 9

Manual Meters Preset Meters

MOBIL1 5W-20 MOBIL1 5W-20

MANUAL MANUAL
TOTALS PRESET
TOTALS
ti12184a
ti12175a

FIG. 10

312865F 11
Setup Mode Screens

Main Setup Screen (FIG. 12)

All Meters Displaying Setup Screen from an Operation
Mode Screen
The Main Setup Screen is the first screen displayed
when you enter the Setup Mode. This screen displays a
list of the available Setup Screens and also includes a
link back to the Home Screen.

Manual Meters Screens:

UNITS/LIMIT
CALIBRATE
BANNER (b) (a)
LANGUAGE
HOME
ti11824a

Preset Meters include all the Manual Meters Setup FIG. 11

Screens and also a PRESET screen.
1. Hold down the RIGHT ARROW (a) only, for a few
UNITS/LIMIT seconds (FIG. 11).
CALIBRATE
PRESET 2. Then at the same time, also press the center,
BANNER ENTER button (b) (FIG. 11). Hold both buttons down
LANGUAGE until the Main Setup Screen shown in FIG. 12 dis-
HOME plays.

Manual Meters Preset Meters

A A

UNITS/LIMIT UNITS/LIMIT
CALIBRATE CALIBRATE
B BANNER 1
B PRESET
LANGUAGE BANNER 1
HOME LANGUAGE
1.23.45
HOME 1.23.45

ti12177a ti12186a

FIG. 12

Main Screen Features (FIG. 12)
A. Screen Identifier Icon: Wrench icon displays in the
upper right corner when user is on the Main Screen of
the Setup screens.
B. Setup Screens: Screens available to user.
1. Use UP or DOWN ARROWS to select a screen from
the list.
2. Press center, ENTER button to confirm selection.
Selected screen displays.

1. Software Version Number: Reference number. You

may be asked to provide this number when contacting
Graco for technical support.

12 312865F

Units/Limit Screen (FIG. 13)
For All Meters
Sets the units of measurement to pints, quarts, liters, or gallons.
Manual Meters
UNITS = QTS C UNITS = QTS
QTS E D
FIG. 13
Units/Limit Screen Features (FIG. 13)
All meters include C - E
C. Units Mode: Displays measurement unit that was
selected using the Set Measurement Units
button (E).
D. Wrench Icon: Returns user to Main Setup Screen.
E. Set Measurement Units button/field: Sets unit of
measurement as pint, quart, gallon or liter.
To change/set the Unit of Measurement:
1. Use LEFT or RIGHT ARROW to move curser to the
Set Measurement field (E).
2. Use UP or DOWN ARROWS to display measure-
ment unit choices: PTS, QTS, L, GAL.
3. Press center, ENTER button to confirm selection.
Selected measurement unit is displayed on screen
(C).
4. When you are finished making changes, use the
RIGHT ARROW to move curser over Wrench icon.
5. Press center, ENTER button to return to Main Setup
Screen.
312865F
Setup Mode Screens
Preset Meters
C
G MANUAL LIMIT = 5.0
E QTS F 5.0 D
ti12191a
Preset meters also include F - G
F. Set Manual Dispense Limit field: Sets maximum
quantity of fluid that can be dispensed in Manual Mode.
To change/set the Manual Dispense Limit:
1. Use RIGHT ARROW to move curser to Manual Dis-
pense Limit field (F).
2. Use UP or DOWN ARROWS to increase and
decrease displayed amount.
3. When amount you want to use is shown in field,
press center, ENTER button to confirm amount.
Confirmed amount displays on screen (G).
4. When you have finished making changes, use the
RIGHT ARROW button to move curser over Wrench
icon.
5. Press center, ENTER button to return to Main Setup
Screen.
G. Manual Limit Confirmation: Displays maximum
quantity of fluid that can be manually dispensed at one
time. Amount is assigned on the task bar Set Manual
Dispense Limit field (F). Preset dispense amounts are
not affected by the manual dispense limit you set.
13
Setup Mode Screens

Calibrate Screen (FIG. 14)

For All Meters All meters include D - M
D. Wrench Icon: Returns user to Main Screen.
Recalibrates the meter for different fluids.
J. Calibration Factor: Displays amount operator
Table 1. Calibration Factors
dispensed during meter calibration.
Calibration Number
Fluids Quarts Liters K. Preset Calibration Factor: Preset calibration
amount displays.
Oil (10W - 30) 173 183

173 183 Adjusting the Preset Calibration Factor:

Gear Lube
1. Use your LEFT or RIGHT ARROW to move the
Automatic 167 176
curser to the Calibration Factor Field (K) .
Transmission Fluid
159 168 2. Use the UP or DOWN ARROW to manually adjust
Antifreeze
the Preset Calibration Factor up or down (this can
Calibration factors at 70F (21C) at 2.0 gpm (7.6 lpm). only be done on Calibrate Screen 1 (FIG. 14).
Calibration number may vary slightly due to temperature
or flow rate. 3. Press center, ENTER button to confirm new setting.
New setting displays in Calibration Factor field (J).
Calibrate Screen 1 L. Start/End button: Clicked at the start and completion
of calibration. See Recalibrating the Meter (page 15).

M. Dispense: Only appears on Screen 2 (FIG. 14).

J
Displays amount operator dispensed during calibration
test.

L D
ti12173a
K

Calibrate Screen 2

L
ti12174a
FIG. 14

14 312865F
 Setup Mode Screens

Recalibrating the Meter (FIG. 14) 3. Dispense exactly 1 quart (or 1 liter) of fluid into a
calibrated 1 quart (or 1 liter) container.
The meter is shipped from the factory with the default
calibration factor for 10W30 motor oil - at 70F (21C).
The Calibration Factor will appear on the screen in
This calibration factor is sufficiently accurate for most
the Calibration Factor field (J).
oils. If other fluids are used or if greater accuracy is
required, the meter can be recalibrated by performing
4. Use the LEFT or RIGHT ARROWS to select END
one of the following recalibration methods.
(L) on Calibrate Screen 2.
1. Choosing a Calibration Factor From the
5. Press the center, ENTER button to confirm selec-
Calibration Table 1 tion. Calibrate Screen 1 will appear.

Calibration factors provided in Table 1 (page 14),
are only approximate, but sufficient for most appi-
cations. For the most accuracy, use method 2,
Manual Calibration Procedure.
1. Use LEFT or RIGHT ARROW to move the curser to
the Calibration Factor Field (K) .
2. Use the UP or DOWN ARROWS to manually adjust
the Preset Calibration Factor up or down until the
number displayed matches the calibration factor you
have chosen from Table 1.
3. Press center, ENTER button to confirm new setting.
New setting displays in Calibration Factor field (J).
4. Use the RIGHT ARROW button to move curser over
Wrench icon.
5. Press center, ENTER button, to return to Main
Setup Screen.
6. When you have finished making changes, use the
RIGHT ARROW button to move curser over Wrench
icon.
7. Press center, ENTER button, to return to Main
Setup Screen.
To attain the most accurate calibration:
Use the manual calibration procedure (Method 2).
Use a certified, graduated cylinder; either 1-Quart or
1-Liter volume in the system of Units to be used
(either English or SI) for real-time dispenses.
Calibrate using the exact fluid to be dispensed, at
the temperature expected during dispense.
After calibration check your results by measuring a
dispense.
Be sure to remove all fluid from graduated cylinder
between calibration attempts.

OR Be sure meter is set to proper system of units for

container you are using.
2. Manual Calibration Procedure
Once the meter has been calibrated, the unit of
See FIG. 14, page 14 for the Calibrate Screens 1 and 2
measure can be changed to any other unit, without
referenced in the following instructions.
the need for recalibration.
When an English unit (gallon, quarts, pints) is
set as the measurement unit on the Units/Limit
Screen, page 13, use a one quart graduated
cylinder to calibrate the meter.
When a System International Unit (SI) (Liter) is
set as the measurement unit on the Units/Limit
Screen, use a one Liter graduated cylinder to
calibrate the meter.

1. Use the LEFT or RIGHT ARROWS to select START

(L) on Calibrate Screen 1.

2. Press the center, ENTER button to confirm selec-

tion. Calibrate Screen 2 will appear.

312865F 15
Setup Mode Screens

Preset Screen (FIG. 15)

For Preset Meters Only To set Preset amounts (FIG. 15):

Sets the default preset amounts. Typically, you would 1. Use the LEFT or RIGHT ARROWS to select one of
enter amounts you most frequently dispense. the three amount fields (Q).

2. Use the UP or DOWN ARROWS to increase or

decrease the number appearing in the field until the
PRESET desired amount displays.

1 2 3 Pressing and holding the ARROW button down,

increases the scrolling speed.
4.0 6.0 10 3. Press center, ENTER button to confirm amount.

Q P QTS
The amounts displayed do not automatically recal-
culate quantities when changing between measure-
D ment units. For example, if you change from quarts
to liters you must manually change the preset
ti12188a amounts.
FIG. 15

4. When you have finished making changes, use the

Preset Meters include D, P and Q
LEFT OR RIGHT ARROW button to move curser
D. Wrench Icon: Returns user to Main Screen. over Wrench icon.

P. Measurement Unit: Set on Units/Limit Screen, 5. Press center, ENTER button, to return to Main
page 13. Setup Screen.

Q. Set Preset Amounts: Sets dispensing options for

the Preset Dispense mode.

Sets up to 3, default preset quantities. The amounts can

be listed in any order and do not have to be in a numeric
order.

16 312865F

Banner Screen (FIG. 16)
For All Meters
Creates the information banner displayed across top of
the Home, Manual and Preset Screens.
M O B I L 1 5 W R ENGLISH
- 2 0
ti12181a D ENGLISH
FIG. 16
Banner Screen Features D and R
D. Wrench Icon: Returns user to Main Screen.
R. Banner field: Information line. Provides space for up
to 11 numeric and alpha characters and/or spaces.
Using the DOWN ARROW button when a field is blank
will also provide the following characters for selection:
(period) . ; (forward slash) / ; or (dash) - .
To create a banner:
1. Use the UP or DOWN ARROWS to scroll through
numerals, then alpha characters and then
blank/spaces.
2. Press center, ENTER button to select characters.
When character is selected, curser automatically
moves to the next character field.
Use the RIGHT ARROW button to skip fields or if
you do not need to use all 11 spaces, to return
curser to the Wrench icon. After 11th character has
been confirmed, curser automatically moves to
Wrench icon (D).
3. Use the center, ENTER button, to return to the Main
Setup Screen.
312865F
Setup Mode Screens
Language Screen (FIG. 17)
For All Meters
Sets language preference for text displayed on meter.
Choices include English and Spanish.
LANGUAGE =
S
T D
FIG. 17
Language Screen Features D, S, and T
D. Wrench Icon: Returns user to Main Screen.
S. Language field: Identifies selected language.
T. Language field/button: When curser is over this
button, each time UP or DOWN arrow is pressed, the
name of the Language displayed on the button changes.
To select your language:
1. Use the LEFT or RIGHT ARROW to move the
curser to the Language field/button (T).
2. Use UP or DOWN ARROWS to view language
choices.
3. When the name of your language is displayed on
the field/button (T), press the center ENTER button
to confirm selection.
The selected language is then displayed on screen in
Language field (S).
After you press the center, ENTER button, the name on
the field/button will also change from SPANISH to
EPANOL and will appear this way on both the Language
button (T) and in the Language field (S) on the screen.
4. When you have finished making changes, use the
LEFT OR RIGHT ARROW button to move curser
over Wrench icon.
5. Press center, ENTER button, to return to Main
Setup Screen.
17
Dispensing Fluid and Operation Mode Screens

Dispensing Fluid and Operation Mode Screens

FIRE HAZARD: Conductive metal surfaces on the

meter must not make contact with any positively
charged metal surface, including (but not limited to),
the starter solenoid terminal, alternator terminal or
battery terminal. Such contact could cause electrical
arcing and a fire.

If you are in the Setup Mode, to display the Operation Mode Screens use the UP or DOWN ARROW button to select
HOME from the list. Press the Center ENTER button to display the Operation Mode Home Screen shown in FIG. 18.
A complete description of the Setup Mode Screens begins on page 11.

Home Screen (FIG. 18)

All Meters

Manual Meters Preset Meters

D MOBIL1 5W-20 A D MOBIL1 5W-20 A

MANUAL B
MANUAL
TOTALS B PRESET
TOTALS
C C

ti12175a ti12184a
FIG. 18

All Meters include Include A - D

A. Screen Identifier Icon: House displays when user is 1. Use UP or DOWN ARROWS to scroll through
on the Home Screen. options.

B. Operation Screens: List/menu of screen choices 2. Press center, ENTER button to confirm selection
available to user. Operation Screen choices include: and display the screen.

Manual Meters C. Battery Indicator: Appears only on Home Screen.

Shows current battery charge strength. Appears and
MANUAL flashes on all screens when batterys charge is low.
TOTALS
Preset Meters D. Information Banner: Configurable information
banner. Data is input on Setup Mode Banner Screen,
MANUAL page 17.
PRESET
TOTALS

18 312865F
 Dispensing Fluid and Operation Mode Screens

Manual Dispense (FIG. 19) To dispense in Manual Mode:

All Meters If display was asleep, press any button to wake it up.
Preset shown
D MOBIL1 5W-20
MOBIL1 5W-20

H
10.56 QTS E
MANUAL
PRESET
G F
TOTALS
ti12178a
FIG. 19 ti12180a

FIG. 20
See FIG. 19 for terms D - H
1. From HOME screen, use the UP or DOWN
D. Information Banner: Configurable information
ARROWS to select MANUAL (FIG. 20).
banner. Data is input on Setup Mode Banner Screen,
page 17.
2. Press center, ENTER button to confirm selec-
tion.The Manual Dispense screen (FIG. 21) appears.
E. Unit of Measurement: Identifies unit of
measurement, pint, quart, gallon or liter. Measurement
Unit is set on Setup Mode Units/Limits Screen, page
13. MOBIL1 5W-20
F. Home Icon: Returns user to Home Screen.

G. Reset: Resets counter (H) to zero. H 10.56 QTS

H. Counter: Before dispense has begun, display reads

0.00. As fluid is dispensed, counts up from zero.

To reset counter to zero after a dispense: G

ti12178a
FIG. 21
1. Use the LEFT or RIGHT ARROW button to move
curser to RESET (G).
3. Squeeze trigger to dispense fluid. If using a Preset
2. Press center ENTER button. The displayed amount meter, trigger may be locked during the dispense.
in field H returns to zero.
Fluid flows. The amount displayed counts up from zero or
from the previously dispensed amount
(FIG. 21) and displays in field H.

4. Release, or for Preset meters only, unlock trigger

when you have dispensed the desired amount of
fluid.

Fluid flow stops. Amount dispensed displays in field H.

5. Use LEFT or RIGHT ARROW to move curser to

RESET button (G). Press center ENTER button to
reset the displayed amount in field H to zero.

312865F 19
Dispensing Fluid and Operation Mode Screens

Preset Dispense (FIG. 22) L. Preset Quantities: Use the UP or DOWN ARROW to
select field L on the task bar.

Preset Meters Only a. Use the UP or DOWN ARROWS to scroll

through the 3 available Preset Quantities (L).
Each time you press the UP or DOWN
ARROWS, one of the 3 preset amounts dis-
D MOBIL1 5W-20 plays on the task bar in field L.
b. When the Preset Quantity you want to dispense

2.50
is shown in field L, press the center, ENTER
H QTS E button to select it.

J XXXXXXXXXXXXXXXX
If a suitable preset quantity is not available, select
G 4.0 an amount that is closest to the amount you want to
dispense. Amounts can be modified following the
ti122410a F procedure described on page 21.
L
FIG. 22

See FIG. 22 for terms D - L

D. Information Banner: Configurable information
banner. Data is input in Setup Mode, Banner Screen,
page 17.

E. Unit of Measurement: Identifies unit of

measurement, pint, quart, gallon or liter. Unit is selected
in Setup Mode, Units/Limit Screen, page 13.

F. Home Icon: Returns user to Home Screen.

G. Reset: Resets counter (H) to zero.

H. Counter: Before dispense has begun, display reads

0.00. As fluid is dispensed, counts up from zero. At the
same time the Progression Bar (J) displays a real-time,
visual representation of the progress made toward
completing the dispense.

J. Progression Bar: Displays a real-time, visual

representation of the progress made toward completing
the dispense. Runs in conjunction with Counter (H).

For example, in FIG. 22, a partial dispense of 2.5 quarts

of the total Preset Dispense of 5.0 quarts is shown. The
Progression Bar shows that approximately half the
dispense is complete.

20 312865F
 Dispensing Fluid and Operation Mode Screens

To modify the amount selected:

a. Use the UP or DOWN ARROW to scroll up or

down to increase or decrease the amount
shown in field L. Each time you press the UP or
DOWN ARROW the amount will increase or
decrease in increments of 0.1 units.

To speed up the scrolling progression, press

and hold the UP or DOWN ARROW.

b. IMPORTANT!!! When the new dispense

amount is shown in field L, the number
flashes, indicating a change has been made
that requires confirmation.

To confirm new amount you MUST PRESS

the center, ENTER button on the key pad
within 15 seconds. If you begin a dispense
without confirming the new amount, the Preset
Amount will return to the previous confirmed
amount shown in field L.
For example, in FIG. 23 (below) the original, confirmed
Preset Dispense amount (A) was 4.0 qts. The amount
was increased to 8.0 quarts and because it has not
been confirmed, is flashing on the screen (B). After the
user confirmed this change by pressing the center
ENTER button on the key pad, the new dispense
amount no longer flashes and is now set to dispense 8.0
quarts (C).

MOBIL1 5W-20

2.50 QTS

XXXXXXXXXXXXXXXX

A
4.0
B
8.0
C 8.0
FIG. 23

To permanently modify the default Preset Quantities,

see To set Preset amounts: on page 16.

312865F 21
Dispensing Fluid and Operation Mode Screens

To dispense in Preset Mode: 3. Squeeze trigger to begin dispensing fluid. The trig-
ger may be locked during the dispense.
If the display was asleep, press any button to wake up
the display. Fluid flows. The amount displayed counts up from
zero or from the previously dispensed amount
(FIG. 25) and displays in field H. A visual
MOBIL1 5W-20 representation of the dispense progression also
appears on the progression bar (J).

When the preset amount has been dispensed, fluid

MANUAL flow stops automatically. The total dispensed
amount appears in field H.
PRESET
TOTALS If you want to stop fluid flow before the preset
amount is dispensed, release or unlock trigger. To
continue dispensing fluid, squeeze and/or lock
ti12242a trigger again. Dispensed amount shown in field H
FIG. 24 and on progression bar (J) continues to count up
toward preset amount.
1. From HOME screen, use the UP or DOWN
If you want to continue dispensing fluid after preset
ARROWS to select PRESET (FIG. 24).
amount has been dispensed, squeeze trigger. The
2. Press center, ENTER button to confirm selec- meter continues dispensing fluid in Manual Mode
tion.The Preset Dispense screen (FIG. 25) appears. until you release trigger.

4. Use LEFT or RIGHT ARROW to move curser to

MOBIL1 5W-20 RESET button (G).

5. Press center ENTER button to reset the displayed

amount in field H to zero and clear the progression
H 2.50 QTS bar (J).

J XXXXXXXXXXXXXXXX

G 4.0
ti12410a
FIG. 25

22 312865F
 Dispensing Fluid and Operation Mode Screens

Totals Screen (FIG. 26) To display Totals Screen:

All Meters If the display was asleep, press any button to wake up
the display.

M MOBIL1 5W-20
3485 QTS

N 14953 GAL
MANUAL
PRESET
TOTALS
G F
ti12190a
ti12243a
FIG. 26
FIG. 27

See FIG. 26 for terms F, G, M - P

1. From HOME screen, use the UP or DOWN
F. Home Icon: Returns user to Home Screen. ARROWS to select TOTALS (FIG. 27).

G. Reset: Resets counter (M) to zero.
M. Resettable Total: Shows cumulative amount that
has been dispensed in all modes. Can be reset to zero
at any time with Reset button (G).
N. Total: Shows cumulative amount that has been
dispensed in all modes for the life of the unit. Cannot
be reset.
2. Press center, ENTER button to confirm selec-
tion.The Totals screen (FIG. 26) appears.
3. To reset Resettable Total field (M) to zero, use LEFT
or RIGHT ARROW to move curser over RESET but-
ton (G).
4. Press center ENTER button to reset the displayed
amount in field M to zero.

When the Total (N) reaches 999,999 the count resets

automatically to 000.

312865F 23
Troubleshooting

Troubleshooting

Relieve pressure, page 7, before you check or repair the meter. Be sure all other valves, controls and pump are
operating properly.

When calling for Technical Assistance you may be asked to provide the Software Version that is being used by
your meter. Refer to FIG. 10, page 11, item #1 for help determining where this information is shown on your
meter.

Problem Cause Solution

Battery icon is blinking.
Display does not activate.
Cannot read display
Batteries are low.
Batteries are defective.
Electronic control is malfunctioning.
Contrast is set too high or too low to
be viewed in work area
Replace batteries, page 27.
Replace batteries, page 27.
Replace the electronic bezel assem-
bly. (See Manual Meters Parts page
34 or Preset Meters Parts page 36 to
identify which kit is required for your
meter).
Adjust contrast. See Adjusting
Screen Contrast Using LEFT or
RIGHT ARROWS, page 10.
1. Relieve pressure, page 7.

2. Clean or replace filter. Order Fil-

Filter is clogged.
Pump pressure is low.
Twist lock nozzle not fully open.
Slow or no fluid flow.
ter Kit 255885.
3. If the problem remains, contact
your Graco distributor for repair
or replacement.
Increase pump pressure.
Aim nozzle into bucket or rag. Fully
open nozzle.

Do not trigger meter when nozzle

Displayed dispensed amount is not
accurate.
Meter leaks from cover/control.
is closed! If you do accidentally trig-
ger the meter with the nozzle closed,
point nozzle into a waste bucket and
open the nozzle to relieve pressure
and expel built up fluid.
Shut-off valve is not fully open. Fully open shut-off valve.
Foreign material is jammed in the Contact your Graco distributor for
meter housing. repair or replacement.
Unit needs to be calibrated for the Calibrate the meter for the fluid that is
fluid that is being dispensed. being dispensed. See Calibrate
Screen, page 14.
Poor seal at metering cover chamber. Contact your Graco distributor for
repair or replacement.

24 312865F

Problem
Preset Models only - Trigger does not Excessive dirt buildup is causing trip
reset sufficiently to dispense fluid. rod to stick.
Meter leaks from twist lock nozzle.
It is important to distinguish
between the two causes of this
problem. A new nozzle will NOT
correct a fluid leak caused by a
faulty valve.
Meter leaks from swivel.
Unit does not stop dispensing when
assumed preset amount is dis-
pensed.
312865F
Troubleshooting
Cause Solution
Clean trip rod or replace (page 28).
Order Kit 255889.
Twist lock nozzle has a damaged Replace nozzle. See Step 1 in Instal-
seal. lation Procedure, page 9.
Valve has damaged or obstructed Clean valve stem and o-rings or
seals. replace. Order Kit 255888.
Poor swivel/hose connection. Apply PTFE tape (leave a minimum 2
engaged threads uncovered for elec-
trical continuity) or sealant to threads
of hose and tighten the connection.
See Step 3 in Installation Procedure,
page 8.
Poor swivel/meter housing connec- Torque the fitting to 20-25 ft.-lbs.
tion.
Swivel seals have deteriorated and Replace swivel.
leak.
Valve is dirty. Clean valve.
Low battery. Replace batteries, page 27.
Solenoid not functioning (Preset Replace solenoid.
only).
25
Troubleshooting

Error Codes
Error codes are listed below. Even in an error condition the unit keeps track of the amount dispensed. With any error
code displayed you can:

Select Manual option on Home Screen.

Error code is cleared. Unit switches to Manual mode and dispensed amount is displayed.

Select reset option.

Error code is cleared, Unit switches to Auto mode and the present amount is displayed.

Error Code Cause Solution

Err 1 Battery voltage is low
Switch Error: Error occurred with
pick-up in internal gear.
Err 2 or
Unit was dropped or unit encountered Select Reset, item G, page 19.
excessive vibration during shipping.
Flow has continued after it should
have shut off.
Err 4 or
Flow has occurred in lockout condi-
tion.
In Manual Mode only.
The unit has dispensed the shut-off
Err 5
default amount and has stopped fluid
flow.
A present dispense amount of zero
was entered for the dispense or is
Err 6
stored as the default and a Preset
dispense was attempted.
Battery voltage is too low.
Change battery, page 27.
Ensure that your flow rate is not
higher than 14 gpm (37.8 lpm). For
further assistance, contact your
Graco distributor.
Check for low battery symbol and
replace batteries if indicated, page
27. For further assistance, contact
your Graco distributor.
Navigate to Home screen. Then
re-enter Dispense Screen.
Select Reset, item G, page 19 and
dispense again.To change the
shut-off default amount, see
Units/Limits Screen, page 13.
Enter an amount that is not zero. See
Preset Dispense Screen, page 20.
Change battery, page 27.

or
CAP ERROR: Error has occurred in Replace the electronic bezel assem-
Err7
control. bly. (See Manual Meters Parts page
34 or Preset Meters Parts page 36 to
identify which kit is required for your
meter).

26 312865F
 Service

Service
See Parts List, page 41, for reference numbers included in the following Service instructions.

Replacing the Battery

Only use the size and type of batteries specified in

this manual.

Batteries required to meet life expectancy:

Energizer E91

Be sure to follow the correct polarity when

installing batteries in the battery compartment 47
(FIG. 28). Reversed batteries may damage this
meter.

Do not mix different types of batteries together or

old batteries with fresh ones. Always replace all 4
batteries with 4, fresh, new batteries.
ti10984a

The low battery and dead battery displays are explained

FIG. 28
in the Troubleshooting Table, page 24.

To change the battery: 4. Replace cover. The cover is designed to only fit on
battery compartment one way. The notch (a) on
1. Press firmly on battery compartment cover. Using a cover fits into slot (b) on compartment. (FIG. 29).
flat screwdriver turn latch screw counter-clockwise .

1/2 turn.

2. Remove the battery compartment cover and batter-

ies.

3. Install new batteries. See FIG. 28 for battery orienta- (b)

tion.

(a)

FIG. 29

5. Press down firmly on cover. Using a flat screwdriver

turn latch screw clockwise 1/2 turn.

312865F 27
Service

Trip Rod Repair 4. With your finger, carefully lift up clip (D) to discon-
nect battery lead (B) from battery module.
(SDP5 & SDP15 Meters Only)

B
D
Disassembly
1. Relieve Pressure, page 7.

2. Use a Torx (T20) wrench to remove 4 corner screws

(A) located on the bottom of the meter (FIG. 30). ti11938a
Keep these screws for reassembly. FIG. 32

A NOTICE
Do not use a screw driver or any other tool to lift up
clip (D) when disconnecting battery lead (B) from bat-
tery module. If the clip is damaged or broken it cannot
be repaired; you will have to replace the battery mod-
ule. Order Part No. 255197.
A

ti11936a
FIG. 30

3. Turn meter over and tilt cover back (FIG. 31).

You will not be able to completely remove the cover

until you disconnect the leads to the battery, sole- 5. Unsnap solenoid lead (C) (FIG. 33).
noid and remove the reed switch PCB.

C
C

ti11939a
B
FIG. 33

ti11937a
FIG. 31

28 312865F
 Service

6. Remove two screws (D) holding reed switch board 8. Remove guard (9) by inserting your thumb or finger
to the cover plate (FIG. 34). Keep these screws for behind the cover and pry it loose. Then slide guard
reassembly. Remove cover assembly. down and out of groove on housing (FIG. 36).

9
ti12009a

ti11940a
FIG. 36
FIG. 34

9. Unscrew solenoid (12) and remove from meter

7. Remove and discard o-ring (5) (FIG. 35).
housing (FIG. 37). If necessary, a pliers can be used
to loosen solenoid.

12

ti11941a
FIG. 35 ti12238a
FIG. 37

312865F 29
Service

10. Place meter in a vise as shown in FIG. 38. Use new 13. Remove trip rod assembly from meter housing.
trip rod from your kit (2) or a non-metal rod or dowel
to push trip rod through meter housing (FIG. 38 and
Be careful when you remove the trip rod assembly.
FIG. 39) far enough to access pin (19) holding
Cover the balls with your fingers or a rag to prevent
together trip rod and trigger.
them from falling out.

ti12013a
19
ti12011a FIG. 41
FIG. 38

11. Use a pick to push pin (19) out (FIG. 39).

Cleaning Trip Rod
a. If the trigger does not reset sufficiently to dis-
pense fluid, clean trip rod and spring with a soft
brush and cleaning fluid such as mineral spirits.

b. Inspect trip rod and spring. If damaged, replace

using Trip Rod Replacement Kit 255889.

19
ti12012a
FIG. 39

12. Remove trigger assembly (6) from meter housing.

ti12016a

FIG. 40

30 312865F
 Service

Reassembly 5. Install trigger assembly (8) (FIG. 44). Push pin (19)
through holes in trigger and trip rod assembly.
Use all the new parts provided in the kit. Do not reuse
the old parts.
8
1. Insert balls (3) in trip rod (2) (FIG. 42).

2. Slide spring (1) over trip rod (2) (FIG. 42). 2

3 19
ti12015a

FIG. 44

2 6. Install solenoid (12). Finger tighten securely.

1 12

ti12014a

FIG. 42

3. Insert trip rod assembly in opening in meter housing ti12238a

(FIG. 43).

FIG. 45

7. Install o-ring (5).

FIG. 43

4. Turn meter over and place in vise. Align holes in trig-

ger assembly with holes in trip rod (2). Use the old
trip rod or a non-metal rod or dowel to push trip rod ti11941a
up and out of the meter housing (FIG. 44) far enough
to see hole for pin (19) to slide into, however, do not FIG. 46
install pin in this step.

312865F 31
Service

8. Reinstall reed switch board in meter housing. Use 2

screws (D) to secure reed switch PCB to cover NOTICE
plate. Tighten screws until they bottom out.
Do not use a screw driver or any other tool to lift up
clip (D) when reconnecting battery lead (B). If the clip
is damaged or broken it cannot be repaired; you will
have to replace the battery module. Order Part No.
255197.

D D

ti11940a

FIG. 47

9. Reconnect lead (B) to battery by carefully sliding

connector over battery terminals (E) until it snaps 10. Reconnect solenoid lead (C) (FIG. 49).
securely into place under clip (D) (FIG. 48).

D E
C

ti11939a
FIG. 49

ti11938ab 11. Position cover over meter housing.

NOTICE
When replacing cover, be careful not to pinch wires.
FIG. 48

32 312865F
 Service

12. Replace 4 screws (A). Torque each to 24-35 inch

pounds.

ti11936a
FIG. 50

13. Install guard (9).

ti12009a
FIG. 51

312865F 33
SDM5 & SDM15 Manual Meters Parts

SDM5 & SDM15 Manual Meters Parts

(

Ref Part Description Qty

2 115477 SCREW, mach, torx pan hd 6
5 120812 O-RING, seal 1
6 15K418 TRIGGER, meter 1
9 15K464 GUARD, bumper 1
11 HOUSING, meter 1
13 15K600 CARTRIDGE, valve 1
14 15W020 STEM, valve 1
17 255197 MODULE, battery 1
18 256493 KIT, repair, electronic bezel,
includes 18a and instruction man-
ual 312942
18a LABEL, control, overlay 1
19 120850 PIN, dowel M4 2
24 255888 KIT, repair, valve and seal
includes 24a-24e and instruction
manual 312939
24a PACKING, o-ring 1
24b PACKING, o-ring 1
24c PACKING, o-ring 1
24d O-RING, 2
24e SPRING, compression 6.1 x 76mm 1
28 120853 PIN, dowel 1
31 247344 SWIVEL, straight, 1/2-14 NPT, 1
includes 31a (used with 255348,
255349, 255350, 255802, 255803,
255804, 256836, 256837)
247345 SWIVEL, straight, 3/4-14 NPT 1
includes 31a (used with 255800,
255801)
31a 105765 O-RING 1
32 15T366 BOOT, swivel, 3/4 hose, black 1
(standard with meter)
15T367 BOOT, swivel, 3/4 hose, red 1
15T368 BOOT, swivel, 3/4 hose, blue 1
15T369 BOOT, swivel, 3/4 hose, green 1
15T370 BOOT, swivel, 3/4 hose, yellow 1
34 255885 KIT, filter, includes 34a-34c
34a FILTER, wire, 40 mesh 10
34b PACKING, o-ring 10
34c SPACER, strainer 10
39 15R057 BUSHING, stationary, rod 1
40 15R056 ROD, stationary 1
41 115999 RING, retaining 1
47 121413 BATTERY, pkg, 4 count, alkaline, 1
AA (page 27)
49 15T259 LABEL, CE 1
50 15T492 SPACER, 1/4 OD x 0.9 th 4
51 15T603 GUARD, right 1
52 15T604 GUARD, left 1
53 117436 SCREW, thd forming 2

Replacement Danger and Warning labels, tags and

cards are available at no cost.

34 312865F
 SDM5 & SDM15 Manual Meters Parts

18a
3 Torque to 25-35 IN. LBS

5 Torque to 20-30 FT. LBS 18

17 / 47

41

39

40

11
28
52
3 2 49
34
34a 6
34b 50
34c

32
24e
51
53
19
31a 24b
5 31 24c 24d

14
5 13
ti11916a
24a

312865F 35
SDP5 & SDP 15 Preset Meters Parts

SDP5 & SDP 15 Preset Meters Parts

(

Ref Part Description Qty Ref Part Description Qty

2 115477 SCREW, mach, torx pan hd 6 47 121413 BATTERY, pkg, 4 count, alkaline, 1
3 255889 KIt, repair, trip rod, includes 3a-3c 1 AA (page 27)
and instruction manual 312944 49 15T259 LABEL, CE 1
3a BALL,5 MM, carbide 3 51 15T603 GUARD, right 1
3b ROD 1 52 15T604 GUARD, left 1
3c SPRING, compression 10.67 mm 1 53 117436 SCREW, thd forming 2
5 120812 O-RING, seal 1
6 15K418 TRIGGER, meter 1 Replacement Danger and Warning labels, tags and
7 15K443 ARM, trip 1 cards are available at no cost.
8 15K446 PLATE, ratchet 1
9 15K464 GUARD, bumper 1
11 HOUSING, meter 1
12 15W093 SOLENOID 1
13 15K600 CARTRIDGE, valve 1
14 15W020 STEM, valve 1
15 15K602 SPRING, torsion 1
17 255197 MODULE, battery 1
18 256494 KIT, repair, electronic bezel, 1
includes 18a and instruction man-
ual 312942
18a LABEL, control, overlay 1
19 120850 PIN, dowel M4 2
24 255888 KIT, repair, valve and seal,
includes 24a-24e and instruction
manual 312939
24a PACKING, o-ring 1
24b PACKING, o-ring 1
24c PACKING, o-ring 1
24d O-RING, 2
24e SPRING, compression 6.1 x 76mm 1
28 120853 PIN, dowel 1
31 247344 SWIVEL, straight, 1/2-14 NPT, 1
includes 31a (used with 255200,
255351, 255352, 255355, 255356,
256838, 256839)
247345 SWIVEL, straight, 3/4-14 NPT 1
includes 31a (used with 255353,
255354)
31a 105765 O-RING 1
32 15T366 BOOT, swivel, 3/4 hose, black 1
(standard with meter)
15T367 BOOT, swivel, 3/4 hose, red 1
15T368 BOOT, swivel, 3/4 hose, blue 1
15T369 BOOT, swivel, 3/4 hose, green 1
15T370 BOOT, swivel, 3/4 hose, yellow 1
34 255885 KIT, filter, includes 34a-34c 1
34a KIT, filter, wire, 40 mesh 10
34b PACKING, o-ring 10
34c SPACER, strainer 10

36 312865F
 SDP5 & SDP 15 Preset Meters Parts

3 Torque to 25-35 IN. LBS

5 Torque to 20-30 FT. LBS 18a

18

17 / 47

12

3a

3b
3

3c
5
52
28 11
34
49
34a
34b 15 6 19
34c 3 2
24e

53 24d
51
24b
31a 7
24c
5 31
5 13 14 8
32
24a
ti10617a
9

312865F 37
Nozzle (33) and Extension (20) Kits

Nozzle (33) and Extension (20) Kits

Part No. Description Fluid Type

Automatic, non-drip quick close nozzle with

255852* Oil
rigid extension. ti11827

ti11826

Automatic, non-drip quick close nozzle with

255853* Oil ti11827
flexible extension

ti11825

Non-drip, quick close nozzle with rigid

255854 Gear Lube ti11830
extension

ti11831

Non-drip, quick close nozzle with rigid exten- ti11828

255855* Anti-freeze
sion

ti11826

Non-drip, quick close nozzle with flexible

255856* Anti-freeze ti11828
extension

ti11825

*Used for dispensing 5gpm (22.7 lpm) or less.

continued on page 32

38 312865F
 Nozzle (33) and Extension (20) Kits

Part No. Description Fluid Type

Non-drip, quick close, high-flow nozzle with Oil and

255857
rigid extension Anti-freeze
ti11829
ti11826

Non-drip, quick close, high flow nozzle with Oil and

255858
flexible extension Anti-freeze
ti11829

ti11825

312865F 39
Nozzle (33) and Extension (20) Kits

Nozzle (33) Kits

255459* Automatic, non-drip, quick-close nozzle Qty Oil
BODY, nozzle 1
O-RING, packing 1
SPRING, compression 1
O-RING, packing 1
STEM, nozzle, valve 1
SEAT, valve 1
255460* Automatic, non-drip, quick-close nozzle Anti-freeze
BODY, nozzle 1
SPRING, compression 1
O-RING, packing 1
STEM, nozzle, valve 1
O-RING, packing 1
SEAT, valve 1
255461 Automatic, non-drip, high-flow nozzle Oil and Antifreeze
STEM, nozzle 1
BODY, nozzle 1
O-RING, packing 1
O-RING, packing 1
O-RING, packing 1
255470 Non-drip, quick-close nozzle Gear Lube
Housing 1
Body, nozzle 1
O-RING, packing 1
O-RING, packing 1
Plug, Hollow, hex 1
*Used for dispensing 5gpm (22.7 lpm) or less.

Thermal Relief Kits (page 6)

Part No.
Description PSI (bar) Rating
112353 Diaphragm pump for fuel dispense, valve only 50 psi (.34 MPa, 3.4 bar)
235998 Mini Fire-Ball 225, 3:1 600 psi (4.1 MPa, 41 bar)
237601 Fire-Ball 425, 3:1 600 psi (4.1 MPa, 41 bar)
237893 Fire-Ball 300, 5:1 900 psi (6.2 MPa, 62 bar)
248296 Fire-Ball 300, 5:1 (same as 237893 without bung 900 psi (6.2 MPa, 62 bar)
adapter and swivel. Includes 6-foot hose)
238899 Diaphragm pump 150 psi (1 MPa, 10.4 bar)
240429 Fire-Ball 425, 6:1 and 10:1 1600 psi (11 MPa, 110 bar)
248324 Fire-Ball 425, 6:1 and 10:1 (same as 240429 1600 psi (11 MPa, 110 bar)
minus bung adapter and swivel. Includes 6-foot
hose)

40 312865F
 Technical Data

Technical Data
Flow range* 0.26 to 14 gpm (1 to 53 lpm)
Maximum Working Pressure 1500 psi (10 MPa, 103.4 bar)
Maximum Working Pressure
(50:50 antifreeze/water mix) 900 psi (6.2 MPa, 62 bar)
Units of Measure pints, quarts, gallons, liters (factory set to quarts)
Weight 5 pounds (2.26 kg)
Dimensions (without extension)
Length 13 inches (33 cm)
Width 3.75 inches (9.5 cm)
Height 5.75 inches (14.6 cm)
Units of measure factory set in quarts
maximum totalizer amount = 999,999 gallons or liters
maximum recorded dispensed volume = 999.99 units
maximum preset volume (Preset only) = 999.9 units
Inlet 1/2-14 npt or 3/4-14 npt
Outlet 3/4-16 straight thread o-ring boss
Operating temperature range 4 F to 158F (-4C to 70C)
Storage temperature range -40F to 150F (-40C to 70C)
Battery** 4AA alkaline or lithium batteries
Expected battery life in typical shop 1 year
environment
Wetted parts aluminum, stainless steel, PBT/PC, zinc,
nitrile rubber, CS
Fluid compatibility antifreeze, gear oil, crankcase oil, ATF
Meter pressure loss 80 psi @ 10 gpm
Accuracy +/- 0.5 percent

*Tested in 10W motor oil. Flow rates vary with fluid pressure, temperature and viscosity.
**Battery required to meet life expectancy: Energizer Alkaline E91.
At 2.5 gpm (9.5 lpm), at 70F (21C), with 10-weight oil and 1 gallon dispensed. May require calibration; out-of-box
accuracy is +/- 1.25 percent.

312865F 41
Graco Extended Metered Dispense Valve Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. Graco will, for a period of five (5) years from the date of sale, repair
or replace any non-electronic part of the equipment determined by Graco to be defective. Graco will also for a period of three (3) years from the
date of sale, repair, or replace any meter electronic components determined by Graco to be defective. This warranty applies only when the
equipment is installed, operated and maintained in accordance with Gracos written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Gracos sole obligation and buyers sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rdaction du prsente document sera en Anglais, ainsi que tous documents, avis et procdures judiciaires excuts, donns ou intents, la suite
de ou en rapport, directement ou indirectement, avec les procdures concernes.

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.
This manual contains English. MM 312865
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2008, Graco Inc. is registered to ISO 9001
www.graco.com
Revised 2/2009
 Instructions Parts List
Parts

ProShot
Grease Dispense Valve 309032J

For high pressure grease dispense.

8000 psi (55 MPa, 552 bar) Maximum Working Pressure

Model No. 242055, Series B, 1/4 npt Fluid Inlet

Model No. 242056, Series B, 1/4 npt Fluid Inlet with Coupler
Model No. 242057, Series B, 3/8 npt Fluid Inlet
Model No. 242058, Series B, 3/8 npt Fluid Inlet with Coupler

Important Safety Instructions

Read all warnings and instructions in this manual.
Save these instructions.

GRACO INC.P.O. BOX 1441MINNEAPOLIS, MN55440-1441

Copyright 1999, Graco Inc. is registered to I.S. EN ISO 9001
 Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . 8
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . 5

Symbols
Warning Symbol Caution Symbol

WARNING CAUTION
This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to
injury or death if you do not follow the instructions. or destruction of equipment if you do not follow the
instructions.

WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

D This equipment is for professional use only.

D Read all instruction manuals, tags, and labels before operating the equipment.

D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.

D Do not alter or modify this equipment.

D Do not exceed the maximum working pressure of the lowest rated system component. This equip-
ment has a 8000 psi (55 MPa, 552 bar) maximum working pressure.

D Check equipment daily. Repair or replace worn or damaged parts immediately.

D Handle hoses carefully. Do not pull on hoses to move equipment.

D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 66_C (150_F) or below 40_C (40_F).

D Comply with all applicable local, state, and national fire, electrical, and safety regulations.

D Do not use a low pressure flexible extension on a high pressure dispensing valve.

D Do not attempt to force lubricant into a fitting.

2 309032
 WARNING
SKIN INJECTION HAZARD
Spray from the valve, leaks or ruptured components can inject fluid into your body and cause ex-
tremely 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 valve at anyone or at any part of the body.

D Do not put your hand or fingers over the grease fitting coupler.

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

D Tighten all fluid connections before operating the equipment.

D Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
Do not repair high pressure couplings; you must replace the entire hose.

D Use only Graco approved hoses.

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.

Pressure Relief Procedure
WARNING
INJECTION HAZARD
Fluid under high pressure can be in-
jected through the skin and cause seri-
ous injury. To reduce the risk of an injury
from injection, splashing fluid, or moving parts, fol-
low the Pressure Relief Procedure whenever you:
D are instructed to relieve the pressure,
D stop dispensing,
D check or service any of the system equipment,
D or install or clean the nozzle.
To reduce the risk of serious bodily injury, including
fluid injection, splashing in the eyes or on the skin, or
injury from moving parts, always follow this procedure
whenever you shut off the pump, and before inspect-
ing, removing, cleaning or repairing any part of the
pump or system.
1. Close the supply pumps bleedtype master air
valve (required in pneumatic systems).
2. Open the dispensing valve until pressure is fully
relieved.
3. Open the fluid drain valve at the pump fluid outlet.
Leave the drain valve open until you are ready to
use the system again.
NOTE: If you suspect the dispensing valve,
extension or grease fitting coupler is clogged, or
that pressure has not been fully relieved after
following all the previous steps, using a rag VERY
SLOWLY loosen the coupler or hose end coupling
and allow pressure to be relieved gradually, then
loosen the part completely. Now clear the clog.

309032 3
 Operation
This dispense valve provides positive control of high pressure lubricants. When supplied with air, the pump will start
when the valve is triggered and will stall against pressure when the trigger is released.

Adjustment
2. To adjust the clearance, loosen the top nut (Fig. 1,
WARNING item 5) and turn the bottom nut (5) in or out as
needed. To increase grease flow turn bottom nut
To reduce the risk of serious injury whenever you in. To reduce grease flow turn bottom nut out. Hold
are instructed to relieve pressure, always follow the the bottom nut in place and securely tighten the
Pressure Relief Procedure on page 3. top nut.
1. Relieve the pressure.

7
Yoke
5

Rod Guide

11

Torque 90 110 ft. lbs.

TI0628
Fig. 1

4 309032
 Service
9. Push plunger rod (15) through seal (4). Be careful;
WARNING seat (14), ball (2) and copper gasket (6) will fall out
bottom.
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the 10. Replace all parts included in service kit 243446.
Pressure Relief Procedure on page 3.
11. Reassemble valve.
1. Relieve the pressure.

2. Check all parts thoroughly when disassembling, WARNING

and carefully replace any that are worn or dama-
ged.
3. Remove bottom seat adapter (10) from grease gun
body (9). See parts listing on page 6.
12. With trigger in free position tighten bottom nut (5)
4. Remove acorn nuts (1) and bolts (17) from trigger
guard (12). Remove trigger guard (12).
5. Remove outlet adapter (7).
To reduce the risk of serious injury after servicing
valve, always make sure the valve is in the closed
position with trigger released.
until yoke bottoms out on rod guide, See Fig.1,
(this is the maximum flow setting). Back off nut
approximately 1/8 turn. Hold bottom nut in place
and securely tighten top nut.

6. Remove hex nuts (5). 13. If additional adjustment is desired, follow adjust-
ment procedure on page 4.
7. Remove yoke (16).
14. For specific operational problems, see TROUBLE-
8. Remove rod guide (18) from grease gun body (9). SHOOTING GUIDE on page 5.

Troubleshooting Guide
Problem Cause Solution
Grease flows with trigger released Damaged ball Install service kit
Damaged seat Install service kit
Out of adjustment Readjust (See Figure 1)
Missing ball Install service kit
No grease flow when trigger Out of adjustment Readjust (See Figure 1)
pulled Plugged seat Clean seat
Disassembled plunger and rod Reassemble
Grease leaking out of bottom of Loose bottom adapter Tighten adapter (See Figure 1)
gun Missing copper Gaskets Install service kit
Worn copper Gaskets Install service kit
Grease leaking out the top of gun Worn seal in top of gun Install service kit
Short seal life Worn plunger rod Install service kit
Trigger will not move Bent guard Replace guard
Bent pivot pin Install service kit
Damaged handle Replace trigger

309032 5
 Parts
12

17*

18*
1*
4* 6*
5*
2*
16* 15* 14*
8a
6

9**
10
8b

3*

11 TI0629b

Ref Part Description Qty. Ref Part Description Qty.

No. No. No. No.
1* NUT, selflocking, 1032 2 10 195610 1/4 ADAPTER, seat 1
2* BALL, carbide 1 Model 242055 and 242056 only
3* SPRING, compression 1 195620 3/8 ADAPTER, seat 1
4* SEAL 1 Model 242057 and 242058 only
5* NUT, hex, 1032 2 11 196999 TRIGGER 1
6* GASKET, copper 2 12 195612 GUARD, trigger 1
7 196783 ADAPTER, outlet; 1/8 npt 1 14* SEAT, valve 1
8 200389 NOZZLE 1 15* PLUNGER/ROD ASSY. 1
Includes items 8a and 8b 16* YOKE 1
Model 242056 and 242058 only 17* SHAFT, pivot 2
8a TUBE, adapter (not sold separately) 1 18* GUIDE, rod 1
8b 200325 COUPLER 1
Model 242056 and 242058 only
9** BODY, grease gun 1

* Items included in Service Kit 243446 only.

** Not available.

6 309032
 Technical Data
Category Data
Maximum Working Pressure 8000 PSI
Inlet Size 1/4 or 3/8
Wetted Parts Chrome Vanadium, Polyurethane, Brass, Carbon Steel, Alloy Steel

Notes

309032 7
 Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from
defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended,
or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the
equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained
in accordance with Gracos written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub-
stitution of nonGraco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Gracos sole obligation and buyers sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD
BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches,
hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in mak-
ing any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais-
sent avoir convenu que la rdaction du prsente document sera en Anglais, ainsi que tous documents, avis et procdures judiciaires
excuts, donns ou intents la suite de ou en rapport, directement ou indirectement, avec les procedures concernes.

Graco Information
TO PLACE AN ORDER, contact your Graco distributor, or call one of the following numbers
to identify the distributor closest to you:
18005339655 Toll Free
6126236928
6123783590 Fax

All information, illustrations and specifications in this document are based on the latest product information available at the time
of publication. The right is reserved to make changes at any time without notice.
MM 309032

Graco Headquarters: Minneapolis

International Offices: Belgium, Korea, China, Japan

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 554401441

www.graco.com
PRINTED IN U.S.A. 309032 12/1999, Revised 06/2005
8 309032
 Instructions Parts List

ALUMINUM

Huskyt 716 AirOperated

Diaphragm Pump 308573Z1
100 psi (0.7 MPa, 7 bar) Maximum Fluid Working Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Input Pressure

Part No. 241906, Series C

BunaN diaphragms and balls
Restricted air inlet to maximize pumping efficiency for
evacuation systems

Patents Pending

9246A
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 554401441

Copyright 1995, Graco Inc. is registered to I.S. EN ISO 9001
 Table of Contents Symbols
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Warning Symbol
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 WARNING
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 This symbol alerts you to the possibility of serious
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 injury or death if you do not follow the instructions.
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Caution Symbol
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CAUTION
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . 28 This symbol alerts you to the possibility of damage to
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 or destruction of equipment if you do not follow the
instructions.

WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS
 This equipment is for professional use only.

 Read all instruction manuals, tags, and labels before operating the equipment.

 Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.

 Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

 Check equipment daily. Repair or replace worn or damaged parts immediately.

 Do not exceed the maximum working pressure of the lowest rated component in your system. This
equipment has a 100 psi (0.7 MPa, 7 bar) maximum working pressure at 100 psi (0.7 MPa, 7
bar) maximum incoming air pressure.

 Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturers warnings.

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

fluids containing such solvents in aluminum pumps. Such use could result in a serious chemical
reaction, with the possibility of explosion.

 Do not use hoses to pull equipment.

 Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82C (180F) or below 40C (40F).

 Do not lift pressurized equipment.

 Wear hearing protection when operating this equipment.

 Comply with all applicable local, state, and national fire, electrical, and safety regulations.

2 308573
 WARNING
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.

 Know the specific hazards of the fluid you are using.

 Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.

 Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

 Pipe and dispose of the exhaust air safely, away from people, animals, and food handling areas. If
the diaphragm fails, the fluid is exhausted along with the air. See Air Exhaust Ventilation on
page 9.

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.

 Ground and bond the equipment. Refer to Grounding on page 4.

 If there is any static sparking or you feel an electric shock while using this equipment, stop pump-
ing immediately. Do not use the equipment until you identify and correct the problem.

 Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being pumped.

 Pipe and dispose of the exhaust air safely, away from all sources of ignition. If the diaphragm fails,
the fluid is exhausted along with the air. See Air Exhaust Ventilation on page 9.

 Keep the work area free of debris, including solvent, rags, and gasoline.

 Electrically disconnect all equipment in the work area.

 Extinguish all open flames or pilot lights in the work area.

 Do not smoke in the work area.

 Do not turn on or off any light switch in the work area while operating or if fumes are present.

 Do not operate a gasoline engine in the work area.

308573 3
 Installation
Grounding
 Air and fluid hoses: use only electrically conductive
WARNING hoses.

FIRE AND EXPLOSION HAZARD
This pump must be grounded. Before
operating the pump, ground the system
as explained below. Also read the sec-
tion FIRE OR EXPLOSION HAZARD on
page 3.
Check your system electrical continuity after the initial
installation, and then set up a regular schedule for
checking continuity to be sure proper grounding is
maintained.
To reduce the risk of static sparking, ground the pump
and all other equipment used or located in the pumping
area. Check your local electrical code for detailed
grounding and bonding instructions for your area and
type of equipment.
 Air compressor: follow the manufacturers recom-
mendations.
 Suction device nozzle: must be bonded to metal
container from which it is suctioning by firm metal-
to-metal contact to a properly grounded suction
hose and pump.
 Piping, valves and fittings: use only electrically
conductive materials. Bond and ground per code.
 Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive.
Do not place the pail on a non-conductive surface,
such as paper or cardboard, which interrupts the
grounding continuity.

Ground and bond all of this equipment:  Waste storage tank: follow your local code.
 Pump: attach a ground wire (Y) to the grounding
strip (111) with the screw (121), lockwasher (122)
and nut (123), as shown in Fig. 1, and per code.
Connect the clamp end of the ground wire to a true
earth ground. Order Part No. 222011 Ground Wire
and Clamp.

123
122

111

121

9247A
Fig. 1

4 308573
 Installation
Typical Installation Description
Fig. 2 shows a system for the fast evacuation of gear
oil from vehicles. One centrally-mounted Husky 716
pump can have suction line drops to up to four service
bays, when activated singly. Interchangeable, nylon
suction wands are available to fit most differentials.
One control valve at each bay remotely activates the
pump and quickly suctions the gear oil. This system
can also be used to remove waste oil from rolling
waste oil drain carts, using a high capacity wand.
Fig. 3 shows a system for the fast evacuation of waste
oil from rolling waste oil receivers, or for general fluid
transfer applications. In waste oil evacuation systems,
roll the receivers up to a centrally mounted Husky 716
pump. Couple a quick disconnect coupler to a mating
connector on the waste oil receiver. Turn on the pump
and the oil is quickly evacuated from the receiver and
sent to a waste oil storage tank.
General Information
 The Typical Installations in Figs. 2 and 3 are only
guides for selecting and installing system compo-
nents. Contact your Graco distributor for assistance
in planning a system to suit your needs.
 Always use Genuine Graco Parts and Accessories.
 Installation and use must be in accordance with the
Flammable and Combustible Liquids Code (NFPA
30) and Automotive and Marine Service Station
Code (NFPA 30A) and must comply with all local,
state and federal codes.
 Use a compatible, liquid thread sealant on all male
threads. Tighten all connections firmly to avoid air
or fluid leaks.
 Reference numbers and letters in parentheses refer
to the callouts in the Figures and the parts lists on
pages 20 to 21.
 Always mount the pump in the upright position as
shown in Figs. 2 and 3. A non-upright position
prevents checks from operating properly.
CAUTION
Safe Operating Temperatures
Minimum: 40 F (4 C)
Maximum: 225 F (107 C)
These temperatures are based upon mechanical stress
only and may be significantly altered by pumping certain
chemicals. Consult engineering guides for chemical com-
patibilities and temperature limits, or contact your Graco
distributor.
WARNING
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.
 Read TOXIC FLUID HAZARD on page 3.
 Use fluids and solvents which are compatible
with the equipment wetted parts. Refer to the
Technical Data section of all equipment manu-
als. Read the fluid and solvent manufacturers
warnings.
Tightening Screws Before First Use
Before using the pump for the first time, check and
retorque all external fasteners. See Torque Se-
quence, page 22. After the first day of operation,
retorque the fasteners. Although pump use varies, a
general guideline is to retorque fasteners every two
months.
Mountings
 Be sure the mounting surface can support the
weight of the pump, hoses, and accessories, as
well as the stress caused during operation.
 The Husky 716 Pump can be used in a variety of
installations. See Figs. 2 and 3 for examples.
 Secure the pump with screws and nuts.
308573 5
 Installation
Example of a Gear Oil Receiver Evacuation System
J

J K J K J

D KEY
A Pump air regulator
Bay 1 Bay 2 Bay 3 B Air line quick coupler (required)
C Fluid drain valve (required)
F D Control valve
E Suction wand
K G F Suction hose
E G Fluid quick coupler
H Husky 716 pump
J Electrically conductive, bonded
J air supply line
K Electrically conductive, bonded
fluid line to pump
L Electrically conductive, bonded
J B H L waste oil line to storage tank
A Y Ground wire (required; See page 4
for installation instructions. Pump
must be properly grounded and entire
Y system electrically bonded.)

C
J
9249A
Fig. 2

J Example of a Waste Oil Evacuation System,

or General Fluid Transfer Application
J J
A L Shown with fluid inlet and outlet ports facing
forward (see page 8).
NOTE: Air inlet restrictor may be removed for
higher flow capabilities.
H
G C
S
KEY
B
A Pump air regulator
Y B Air line quick coupler (required)
F C Fluid drain valve (required)
D D Wall-mount bracket (Part No. 224835)
F Electrically conductive suction hose
G Fluid quick coupler
M H Husky 716 pump
J Electrically conductive, bonded air supply line
L Electrically conductive, bonded waste oil line to storage tank
M Waste oil receiver
S 90 Elbow (required for wall mount applications)
Y Ground wire (required; See page 4 for installation instruc-
tions. Pump must be properly grounded and entire system
electrically bonded.)

9250A
Fig. 3
6 308573
 Installation
Air Line
WARNING
An air line quick coupler (B) is required in your
system to relieve air trapped between this valve
and the pump. See Fig. 2. Trapped air can cause
the pump to cycle unexpectedly, which could result
in serious injury, including splashing in the eyes or
on the skin, injury from moving parts, or contamina-
tion from hazardous fluids.
CAUTION
Before connecting the permanent air line to the
regulator (A), blow out all lines with air to remove
contaminants that can clog or damage the regulator,
hose, or pump air valve.
CAUTION
The pump exhaust air may contain contaminants.
Ventilate to a remote area if the contaminants could
affect your fluid supply. See Air Exhaust Ventilation
on page 9.
1. Install the air line accessories as shown in Fig. 2.
Mount these accessories on the wall or on a
bracket. Be sure the air line supplying the acces-
sories is electrically conductive and bonded.
2. Use the air regulator (A) to control the pump fluid
outlet pressure. The fluid pressure will be the
same as the setting on the regulator gauge.
3. Install an electrically conductive, flexible air hose
(J) between the regulator (A) and the 1/4 npt(f)
pump air inlet (air restrictor in evacuation applica-
tions). Use a minimum 1/4 in. (6.3 mm) ID air
hose. Screw an air line quick disconnect coupler
(B) onto the end of the air hose (J), and screw the
mating fitting into the pump air inlet snugly. Do not
connect the coupler (B) to the fitting yet.
Fluid Supply Line
 Use electrically conductive fluid hoses (J or F). Be
sure the lines are bonded all the way from the fluid
supply to the grounded pump.
 The pump fluid inlet is 3/4 npt(f). See Fig. 4. Screw
the fluid fitting into the pump inlet snugly. Do not
overtighten.
 For the Gear Oil Evacuation System, install a
control valve (D) and an appropriate wand (E). See
Fig. 2.
 For the Waste Oil Receiver Evacuation System,
connect an appropriate suction hose (F) and fluid
quick coupler (G) between the pump fluid inlet and
the waste oil receiver (M). See Fig. 3.
 If the inlet pressure to the pump is more than 25%
of the outlet working pressure, the ball check valves
will not close fast enough, resulting in inefficient
pump operation.
 At inlet fluid pressures greater than 15 psi
(100 kPa, 1.0 bar), diaphragm life will be shortened.
Fluid Outlet Line
WARNING
A fluid drain valve (C) is required in your system to
relieve pressure in the hose if it is plugged. See
Figs. 2 and 3. The drain valve reduces the risk of
serious injury, including splashing in the eyes or on
the skin, or contamination from hazardous fluids
when relieving pressure. Install the valve close to
the pump fluid outlet.
 Use electrically conductive fluid hoses (L). Be sure
the lines are bonded all the way from the grounded
pump to the waste storage tank.
 The pump fluid outlet is 3/4 npt(f). See Fig. 4.
Screw the fluid fitting into the pump outlet snugly.
Do not overtighten.
 Install a fluid drain valve (C) near the fluid outlet.
See the WARNING above.
 Also read Fluid Pressure Relief Valve, on
page 8.
308573 7
 Installation
Changing the Orientation of the Fluid Inlet Fluid Pressure Relief Valve
and Outlet Ports

You can change the direction of the fluid inlet and

outlet manifolds (102), if desired. Model 241906 is
shipped with the fluid inlet manifold pointing toward the
air inlet and the fluid outlet manifold pointing away from
the air inlet. See Fig. 4.
CAUTION
Some systems may require installation of a pressure
relief valve at the pump outlet to prevent overpres-
surization and rupture of the pump or hose. See
Fig. 5.

Thermal expansion of fluid in the outlet line can

1. Remove the bolts (105) holding the manifold (102)
to the covers (101). Save the attaching hardware.
2. Turn the manifold to the desired position, and
reinstall the hardware. Torque the bolts (105) to 80
to 90 inlb (9 to 10 Nm). See Torque Sequence,
page 22.
cause overpressurization. This can occur when using
long fluid lines exposed to sunlight or ambient heat,
or when pumping from a cool to a warm area (for
example, from an underground tank).
Overpressurization can also occur if the Husky pump
is being used to feed fluid to a piston pump, and the
intake valve of the piston pump does not close,
causing fluid to back up in the outlet line.

Pressure Relief Kit 238428 is available for use on

aluminum Husky 716 pumps and may be purchased
1 Torque to 8090 inlb (910 Nm). See Torque
Sequence, page 22. separately.
2 1/4 npt(f) Air Inlet
KEY
3 3/4 npt(f) Fluid Inlet N 3/4 npt(f) Fluid Inlet Manifold
4 3/4 npt(f) Fluid Outlet (on opposite side) P 3/4 npt(f) Fluid Outlet Manifold
R Pressure Relief Valve, Part No. 113497
105 1
2 102 4 Install valve between fluid inlet and outlet ports. Other parts
5 shown are included in Pressure Relief Kit 238428.

101 R 5

102 3 9257A
Fig. 4 N 9285A
Fig. 5

8 308573
 Installation
Air Exhaust Ventilation
WARNING
FIRE AND EXPLOSION HAZARD
Be sure to read FIRE OR EXPLOSION
HAZARD and TOXIC FLUID HAZARD
on page 3, before operating this pump.
Be sure the system is properly ventilated
for your type of installation. You must
vent the exhaust to a safe place, away from peo-
ple, animals, food handling areas, and all sources
of ignition when pumping flammable or hazardous
fluids.
Diaphragm failure will cause the fluid being
pumped to exhaust with the air. Place an appropri-
ate container at the end of the air exhaust line to
catch the fluid. See Fig. 6.
The air exhaust port is 3/8 npt(f). Do not restrict the air
exhaust port. Excessive exhaust restriction can cause
erratic pump operation.
To exhaust to a remote location:
1. Remove the muffler (W) from the pump air exhaust
port.
2. Install an electrically conductive air exhaust hose
(X) and connect the muffler to the other end of the
hose. The minimum size for the air exhaust hose
is 3/8 in. (10 mm) ID. If a hose longer than 15 ft
(4.57 m) is required, use a larger diameter hose.
Avoid sharp bends or kinks in the hose.
3. Place a container (Z) at the end of the air exhaust
line to catch fluid in case a diaphragm ruptures.
See Fig. 6.

VENTING EXHAUST AIR

See Fig. 2 for accessories
KEY
W Muffler
X Electrically Conductive Air Exhaust Hose
Z Container for Remote Air Exhaust

9253A
Fig. 6

308573 9
 Operation
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The equipment stays pressurized until pressure is
manually relieved. To reduce the risk of serious
injury from pressurized fluid, accidental spray from
the gun or splashing fluid, follow this procedure
whenever you
 Are instructed to relieve pressure
 Stop pumping
 Check, clean or service any system equipment
 Install or clean fluid nozzles
1. Close the air regulator by turning counterclockwise
as far as possible.
2. Disconnect the air line quick coupler to relieve air
pressure.
3. Open the dispensing valve, if used.
4. Open the fluid drain valve to relieve all fluid pres-
sure, having a container ready to catch the drain-
age.
Flush the Pump Before First Use
The pump was tested in air, to eliminate possible
contamination of the fluid you are pumping by test
fluids. Prior to use, flush the pump thoroughly with a
compatible solvent. Follow the steps under Starting
and Adjusting the Pump.
10 308573
Starting and Adjusting the Pump
All Systems
WARNING
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. Do not lift a pump under
pressure. If dropped, the fluid section may rupture.
Always follow the Pressure Relief Procedure at
left before lifting the pump.
1. Be sure the pump is properly grounded and
bonded. Read FIRE OR EXPLOSION HAZARD
on page 3.
2. Check all fittings to be sure they are tight. Use a
compatible liquid thread sealant on all male
threads. Tighten the fluid inlet and outlet fittings
snugly. Do not overtighten the fittings into the
pump.
3. For the first startup: Connect the fluid inlet hose
to the pump and place the other end of the hose in
a two quart container of oil. Start the pump follow-
ing Steps 1, 3 and 4 in either of the following
startup procedures. When the container is empty,
shut off the air to the pump and reconnect the
hose to the suction line. This procedure wets the
pump internal parts to ensure maximum suction.
 Operation
Waste Receiver Evacuation Systems, or General
Fluid Transfer Applications (See Fig. 3)
1. Connect the suction hose (F) to the waste oil
receiver (M) with a fluid quick coupler (G).
2. Be sure the drain valve (C) is closed.
3. Connect the air hose (J) to the pump with an air
line quick coupler (B). A 90 elbow (134) is sup-
plied for use in wall mount applications.
4. Open the air regulator (A) until the pump starts to
cycle.
5. Adjust the air regulator. Do not use higher air
pressure than needed for the pump to provide
good suction. Increasing the pump cycle rate does
not necessarily improve suction.
Gear Oil Evacuation Systems (See Fig. 2)
1. Attach an appropriate wand (E) to the suction hose
(F).
2. Be sure the air inlet restrictor (125) is attached to
the pump.
3. Be sure the drain valve (C) is closed.
4. Connect the air hose (J) to the pump with an air
line quick coupler (B).
5. Open and set the air regulator (A) between 40 and
50 psi (280340 kPa, 2.83.4 bar), adjusting for
best operation.
6. Place the suction wand (E) in the differential or
fluid to be pumped.
7. Pull the control valve (D) handle down to start the
pump.
8. Adjust the air regulator. Do not use higher air
pressure than needed for the pump to provide
good suction. Increasing the pump cycle rate does
not improve suction.
9. Push the control valve (D) handle up when fin-
ished. Place the wand in the holder on the control
valve.
NOTE: Be sure the control valve handle is closed
when the evacuation is completed. Failure to close it
may prevent other service bays on the line from devel-
oping full suction.
Pump Shutdown
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
At the end of the work shift, relieve the pressure.
308573 11
 Maintenance
Lubrication Tightening the Clamps
Do not lubricate the air line or air valve. Excessive When tightening the clamps (109), apply thread lubri-
lubrication can cause the pump to malfunction. cant to the bolts and be sure to torque the nuts (110)
to 80 to 90 inlb (9 to 10 Nm). See Torque Se-
quence, page 22. See Fig. 7.
Flushing and Storage
Apply thread lube to bolts and torque nuts to
1 80 to 90 inlb (9 to 10 Nm). See Torque
WARNING Sequence, page 22.

To reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.

Flush the pump often enough to prevent the fluid you

are pumping from drying or freezing in the pump and
damaging it. Flush with a fluid that is compatible with
the fluid you are pumping and with the wetted parts in 109
your system. Check with your fluid manufacturer or
supplier for recommended flushing fluids and flushing
frequency.

Always flush the pump and relieve the pressure

before storing it for any length of time.
110
1
Grounding Continuity Check
Check your system electrical continuity regularly to be
sure proper grounding is maintained.

Tightening Threaded Connections

Before each use, check all hoses for wear or damage,
and replace as necessary. Check to be sure all
threaded connections are tight and leakfree.
Check fasteners. Tighten or retorque as necessary.
Although pump use varies, a general guideline is to
retorque fasteners every two months. See Torque
Sequence, page 22.
9254A
Fig. 7
Preventive Maintenance Schedule
Establish a preventive maintenance schedule, based
on the pumps service history. This is especially impor-
tant for prevention of spills or leakage due to dia-
phragm failure.

12 308573
Notes

308573 13
 Troubleshooting
1. Relieve the pressure.
WARNING
2. Check all possible problems and causes before
To reduce the risk of serious injury whenever you disassembling the pump.
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.

PROBLEM CAUSE SOLUTION

Pump will not cycle, or cycles once Air valve is stuck or dirty. Use filtered air.
and stops.
Pump cycles at stall or fails to hold Leaky check valves or o-rings. Replace.
pressure at stall.
Worn check balls or guides. Replace.
Check ball wedged in guide. Repair or replace.
Worn diaphragm shaft seals. Replace.
Pump operates erratically. Clogged suction line. Inspect; clear.
Sticky or leaking check valve balls. Clean or replace.
Diaphragm ruptured. Replace.
Air bubbles in fluid. Suction line is loose. Tighten.
Diaphragm ruptured. Replace.
Loose manifolds or damaged man- Tighten manifold bolts or nuts; re-
ifold o-rings. place o-rings.
Loose fluid side diaphragm plates. Tighten.
Fluid in exhaust air. Diaphragm ruptured. Replace.
Loose fluid side diaphragm plates. Tighten.
Worn diaphragm shaft seals. Replace.
Pump exhausts air from clamps. Loose clamps. Tighten clamp nuts.
Air valve o-ring is damaged. Inspect; replace.
Pump leaks fluid from check valves. Worn or damaged check valve Inspect; replace.
o-rings.
No fluid output, and pump cycles Pump mounted incorrectly. Mount the pump in the upright posi-
rapidly. tion.

14 308573
 Service
Air Valve (Husky 716 Pumps)
NOTE: Air Valve Repair Kit 241657 is available. Parts included in the kit are marked with a dagger () in Fig. 8 and
in the Parts Drawings and Lists. A tube of general purpose grease 111920 is supplied in the kit. Service the air
valve as follows. See Fig. 8.

NOTES:
WARNING
 When you install each u-cup packing (2) on each
To reduce the risk of serious injury whenever you carriage plunger (7), make sure the lips of the
are instructed to relieve pressure, always follow the u-cup packing face toward the clip end (the
Pressure Relief Procedure on page 10. smaller end) of the carriage plunger.

1. Relieve the pressure.
2. Remove the cover (10) and the o-ring (4).
3. Remove the carriage plungers (7), carriages (8),
carriage pins (9), and valve plate (14) from the
center housing (11).
4. Clean all the parts, and inspect them for wear or
damage.
NOTE: If you are installing the new Air Valve
Repair Kit 241657, use all the parts in the kit.
 When you slide the carriage plungers (7) into the
bores, slide them in with the clip ends (the smaller
ends) facing toward the center of the center hous-
ing (11).
7. Grease the carriage pins (9), and slide the carriage
pins into the carriage pin bores.
8. Install the carriages (8). Make sure the carriages
engage the clip ends of the carriage plungers (7)
and carriage pins (9).

5. Grease the lapped surface of the valve plate (14),

and install the valve plate with the lapped surface
facing up.
6. Grease the bores of the center housing (11), install
the u-cup packings (2) on the carriage plungers
(7), and slide the carriage plungers into the car-
riage plunger bores. See the following important
installation notes:
8
9. Grease the o-ring (4), and seat it in the groove
around the cover opening of the center hous-
ing (11).
10. Screw the cover (10) into the center housing, and
torque the cover to 80 to 100 inlb (9.0 to 13.6
Nm).

NOTE: Center housing (11) is shown 1 10

separated from the air covers, but it is not
necessary to remove the air covers for this
5 4 2 3 14
service. Leave the center housing and air 5 4 2 4 6 7
covers assembled for this service.
4 6 7

 Included in Air Valve Repair Kit 241657 4 2

1 Torque to 80100 inlb (9.013.6 Nm).

2 Apply grease.

3 Apply grease to lapped face. 11

4 Apply grease to bores of center housing (11) before installing.

5 Seal lips face clip end (the smaller end) of carriage plunger (7).
9 2
6 Install with the clip ends (the smaller ends) facing toward center 8
of center housing (11). 9 2
9069A
Fig. 8
308573 15
 Service
Tools Required 1 Torque to 80 to 90 in-lb (9 to 10 Nm). See
Torque Sequence, page 22.
 Torque wrench 1 105
 9/16 in. socket wrench
 O-ring pick
107

Ball Check Valves

NOTE: Fluid Section Repair Kit D05277 is available.

Kit parts are marked with an asterisk, for example
102
(301*). Use all the parts in the kit for the best results.
Always replace the o-rings (139*) with new ones
whenever they are removed for any reason. *139

*202
*301
WARNING
*201
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the *139
Pressure Relief Procedure on page 10.
106

1. Relieve the pressure. Disconnect all hoses.

101
2. Remove the pump from its mounting.

106
3. Unscrew the four bolts (105), washers (107), and
nuts (106) holding the top manifold (102) to the
covers (101). Lift the manifold off the pump. See
Fig. 9.
*139

4. Remove the outer o-ring (139*), ball stop (202*), *202

ball (301*), ball guide (201*), and inner o-ring
*301
(139*) from each of the covers (101).
*201
5. Turn the pump over. Remove the bolts (105), nuts *139
(106), feet (108) and bottom manifold (102).

6. Remove the outer o-ring (139*), ball guide (201*), 102

ball (301*), ball stop (202*), and inner o-ring (139*)
from each of the covers (101).

7. Clean all parts. Inspect parts and replace worn or

damaged ones. 1 105

9256A
8. Reassemble. Follow all notes in Fig. 9. Be sure the
ball checks are assembled exactly as shown. Fig. 9

16 308573
 Service
Diaphragms
NOTE: Fluid Section Repair Kit D05277 is available.
Parts included in the kit are marked with an asterisk in
Fig. 10 and in the Parts Drawings and Lists. General
purpose grease 111920 and Blue Loctite 113500 are
supplied in the kit. Service the diaphragms as follows.
See Fig. 10.
Disassembly
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
1. Relieve the pressure.
2. Remove the manifolds (102) and fluid cov-
ers (101).
NOTE: Make sure all the check valve parts stay in
place. See Fig. 9 on page 16.
3. Remove the grounding strip from the vee clamps
(109), and remove the vee clamps.
4. Remove one of the fluid-side diaphragm plates
(133) (whichever one comes loose first when you
use a wrench on the hex of each), and pull the
diaphragm shaft out of the center housing (11).
5. Use a wrench on the flats of the diaphragm shaft
(15) to remove the other fluid-side diaphragm plate
(133) from the diaphragm shaft.
6. Remove the screws (141) and air covers (136),
and remove all old gasket (12) material from the
ends of the center housing (11) and the surfaces of
the air covers. This will loosen the exhaust cover
(13) and o-ring (4) for removal.
7. Remove the diaphragm shaft u-cups (16) and pilot
pin o-rings (1).
8. Inspect all parts for wear or damage, and replace
as necessary.
Reassembly
1. Insert a diaphragm shaft u-cup (16*) and a pilot pin
o-ring (1) into the end of the diaphragm shaft bore
of the center housing (11).
NOTE: Make sure the lips of the u-cup face out of
the center housing.
2. Line up the holes in the gasket (12) with the holes
in the end of the center housing (11), and use six
screws (141) to fasten an air cover (136) to the
end of the center housing (11). Torque the screws
to 35 to 45 in-lb (4.0 to 5.0 N-m).
3. Position the exhaust cover (13) and o-ring (4) on
the center housing (11).
4. Repeat steps 1 and 2 for the other end of the
center housing and the remaining air cover.
5. Apply medium-strength (blue) Loctite or equivalent
to the threads of the screws (140). Install on one
end of the diaphragm shaft (15) the following parts
(see proper order in Fig. 10): air-side diaphragm
plate (6), diaphragm (401), fluid-side diaphragm
plate (133), o-ring (115), and screw (140).
NOTE: The words AIR SIDE on the diaphragm
(401) and the flat side of the air-side diaphragm
plate (6) must face toward the diaphragm
shaft (15).
6. Put grease on the diaphragm shaft (15), and
carefully (do not damage the shaft u-cups, 16) run
the diaphragm shaft (15) through the center hous-
ing (11) bore.
7. Repeat step 5 for the other end of the diaphragm
shaft (15), and torque the diaphragm shaft screws
(140) to 80 to 90 in-lb (9 to 10 N-m) at 100 rpm
maximum.
8. Apply thin, even film of grease to inside of vee
clamp (109).
9. Position the fluid covers (101), install the vee
clamps (109) around the fluid and air covers,
install the grounding strip on the vee clamps, and
torque the vee clamp nuts to 80 to 90 in-lb (9 to 10
Nm). See Torque Sequence, page 22.
When you install the vee clamps, orient the center
housing (11) so the air inlet is approximately 45
above horizontal and the muffler (3) is approxi-
mately horizontal.
10. Make sure all the check valve parts are in place.
See Fig. 9 on page 16.
11. Install the manifolds (102), and torque the manifold
bolts (105) to 80 to 90 in-lb (9 to 10 Nm). See
Torque Sequence, page 22.
308573 17
 Service
Diaphragms (Husky 716)

11
*1
105
7 4
13

102 1
2 141 *16 3

12*

136
3

101
109 4 *401 5 6

15 3
*115 133
102
6 140

105 * Included in Fluid Section Repair Kit D05277

7
1 Install with lips facing out of center housing (11).

2 Torque to 35 to 45 in-lb (4.0 to 5.0 N-m).

3 Apply grease.

4 The words AIR SIDE on diaphragm and backup diaphragm must face
toward diaphragm shaft (15).

5 Flat side of the air-side diaphragm plate must face

toward diaphragm shaft (15).

6 Apply medium-strength (blue) Loctite or equivalent

to threads, and torque to 80 to 90 in-lb (9 to 10 Nm) at
100 rpm maximum.

7 Torque to 80 to 90 in-lb (9 to 10 Nm). See

Torque Sequence, page 22. 9271A

Fig. 10

18 308573
Notes

308573 19
 Parts
125
 Included in Air Valve Repair Kit 241657
10 8 7
* Included in Fluid Section Repair Kit D05277 2

4
105 102 14
103 8
107 9

112 11

*1
*12
136
*139
16*
*202
4
*301
13
*201
3
*139
106 141 15
*401 6

101
117 133
106 109
*115
140
*139

*202 Grounding Detail

*301

*201
*139 123
102 122
112

121
110
105 108

20 308573
 Parts
Ref. Ref.
No. Part No. Description Qty No. Part No. Description Qty
1* 114866 PACKING, o-ring 2 112 102726 PLUG, steel; 3/4 npt 2
2 108808 PACKING, u-cup, carriage 2 115* 110004 O-RING; PTFE 2
3 112933 MUFFLER 1 117 186205 LABEL, warning 1
4 162942 PACKING, o-ring 2 121 102790 SCREW; 1024; 0.31 in. (8 mm) 1
6 195025 PLATE, diaphragm, air side 2 122 100718 LOCKWASHER; #10 1
7 192594 PLUNGER, carriage 2 123 100179 NUT, hex; 1024 1
8 192595 CARRIAGE 2 133 191837 PLATE, diaphragm, fluid side; sst 2
9 192596 PIN, carriage 2 125 238084 RESTRICTOR, air; brass with 1
10 192597 COVER, valve chamber 1 acetal restrictor
11 192602 HOUSING, center 1 134 100840 ELBOW, street; 1/4 npt x 1/4 1
npsm; for use in wall mount ap-
12* 192765 GASKET 2 plications; not shown
13 194247 COVER, exhaust 1 136 194246 COVER air 2
14 194269 PLATE, valve 1 139* 110636 O-RING; PTFE 8
15 192601 SHAFT, diaphragm 1 140 113747 SCREW, flange; hex head 2
16* 108808 PACKING, u-cup, diaphragm 2 141 114882 SCREW, machine, phillips; 12
101 185622 COVER, fluid; aluminum 2 pan head
102 185624 MANIFOLD; aluminum; NPT 2 201* 186691 GUIDE; acetal 4
103 189220 LABEL, warning 1 202* 186692 STOP; acetal 4
105 112912 SCREW; 3/816; 8 301* 108944 BALL; buna-N 4
2.25 in. (57.2 mm) 401* 190148 DIAPHRAGM; buna-N 2
106 112913 NUT, hex; 3/816; sst 8
* These parts are included in Fluid Section Repair Kit
107 112914 WASHER, flat; 3/8 in.; sst 4 D05277, which may be purchased separately.
108 186207 BASE, feet 2
 These parts are included in Air Valve Repair Kit 241657,
109 189540 CLAMP, vee 2 which may be purchased separately.
110 112499 NUT, clamp; 1/428 2
 Replacement Danger and Warning labels, tags, and
111 191079 STRIP, grounding 1 cards are available at no cost.

308573 21
 Torque Sequence
Always follow torque sequence when instructed to torque fasteners.

1. Left/Right Fluid Covers 3. Outlet Manifold

Torque bolts to 8090 inlb (910 Nm) Torque Bolts to 8090 inlb (910 Nm)
9
7

2 1

8 10

FRONT VIEW
TOP VIEW

2. Inlet Manifold
Torque bolts to 8090 inlb (910 Nm)
5
3

4 6

BOTTOM VIEW

22 308573
 Dimensions

FRONT VIEW
4.25 in. 4.44 in.
(108.0 mm) (112.8 mm)

1/4 npt(f)
Air Inlet

10.43 in.
(264.9
mm)
9.18 in.
(233.2
mm)

7.37 in. 7.80 in.

(187.2 mm) (198.1
mm)

1.38 in.
(35.1 mm) 9257A

6.62 in.
(168.1 mm)
3/4 npt(f)
Fluid Inlet

SIDE VIEW
2.76 in.
(62.5 mm)
3/4 npt(f)
Fluid Outlet

PUMP MOUNTING HOLE PATTERN

Four 0.28 in.
(7.1 mm)
Diameter Slots

4.29 in.
(109.0 mm)

6.62 in.
(168.1 mm)
4.29 in.
3/4 npt(f) (109.0 mm)
Fluid Inlet
6.04 in.
(153.4 mm)
9254A 9078A

308573 23
 Technical Data
Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar)
Air pressure operating range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 to 100 psi (0.18 to 0.7 MPa, 1.8 to 7 bar )
Maximum air consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 scfm (0.672 cubic meters/min.)
Maximum free flow delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 gpm (61 l/min)
Maximum pump speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 cpm
Gallons (Liters) per cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04(0.15)
Maximum suction lift (water w/buna balls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ft (4.5 m) dry,
25 ft (7.6 m) wet
Maximum size pumpable solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/32 in. (2.5 mm)
Sound power level (measured per ISO standard 96142)
At 70 psig (0.48 MPa, 4.8 bar) at 50 cycles per minute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 dBa
At 100 psig (0.7 MPa, 7 bar) at maximum cycles per minute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 dBa
Sound pressure level (measured 1 meter from pump)
At 70 psig (0.48 MPa, 4.8 bar) at 50 cycles per minute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 dBa
At 100 psig (0.7 MPa, 7 bar) at maximum cycles per minute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 dBa
Air inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 npt(f)
Air exhaust port size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 npt(f)
Fluid inlet size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt(f)
Fluid outlet size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt(f)
Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . buna-N, acetal, aluminum, stainless steel, PTFE, zinc-plated steel
Non-wetted external parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . polypropylene, stainless steel, polyester (labels),
nickel-plated brass, epoxy-coated steel (feet)
Weight (approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 lb (3.9 kg)
Loctite is a registered trademark of the Loctite Corporation.

24 308573
 Performance Charts
Fluid Outlet Pressure
Test Conditions: Pump tested in water with inlet submerged.
100
(0.7, 7)

A
Fluid Pressure Curves
FLUID OUTLET PRESSUREpsi (MPa, bar)

A at 100 psi (0.7 MPa, 7 bar) air pressure

80
(0.55, 5.5) B at 70 psi (0.48 MPa, 4.8 bar) air pressure
C at 40 psi (0.28 MPa, 2.8 bar) air pressure

B
60
(0.41, 4.1)

40
(0.28, 2.8) C

20
(0.14, 1.4)

0
0 2 4 6 8 10 12 14 16
(7.6) (15.2) (22.7) (30.3) (37.9) (45.4) (53.0) (60.6)

FLUID FLOWgpm (lpm)

To find Fluid Outlet Pressure (psi/MPa/bar) at a

specific fluid flow (gpm/lpm) and operating air
pressure (psi/MPa/bar):
1. Locate fluid flow rate along bottom of chart.
2. Follow vertical line up to intersection with selected
fluid outlet pressure curve.
3. Follow left to scale to read fluid outlet pressure.

308573 25
 Performance Charts
Air Consumption
Test Conditions: Pump tested in water with inlet submerged.

30
(0.84) A

Air Consumption Curves
AIR CONSUMPTIONscfm (cubic meters/min)

A at 100 psi (0.7 MPa, 7 bar) air pressure
B at 70 psi (0.48 MPa, 4.8 bar) air pressure

25
(0.70)
C at 40 psi (0.28 MPa, 2.8 bar) air pressure

20





(0.56) B

15




(0.42)

C
10

(0.28)

5



(0.14)

0
0
2 4 6 8 10 12 14 16
(7.6) (15.2) (22.7) (30.3) (37.9) (45.4) (53.0) (60.6)

FLUID FLOWgpm (lpm)

To find Pump Air Consumption (scfm or m /min) at a

specific fluid flow (gpm/lpm) and air pressure
(psi/MPa/bar):
1. Locate fluid flow rate along bottom of chart.
2. Read vertical line up to intersection with selected air
consumption curve.
3. Follow left to scale to read air consumption.

26 308573
Notes

308573 27
 Graco Warranties
Graco Standard Husky Pump Warranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the
date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco,
Graco will, for a period of five years from the date of sale, repair or replace any part of the equipment determined by Graco to be
defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Gracos written
recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub-
stitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Gracos sole obligation and buyers sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within six years of the date
of sale.

Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide
purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais-
sent avoir convenu que la rdaction du prsente document sera en Anglais, ainsi que tous documents, avis et procdures judiciaires
excuts, donns ou intents la suite de ou en rapport, directement ou indirectement, avec les procedures concernes.

Extended Product Warranty

Graco warrants all Husky 205, 307, 515, 716, 1040, 1590, 2150, and 3275 air valve center sections to be free from defects in material
and workmanship for a period of fifteen years from date installed in service by the original purchaser. Normal wear of items such as
packings or seals are not considered to be defects in material and workmanship.

Five years Graco will provide parts and labor.

Six to Fifteen years Graco will replace defective parts only.

Graco Information
TO PLACE AN ORDER, contact your Graco distributor, or call one of the following numbers
to identify the distributor closest to you:
18003280211 Toll Free
6126236921
6123783505 Fax

All written and visual data contained in this document reflect the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
This manual contains English. MM 308573
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 554401441
www.graco.com
308573 06/1995, Revised 01/2007
28 308573
 HYDRAULICS INC.

Balanced oil temperatures - the key to efficiency in hydraulics

Maintaining the correct system temperature is important to
ensure optimum performance in a hydraulic system.
140
In many hydraulic systems, up to 50% of the available
horsepower can be lost due to inefficiencies in the system.
These inefficiencies include friction, pressure drops and 130 150
changes/interruption of flow. The end result of these losses is
the production of heat.

When the heat generated is greater than the amount that can be 120 o
F 160
naturally dissipated by the system, the fluid temperature will
rise until the rate of heat production is equal to the amount of
heat dissipated. Unfortunately, in many systems, this point of We recommend that the working temperature is held between 1300 F and
equilibrium is at a temperature that can damage both the fluid 1500 F. (for mobile hydraulic systems). A correctly calculated cooler ensures
and hydraulic components. optimum efficiency.

Harmful side effects of excessive temperature include
reduction in fluid lubricity, destruction of helpful fluid
additives, oxidation of the fluid and varnishing of system designed for mobile hydraulic
components. These effects in turn lead to greater energy
losses and more heat generation, forming a destructive cycle.
The cooler provides reliable
temperature control
The oil cooler dissipates heat from the system providing
reliable temperature control of hydraulic fluids. The correct
size of cooler and type of fluid ensure a properly operating
system. Inherent advantages include:
OAD and OAH cooler specially
applications
The OilAir OAD cooler (DC-motor driven fan) and OAH
cooler (Hydraulic motor driven fan) are designed primarily for
mobile applications. Typical applications include:
Cooling of mobile hydraulics such as cranes, logging
equipment and mining equipment.
Re-cooling of compressors on the air side as well as on the
oil side.
Cooling of Diesel-engine oils.

Hydraulic system life extended by 3-5 times. Cooling of mobile hydraulics on drill rigs.

Long lasting oil durability. Additional cooling of engine oils and mobile hydraulics
under extreme conditions (such as tropical environments).
Reduced internal potential for leaks.
Cooling of engine oils on mobile and stationary generating
Prolonged lubricating qualities. units.
Improved hydraulic efficiency.

OilAir offers the best cooler to
meet every requirement.
At OilAir we specialize in solving complicated overheating
problems in all types of hydraulic systems. Our wide range of
cooler sizes and types enables us to offer the cooler that best
meet your needs. Our other wide range of standard air oil
coolers are grouped in four main series:
A typical field application for the OAD
is cooling of mobile cranes. Minimized
operating costs and fast loading are
two very important benefits with a
correct hydraulic system temperature.
Compact size and lightweight
permit easy installation in all
kinds of mobile applications.

OAI AC motor driven air oil cooler designed for

industrial and stationary equipment.
OAO AC motor driven offline air oil cooler with an
integrated circulation pump.
OAH Hydraulic motor driven air oil cooler designed for
mobile equipment.
OAD DC motor driven air oil cooler designed for mobile
equipment.

2
 OAD
Cooling Capacities
2000
See example for obtaining the total
1800 cooling capacity from the graph.
33

1600

1400
23

1200
Btu/hr/ F
0

1000

16
800

11
600

07
400
04
200

0
0 10 20 30 40 50 60 70 80 90
Flow Rate (gpm)

Oil pressure drop curves with correction factors for other viscosities Model BPO
60
Pressure Drop at 150 SSU (psi)

Correction Factor

50 2

1
33
23
0
50 150 250 350 450
40 SSU
1
,1

30 04
07

20

10

0
0 20 40 60 80

Oil Flow Rate (gpm)

3
 HYDRAULICS INC.

Typical characteristics that make the OilAir Technical Specifications for the
OAD type of air oil cooler ideal for mobile Cooler core
applications.
Dynamic working pressure: 200 psi.
Maximum static pressure: 300 psi
Compact size and lightweight.
Maximum oil inlet temperature in 2500F. Oil temperature
High physical strength and durability. above this will reduce maximum working pressure rating.
Extremely quiet compared to conventional air oil coolers.
Easy to retrofit on all types of machines.
Unlimited utilization of all accessory units
Fluid compatible with OAD
Ease of maintenance (held together by 8 bolts only)
aluminum cooler core
OAD Material
Mineral oils
Core: Aluminum Oil/water emulsion
Fan Blades: Fiber glass reinforced polypropylene Water glycol
Fan Housing: Steel Phosphate ester
Fan Guard: Steel

Surface treatment Factors affecting heat dissipation

All steel components are electrostatic blast coated with
epoxy plastic powder.
The cooler core has a layer of protective diffused zinc to
withstand corrosion before receiving a final coat of
electrostatic epoxy plastic powder.
Consult OilAir Hydraulics Inc. for use in aggressive or
corrosive environments.
Limits of heat dissipation in graph +/- 6%
Viscositys above 450 SSU (70 cSt) will cause reduction in
heat dissipation. Consult our factory.
For aggressive environments ambient air may contain dust
particles that will increase air fin clogging coefficient.
Operating coolers at altitudes above 1300 feet will reduce
heat dissipation. Consult factory.

Technical Specifications for

OAD-04 OAD-07,11, 16
23** & 33**
Electrical Motors
Weight 4.6 Lbs 5.39 Lbs Long lasting, high quality motors available
RPM 3350 rpm 3060 rpm in 12V and 24V DC.
Noise Level 70 dB(A) 70 dB(A) Enclosed for protection

Protection Standard IP 64 IP 64
Please refer table on page 5 for power consumption

Insulation Class H H
Ambient Temp. -22 F to +176F -220F to + 1760F
0

Life Expectancy 5,000 Hrs. 8,000 - 10,000 Hrs.

** OAD 23 & 33 is twin-fan motor

Dimensions in Inches

Type A B C D E F G H I

OAD 04 9.84 8.66 - 2.91 10 0.15 8.58 3 0.55

OAD 07 13.38 11.81 - 3.54 13.54 0.15 8.18 3.54 0.98
OAD 11 15.74 14.17 8.93 3.22 15.6 0.15 8.97 3.97 0.8
OAD 16 17.95 16.37 9 3.14 18.14 0.15 8.97 3.97 1.08
OAD 23* 24.2 14 12 4.68 25 0.78 8.97 11.41 5.11
OAD 33* 24.8 14.6 15.98 3.38 26.7 0.78 10.2 11.41 5.11
** OATBD 23 is dual fan

4
 OAD
G

OAD 04 J
2.56

D
AIR

E
B

F
I
A Slot o .433x.67 (4x)
.39 H .39

OAD 7, 11&16
External Bypass Option G
J 2.56

D
AIR

C
E
F
B I
A Slot o .35x1.14 (4x) .39 H .39

OAD 23 & 33
G

External Bypass Option J 2.56

K
D
C

AIR
E
F

B o.5(4x) I 1.61
A .59 H .59

Type J K Air Flow Max. cons.of current Fuse Weight Lbs

CFM OAD 24V 12V OAD 24V 12V (Approx)

OAD 04 1.96 1-5/16-12UN 509 6A 10A 10A 15A 10

OAD 07 1.57 1-5/16-12UN 806 11A 20A 15A 25A 22
OAD 11 2.36 1-5/16-12UN 1082 11A 20A 15A 25A 27
OAD 16 2.36 1-5/16-12UN 1315 11A 20A 15A 25A 33
OAD 23* 2.36 1-5/16-12UN 2015 2x11A 2x20A 2x15A 2x25A 55
OAD 33* 3.93 1-5/8-12UN 2892 2x11A 2x20A 2x15A 2x25A 66

5
 HYDRAULICS INC.
Piping diagram for the OAD air oil cooler
No Bypass
M M
Type OAD 04
Oil inlet connection may be
located either on the right or on the
left side of the matrix. The oil
outlet connection is always located
on the opposite side of the matrix.
With Thermo Switch Model C & CB
M
Built in External By-Pass Valve
Model BP1
M BP1.5 = With built-in by-pass valve 65 psi
6
No Bypass
Type OAD 07 - OAD 33
Oil inlet connection may be
located either on the right or on the
left side of the matrix. The oil
outlet connection is always located
on the opposite side. There are two
connections on the left side, one
of these has be plugged.
Model Code
OAD 11 - x - x - x
Cooler
Size
DC-motor
Voltage 12V or 24V
Ordering Example: OAD 11 - 12V - BP1.2 - CB120
With Bypass
M
Type OAD 07 - OAD 33
Oil inlet connection is located on
the left side of the matrix (on the
by-pass valve side). The oil outlet
connection is always located on
the opposite side. There are two
connections on the left side, one
of these has to be plugged.
Thermo-contacts available:
Temp TV 100/120/160/175 F
C100 = With thermo-contact set at 100F
CB120 = With relay, fuse, switch box,
thermo-contact TV 120F
Type of by-pass valve
BP1.2 = With built-in-by-pass valve 20 psi
 OAD

Service instructions
Location
Noise level
Place the cooler so that
there is an unrestricted The noise level of the oil cooler may vary within +/-3 dB
air flow to and from the AIR (A) depending on reflections from surrounding objects,
cooler. The distance natural frequency and other interference sources etc.
from the nearest wall 1/2 core 1/2 core
should not be less than height height Suspension
half the height of the The very rigid cooler construction permits both vertical and
core. horizontal mounting. Mounting is facilitated by four
mounting holes in each support leg of the cooler. There is a
Cleaning of air fins mounting flange in the front of the air oil cooler for wall
The easiest way to clean the air fins is by using compressed mounting next to a ventilator shaft or similar structure.
air or rinsing with water. Fouling can be dealt with using a
degreasing agent and a high pressure washing system. Connection to the system
When using a high pressure washing system, point the jet The air oil cooler is intended to cool the systems return oil.
carefully parallel to the air fins. Use hydraulic hoses both to and from the cooler. Avoid
hydraulic tubes, unless stress-free joints can be guaranteed.
Cleaning the inside of If there is a risk of pressure spikes or flow peaks the cooler
oil cooling tubes should be installed with a bypass valve. If the viscosity of
the oil is 450 ssu at cold start, use a full flow pressure or
Connect the cooler to a closed circuit and flush the inside
temperature bypass valve external to the cooler.
with perchlorethylene. After cleaning, the radiator should
be flushed with oil before reconnecting to the hydraulic
system.

Useful Technical Information Examples

Recommended Maximum Oil Temperature:
Industrial Hydraulic Systems: 110F - 130F Given: Fluid Type SAE 10
Mobile Hydraulic Systems: 130F - 150F Flow Rate 25 GPM
Mobile Hydrostatic Transmission: 160F - 170F Desired Oil Temperature 130F
(Inlet to Cooler)
Formulas Ambient Air Temperature 80F
1 HP = 746 Watts = 2545 Btu/hr Altitude <3,000 feet
1 kW = 1.34 HP = 3412 Btu/hr Heat Dissipation Required 30,000 Btu/hr
Temperature conversion F = C x 1.8 +32
Required: Type of air oil cooler
Heat Equivalent of Fluid Power
HP heat = (PSI x GPM)/1714 Temperature Difference (T)
BTU/hr heat generation = 1.5 x PSI x GPM (T) = 130F - 80F = 50F
Heat dissipation per F (P) = 30,000/50
Heat Radiation from Steel Reservoirs P = 600 Btu/hr/F
HP Radiation = .001 x T.D. x A Refer to the cooler capacity chart.
Where A = Surface area in Sq. Ft. Plot the 600 Btu/hr/F against the flow
TD = Temperature difference in F
Between reservoir surface and of 25 GPM
surrounding air We recommend Cooler model #OAD 11

7
 HYDRAULICS INC.
A r o u n d
t h e
Australia
Olaer Fawcett Christie Pty Ltd
1/13 Sydenham Rd., Brookvale
P. O. Box 57, Warringah Mall
Sydney, NSW 2100
Tel: +61 2 9938 4444
Fax: +61 2 9938 6879
Austria
Olaer Speicher-Technik GmbH
Haiderstrasse 38
AT-4052 Ansfelden
Tel: +43 7229 80306
Fax: +43-7229 80306-21
Belgium
S.A. Olaer Benelux N.V.
Doornveld 4
BE-1731 Zellik
Tel: +32 2 466.15.15
Fax: +32 2 466.16.24
Denmark
Oiltech AB
Mollebaekvej 14
DK-9632 MOLDRUP
Tel: +45 86 69 20 38
Fax: +45 86 69 23 38
Finland
Oiltech Hydraulics OY
Vattuniemenkatu 8, Pl 190
FI-00210 Helsinki
Tel: +358 9 682 0422
Fax: +358 9 682 2376
France
Olaer Industries S.A.
16, rue de Seine, B.P. 7
FR-92704 Colombes Cedex
Tel: +33 1 41 19 17 00
Fax: +33 1 41 19 17 20
copyright 2002 OilAir Hydraulics, Inc.
HYDRAULICS INC.
OILAIR HYDRAULICS, INC.
11505 West Little York
Houston, Texas 77041
Tel: (713) 937-8900
Fax: (713) 937-0438
www.fluidpower.com
Norway
Oiltech AS
W o r l d Dynamitveien 23, PB 133
NO-1401 Ski
Tel: +47 64 87 42 65
Fax: +47 64 87 43 21
Germany
Olaer Industries GmbH Poland
Zum Gunterstal 4 Oiltech AB
DE-66440 Blieskastel UL. Pytlasinskiego 13A
Tel: +49 6842 9204 0 PL-00777 WARSZAWA
Fax: +49 6842 9204 15 Tel: +48 601 217440
Fax: +48 22417992
Holland
Olaer Nederland B. V. South Africa
De Lind 10, Postbus 75 Fawcett Christie Hydraulics
NL-4840 AB Prinsenbeek c/o Rolton Products CC
Tel: +31 76-5412453 P.O. Box 43244
Fax: +31 76-5411502 ZA-Industria 2042
Tel: +27 11 474 3095
Hong Kong Fax: +27 11 474 8384
Olaer Asia Pacific Ltd
Unit 12, 12/F, Block B Spain
Hoi Luen Ind. Building Olaer-Oiltech Iberica, S.A.
55 Hoi Yuen Rd, Kwun Tong Travesia Industrial, no 29
Kowloon ES-08907 LHospitalet de LI.
Tel: +852 23 31-27 80 (Barcelona)
Fax: +852 23 31-29 00 Tel: +34 3 336 14 12
Fax: +34 3 335 71 86
India
Narsipur Fawcett Christie Sweden
Hydraulics Oiltech AB
C 30 Shankara Park Forradsvagen 2
Bangalore 560 004 SE-181 41 Lidingo
Tel: +91 806 61 05 08 Tel: +46 8 765 16 00
Fax: +91 806 61 17 16 Fax: +46 8 767 97 56
Italy Switzerland
Olaer Italiana S.pA. Olaer (Schweiz) AG
Strada Fantasia 83 Bonnstrasse 3
IT-10040Leini (TO) CH-3186 Dudingen
Tel: +39 11 998.02.22 Tel: +41 26 492 70 00
Fax: +39 11 998.02.02 Fax: +41 26 492 70 70
Korea United Kingdom
Fawcett Christie Korea Ltd. Fawcett Christie Hydraulics Ltd.
2NA-702, 1259-1 Shi-Wha Sandycroft Industrial Estate
Industrial Complex Chester Rd, Sandycroft
Joung Wang-dong Deeside, Flintshire CH5 2QP
Shi Hung-Shi, Kyunggi-Do Noth Wales
Tel: +82 345 499 07 97 Tel: +44 1244 535515
Fax: +82 345 499 22 49 Fax: +44 1244 533002
Printed in the USA Bulletin OAD
SERIES P3000, P5000, P7500
GEAR PUMPS
CONTENTS

Table of Content Page

Wear, Checking parts for...................................................................................................3

Thrust Plates.....................................................................................................................3
Diverter Plates, Installing PERMCO...................................................................................3
Bearings; Checking for wear..............................................................................................3
Gear Housing, checking for wear.......................................................................................3
Covers, Shaft-end and port-end: Checking for wear...........................................................3
Types of PERMCO Pumps: Type I, II..................................................................................3
Exploded Views: PERMCO Pumps and parts..................................................................4-6
Parts numbers, PERMCO Pumps and Motors....................................................................7
Type I Pump: disassembly..................................................................................................8
reassembly...............................................................................................12
Type II Pump: disassembly.................................................................................................8
reassembly........................................................................................................12
Torques for reassembling, Table of...................................................................................15
Trouble Shooting; List of symptoms and cures.................................................................17
Motors, PERMCO Pumps used as ...................................................................................18
Parts, How to order PERMCO replacement; information needed......................................19

2
If you intend to rebuild a pump that has thrust plates
and you wish to replace the thrust plates with
Permco diverter plates, inspect the original port end
cover, shaft end cover, gear housing and bearing
carriers very carefully. To obtain the maximum
performance from diverter plates, all of the above
components must be in good condition with minimal
amount of wear. The following areas of wear are
the most critical. . and often overlooked:
1. Shaft end covers, port end covers, and bearing
carriers. . .Check bearing bores for out-of
roundness or elliptical shape. If more than 0.003"
out-of-round, do not use.
2. Gear housings... If the wear pattern on the
inlet side is in excess of 0.003" depth, do not
use.
3. Gears... Inspect very carefully. If you have
scored, scuffed or pitted journals, scratched or
scuffed tooth faces, deep nicks on tooth edges,
do not use; install new drive and driven gear.
4. Bearings... A loose fit between gear hub and
bearing ID may not mean a bad bearing. The
misalignment it can cause is detrimental to good
pump performance. We recommend installing a
complete set of new bearings at each rebuild.
5. Seals. . .It is recommended that all seals be
replaced on any rebuild job.
Putting Permco diverter plates into a pump and
reusing the old worn parts will not necessarily
restore the pump to the high efficiency and
performance of a new Permco pump. Merely
installing new Permco diverter plates cannot restore
the pump to its original performance. Permcos high
efficiency, performance, and life expectancy are
based on using all new PERMCO parts.
3
If you are rebuilding a Permco gear pump, you must
not install thrust plates of another make. Tolerances
and finishes on Permco parts are held closer than
those of other manufacturers of pump parts. For
warranty repairs under any circumstances, you
must not substitute other makes of parts in a
Permco pumps. USE ONLY GENUINE PERMCO
PARTS.
You can successfully use Permco diverter plates to
rebuild other makes of pumps to obtain increased
operating pressures and pump life. However, read
the above paragraphs carefully.
If you have any questions about rebuilding Permco
pumps or about using Permco parts to upgrade other
makes of pumps, call your local Permco pump and
parts distributor.
TWO TYPES OF PUMPS
There are two types of Permco pumps as
determined by the configuration of the shaft end
covers... Type I & Type II. There are slight
differences in disassembly and reassembly
procedures, according to each shaft end cover. Also
Type II is normally shorter from front to back than
Type I. This is because no outboard bearing is used.
Be sure you know which type you are working on.
CLEANLINESS IS HIGHLY IMPORTANT
WARNING. Before you start disassembling the
pump, clean up your work bench. This will avoid
the headaches and danger of getting dirt, metal
fragments, and foreign objects into the fine-finished
cavities and threads of the pump and components,
and eventually into the entire hydraulic system. In
pump maintenance, extreme cleanliness is most
important.
4
5
6
 PARTS LIST
Item No. Description Part Number Item No. Description Part Number
On On
Drawing Drawing

3000 SERIES PUMPS/MOTORS 16 Thrust Plate (TP) X-0947

Teflon Coated Thrust Plate X-0947-TC
1 Snap Ring W023-206 Diverter Plate X-0947-DS
2 Outboard Bearing W58-39 Bi-Rotational Diverter Plate X-0947-BRD
3 Double Lip Seal W62-26-16 17 Gasket Seal TA-2995-244
4 Bearing Carrier UA-0558-2 18 Housing LZ-0577- ** - **
5 Seal Retainer ZD-0558 19 Drive Shaft & Gear Set ** -0024L- * - **
6 High Pressure Seal W62-49-9 20 Port End Cover (PEC) YZ-0592- *
7 Shaft End Cover (SEC) ** - 0574- * 21 5/8" Grade 8 Washers W033-2
8 Check Valve Assembly L-0280-K 22 5/8-11 Grade 8 Threaded Rod ZD-0391- ***
9 Continental Shaft ** -0024 23 5/8-11 Grade 8 Hex Nut W3-65
10 Spacer SA-0558 24 Bearing Carrier ** -0576- ** - ***
11 Snap Ring W86-100 25 Connecting Shaft XZ-0022
12 Pump Shaft Seal W62-26-18 26 Gear Set LZ-0995L- **
13 Motor Shaft Seal W62-49-11 28 Grade 8 Hex Head Cap Screw W1- **
14 Ring Seal KA-0558-1XS
15 Crowned Roller Bearing X-0921
16 Thrust Plate (TP) ZZ-0947 7500 SERIES PUMPS/MOTORS
PUMPS/MOT
Teflon Coated Thrust Plate ZZ-0947-TC
Diverter Plate ZZ-0947-DS 1 Snap Ring W85-315
17 Gasket Seal TA-2995-242 2 Outboard Bearing W58-48
18 Housing QZ-0577- ** - ** 3 Double Lip Seal W62-26-10
19 Drive Shaft & Gear Set ** -0024L- * - ** 4 Bearing Spacer UA-0558
20 Port End Cover WZ-0592- * 5 Seal Retainer QZ-0961
21 5/8" Grade 8 Washers W033-2 6 High Pressure Seal W62-49-1
22 5/8-11 Grade 8 Threaded Rod ZD-0391- *** 7 Shaft End Cover (SEC) ** -0574- *
23 5/8-11 Grade 8 Hex Nut W3-65 8 Check Valve Assembly L-0280-K
24 Bearing Carrier ** -0576- ** - *** 9 Continental Shaft ** -0024
25 Connecting Shaft YZ-0022 10 Spacer ZE-0558
26 Gear Set U-0996L- ** 11 Snap Ring W86-137
28 Grade 8 Hex Head Cap Screw W1- ** 14 Ring Seal VA-0558-1XS
15 Crowned Roller Bearing Q-0921
5000 SERIES PUMPS/MOTORS
PUMPS/MOT 16 Teflon Coated Thrust Plate AZ-0947
Diverter Plate AZ-0947-DS
1 Snap Ring W023-283 Bi-Rotational Diverter Plate AZ-0947-BRD
2 Outboard Bearing W58-47 17 Gasket Seal TA-2995-252
3 Double Lip Shaft Seal W62-26-17 18 Housing RZ-0577- ** - **
4 Bearing Spacer UA-0558-1 19 Drive Shaft & Gear Set ** -0024L- * - **
5 Seal Retainer ZB-0558 20 Port End Cover (PEC) XZ-0592- *
6 High Pressure Seal W62-49-8 21 5/8" Grade 8 Washers W033-2
7 Shaft End Cover (SEC) ** -0574- * 22 5/8-11 Grade 8 Threaded Rod ZD-0391- ***
8 Check Valve Assembly L-0280-K 23 5/8-11 Grade 8 Hex Nut W3-65
9 Continental Shaft ** -0024 24 Bearing Carrier ** -0576- ** - ***
12 Pump Shaft Seal W62-26-17 25 Connecting Shaft ZA-0022
13 Motor Shaft Seal W62-49-8 26 Gear Set OZ-0995L- **
14 Ring Seal MA-0558-1XS 27 O-Ring K-2995-164
15 Crowned Roller Bearing R-0921 28 Hex Head Cap Screw W1-*

7
DISASSEMBLY All Series:
1. With a sharp metal scribing tool, grease pencil,
Magic Marker, or paint, make an indexing mark
that runs straight across a surface of the port
end cover (20), gear housing (18), and shaft end
cover (7). This will enable you to reassemble
these parts into the same position when you put
the unit back together.
2. Clamp the unit in a vise, shaft end down.
3. Remove the cap screws or threaded rod (22) and
washers (21) at the rear of the unit that hold the
port end cover (20) and the gear housing (18)
together. Remove the port end cover (20) and
diverter plate (16) or thrust plate (16).
The roller bearings (15) will remain with the port
end cover (20). On those units with thrust plates,
the pocket seals will come out easily. (Permco
pumps having diverter plates do not require
pocket seals.)
4. Remove the pump drive gear, the driven gear,
and the gear housing (18) from the shaft end
cover (7). BE CAREFUL to keep the drive gear
and the driven gear together; you must
reassemble them as the original pair, since they
have been worked-in together.
3000/5000 Series Pumps,
Types I and II.
Disassembly of Shaft End Cover
1. If unit is equipped with a shaft bearing (2) or
spacer (4), set the partially disassembled unit
(shaft end cover (7)) from which the gear housing
was separated in a vise with the pilot end up.
If unit is a Type II, it cannot be fitted with a shaft
bearing (2) or spacer (4). Skip Step 2 below,
and proceed to Step 3.
2. Remove the snap ring (1) from the shaft end
cover (7). If a bearing is present, pull it out with
a bearing puller; (this is not a press fit.) In units
used as motors, a bearing (2) or bearing spacer
(4) should be removed. Then remove the seal
retainer (5).
3. Turn the shaft end cover into pilot-down
position to make diverter plate (16) accessible.
4. Using a knife blade or thin-blade screwdriver pry
the diverter plate (16) very gently off the
bearings of the shaft end cover (7). Bearings
should remain in cover. If they dont, or can be
removed by hand, discard cover. If working on
another make of pump to be refitted with
PERMCO diverter plates, remove the pocket
seals and throw away; on PERMCO Pumps, no
pocket seals are required.
8
5. If you plan to replace the bearings, use a
bearing puller to pull the roller bearings (15)
out of the shaft end cover.
If you do pull the bearings, check the bores for
out-of round and elliptical shape. If out-of-round
is over 0.003", DO NOT RE-USE.
6. Examine ring seal (14); if worn, replace. Do
this by pulling the drive gear bearing.
7. Remove lip seal (3, if pump; 6, if motor) by
inserting a curved tool between the seal and
shaft end cover (7). Tap out seal and discard.

Disassembly of Type I"C

(Continental) Shaft End Cover
The Type I "C unit has a separate shaft and gear
set.
Disassembly will follow the same steps as described
above. Tap the drive shaft assembly out of the shaft
end cover. The shaft (9) must then be pressed out
with the bearing (2).
Bearing (2) will be removed from shaft (9) as follows:
For 3000 Series, all C shafts
1. Remove snap ring (11) and spacer (10) from
gear end of shaft (9).
2. Press the bearing (2) off the GEAR end of the
shaft (9).
For 5000 Series
Press the bearing (2) off the DRIVE end of the
shaft (9).

7500 Series Pumps

Disassembly of Shaft End Cover
1. Set the partially-disassembled unit (shaft end
cover 7) from which the gear housing has been
separated in the vise, pilot-end up.
2. Remove the snap ring (1) from the shaft end
cover (7). The bearing (2) or bearing spacer (4)
can now be removed. It is a slip fit. A bearing
puller can be used, if necessary.
3. Remove the seal retainer (5). Discard the O-
ring (27).
4. Remove the seal by inserting a curved tool
between seal and seal retainer (5), tapping it
out, and discarding.
5. Turn shaft end cover (7) pilot-end down in
vise. Diverter plate will now be accessible.
6. With a knife blade or thin-blade screwdriver, very
gently pry diverter plate (16) off the bearings of
the shaft end cover (7). If working on another
make of pump to be refitted with PERMCO
diverter plates, remove the pocket seals and
throw away. PERMCO pumps and diverter plates
require no pocket seals.
7. Use a bearing puller to pull the roller bearings
9
 (15) out of the shaft end cover (7), if you plan
to replace bearings. If you pull the bearings,
check bores for out-of-round condition and
elliptical shape. If more than 0.003" out-of-
round, do not use again.
8. Examine the ring seal (14). Replace if worn by
pulling the drive gear bearing.
Type C pump has a separate shaft-and-gear set.
Disassembly of Type C (Continental) Shaft
End Cover
Follow the steps described above for the
standard shaft end cover. However, on the Type
C unit, the shaft (9) will be pressed out of the
cover (7) along with the bearing (2).
Separate the shaft (9) from the bearing (2) as
follows:
1. Remove snap ring (11) and spacer (10)
from gear end of shaft (9).
2. Press bearing (2) off gear end of shaft (9).

Disassembly of All Series

Gear Housing; Single Units and
Multiple Units
1. Remove square gasket seals (17) from gear
housing (18), and discard. Have identical
replacements at hand for reassembly. DO NOT
USE O RINGS. Check for depth of wear in gear
housing at this time; use a telescoping gage and
a micrometer. If wear pattern on gear housing
exceeds 0.003", discard housing and
replace with a new one.
Figure A shows a satisfactory housing with little
wear. Figure B shows a housing with excessive
wear; notice large cavities that indicate cavitation
was present.
Examine the housing for cracks (Figure C). This
is caused by overpressure or by possible over
tightening of an NPT thread.
If a new gear housing is required and a large
port is present, step-drill the housing (Figure D)
if PERMCO diverter plates are to be installed.
2. Examine gears for wear, scuffed or pitted
journals, scratched or scuffed tooth faces, or
deep nick on tooth edges. If any of these defects
are present, install new drive and driven gears.
Figure E shows a satisfactory gear hub, with no
nicks. Figures F and G show gear hubs that are
breaking down from contamination, over-
pressurization, pressure shock, or bearing
failure. On examination of gear faces, some
scratches may be found; if they can be removed
by stoning, the set can be reused (see Figures
H and I).
Also examine the ring seal surface (Figure J)
for wear.
Figure K shows a rotating group that ran without oil.
10
 For Multiple units:
3. Remove the connecting shaft (25).
4. Remove the bearing carrier (24), diverter plate
(16) or thrust plate, bearings (15), and ring seals
(14), using procedure described previously for
disassembly.

Port End Cover

1. Use a knife blade or thin-blade screwdriver to
gently pry the diverter plate (16) or the thrust
plate off the bearings (15) of the port end cover
(20).
2. When working on pumps other than PERMCO
Pumps, remove and discard the pocket seals.
When installing PERMCO diverter plates, you
do not install replacement pocket seals;
PERMCO Diverter Plates do not require pocket
seals.
3. If you plan to replace the two shaft roller bearings
(15) with new ones, pull the bearings (15) out of
the port end cover (20) with a bearing puller.
4. Examine the ring seal (14). If worn, replace by
pulling the drive gear bearing (15) out, leaving
the driven gear bearing (15) in place.

Examine all diverter or thrust plates. Some wear

will always appear, because of gear flexing. Figure
L indicates very slight wear, with some scratches
because of contamination. Figure M shows wear in
the trapping area caused by contamination.
In bi-rotational units where there are two trapping
grooves, a diagonal groove may develop connecting
the two slots. This is caused by contamination.

Figure N shows the effect of cavitation... the rapid

formation and collapse of vapor cavities within a
fluid. This effect is caused by high-vacuum inlet
conditions or by air entering the pump inlet.

11
REASSEMBLY 3000/5000 Series Pumps:
Reassembly of Shaft End Cover:
1. Grip shaft end cover (7) gear end up. Place
ring seal (14) in bearing bore of shaft end
cover (7) with the flat side down.
2. Replace the two roller bearings (15) in the bores
of the shaft end cover (7). Take care that the
bearings do not cock or wedge between ring seal
(14) and bottom of bearing counter-bore.
3. Place shaft end cover (7) in a soft-jaw vise.
Turn cover (7) end-for-end, and clamp with
flange end up.
4. Apply Loctite Adhesive Sealant No. 271 to
outside of seal (3, 6, 12, or 13). Press seal into
shaft end cover (7) until seal is flush with counter-
bore. If working on a Type I pump, which has no
outboard bearing, or a Type II pump, assembly
of shaft end cover is now complete.
If working on Type I unit having bearing or
bearing spacer and integral gear shaft continue
as follows:
5. In motors only, insert the seal retainer (5) into
the shaft end cover (7).
6. Guide the bearing (2) or bearing spacer (4)
into the shaft end cover (7). This is NOT a
press fit.
7. Install snap ring (1) into the groove.
Reassembly of shaft end cover (7) is now
complete.

3000/5000 Continental Shafts

For Type I pumps with C type shafts, follow the
above Steps 1 through 5. Then proceed as
follows:

For 3000 Series: All C Shafts

6. Press the outboard bearing (2) on the drive
shaft (9), from the gear end.
7. Push the spacer (10) over the end of the shaft
(9). Install the snap ring (11) in the groove on
the shaft (9).
8. Press the bearing (2) and spacer (10) tightly
against the snap ring (11).
9. Lubricate the drive shaft (9), and put this
assembly into the shaft end cover (7). Be careful
not to damage seal (12 or 13).
10.Install the snap ring (1) into the groove of shaft
end cover

Assembly of shaft end cover is now completed.

12
For 5000 Series: C shafts
Follow Steps 1 through 5 from previous page then
proceed as follows:
6. Press the outboard bearing (2) onto the drive
shaft (9) from the drive shaft end.
7. Lubricate the drive shaft (9), and put this
assembly into the shaft end cover (7). Be careful
not to damage seal (12 or 13).
8. Install snap ring (1) into the shaft end cover
groove. Assembly of shaft end cover is now
completed.

7500 Series
Reassembly of Shaft End Cover:
1. Grip shaft end cover (7), gear end up. Place ring
seal (14) in the bearing bore of the shaft end
cover (7) with flat side down.
2. Replace the two roller bearings (15) in the bores
of the shaft end cover (7). Take care that the
drive bearing (15) does not cock or wedge
between the ring seal and bottom of bearing
counter-bore.
3. Place shaft end cover (7) in a soft jaw vise.
Turn cover end-for-end, and clamp with flange
end up.
4. Apply Loctite Adhesive Sealant No. 271 to
outside of seal (3 or 6). Press seal into seal
retainer (5) metal side down. Be careful not to
damage seal. Install O-ring (27) on outside of
seal retainer (5).
5. Push this assembly into shaft end cover (7), with
seal on inboard side. You can install bearing or
bearing spacer and snap ring now, or at the end
of assembly.

Continental Shafts
For Type I pumps with C Type shafts, follow the
above steps 1 through 4; then proceed as follows:
5. Push seal assembly into shaft end cover (7)
with seal on inboard side.
6. Press the outboard bearing (2) on the drive
shaft (9) from the gear end.
7. Push spacer (10) over the end of the shaft (9).
Install snap ring (11) in the groove on shaft (9).
8. Press the bearing (2) and spacer (10) tightly
against the snap ring (11).
9. Lubricate the drive shaft (9), and put this
assembly into the shaft end cover (7). Be
careful not to damage the seal.
10.Install the snap ring (1) in the groove. The
shaft end cover reassembly is now complete.

13
 All Series
Reassembly of Port End Covers
1. If you removed the two roller bearings (15) or
the ring seal (14) during disassembly, install new
bearings (15) and ring seal (14) in the port-end
cover (20). Place the ring flat side down in the
drive gear bearing bore, and make a medium
press fit.
2. Place the diverter plate (16) over the two roller
bearings (15). The counter-bored side of the
diverter plate (16) should be placed over the
bearings (15) with the high-pressure crescent
recesses toward the pump inlet side. Double-
check the placement of the diverter plate (16)
for correct positioning.
Reassembly of Bearing Carrier
1. If you . removed the four roller bearings (15) or
ring seals (14) during disassembly, install new
bearings (15) and ring seals (14) in the bearing
carrier (24). Place the ring seals (14) flat side
down in the drive gear bearing bore and press
bearing with a medium press fit.
2. Place the diverter plate (16) over the two roller
bearings (15). The counter-bored side of the
diverter plate (16) should be placed over the
bearings (15) with the high-pressure crescent
recesses on the pump inlet side. Double-check
the placement of the diverter plate (16) for
correct positioning.
Final Reassembly
1. Clamp the shaft end cover (7) assembly in a
soft jaw vise, gear end up.
2. Place the diverter plate (16) over the two roller
bearings (15). The counter-bored side of the
diverter plate (16) should be placed over the
bearings (15) with the high-pressure crescent
recesses on the pump inlet side. Double-check
the placement of the diverter plate (16) for
correct positioning.
3. Pour a little hydraulic oil, STP or a compatible
fluid over face of diverter plate (16) to lubricate
gears immediately on start-up. Gently stone the
sides of each gear (19 and 26) to remove any
burrs. Dip entire gear into cleaning solvent to
remove all dirt and metal dust. Install drive gear
first, then the driven gear. Be sure both gears
are firmly in contact with diverter plate.
4. Lightly grease square gasket seals (17) and
carefully install them in the grooves in the two
faces of the gear housing (18). Be sure they are
fully seated.
5. Carefully place the gear housing sub-assembly
over the gears, on top of the shaft end cover
(7). Make sure the square gasket (17) is not
pinched or cocked, then tap the gear housing
14 (18) down on the shaft end cover (7) with a soft
 mallet. Pour a little fluid over the gears while
rotating the drive shaft. This will provide
immediate lubrication when starting up pump.
(If the unit is a single one, skip Step 6 and go to
Step 7.)
6. Position the assembled bearing carrier over the
gear journals and gently tap it into place. Be sure
the high-pressure crescents of the diverter plate
(16) are positioned towards the pump low-
pressure side. Install the connecting shaft. (25)
Repeat Steps 3 through 7, above, until you attach
the final gear housing (18). Then pick up at Step
7, below.
7. Place the port end cover (20) over the gear hubs
(19) and place in gear housing (18), face down.
The drive gear has longer bearing hubs to
engage the ring seal. Tap the port end cover (20)
assembly gently down on the housing (18) with
a soft mallet. Be sure the square gasket (17) is
not pinched or cocked.
8. Put flat washers (21) over cap screws (22), or
use Grade 8 threaded rod. Place screws or
threaded rod in holes in port end cover (20).
Tighten evenly and alternately with a torque
wrench to recommended torque shown in table.
Recommended torque for pumps and motors
Torque
Series Size No. Req.
Lb.ft.
5/8-11
3000/5000 UNC-2A 4 200
3100/5100 Thread
5/8-11
7500/7600 UNC-2A 8 200
Thread
Note: All bolts or tie rods must be SAE Class 8,
with 150,000 PSI minimum tensile strength.
9. Test the assembled pump for free rotation by
turning drive shaft by hand, using a wrench for
leverage. Caution: Wrap several layers of cloth
around shaft ends before applying wrench. The
shaft should turn with slight effort, NO hard spots
and NO rubbing noises.
If your pump or motor is a 3000/5000 or 7500
C series, it is ready to put back in service.
But if it is a standard 7500 series unit, and you did
not install the bearing and snap ring earlier, proceed
to the following steps before putting it in service:
10. Release the unit from the vise and turn end-
for-end so that the shaft end is facing up. Re-
clamp unit in vise.
11. Install bearing (2) or bearing spacer (4). This
is a slip fit over the shaft (9) and into shaft end
cover (7).
12. Install the snap ring (11) into groove. Your
standard 7500 series unit is now ready to put
back in service.
15
START-UP INSTRUCTIONS FOR
PERMCO PUMPS
FOLLOW THESE INSTRUCTIONS CAREFULLY. If you
dont, you can instantly ruin your pump if the relief

1. Before you operate the pump, unscrew the main relief

valve adjusting screw on the main hydraulic system.
OR remove adjusting shims or spacers.
2. Run the pump about five minutes under ZERO
PRESSURE, with all control valves in neutral position.
If the test system has a throttling valve, set it at 100
psi. above users expected operating pressure.
3. If everything seems to function properly and no
unusual noises are heard, back-off the throttling valve
to zero. Shut down the system.
4. Adjust the relief valve pressure to the setting your
hydraulic system requires.

LUBRICATION OF PERMCO
PUMPS
1. The hydraulic oil used in the entire circuit provides
the lubrication for all parts of the pump. KEEP THIS
OIL CLEAN AND FREE OF DIRT. PERMCO
recommends a 25-micron return filter and a 149-
micron (100-mesh screen) suction filter to fully protect
the pump and system from excessive wear and
damage from dirt.
2. If the pump fails and you think metal particles have
gotten in the circuit:
a. Drain ALL oil from the whole system,
b. Flush the system with kerosene,
c. Refill the system with fresh oil of correct
grade,
(These are correct oils:
Viscosity index at 100F (37C): 90 or higher;
Viscosity SUS at 100 F (37 C): 150 to 300
(32-65 CST);
Aniline point: 165 or higher;
Anti-foam and anti-oxidant additives.)
3. Temperature of oil should never exceed 185F
(85 C.)
4. NEVER use low-viscosity naphtha-base oils, aircraft
hydraulic fluids, or automotive brake fluids without
consulting PERMCO, INC. or a Permco distributor.
5. For extended operation at temperatures below 20 F
(-7 C) always use a low-pour-point oil of top quality.

16
 TROUBLE SHOOTING
PROBLEM
EXCESSIVE NOISE IN PUMP
Insufficient Fluid
Fluid is too heavy
Oil filter is dirty
Suction line too small
Clogged suction line
Pump over-speeding
Air vent on fluid
reservoir clogged
Air bubbles in fluid
Filter too small
Coupling misalignment
Air leaks at pump intake on
pump shaft packing or inlet
pipe
Worn or broken pump parts
FOAMING FLUID
Improper fluid
Low fluid level
Inadequate baffling in tank
Air leaking into suction
line between reservoir and
pump
OIL LEVEL IN TANK CONTINUES TO
DROP
Oil level in tank continues to
drop
REMEDY
Replenish fluid to proper level, with
proper grade
Drain system and refill with
specified grade of fluid
Clean or replace filter element
Install larger suction line
Clean line thoroughly
Check pump maximum speed;
Slow down pump driver; Or install
larger pump
Clean or replace breather on
reservoir
Drain system and refill with non-
foaming hydraulic fluid
Replace with larger filter
Realign flexible coupling between
pump and driver
Drip oil over suspected joint; listen
for change in sound of pump;
tighten joints
Replace parts as necessary
Drain system and refill to correct
level with proper grade of anti-
foaming fluid
Top off with proper grade of anti-
foaming fluid
Install correct baffling
Tighten all connections
Indicates a broken pipe line or a
pipe left out between a bulkhead
coupling and the bottom of the tank
after cleaning tank. Replace pipe.
17
PROBLEM
Pump rotating in wrong
direction
Pump fails to prime itself
a. Air leak into suction line
b. Oil is too heavy
c. System not in Neutral
SYSTEM LACKS ANY PRESSURE
WITH PUMP RUNNING
Relief valve not set correctly
Relief valve leaking
Broken relief valve spring
Flow of fluid to tank
is unrestricted
Internal leakage in control
valve or power cylinder
EXCESSIVE WEAR IN PUMP
Abrasive contaminants in
fluid
Fluid too light for pump
service
Sustained pressure above
pump maximum rating
REMEDY
IMMEDIATELY STOP PUMP
DRIVER to prevent damaging
pump. Then reverse direction of
pump rotation
Tighten up joints. Drain system and
replace fluid with proper grade of
anti-foaming fluid
Open valve on pressure side of
pump, or install air bleed valve
Use pressure gauge and reset
valve to specified pressure
Check relief valve seat for score
marks. Reseat by grinding. Or
replace.
Replace spring; reset relief valve
Check for control valve in Neutral
or for open return line
Repair or replace leaking valve or
cylinder
Drain and flush entire system.
Install new filter. Fill system with
fresh oil of proper grade or filter
contaminated oil through a
10-micron filter before refilling.
Operate pump an hour. Drain
system again. Install new filter
element and fluid.
Drain and replace with anti-foaming
fluid of proper grade.
Check and reset relief valve
pressure, using pressure gauge.
PROBLEM
Sustained excessive
speed at pressure above
pump maximum rating
Drive misalignment;
Tight belt; weight of pump
supported by its drive shaft
Entrapped air in hydraulic
system
OVERHEATED FLUID
Fluid too heavy
Fluid too light for high
temperature pump location
Dirty fluid
Dirt or chip caught between
plunger and seat of relief
valve
Incorrect setting on relief
valve
Worn pump permits oil to
bypass internally
Relief valve leaks or not
operating
Excessive friction caused by
pump components over-
torqued
Undersize hoses and valves
in system
Restrictions and excessive
bends in lines
Inadequate reservoir
prevents adequate cooling
of fluid
Internal leaks not in pump
PUMP NOT EFFICIENT
Worn pump parts reduce
pump efficiency
Air in system
REMEDY
Recheck pump rated speed.
Slow down driver to produce
this speed.
Check pump/driver
coupling or belt alignment.
Install adequate support
for pump.
Bleed air from hydraulic
system
Drain system and refill with
lighter g ra d e of
anti-foaming fluid.
Drain system and refill with
heavier weight anti-foaming
fluid.
Drain and flush system;
refill with proper grade of
anti-foaming fluid; replace
filter element.
Disassemble relief valve and
remove contaminant. Check
condition of filter to prevent
recurrence.
Use gauge and adjust relief
va l v e s e t t i n g t o c o r r e c t
pressure
Repair worn pump parts or
replace pump.
Repair or replace relief valve
Disassemble pump and back
off over-torqued component
to tightness specified in this
maintenance manual
Replace with proper size
hose and valves
Re - p l u m b system
eliminate restrictions
Install larger reservoir or
add fluid radiator
Locate and repair leaks
Repair or replace pump
Bleed air from system;
check line connections for
air leaks
PROBLEM REMEDY
Internal leak in control Repair or replace control
valve or cylinder. va l v e . Re p l a c e c y l i n d e r
packing. Check cylinder walls
for scoring and replace if
necessary.
Erratic pump performance:
a. If pump runs slow on a. Drain system and refill
startup, and speeds up with lighter grade anti-
after fluid is warm, fluid foaming fluid.
fluid grade is too heavy.
b. If pump slows down b. Drain system and refill with
after fluid has heated up, heavier grade anti-foaming
fluid is too light fluid.
MOTOR DOESNT DEVELOP
PROPER TORQUE OR SPEED
(when pump is used as a motor)
Relief valve incorrectly Use a pressure gauge and
adjusted increase relief valve pressure
setting to proper level
Relief valve sticking open Disassemble relief valve and
remove dirt from under ball
or piston. Check condition of
filter to prevent recurrence.
Flow of fluid to tank is Check for control valve in
unrestricted Neutral or for open return
line.
Insufficient pump Use pressure and flow gauges
pressure or volume to check pump out-put and
pressure.
Misalignment of Realign belt drive or cou-
pump/driver pling, recheck torque
requirements of pump for
maximum input.
MOTOR SUBJECTED
TO OVERPRESSURE
to (when pump is used as hydraulic motor)
If you have used a standard control valve to control a
hydraulic motor, serious and catastrophic harm can result.
When the standard control valve is returned to Neutral,
to start or stop the motor sudden excessive pressure
develops. This pressure can burst seals, fracture drive
shafts, burst housings, and rupture hoses.
18
 HOW TO ORDER PARTS
ALWAYS GIVE US THE SERIES NUMBER, please. 2. Bearing arrangement:
It instantly tells us what PERMCO Pump or Motor With or without outboard bearings? Double out-
you want parts for. You will find this Series Number board bearings? Bearing measurements? Any
on the nameplate. drains or grease fittings?
3. Drive shaft:
IF YOU CANNOT SUPPLY THE SERIES NUMBER,
Diameter of shaft end? Keyed or not? Length of
Please answer these questions:
spline? Number of spline teeth O.D.? Total
length of shaft?
1. Is the unit a pump or a hydraulic motor?
4. Housing:
2. If a pump, which way does it rotate when you
Width of housing? Inside diameter of ports?
look at it from the shaft end? Clockwise? Or
5. Port end cover:
counter-clockwise?
Inside diameter of ports?
3. How many gear housing sections does the unit 6. Bearing carrier:
have? Inside diameter of ports? Direction of flow thru
4. Check Series Identification Table below to internal passage or coring?
determine series. 7. Gears:
STEPS IN IDENTIFICATION: Gear tooth width? Gear O.D. measured over teeth?
1. Shaft end cover: If gears are integral, describe drive end of drive
Mounting flange: Is it pad mounting or foot gear, as in Paragraph 3 above.
mounting? How many bolts, 2, 4, 6, 8? If round
flange, measure pilot diameter, center diameter,
and bolt-hole diameters.

SERIES IDENTIFICATION

STUD HOLES CONTINENTAL INTEGRAL HOUSING HOUSING WIDTH =

SERIES STUD DIA. (Two-Piece Drive (One-Piece Drive
No. and Dia. Height GEAR WIDTH, +
Shaft & Gear Set) Shaft & Gear Set)

1200 10-9/16 1/2 X 7 1/2

1500 4-9/16 1/2 X 5-1/4 3/4

2500 4-11/16 5/8 X 6 3/4

3700 8-9/16 1/2 X 7-5/16 1

3000
4-11/16 5/8 * X 5-3/8 3/4
3100 (Doweled)

5000
4-11/16 5/8 * X 6 3/4
5100 (Doweled)

7500
8-11/16 5/8 * X 7-7/8 1
7600 (Doweled)

* Continental (Two-Piece Drive Shaft & Gear Set) available on Series 3000, 5000 and 7500 as specials; consult factory.

19
 Coolant Heaters

DBW 2010
DBW 2020
DBW 300

Operating Instructions
North American Headquarters
3333 John Conley Drive
Lapeer, MI 48446
Phone (810) 245-2400
Toll-free (800) HEATER-1
Fax (810) 664-7720

Canadian Operations
Toll-free (800) 667-8900

Rev. 11/00 699540 (English) Website: www.webasto.com

WEBASTO DBW SERIES HEATERS CONTENTS

Introduction
Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General Safety Regulations and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Meaning of Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Description
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Coolant Heater DBW 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Coolant Heaters DBW 2020 / 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Operating Instructions
Operating your Webasto DBW Series Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Switching On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Switching Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation with 7-Day Digital Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Setting the Digital Timer (Models 1529 & 1531) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7-Day Digital Timer Programming and Operating Instructions (Models 1529 & 1531) . . . . . . 14
Operation with 7-Day Electronic Timer Model CDN-1224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Timer Operation Modes (Model CDN-1224) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

I
WEBASTO DBW SERIES HEATERS CONTENTS

Dip Switch Programming (Model CDN-1224) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Timer Operation (Model CDN-1224) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Maintenance
Maintenance of the Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Basic Troubleshooting
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Malfunction Identification - DBW Series Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Sequence of Events - DBW Series Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Technical Data
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Heater Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
U 4810 and U 4846 Coolant Pump Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
U 4814, U 4851 and U 4852 Coolant Pump Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

II
WEBASTO DBW SERIES HEATERS INTRODUCTION

Introduction

Important Information

The heater must be installed according to the Installation Instructions and must be examined by an officially
recognized, Webasto authorized installation/ servicing facility.
When the heater is installed in vehicles used for the transportation of dangerous or inflammable goods, or in
boats, the appropriate regulations must be observed.
Webasto Thermosystems, Inc. does not recommend the installation and servicing of Webasto products by
untrained, unauthorized personnel or end-users.
Installations and servicing of Webasto products by untrained, unauthorized personnel and end-users will release
Webasto Thermosystems, Inc. and Webasto authorized distributors, dealers and personnel from responsibility for
damage to Webasto product or collateral property and personal injury.
Any use, operation, installation, modification or application of the product not described in Webasto manuals, or
subjecting the product to extreme or unusual conditions beyond the limits of specified performance characteristics
is misuse of the product.
Failure to comply with all operation, installation, and servicing instructions is a misuse of Webasto product.
The same applies for repairs without using genuine Webasto service parts. This will void the coolant heaters
Official Marks of Conformity.
In the vicinity of the coolant heater, a temperature of 185 F (85 C) must not be exceeded under any
circumstances (e.g. during body paint work). A violation of this temperature limit may cause permanent damage
to the electronics.

1
WEBASTO DBW SERIES HEATERS INTRODUCTION

When checking the coolant level, proceed in accordance with the vehicle manufacturers instructions.
The coolant in the heating circuit of the heater must contain a minimum of 10% of a quality brand glycol based
anti-freeze.
The pressure setting of the coolant filler cap should be between 0.4 and 2 bar (6 p.s.i. and 28 p.s.i.).
The coolant heater may only be operated within the specified operating voltage range designated by type.
The coolant heater may only be operated with the specified fuel (Diesel 1, Diesel 2, Arctic grade, Kerosene and
certain military spec. fuels).
The operational state of the heater, i.e. an indication On or Off, must be clearly visible to the operator.
If electrical welding is to be done on the vehicle, the main positive and negative feed cables should be
disconnected from the battery and securely connected to the chassis. This is necessary to protect the electronic
control unit from voltage surges.

WARNING
Due to the danger of poisoning and suffocation, the heater must not be operated in enclosed areas, such as garages
or workshops, without an exhaust venting system, not even if the start-up is activated by the timer or remote start
device.

At filling stations and fuel depots the heater must be switched off as there is a potential danger of explosions.

Where flammable fumes or dust may build up (e.g. in the vicinity of fuel, coal, wood, cereal grain deposits or similar
situations) the heater must be switched off to prevent explosions.

2
WEBASTO DBW SERIES HEATERS INTRODUCTION

General Safety Regulations and Information

The general safety regulations for the prevention of accidents and relevant operating safety instructions must be
observed at all times. The specific safety regulations applicable to this manual are highlighted in the individual
chapters by Warnings, Cautions and Notes.

Meaning of Warnings, Cautions, and Notes

Warnings, Cautions and Notes in this manual have the following meaning:

WARNING
This heading is used to highlight that non-compliance with instructions or procedures may cause injuries or lethal
accidents to personnel.

CAUTION
This heading is used to highlight that non-compliance with instructions or procedures may cause damage to
equipment.

NOTE:
This heading is used to highlight and draw specific attention to information.

3
WEBASTO DBW SERIES HEATERS INTRODUCTION

4
WEBASTO DBW SERIES HEATERS DESCRIPTION

General Description
1 Electronic control unit
Coolant Heater DBW 2010 2 Motor
3 Electronic ignition coil
1 2 3 4 5 23 6 7 8 10 11 12 13 14 4 Coupler
5 Combustion air fan
25 24 26 6 Fuel solenoid valve
7 Electrode holder
8 Coolant outlet
9 Coolant inlet
10 Ignition electrodes
11 Fuel nozzle
12 Overheat fuse (white wires)
13 Control thermostat
14 Temperature limiter
15 Heat exchangers
16 Combustion chamber
17 Combustion air swirler
18 Exhaust pipe
19 Flame detector
20 Fuel pump
22 21 20 19 18 17 16 15 9 21 Fuel supply/ return pipes
22 Combustion air adjusting shutter
Fig. 1: Major Components of the DBW 2010 Coolant Heater
23 Fuel pump drive gearing
24 Nozzle pre-heater
25 Preheat thermostat (blue & green wires)
26 Air bleed screw

5
WEBASTO DBW SERIES HEATERS DESCRIPTION

Coolant Heaters DBW 2020 / 300

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 Electronic control unit

2 Motor
3 Electronic ignition coil
4 Coupler
5 Combustion air fan
6 Fuel solenoid valve
7 Electrode holder
8 Coolant inlet
9 Ignition electrodes
10 Fuel nozzle
11 Overheat fuse (white wires)
12 Control thermostat
13 Temperature limiter
14 Coolant outlet
15 Heat exchangers
16 Combustion chamber
17 Combustion air swirler
18 Exhaust pipe
19 Flame detector
22 21 20 19 18 17 16 15 20 Fuel pump
21 Fuel supply/ return pipes
Fig. 2: Major Components of the DBW 2020 / 300 Coolant Heaters 22 Combustion air adjusting shutter

6
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

Operating Instructions

Operating your Webasto DBW Series Heater

WARNING
Due to the risk of carbon monoxide poisoning and asphyxiation, the heater must never be operated in closed spaces
such as garages and workshops without adequate exhaust extraction.

WARNING
Due to the risk of fire or explosion, the heater must be switched off while refueling and at fueling stations.

WARNING
Due to the risk of explosion, the heater must never be operated in areas where explosive materials, fumes or dusts
may be present.

7
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

Switching On
Before switching the Webasto heater on, open any shut off valves and set vehicle heater controls to the Hot
position. Depending on the type of control installed, the heater can be operated by the following methods.

Timer: Switch:

Using a Timer:
Upon pressing the Instant Heat button on the timer face, the Operation Indicator on the timer lights up and the
heater begins operation.

Using a Switch:
When the switch is used for switching ON the Webasto heater, the Operation Indicator integrated in the switch is
illuminated.

8
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

Heater Start-up Sequence:

Upon switching on, an operating indicator light will illuminate.
The combustion air fan, fuel pump and circulation pump start operation. (If fitted and temperature is < 0 C (< 32 F)
nozzle preheating is also activated).
After approximately 15 seconds the fuel solenoid valve opens allowing fuel to flow to the nozzle where it is atomized
and sprayed into the combustion chamber. At the same time, a high voltage ignition spark is generated at the
electrode tips simultaneously igniting the fuel air mixture. A photo control device detects a flame in the combustion
chamber and deactivates the ignition system (combustion process is self-sustaining). At this point the heater is
working and producing heat.

The Webasto heater will cycle on and off until:

1. System coolant reaches operating temperature.
2. The Webasto heater is switched off.
3. Time has elapsed on the timer.
4. The vehicle battery voltage drops below 10.5V for 12 volt systems or 20.0V for 24 volt systems.
5. The Webasto heater runs out of fuel.
6. A fault lock out occurs, indicated by the operating indicator light being off during the cool down cycle (as would
happen during an overheat situation.

NOTE:
If the heater is switched on while the engine is at operating temperatures above 140 F (60 C) for orange and white
wire thermostat or 155 F (68 C) for red and green wire thermostat, only the operation indicator and the coolant
circulation pump will be activated. Depending on the type of thermostat installed, the engine coolant temperature
must fall below 140 F (60 C) or 155 F (68 C) at the heater before the heater will begin heating operation.

9
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

Switching Off
When heating is no longer required, switch the Webasto heater off. The fuel solenoid valve interrupts the fuel supply
and combustion stops. The indicator light turns off. The Combustion air fan and the water pump continue operation
for approximately 150 seconds (after-run cycle) purging the combustion chamber of any fumes and cooling the
heater.

NOTE:
Switching the Webasto heater on during the cool-down (after-run cycle) period is allowed. The heater will revert to
normal operational mode.

Engine Preheating
1. Set the timer 10 min. to 120 min. before you want to start the engine. The heater will start up at the set time.
(See timer operating instructions). Or switch the toggle switch or Instant On switch on your timer in the vehicle
dash to On. The heater will start up.

2. When the run time has elapsed on your timer or engine preheating is no longer required, switch the Webasto
heater Off. The heater will begin the after-run (cool-down) cycle.

NOTE:
Make sure all coolant and cab heater valves are open before operating the heater in the preheat mode.

10
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

Operation with 7-Day Digital Timer (Model 1529 Shown)

The digital timer with 3 time settings permits the

Webasto heater to be switched on and off instantly, or
automatically at 3 programmable starting times.

The operating time of the heater can be pre-selected.

It is possible to program 3 different heating times
according to your individual needs.

Only one preset starting time can be activated at any

one time. When the ignition is switched on, the
current time of the day and the day of the week are
displayed.

When the heater is in operation, the display and the

buttons of the timer are illuminated.

11
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

Programmed Heater Operation

Three memory locations numbered 1 to 3 are available. Each memory location can be assigned a given time
together with the day of the week.

Pre-selected Starting Times

The pre-selected starting time is the time at which the heater will be switched on automatically.
We recommend that memory locations 1 and 2 be used for presetting starting times within 24 hours of setting the
timer. Memory location 3 can be used for a starting time within the next 7 days of setting the timer.

NOTE:
We recommend that memory locations 1 and 2 be used for presetting starting times within a 24 hour period of setting
the timer. Memory location 3 can be reserved for a starting time within the next 7 days of setting the timer. Location
3 is useful for occasional weekend or field trip operations outside of the normal schedule. By repeatedly pressing the
button on the 1529 timer or button on the 1531 timer, starting time program 1, 2 or 3 can be viewed and preset.

Operating Time
The period of time during which the heater is in operation is referred to as the operating time. The heater remains in
operation for as long as the operating time has been preset. Heater operation can be pre-selected for any time from
a minimum of 1 minutes (a minimum of 10 minutes is recommended) to a maximum of 120 minutes (factory preset is
60 minutes).

Remaining Operating Time

The remaining operating time refers to the period of time the heater still continues to remain in operation. It can only
be changed while heater is in operation.

12
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

Setting the Digital Timer (Models 1529 & 1531)

After the power has been connected, all symbols on the digital display are flashing. The time of the day and the day
of the week must be set.

All flashing displays and symbols of the timer can be set by means of the and buttons.
If the and buttons are not pressed within 5 seconds, the currently displayed time or function will be stored.
When the and buttons are pressed for more than 2 seconds, the quick digit advance mode is activated.

1 Program number for preset time.

2 Time of day / preset time / operating duration display.
3 Day of the week display.
4 Operation indicator.
5 Setting / viewing the time; setting / recalling day of the week.
6 Presetting / recalling starting time; setting / recalling day of the week.
Note: Timer model 1531 uses a symbol for the programming key.
7 Heater On/Off.
8 Reverse key for setting time of day or heater start-up time; viewing
and reducing operating duration / remaining operating time.
9 Forward key for setting time of day or heater start-up time; presetting
day of start-up; viewing and extending operating duration / remaining
Fig. 3: 7-Day Digital Timer (Model 1529) operating time.

13
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

7-Day Digital Timer Programming and Operating Instructions (Models 1529 & 1531)
Setting the time and Press the button for more than 2 seconds. Time display flashes.
day of the week Press the or button to set time of day. Wait 5 seconds. Time is now stored.
Day of week flashes.
Press or button to set day of week. Wait 5 seconds. Day of week is now stored.
Viewing the time With ignition ON:
Continuous display of current time and day of the week.
With ignition OFF:
Briefly press button. Display of current time and weekday appears for 5 seconds.
Switching heater on With ignition ON:
for instant heater Press button. Heater is switched on (continuous heating) and continues to operate until
operation button is pressed again or ignition is switched off.
With ignition OFF:
Press button. Heater is switched on for the preset operating time
(the factory-set heater operating duration is 60 minutes).
Switching the Press button. Heater begins cool-down (after-run) cycle and is switched off thereafter.
heater off
Table 1: Digital Timer Instructions

14
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

Programming Press or button. Memory location number flashes.

heater-starting time Press or button to preset starting time. Wait 5 seconds. Starting time is now stored.
Day of week flashes.
Press or button to set day of week. Wait 5 seconds. Day of week is now stored.
The number of memory location remains on the display.
The timer is now in the programmed mode and switches heater on at the preset time.
Recalling/canceling To recall: Press or button until the desired memory location number is displayed.
pre-selected times Read off preset time.
To cancel: Press or button repeatedly until the memory location numbers are no
longer visible on the display.
Programming The heater must be switched off. Press the button.
duration of Operating time flashes.
operating time Press or button to set operating duration time between 1 and 120 minutes (minimum
10 minutes recommended).
Setting the Heater must be in operation.
remaining Press button. Remaining operating time flashes.
operating time Press or button to set remaining operating time. Wait 5 seconds. The remaining
operating time is now stored.
Table 1: Digital Timer Instructions (continued)

15
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

Operation with 7-Day Electronic Timer Model CDN-1224

The 7-Day Electronic Timer Model CDN-1224 permits the Webasto heater

12:00
H P to be switched on and off instantly, or automatically.
T The timer allows for 1 preset start time once within a 24 hour period on
any one day up to 7 days in advance.
S M T W T F S
The current time and weekday must be preset before any other
programming features can be accomplished.
Set Clock
Set Timer The 7-Day Electronic Timer is designed to operate on both 12 and 24 volt
Heater
Timer
systems.
Set on/off Display
on/off
manual
Day Hour Operational characteristics of both timer and heater can be tailored to the
Minute

requirements of the heating application by pre-programming of the timer.

This is normally done at the time of installation. Four dip switches located on the back panel of the timer are provided
for changing the operational characteristics of the timer. These settings can be revised at any time should your
heating requirements change.

CAUTION
Timer requires dismounting and disconnecting of power source before revising dip switch settings.
For complete timer installation and operation instructions, refer to the 7-Day Electronic Timer Model CDN-1224
Operating Instructions manual available from your Webasto agent under part number 907111.

16
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

Timer Operation Modes (Model CDN-1224)

Truck or Bus Operation
By flipping one of the dip switches on the back of the unit, the timer can be set for either truck or bus operation. The
tables shown below illustrates the timing sequence associated with operation in either of these modes.

Bus Application
Ignition wire is connected and dip switch #3 is in bus mode.
Whether the heater is turned on manually or automatically, it will stay on until the timer duration ends. Except, when
the heater is turned on manually while the bus is running (ignition key turned on), the heater will shut off when the
ignition key is turned off, or the heater on/off button is pressed.

Truck Application for Preheat Mode Only

Ignition wire is disconnected and dip switch #3 is in truck mode.
Pre-set Mode Heater on Timer duration ends Heater turns off after time duration ends
Manual Mode Heater on Timer duration ends Heater turns off after time duration ends

Truck Application for Preheat and Sleeping Modes

Ignition wire is always live and dip switch #3 is in truck mode.
Pre-set Mode Heater on Timer duration ends Heater turns off after time duration ends
Manual Mode Heater on Timer duration ends Heater stays on until turned off manually

17
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

Dip Switch programming

(Model CDN-1224) Dip Switch

1 2 3 4
Location

OPEN
Prior to installing the timer, all dip switches must be set
to the requirements of your application.

The dip switches allow for setting the clock in either

AM/PM mode or 24 hour (military) mode. Also included
is the ability to select the desired heater run time of 30,
60, 90 or 120 minutes.

Dip switch settings are accessed through a cut out on

the rear panel of the timer.

Fig. 4: Rear Panel of Timer

NOTE:
Dip switch settings are to be selected PRIOR to connection of power source and programming of all other timer
functions.

18
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

Switch 1 & 2 control timer on duration.

1
2

2
3

3
4

4
30 Minute 60 Minute 90 Minute 120 Minute

Switch 3 controls truck vs. bus operation. Switch 4 controls 12 vs. 24 hour clock.
1

1
2

2
3

3
4

4
Bus Mode Truck Mode 12 hour clock 24 hour clock

Default settings for new timers are:

Truck - 60 minute operation time, 12 hour clock
Bus - 60 minute operation time, 12 hour clock

19
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

Setting the Electronic Timer

(Model CDN-1224) 1

12:00
2 H P 4
1 Time Display
3 T
2 Heater on/off indicator LED (green)
3 Timer active status LED (yellow)
4 Clock time status LED (red)
This LED will be on during PM time when AM/PM
5 S M T W T F S
dip switch setting is selected
5 Days of the week LEDs (red)
6 Function buttons
Set Clock
Set Timer
Heater
6 Timer
Set on/off Display
on/off
manual
Day Hour Minute

Fig. 5: 7-Day Electronic Timer Model CDN-1224

20
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

Clock Programming (Present Time and Day)

Set Display
Depress buttons Set and Display simultaneously to start programming
NOTE: Time display will begin to flash. AND Minute

Heater
on/off
Depress button Day to select day of week. manual
Day

Depress button Hour to select correct hour. Timer

on/off
NOTE: If the dip switch setting is in the AM/PM mode, the red PM LED will respond.
Hour

Depress button Minute to select correct minute. Display

Minute

Depress button Set to end timer programming.

NOTE: If Set button is not depressed within 15 seconds, programming function Set
will end automatically.

21
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

Timer Programming (Timed Heater Start Setting)

Timer
Set
Depress buttons Set and Timer on/off simultaneously to start programming. on/off
NOTE: The yellow T LED will flash AND Hour

Heater
on/off
Depress button Day to select day heater is to come on. manual
Day

Timer
Depress button Hour to select correct hour. on/off

Hour

Depress button Minute to select correct minute. Display

Minute

Depress button Set to end timer programming.

NOTE: If Set button is not depressed within 15 seconds, programming function Set

will end automatically

22
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

Timer Operation (Model CDN-1224)

Manual Operation
Heater
To manually turn the heater on, press the heater on/off manual button. The heater on/off indicator LED on/off
manual
(green) will come on. Press this button a second time to turn the heater off.
Day

Timer Operation
Depress the timer on/off button to activate or deactivate the timer. If the timer is active, the timer status Timer
on/off
LED (yellow) will light and the heater will come on when the next timing program is reached.
The tables on page 17 depicts the performance of the timer based upon truck or bus operation. Hour

Display Stand By Mode

Display
To save battery life, the display will go blank after about 5 minutes if there is no activity. To reactivate
the display, press the DISPLAY button. MInutes

23
WEBASTO DBW SERIES HEATERS OPERATING INSTRUCTIONS

24
WEBASTO DBW SERIES HEATERS MAINTENANCE

Maintenance of the Heater

To ensure functional reliability of the heater the following maintenance must be performed:

check combustion air inlet and exhaust outlet for contamination and clean as required.
outside the heating season the heater should be operated with the vehicle engine cold approximately every four
weeks for 10 minutes setting the heating system to "warm" and opening all appropriate coolant flow control
valves. This avoids difficulties in the startup at the beginning of the heating season and prolongs heater motor
and bearing life.
after replacing the coolant of the vehicle engine ensure proper bleeding of the heater after bleeding the vehicle
cooling system. Start the vehicle engine and turn OEM heater system on in full heat mode. Switch on heater
circulation pump (if separate switch is available) or operate heater for 5 seconds to run circulation pump using
rundown cycle. Repeat procedure as required until warm air comes out of heating ducts. Replenish coolant to
manufacturer's instructions if level is low.
before the heating season (point of time when weather conditions cause increased use of equipment) the fuel
filter or filter cartridge must be replaced to prevent malfunctions.
the heater should be checked on regular intervals by a Webasto service agent, the latest before the beginning of
the heating season.

25
WEBASTO DBW SERIES HEATERS MAINTENANCE

26
WEBASTO DBW SERIES HEATERS BASIC TROUBLESHOOTING

Basic Troubleshooting

CAUTION
Troubleshooting requires profound knowledge about structure and theory of operation of the heater and components.
Troubleshooting and fault correction should only be performed by Webasto trained, skilled personnel unless
otherwise stated in this manual.

General Information
This section describes troubleshooting procedures for DBW Series coolant heaters. Troubleshooting is normally
limited to the isolation of defective components.

Before troubleshooting, check for and eliminate the following defects:

fuel supply (plugged fuel filter, kinked fuel line)
corrosion on battery terminals
blown fuses
corrosion on electrical wiring, connections and fuses
loose contacts or improper crimping on connectors
shut down initiated by temperature limiter thermostat (automatic reset)
shut down initiated by overheat fuse

27
WEBASTO DBW SERIES HEATERS BASIC TROUBLESHOOTING

Malfunctions
The DBW Series of coolant heaters are designed with automatic, self-monitoring systems that will shut the heater off
in the event of a problem.

The heater will switch itself off automatically if combustion does not start after the heater has been switched on, or if
the flame goes out, or if the heater overheats. The operation indicator light will go out to signify a problem.

The following steps can be taken to determine and correct obvious problems.
If the operation indicator light does not come on at the same time as the heater is switched on, check and, if
necessary, replace fuse (F2). If the operation indicator light comes on when the heater is switched on, but goes out
after about 30 seconds, check and, if necessary, replace fuse (F3).
NOTE:
In most heater models, the fuses referred to in the above paragraph can be located on the back wall of the heater
enclosure or are tray. Some models may also utilize a 30 amp. main fuse at the battery connection.
If overheating has occurred, locate and correct the problem. On the DBW 2010 Arctic, DBW 2020 and DBW 300
series heaters, it may be necessary to replace the overheat melt fuse located under the thermostat cover on top of
the heater. The fuse can be identified by the two white wires protruding from its top. The fuse is screwed hand tight
into a dry well plug. Do not over tighten the fuse when replacing. On all other DBW 2010 heaters not equipped with
an overheat fuse, simply correct the cause of overheating and allow the heater to cool down.

If a lock-out condition occurs due to a malfunction, this condition can be cleared and the control unit reset by
switching the heater off and switching it back on again. If the heater goes to lock-out once again after correcting all
obvious problems, consult your nearest Webasto Service Station.

28
WEBASTO DBW SERIES HEATERS BASIC TROUBLESHOOTING

Malfunction Identification - DBW Series Heaters

This table is intended to assist the swift diagnosis of

simple malfunctions, which have obvious symptoms.
It cannot replace the detailed knowledge of an expert
workshop. For assistance, please contact one of the
workshops recommended in the list of service stations.

Table 2: Quick Check Matrix

29
WEBASTO DBW SERIES HEATERS BASIC TROUBLESHOOTING

Sequence of Events - DBW Series Heaters

The normal sequence of events illustrated here may be used in conjunction NOTE:
with the malfunction identification table to help determine heater problems. After the correction of a
malfunction, a functional
Table 3: Sequence of Events test must always be
performed with the heater
installed in the vehicle in
its operational position.

30
WEBASTO DBW SERIES HEATERS TECHNICAL DATA

Technical Data Heater DBW 2010 DBW 2020 DBW 300

Mark of conformity ~ S 129 ~ S 136 ~ S 164
Heater design principle High pressure fuel atomizing nozzle
General Information Heat output kW/h (BTU/h) 13.1 (45,000) 23.3 (80,000) 30 (104,000)
Fuel Diesel #1, Diesel #2, Arctic grade and Kerosene
Where no threshold values are specified,
Maximum fuel consumption l/h (US gal/h) 1.5 (0.4) 3.0 (0.79) 4.0 (1.05)
technical data are understood to include
standard tolerances for heater units of 10% Rated nominal voltage V 12 or 24
at ambient temperature of + 20 C (+ 68 F) Operating voltage V 10 ... 14 or 20 ... 28
and at nominal voltage. Nominal power consumption W 60 120 130
(without circulation pump)
Electrical components: Permissible operating ambient C (F) - 40 ... + 60 (- 40 + 140)
temperature range
Control unit, fan and circulation pump (heater, control unit, circulation pump)
motors, solenoid valve, igniter box, heater Permissible storage temperature C (F) + 85 max. (+ 185)
cartridge, nozzle pre-heater and timer are Permissible operating pressure bar (psi) 0.4 ... 2.0 (06 29)
voltage sensitive components. Temperature of coolant system
limiter, overheat fuse, control thermostat, Minimum capacity of circuit l (US. Gal) 10.00 (2.64)
flame sensor and switches are voltage CO2 in exhaust at nominal voltage Vol.-% 10.5 ... 11.0
independent components.
CO in exhaust at nominal voltage Vol.-% 0.2 maximum
Dimensions of heater length mm (in.) 584 (23) 680 (26-23/32)
width mm (in.) 205 (8-1/6) 240 (9-1/2)
Heater Data height mm (in.) 228 (10) 279 (10-29/32)
Weight (without enclosure) 15 kg (33 lbs.) 22 kg (48 lbs.)
Refer to adjacent table
Table 4: Heater Data

31
WEBASTO DBW SERIES HEATERS TECHNICAL DATA

U 4810 and U 4846 Coolant Pump Data

Recommended coolant circulation pumps for DBW 2010 heaters.

Coolant Circulation Pump U 4810 U 4846

Volume flow l/h (US. Gal/min) 1600 (6.0) @ 0.15 bar 1650 (7.0) @ 0.15 bar
Nominal voltage V 12 or 24 12 or 24
Operating voltage range V 10 ... 14 or 20 ... 28 10 ... 14 or 20 ... 28
Nominal power consumption W 25 28
Dimensions of length 173 mm (6.8 in.) 128 mm (7.16 in.)
coolant circulation pump width 94 mm (3.7 in.) 94 mm (3.7 in.)
height 77 mm (3.0 in.) 82 mm (3.32 in.)
Hose connection O.D. 38.0 mm (1.5 in.) 20.0 mm (0.78 in.)
Weight kg (lb.) 2.1 (4.63) 0.85 (1.88)
Table 5: U 4810 & U 4846 Coolant Pump Data

NOTE:
The allocation of circulation pumps to heater units must be in accordance with coolant resistances.

32
WEBASTO DBW SERIES HEATERS TECHNICAL DATA

U 4814, U 4851 and U 4852 Coolant Pump Data

Recommended coolant circulation pumps for DBW 2020 and DBW 300 heaters.

Coolant Circulation Pump U 4814 U 4851 & U 4852

Volume flow l/h (US. Gal/min) 5200 (22.9) @ 0.15 bar 6000 (26.4) @ 0.4 bar
Nominal voltage V 12 or 24 24
Operating voltage range V 10 ... 14 or 20 ... 28 18 ... 32
Nominal power consumption W 104 209
Dimensions of length 221 mm (8.7 in.) 285 mm (11.22 in.)
coolant circulation pump width 100 mm (3.94 in.) 115 mm (4.52 in.)
height 105 mm (4.14 in.) 110 mm (4.33 in.)
Hose connection O.D. 38.0 mm (1.5 in.) 38.0 mm (1.5 in.)
Weight kg (lb.) 2.1 (4.63) 2.7 (5.95)
Table 6: U 4810 & U 4846 Coolant Pump Data

NOTE:
The allocation of circulation pumps to heater units must be in accordance with coolant resistances.

33
WEBASTO DBW SERIES HEATERS NOTES

NOTES

34
 North American Headquarters
3333 John Conley Drive
Lapeer, MI 48446
Phone (810) 245-2400
Toll-free (800) HEATER-1
Fax (810) 664-7720

Canadian Operations
Toll-free (800) 667-8900

Rev. 11/00 699540 (English) Website: www.webasto.com

 Coolant Heaters
Chauffage eau

DBW 2020
Diesel - 12/24 Volts

DBW 300
Diesel - 12/24 Volts

DBW 350
Diesel - 24 Volts

Service Parts List

Liste des pices dentretien

11/2004
P/N 5000954A
Contents / Table des matires DBW 2020 / 300 / 350

Topic / Matire
Heaters / Rchauffeur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
Parts for burner head / Pices pour la tte de brleur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 1 - 3
Parts for heat exchanger / Pices pour l'changeur de chaleur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 4 - 6
Heater harness / Harnais de rchauffeur. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 7
Parts for nozzle preheat system / Les pices pour le bec prchauffent. . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 8
Electrical parts / Pices lectriques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 9 - 10
Parts for fuel supply / Pices affrentes au alimentation en combustible . . . . . . . . . . . . . . . . . . . . . . . . . Figure 11
Supplementary parts for compact heaters / Pices supplmentaires pour les rchauffeurs compacts . . . . Figure 12
Parts for heating water system / Pices affrentes au systme deau chaude. . . . . . . . . . . . . . . . . . . . . . Figure 13
Parts for exhaust system / Pices pour le dispositif d'chappement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13
Parts for mounting / Pices pour le support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 13
Parts for water circulation pump / Pices pour la pompe de circulation de l'eau . . . . . . . . . . . . . . . . . . . Figure 14 - 17
Diagnostic and service equipment / quipement de diagnostic et de service . . . . . . . . . . . . . . . . . . . . . . Figure 18
Service Value Kits / Service les kits de valeur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 33
For additional accessory parts refer to the accessories catalogue.
Pour d'autres accessoires consulter le catalogue d'accessoires.

For replacement heaters see / Pour le rchauffeurs de rechange voyez:

DBW 2020.63 . . . . . 12 V Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
DBW 2020.64 . . . . . 24 V Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
DBW 300.26 . . . . . . 12 V Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
DBW 300.53 . . . . . . 24 V Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4

Complete heater kits with enclosure / Accomplissez les kits de rchauffeur avec la clture:
DBW 2020.63 - 12 V Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 920462
DBW 2020.64 - 24 V Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 920464
DBW 300.26 - 12 V Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 920467
DBW 300.53 - 24 V Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 920469
Refer to the 2004 Product Catalog (P/N 909062) for details of the above heater kits.
Rfrez-vous au catalogue 2004 de produit (P/N 909062) pour des dtails des kits ci-dessus de rchauffeur.

2 Webasto Product N.A., Inc. www.techwebasto.com

Column A/N: Indicates which parts are modified, which parts are new:
A = modification N = new part

Column Description: Sub-assemblies or components (marked by a point) - offset to the right - are contained in
the assembly which is offset one point less.

Example:
fuel pump = assembly
solenoid valve = sub-assembly
gasket = component

The parts dependent on 12 Volt with red label or dot

voltage are marked: 24 Volt with green label or dot

Sparation A/N: Afin de metre en vidence les nouvelles pices et les pices transformes, vous trouverez
le repre suivant:
A = transformation N = nouvelles pices

Dsignation abrge: Les sous-ensembles marqus par points sont inclus dans les pices les prcdant et tant
prcds d'un nombre de points infrieurs ou d'aucun point.

Exemple:
pompe combustible = pice principale
lectrovanne = sous-ensemble inclus dans la pompe combustible
joint torique = inclus dans I'lectrovanne

Pices diffrentes selon 12 volts avec inscription rouge ou point rouge

tension 12 ou 24 volts: 24 volts avec inscription verte ou point vert

Subject to modification / Sous rserve de modifications

www.webasto.us Webasto Product N.A., Inc. 3

 DBW 2020 / 300 / 350 - fig. 1

4 7
8 6 20
5 19
18

17

16
3
1 Relays required for DBW 2020 / 300 12 Volt

2
until December 1993 (early harness)

12 Relais requis pour DBW 2020/300 12 volts

jusqu' dcembre 1993 (harnais tt)
13
14
15

11

10
9

Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
Heaters / Rchauffeur
no fig. 1 33751C DBW 2020.63 12 Volt, Diesel replacement heater
rchauffeur de rechange
no fig. 1 40345C DBW 2020.64 24 Volt, Diesel replacement heater
rchauffeur de rechange
no fig. 1 63746B DBW 300.26 12 Volt, Diesel replacement heater
rchauffeur de rechange
no fig. 1 63745B DBW 300.53 24 Volt, Diesel replacement heater
rchauffeur de rechange
Replacement burner heads do not include the nozzle preheat system. For applications requiring the preheat system, order 24 volt preheat
kit P/N 5000665A seperately. Refer to figure 8 for 12 volt burner heads.
Les ttes de brleur de rechange n'incluent pas le bec prchauffent le systme. Pour des applications exigeant le systme de prchauffage,
l'ordre 24 volt prchauffent le kit N/P 5000665A seperately. Rfrez-vous au schma 8 pour des ttes de brleur de 12 volts.
no fig. 1 1300476B burner head 12 Volt, Diesel DBW 2020.63 with control unit
tte de brleur 12 Volt, Diesel avec botier de commande
no fig. 1 5000232B burner head 24 Volt, Diesel DBW 2020.64 with control unit
tte de brleur 24 Volt, Diesel avec botier de commande
no fig. 1 5000173B burner head 24 Volt, Diesel DBW 2020.64 for MCI D - with control unit
tte de brleur 24 Volt, Diesel pour MCI D - avec botier de
commande
no fig. 1 1300478B burner head 12 Volt, Diesel DBW 300.54 with control unit
tte de brleur 12 Volt, Diesel avec botier de commande
no fig. 1 1300477B burner head 24 Volt, Diesel DBW 300.53 with control unit
tte de brleur 24 Volt, Diesel avec botier de commande
Parts for burner head / Pices pour la tte de brleur
1 1 1 287962 electronic control unit SG 1553 12 V
botier de commande SG 1553

4 Webasto Product N.A., Inc. www.techwebasto.com

 Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
2 1 1 1 30607B electronic control unit SG 1553 24 V
botier de commande SG 1553
3 1 1 1 362107 retaining clip - control unit
circlip - botier de commande
4 1 1 388807 electronic ignition unit 12 V
centrale dallumage (lectronique)
4 1 1 1 388815 electronic ignition unit 24 V
centrale dallumage (lectronique)
5 2 2 2 404918 socket
douille
6 X X X 178624 high-tension ignition cable sold per meter
cble d'allumage haute-tension vendu par mtre
7 2 2 2 326666 electrode plug
prise pour lectrode
8 4 4 4 470562 self tapping screw M3.5 x 14
vis de tapement d'individu
9 1 1 1 350427 air intake socket 80mm
buse d'aspiration
10 1 1 1 436410 protection cover
couverture de protection
11 2 2 2 50101660A warning label
plaque de danger
12 5 5 5 152269 washer - lock A4.3 DIN 6798
rondelle - serrure
13 5 5 5 147729 screw M4 x 12
vis
14 1 1 1 298816 bracket
support
15 2 2 901398 relay 12 V
relais
15 2 248401 relay 24 V
relais
16 1 1 106078 drive motor - complete 12 V
moteur - accomplissez
16 1 1 1 106082 drive motor - complete 24 V
moteur - accomplissez
17 3 3 3 488631 combination screw AM5 x 12
vis universelle
18 3 3 3 22428A combination screw AM5 x 16
vis universelle
19 1 1 1 35068A A flange
bride
20 2 2 2 397563 clutch half replace in pairs
elment dembrayage change per paires
no fig. 1 1 1 906215 connector / terminal kit - control unit SG 1553 includes 2-pole, 6-pole, and 8-pole
connector housings and 16 female
terminals
kit de connecteur et d'insertion - unit de commande SG 1553 inclut des logements du connecteur 2-
ple, 6-ple et 8-ple et 16 insertions
femelles

X = Quantity as required / Nombre suivant les besoins

www.webasto.us Webasto Product N.A., Inc. 5

 DBW 2020 / 300 / 350 - fig. 2
8
7

6
DBW 2020 / 300
5

4
18
3
2
1 17
14
9 16
15

14

13
12
11 19
10 DBW 350

Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
Parts for burner head / Pices pour la tte de brleur
1 4 4 148245 screw - allen socket M6 x 20 DIN 912
vis - douille d'Allen
2 4 4 152560 washer - lock B6 DIN128
rondelle - serrure
3 1 1 286354 motor carrier
bride support moteur
4 1 1 398144 shaft 8mm
arbre
5 1 1 275611 fan rotor
rotor de turbine
6 1 1 286303 intermediate casing
cuvelage intermdiaire
7 1 1 288993 rubber grommet - elongated hole accommodates nozzle preheat harness
douille en caoutchouc - trou ovale adapte au bec prchauffent le harnais
8 5 5 270903 rubber grommet - round hole
douille en caoutchouc - trou rond
9 1 1 378321 bearing set - shaft mounting
pices pour le montage de larbre
10 4 277169 screw - allen socket M6 x 65 DIN 912
vis - douille d'Allen
11 4 152560 washer - lock B6 DIN128
rondelle - serrure
12 1 286354 motor carrier
bride support moteur
13 1 396907 shaft 8mm
arbre

6 Webasto Product N.A., Inc. www.techwebasto.com

 Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
14 2 275611 fan rotor
rotor de turbine
15 1 286346 guide ring
bride de centrage
16 1 275433 deflector
dflecteur
17 1 286303 intermediate casing
cuvelage intermdiaire
18 5 270903 rubber grommet - round hole
douille en caoutchouc - trou rond
19 1 402125 bearing set - shaft mounting
pices pour le montage de larbre

www.webasto.us Webasto Product N.A., Inc. 7

 DBW 2020 / 300 / 350 - fig. 3

7 9
8 10 11
5
6

12
13
2 3
1 14
15
21
16 22 23
24
17 27
20 28 25
32 26
33
19 30
18 31
33
32 Nozzle holder preheating - see fig. 8
Prchauffage du porte-gicleur - voir fig. 8

Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
Parts for burner head / Pices pour la tte de brleur
1 1 1 322083 fuel solenoid and valve assembly 12 V
aimant dlectrovanne
1 1 1 1 322091 fuel solenoid and valve assembly 24 V
aimant dlectrovanne
2 1 1 1 386650 fuel solenoid repair kit
kit de rparation de solnode de carburant
3 1 1 1 260487 gasket ring
joint
4
5 1 1 1 66185A clamp - electrodes
platine de fixation - lectrodes
6 2 2 2 274313 electrodes - ignition
lectrodes - allumage
7 1 1 1 147249 screw M6 x 20 DIN 933
vis
8 1 1 1 152560 washer - locking A6 DIN 128
rondelle - serrure
9 1 1 1 296740 photocell plate heaters without nozzle preheat system
plat de cellule photo-lectrique les rchauffeurs sans bec prchauffent
le systme
10 1 1 1 109530 photocell plate heaters with nozzle preheat system
plat de cellule photo-lectrique les rchauffeurs avec le bec
prchauffent le systme
11 1 1 1 453048 retaining ring A22 DIN 7993
bague de retenue
12 1 1 1 215171 flame detection photocell
cellule photo-lectrique

8 Webasto Product N.A., Inc. www.techwebasto.com

 Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
13 1 1 1 147699 screw - self tapping M4 x 6 DIN 7985
vis parker tte bombe
14 1 341304 high-pressure nozzle 0.60 GPH, 60 H see fig. 4 - use with #342637
gicleur haute pression voir la fig. 4 - employez avec #342637
14 1 470716 high-pressure nozzle 0.65 GPH, 80 H see fig. 5 - use with #464333
gicleur haute pression voir la fig. 5 - employez avec #464333
14 1 391697 high-pressure nozzle 0.85 GPH, 80 W see fig. 4 - use with #394424
gicleur haute pression voir la fig. 4 - employez avec #394424
14 1 470724 high-pressure nozzle 0.85 GPH, 80 H see fig. 5 - use with #464333
gicleur haute pression voir la fig. 5 - employez avec #464333
14 1 469556 high-pressure nozzle 1.0 GPH, 80 S see fig. 5 - use with #464333
gicleur haute pression voir la fig. 5 - employez avec #464333
15 1 1 1 412198 holder - nozzle
support de bec
16 1 1 1 103512 plate - nozzle holder
embase de pompe
17 2 2 2 488631 screw - combination AM5 x 12
vis - combinaison
18 1 1 1 152390 retaining ring M6 x 0.7 DIN 471
bague de retenue
19 1 1 1 371289 gear - spur straight
roue droite
20 4 4 4 22428A screw - combination AM5 x 16
vis - combinaison
21 1 1 1 50275476A high-pressure pipe aluminum fuel pump / pompe
pipe haute pression d'essence en aluminium #5000177A
22 1 1 1 5000216A N high-pressure pipe - service kit for zinc or aluminum fuel pump for / pour # 72027B & 5000177A
pipe haute pression - service le kit pour la pompe d'essence de zinc includes instructions
ou d'aluminium inclut des instructions
23 2 2 2 277282 screw - allen socket M4 x 30 8.8 DIN 912
vis - douille d'Allen
24 2 2 2 152544 washer - lock A4 DIN 128
rondelle - serrure
25 1 1 1 72027B fuel pump 10 bar (145 psi) zinc body pump
pompe combustible barre 10 (145 psi) pompe en zinc
26 1 1 1 5000177A N fuel pump 10 bar (145 PSI.) upgrade - aluminum body pump
pompe combustible barre 10 (145 psi) mise niveau - pompe en aluminium
27 1 1 1 355836 valve - pressure control
soupape de rglage de pression
28 1 1 1 310344 filter screen
filtre
29
30 1 1 1 111375 fuel supply line - barb connection
canalisation d'alimentation de carburant - raccordement de bavure
30 1 1 1 92173A N fuel supply line - JIC #4 threaded connection
canalisation d'alimentation de carburant - JIC #4 raccordement filet
31 1 1 1 462659 fuel return line - barb connection
canalisation de retour de carburant - raccordement de bavure
31 1 1 1 92172A N fuel return line - JIC #6 threaded connection
canalisation de retour de carburant - JIC #6 raccordement filet
32 2 2 2 65513A hollow screw DIN 7643 LL6
vis creuse
33 4 4 4 151157 washer - copper A10 x 13.5 DIN 7603Cu
rondelle - cuivre
no fig. X X X 143820 grease - special in tube at 100g ISOFLEX LDS 18 for gears
grasse - spciale en tube 100g pour engrenage

www.webasto.us Webasto Product N.A., Inc. 9

 DBW 2020 / 300 / 350 - fig. 4

built in until DBW 2020.31 / DBW 300.10 inclusively 10 11

pice fournie jusqu'au modele DBW 2020.31 5 9

6
7
2
8

21 17
20
18
80
19

casting built in until DBW 300.10 inclusively

casting built in until DBW 2020.31 inclusively
pice fournie jusqu'au modele DBW 300.10
pice fournie jusqu'au modele DBW 2020.31

Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
Parts for heat exchanger / Pices pour l'changeur de chaleur
1 1 342637 combustion chamber - for heat exchanger with 80 mm exhaust DBW 2020 (early type)
chambre de combustion - pour l'changeur de chaleur avec 80 mm DBW 2020 (premier type)
d'chappement
2 1 394424 combustion chamber - for heat exchanger with 80 mm exhaust DBW 300 (early type)
chambre de combustion - pour l'changeur de chaleur avec 80 mm DBW 300 (premier type)
d'chappement
3-4
5 1 1 395749 heat exchanger - with 80mm exhaust
changeur de chaleur - avec 80mm d'chappement
6 2 2 2 1301275A eye bolt M8 x 40
boulon oeilleton
7 2 2 2 348449 pin - grooved 8 x 16 DIN 1475 zinc plated steel
tenno encoche acier plaqu par zinc
8 2 2 2 461563 nut - hex flange M8
crou - avec la rondelle
9 1 1 1 289329 angle bracket - copper for overheat and control thermostats
support querre - cuivre pour des thermostats de surchauffe et
de commande
10 1 1 1 279110 fitting - fuse for overheat fuse
raccord - fusible pour le fusible thermique
11 1 1 1 352500 cotter pin hinge pin
goupille goupille de charnire
12-16
17 2 2 136204 turnbuckle - short
tendeur vis - court
18 2 2 1301911A tightening clamp
collier de serrage

10 Webasto Product N.A., Inc. www.techwebasto.com

 Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
19 1 1 454370 support
support
20 1 1 149314 plug fitting M10
raccord
21 1 1 65514A gasket ring A22 x 27 DIN 7603 Cu
joint

www.webasto.us Webasto Product N.A., Inc. 11

 DBW 2020 / 300 / 350 - fig. 5

10 11
built in from DBW 2020.33 / DBW 300.16
a partir de modele DBW 2020.33 / DBW 300.16 5 9

6
7
1
8

21
20
16
15
70

sheet metal type built in from DBW 2020.33 / DBW 300.16

a partir de modele DBW 2020.33 / DBW 300.16

Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
Parts for heat exchanger / Pices pour l'changeur de chaleur
1 1 1 1 464333 combustion chamber - for heat exchanger with 70mm exhaust DBW 2020 (late type)
chambre de combustion - pour l'changeur de chaleur avec 70mm DBW 2020 (type en retard)
d'chappement
2-4
5 1 1 1 469084 heat exchanger - with 70mm exhaust
changeur de chaleur - avec 70mm d'chappement
6 2 2 2 1301275A eye bolt M8 x 40
boulon d'oeil
7 2 2 2 348449 pin - grooved 8 x 16 DIN 1475 zinc plated steel
tenno encoche acier plaqu par zinc
8 2 2 2 461563 nut - hex flange M8
crou - avec la rondelle
9 1 1 1 289329 angle bracket - copper for overheat and control thermostats
support querre - cuivre pour des thermostats de surchauffe et
de commande
10 1 1 1 279110 fitting - fuse for overheat fuse
raccord - fusible pour le fusible thermique
11 1 1 1 352500 cotter pin hinge pin
fixation de la goupille goupille de charnire
12-14
15 1 1 1 362115 clamp
bride
16 1 1 1 463027 fuel line support
ligne de carburant appui
17-19

12 Webasto Product N.A., Inc. www.techwebasto.com

 Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
20 1 1 1 149314 plug fitting M10
raccord
21 1 1 1 65514A gasket ring A22 x 27 DIN 7603 Cu
joint

X = Quantity as required / Nombre suivant les besoins

www.webasto.us Webasto Product N.A., Inc. 13

 DBW 2020 / 300 / 350 - fig. 6

15

1
16 8

4 3
5 2 9

10

Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
Parts for heat exchanger / Pices pour l'changeur de chaleur
1 1 1 1 487627 cap - thermostat protection
couverture - protection de thermostats
2 1 1 1 28864A clamp - nylon white 6.5 mm
platine de fixation - blanc
3 1 1 1 147702 screw - self tapping M4 x 8 DIN 7985
vis parker tte bombe
4 1 1 1 273481 screw for brackets and protection cap
vis pour les appuis et la couverture de
protection
5 1 1 1 273473 bracket - buss bar
support - barre de buss
6 1 1 1 298816 bracket
support
7 1 1 1 406287 fuse - overheat (yellow) 138 C (280 F)
fusible - surchauffe (jaune)
8 1 1 1 354902 thermostat - control 75 C (167 F) red/green
thermostat - commande vert/rouge
9 1 1 1 608719A thermostat - overheat 107 C (225 F) green/green - auto reset
thermostat - surchauffe vert/vert - remise automatique
10 1 1 1 408719 thermostat - overheat 117 C (242 F) light green/light green - manual reset
thermostat - surchauffe vert clair/vert clair - remise manuelle
11-14
15 1 1 1 308331 knurled nut
crou molet
16 cap - thermostat protection DISCONTINUED - OBSOLETE
couverture - protection de thermostats CESS - DSUET

14 Webasto Product N.A., Inc. www.techwebasto.com

 DBW 2020 / 300 / 350 - fig. 7

4
1 3
3
5

7
1
4

2 2 3
3 control thermostat (remote option)
5 1 aquastat (option distance)
control unit
2 botier de commande
overheat fuse / temperature limiter /
6 3 control thermostat
scurit de temprature /
7 limiteur de temprature / aquastat
flame detection photocell
4 cellule photo-lectrique
1
fuel solenoid valve
5 lectrovanne
motor
2 6 moteur
electronic ignition unit
7 centrale d'ignition

Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
Heater harness / Harnais de rchauffeur
1 1 1 444170 heater harness - with remote control-thermostat option
harnais de rchauffeur - avec l'option de raccordement distance de
commande-thermostat
2 1 469513 heater harness - with remote control-thermostat connection
harnais de rchauffeur - avec le raccordement distance de
commande-thermostat
3 1 1 352969 terminal block 6-way
connecteur bornes 6 ples

www.webasto.us Webasto Product N.A., Inc. 15

 DBW 2020 / 300 / 350 - fig. 8

1 2
3

7
6
5
4

14

8 11
9 13

10
12

Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
Parts for nozzle preheat system / Les pices pour le bec prchauffent
1 1 1 1 19723B clip - nozzle preheat element
agrafe - le bec prchauffent l'lment
2 1 1 50410799A element - nozzle preheat 12 V
lment - le bec prchauffent
3 1 1 1 50420042A element - nozzle preheat 24 V
lment - le bec prchauffent
4 1 1 1 104012 thermostat assembly - preheat
thermostat assemble - prchauffez
5 1 1 1 109530 photocell plate
plat de cellule photo-lectrique
6 1 1 1 152269 washer - lock A4.3 DIN 6798
rondelle - serrure
7 1 1 1 147044 hexagon nut M4 DIN 6924
crou six-pan
8 1 1 901398 relay - preheat 12 V
relais - prchauffez
9 1 1 1 901401 relay - preheat 24 V
relais - prchauffez
10 1 1 1 50101804A preheat harness 3-way power supply connector
prchauffez le harnais connecteur de puissance 3-way
11 1 1 1 109697 preheat kit - complete 24 V (nozzle holder not included) 3-way power supply connector
prchauffez le kit - accomplissez 24 V (support de bec non inclus) connecteur de puissance 3-way
12 620265A preheat harness - with thermostat 2-way power supply connector
prchauffez le harnais - avec thermostat connecteur de puissance 2-way
13 5000665A preheat kit - complete 24 V (nozzle holder not included) 2-way power supply connector
prchauffez le kit - accomplissez 24 V (support de bec non inclus) connecteur de puissance 2-way

16 Webasto Product N.A., Inc. www.techwebasto.com

 Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
14 1 1 1 412198 holder - nozzle
support de bec

www.webasto.us Webasto Product N.A., Inc. 17

 DBW 2020 / 300 / 350 - fig. 9

1
2 3
+

11
12 15 16
9
10 13
14

ON

OF
F

Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
Electrical parts / Pices lectriques
1 1 1 905811A wiring harness - internal (inclosure application) no nozzle preheat provision
harnais de cblage - interne (application de clture) aucun bec ne prchauffent la
disposition
2 1 1 906960A wiring harness - internal with nozzle preheat harness provision (inclosure application)
harnais de cblage - interne avec le bec prchauffez la disposition de (application de clture)
harnais
3 1 1 905799C wiring harness - external (inclosure application)
harnais de cblage - externe (application de clture)
4 1 1 5000809A N fuse holder upgrade kit - with mounting hardware and installation replaces former fuse blocks / remplace
instructions d'anciens blocs de fusible 901748 &
le kit d'adaptation de support de fusible - avec le matriel de support 14878A
et les instructions d'installation
9 1 1 905103 toggle switch 12 V (includes On/Off plate) with indicator light
interrupteur levier 12 V (inclut le plat "Marche/Arrt") avec ampoule
10 1 1 1 905104 toggle switch 24 V (includes On/Off plate) with indicator light
interrupteur levier 24 V (inclut le plat "Marche/Arrt") avec ampoule
11 1 1 82774A digital timer - 1529 12 V 7-day / 3-program
montre digitale - 1529 de sept jours/3-programmes
12 1 1 1 82775A digital timer - 1529 24 V 7-day / 3-program
montre digitale - 1529 de sept jours/3-programmes
13 1 1 28443A light bulb 12 V for #82774A
ampoule pour #82774A
14 1 1 1 28447A light bulb 24 V for #82775A
ampoule pour #82775A
15 1 1 1 474630 mounting frame for timer
bti de support pour le temporisateur

18 Webasto Product N.A., Inc. www.techwebasto.com

 Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
16 1 1 1 475866 mounting housing for timer rubber
logement de support pour le temporisateur le caoutchouc

www.webasto.us Webasto Product N.A., Inc. 19

 DBW 2020 / 300 / 350 - fig. 10

1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 20 25 26
21

Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
Electrical parts / Pices lectriques
1 X X X 178799 connector housing - female 1-pole uses insert # 176389 (male)
module de raccordement - femelle1-ple utilisations # 176389 (mle)
2 X X X 178705 connector housing - male 1-pole uses insert # 176613 (female)
module de raccordement - mle 1-ple utilisations # 176613 (femelle)
3 X X X 178802 connector housing - female 2-pole uses insert # 176389 (male)
module de raccordement - femelle2-ples utilisations # 176389 (mle)
4 X X X 178713 connector housing - male 2-pole uses insert # 176613 (female)
module de raccordement - mle 2-ples utilisations # 176613 (femelle)
5 X X X 178721 connector housing - male 2-pole uses insert # 176613 (female)
module de raccordement - mle 2-ples utilisations # 176613 (femelle)
6 X X X 620275 connector housing - female 2-pole uses insert # 176389 (male)
module de raccordement - femelle2-ples utilisations # 176389 (mle)
7 X X X 178810 connector housing - female 4-pole uses insert # 176389 (male)
module de raccordement - femelle4-ples utilisations # 176389 (mle)
8 X X X 178748 connector housing - male 4-pole uses insert # 176613 (female)
module de raccordement - mle 4-ples utilisations # 176613 (femelle)
9 X X X 178837 connector housing - female 6-pole uses insert # 176389 (male)
module de raccordement - femelle6-ples utilisations # 176389 (mle)
10 X X X 328529 connector housing - male 6-pole uses insert # 176613 (female)
module de raccordement - mle 6-ples utilisations # 176613 (femelle)
11 X X X 342777 connector housing - female 8-pole uses insert # 176389 (male)
module de raccordement - femelle8-ples utilisations # 176389 (mle)
12 X X X 178764 connector housing - male 8-pole uses insert # 176613 (female)
module de raccordement - mle 8-ples utilisations # 176613 (femelle)
13 X X X 901542 socket - relay 5-pole uses insert # 176613 (female)
douille - relais 5-ples utilisations # 176613 (femelle)

20 Webasto Product N.A., Inc. www.techwebasto.com

 Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
14 X X X 176613 metal insert - female
insertion en mtal - femelle
15 X X X 176389 metal insert - male
insertion en mtal - mle
16-19
20 X X 901398 relay 12 V
relais
21 X X X 901401 relay 24 V
relais
22-24
25 X X X 103737 fuse - ATO tan 5 amp
coupe-circuit - ATO tan
25 X X X 103741 fuse - ATO brown 7.5 amp
coupe-circuit - ATO brun
25 X X X 905610 fuse - ATO red 10 amp
coupe-circuit - ATO rouge
25 X X X 24981A fuse - ATO blue 15 amp
coupe-circuit - ATO bleu
25 X X X 103922 fuse - ATO yellow 20 amp
coupe-circuit - ATO jaune
25 X X X 103745 fuse - ATO clear 25 amp
coupe-circuit - ATO transparent
25 X X X 905530 fuse - ATO green 30 amp
coupe-circuit - ATO vert
26 X X X 901402 fuse - ATM tan 5 amp
coupe-circuit - ATM tan
26 X X X 5000806A fuse - ATM brown 7.5 amp
coupe-circuit - ATM brun
26 X X X 901406 fuse - ATM red 10 amp
coupe-circuit - ATM rouge
26 X X X 5000807A fuse - ATM blue 15 amp mini fuse
coupe-circuit - ATM bleu coupe-circuit - mini
26 X X X 901404 fuse - ATM yellow 20 amp
coupe-circuit - ATM jaune
26 X X X 5000353A fuse - ATM clear 25 amp
coupe-circuit - ATM transparent
26 X X X 5000808A fuse - ATM green 30 amp
coupe-circuit - ATM vert
no fig. 1 1 1 906215 connector / terminal kit - control unit SG 1553 includes 2-pole, 6-pole, and 8-pole
connector housings and 16 female
terminals
kit de connecteur et d'insertion - unit de commande SG 1553 inclut des logements du connecteur 2-
ple, 6-ple et 8-ple et 16 insertions
femelles

X = Quantity as required / Nombre suivant les besoins

www.webasto.us Webasto Product N.A., Inc. 21

 DBW 2020 / 300 / 350 - fig. 11

10
4

2 11

5 12
1

3 6
15

78
17
16
9 18

Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
Parts for fuel supply / Pices affrentes au alimentation en combustible
1 X X X 903210A fuel standpipe assembly - universal
tube d'extraction de carburant - universel
2 X X X 905742A fuel standpipe
tube d'extraction de carburant
3 X X X 906002 tank boss kit (bag)
kit de patron de rservoir (sac)
4 X X X 603364 terminal bolt 1/4 female NPT
boulon terminal 1/4"NPT femelle
5 X X X 903758 fuel shutoff valve
robinet d'isolement de carburant
6 X X X 603362 barb fitting 1/4 male NPT x 1/4 hose barb
connecteur de bavure bavure masculine de tuyau de 1/4"
NPT X 1/4"
7 1 1 1 901299 barb fitting JIC #4 x 1/4 hose barb
connecteur de bavure bavure de tuyau de JIC #4 X 1/4"
8 1 1 1 901331 barb fitting JIC #6 x 1/4 hose barb
connecteur de bavure bavure de tuyau de JIC #6 X 1/4"
9 X X X 900004 barb fitting 1/4 male NPT x 1/4 hose barb
connecteur de bavure bavure masculine de tuyau de 1/4"
NPT X 1/4"
10 X X X 900401 bushing 1/2 x 1/4 NPT
douille
11 X X X 903709 fuel line 1/4 sold per meter
ligne de carburant vendu par mtre
12 X X X 600146 hose clamp 8 - 12mm stainless steel
collier de la conduite acier inoxydable
13-14

22 Webasto Product N.A., Inc. www.techwebasto.com

 Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
15 1 1 1 905707 fuel filter mounting bracket for item number 16, 17
support de filtre d'essence pour l'article numro 16, 17
16 1 1 1 5000949A fuel filter kit
kit de filtre d'essence
17 1 1 1 900400 fuel filter head origin - USA
tte de filtre d'essence origine - Etats-Unis

18 1 1 1 900001 fuel filter replacement cartridge

cartouche filtrante

X = Quantity as required / Nombre suivant les besoins

www.webasto.us Webasto Product N.A., Inc. 23

 DBW 2020 / 300 / 350 - fig. 12

1 2 3 5 6 7

8 9 11 12 13
10

Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
Compact heaters: Fuel filter and water pump are mounted on the heater. Listing of parts which are different or supplementary to the
standard model.
Rchauffeurs compacts: Le filtre d'essence et la pompe d'eau sont monts sur le rchauffeur. Liste des pices qui compltent diffrentes ou
au modle standard.
1 X X X 330027 hose clamp 10mm
collier de la conduite
2 X X X 481947 pipe clip 10mm
collier de serrage
3 X X X 903709 fuel line 1/4 sold per meter
ligne de carburant vendu par mtre
4
5 2 2 2 150762 hollow screw LL 10 DIN 7643
vis creuse
6 2 2 2 150711 banjo fitting
raccord de tubulure annulaire
7 4 4 4 151203 washer - copper A14 x 18 DIN 7603
rondelle - cuivre
8 2 2 2 902428 hose clamp 34 - 57mm stainless steel
collier de la conduite acier inoxydable
9 1 1 1 50106023A hose 38mm x 65mm long
tuyau
10 1 1 1 19621A hose 38mm x 82mm long
tuyau
11 2 2 2 109492 turnbuckle - long
tendeur vis - long
12 2 2 2 1301911A tightening clamp
collier de serrage

24 Webasto Product N.A., Inc. www.techwebasto.com

 Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
13 1 1 1 21324A stand for coolant circulation pumps U 4814,
U 4816, U 4851 and U 4852
support pour les pompes de circulation de
l'eau U 4814, U 4816, U 4851 et U
4852

www.webasto.us Webasto Product N.A., Inc. 25

 DBW 2020 / 300 / 350 - fig. 13

1 2 6 7 8 81 81 71 71 71
3

11 12 14 15
13 16 18
17

19 25 26 29 30 31 32 33 34
20 27 28
21
22
23
24

Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
Parts for heating water system / Pices affrentes au systme deau chaude
1 4 4 4 902428 hose clamp 34 - 57mm stainless steel
collier de la conduite acier inoxydable
2 2 2 2 211524 rubber elbow 38mm (1.5 in.) origin - Germany
coude en caoutchouc origine - Allemagne
3 2 2 2 50211524A N rubber elbow 38mm (1.5 in.) origin - Canada
coude en caoutchouc origine - Canada
4-5
6 1 1 43308A A thermostat switch 78 C (172.4 F)
aquastat interrupteur
7 1 1 217336 washer - copper A22 x 27 DIN 7603
rondelle - cuivre
8 1 1 138169 connecting pipe 38mm (1.5 in.)
pipe de raccordement
9-10
Parts for exhaust system / Pices pour le dispositif d'chappement
11 1 1 132748 exhaust pipe extension 81mm x 100mm long
tubulure d'chappement
12 1 1 132756 exhaust pipe extension 81mm x 98mm long
tubulure d'chappement
13 1 1 220701 exhaust pipe extension 81mm x 133mm long
tubulure d'chappement
14 1 1 1 460176 exhaust pipe extension 71mm x 90mm long
tubulure d'chappement
15 1 1 1 82929A exhaust pipe extension 71mm x 75mm long
tubulure d'chappement

26 Webasto Product N.A., Inc. www.techwebasto.com

 Quantity
Item Nombre Part No. Description Remarks
A/N
Repre Rfrence Dsignation Remarques
2020 300 350
16 1 1 1 460079 exhaust pipe extension 71mm x 98mm long
tubulure d'chappement
17 1 1 1 460087 exhaust pipe extension 71mm x 133mm long
tubulure d'chappement
18 1 1 1 465380 exhaust elbow 71mm
coude d'chappement
19 X X X 5000287A N exhaust tubing 70mm x 1.0m
tuyauterie d'chappement
20 X X X 5000329A N exhaust tubing 70mm x 2.0m
tuyauterie d'chappement
21 X X X 5000638A N exhaust tubing 70mm x 2.5m
tuyauterie d'chappement
22 X X X 5000330A N exhaust tubing 70mm x 5.0m
tuyauterie d'chappement
23 X X X 5000331A N exhaust tubing 70mm x 10m
tuyauterie d'chappement
24 X X X 50479721A N exhaust tubing 70mm x 20m
tuyauterie d'chappement
Parts for mounting / Pices pour le support
25 1 1 905499 enclosure cover - black coated steel
couverture de clture - acier enduit noir
26 1 1 905498B enclosure base - black coated steel
base de clture - acier enduit noir
27 1 1 901260 enclosure cover - stainless steel
couverture de clture - acier inoxydable
28 1 1 901256B enclosure base - stainless steel
base de clture - acier inoxydable
29 4 4 667605 hexagon screw M8 x 20mm - stainless steel
vis d'hexagone M8 x 20mm - acier inoxydable
30 4 4 601027 lock washer M8
rondelle de freinage
31 4 4 601025 flat washer M8
rondelle plate parts for enclosure
32 4 4 601048 panel nut M8 Pices pour la clture
crou de panneau
33 1 1 905682 rubber grommet - small
bague de passage - petit
34 1 1 900461 rubber grommet - large
bague de passage - grand

X = Quantity as required / Nombre suivant les besoins

www.webasto.us Webasto Product N.A., Inc. 27

 DBW 2020 / 300 / 350 - fig. 14
1 4 U 4814
5

38
38

6
10 11
3 9
8

Quantity
Item Nombre Part No. Description Remarks
U 4814 A/N
Repre Rfrence Dsignation Remarques
12V 24V
Parts for water circulation pump / Pices pour la pompe de circulation de l'eau
1 1 43152D circulation pump U 4814 24 V
pompe de circulation U 4814
2 901300 circulation pump U 4814 24 V MCI with Deutsch electrical connector
pompe de circulation U 4814 MCI avec la prise lectrique de Deutsch
3 906079 circulation pump U 4814 24 V with Packard electrical connector
pompe de circulation U 4814 avec la prise lectrique de Packard
4 1 43149B circulation pump U 4814 12 V
pompe de circulation U 4814 includes mounting bracket and clamp
5 1 43150B circulation pump U 4814 24 V inclut le support et la bride
pompe de circulation U 4814
6 1 1 50906084A A seal and gasket set
ensemble de joint et de garniture
7 1 1 30155B A splashguard
bavette
8 1 1 5097664A A front housing kit
kit de couverture
9 1 1 5000153A N circulation pump rebuild kit includes item 6 and 8
kit de reconstruction de pompe de circulation inclut le point 6 et 8
10 1 1 139661 gear clamp 60 - 80mm
collier de serrage
11 1 1 37269A stand
support

28 Webasto Product N.A., Inc. www.techwebasto.com

 DBW 2020 / 300 / 350 - fig. 15

1 U 4816

38
38

7 8
2

Quantity
Item Nombre Part No. Description Remarks
U 4816 A/N
Repre Rfrence Dsignation Remarques
24V
Parts for water circulation pump / Pices pour la pompe de circulation de l'eau
1 1 42640B circulation pump U 4816 24 V includes mounting bracket and clamp
pompe de circulation U 4816 inclut le support et la bride
2 1 50906084A A seal and gasket set
ensemble de joint et de garniture
3 1 30155B A splashguard
bavette
4 1 5097664A A front housing kit
kit de couverture
5 1 5000153A N circulation pump rebuild kit includes item 2 and 4
kit de reconstruction de pompe de circulation inclut le point 2 et 4
6 1 166480 carbon brush for motor
brosse de carbone pour le moteur
7 1 139629 gear clamp 90 - 110mm
collier de serrage
8 1 233641 stand
support

www.webasto.us Webasto Product N.A., Inc. 29

 DBW 2020 / 300 / 350 - fig. 16
1 2 U 4851

10 11
3

Quantity
Item Nombre Part No. Description Remarks
U 4851 A/N
Repre Rfrence Dsignation Remarques
24V
Parts for water circulation pump / Pices pour la pompe de circulation de l'eau
1 1 92195B A circulation pump U 4851 24 V with Packard electrical connector
pompe de circulation U 4851 avec la prise lectrique de Packard
2 92730C circulation pump U 4851 24 V Nova Bus (Volvo)
pompe de circulation U 4851
3 1 50906084A A seal and gasket set
ensemble de joint et de garniture
4 1 30155B A splashguard
bavette
5 1 5097664A A front housing kit
kit de couverture
6 1 5000153A N circulation pump rebuild kit includes item 3 and 5
kit de reconstruction de pompe de circulation inclut le point 3 et 5
7 1 *97351A A motor 24 V
moteur
8-9
10 1 139629 gear clamp 90 - 110mm
collier de serrage
11 1 233641 stand
support

* Contact Webasto North America for part availability / Contact Webasto North America pour la disponibilit de partie

30 Webasto Product N.A., Inc. www.techwebasto.com

 DBW 2020 / 300 / 350 - fig. 17
1 U 4852

38 38

10 11
3

Quantity
Item Nombre Part No. Description Remarks
U 4852 A/N
Repre Rfrence Dsignation Remarques
24V
Parts for water circulation pump / Pices pour la pompe de circulation de l'eau
1 1 1300068C A circulation pump U 4852.06 24 V with Packard electrical connector
pompe de circulation U 4852.06 avec la prise lectrique de Packard
2 1 *97351A A motor 24 V with centering ring and external rotor
moteur avec bague de centrage et rotor
extrieur
3 1 *72093A N magnetic coupling assembly with internal rotor and locking head
accouplement magntique avec rotor intrieur et tte darrt
4 1 5097664A A front housing kit
kit de couverture
5-9
10 1 139629 gear clamp 90 - 110mm
collier de serrage
11 1 233641 stand
support

* Contact Webasto North America for part availability / Contact Webasto North America pour la disponibilit de partie

www.webasto.us Webasto Product N.A., Inc. 31

 DBW 2020 / 300 / 350 - fig. 18
1 2 3 4 5

al
p eci ase
8 S Gre
80 10
0
S1
LD aring
40 12
0

16
Be
0
20
0

6 7

t
ain
D gP e
RE ckin on
/ Lo ilic
cS
e
g ub
tri
n
rki oz
.T
Ma lec 2
Die ease
G r

Item Quantity Part No. Description Remarks

A/N
Repre Nombre Rfrence Dsignation Remarques
Diagnostic and service equipment / quipement de diagnostic et de service
1 1 440280 diagnostic testing apparatus
appareil d'essai diagnostique
2 1 905491A extension harness for diagnostic testing apparatus 1.5 m (5 ft.)
harnais de prolongation pour l'appareil d'essai diagnostique
3 1 310646 electrode alignment setting gauge
mesure pour des lectrodes d'allumage
4 1 600190 fuel pressure gauge with adapter
manomtre pour le carburant avec l'adapteur
5 1 143820 bearing grease - isoflex LDS18 special - 400 gram tube
soutenant la graisse - isoflex LDS18 spcial - tube de 400 grammes
6 1 154245 locking paint - red
peinture de fermeture - rouge
7 1 50000043 dielectric silicone grease 2 oz. for electrical connectors
graisse dilectrique de silicone pour les connecteurs lectriques
no fig. 1 699745 service and repair manual - DBW Series
manuel de service et de rparation - srie de DBW

32 Webasto Product N.A., Inc. www.techwebasto.com

Service Value Kits / Service les kits de valeur
Webasto Service Value Kits. Save time and money, and extend performance of your heating systems.
Webasto service les kits de valeur. conomiser le temps et l'argent, et prolongez l'excution de vos systmes de chauffage.

Electrical rebuild kit / Kit lectrique de reconstruction

DBW 2020 / DBW 300 - 24 Volt

P/N 50000027
Control unit / Unit de commande (24 Volt)
Fuel solenoid valve / Valve de solnode de carburant (24 Volt)
2 Electrodes / lectrodes
Flame detector / Dtecteur de flammes
Electronic ignition coil / Unit lectronique d'allumage
Internal wiring harness (not shown) / Harnais de cblage interne
(non montr)

Partial rebuild kit / Kit partiel de reconstruction

DBW 2020 - 24 Volt

P/N 50000045
Electric motor / Moteur lectrique
Bearings / Roulements
Clutch couplings / Accouplements d'embrayage
Bearing shaft / Axe de roulement
2 Nozzles / Becs
2 Overheat fuses / fusibles thermiques

DBW 2020 - Basic maintenance kit / Kit de base d'entretien

P/N 50000044
2 Nozzles / Becs
2 Overheat fuses / fusibles thermiques

DBW 300 - Basic maintenance kit / Kit de base d'entretien

P/N 5000961A
2 Nozzles / Becs
2 Overheat fuses / fusibles thermiques

DBW 2020 - Service pack - Nozzles / Paquet de service - becs

P/N 50000025
12 Nozzles / Becs
0.65 GPH / 80 A
80,000 Btu/h

DBW 300 - Service pack - Nozzles / Paquet de service - becs

P/N 5000957A
12 Nozzles / Becs
0.85 GPH / 80 H
104,000 Btu/h

www.webasto.us Webasto Product N.A., Inc. 33

 Webasto Product N.A., Inc.
15083 North Road
Fenton, MI 48430
Technical Assistance Hotline
USA: (800) 555-4518
Canada: (800) 667-8900
www.webasto.us
Org. 10/2004 Rev. 11/2004 P/N 5000954A www.techwebasto.com
 Webasto Product N.A., Inc.
Technical Assistance Hotline
USA: (800) 555-4518
Canada: (800) 667-8900

P/N 699.745 1/2004 www.webasto.us

 Table of Contents
Overview 1

Pump Disassembly 2

Control Disassembly / Reassembly 7

Pump Reassembly 13

Adjustment Procedures DR Control 19

Adjustment Procedures DRG Control 20

Adjustment Procedures DFR / DFR1 Control 21

Adjustment Procedures DFLR Control 22

Torque Specifications 26
 Overview

The life expectancy of all hydraulic components is directly related to the cleanliness of the hydraulic system that it
operates within. Typically, the cleaner the hydraulic system is maintained, the longer life expectancy the hydraulic
components will have.

Component life is dependent upon the system cleanliness, duty cycle, operating parameters, and the
environment. Noting there are many variances in maintaining a reliable hydraulic system, there must be an
adequate maintenance schedule established to maximize component life.

Since it is generally agreed that contamination is the number one cause of hydraulic component failure, during
commissioning of any repaired hydraulic unit, every effort must be made to keep the system clean and avoid all
outside contamination.

Always consider safety when working with hydraulic systems. Wear appropriate safety apparel. Recheck
all hydraulic connections for tightness before turning the system on. Always follow the manufacturers
recommendations of the equipment before beginning any work.

It is always recommended that the component being removed on the manufacturers equipment be thoroughly
cleaned of all surface debris and serial numbers and model numbers be recorded of the components being
removed for use as future reference.

1
Pump Disassembly
1
Remove the shaft key (if applicable).

2
Remove the external shaft seal retaining ring.

3
Turn unit over with shaft assembly pointing down and
remove the four 6mm control assembly retaining bolts.

4
Remove the control assembly and set aside for
later disassembly and inspection.

2
 Pump Disassembly continued

5
Mark the port cover to the housing. Remove the fixing
bolts, and lift off the port cover with care.

6
Remove the valve plate from the port plate, taking
special care not to scratch or gouge the sealing
surfaces.

7
Remove control piston, counterpiston and spring from
pump body.

8
Remove the tapered rear bearing and adjustment shim.

3
 Pump Disassembly continued

9
Turn unit on its side and remove the cylinder block
assembly, pistons, retaining ball, retainer plate, cradle
assembly, and cradle bearings. (This may not come out
as an assembly).

10
Mark the pressure side of the yoke for reassemble.

11
Remove shaft and front bearing assembly.

12
Remove the four o-rings from the port plate.

4
 Pump Disassembly continued

13
Remove the large o-ring from the main housing.

14
Disassemble locking nut from the max volume adjusting
rod located at the rear of the port plate (if applicable).

15
Record the length of the exposed thread. This will be
needed during reassembly of the unit.

16
Use a suitable bearing puller and remove the front
bearing race.

5
 Pump Disassembly continued

17
Check condition of control and counter pistons. If worn
or sticking, remove control piston and guide and counter
piston and guide for replacement. NOTE: The screw
in stems are loc-tited in place and will require heat to
remove.

18
Use a suitable bearing puller to remove the rear bearing
race from the port plate. (Take care not to damage the
lapped surface.)

6
Control Disassembly / Reassembly

1
Remove the three sealing o-rings on bottom of control.

2
To ensure control is reassembled with the same
approximate control settings measure distance from
face of adjusting screw plug.

3
Remove the lock nuts on the pressure adjusting screws.

4
Remove the spring chambers from the control housing.

7
 Control Disassembly/Reassembly
continued

5
Remove the pressure adjustment screw plug assembly.

6
Remove the spring, collar, and cup.

7
Remove the two sealing plugs from the control body.

8
Remove DR and FR spool assemblies. Check for
smooth movement throughout control housing. (Do not
mix spools up.)

8
 Control Inspection
1
Inspect the pressure adjustment screws for wear and
damage. Clean all components before reassembly.

DFR SHOWN

9
 Control Inspection continued

2
Inspect the springs, spring collar, and spring cup for
wear and damage.

3
Carefully inspect the spools ensuring the sealing lands
are free of any nicks or scratches. Also check the spool
ends that contact the spring collar for wear.

4
Check the spool bores within the control housing for
scoring or excessive wear.

10
 Control Reassembly
1
If after inspection it is determined that controller is to
be reused, thoroughly clean then lubricate all parts with
clean hydraulic fluid.

2
Install the FR and DR compensator spools into their
respective bores in the control housing, checking for free
movement of the spool within its bore.

3
Install new o-rings on the sealing plugs opposite the
adjustment end on the control housing body and tighten.

4
Install new o-rings onto the adjusting screw and spring
cups.

11
 Control Reassembly continued
5
Tighten both spring chambers into the control housing.

6
Adjust screw adjuster in the spring cups until they
reach the measurements taken in step two on Control
Disassembly.

7
Install locking nuts and leave loose (to be secured
upon final control adjustment). (See control setup for
adjustment procedure).

8
Install new o-rings to the bottom side of the controller
and place aside for later reattachment to the pump.

Important Note: If it is determined that any of the controller parts

are damaged or worn excessively, it is recommended that the
complete controller assembly be replaced.

12
 Pump Reassembly
It is recommended that all repairs be performed in a clean lint free environment and that all seals be replaced upon
reassembly. It is a good idea to check that all parts being replaced are correct for the model number and design of
unit being serviced.

1
Turn housing over so that the pump pilot faces up and
install seal retaining snap ring.

2
Lubricate the new seal and while keeping the seal
perpendicular to the pump shaft, press the new seal
down into the housing using the retaining ring as a stop
for the seal.

3
Install new bearing race into the housing.

4
Install new bearing race into port plate.

13
 Pump Reassembly continued

5
Inspect sealing area on shaft for any defects.

6
Install preload shim and rear bearing cone onto shaft,
assemble into pump housing and torque to appropriate
values (see torque chart).

7
Measure distance between pump housing and port plate
and adjust shim thickness to arrive at an initial preload
of 0-.002 thousandths. Alternative method p. 25.

8
Remove port plate from pump housing and place aside
for later attachment.

14
 Pump Reassembly continued

9
Remove shaft assembly from pump housing.

10
Lubricate lips of shaft seal and carefully install the shaft
assembly into the pump body.

11
Grease cradle bearings and assemble into pump
housing.

12
Install the yoke assembly into the cradle bearings,
making sure that the long relief on the yoke bearing is
located on the pressure side of the pump and the yoke
moves freely.

15
 Pump Reassembly continued

13
Assemble the rotating group, making sure all
components move freely and are located in place.

14
Install into the pump housing, making sure that the yoke
and cradle bearings do not move out of position.

15
Install shim and rear bearing cone.

16
If removed reinstall the control piston and counter piston
guides on to the port plate (use loctite #277) then install
the control piston on the control piston guide and the
counter piston spring along with the counter piston onto
the counter piston guide.

16
 Pump Reassembly continued

17
Install the valve plate onto the port plate (lining up the
locating pin on the port plate with the alignment slot on
the valve plate).

18
Install the four sealing o-rings in the port plate.

19
Install large body o-ring seal.

20
Install completed port plate assembly onto the pump
body, making sure that the scribe marks are aligned.
Install four fixing bolts and torque to required values
(see torque chart).

17
21
Install control assembly and torque four fixing bolts to
appropriate values. 41 in lb (12 Nm)

22
Install max volume stop, sealing washer, locknut and
protective cap into the port plate and tighten securely.

23
Replace key if applicable. Check that unit will turn
freely.

YOUR UNIT IS NOW READY FOR TESTING.

18
 Adjustment Procedures DR Control
Set Up Procedure DR Controller
1. Conversion of DFR1 to DR controller:

a) Remove protective cap nut from FR (flow control spool). This is the spool furthest from pump body.

b) Loosen locking nut and turn FR adjustment screw clockwise until it bottoms out.

c) Tighten locking nut and replace protective cap nut.

d) Make sure X port is plugged with 7/16-20 UNF straight thread plug. (#4 ORB)

2. SET UP - DR (pressure) controller without additional system relief:

a) Remove protective cap nut from DR (pressure control) spool. This is the spool closest to pump body.

b) Loosen locking nut and turn DR controller adjustment screw counter clockwise until no spring
tension can be felt.

c) Start pump and adjust system so as to provide a no flow-system blocked (dead head) condition.

d) Turn DR controller adjustment screw clockwise to required system operating pressure.

e) Tighten locking nut, and secure protective cap nut.

NOTE: If system is utilizing an additional relief valve - to avoid system overheating - make sure additional relief is set
to a minimum of 150 psi higher than DR controller pressure setting!

19
 Adjustment Procedures DRG Control
DRG Remote Pressure Controller Set Up
Although identical in appearance, the DFR and DRG controllers are not interchangeable. The DRG controller utilizes
a different FR control spool which allows system oil into the FR spool spring chamber, and is accessible through
the X port connection. A remote relief valve can be connected to the X port controlling oil pressure in the FR spring
chamber, thus controlling pump pressure.

1. DRG (remote pressure) controller set up:

a) Turn remote pressure control clockwise until the adjusting screw bottoms out.

b) Remove protective cap nut from FR (flow control spool). This is the spool furthest from pump body.

c) Loosen locking nut and turn FR adjustment screw clockwise until it bottoms out.

d) Remove protective cap nut from DR (pressure control spool). This is the spool closest to pump body.

e) Loosen locking nut and turn DR controller adjustment screw counter clockwise until spring tension
is removed from the spool.

f) Start pump and adjust system so as to provide a no flow-system blocked (dead head) condition.

g) Turn DR controller adjustment screw clockwise to required system operating pressure.

h) Tighten locking nut, then reinstall and tighten protective cap nut on DR controller adjustment screw.

i) Turn remote relief valve counter clockwise to its lowest setting.

j) Turn FR controller adjustment screw counter clockwise to approximately 200 psi then turn clockwise
to a final setting of 300 psi.

k) Tighten locking nut, then reinstall and tighten protective cap nut on FR adjustment screw.

l) Turn remote relief valve to desired operating pressure.

20
 Adjustment Procedures DFR / DFR1 Control
DFR/DFR1 (Load Sensing) Controller Set Up
The DFR controller provides an internal bleed down orifice to prevent pressure from being trapped in the load sense
line and preventing the pump from going into standby during operation or at shutdown. The DFR1 controller does not
provide this bleed down feature.

The DFR/DFR1 (load sensing controller) will vary the swash plate angle to maintain an operating pressure at a
pressure slightly higher than what is required to move the load. This differential is controlled by the pressure value
set at the FR flow control spool adjustment.

1. DFR (load sense) controller set up:

a) Remove protective cap nut from FR (flow control spool). This is the spool furthest from pump body.

b) Loosen locking nut and turn FR adjustment screw clockwise until the adjusting screw bottoms out.

c) Remove protective cap nut from DR (pressure control) spool. This is the spool closest to pump body.

d) Loosen locking nut and turn DR controller adjustment screw counter clockwise until spring tension
is removed from the spool.

e) Start pump and adjust system so as to provide a no flow-system blocked (dead head) condition.

f) Turn DR controller adjustment screw clockwise to required system operating pressure.

g) Tighten locking nut, then reinstall and tighten protective cap nut on DR controller adjustment screw.

h) Turn off pump drive and disconnect sensing line from X port at FR control and cap load sense line
with an appropriate plug.

i) Restart pump and proceed to turn FR controller adjustment screw counter clockwise (system
pressure should start to decrease). Continue adjusting counter clockwise until a pressure of
approximately 200 psi is observed, then turn adjustment screw clockwise to desired pressure
differential setting (approx 300-400 psi).

j) Tighten locking nut, then reinstall and tighten protective cap nut on FR adjustment screw.

k) Stop pump drive, remove plug and reconnect load sense line to X port.

UNIT IS NOW READY FOR OPERATION.

21
 Adjustment Procedures DFLR Control
DFLR Horsepower Limiting Controller Set Up
A DFLR control is used when the prime mover has less than the necessary horsepower to drive full pump flow at full
pressure. This control will move the swash plate angle to maintain desired operating pressure while staying within the
maximum power limit available from the prime mover.

A requirements for setup:

1 clamp on ammeter
2 pressure gauge
3 flow meter
4 load valve

The LR (horsepower limiter) controller is located on the side of the pump body. It is connected to the FR spool spring
chamber via a steel tube connection. It has two adjustments on one stem (large & small) and they are located under
the protective cap.

a) Remove protective cap nut from FR (flow control spool) this is the (spool furthest from pump body).

b) Loosen locking nut and turn FR adjustment screw clockwise until it bottoms out.

c) Remove protective cap nut from DR (pressure control) spool this is the spool closest to pump body.

d) Loosen locking nut and turn DR controller adjustment screw counterclockwise until spring tension is
removed from the spool.

e) Start pump and adjust system so as to provide a no flow-system blocked (dead head) condition.

f) Turn DR controller adjustment screw clockwise to required system operating pressure.

g) Tighten locking nut then reinstall and tighten protective cap nut on DR controller adjustment screw.

h) Turn off pump drive and disconnect sensing line from X port at FR control and cap load sense line
with an appropriate plug.

i) Restart pump and proceed to adjust FR controller adjustment screw to a value of 300PSI.

j) Tighten locking nut then reinstall and tighten protective cap nut on FR adjustment screw.

k) Stop pump drive remove plug and reconnect load sense line to x port.

l) Calculate for later use:

PSI = HP x efficiency (0.85) x 1740 GPM (U.S.)
BAR = KW x efficiency (0.85) x 600 L/min

m) Review motor nameplate information and record full load amp rating for the voltage you are using.

n) Install flow meter and load valve (adjusted to full open) into pump outlet line and install ammeter
around one of the motor power leads.

o) Start pump- flow meter should read full pump flow and ammeter should be reading below full load amps.

p) Slowly close load valve while watching ammeter and bring motor to full load amperage as noted
on motor name plate. Flow meter should stay at full pump flow; pressure gauge should read close
to PSI as calculated in step L above.
22
DFLR Horsepower Limiting Controller Set Up continued
q) Continue slowly closing load valve to bring motor slightly above full load amps (do not go above 10%
of motor nameplate full load amp rating).

r) Now turn power valve large adjustment counter clockwise to bring amp reading below full flow amps.

s) Now turn power valve large adjustment clockwise and bring motor back up to full load amps.

t) Observe flow meter and pressure gauge. Flow should be about 10% less than full flow and
pressure should be the same as observed in step P.

u) Open the load valve then slowly close it while watching ammeter and bring motor up to full
load amps. All readings should be very close to those observed in step P above.

v) Continue to close load valve while watching ammeter. Ammeter should never fluctuate more
than a small amount either side of full load amps as pressure goes up and flow goes down.

w) Continue to close load valve until pump compensator takes over. Oil flow should stop and
pressure should hold at desired system operating pressure. (The load valve should be fully
closed at this point.)

x) If you find ammeter is moving more than 5% either side of full load amps

y) Loosen small adjustment lock nut on power valve.

z) Open and close the load valve; if the ammeter is falling 5% below full load amps turn
small adjustment screw clockwise.

aa) If ammeter is reading 5% above full load amps turn small adjustment screw counterclockwise.

bb) Repeat procedure as necessary until ammeter stays at or just below full load amp rating.

cc) Open load valve tighten small adjustment lock nut stop pump, replace cap, remove test equipment.

23
DFLR Horsepower Limiting Controller Set Up continued

24
DFLR Horsepower Limiting Controller Set Up continued

Identify the required preload on the shaft:

Pre load required = .002 (0.05 mm).

Due to the build up of difference tolerances from pump to pump, it is imperative that this operation is always carried out.

1. We assemble the bearings on the shaft (top and bottom).

2. We fit the shaft into the housing.
3. We fit the valve plate to the housing, ensuring the bearing for the valve plate is correctly located.
4. We do not fit any other internal parts.
5. We measure the amount of movement the shaft has when fitted (dimension X).
6. We add the pre load required:
X plus .002 (0.05 mm) = Dimension Y.
Dimension Y is the thickness of the shim required.
Note: This operation must be done for each pump that is repaired.

25
Torque Specifications
FT/LBS Nm

VS / VSO 18 20 27

VS / VSO 28 31 42

VS / VSO 45 53 72

VS / VSO 71 85 115

VS / VSO 100 100 135

Metaris accepts no responsibility for possible errors in catalogs, brochures and other printed maerial. Metaris
reserves the right to alter its products without prior notice.

26
 An OME GA Te c h n o l o g i e s Co m p a n y

BG18- 1/ -3
Bar Graph Indicators

INSTRUCTION
SHEET M2126/0900

BG18 SERIES BAR GRAPH INDICATORS provide dynamic analog visualization of any event represented by an electrical signal. Their large,
bright 30 segment LED BARGRAPH displays are particularly well suited for applications where readings must be taken at a distance.
The following models are available:

BG18-1: BAR-GRAPH INDICATOR

BG18-3: BAR-GRAPH INDICATOR WITH DUAL SET-POINT.

FRONT VIEW REAR VIEW

FIG. 1 FIG. 2

SET-POINT 1 (AL1)
PR-2

A
B
C
D
P2
PS

10
Signal input
-
+
C
Set-point 1 (AL1) NO
optional NC
P0
6 5 4 3 2 1

NC

P1 Set-point 2 (AL2) NO

optional C

(Negative for DC Power) -

PR-1
Power supply

(Positive for DC Power) +

P0 : Trimmer for Zero Adjust

PS : Trimmer for Span Adjust

PR1 : Pushbutton for Set-point 1 value display over the Bar. SET-POINT PROGRAMMING
P1 : Adjustable trimmer for Set-point value change over the Bar.
Press the PR1 pushbutton and turn the P1 trimmer until the
SET-POINT 2 (AL2) desired point. The display will be flashing according to the flash-
function jumper selection.
PR2 : Pushbutton for Set-point 2 value display over the Bar. Same procedure for the Set-point 2.
P2 : Adjustable trimmer for Set-point value change over the Bar.

FIG. 3
FLASH FUNCTION JUMPERS SELECTION

AL-1 AL-2
FLASHING BAR FUNCTION ON WHEN :
F F G K L
L K
G SIGNAL INPUT EQUAL TO OR LESS THAN SET-POINT --- x --- x

SIGNAL INPUT EQUAL TO OR GREATER THAN SET-POINT x --- x ---

MOTHER BOARD FUNCTION FLASHING OUT OF SERVICE --- --- --- ---
SOLDER SIDE
"X" = CLOSE JUMPER " - - - " = OPEN JUMPER

STANDARD POWER SUPPLY

OPTION POWER OPTION POWER

220 220 Vac 50/60 Hz 48 48 Vac 50/60Hz
STD 110 Vac 50/60 Hz 15/30 VDC 15...30 Vdc. -10% (3.5 W)

24 24 Vac 50/60 Hz 24/65 VDC 24...65 Vdc (4 W) isolated

MSS0195APC1B
 BG18- 1/ -3

SIGNAL INPUTS SELECTION FIG. 4

B A
C
Model Signal Jumper Resistor Rb
No Suffix Input A B C N Value
F E H J
L K
G D
-P1 0 - 100 mV --- x x --- ----------
-P2 0-1 V x --- x --- ----------
M
-P3 0 - 10 V x --- --- --- 110 K
-P4 0 - 100 V x --- --- --- 10 K MOTHER BOARD
SOLDER SIDE
-P5 0 - 1 mA --- x x --- 100
-P6 0 - 20 mA x --- x --- 49.9 N
-P7 4 - 20 mA x --- x x 49.9

" x " = CLOSE JUMPER " - - - " = OPEN JUMPER

RESISTOR Rb
CONTROL MODES SELECTION

AL-1 AL-2

RELAY ON, WHEN THE INPUT VALUE IS: D E H J

LESS THAN OR EQUAL TO SET-POINT VALUE --- x --- x

GREATER THAN OR EQUAL TO SET-POINT VALUE x --- x ---

"X" = CLOSE JUMPER " - - - " = OPEN JUMPER MOTHER BOARD

COMPONENT SIDE

CONTACT CLOSURES FOR SET-POINT FIG. 5

OUTPUT ...................... 1 FORM "C" RELAY FOR EACH SET-POINT
VOLTAGE MAX. .......... 250 Vac.
CURRENT MAX ........... 2 Aac. RESISTIVE LOAD

MECHANICAL DIMENSIONS mm (in)

13 102 15 48
(0.51) (4.02) (0.59) (1.89) PANEL CUTOUT
5 max. (0.20) FIG. 6
(3.64)
92.5
(3.78)
96

44.5
(1.75)

WARRANTY/DISCLAIMER A n O M E G A Te c h n o l o g i e s C o m p a n y

OMEGA warrants this unit to be free of defects in materials and workmanship and to give Servicing USA and Canada: Call OMEGA Toll Free
satisfactory service for a period of 13 months from date of purchase.OMEGA Warranty adds USA Canada
an additional one (1) month grace period to the normal one (1) year product warranty to One Omega Drive, Box 4047 976 Bergar
cover handling and shipping time. This ensures that OMEGA's customers receive maximum Stamford, CT 06907-0047 Laval (Quebec) H7L 5A1
coverage on each product. If the unit should malfunction, it must be returned to the factory Telephone: (203) 359-1660 Telephone: (514) 856-6928
for evaluation. OMEGA's Customer Service Department will issue an Authorized Return (AR) FAX: (203) 359-7700 FAX: (514) 856-6886
number immediately upon phone or written request. Upon examination by OMEGA, if the unit
is found to be defective it will be repaired or replaced at no charge. However, this Sales Service: 1-800-826-6342 / 1-800-TC-OMEGASM
WARRANTY is VOID if the unit shows evidence of having been tampered with or shows Customer Service: 1-800-622-2378 / 1-800-622-BESTSM
evidence of being damaged as a result of excessive corrosion; or current; heat; moisture or Engineering Service: 1-800-872-9436 / 1-800-USA-WHENSM
vibration; improper specification; misapplication; misuse or other operating conditions TELEX: 996404 EASYLINK: 62968934 CABLE: OMEGA
outside of OMEGA's control. Components which wear or which are damaged by misuse are Servicing Europe: One OMEGA Drive, River Bend
not warranted. These include contact points, fuses and triacs.
.OMEGA is pleased to offer suggestions on the use of its various products.
Thecnology Centre
Northbank, Irlam, Manchester
However OMEGA neither assumes responsability for any omissions or errors
nor assumes liability for any damages that result from the use of its products M44 5EX , England
in accordance with information provided by OMEGA, either verbal or written. Telephone: 44 (161) 777-6611 FAX: 44 (161) 777-6622
OMEGA only warrants that the parts manufactured by it will be as specified
and free of defects. OMEGA MAKES NO OTHER WARRANTIES OR REPRE-
SENTATIONS OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EX- RETURN REQUESTS / INQUIRIES
CEPT THAT OF TITLE AND ALL IMPLIED WARRANTIES INCLUDING ANY Direct all warranty and repair requests/inquiries to the OMEGA ENGINEERING Customer
WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PUR- Service Department. BEFORE RETURNING ANY PRODUCT(S) TO OMEGA, PURCHASER
POSE ARE HEREBY DISCLAIMED. MUST OBTAIN AN AUTHORIZED RETURN (AR) NUMBER FROM OMEGA'S CUSTOMER
LIMITATION OF LIABILITY: The remedies of purchaser set forth herein are SERVICE DEPARTMENT (IN ORDER TO AVOID PROCESSING DELAYS). The assigned
exclusive and the total liability of OMEGA with respect to this order, whether AR number should then be marked on the outside of the return package and on any
based on contract, warranty, negligence, indemnification, strict liability or correspondence.
otherwise, shall not exceed the purchase price of the component upon which FOR WARRANTY RETURNS, please have FOR NON-WARRANTY REPAIRS, consult
liability is based. In no even shall OMEGA be liable for consequential, the following information available BE- OMEGA for current repair charges. Have
incidental or special damages. FORE contacting OMEGA: the following information available
CONDITIONS: Equipment sold by OMEGA is not intended to be used, nor shall it be used: 1. P.O. number under which the product BEFORE contacting OMEGA:
(1) as a "Basic Component" under 10 CFR 21 (NRC), used in or with any nuclear installation was PURCHASED. 1. P.O. number to cover the COST of the
or activity; or (2) in medical applications or used on humans. Should any Product(s) be used 2. Model and serial number of the product repair,
in or with any nuclear installation or activity, medical application, used in humans, or misused under warranty, and 2. Model and serial number of product, and
in any way. OMEGA assumes no responsibility as set forth in our basic WARRANTY/ 3. Repair instructions and/or specific 3. Repair instructions and/or specific
DISCLAIMER language, and, additionally, purchaser will indemnify OMEGA and hold problems relative to the product. problems relative to the product.
OMEGA harmlees from any liability or damage whatsoever arising out of the use of the OMEGA's policy is to make running changes, not model changes, whenever an improvement
Product(s) in such a manner. is possible. This affords our customers the latest in technology and engineering.
OMEGA is a registered trademark of OMEGA ENGINEERING, INC.
Copyright 1998 OMEGA ENGINEERING, INC. All rights reserved. This documentation may
not be copied, photocopied, reproduced, translated, or reduced to any electronic medium or
machine-readable form, in whole or in part, without prior written consent of OMEGA
ENGINEERING, INC.
 Compact Switch
Features
Pressure Series 96201, 96211, 96221
Compact size
Low & high pressures including vacuum
Extremely versatile
Optional DIN and conduit connectors
NEMA 1 & 4; IP65
Single pole double throw snap action switching
Factory preset or field adjustable

Applications
Pump & compressor monitoring
Air proving in HVAC systems
Engine monitoring
Machine tools
Hydraulic power units
Mobile hydraulics
Medical equipment
Irrigation systems
General industrial applications

General Specifications*
Accuracy: 2% of full range Temperature Range:
Switch: Series 96201: -40 to +165F (-40 to +74C)
Type: SPDT snap action; single circuit Series 96211: -20 to +165F (-29 to +74C)
Series 96221: 0 to +165F (-18 to +74C)
Rating: 5 Amp @ 125/250 VAC (Class BB Adjustment Capability: Models L96201, L96211 and
microswitch - standard) L96221 are factory set and
10 Amp @ 125/250 VAC (Class CC permanently locked.
microswitch) Models 96201, 96211, and 96221
5 Amp @ 30 VDC (Class BB and CC are field adjustable via an external
microswitches) adjustment sleeve.
Wetted Parts: Pressure Setpoint
Process Fitting: Brass (standard); 416 stainless steel Adjustment: Secure hex body with open-end
(optional) wrench; hand turn adjustment
sleeve:
O-Ring Seals & Buna-N (standard)
Diaphragms: Clockwise (counterclockwise for
vacuum models) to increase.
Piston (96201 models): Stainless steel; Teflon back-up ring
Electrical Connection: 12 free leads, #18 AWG Counterclockwise (clockwise for
vacuum models) to decrease set
Enclosure Ratings: NEMA 1 (plastic - standard) point.
NEMA 4 (when ordered with -T4
or -T5 options) Shipping Weight: Approximate 0.95 lbs.
IP65 (when ordered with T2 DIN
connection option
Pressure Connection: 1/4 NPT male (standard) Wiring Code
Approvals:
UL: UL recognized component (UR); PRESSURE VACUUM
With optional conduit connector (-T4 LEAD COLOR PIN COLOR PIN
or -T5 option) becomes UL listed. UL NORMALLY CLOSED BLUE 2 RED 3
File No. E42816.
COMMON PURPLE 1 PURPLE 1
CSA: CSA #LR22354 NORMALLY OPEN RED 3 BLUE 2
* See product configurator for additional options.

1
Compact Switch Series 96201, 96211, 96221
Technical Drawings
Dimensions in inches (mm)

!002/8
&2%% &2%%,%!$3

,%!$3 ./ 
4!-0%2 (%8
 # .# 2%3)34!.4
3%43#2%7 

 4!-0%2 @4/04)/./.,9
%6)$%.43%!, #/..%#4).'
,/#+%$!.$ @,OPTIONONLY #!",%',!.$
0%2-!.%.4,9  /$ 
3%!,%$  
@,OPTIONONLY  
 

  


"ARKSDALE)NC "ARKSDALE)NC 
"ARKSDALE)NC ,OS!NGELES#!
,OS!NGELES#!  "ARKSDALE)NC
,OS!NGELES#!
 ,OS!NGELES#ALIFORNIA
5, 5,

 7!2.).' 53%).34!,,!.$-!).  7!2.).' 53%).34!,,!.$-!).

 (%8 7!2.).' 53%).34!,,!.$-!).

7!2.).' 53%).34!,,!.$-!).


 490
.04-!,% 
02%3352%0/24
4-/$)&)#!4)/.
34!.$!2$-/$%, 4-/$)&)#!4)/. 4-/$)&)#!4)/.
&2%%
,%!$3

Product Configurator Example: 96211-BB3 SS -T5 -V (%8



Prefix 
L Factory set and permanently locked (optional)

T Tamper resistant setscrew (optional) 
"ARKSDALE)NC
,OS!NGELES#ALIFORNIA

5, 5,
7!2.).' 53%).34!,,!.$-!).

Base Model
Adjustable Range Approx. Deadband Proof
Decreasing - psi (bar) Increasing - psi (bar) (Actuation Value) Pressure
4-/$)&)#!4)/.
Min. Max. Min. Max. psi (bar) psi (bar)
96221-BB1 1 Hg 28 Hg 6 Hg 30 Hg .5 - 8 Hg 30 (2) Hg Vacuum
Options
96211-BB1 2.5 (.2) 12.8 (.9) 3 (.2) 15 (1) .3 - 3 (.02 - .21) 1000 (68)
Low Pressure

SJO cable, #18 AWG

Diaphragms

96211-BB2 5 (.3) 31 (2) 6 (.4) 35 (2.4) .5 - 6 (.03 - .41) 1000 (68) -JXXX
(XXX = inches)
96211-BB3 8.5 (.6) 44 (3) 10 (.6) 50 (3.4) .5 - 8 (.03 - .55) 1000 (68)
-Z1 Cleaned for oxygen service
96211-BB4 22.5 (1.5) 112 (8) 25 (1.8) 125 (8.5) 1 - 15 (.07 - 1.03) 1000 (68)
Gold contact limit swtich,
96211-BB5 70 (5) 220 (15) 80 (5.5) 250 (17) 5 - 40 (.34 - 2.76) 1000 (68) -Z12
1 A, 125 VAC
96211-BB6 110 (7) 440 (30) 130 (9) 500 (34) 10 - 75 (.69 - 5.17) 1000 (68)
DIN 43650 base only
-Z17
96201-BB1 190 (13) 450 (31) 250 (17) 600 (41) 30-150 ( 2.07 -10.35) 7000 (476) (no mating plug)
High Pressure
Diaphragms

96201-BB2 360 (24) 1450 (105) 430 (29) 1700 (116) 40-400 (2.76 - 27.59) 7000 (476) Unshielded cable,
-Z24
#18 AWG PVC
96201-BB3 1450 (105) 3900 (265) 1650 (112) 4400 (300) 100-750 (6.90 - 51.72) 7000 (476)
96201-BB4 3650 (248) 6700 (456) 4000 (272) 7500 (510) 200-1000 (13.79-68.96) 12000 (816) 7/16-20 SAE pressure
-P1
Fitting with O-ring
96201-BB5 300 (20) 2500 (170) 380 (26) 3000 (200) 80-500 (5.52-34.48) 7000 (476)
1
-CC 10A @ 125/250VAC Limit Switch (replace -BB with -CC) -WXXX Extra wire length (XXX = inches)
2
-SXXX Factory preset (consult factory)

Fitting Option
Blank Brass (Standard) Electrical Connectors Diaphragm/O-ring Material
Stainless steel (not available Blank 12 free leads (standard) Blank Buna-N (standard)
SS
with vacuum models) -E Ethylene propylene (EPR)
-T1 1/4 male spade terminals
-T2 DIN Connector, 43650 type -N Neoprene
1/2 NPT male conduit -V Viton
-T4
connector with free leads

NOTES: -T5 1/2 NPT female conduit

1 Not available with DIN connector (-T2 option) connector with free leads
2 No charge for factory set (L- option) models

3211 Fruitland Avenue Los Angeles, CA 90058  800-835-1060 Fax: 323-589-3463 www.barksdale.com
2
See Barksdales Standard Conditions of Sale Specifications are subject to modification at any time Bulletin #S0073-E 09/07 2007 Printed in the U.S.A.