Graco Series A Operation manual

Instructions - Parts List
Overspray Masking
Liquid System 308069P
EN
For airspray application of fluids. For professional use only.
System
Model 224826
with Stainless Steel Pump*
Pump
Model 224825, Series A
Stainless Steel*
2700 psi (18.6 MPa, 186 bar) Maximum Working Pressure
80-90 psi (0.55-0.62 MPa, 5.5-6.2 bar) recommended regulated air inlet pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
NOTICE
This pump is factory tested in oil. To avoid contami-
nating the masking liquid or the surface being
painted, flush the pump before immersing it in the
masking liquid. Use water only to flush. Paint solvents
will damage the seals. Follow the set-up procedure
carefully, and pay special attention to the Flushing
procedure on page 6.

2308069P
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Prepare for Installation . . . . . . . . . . . . . . . . . . . . 5
Setup for Initial Flushing . . . . . . . . . . . . . . . . . . . 6
Initial Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 8
Prime the System . . . . . . . . . . . . . . . . . . . . . . . . 8
Selecting a Tip . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installing the Spray Tip . . . . . . . . . . . . . . . . . . . . 9
Changing Spray Tips . . . . . . . . . . . . . . . . . . . . . 10
Clearing a Clogged Spray Tip . . . . . . . . . . . . . . 10
Adjusting the Spray Pattern and Spraying Pressure
10
Practice Spraying . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Weekly Flushing . . . . . . . . . . . . . . . . . . . . . . . . 12
Flushing Before Storing . . . . . . . . . . . . . . . . . . . 12
Pump Packing Nut Adjustment . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . 16
Air Motor and Throat Disassembly . . . . . . . . . . 16
Air Motor and Throat Reassembly . . . . . . . . . . . 17
Displacement Pump Disassembly . . . . . . . . . . . 18
Displacement Pump Reassembly . . . . . . . . . . . 19
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . .24

Warnings
308069P 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
WARNING
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.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
SKIN INJECTION HAZARD
High-pressure fluid from gun, 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 spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.

Warnings
4308069P
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 com-
ponent. 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 manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is
not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer
WARNING

Installation
308069P 5
Installation
Learn how to use the gun’s trigger safety latch before
operating the system.
The high pressure, airless spray gun supplied with this
system is equipped with a trigger safety latch. When set,
this latch prevents the gun from being triggered acciden-
tally. Read more about gun safety in the warning sec-
tion, Skin Injection Hazard.
Set the trigger safety latch whenever you stop spraying,
even for only a minute, or if changing a tip.
Grounding
Pump: use ground wire and clamp (FIG. 2). Remove the
ground screw (Z) and insert through the eye of ring ter-
minal at end of ground wire (Y). Fasten the ground
screw back onto the pump and tighten securely. Con-
nect ground clamp to a true earth ground.
Air and fluid hoses: use only electrically conductive
hoses.
Air compressor: follow manufacturer’s recommenda-
tions.
Spray gun: ground through connection to a properly
grounded fluid hose and pump.
Fluid supply container: follow local code.
Object being sprayed: follow local code.
Any pails used when flushing: use only metal,
grounded pails when flushing. Make firm metal-to-metal
contact between a metal part of the spray gun and a
pail. Use the lowest pressure possible.
Prepare for Installation
Supply the following equipment to complete the installa-
tion of this system:
1. An adjustable wrench and a screwdriver.
2. A grounding wire and clamp for the air motor.
3. The compressed air supply with a hose that easily
reaches the air regulator assembly.
FIG. 1
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.
TO RELEASE THE LATCH
FOR THE OFF SAFE, or
spraying position, gently
pull up on the latch and
turn it so it is parallel with
the gun body.
TO SET THE LATCH IN
THE SAFE, or
non–spraying position,
turn it so it is at right
angles to the gun body.
7546A
FIG. 2
Y
Z

Installation
6308069P
4. Two 5 gallon flushing containers, one with warm
soapy water, and one with cool, clean water.
Setup for Initial Flushing
Refer to FIG. 3 for the following instructions.
1. Screw the air regulator assembly into the air inlet of
the motor.
2. Remove the quick-disconnect coupler from the nip-
ple. To disconnect, pull back on the sleeve of the
coupler and pull it away from the nipple. Screw the
coupler onto the air line. Do not connect the air line
to the pump until you are instructed to in the Initial
Flushing,page 6, or Operation, page 8, section.
3. Screw the swivel fitting of the spray hose onto the
pump outlet nipple, and tighten it securely with a
wrench.
4. Follow the grounding instructions on page 5.
Initial Flushing
1. Mount the pump in a 5 gallon pail of warm, soapy
water.
2. Be sure there is no spray tip in the sun. See FIG. 7 if
the tip needs to be removed.
3. Set the trigger safety latch. (FIG. 1)
4. Be sure the air regulator handle is turned to zero
(fully left as you look at it).
5. Connect the air line to the pump.
6. Release the trigger safety latch.
7. Aim the gun into the flushing pail and squeeze the
gun trigger and hold it open.
8. Slowly open the air regulator until the pump is run-
ning slowly and smoothly.
9. Using very low pressure, direct the spray from the
fun back into the flushing container. Circulate the
soapy water in this way for several minutes. Then
release the trigger, set the trigger safety latch, and
disconnect the air line to the pump.
10. Switch the pump to the clean container of water.
Connect the air line, release the trigger safety latch,
and repeat Step 9, above.
NOTICE
Do not use with pain solvents to flush, which will dam-
age the pump seals.
FIG. 3
AIR REGULATOR & GAUGE
AIR LINE
QUICK DISCONNECT NIPPLE
QUICK DISCONNECT COUPLER
SPRAY HOSE
SPRAY GUN
RAC V
TIP GUARD
GROUND WIRE & CLAMP
purchase separately
OUTLET NIPPLE
NOTICE
This pump is factory tested in oil. To avoid contami-
nating the masking liquid or the surface being
painted, flush the pump before immersing it in the
masking liquid.

Installation
308069P 7
11. Raise the pump out of the pail. Trigger the fun to
force the water from the system. DO NOT run the
pump dry for more than 10 seconds to avoid damag-
ing the pump packings.
Pump Installation
NOTE: Be sure the system has been thoroughly
flushed.
1. Loosen the hose clamp on the suction hose. Slide
the suction hose as far as possible onto the pump
intake valve.
2. Slide the clamp up and tighten its screw snugly.
A loose clamp prevent the pump from getting ade-
quate fluid supply, which results in low fluid flow
and/or spitting air from the gun.
3. Remove the bung cover from the drum and open the
vent hole.
4. Loosen the thumbscrew on the bung adapter.
5. Slide the suction hose and pump through the bung
hole in the drum cover. Before the final positioning
of the pump, screw the bung adapter firmly into the
bung hole. Now position the pump as follows:
a. For 55 gallon drums: Slide the pump into the
drum until you sense that the strainer is at the
bottom of the drum. Tighten the thumbscrew
snugly.
b. For 16 gallon drums: Slide the pump into the
drum and allow the suction hose to curl around
the side and rest on the bottom of the drum.
Tighten the thumbscrew snugly.
c. For 5 gallon demo pails: Remove the suction
hose and strainer. Install the accessory pail
cover (Part No. 222058). Slide the pump into the
pail until the intake valve is 1/2” off the bottom of
the pail. Tighten the bung adapter thumbscrew
snugly.
FIG. 4
AIR REGULATOR & GAUGE
AIR LINE
QUICK DISCONNECT NIPPLE
QUICK DISCONNECT COUPLER
SPRAY GUN
RAC V
TIP GUARD
GROUND WIRE & CLAMP
purchase separately
16 GALLON DRUM
Note how suction tube curls around the
sides and bottom of the drum.
VENT HOLE
BUNG HOLE
DISPLACEMENT PUMP
HOSE CLAMP
SUCTION TUBE
STRAINER
DRAIN
VALVE
5 GALLON PAIL
BUNG ADAPTER
THUMBSCREW

Operation
8308069P
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Engage the gun’s trigger safety latch.
2. Close the air regulator and disconnect the air supply
hose.
3. Disengage the trigger safety latch. Hold a metal part
of the gun firmly to the side of a grounded metal
waste pail and trigger it to relieve the fluid pressure.
4. Engage the trigger safety latch.
5. Place a pail under the drain valve and open the
drain valve to be sure all fluid pressure is relieved.
NOTE: If you suspect that the tip guard or hose is
clogged, or that pressure has not been fully relieved
after following the steps above, very slowly loosen the
tip guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely.
Prime the System
1. Set the trigger safety latch. (FIG. 1)
2. Remove the spray tip from the gun, if it is installed.
See Changing Spray Tips on page 10.
3. Be sure the air regulator handle is turned to zero
(fully turned to the left).
4. Connect the air line to the pump.
5. Release the trigger safety latch.
FIG. 5
AIR REGULATOR & GAUGE
AIR LINE
QUICK DISCONNECT NIPPLE
QUICK DISCONNECT COUPLER
SPRAY
GUN
TIP GUARD
TIGHTEN TO
CLOSE
DRAIN VALVE DETAIL
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.

Operation
308069P 9
6. Hold a metal part of the gun firmly against and
aimed into a grounded metal pail. Squeeze the gun
trigger and hold it open. (FIG. 6)
7. Slowly open the air regulator until the run is running
slowly and smoothly.
8. Dispense about 1 pint of masking liquid to be sure
all air is pushed out of the system and the liquid
flows freely.
9. Release the trigger and set the trigger safety latch.
(FIG. 1)
10. Check all fluid connections for leaks; relieve pres-
sure (see page 8) before tightening connections.
Selecting a Tip
Two tips are provided with the gun. The size is marked
on the cylinder handle. The size 621 tip comes installed
on the tip guard. Each tip comes with a square ring and
seal. Refer to Changing Spray Tips on page 11 and fig7.
• Use the 211 size tip for narrow surfaces such as
door jambs.
• Use the 621 size tip for wide or larger surfaces.
Installing the Spray Tip
1. Be sure the trigger safety latch is engaged.
2. Install the tip cylinder. Hold the cylinder with the
arrow handle straight up. Push the cylinder into the
tip guard so the flange on the cylinder fits into the
slots at the base of the tip guard. (FIG. 7)
3. Turn the arrow handle in the direction of the tip
guard, which is the spraying position. (FIG. 8)
If the tip guard was removed from the gun and you
are reinstalling it:
4. Be sure the seal and square ring are in place as
shown in FIG. 7. If not, place the seal on the end of a
pencil with the curved side out. Guide the seal into
the retaining nut and turn it until it straddles the cyl-
inder. Drop in the square ring and press it down.
FIG. 6
NOTICE
To avoid damaging the tip guard:
• Never use a wrench to turn the plastic tip guard,
which causes internal damage.
• Never hang the fun by the tip guard.
MAINTAIN FIRM
METAL-TO-METAL
CONTACT BETWEEN
GUN AND
GROUNDED METAL
CONTAINER
GROUND
WIRE
FIG. 7
FIG. 8
TIP GUARD
TIP CYLINDER
ARROW HANDLE
RETAINING NUT
SEAL
SQUARE RING
FLANGE
curved side faces retaining nut
SLOT
TIP SIZE MARKED HERE
ARROW HANDLE
SHOWN IN THE
TIP CLEARING POSITION
ARROW HANDLE
SHOWN IN THE
SPRAYING POSITION
Rotate handle up and
toward back of the gun
then trigger the gun to
clear an obstruction.

Operation
10 308069P
5. Screw the retaining nut snugly onto the gun, holding
the tip guard in the desired direction while tightening
the nut. See Step 4 of Adjusting the Spray Pattern
and Spraying Pressure on page 10 for more infor-
mation on adjusting the direction of the spray pat-
tern.
Changing Spray Tips
1. Relieve the pressure. See page 8.
2. Rotate the arrow handle until it is straight up.
3. Pull out the tip.
4. Install the new tip and rotate it to the spraying posi-
tion.
Clearing a Clogged Spray Tip
1. If the spray tip clogs, release the gun trigger, and set
the trigger safety latch.
2. Turn the arrow handle up and back toward the gun
body. (FIG. 8)
3. Release the trigger safety latch.
4. Trigger the gun into a pail. This usually forces out
the obstruction.
5. Set the trigger safety latch again.
6. Return the arrow handle to the spraying position.
7. Release the trigger safety latch and resume spray-
ing.
8. If the tip is still clogged, close the air regulator, dis-
connect the air line, try triggering the gun into a pail,
and open the drain valve.
9. Remove the spray tip and clean it. Refer to manual
307848, supplied.
Adjusting the Spray Pattern and
Spraying Pressure
Refer to FIG. 9 for the following instructions.
NOTE: If the system is not primed, follow the Prime the
System procedure on page 8.
1. Set u p a large piece of paper or cardboard to spray
on for testing the spray pattern.
2. Release the trigger safety latch.
3. Aim the gun at the cardboard and trigger it briefly.
Check the spray pattern. Adjust the air pressure just
until spray from the fun is completely atomized. 3M
recommends 80 to 90 psi (0.55 to 0.62 MPa, 5.5 to
6.2 bar) air pressure at the air inlet gauge for the
best results.
4. To adjust the direction of the spray pattern, set the
trigger safety latch and loosen the tip guard retain-
ing nut. (FIG. 7)
5. Position the tip guard horizontally for a horizontal
pattern or vertically for a vertical pattern.
6. Retighten the retaining nut.
FIG. 9
SPOTTY
PATTERN
–
INCREASE
PRESSURE
GOOD
FULL
PATTERN
TIP GUARD SHOWN
IN POSITION FOR
VERTICAL PATTERN

Operation
308069P 11
Practice Spraying
Read the spray techniques in Steps 1-5 below and FIG.
10 and FIG. 11, and follow 3M’s recommendations on
application of the masking liquid.
1. Begin triggering and moving gun just before first
edge of target surface.
2. Keep gun moving horizontally or vertically at a
steady rate.
3. Release trigger just as you approach other edge of
target surface, but keep the gun moving until it has
passed the edge.
4. Hold the gun perpendicular (at right angles) to the
target surface. Hold the gun as even 12 to 14” from
the target surface. (FIG. 11)
5. Lap each stroke 50% over the previous stroke to
produce a uniform material thickness. (FIG. 11)
FIG. 10
CORRECT
WRONG
TARGET
SURFACE
1. 2. 3.
FIG. 11
LAP EACH STROKE
50% OVER THE
PREVIOUS STROKE
TARGET SURFACE 12 TO 14” INCHES
KEEP GUN
PERPENDICULAR TO
TARGET SURFACE

Maintenance
12 308069P
Maintenance
1. Keep the pump and hose fully primed with the
masking liquid when it is not in use. This is done by
relieving the pressure.
2. Lubricate the air motor daily. Disconnect the regula-
tor, place about 15 drops of light machine oil in the
pump air inlet, reconnect the regulator and turn on
the air supply to blow oil into the motor.
3. If fluid drips steadily from the motor weep port, or
the pump requires more than 35 psi (0.24 MPa, 2.4
bar) air pressure to cycle when the gun is triggered,
adjust the packing nut. See Pump Packing Nut
Adjustment, page 13.
Weekly Flushing
Equipment Needed:
4 gallons warm water: use empty 3M container
5 gallon bucket for water
Cloth rags
1. Turn the air regulator handle to zero (fully left). Dis-
connect the air hose.
2. Remove the spray tip from the gun. (FIG. 7)
3. Pour 4 gallons of warm water into the empty 3M
container.
4. Move the pump to the flushing container.
5. Connect the airline to the pump.
6. Release the trigger safety latch.
7. Aim the fun into the flushing pail and squeeze the
gun trigger and hold it open.
8. Slowly open the air regulator until the pump is run-
ning slowly and smoothly.
9. Using very low pressure, direct the spray from the
gun back into the flushing container. Circulate the
water in this way for serval minutes. Then release
the trigger, set the trigger safety latch, and discon-
nect the air line to the pump.
10. Raise the pump out of the pail. trigger the gun to
force the water from the system. DO NOT run the
pump dry for more than 10 seconds to avoid damag-
ing the pump packings.
11. Wash the exterior of the pump and all components
with a cloth and water. Scrub any dirty areas and
threads to remove residue.
12. Dry the pump and all components with a clean, dry
cloth.
NOTE: If you plan to use the pump again soon, prime it
with masking material.
If you plan to store the pump, continue as follows:
Flushing Before Storing
1. Flush as in Steps 1 through 11, above, but use
warm, soapy water.
2. Move the pump to a container of mineral spirits.
NOTICE
Do not allow the supply container to be completely
emptied. If that happens, the pump will start to run
too fast and it could be damaged. If the pump starts
to run too fast, disconnect the air line immediately.
Prime the system with masking liquid (see page 8) or
flush it as instructed in Weekly Flushing.
NOTICE
Thorough flushing is required at the end of each
work week and before using a system that has been
stored. Flushing keeps a system free of dried or
aging material, such as discolored or jellied
material.
NOTICE
Do not use paint solvents to flush, which will damage
pump seals.

Maintenance
308069P 13
3. Trigger the gun into the flushing container. When
mineral spirits appear at the fun, release the trigger
and set the trigger safety latch. Remove the pump.
4. Release the trigger safety latch. Trigger the gun to
force the mineral spirits from the system. DO NOT
run the pump dry for more than 10 seconds to avoid
pump packing damage.
5. Disconnect the hose and fun and store the pump.
Pump Packing Nut Adjustment
NOTE: Perform this adjustment if:
a. Material drips steadily from the air motor weep
hole, which indicates the packings are too
loose.
b. The pump requires more than 35 psi (0.24 MPa,
2.4 bar) air pressure to cycle when the gun is
triggered, which indicates the packings are too
tight.
1. Relieve the pressure. See Pressure Relief Proce-
dure on page 8.
2. Remove the six screws (24) using a 1/4” nut driver.
Remove the muffler plate. (FIG. 12)
3. Check to see that the air motor piston is at the top of
the stroke. If it is not, while keeping your fingers
away from moving parts, apply very low pressure
air to the air inlet to move the piston up. Close the
air regulator and disconnect the air supply hose.
(FIG. 13)
4. Use a 1/4” diameter rod to tighten the packing nut.
First loosen the nut, then tighten snugly, and finally
tighten 1/4 turn more. (FIG. 14)
5. Replace the muffler cover and the six screws (24).
(FIG. 12)
6. Reconnect the air line. After the pump is started, it
should run at 20 psi (0.138 MPa, 1.38 bar) with no
load. Start up may require additional air pressure.
FIG. 12
24
20
BASE
FIG. 13
FIG. 14
WEEP HOLE LOCATED
OPPOSITE FLUID OUTLET
AND IN BOTTOM OF BASE
BASE
PISTON
PINCH POINT
FLUID
OUTLET
1/4” DIA. ROD
PACKING NUT

Troubleshooting
14 308069P
Troubleshooting
NOTE: Check all other possible problems and solutions
before disassembling the pump.
Never operate the pump with the warning plate (20)
or the identification plate (40) removed. These plates
protect your fingers from pinching or amputation by
moving parts in the air motor.
Problem Cause Solution
Pump fails to operate
Low air supply pressure or
restricted air lines Increase air supply; clear*
Closed valves Open
Clogged fluid lines, hoses, valves,
etc. Clear*
Damaged air motor Service air motor
Empty fluid supply container Refill and reprime, or flush
Continuous air exhaust Worn or damaged air motor gasket,
packing, seal, etc. Service air motor
Erratic pump operation
Empty fluid supply container Refill and reprime, or flush
Held open or worn intake valve or
piston packings Clear; service
Pump operates, but output is low on
the up stroke
Held open or worn piston or pack-
ings Clear; service
Pump operates, but output is low on
the down stroke Held open or worn intake valve Clear; service
Pump operates, but output is low on
both strokes
Low air supply pressure or
restricted air lines Increase air supply; clear*
Closed valves Open
Empty Fluid supply container Refill and reprime, or flush
Clogged fluid lines, hoses, valves,
etc. Clear*
Packing nut is too tight Loosen
Loose packing nut or worn packings Tighten; replace
Material drips steadily from weep
port in motor base
Throat packing nut loose Tighten packing nut
Throat packing worn Replace packing

Troubleshooting
308069P 15
*Relieve the Pressure. Disconnect the fluid hoses. If the pump start when the air is turned on again, the hose or
gun is clogged.
Pump chattering
Packing nut too tight Loosen packing nut
Packing worn/material dried on I.D.
of packing Inspect/replace packing
Material dried on rod Clean or replace rod
Pump fails to prime
No material Fill or replace container
Air leak between intake valve and
suction tube (55 gallon unit only) Tighten or replace clamp or hose
Material or other contamination on
ball seats Inspect and clean
Intake ball stuck Inspect, clean or replace
Inlet strainer plugged Clean strainer
Problem Cause Solution

Service
16 308069P
Service
Before Starting
Have all necessary parts on hand. Always replace the
glands and bearing when replacing the packings. Use
all the parts in the repair kits for the best results.
Air Motor and Throat
Disassembly
1. Flush the pump and relieve the pressure. See Pres-
sure Relief Procedure on page 8.
2. Disconnect the hoses, remove the pump from its
mounting, and clamp the air motor base in a vise.
3. Use a strap wrench on the riser tube (12) to screw it
out of the air motor base (55).
4. Pull the connecting rod (10) down as far as it will go.
5. Use a hammer and punch to remove the roll pin (4).
Unscrew the connecting rod (10). (FIG. 15)
6. Manually push up on the piston rod (41) to move the
piston assembly (59) up as far as it will go. Unscrew
the cap nut (47). Pull the nut up. Grip the trip rod
(54) with padded pliers and screw the nut off the
rod. (FIG. 15)
7. Remove the six screws (25). Pull the cylinder
straight up off the piston. (FIG. 15)
8. Use a screw driver to push down on the trip rod
yoke (28) and snap the toggles down. (FIG. 16)
NOTICE
Do not damage the plated surface of the trip rod (54).
Damaging the surface of the trip rod can result in
erratic air motor operation. Use the special padded
pliers, Part No. 207579, to grasp the rod.
NOTICE
To avoid damaging the cylinder wall, life the cylinder
straight up off the piston. Never tilt the cylinder as it is
being removed.
FIG. 15
25
59
51
47
55
27
54
4
10
41
43
49
42
44
50
38
39
V–PACKINGS:
SEE DETAIL
BELOW
48
72
LIPS OF V–PACKINGS
MUST FACE DOWN

Service
308069P 17
9. Remove the lockwires (34) from the adjusting nuts
(33) of the transfer valves. Screw the top nuts off.
Screw the stems (45) out of the grommets (32) and
the bottom nuts (30). Take the valve poppets (52) off
the stems and squeeze them firmly to check for
cracks. (FIG. 16)
10. Grip the pivot pins (30) with pliers. Compress the
springs (31) and swing the toggle assembly (N) up
and away from the piston lugs (L). Remove the
parts. Check to see that the valve actuator (35) is
supports by the spring clips (58), but slides easily
into them. (FIG. 16)
11. Remove the trip rod yoke (28), actuator (35) and trip
rod (54). Check the exhaust valve poppets (53) for
cracks. To remove the exhaust valve poppets (53),
stretch them out and cut with a sharp knife. (FIG. 16)
12. Remove one muffler plate (20 or 40). Pull the piston
(59) up out of the base. Remove the throat packing
nut (42) and packings. (FIG. 15)
Air Motor and Throat
Reassembly
1. Clean all the parts in a compatible solvent and
inspect for wear or damage. Check the polished sur-
faces of the piston, piston rod, and cylinder wall for
scratches or wear. A scored rod will cause prema-
ture packing wear and leaking. Use all the repair kit
parts and replace other parts as necessary.
2. Lubricate all parts with a light, waterproof grease.
3. One at a time, install these parts in the base (55):
the gland (49), alternately install three reinforced
packings (48) and two nitrile packings (72) with lips
facing down, bearing (50), back up washer (43), flat
packing (44), and loosely screw in the packing nut
(42). Be sure the o-rings (38 and 39) are in place.
(FIG. 15)
4. Install the poppets (52) on the valve stems (45). Pull
the exhaust valve poppets (53) into the valve actua-
tor (35) and clip off the top parts shown with dotted
lines. (FIG. 17)
FIG. 16
To reduce the risk of pinching or amputating your
fingers, always keep fingers clear of the toggle
assemblies (N).
M
PUSH TOGGLES (M) IN
AND THEN UP
(SHOWN IN THE DOWN
POSITION HERE)
TURN WIRES UP
28
54
34
33
45
52
59
55
30
37
32
L
53
58
31
33
To remove
toggles,
Push IN,
Swing UP,
Ease OUT
FIG. 17
CUT OFF TOPS OF
POPPETS AS
INDICATED BY
DOTTED LINES
0.145”
(3.7 mm)
CUTAWAY VIEW
54
58
35
52
33
32
33
45
53
59
36

Service
18 308069P
5. Install the grommets (32) in the valve actuator (35).
Install the trip rod (54) in the piston (59). Place the
trip rod yoke (28) and valve actuator (35) on the trip
rod. Be sure the o-ring (36) is in place and that the
valve actuator is supported by the spring clips (58),
and then reassemble the valve mechanism. (FIG.
16)
6. Install the bottom adjusting nuts (33) on the valve
stems (45) and screw the stems into the grommets
(32). Screw the top nuts (33) on the stems. Tighten
the nuts (33) just enough to slightly compress the
grommet (32). Before installing the lockwires (34) in
the adjusting nuts, use the special gauge, Part No.
171818, to adjust the transfer valve so there is 0.145
in. (3.7 mm) clearance between the poppets (52)
and the seat when it is open. (FIG. 17)
7. Install the springs (31) and pivot pins (30) on the
toggle arms (37). Snap the toggles to the up posi-
tion. (FIG. 16)
8. Carefully lower the cylinder (51) over the piston (59)
and onto the base (55). Secure with the six screws
(25).
9. Manually push on the piston rod (41) to move the
piston (59) up as far as it will go. Grip the trip rod
(54) with padded pliers and screw the cylinder cap
nut (47) onto the trip rod. Pull the piston rod (41) to
move the piston downward. Be sure the o-ring (27)
is in place at the top of the cylinder (51), and then
screw the cap nut into the cylinder.
10. Screw the connecting rod (10) into the piston rod
(41) and secure with the pin (4). Screw the riser
tube (12) into the base (55).
11. Install the muffler plates (20, 40). Tighten the throat
packing nut (42) just until snug.
12. Connect an air hose and run the pump slowly (about
30 psi [0.24 MPa, 2.4 bar]) to see that it operates
smoothly.
13. Remount the pump and reconnect the ground wire.
Displacement Pump
Disassembly
Before starting have all necessary parts on hand.
Always replace the glands and bearing when replacing
the packings. Use all the parts in the repair kits for the
best results.
1. Flush the pump and relieve the pressure. See Pres-
sure Relief Procedure, page 8.
2. Disconnect the hoses, remove the pump from its
mounting, and clamp the air motor base in a vise.
3. Unscrew the intake valve body (22) from the riser
tube (12). (FIG. 18)
4. Disassemble the intake valve.
5. Clean and inspect the parts for wear or damage,
and replace parts as needed. Unless further service
is needed, reassemble and reinstall the intake
valves, using liquid sealant on the male threads.
(FIG. 18)
6. Use a strap wrench on the riser tube (12) to screw it
out of the air motor base (55). Carefully inspect the
smooth inner surface of the cylinder for scoring or
irregular surfaces. Such damage causes premature
packing wear and leaking. Replace part if damaged.
7. Unscrew the piston body (13) from the piston cou-
pling (14). Remove the ball (2), seat (19), gasket (6),
bearing (18), packing (17), and seal (16). Do not
remove the press-fit brass bearing (15). (FIG. 18)
NOTE: If the pressure-fit brass bearing (15) needs to be
replaced, clamp it in a vise and drive the piston body
(13) out with a plastic hammer. The new bearing must
be started onto the piston body squarely.

Service
308069P 19
Displacement Pump
Reassembly
1. Clean and inspect the parts and replace any that
are worn or damaged. Be sure to check the copper
gasket (46) in the motor base (55). Lubricate the
parts with a light, waterproof grease.
2. Install the seal (16), packing (17), bearing (18), gas-
ket (6), seat (19), and ball (2) on the piston body
(13). The check ball seat (19) may be reversed, if
needed, to provide a new seat. Screw the piston
body (13) into the piston coupling (14).
3. Screw the riser tube (12) into the air motor base
(55).
4. Reinstall the ball (3), gasket (7), ball stop (21) and
other gasket (7) in the intake valve housing (22).
Screw the housing onto the riser tube (12).
5. Be sure the ground wire is connected before regular
operation of the pump.
FIG. 18
17
7
73
21
22
12
13
16
15
18
6
2
19
4
4
14
10
4
46
55

Parts
20 308069P
Parts
Model 224825, Series A
10
14
2
19
6
18
17
12
3
22
21
13
15
47
27
51
35
29
37
31
30
28
34
33
32
33
54
57
58
36
59
52
45
41
4
38
55
20
24
60
63
25
40
4
53
39
42
44
43
50
48
LIPS OF
V–PACKINGS
MUST FACE
DOWN
49
16
7
7
65
67
46
68
69
68
70
7
74
72
4