Graco Series D Operation manual

5 Gallon Duo Paint Sprayer
A portable one or two gun circulating supply package.
360 psi (25 bar) Maximum Working Pressure
180 psi (12 bar) Maximum Air Inlet Pressure
Part No. 205585, Series D
With Agitator
Part No. 205584, Series A
Without Agitator
Part No. 205595, Series E
Bare Pump Assembly
Instructions – Parts List
306713N
Important Safety Instructions.
Read all warnings and instructions in
this manual. Save these instructions.
See page 2 for Table of Contents
Model 205585 Shown
0359
II 1/2 G T6
II 1/2 G T6
II 1/2 G T6
ITS03ATEX11227
ITS03ATEX11251
ITS03ATEX11251
02121B

2 306713
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Information 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
DDo not alter or modify this equipment.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 22 for the maximum working pressure of this equipment.
DUse 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 manufacturer’s warnings.
DDo not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in aluminum equipment. Such use could result in a serious chemical
reaction, with the possibility of explosion.
DDo not use hoses to pull equipment.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82_C (180_F) or below –40_C (–40_F).
DWear hearing protection when operating this equipment.
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.

306713 3
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.
DGround the equipment and the object being sprayed. Refer to Grounding on page 4.
DIf 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.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
DKeep the spray area free of debris, including solvent, rags, and gasoline.
DElectrically disconnect all equipment in the spray area.
DExtinguish all open flames or pilot lights in the spray area.
DDo not smoke in the spray area.
DDo not turn on or off any light switch in the spray area while operating or if fumes are present.
DDo not operate a gasoline engine in the spray 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.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
MOVING PARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
DKeep clear of all moving parts when starting or operating the pump.
DBefore servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the
equipment from starting unexpectedly.

4 306713
Setup
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
Prepare the Operator
All persons who operate the equipment must be
trained in the safe, efficient operation of all system
components as well as the proper handling of all fluids.
All operators must thoroughly read all instruction
manuals, tags, and labels before operating the equip-
ment.
Prepare the Site
The pump requires 3.75 scfm (0.105 m#/min) of com-
pressed air while operating at 100 psi (7 bar) air pres-
sure and 60 cycles per minute. Ensure that you have
an adequate compressed air supply.
Refer to Fig. 2. Bring a compressed air supply line (D)
from the air compressor to the pump location. Be sure
all air hoses (F) are properly sized and pressure-rated
for your system. Use only electrically conductive
hoses.
Keep the site clear of any obstacles or debris that
could interfere with the operator’s movement.
Have a grounded, metal pail available for use when
flushing the system or draining the fluid filter.
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE AND EXPLOSION
HAZARD on page 3.
1. Pump: use a ground wire and clamp. See Fig. 1.
Loosen the grounding lug locknut (W) and washer
(X). Insert one end of the 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 (supplied with Model 205585).
Fig. 1
W
X
Y
Z
0864
2. Air and fluid hoses: use only electrically conductive
hoses.
3. Air compressor: follow manufacturer’s recommen-
dations.
4. Spray gun: ground through connection to properly
grounded hoses and pump.
5. Fluid supply container: follow your local code.
6. Object being sprayed: follow your local code.
7. Solvent pails used when flushing: follow 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 continu-
ity.
8. To maintain grounding continuity when flushing or
relieving pressure, hold a metal part of the spray
gun firmly to the side of a grounded metal pail,
then trigger the gun.

306713 5
Setup
Available Accessories (must be
purchased separately)
NOTE: Always use Genuine Graco Parts and Acces-
sories, available from your Graco distributor. If you
supply your own accessories, be sure they are ade-
quately sized and pressure rated for your system.
Fig. 2 is only a guide for selecting and installing sys-
tem components and accessories. Contact your Graco
distributor for assistance in designing a system to suit
your particular needs.
Air Line Accessories
WARNING
A red-handled bleed-type master air valve (E) is
required in your system to help reduce the risk of
serious injury, including 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.
DThe red-handled 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 filter/regulator
(G). Order Part No. 113329 Bleed Valve (supplied
with Model 205585).
DThe air filter/regulator (G) controls pump speed
and outlet pressure by adjusting the air pressure to
the pump and the air spray gun. It also removes
harmful dirt and moisture from the compressed air
supply. Locate the pump air filter/regulator up-
stream from the bleed-type master air valve (E).
Also, supply an air filter/regulator at each spray
booth.
DAn air line lubricator (J) provides automatic air
motor lubrication. Install downstream from the
pump air filter/regulator (G).
DInstall additional air bleed valves (M) at each air
line drop, to isolate accessories for servicing.
Fluid Line Accessories
WARNING
A fluid drain valve (K) is required in your system to
help reduce the risk of serious injury, including
splashing of fluid in the eyes or on the skin.
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.
DThe fluid drain valve (K) is required in your sys-
tem to relieve fluid pressure in the hose and gun
(see the WARNING above).
DInstall a fluid filter (H) to remove impurities from
the fluid before it reaches the spray gun (L).
DInstall a fluid pressure regulator (A) to provide
precise fluid pressure control at each spray booth.
Supplied Components
Refer to Fig. 3.
DThe pump air valve (4) controls the pump speed
by adjusting the supply of air to the pump.
DThe pump restrictor valve (12) adjusts the fluid
pressure by restricting the fluid flow.
DThe agitator (N) is supplied on Model 205585
only. To prevent fluid from settling out, operate the
agitator as explained in its separate manual
306565.

02126
KEY
A Fluid Pressure Regulator
B Circulating Fluid Return Line
C Circulating Fluid Supply Line
D Main Air Supply Line
E Red-Handled Bleed-Type Master
Air Valve (required, for pump;
supplied on Model 205585)
F Electrically Conductive Air Supply Hose
G Air Filter/Regulator
H Fluid Filter
J Air Line Lubricator
K Fluid Drain Valve (required)
L Air Spray Gun
M Bleed-Type Master Air Valve
(for accessories)
N Agitator (supplied on Model 205585)
P Pump
Y Ground Wire (required; see page 4
for installation instructions;
supplied on Model 205585)
Fig. 2
G
A
G
J
E
Y
K
H
B
C
C B
D
B
C
F
56” (1422 mm)
approximately
51” (1295 mm)
approximately
F
C
L
M
N
P
M
Fluid Flow Fluid Flow
Air Flow
Return Flow Return Flow
Air Flow
Return Flow Fluid
Flow
Return
Flow
Fluid
Flow
Air
Flow Air Flow
6 306713
Setup
Connect the Hoses and Gun
NOTE: Be sure the hoses are properly sized and
pressure-rated for your system. Use only electrically
conductive hoses.
For One to Five Guns, Circulating System
1. Install a fluid pressure regulator (A) at each spray
booth. See Fig. 2.
2. Install an air filter/regulator (G) and an air bleed
valve (M) at each spray booth.
3. Connect an air supply hose (F) between the air
filter/regulator (G) and the air inlet of the gun (L).
4. Connect a fluid return line (B) between the fluid
regulator (A) and the return port of the pump.
5. Connect a fluid supply line (C) between the fluid
outlet of the pump and the fluid regulator (A).
6. Connect a fluid hose (C) between the fluid regula-
tor and the fluid inlet of the spray gun.
7. Connect an air supply hose to the air inlet of the
pump (R). See Fig. 3.

306713 7
Setup
For a One Gun, Direct Supply System
1. Install a fluid pressure regulator (A) at the spray
booth. See Fig. 2.
2. Install an air filter/regulator (G) and an air bleed
valve (M) at the spray booth.
3. Connect an air supply hose (F) between the air
filter/regulator (G) and the air inlet of the gun (L).
4. See Fig. 3. Connect a fluid supply line (C) between
the pump fluid outlet nipple (59) and the fluid
regulator (A).
5. Connect a fluid hose (C) between the fluid regula-
tor and the fluid inlet of the spray gun.
6. Connect an air supply hose to the air inlet of the
pump (R).
For a Two Gun, Direct Supply System
NOTE: Order Outlet Manifold 203171 for two gun,
direct supply operation.
1. Remove the nipple (59) from the fluid outlet of the
pump. See Fig. 3.
2. Install the manifold studs in the fluid outlet (S) and
return (T) ports of the pump. Tighten the manifold
setscrews (U) to secure. See Fig. 4.
3. Install a fluid pressure regulator (A) at each spray
booth. See Fig. 2.
4. Connect two fluid hoses to the manifold outlets
(V). Connect the other end of the hoses to the fluid
regulators (A).
5. Connect a fluid hose (C) between the fluid regula-
tor (A) and the fluid inlet of the spray gun (L).
6. Install an air filter/regulator (G) and an air bleed
valve (M) at each spray booth.
7. Connect an air supply hose (F) between the air
filter/regulator (G) and the air inlet of the gun (L).
8. Connect an air supply hose to the air inlet of the
pump (R).
02121
Fig. 3
59
R
Model 205585 Shown
4
12 N
02122
Fig. 4
ST
U
U
V
V
R
Model 205585 Shown

8 306713
Operation
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The system pressure must be manually relieved to
prevent the system from starting or spraying acci-
dentally. To reduce the risk of an injury from acci-
dental spray from the gun, splashing fluid, or
moving parts, follow the Pressure Relief Proce-
dure whenever you:
Dare instructed to relieve the pressure,
Dstop spraying,
Dcheck or service any of the system equipment,
Dor install or clean the spray nozzle.
1. Close the red-handled bleed-type master air valve
(E, required in your system). Leave the pump air
valve (4) open.
2. Close the pump restrictor valve (12).
3. Shut off the air to the agitator (if used).
4. Hold a metal part of the gun firmly to the side of a
grounded metal pail, and trigger the gun to relieve
pressure.
5. Open the drain valve (required in your system),
having a container ready to catch the drainage.
6. Leave the drain valve open until you are ready to
spray again.
If you suspect that the spray nozzle or hose is com-
pletely clogged, or that pressure has not been fully
relieved after following the steps above, very slowly
loosen the nozzle retaining ring or hose end coupling
and relieve pressure gradually, then loosen completely.
Now clear the nozzle or hose.
Packing Nut
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
Check the tightness of the packing nut (106) periodi-
cally. The nut should be tight enough to prevent leak-
age. Do not overtighten the packing nut. Relieve
pressure before adjusting the nut.
Flush the Pump Before First Use
The pump is tested with lightweight oil, which is left in
to protect the pump parts. If the fluid you are using
may be contaminated by the oil, flush it out with a
compatible solvent. See Flushing on page 12.
Lubrication
If you are not using an accessory air line lubricator,
manually lubricate the motor daily. Disconnect the air
line at the pump air inlet, place about 15 drops of light
machine oil in the pump air inlet, reconnect the air line
and turn on the air supply to blow air into the motor.
Using the Agitator
When starting the agitator, gradually increase the
speed of the agitator by turning its needle valve (W)
until a vortex begins to form in the fluid. Reduce the
speed slightly. See Fig. 5.
For further agitator operating instructions, refer to the
separate agitator manual 306565.

306713 9
Operation
Prime the Pump (Direct Supply Systems)
1. See Figs. 2 and 5. Remove the spray nozzle from
the gun. See the gun instruction manual.
2. Close all bleed-type air valves (E, M).
3. Close the pump air filter/regulator (G).
4. Close the fluid drain valve (K).
5. Check that all fittings throughout the system are
tightened securely.
6. Connect the air supply line to the pump air inlet.
7. Open the bleed-type air valves (E, M). Open the
air filter/regulator (G).
8. Hold a metal part of the gun firmly to the side of a
grounded metal pail and hold the trigger open.
WARNING
COMPONENT RUPTURE HAZARD
To reduce the risk of overpressurizing
your system, which could cause compo-
nent rupture and serious injury, never
exceed the specified Maximum Incoming Air Pres-
sure to the pump (see the Technical Data, on
page 22).
9. Slowly open the pump air valve (4) until the pump
starts. Use the air valve to control pump speed
and fluid pressure. Always use the lowest pressure
necessary to get the desired results. Higher pres-
sures cause premature nozzle and pump wear.
10. Cycle the pump slowly until all air is pushed out
and the pump and hoses are fully primed.
11. Release the gun trigger and lock the trigger safety.
The pump should stall against pressure.
12. With the pump and lines primed, and with ade-
quate air pressure and volume supplied, the pump
will start and stop as you open and close the gun.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
13. Relieve the pressure. Install the spray nozzle in
the gun, as explained in the gun manual.
CAUTION
Do not allow the pump to run dry. It will quickly
accelerate to a high speed, causing damage. If your
pump is running too fast, stop it immediately and
check the fluid supply. If the container is empty and
air has been pumped into the lines, refill the con-
tainer and prime the pump and the lines, or flush and
leave it filled with a compatible solvent. Eliminate all
air from the fluid system.

10 306713
Operation
Prime the Pump (Circulating Systems)
1. See Fig. 5. Remove the spray nozzle from the
gun. See the gun instruction manual.
2. Close all bleed-type air valves (E, M).
3. Close the pump air filter/regulator (G).
4. Close the fluid drain valve (K).
5. Check that all fittings throughout the system are
tightened securely.
6. Connect the air supply line to the pump air inlet.
7. Open the restrictor valve (12) by turning the knob
clockwise as far as possible.
8. Open the bleed-type air valves (E, M). Open the
air filter/regulator (G).
9. Hold a metal part of the gun firmly to the side of a
grounded metal pail and hold the trigger open.
WARNING
COMPONENT RUPTURE HAZARD
To reduce the risk of overpressurizing
your system, which could cause compo-
nent rupture and serious injury, never
exceed the specified Maximum Incoming Air Pres-
sure to the pump (see the Technical Data, on
page 22).
10. Open the pump air valve (4) until the pump runs at
about 50 cycles per minute. Adjust the pump air
valve to maintain speed while closing the restrictor
valve (12) to obtain the desired fluid pressure in
the line. Always use the lowest pressure neces-
sary to get the desired results. Higher pressures
cause premature tip and pump wear.
11. When the pump speed and fluid pressure have
been adjusted, tighten the restrictor valve locknut.
12. Release the gun trigger and lock the trigger safety.
The pump will run continuously and speed up or
slow down on demand, until the air is shut off.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
13. Relieve the pressure. Install the spray nozzle in
the gun, as explained in the gun manual.
CAUTION
Do not allow the pump to run dry. It will quickly
accelerate to a high speed, causing damage. If your
pump is running too fast, stop it immediately and
check the fluid supply. If the container is empty and
air has been pumped into the lines, refill the con-
tainer and prime the pump and the lines, or flush and
leave it filled with a compatible solvent. Eliminate all
air from the fluid system.

306713 11
Operation
02121
KEY
4 Pump Air Valve
12 Pump Restrictor Valve
E Red-Handled Bleed-Type Master Air Valve
N Agitator
W Agitator Needle Valve
Fig. 5
Model 205585 Shown
E
4
12 N
W

12 306713
Operation
Shutdown and Care of the Pump
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
For overnight shutdown, stop the pump at the bottom
of its stroke to prevent fluid from drying on the ex-
posed displacement rod and damaging the throat
packings. Relieve the pressure.
Always flush the pump before the fluid dries on the
displacement rod. See Flushing below.
Flushing
WARNING
FIRE AND EXPLOSION HAZARD
Before flushing, read the section FIRE
AND EXPLOSION HAZARD on page
3. Be sure the entire system and flush-
ing pails are properly grounded. Refer to
Grounding on page 4.
Flush the pump:
DBefore the first use
DWhen changing colors or fluids
DBefore fluid can dry or settle out in a dormant pump
(check the pot life of catalyzed fluids)
DBefore storing the pump.
Flush with a fluid that is compatible with the fluid you
are pumping and with the wetted parts in your system.
Check with your fluid manufacturer or supplier for
recommended flushing fluids and flushing frequency.
CAUTION
Never leave water or water-base fluid in the pump
overnight. If you are pumping water-base fluid, flush
with water first, then with a rust inhibitor such as
mineral spirits. Relieve the pressure, but leave the
rust inhibitor in the pump to protect the parts from
corrosion.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
1. Relieve the pressure.
2. Remove the spray nozzle from the gun.
3. Hold a metal part of the gun firmly to the side of a
grounded metal pail.
4. Start the pump. Always use the lowest possible
fluid pressure when flushing.
5. Trigger the gun.
6. Flush the system until clear solvent flows from the
gun.
7. Relieve the pressure.
8. Clean the spray nozzle separately, then reinstall it.

306713 13
Notes

14 306713
Troubleshooting
Problem Cause Solution
Low fluid output. Fluid line, air line, or spray gun
clogged.
Check and clear.
Clogged fluid regulator or manifold. Check and clear.
Restricted main air supply. Check. Open bleed-type master air
valves.
Empty fluid supply container. Refill.
Wrong restrictor valve setting. Adjust; see page 10.
Dried fluid on the displacement rod. Clean the pump. Always stop the
pump at the bottom of its stroke.
Worn pump valves or packings. Replace. See page 16.
Erratic agitator operation. Low air supply. Increase the air supply.
The agitator motor is rusted or dirty. See manual 306565 to service.
NOTE: Check all possible causes and solutions before disassembling the unit.
Service
Before You Start
1. Have all the necessary repair parts on hand.
Recommended spare parts are indicated in the
parts list with a check mark, for example (18n).
2. Repair Kit 207848 is available. Parts included in
the kit are marked with an asterisk, for example
(102*). Use all the parts in the kit for the best
results.
3. Use a compatible solvent to clean parts. Inspect
parts for wear or damage and replace as needed.
Scoring or irregular surfaces on the displacement
rod (111) or polished inner wall of the cylinder (110)
cause premature packing wear and leaking. Check
these parts by holding the parts up to a light at a
slight angle.
4. Flush the system, if possible. See page 12.
5. Disconnect the hoses from the pump and remove
it from its mounting. Clamp the pump in a vise.

306713 15
Service
WARNING
To reduce the risk of injury from trapped air pres-
sure when servicing the air motor, always remove
air cap (11) from air cylinder (47) before removing
air cylinder from base (68).
Air Motor
1. Remove the shield capscrew (28) and the shield
(56).
2. Unscrew the air cap (11) from the air cylinder (47).
To remove the spring (35), gently pry under the
coils in the direction of the helix. Check the spring
and gasket (60) and replace as necessary.
3. Unscrew the air cylinder (47) from the base.
4. Hold the air exhaust plate (18) with a pliers (P) and
the flats of the air piston rod (10) with a wrench
(N), and unscrew the piston and valve assembly
(13). See Fig. 6. Remove the washer (37) and
spring (36).
5. Disassemble and wash the parts thoroughly in a
compatible, non-flammable solvent. Blow dry and
inspect the parts for wear or damage.
6. If any valve plate spacers (15) are damaged,
replace all three to maintain the correct clearance
between the valve plates (17, 18) and the seats.
See Fig. 7.
7. When reassembling, apply locking compound to
the threads of the screws and torque to 10–14 in-lb
(1.1–1.6 NSm). With the washer (37) in place,
apply thread sealant to the threads of the piston.
Carefully screw the piston (11) onto the shaft (23)
by hand so it is securely fastened. Do not use a
pliers on the air exhaust plate while tightening.
When installed, there should be a 0.8 mm (0.032
in.) minimum clearance between the washer (37)
and the piston shaft shoulder. See Fig. 6.
Restrictor Valve
1. Remove the stem (12) and o-ring (34) from the
base. See Fig. 8.
2. Remove the seat (57) from the pump return port
with a screwdriver.
3. Clean and inspect all parts for wear or damage
and replace if necessary.
02124
Fig. 6
1
N
18
P
Do not use a pliers on the air exhaust plate while tightening.
1
10
37
2Minimum 0.8 mm (0.032 in.) clearance between washer (37)
and piston shaft shoulder.
2
13
02125
Fig. 7
1
2
14
17
15
18
Apply locking compound to threads.
Torque to 10–14 in-lb (1.1–1.6 NSm).
1
1 2
02130
Fi
g
. 8
57
34
12

16 306713
Service
Displacement Pump
Intake Valve
1. Unscrew the intake valve (109*) from the cylinder
(110*) and disassemble. See Detail B of Fig. 9.
2. Clean and inspect all parts for wear or damage.
3. Reassemble the valve. To reseat the ball (102*),
hold it against the seat with a brass rod and tap
with a hammer. Unless further service is needed,
apply thread sealant to the threads of the intake
valve, screw it into the cylinder, and tighten se-
curely.
Piston
1. Unscrew the cylinder (110*) from the outlet hous-
ing (112) and pull the cylinder down to expose the
piston. Unscrew the piston stud (107) and remove
the packings (103*), ball (101*), and washers (104,
105). See Detail B of Fig. 9.
2. Clean and inspect all parts for wear or damage
and replace them if necessary.
3. To reseat the ball (101*), hold it against the seat
with a brass rod and tap with a hammer. Reas-
semble in the reverse order of disassembly. Screw
the stud (107) into the displacement rod (111) and
torque to 20–30 ft-lb (27–41 NSm).
Throat Packings
1. To remove the displacement pump, remove the
lower locknut (39) from the return tube (64). Dis-
connect the union (30) from the supply tube (62).
Remove the cotter pin (27) to free the upper end of
the connecting rod (63). Remove the cotter pin
from the lower end of the connecting rod and
unscrew the rod from the displacement rod (111).
See Detail A of Fig. 9.
2. Unscrew the cylinder (110*) from the outlet hous-
ing (112). If the displacement rod (111) is seized by
dried fluid, soak in a compatible solvent before
disassembling; do not try to break loose by twist-
ing the rod.
3. Unscrew the packing nut (106) and remove the
bearing (113*), packing (114*), and o-ring (115*).
Clean and inspect all parts for wear or damage
and replace if necessary.
4. Make sure that all parts are completely free of
paint fillers and pigments. Fill the displacement rod
cavity with heavy grease and reassemble in the
reverse order of disassembly.
5. When reconnecting the displacement pump to the
air motor, first tighten the union (30) onto the
supply tube (62), then screw the upper nut (39) on
the return tube down to the outlet housing (112)
and lock in place with the lower lockwasher (25)
and nut (39).

306713 17
Service
Fig. 9
1
3
4
2
05693
See Fig. 7.
See Detail A at left.
See Detail B at left.
1
2
3
Detail A: Pump Throat
Detail B: Intake Valve and piston Valve
28
56
55
35
47
12
Torque to 20–30 ft-lb (27–41 NSm).
4
11
*60
37
36
38*
31*
10
33*
61
12
64
63
62
*24
*27
30
112 39
25
39
111
110
109
109
*102
108
107
*101
110
111
105
103*
104
103*
105
39
25
39
115*
113*
54*
106
27*
64
63
62
30
*114
112
110
5 Lips face up.
6 Lips face down.
5
6
65

18 306713
Parts
Part No. 205585, Series D (includes items 1–99)
Ref.
No. Part No. Description Qty.
1 204534 HOOK, cover 2
2 204535 HANDLE, clamp 2
3 205595 2:1 STANDARD PUMP, Series E;
See page 21 1
67 206755 CORD, wire; no. 8 screw size loops;
5–1/2” (138 mm) long 1
68 207351 BASE, pump mounting 1
69 100016 LOCKWASHER, spring; 1/4” 2
70 100015 NUT, hex; 1/4–20 thd size 2
71 100063 PIN, cotter; 1/16” (1.5 mm) diameter;
1/2” (13 mm) long 2
74 100721 PLUG, slotted hd pipe; 1/4 npt 1
75 100933 SCREW, self tap type “f”; no. 8–32;
3/8” (10 mm) long 2
76 101108 PAIL; 5 gallon (19 liter) 1
78 101962 SCREW, socket hd set; 1/4–20 x
3/8” (10 mm) long 2
80 156593 O-RING; nitrile rubber 1
81 158223 WASHER, flat 2
82 164724 HOSE, air; 1/4” (6 mm) ID;
1/8 npt(mbe); 10” (254 mm) long 2
83 161395 PIN, handle pivot 2
85 164725 COVER, pail 1
86 164726 PLUG, fill 1
87 164815 TEE, pipe; 1/8 npt (m x f x f) 1
89 167709 BOLT, hook 2
90 224571 AGITATOR, 5 gallon (19 liter);
see 306565 for parts 1
93 101690 WRENCH, allen (not shown) 1
96 100124 NIPPLE; 1/4 npt 1
97 113329 BLEED VALVE, red-handled;
1/4 npt (fbe) 1
98 156823 UNION, swivel; 1/4 npt(m) x
1/4 npsm(f) 1
99 237569 GROUND WIRE AND CLAMP 1
02123
A
A
B
B
12
3
6
7
68
71
74
76
81
82
82
8
2
83
85
8
6
87
90
99
96
97
98
8
089
69
70
78
75

306713 19
Parts
Part No. 205584, Series A (includes items 1–89)
Ref.
No. Part No. Description Qty.
1 204534 HOOK, cover 2
2 204535 HANDLE, clamp 2
3 205595 2:1 STANDARD PUMP, Series E;
See page 21 1
67 206755 CORD, wire; no. 8 screw size loops;
5–1/2” (138 mm) long 1
68 207351 BASE, pump mounting 1
69 100016 LOCKWASHER, spring; 1/4” 2
70 100015 NUT, hex; 1/4–20 thd size 2
71 100063 PIN, cotter; 1/16” (1.5 mm) diameter;
1/2” (13 mm) long 2
72 100403 PLUG, pipe 1
74 100721 PLUG, slotted hd pipe; 1/4 npt 1
75 100933 SCREW, self tap type “f”; no. 8–32;
3/8” (10 mm) long 2
76 101108 PAIL; 5 gallon (19 liter) 1
77 101342 PLUG, button 1
78 101962 SCREW, socket hd set; 1/4–20 x
3/8” (10 mm) long 2
80 156593 O-RING; nitrile rubber 1
81 158223 WASHER, flat 2
82 164724 HOSE, air; 1/4” (6 mm) ID;
1/8 npt(mbe); 10” (254 mm) long 2
83 161395 PIN, handle pivot 2
84 162453 NIPPLE, pipe; 1/4 npt x 1/4 npsm 1
85 164725 COVER, pail 1
86 164726 PLUG, fill 1
87 164815 TEE, pipe; 1/8 npt (m x f x f) 1
89 167709 BOLT, hook 2
05979
A
A
12
3
67
68
71
74
76
81
82
83
85
86
87
84
80 89
69
70
78
72
77
75

02128B
28
56
55
11
35
*60
47
13
37
36
10
*27
*38
*31
*24
34*
12
94
95
59
57
40
33*
61
22
4
18
16
15
19
17
14
62
30
63
64
39
54*
106
113*
114*
115*
*27
112
25
39
111
101*
105
103*
104
103*
105
107
110
108
102*
109
21
4e4f 4d 4a
4b
4c
20 306713
Parts
Part No. 205595 Standard Pump, Series E (includes items 495)
Part No. 203367 Displacement Pump, Series B (includes items 101–115)