Graco 203872 Operation manual

306518
Rev. V
First choice when
quality counts.t
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
5:1 Ratio Fire-BallRPumps
900 psi (6.2 MPa, 62 bar) Maximum Working Pressure
180 psi (1.2 MPa, 12 bar) Maximum Air Input Pressure
Oil Pumps
These pumps are designed to pump lubricating
fluids only.
CAUTION
See page 19 for pump Model Numbers.
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Models and Dimensional Drawings 19. . . . . . . . .
Mounting Hole Layout 19. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Motor and Throat Service 11. . . . . . . . . . . . . . . . . . . .
Displacement Pump Service 15. . . . . . . . . . . . . . . . . . . .
Air Motor Parts List 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Motor Parts Drawing 16. . . . . . . . . . . . . . . . . . . . . . . .
Pump Parts Drawing 17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Parts List 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 20. . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 20. . . . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1994, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
05750
Models 203872
203857
204254
222087
Model 203876
05751
Parts

2 306518
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.
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. Use only genuine Graco parts and accessories.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure of the lowest rated component in your system.
This equipment has a 900 psi (6.2 MPa, 62 bar) maximum working pressure at 180 psi
(1.2 MPa, 12 bar) maximum incoming air pressure.
DUse 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 manufacturer’s
warnings.
DDo not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents,
or fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
DHandle hoses carefully. Do not pull on hoses to move 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).
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
WARNINGWARNING

3306518
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.
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.
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.
DIf a fluid injection injury occurs, get emergency medical care at once. Do not treat as a
simple cut. Tell the doctor exactly what fluid was injected.
DDo not point the dispensing valve at anyone or at any part of the body.
DDo not put your hand or fingers over the end of the dispensing valve.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DUse only extensions and no-drip tips which are designed for use with your dispensing valve.
DDo not use a low pressure flexible nozzle with this equipment.
DFollow the Pressure Relief Procedure on page 8 if the dispensing valve clogs before you
clean, check or service the equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do
not repair high pressure couplings; you must replace the entire hose.
WARNINGWARNING

4 306518
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
DDo not operate the pump with the air motor plates removed.
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.
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 lubricated. See Grounding on page 7.
DIf 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.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being dispensed.
DKeep the dispensing area free of debris, including solvent, rags, and gasoline.
DDo not smoke in the dispensing area.
WARNINGWARNING

5306518
Installation
The typical installation shown in Fig. 1 is only a guide for selecting and installing a pump; it is not an actual system
design. Contact your Graco distributor for assistance in designing a system to suit your needs.
S
A
Key
ABleed-type master air valve (required if quick-
disconnect fitting [L] and coupler [M] are not
installed) Order Part No. 107142.
BAir line filter
CAir regulator and gauge
DPump runaway valve
EAir inlet
FGround wire (required)
Order Part No. 222011.
GPump (Model 204254 shown)
HDrain valve (required)
Order Part No. 210658.
JDispensing valve
KLow-level cut-off valve
LMale quick-disconnect fitting
MFemale quick-disconnect coupler
NAir line lubricator
PFluid hose
RThermal relief kit (required)
Order Part No. 237893.
SBung adapter
Models 204254 and 222087
Fig. 1
A
B
CDE
G
F
H
PJ
L
M
DETAIL A
1/2 in. (13 mm) between foot
spacer and bottom of drum
N
04115A
A
R
K

6 306518
Installation
1. Install the pump on the drum cover so that the
pump’s fluid intake is 1/2 in. (13 mm) off the
bottom of the drum, as shown in Fig. 1.
2. On Models 204254 and 222087, screw the bung
adapter tightly into the drum cover’s bung hole,
adjust the position of the pump in the drum, and
tighten the bung adapter screw to hold the pump.
Always mount the pump firmly to a bracket or a
tank cover. Never operate the pump while it is not
mounted. Such use could damage the pump and
fittings.
CAUTION
System Accessories
CAUTION
Do not hang the air accessories directly on the air
inlet (E). The fittings are not strong enough to
support the accessories and may break. Provide a
bracket on which to mount the accessories.
Four accessories are required in your system: an
air shut-off valve/air bleed device, fluid drain valve,
thermal relief kit, and ground wire. These accesso-
ries help reduce the risk of serious bodily injury,
including fluid injection, splashing in the eyes or on
the skin, injury from moving parts if you are adjust-
ing or repairing the pump, and explosion from
static sparking.
DThe air bleed device relieves air trapped
between it and the air motor after the air supply
is shut off. Trapped air can cause the air motor
to cycle unexpectedly, causing serious injury if
you are adjusting or repairing the pump. Use
either a bleed-type master air valve (A) or a
quick-disconnect coupler (M) and fitting (L).
Install them near the pump air inlet within easy
reach from the pump.
DThe fluid drain valve (H) assists in relieving fluid
pressure in the displacement pump, hoses, and
dispensing valve. Triggering the valve to relieve
pressure may not be sufficient.
DThe thermal relief kit (R) assists in relieving
pressure in the pump, hose, and dispensing
valve due to heat expansion.
DThe ground wire (F) reduces the risk of static
sparking.
WARNING
NOTE: Install these accessories in the order shown
in Fig.1:
DInstall a pump runaway valve (D) to shut off the air
to the pump if the pump accelerates beyond the
pre-adjusted setting. A pump that runs too fast can
be seriously damaged.
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, and it may
get very hot.
CAUTION
DInstall an air line lubricator (N) for automatic air
motor lubrication.
DInstall a bleed-type master air valve (A) to relieve
air trapped between it and the motor when the
valve is closed. Order Part No. 107142. As an
alternative, you can install an air line quick
disconnect coupler (M) and fitting (L) to serve as an
air-bleed device. See Detail A in Fig.1.
DInstall a Thermal Relief Kit (K) on the dispensing
valve side of the pump. To order a 900 psi
(6.2 MPa, 62 bar) Thermal Relief Kit, order Part No.
237893.
DInstall the air regulator (C) to control pump speed
and pressure.
DInstall an air line filter (B) to remove harmful dirt
and contaminants from your compressed air supply.
Install another bleed-type master air valve (A) to
isolate the accessories for servicing.
DInstall a drain valve (H) near the pump fluid outlet.
Order Part No. 210658.
DInstall a suitable fluid hose (P) and dispensing
valve (J).

7306518
Installation
Grounding
Proper grounding is an essential part of maintaining a
safe system.
To reduce the risk of static sparking, ground the pump.
Check your local electrical code for detailed grounding
instructions for your area and type of equipment. Be
sure to ground all of this equipment:
DPump: Use a ground wire and clamp as shown in
Fig. 2.
DAir and Fluid hoses: Use only grounded hoses.
DAir compressor: Follow the manufacturer’s
recommendations.
DFluid supply container: Follow the local code.
DTo 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.
To ground the pump,loosen the grounding lug
locknut (W) and washer (X). Insert one end of a
12-gauge (1.5 mm@) minimum ground wire (Y) into the
slot in the lug (Z), and tighten the locknut securely.
Connect the other end of the wire to a true earth
ground. To order a ground wire and clamp, order Part
No. 222011.
Fig. 2
XW
Y
Z

8 306518
Operation
Pressure Relief Procedure
PRESSURIZED FLUID HAZARD
The equipment stays pressurized until
pressure is manually relieved. To re-
duce the risk of serious injury from
pressurized fluid, accidental spray from the valve,
or splashing fluid, follow this procedure whenever
you
DAre instructed to relieve pressure
DStop dispensing
DCheck, clean, or service any system equipment
DInstall or clean dispensing devices
WARNING
1. Close the pump air regulator and the bleed-type
master air valve (required in your system).
2. Hold a metal part of the dispensing valve firmly to
a grounded metal waste container, and trigger the
valve to relieve the fluid pressure.
COMPONENT RUPTURE HAZARD
The maximum working pressure of each
component in the system may not be the
same. To reduce the risk of overpres-
surizing any component in the system, be sure you
know the maximum working pressure of each
component. Never exceed the maximum working
pressure of the lowest rated component in the
system. Overpressurizing any component can
result in rupture, fire, explosion, property damage,
and serious injury.
To determine the fluid output pressure using the air
regulator reading, multiply the ratio of the pump by
the air pressure shown on the regulator gauge. For
example:
5 (:1) ratio x 100 psi air = 500 psi fluid output
5 (:1) ratio x 0.7 MPa air = 3.5 MPa fluid output
5 (:1) ratio x 7 bar air = 35 bar fluid output
Limit the air pressure to the pump so that no air
line or fluid line component or accessory is over-
pressurized.
WARNING
Starting and Adjusting the Pump
MOVING PARTS HAZARD
Never operate the pump with the warn-
ing plate (20) or the identification plate
(18) removed. These plates protect your
fingers from getting pinched or amputated by
moving parts in the air motor.
WARNING
WARNING
HAZARDOUS VAPORS
The air motor exhaust coming out of the
muffler could contain harmful materials,
such as oil, antifreeze, or some of the
material being pumped.
1. With the air regulator (C) closed, open the
bleed-type master air valves (A), or, if so
equipped, join the quick-disconnect coupler (M) to
the male fitting (L).
2. Open the dispensing valve (J) into a grounded
metal waste container, making firm metal-to-metal
contact between the container and valve.
3. Open the pump air regulator (C) slowly, just until
the pump is running. When the pump is primed
and all air has been pushed out of the lines, close
the dispensing valve.
NOTE: When the pump is primed, and with
sufficient air supplied, the pump starts when the
dispensing valve is opened and shuts off when it is
closed.
4. Adjust the air regulator until you get sufficient flow
from the dispensing valve. Always run the pump
at the lowest pressure necessary to get the
desired results. Do not exceed the maximum
working pressure of any component in the system.

9306518
Operation
5. If your pump accelerates quickly or is running too
fast, stop it immediately and check the fluid supply.
If the supply container is empty and air has been
pumped into the lines, prime the pump and lines
with fluid, or flush it and leave it filled with a
compatible solvent. Be sure to eliminate all air
from the fluid lines.
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, and it may
get very hot.
CAUTION
NOTES:
DThe low-level cut-off valve accessory (K) closes the
pump fluid intake when the fluid level is low, which
prevents air from entering the system.
DA pump runaway valve (D) should be installed on
the air line to automatically shut off the pump if it
starts to run too fast.
6. Read and follow the instructions supplied with
each component in your system.
7. If the pump will be unattended for any period of
time, if there is an air supply interruption, or at the
end of the work shift, shut off the system and
always relieve the pressure.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.

10 306518
Troubleshooting
NOTE: Check all other possible problems and solutions before disassembling the pump.
Problem Cause Solution
Pump fails to operate Inadequate air supply pressure or
restricted air lines Increase air supply; clear
Closed or clogged dispensing
valve Open; clear
Clogged fluid lines, hoses, valves,
etc. Clear
Damaged air motor Service air motor
Exhausted fluid supply Refill and reprime or flush
Continuous air exhaust Worn or damaged air motor gas-
ket, packing, seal, etc. Service air motor
Erratic pump operation Exhausted fluid supply Refill and reprime or flush
Held open or worn intake valve or
piston packings Clear; service
Pump operates, but output low on
up stroke Held open or worn piston packings Clear; service
Pump operates, but output low on
down stroke Held open or worn intake valve Clear; service
Pump operates, but output low on
both strokes Inadequate air supply pressure or restricted air lines Increase air supply; clear
Closed or clogged valves Open; clean
Exhausted fluid supply Refill and reprime or flush
Clogged fluid lines, hoses, valves,
etc. Clear
Before you solve any troubleshooting problems,
relieve the pressure, and disconnect the fluid line. If
the pump starts when the air is turned on again, the
line, dispensing valve, etc., is clogged.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.

11306518
Air Motor and Throat Service
Before You Start
DBe sure you have all necessary parts on hand.
Pump Repair Kit 238286 includes repair parts for
the pump and air motor. Use all the parts in the kit
for the best results. Parts included in the kit are
marked with one asterisk, for example (12*), in the
text and drawings. See the Air Motor Parts List
on page 16 and the Pump Parts List on page 17.
DTwo accessory tools should be used: Padded
Pliers, 207579, are used to grip the trip rod without
damaging its surface. Gauge, 171818, is used to
ensure the proper clearance between the poppets
and seat of the transfer valve.
Disassembly
1. Flush the pump, and relieve the pressure.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
2. Disconnect the ground wire from the grounding lug
(5b), disconnect the hoses, remove the pump from
its mounting, and clamp the air motor base in a
vise horizontally by closing the vice jaws on the
flange.
3. Use a strap wrench on the fluid cylinder (105) to
screw it out of the air motor base (5). See the
Parts Drawing on page 17.
4. Pull the displacement rod (8) down as far as it will
go. See Fig. 3.
5. Using wrenches on the flats of the displacement
rod (8) and on the flats of the fluid piston (110),
unscrew the fluid piston from the displacement rod.
Remove the ball (111) from the end of the
displacement rod, and remove the packing o-ring
(104*) from the fluid piston. See the Parts
Drawing on page 17.
6. Clamp the air motor upright in the vice by closing
the vice jaws below the flange.
7. Unscrew the cylinder cap nut (29) from the top of
the air motor cylinder (17).
8. Pull up on the cylinder cap nut (29) to expose the
trip rod, grasp the trip rod with padded pliers (Part
No. 207579), and unscrew the cylinder cap nut
from the trip rod.
CAUTION
Do not damage the plated surface of the trip rod
(11). Damaging the surface of the trip rod can
result in erratic air motor operation. Use the
special padded pliers to grasp the rod.
9. Remove the six screws (21) holding the air motor
cylinder (17) to the air motor base (5), and
carefully pull the cylinder straight up off of the
piston (2).
CAUTION
To avoid damaging the cylinder wall, lift the cylinder
straight up off of the piston. Never tilt the cylinder
while you are removing it.
10. Pull the air motor piston/displacement rod
assembly (2, 8) clear of the air motor base (5) by
pulling up on the air motor piston.
11. Remove the o-rings (9*, 112*) and u-cup packing
(6*) from the air motor base (5). Use needle-nose
pliers to remove the u-cup packing from the
bottom of the air motor base.
Fig. 3
29
17
05752
1
2
3
5b
5
6
8
9
10
11
24
21
flange

12 306518
Air Motor and Throat Service
12. Remove the o-ring (24*) from the air motor
piston (2).
13. Clamp the displacement rod upright in the vice by
closing the vice jaws on the flats of the
displacement rod.
14. Use a screwdriver to push down on the trip rod
yoke (22) to snap the toggles (M) down. See
Fig. 4.
15. Remove the lockwires (31*) from the adjusting
nuts (30*) of the transfer valves. Screw the top
nuts off. Screw the valve poppet (1*) stems out of
the grommets (12*) and bottom nuts (30*). Take
the valve poppets off of the stems, and squeeze
them firmly to check for cracks.
16. Grip the toggle rockers (26) with pliers. Compress
the springs (27) and swing the toggle assembly
(M) up and away from the piston lugs (L), and
remove the assembly. Check that the valve
actuator (13) is supported by the spring clips (14),
but slides easily into them. See Fig. 4.
MOVING PARTS HAZARD
To reduce the risk of pinching or ampu-
tating your fingers, always keep fingers
clear of the toggle assemblies (M).
WARNING
17. Remove the trip rod yoke (22), actuator (13), and
trip rod (11). Check the exhaust valve poppets
(16*) for cracks.
NOTE: To remove the exhaust valve poppets (16*),
stretch them out and cut them with a sharp knife.
Cleaning and Servicing
1. Clean all the parts carefully in a compatible solvent
and inspect for wear or damage. Use all the repair
kit parts during reassembly, and replace other
parts as necessary.
2. Check the polished surfaces of the air motor piston
(2), displacement rod (8), and cylinder wall (17) for
scratches or wear. A scored rod will cause
premature packing wear and leaking.
3. Lubricate all parts with a light weight,
water–resistant grease.
Reassembly
1. Clamp the displacement rod (8) upright in the vice
by closing the vice jaws on the flats of the
displacement rod.
2. Pull the new exhaust valve poppets (16*) into the
valve actuator (13), and clip off the top parts of the
poppets (shown with dotted lines in the Cutaway
View in Fig. 4).
3. Install the new grommets (12*) in the actuator (22),
place the inlet valve poppets (1*) in the piston, and
thread the bottom valve nuts (30*) onto the stems
of the inlet valve poppets until there are a few
threads left before the threads run out.
NOTE: If you thread the valve nuts too far down
onto the poppets, they will run off of the threaded
part of the poppets.
4. Grease heavily and place the trip rod (11) in the air
motor piston (2), place the actuator (13) in the
yoke (22), and place the well-greased
actuator/yoke assembly in the piston, with the trip
rod going through the center holes of the actuator
and yoke and the stems of the inlet valve poppets
(1*) going through the grommets (12*).
5. Thread the top valve nuts (30*) onto the stems of
the inlet valve poppets (1*) until one thread of the
inlet valve poppets is exposed above the valve
nuts.
6. Install the toggle pins (23) in the yoke (22), place
the toggle arm (25) ends of the toggle assembly
(M) onto the toggle pins, and snap the pivot pin
(26) ends of the toggle assembly into the piston
lugs (L).
7. Measuring with the gauge (Part No.171818),
create 0.145 in. (3.7 mm) of clearance between
the inlet valve poppets (1*) and the piston seat
when the inlet valve is open. See the Cutaway
View in Fig. 4.
NOTE: Adjust the distance between the inlet valve
poppets and the piston seat by turning the top
valve nuts (30*).
8. Tighten the bottom valve nuts (30*) by hand. The
grommets (12*) should be slightly compressed.
9. Align the holes in the valve nuts (30*) and the slots
on the stems of the inlet valve poppets (1*), and
drop the lock wires (31*) through the holes in the
valve nuts and into the slots in the stems of the
inlet valve poppets. Pull the lock wires down
tightly, and bend the ends with pliers so that they
cannot be pulled back out of the holes.

13306518
Air Motor and Throat Service
M
126
25
27
Fig. 4
Cutaway View
2211
31*
30*
1*
30*
1*
2
51*
30*
12*
11
14
13
12*
30*
1*
16*
2
L
16*
14
24*
04118
04119
1
3
4
2
Push toggles (M) in and then up.
Cut off tops of poppets as indicated by dotted lines.
Turn wires up.
0.145 in. (3.7 mm) clearance between
poppets (1*) and seat when it is open.
4
2
3

14 306518
Air Motor and Throat Service
Never re-use the old lock wires. They will get
brittle and break easily from too much bending.
CAUTION
10. Take the assembly out of the vice so that you can
move it around for steps 11 and 12.
11. Grease and install the new o-rings (9*, 24*, 112*).
12. Install the new u-cup packing (6*) through the
bottom of the air motor base, with the lips facing
toward the bottom of the pump.
13. Slide the displacement rod (8) down through the
packings, and lower the air motor piston (2) into
the air motor base (5).
14. Clamp the air motor upright in the vice by closing
the vice jaws below the flange.
15. Carefully lower the air motor cylinder (17) straight
down onto the piston assembly (2). Tighten the six
screws (21) holding the air motor cylinder to the air
motor base (5).
CAUTION
To avoid damaging the cylinder wall, lower the
cylinder straight down onto the piston. Never tilt
the cylinder as it is being lowered.
16. Pull the trip rod (11) so it is sticking up out of the
air motor cylinder (17).
NOTE: You may have to hold the unit upside down
to shake the trip rod loose.
17. Grip the trip rod (11) with padded pliers, screw the
cylinder cap nut (29) onto the trip rod, push the
cylinder cap nut down, and screw it into the top of
the cylinder.
CAUTION
Do not damage the plated surface of the trip rod
(11). Damaging the surface of the trip rod can
result in erratic air motor operation. Use the
special padded pliers to grasp the rod.
18. Place the piston ball (109) in the displacement rod
(8).
19. Clean the threads of the fluid piston (110), apply
Loctiterto the threads, install the new packing
o-ring (104*) on the fluid piston, and thread the
fluid piston onto the displacement rod (8).
20. Clamp the flats of the fluid piston (110) in a vice,
and torque the displacement rod (8) to the piston
to 40 to 60 ft-lb (54 to 81 N.m).
21. Clamp the air motor base (5) in a vise horizontally
by closing the vice jaws on the flange
22. Use a strap wrench to screw the displacement
pump cylinder (105) to the air motor base (5), and
torque to 95 to 105 ft-lb (129 to 142 N.m).
23. Before remounting the pump, connect an air hose
and run the air motor slowly, starting with just
enough air pressure to make the air motor run, and
make sure that it operates smoothly.
MOVING PARTS HAZARD
Never operate the pump with the warn-
ing plate (20) or the identification plate
(18) removed. These plates protect your
fingers from getting pinched or amputated by
moving parts in the air motor.
WARNING
24. Reconnect the ground wire before you resume
regular pump operation.

15306518
Displacement Pump Service
Before You Start
Be sure you have all necessary parts on hand. Pump
Repair Kit 238286 includes repair parts for the pump
and air motor. Use all the parts in the kit for the best
results. Parts included in the kit are marked with one
asterisk, for example (12*), in the text and drawings.
See the Air Motor Parts List on page 16 and the
Pump Parts List on page 17.
1. Flush the pump, and relieve the pressure.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
2. Disconnect the hoses, remove the pump from its
mounting, and clamp the air motor base in a vise
horizontally by closing the vice jaws on the flange.
3. Unscrew the intake valve body (107) from the fluid
cylinder (105). Disassemble the intake valve (see
the Parts Drawing). Clean and inspect the parts
for wear or damage, and replace parts as needed.
Be sure to check the o-ring (108*). Unless further
intake valve service is needed, reassemble and
reinstall, using liquid sealant on the male threads.
4. Use a strap wrench on the fluid cylinder (105) to
screw it out of the air motor base (5). Carefully
inspect the smooth inner surface of the cylinder for
scoring or irregular surfaces. Such damage
causes premature packing wear and leaking, so
replace the part if it is damaged.
5. Using wrenches on the flats of the displacement
rod (8) and on the flats of the fluid piston (110),
unscrew the fluid piston from the displacement rod.
6. Take the ball (111) out of the displacement rod (8),
and take the packing o-ring (104*) off of the fluid
piston (110).
7. Clean and inspect the parts. Use all the repair kit
parts during reassembly, and replace other parts
as necessary.
8. Place the piston ball (109) in the displacement rod
(8).
9. Install the new packing o-ring (104*) on the fluid
piston (110).
10. Clamp the flats of the fluid piston (110) in a vice,
and torque the displacement rod (8) to the piston
to 40 to 60 ft-lb (54 to 81 N.m).
11. Clamp the air motor base (5) in a vise horizontally
by closing the vice jaws on the flange.
12. Use a strap wrench to screw the displacement
pump cylinder (105) to the air motor base (5), and
torque to 95 to 105 ft-lb (129 to 142 N.m).
13. If you disconnected the ground wire, reconnect it
before you resume regular pump operation.

16 306518
Air Motor Parts List
All Models
Ref.
No. Part No. Description Qty.
1* 236079 POPPET, valve 2
2 160614 PISTON, air motor 1
5 238278 BASE, air motor (includes 5a to 5c)
5a 104582 .WASHER, tab 1
5b 104029 .LUG, grounding 1
5cY180233 .LABEL, warning 1
6* 112561 PACKING, u-cup 1
8 191124 ROD, displacement 1
9* 160625 O-RING; buna-N 1
10 160624 O-RING; buna-N 1
11 203965 ROD, trip 1
12* 158367 GROMMET; rubber 2
13 172867 ACTUATOR, valve 1
14 172866 CLIP, spring 2
15 102975 SCREW, rd hd mach; 6–32 x .25”2
16* 170709 POPPET, valve 2
17 160613 CYLINDER, air motor 1
18 222499 PLATE, identification (with muffler) 1
19 100078 SCREW, hex washer hd mach;
no. 8–32 x 0.38”12
20 222501 PLATE, warning (with muffler) 1
21 101578 CAPSCREW, hex hd nylock;
5/16–18 x 0.88”6
22 158360 YOKE, rod, trip 1
23 158362 PIN, toggle 2
24* 160621 O-RING; nitrile rubber 1
25 160623 ARM, toggle 2
26 158364 ROCKER, toggle 2
27 167585 SPRING, helical compression 2
28 156698 O-RING; buna-N 1
29 161435 NUT, cylinder cap 1
30* 160261 NUT, adjusting 4
31* 160618 LOCK WIRE, transfer valve 2
33 160932 GASKET; copper 1
*Included in pump repair kit 238286
YExtra warning labels are available for free.
Air Motor Parts
Drawing
26
29
28
17
31*
30*
27
25
13
30*
12*
16*
24*
14
15
11
23 22
2
33
8
1*
18
20
55b
5a
19
21
9*
10
6*
5c
5c
1
1Lips face down.
05888

17306518
Pump Parts
Drawing
118b
114, 115,
116, or 117
113
107
109
106
105
111
110
118a
104*
108*
05888A
112*
Pump Parts List
Model 203857, Series L
Includes items 101 to 114.
Model 203872, Series L
Includes items 101 to 113 and 115.
Model 203876, Series L
Includes items 101 to 112.
Model 204254, Series P
Includes items 101 to 113, 116, and 118.
Model 222087, Series C
Includes items 101 to 113,117, and 118.
Ref.
No. Part No. Description Qty.
101 238285 AIR MOTOR
Includes items 1 to 33 on page 16. 1
104* 113423 PACKING, o-ring 1
105 191125 CYLINDER, fluid 1
106 157182 RETAINER, ball 1
107 183009 BODY, intake valve 1
108* 156633 O-RING, buna-N 1
109 101190 BALL, steel; 1”(25mm) dia. 1
110 191122 PISTON, fluid 1
111 100279 BALL, steel; 0.88”(22.2 mm) dia. 1
112* 156641 O-RING, buna-N 1
113 110127 SPACER, foot 1
114 191128 TUBE, extension; 21.75”(553 mm) 1
115 191126 TUBE, extension; 14.25”(362 mm) 1
116 191130 TUBE, extension; 26.0”(661 mm) 1
117 191131 TUBE, extension; 36.0”(915 mm) 1
118 222308 BUNG ADAPTER ASSEMBLY
includes items 118a and 118b
118a 104542 . SCREW, cap, hex hd; M8 x 1.25”1
118b 210834 . ADAPTER, bung, bare 1
*Included in pump repair kit 238286

18 306518
Technical Data
Maximum working pressure 900 psi. . . . . . . . . . . . . . . .
6.2 MPa, 62 bar)
Fluid pressure ratio 5:1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Air operating range 40 to 180 psi. . . . . . . . . . . . . . . . . . .
(0.28 to 1.2 MPa, 2.8 to 12 bar)
Air consumption 13 ft3/min for first gpm pumped. . . . . .
(0.096 m3/min for first lpm pumped)
at 100 psi (0.7 MPa, 7 bar);
up to 8 additional ft3/min for each additional gpm
(0.058 additional m3/min for each additional lpm)
with pump operated within recommended range
Pump cycles per gallon (per liter) 30 (7.9). . . . . . . . . . .
Maximum recommended
pump speed 130 cycles per min. . . . . . . . . . . . . . . . . . . 5 gpm (19 lpm)
Recommended speed for
optimum pump life 70 cycles per min. . . . . . . . . . . . . . .
Wetted parts steel, urethane, aluminum, buna-N. . . . .
Approximate weight (Model 203876) 17 lb (7.7 kg). . .
Sound pressure level
(measured at 1 meter from unit) 77.8 dB(A)Sound. . . .
Sound power level
(tested in accordance with ISO9614–2) 85.6 dB(A). . .
(m3/min)

19306518
Pump Models and Dimensional Drawings
3/8 in. npt(f)
air inlet
3/8 in. npt(f)
air inlet
ground-
ing lug
Model 203857, Series L
55-gal. (400 lb) drum size, cover mount
Overall Length: 45.6 in. (1158 mm)
Model 203872, Series L
16-gal. (120 lb) drum size, cover mount
Overall Length: 38.1 in. (968 mm)
Model 203876, Series L
Universal, wall mount
Overall Length: 20.7 in. (526 mm)
8.9 in.
(226 mm)
grounding
lug
1/2 in. npt(f)
fluid outlet
Model 204254, Series P
55-gal. (400 lb) drum size, bung mount
Overall Length: 49.9 in. (1267 mm)
Bung adapter (118) is shown on page 17.
Model 222087, Series C
275-gal. tank size, bung mount
Overall Length: 59.9 in. (1521 mm)
Bung adapter (118) is shown on page 17.
Model 203872
26.3 in. (668 mm)
Model 203857
33.8 in. (859 mm)
Model 204254
38.1 in. (968 mm)
Model 222087
48.1 in. (1222 mm)
1/2 in.
npt(f)
fluid
outlet
Mounting Hole
Layout
04127
05750
05754
2-Hole Mounting Pattern 4-Hole Mounting Pattern
Two 0.265-in. (6.73 mm)
diameter holes on 5-in.
(127 mm) bolt circle
Four 0.265-in. (6.73 mm)
diameter holes on 5-in.
(127 mm) bolt circle
Gasket,
Part No.
161023
3-in. (76.2 mm)
diameter hole

20 306518
Manual Change Summary
This manual went from Rev. T to Rev. V to add fluid pressure and sound data.
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 Graco’s 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.
Graco’s sole obligation and buyer’s 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 rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures
judiciaires exécutés, donnés ou intentés àla suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
Graco Phone Number
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1–800–367–4023 Toll Free
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
Foreign Offices: Belgium, Korea, Hong Kong, Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
www.graco.com
PRINTED IN U.S.A. 306518 July 1955, Revised February 2000