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.