Graco 206405 Datasheet

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1996, Graco Inc. is registered to I.S. EN ISO 9001
15:1 Fire-BallR300 Pumps
For pumping petroleum–based undercoating material.
2700 psi (18.6 MPa, 186 bar) Maximum Working Pressure
180 psi (1.2 Ma, 12 bar) Maximum Air Input Pressure
Model No. 206405, Series K
35 lb. pail size
Model No. 206699, Series J
120 lb. drum size
Model No. 206700, Series J
400 lb. drum size
306531AD
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Guide 12. . . . . . . . . . . . . . . . . . .
Air Motor Service 13. . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Service 16. . . . . . . . . . . . . .
Parts 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 23. . . . . . . . . . . . . . . . . . . .
Dimensional Drawings 23. . . . . . . . . . . . . . . . . . .
Technical Data 23. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 24. . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 24. . . . . . . . . . . . . . . . . . .
04208B
WARNING
This product is designed to be used for pumping
non-corrosive and non-abrasive fluids only. Any
other use can cause unsafe operating conditions
and result in component rupture, fire, or explosion,
which can cause serious injury, including skin
injection.
Model 206405 Shown
Important Safety instructions
Read all warnings and instructions in this manual.
Save these instructions.

2 306531
Symbols
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 Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death 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. 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 stated on the equipment or in the Technical Data
for your equipment. Do not exceed the maximum working pressure of the lowest rated component
in your system.
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.
DHandle hoses carefully. Do 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 66_C (150_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.

306531 3
WARNING
SKIN INJECTION HAZARD
Spray from the gun, 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.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate
surgical treatment..
DDo not point the gun at anyone or at any part of the body.
DDo not put your hand or fingers over the spray tip.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DDo not “blow back” fluid; this is not an air spray system.
DAlways have the tip guard and the trigger guard on the gun when spraying.
DCheck the gun diffuser operation weekly. Refer to the gun manual.
DBe sure the gun trigger safety operates before spraying.
DClose the gun ball valves when you stop spraying.
DLock the gun trigger safety when you stop spraying.
DFollow the Pressure Relief Procedure on page 8 if the spray tip clogs and before cleaning,
checking or servicing 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.
DFluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
DKeep clear of all moving parts when starting or operating the pump.
DBefore checking or servicing the equipment, follow the Pressure Relief Procedure on page 8 to
prevent the equipment from starting unexpectedly.

4 306531
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 7.
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.
DBefore operating this equipment, electrically disconnect all equipment in the spray area.
DBefore operating this equipment, extinguish 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.

306531 5
Notes

6 306531
Installation
Fig. 1
KEY
AElectrically Conductive Air Hose
BFemale Quick Disconnect Coupler
CMale Quick Disconnect Fitting
DAir Line Filter
EAir Regulator and Gauge
FBleed-Type Master Air Valve
GAir Line Lubricator
HPump Runaway Valve
JPump Air Inlet
KGround Wire
LPressure Drain Valve
MElectrically Conductive Fluid Hose
NSpray Gun
A
C
EFG
JH
M
L
B
D
N
1/2 in.
(13 mm)
K
04209
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawings.
Figure 1 is only a guide to selecting and installing
optional and required accessories. For help in design-
ing a system to suit your needs, contact your Graco
distributor.
Mount the pump to suit the type of installation planned.
See page 23 for dimensions and mounting hole layout.
System Accessories
WARNING
To reduce the risk of serious injury including skin
injection, splashing in the eyes or on the skin, and
injury from moving parts, if you are adjusting or
repairing the pump, two accessories are required
in your system: a bleed-type master air valve (F)
and a pressure drain valve (L).
The bleed-type master air valve (F) 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 if you are adjusting or
repairing the pump. Install the valve near the pump
air inlet, within easy reach of the pump.
The pressure drain valve (L) assists in relieving
fluid pressure in the displacement pump, hoses
and gun. Triggering the spray gun to relieve pres-
sure may not be sufficient.

306531 7
Installation
CAUTION
Provide a bracket for mounting the air accessories.
The fittings are not strong enough to support the
accessories and may cause one or more to break.
NOTE: Install the accessories in the order shown in
Figure 1.
DA pump runaway valve (H) shuts off the air to the
pump if the pump accelerates beyond the pre-ad-
justed setting. A pump which runs too fast can be
seriously damaged.
DAn air line lubricator (G) provides automatic air
motor lubrication.
DA bleed-type master air valve (F) relieves air
trapped between it and the motor when the valve is
closed. Order Part No. 107142.
DThe air regulator (E) controls pump speed and
pressure.
DAn air line filter (D) removes harmful dirt and
contaminants from your compressed air supply.
DA drain valve (L) is required near the pump fluid
outlet to relieve fluid pressure in the pump, hose
and gun. Order Part No. 210657.
DInstall an electrically conductive fluid hose (M) and
spray gun (N).
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
below.
DTruck bed or platform: according to your local code.
DFluid hoses: use only electrically conductive hoses.
DAir compressor: follow manufacturer’s recommen-
dations.
DSpray gun: grounding is obtained through connec-
tion to a properly grounded fluid hose and pump.
DObject being sprayed: according to local code.
DFluid supply container: according to local code.
DAll solvent pails used when flushing or relieving
pressure, always hold a metal part of the gun firmly
to the side of a grounded metal pail, then trigger the
gun.
To ground the pump:
To ground the pump,use a ground wire and clamp as
shown below. Remove the ground screw (Z) and insert
through the eye of ring terminal at end of ground wire
(Y). Fasten the ground screw back onto the pump and
tighten securely. Connect the other end of the ground
wire to a true earth ground. See Fig. 2. To order a
ground wire and clamp, order Part No. 222011.
Fig. 2 TI1052
Y
Z

8 306531
Operation
Pressure Relief Procedure
WARNING
SKIN INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
Dare instructed to relieve the pressure,
Dstop spraying,
Dcheck or service any of the system equipment,
Dor install or clean the spray tips.
1. Lock the spray gun trigger safety.
2. Close the pump air regulator. Close the bleed-type
master air valve (required in your system).
3. Unlock the gun trigger safety.
4. Hold a metal part of the spray gun firmly to a
grounded metal waste container and trigger the
gun to relieve the fluid pressure.
5. Lock the gun trigger safety.
6. Open the pump drain valve (required with your
system) and leave it open until you are ready to
spray again.
If you suspect that the spray tip or hose is clogged or
that fluid pressure is not fully relieved after following
the steps above, very slowly loosen the tip guard
retaining nut or hose end coupling and relieve pressure
gradually. Clear the tip or hose obstruction.
WARNING
COMPONENT RUPTURE HAZARD
Overpressurizing any component can
result in rupture, fire, explosion, property
damage, and serious injury. To reduce
the risk of overpressurizing, know the Maximum
Working Pressure of the lowest rated component in
your system, and limit the air to the pump so that
you never exceed that pressure.
To determine the fluid output pressure using the air
regulator reading, multiply the pump ratio by the air
pressure you set on the regulator gauge. Example:
15 (:1) ratio x 100 psi air = 1500 psi fluid output
[15 (:1) ratio x 7 bar air = 105 bar fluid output]
WARNING
Never operate the pump with the warning plate
(20) or the identification plate (40) removed. These
plates protect your fingers from pinching or am-
putation by moving parts in the air motor.
Starting and Adjusting the Pump
1. With the air regulator (E) closed, open the bleed-
type master air valve (F).
2. Connect the air hose.
3. Trigger the spray gun (N) into a grounded metal
pail, making firm metal-to-metal contact.
4. Open the pump air regulator (E) slowly, just until
the pump is running. When the pump is primed
and all air has been pushed out of the lines, re-
lease the spray gun trigger. With sufficient air
supplied, the pump starts when the spray gun is
triggered and shuts off when the trigger is re-
leased.
5. Adjust the air regulator just until you get adequate
flow from the spray gun. Always run the pump at
the lowest speed necessary.
CAUTION
Never allow the pump to run dry of the fluid being
pumped. A dry pump will quickly accelerate to a high
speed, possibly damaging itself. If your pump acceler-
ates quickly, or is running too fast, stop it immediately
and check the fluid supply. If the supply container is
empty and air has been pumped into the lines, 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. Use a pump runaway valve (K) 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, or to shut off the system at the end of the
work shift, always follow the Pressure Relief
Procedure, at the left.

306531 9
Notes

10 306531
Maintenance
Shutdown and General Care
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
DAlways relieve the pressure when you shut down
the pump.
DIf you are pumping fluid that dries or sets up, flush
with a compatible solvent as often as necessary to
prevent buildup in the pump and hoses.
DAfter every 40 hours of operation, adjust the pack-
ing nut (42) as described on page 11.
Flushing
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. To reduce the risk of skin injection, static sparking
or splashing, Relieve the Pressure before flush-
ing.
2. Remove the spray tip.
3. Hold a metal part of the gun firmly to the side of a
grounded metal pail. Use the lowest possible fluid
pressure when flushing.
Lubrication
The accessory air line lubricator (G) provides automat-
ic air motor lubrication. For daily, manual lubrication
follow this procedure:
1. Disconnect the regulator.
2. Place about 15 drops of light machine oil in the
pump air inlet.
3. Reconnect the regulator.
4. Turn on the air supply to blow oil into the motor.

306531 11
Maintenance
Packing Nut Adjustment
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
WARNING
Keep your hand and fingers away from the piston
when it is moving. As the piston moves into the
pump base it can amputate fingers or break tools
caught between the moving parts. Note the pinch
point shown in Fig. 3. Be sure all air and fluid
pressure is fully relieved before adjusting the piston
or packing nut to reduce the risk of amputation.
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 50 psi (.345 MPa, 3.4 bar) air pressure to cycle
when the gun is triggered, which indicates the pack-
ings are too tight, or (c) the pump has been in opera-
tion for 40 hours.
1. Relieve the pressure. Follow the Pressure Relief
Procedure on page 8.
2. Using a 1/4” nut driver, remove the six screws (24)
from one of the muffler plates (20 or 40) and
remove the muffler plate. See Fig. 4.
3. Check to see that the air motor piston is at the top
of the stroke. If it is not, first read the warning
above. Then, 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.
Refer to Fig. 3.
4. Use a 1/4” diameter rod, spanner wrench, or
torque wrench to tighten the packing nut. First
loosen the nut, then tighten snugly, and finally
tighten an additional 1/2 turn (20–25 ft–lbs). See
Fig. 5.
5. Replace the muffler cover, and the six screws.
See Fig. 4.
6. Reconnect the air line. After the pump is started, it
should run at 40 psi (.276 MPa, 2.8 bar) with no
load. Startup may require additional air pressure.
WEEP HOLE LOCATED
OPPOSITE FLUID OUTLET
AND IN BOTTOM OF BASE
Fig. 3
BASE
PISTON
PINCH POINT
FLUID
OUTLET
Fig. 4 24
20
BASE
Fig. 5
1/4” DIA. ROD
PACKING NUT

12 306531
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
Relieve the Pressure before you check or service any
system equipment.
WARNING
Never operate the pump with the warning plate
(20) or the identification plate (40) removed. These
plates protect your fingers from pinching or ampu-
tation by moving parts in the air motor.
NOTE: Check all other possible problems and solu-
tions before disassembling the pump.
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 packings 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 too tight Loosen
Loose packing nut or worn packings Tighten; replace
*Follow the Pressure Relief Procedure on page 8. Disconnect the fluid hose. If the pump starts when the air is
turned on again, the hose or gun is clogged.

306531 13
Air Motor Service
Before you start:
DHave all necessary parts on hand. Always replace
the glands and bearing when replacing the pack-
ings. Use all the parts in the repair kits for the best
results. See page 18 to order the kits.
DAir Motor Repair Kit 206728. Parts included in
this kit are marked with a dagger, (for example,
36†), in the text and drawings.
DDisplacement Pump Repair Kit 206925. Parts
included in this kit are marked with one asterisk,
(i.e., 6*), in the text and drawings.
DTwo accessory tools should be ordered. Use
Padded Pliers, 207579, to grip the trip rod without
damaging its surface. Use Gauge, 171818, to
ensure the proper clearance between the poppets
and seat of the transfer valve.
Air Motor & Throat Disassembly
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. Flush the pump.
2. Relieve the pressure before proceeding.
3. Disconnect the hoses, remove the pump from its
mounting, and clamp the air motor base (55) in a
vise.
4. Use a strap wrench on the riser tube (12) to screw
it out of the air motor base (55).
5. Pull the connecting rod (10) down as far as it will
go.
6. Use a hammer and punch to remove the roll pin
(4). Unscrew the connecting rod (10). See Fig. 6.
CAUTION
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 Number 207579, to grasp the rod.
7. 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. See Fig. 6.
CAUTION
To avoid damaging the cylinder wall, lift the
cylinder (51) straight up off the piston (59). Never tilt the
cylinder as it is being removed.
8. Remove the six screws (25). See Fig. 6. Pull the
cylinder (51) straight up off the piston (59).
9. Use a screwdriver to push down on the trip rod
yoke (28), and snap the toggles down. See Fig. 7.
Fig. 6
25
59
51
47
55
27
54
4*
10
41
43
49*
42
44*
50*
38
39†
48*
04210B
1
2
2Lips of v-packings must face down.
1 See detail below. 12

14 306531
Air Motor Service
Fig. 7
M
28
54
34†
33†
45†
33†45†
59
55
30 37
32†
L
53†58
31
04118
1
1
To remove toggles: push in, swing up, ease out.
Push toggles (M) in and then up (shown in down position).
2
3
2
Turn wires up.
3
Fig. 8
0.145”
(3.7 mm)
Cutaway View
45†
33†
54
58
35
32†
33†
45†
53†
59
36†
1
04119
1Cut off tops of poppets as indicated by dotted lines.
10. Remove the lockwires (34†) from the adjusting
nuts (33†) of the transfer valves. Screw the top
nuts off. Screw the poppet valve stems (45†) out of
the grommets (32†) and the bottom nuts (30). Take
the valve poppets off the stems and squeeze them
firmly to check for cracks. See Fig. 7.
WARNING
To reduce the risk of pinching or amputating your
fingers, always keep fingers clear of the toggle
assemblies (M).
11. Grip the pivot pins (30) with pliers. Compress the
springs (31), and swing the toggle assembly (M)
up and away from the piston lugs (L). Remove the
parts. Check to see that the valve actuator (35) is
supported by the spring clips (58) but slides easily
into them. See Fig. 7.
12. Remove the trip rod yoke (28), actuator (35) and
trip rod (54). See Fig. 7. Check the exhaust valve
poppets (53†) for cracks. To remove the exhaust
valve poppets (53†), stretch them out and cut them
with a sharp knife.
13. Remove one muffler plate (20 or 40). Pull the
piston (59) up out of the base. Remove the throat
packing nut (42) and packings. See Fig. 6.
Reassembly
1. Clean all the parts in a compatible solvent and
inspect for wear or damage. Check the polished
surfaces of the piston (59), piston rod (41), and
cylinder wall (51) for scratches or wear. A scored
rod will cause premature packing wear and leak-
ing. 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*), five v-packings (48*) with lips
facing down, bearing (50*), backup washer (43),
flat packing (44*), and loosely screw in the packing
nut (42). Be sure the o-rings (38 & 39†) are in
place. See Fig. 6.
4. Pull the exhaust valve poppets (53†) into the valve
actuator (35) and clip off the top part shown with
dotted lines. See Fig. 8.
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 reassemble the valve
mechanism. See Fig. 7.

306531 15
Air Motor Service
6. Install the bottom adjusting nuts (33) on the poppet
valve stems (45†) and screw the stems into the
grommets (32†). Screw the top nuts (33†) on the
stems. Before installing the lockwires (34†) in the
adjusting nuts, use the gauge 171818 to adjust
the transfer valve so there is 0.145 in. (3.7 mm)
clearance between the poppets and the seat when
it is open. See Fig. 8.
WARNING
To reduce the risk of pinching or amputating your
fingers, always keep fingers clear of the toggle
assemblies (M).
7. Install the springs (31) and pivot pins (30) on the
toggle arms (37). Snap the toggles to the up
position. Refer to Fig. 7.
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 down. Be sure the o-ring (27) is in
place at the top of the cylinder (51), and screw the
cap nut into the cylinder.
10. Screw the connecting rod (10) into the piston rod
(41) and secure with the pin (4*). Manually push
on the piston rod (41) to move the piston (59) up
as far as it will go. Screw the riser tube (12) into
the base (55).
11. Use a 1/4” diameter rod, spanner wrench, or
torque wrench to tighten the packing nut (42).
Tighten snugly and then tighten an additional 1/2
turn (20–25 ft–lbs).
12. Install the muffler plate (20 or 40) using the six
screws (24).
13. Connect an air hose and run the pump slowly
[about 30 psi (2.1 bar)] to see that it operates
smoothly.
14. Remount the pump and reconnect the ground wire.

16 306531
Displacement Pump Service
Before you start:
1. Have all necessary parts on hand. Whenever you
replace the packings, also replace the glands and
bearing. If you are using a repair kit, use all the
parts for the best results. See the parts pages to
order the kits.
2. Displacement Pump Repair Kit 206925 includes
repair parts for the pump throat and piston. Parts
included in the kit are marked with one asterisk, for
example (6*), in the text and drawings.
3. To replace the throat packings, which are included
in Repair Kit 206728, refer to the Air
Motor and Throat Disassembly on page 13.
Displacement Pump Disassembly
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. Flush the pump.
2. Relieve the Pressure
3. Disconnect the hoses, remove the pump from its
mounting, and clamp the air motor base in a vise.
4. Unscrew the intake valve body (22) from the riser
tube (12). See Fig. 9. 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 valve, using liquid sealant on the male
threads. See Fig. 9.
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 prema-
ture packing wear and leaking, so replace the part
if damaged.
7. Unscrew the piston body (13) from the piston
coupling (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*). See Fig. 9.
04212B
Fig. 9
*17
†7
3*
21
22
12
13 16*
18*
*6
2*
*19
*4 14
10
46
55
*15
*4
7

306531 17
Displacement Pump Service
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.
8. 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.
9. Install the seal (16*), packing (17*), bearing (18*),
gasket (6*), seat (19*) and ball (2*) on the piston
body (13). The check ball seat (19*) may be re-
versed to provide a new seat. Screw the piston
body (13) into the piston coupling (14).
10. Install the gasket (7*[). Screw the riser tube (12)
into the air motor base (55).
11. 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).
12. Be sure the ground wire is connected before
regular operation of the pump.

18 306531
Parts
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
45†
41
*4
38
55
20 24
60
63
25
40
*4
53†
39†
42
44*
43
50*
48*
49*
16*
46
7*†
04213B
Model 206405, Series K
35 lb. pail size
7
7

306531 19
Parts
Model 206405, Series K
35 lb. pail size
Ref
No. Part No. Description Qty.
Ref
No. Part No. Description Qty.
2* 100114 BALL, steel, 0.44” (11.2 mm) dia. 1
3* 100400 BALL, steel, 0.75” (19 mm) dia. 1
4* 101579 PIN, roll, 0.12” (3.2 mm) dia.,
0.75” (19 mm) long 3
6* 150451 GASKET, copper 1
7*†150694 GASKET, copper
(qty 1 in kits 206925 and 206728) 3
10 165970 ROD, connecting,
5 1/4” (133 mm) long 1
12 165971 TUBE, riser,
11–11/16” (297 mm) long 1
13 160939 BODY, piston 1
14 160940 COUPLING, piston 1
15* 160941 BEARING, press fit, brass 1
16* 160942 SEAL, piston; PTFE 1
17* 160943 PACKING, block, nitrile rubber 1
18* 160944 BEARING, piston, brass 1
19* 160945 SEAT, piston, reversible 1
20** 234578 PLATE, warning (with muffler) 1
21 183326 STOP, ball 1
22 191080 HOUSING, intake valve 1
24** 100078 . SCREW, hex washer hd, mach,
8–32 x 3/8” 12
25 101578 . CAPSCREW, hex hd Nylockr,
5/16–18 x 7/8” 6
27 156698 . O-RING, nitrile rubber 1
28 158360 . YOKE, rod, trip 1
29 158362 . PIN, toggle 2
30 158364 . PIN, pivot 2
31 167585 . SPRING, helical compression 2
32†158367 . GROMMET; rubber 2
33†160261 . NUT, adjusting 4
34†160618 . WIRE, lock 2
35 172867 . ACTUATOR, valve 1
36†160621 . O-RING, nitrile rubber 1
37 160623 . ARM, toggle 2
38 160624 . O-RING, nitrile rubber 1
39†160625 . O-RING, nitrile rubber 1
40** 234577 . PLATE, identification,
with muffler 1
41 160639 . ROD, piston 1
42 160640 . NUT, packing 1
43 160641 . WASHER, backup 1
44* 160644 . PACKING, flat leather 1
45†236079 . VALVE, poppet 2
46 160932 . GASKET, copper 1
47 164704 . NUT, cylinder cap 1
48* 162391 . V-PACKING, leather 5
49* 168851 . GLAND, male 1
50* 168852 . BEARING, throat 1
51 160613 . CYLINDER, air motor 1
53†170709 . POPPET, valve, urethane 2
54 203965 . ROD, trip 1
55 204896 . BASE, air motor 1
57 102975 . SCREW, rd hd mach,
6–32 x 1/4” 2
58 172866 . CLIP, spring 2
59 15K534 . PISTON, air motor 1
60 116343 . SCREW, ground 1
63 162718 . ADAPTER, 3/8 npt (m) x
1/4 npt(f) 1
* These parts are included in Pump Repair Kit 206925,
which may be purchased separately.
** These parts are included in Muffler Repair Kit 222559,
which may be purchased separately.
†These parts are included in Air Motor Repair Kit 206728,
which may be purchased separately.

20 306531
Parts
Model 206699, Series J
120 lb. drum size
Model 206700, Series J
400 lb. drum size
10
14
2*
19*
6*
18*
17*
12
3*
22
21
13
15*
27
51
35
29
37
31
30
28
34†
33†
32†
33†
54
57
58
†36
59
45†
41
*4
38
55
20 24
60
63
25
40
*4
53†
39†
42
44*
43
50*
48*
49*
16*
46
7*†
04214B
47
7
7