Graco 224826 User manual

Instructions–Parts List
308069N
ENG
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Overspray Masking Liquid
System
For airspray application of fluids.
7545A
ÄÄ
ÄÄ
2700 psi (18.6 MPa, 186 bar) Maximum Working Pressure
80–90 psi (560–630 kPa, 5.6–6.3 bar) recommended regulated air inlet pressure
System
Model 224826
with Stainless Steel Pump*
Pump
Model 224825, Series A
Stainless Steel*
This pump is factory tested in oil. To avoid contami-
nating the masking liquid or the surface being
painted, flush the pump before immersing it in the
masking liquid. Use water only to flush. Paint sol-
vents will damage the seals. Follow the set-up
procedure carefully, and pay special attention to the
Flushing procedure on page 5.
CAUTION

2308069
Warnings
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 uncertain about usage, 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 system component. This equip-
ment has a 2700 psi (18.6 MPa, 186 bar) maximum working pressure.
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 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).
DDo not touch the heater during operation; it is very hot.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
INJECTION HAZARD
High pressure fluid from dispense device, hose leaks or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgi-
cal treatment.
DDo not point the dispensing device at anyone or at any part of the body.
DDo not put your hand or fingers over the fluid outlet.
DDo not stop or deflect leaks with your hand, body, glove, or rag.
DFollow Pressure Relief Procedure in this manual, when you stop dispensing and before cleaning,
checking or servicing equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

3308069
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.

4308069
Spray Gun Safety
Learn how to use the gun’s trigger safety
latch before operating the system.
The high pressure, airless spray gun supplied with this
system is equipped with a trigger safety latch. When
set, this latch prevents the gun from being triggered
accidentally. Read more about gun safety in the warn-
ing section, FLUID INJECTION on page NO TAG.
Set the trigger safety latch whenever you stop spray-
ing, even for only a minute, or if changing a tip.
TO RELEASE THE LATCH
FOR THE OFF SAFE, or
spraying position, gently
pull up on the latch and
turn it so it is parallel with
the gun body.
Fig. 1
TO SET THE LATCH IN
THE SAFE, or
non–spraying position,
turn it so it is at right
angles to the gun body.
7546A
7547A
Installation
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 as shown in
Fig. 2. 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.
2. Fluid hoses: use only electrically conductive
hoses.
3. Air compressor: follow manufacturer’s recommen-
dations.
4. Spray gun: obtain grounding through connection to
a properly grounded fluid hose and pump.
5. Fluid supply container: according to local code.
6. Object being sprayed: according to local code.
7. Any pails used when flushing: use only metal,
grounded pails when flushing. Make firm metal-to-
metal contact between a metal part of the spray
gun and a pail. Use the lowest pressure possible.
Y
Z
Fig. 2

5308069
Installation
Prepare for installation
You must supply the following equipment to complete
the installation of this system.
1. An adjustable wrench and a screwdriver.
2. A grounding wire and clamp for the air motor.
3. The compressed air supply, with a hose that easily
reaches the air regulator assembly.
4. Two 5 gallon flushing containers, one with warm
soapy water, and one with cool, clean water.
CAUTION
Do not use paint solvents to flush, which will damage
the pump seals.
Setup for initial flushing See Fig. 3.
5. Screw the air regulator assembly into the air inlet
of the motor.
6. Remove the quick disconnect coupler from the
nipple. To disconnect, pull back on the sleeve of
the coupler and pull it away from the nipple. Screw
the coupler onto the air line. Do not connect the air
line to the pump until you are instructed to in the
Initial flushing or OPERATION section.
7. Screw the swivel fitting of the spray hose onto the
pump outlet nipple, and tighten it securely with a
wrench.
8. Follow the grounding instructions in the Ground-
ing section on page 4.

6308069
Installation
Fig. 3
AIR REGULATOR & GAUGE
AIR LINE
QUICK DISCONNECT NIPPLE
QUICK DISCONNECT COUPLER
SPRAY HOSE
SPRAY GUN
RAC V
TIP GUARD
GROUND WIRE & CLAMP
purchase separately
OUTLET NIPPLE
7549A
Initial flushing
CAUTION
This pump is factory tested in oil. To avoid contami-
nating the masking liquid or the surface being
painted, flush the pump before immersing it in the
masking liquid.
1. Mount the pump in a 5 gallon pail of warm, soapy
water.
2. Be sure there is no spray tip in the gun. See Fig. 7
if the tip needs to be removed.
3. Set the trigger safety latch. See Fig. 1.
4. Be sure the air regulator handle is turned to zero
(fully left as you look at it).
5. Connect the air line to the pump.
6. Release the trigger safety latch.
7. Aim the gun into the flushing pail and squeeze the
gun trigger and hold it open.
8. Slowly open the air regulator until the pump is
running slowly and smoothly.
9. Using very low pressure, direct the spray from the
gun back into the flushing container. Circulate the
soapy water in this way for several minutes. Then
release the trigger, set the trigger safety latch, and
disconnect the air line to the pump.
10. Switch the pump to the clean container of water.
Connect the air line, release the trigger safety
latch, and repeat Step 9, above.
11. Raise the pump out of the pail. Trigger the gun to
force the water from the system. DO NOT run the
pump dry for more than 10 seconds to avoid
damaging the pump packings.

7308069
Installation
ÄÄ
ÄÄ
Fig. 4
AIR REGULATOR & GAUGE
AIR LINE
QUICK DISCONNECT NIPPLE
QUICK DISCONNECT COUPLER
SPRAY GUN
RAC V
TIP GUARD
GROUND WIRE & CLAMP
purchase separately
16 GALLON DRUM
Note how suction tube curls around the
sides and bottom of the drum.
Â
VENT HOLE
BUNG HOLE
DISPLACEMENT PUMP
HOSE CLAMP
SUCTION TUBE
STRAINER
DRAIN
VALVE
5 GALLON PAIL
BUNG ADAPTER
THUMBSCREW
7550A
Setup for operation
NOTE: Be sure the system has been thoroughly
flushed.
1. Loosen the hose clamp on the suction hose. Slide
the suction hose as far as possible onto the pump
intake valve.
2. Slide the clamp up and tighten its screw
snugly! A loose clamp prevents the pump from
getting adequate fluid supply, which results in low
fluid flow and/or spitting air from the gun.
3. Remove the bung cover from the drum and open
the vent hole.
4. Loosen the thumbscrew on the bung adapter.
5. Slide the suction hose and pump through the bung
hole in the drum cover. Before the final positioning
of the pump, screw the bung adapter firmly into the
bung hole. Now position the pump as follows.
a. For 55 gallon drums: slide the pump into the
drum until you sense that the strainer is at the
bottom of the drum. Tighten the thumbscrew
snugly.
b. For 16 gallon drums: slide the pump into the
drum and allow the suction hose to curl around
the side and rest on the bottom of the drum.
Tighten the thumbscrew snugly.
c. For 5 gallon demo pails: Remove the suction
hose and strainer. Install the accessory pail
cover, p/n 222058. Slide the pump into the pail
until the intake valve is 1/2” off the bottom of
the pail. Tighten the bung adapter thumbscrew
snugly.
NOTE: Go to Prime the system on page 9.

8308069
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
Fluid under high pressure can be in-
jected 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 tip.
1. Engage the gun’s trigger safety latch.
2. Close the air regulator and disconnect the air
supply hose.
3. Disengage the trigger safety latch. Hold a metal
part of the gun firmly to the side of a grounded
metal waste pail and trigger it to relieve the fluid
pressure.
4. Engage the trigger safety latch.
5. Place a pail under the drain valve and open the
drain valve to be sure all fluid pressure is relieved.
If you suspect that the tip guard or hose is clogged, or
that pressure has not been fully relieved after following
the steps above, very slowly loosen the tip guard
retaining nut or hose end coupling to relieve pressure
gradually, then loosen completely.

9308069
Operation
ÄÄ
Fig. 5
AIR REGULATOR & GAUGE
AIR LINE
QUICK DISCONNECT NIPPLE
QUICK DISCONNECT COUPLER
SPRAY
GUN
TIP GUARD
TIGHTEN TO
CLOSE
DRAIN VALVE DETAIL
Prime the system
1. Set the trigger safety latch. See Fig. 1.
2. Remove the spray tip from the gun, if it is installed.
See Changing spray tips on page 11.
3. Be sure the air regulator handle is turned to zero
(fully left as you look at it).
4. Connect the air line to the pump.
5. Release the trigger safety latch.
6. Hold a metal part of the gun firmly against and
aimed into a grounded metal pail. See Fig. 6.
Squeeze the gun trigger and hold it open.
Fig. 6
MAINTAIN FIRM
METAL-TO-METAL
CONTACT BETWEEN
GUN AND
GROUNDED METAL
CONTAINER
GROUND
WIRE
7. Slowly open the air regulator until the pump is
running slowly and smoothly.
8. Dispense about 1 pint of masking liquid to be sure
all air is pushed out of the system and the liquid
flows freely.
9. Release the trigger and set the trigger safety latch.
See Fig. 1.
10. Check all fluid connections for leaks; relieve pres-
sure before tightening connections.
Select a tip
Two tips are provided with the gun. The size is marked
on the cylinder handle. The size 621 tip comes in-
stalled in the tip guard. Each tip comes with a square
ring and a seal. Refer to Changing spray tips and
Fig. 7.
11. Use the 211 size tip for narrow surfaces such as
door jambs.
12. Use the 621 size tip for wide or large surfaces.

10 308069
Operation
Installing the spray tip
1. Be sure the trigger safety latch is engaged.
2. Install the tip cylinder. Hold the cylinder with the
arrow handle straight up. Push the cylinder into the
tip guard so the flange on the cylinder fits into the
slots at the base of the tip guard. See Fig 7. Then
turn the arrow handle in the direction of the tip
guard, which is the spraying position. See Fig. 8.
If the tip guard was removed from the gun and
you are are reinstalling it:
3. Be sure the seal and square ring are in place as
shown in Fig. 7. If not, place the seal on the end of
a pencil with the curved side out. Guide the seal
into the retaining nut and turn it until it straddles
the cylinder. Drop in the square ring and press it
down.
4. Screw the retaining nut snugly onto the gun,
holding the tip guard in the desired direction while
tightening the nut. See Step 4 of Adjusting the
spray pattern and spraying pressure on
page 12 for more information on adjusting the
direction of the spray pattern.
CAUTION
To avoid damaging the tip guard:
DNever use a wrench to turn the plastic tip guard,
which causes internal damage.
DNever hang the gun by the tip guard.
Fig. 7
TIP GUARD
TIP CYLINDER
ARROW HANDLE
RETAINING NUT
SEAL
SQUARE RING
FLANGE
curved side faces retaining nut
SLOT
TIP SIZE MARKED HERE

11308069
Operation
Changing spray tips
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. Rotate the arrow handle until it
is straight up. Pull out the tip. Install the new tip and
rotate it to the spraying position.
Clearing a clogged spray tip
WARNING
To reduce the risk of serious injury from fluid injec-
tion, use extreme caution when cleaning or chang-
ing spray tips. If the spray tip clogs while spraying,
set the trigger safety latch immediately, then follow
the procedure in Steps 1–5 at right.
Never wipe off buildup around the spray tip until
pressure is fully relieved and the trigger safety latch
is set.
Fig. 8
ARROW HANDLE
SHOWN IN THE
TIP CLEARING POSITION
ARROW HANDLE
SHOWN IN THE
SPRAYING POSITION
Rotate handle up and
toward back of the gun
then trigger the gun to
clear an obstruction.
7555A
7554
A
1. If the spray tip clogs, release the gun trigger, and
set the trigger safety latch.
2. Turn the arrow handle up and back toward the gun
body. See Fig. 8. Release the trigger safety latch.
Trigger the gun into a pail. This usually forces out
the obstruction. Set the trigger safety latch again.
Return the arrow handle to the spraying position.
3. Release the trigger safety latch and resume spray-
ing.
4. If the tip is still clogged, close the air regulator,
disconnect the air line, try triggering the gun into a
pail, and open the drain valve.
5. Remove the spray tip and clean it. Refer to manual
307848, supplied.
NOTE: Continue with Adjust the spray pattern and
spraying pressure on page 12.

12 308069
Operation
Adjusting the spray pattern and spraying
pressure. See Fig. 9.
NOTE: If the system is not primed, follow the proce-
dure on page 9.
1. Set up a large piece of paper or cardboard to
spray on for testing the spray pattern.
2. Release the trigger safety latch.
3. Aim the gun at the cardboard and trigger it briefly.
Check the spray pattern. Adjust the air pressure
just until spray from the gun is completely atom-
ized. 3M recommends 80 to 90 psi air pressure at
the air inlet gauge for the best results.
4. To adjust the direction of the spray pattern, set the
trigger safety latch and loosen the tip guard retain-
ing nut. See Fig. 7. Position the tip guard horizon-
tally for a horizontal pattern or vertically for a
vertical pattern. Retighten the retaining nut.
Practice spraying
Read the spray techniques in Steps 1–5, below and
Figs. 10 and 11, and follow 3M’s recommendations on
application of the masking liquid.
1. Begin triggering and moving gun just before first
edge of target surface. See Fig. 10.
2. Keep gun moving horizontally or vertically at a
steady rate.
3. Release trigger just as you approach other edge of
target surface, but keep gun moving until it has
passed the edge.
4. Hold the gun perpendicular (at right angles) to the
target surface. Hold the gun an even 12 to 14”
from the target surface. See Fig. 11.
5. Lap each stroke 50% over the previous stroke to
produce a uniform material thickness.
Fig. 9
SPOTTY
PATTERN
–
INCREASE
PRESSURE
GOOD
FULL
PATTERN
TIP GUARD SHOWN
IN POSITION FOR
VERTICAL PATTERN
7556A
ÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇ
Fig. 10
CORRECT
WRONG
TARGET
SURFACE
1. 2. 3.
7557A
Fig. 11
LAP EACH STROKE
50% OVER THE
PREVIOUS STROKE
TARGET SURFACE 12 TO 14” INCHES
KEEP GUN
PERPENDICULAR TO
TARGET SURFACE 7558
A

13308069
Maintenance
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.
1. Keep the pump and hose fully primed with the
masking liquid when it is not in use. This is done
by relieving the pressure.
2. Do not allow the supply container to be completely
emptied. If that happens, the pump will start to run
too fast and it could be damaged. If the pump
starts to run too fast, disconnect the air line imme-
diately. Prime the system with the masking liquid
(see page 9) or flush it as instructed in Weekly
flushing.
3. Lubricate the air motor daily. Disconnect the
regulator, place about 15 drops of light machine oil
in the pump air inlet, reconnect the regulator and
turn on the air supply to blow oil into the motor.
4. If fluid drips steadily from the air motor weep port,
or the pump requires more than 35 psi (240 MPa
2.4 bar) air pressure to cycle when the gun is
triggered, adjust the packing nut. See Packing nut
adjustment on page 14.
Weekly flushing
WARNING
Thorough flushing is required at the end of each
work week and before using a system that has
been stored. Flushing keeps a system free of dried
or aging material, such as discolored or jellied
material.
Equipment needed:
4 gallons warm water: use empty 3M container
5 gallon bucket for water
Cloth rags
1. Turn the air regulator handle to zero (fully left as
you look at it). Disconnect the air hose.
2. Remove the spray tip from the gun. See Fig. 7.
3. Pour 4 gallons of warm water into the empty 3M
container.
4. Move the pump to the flushing container.
5. Connect the air line to the pump.
6. Release the trigger safety latch.
7. Aim the gun into the flushing pail and squeeze the
gun trigger and hold it open.
8. Slowly open the air regulator until the pump is
running slowly and smoothly.
9. Using very low pressure, direct the spray from the
gun back into the flushing container. Circulate the
water in this way for several minutes. Then release
the trigger, set the trigger safety latch, and discon-
nect the air line to the pump.
10. Raise the pump out of the pail. Trigger the gun to
force the water from the system. DO NOT run the
pump dry for more than 10 seconds to avoid
damaging the pump packings.
11. Wash the exterior of the pump and all components
with a water and cloth. Scrub any dirty areas and
threads to remove residue.
12. Dry the pump and all components with a clean, dry
cloth.
NOTE: If you plan to use the pump again soon,
prime it with masking material.
If you plan to store the pump, continue as follows.
3. Flushing before storage
1. Flush as in Steps 1 to 11, above, but use warm,
soapy water.
2. Move the pump to a container of mineral
spirits.
CAUTION
Do not use paint solvents to flush, which will damage
the pump seals.
3. Trigger the gun into the flushing container. When
mineral spirits appear at the gun, release the
trigger and set the trigger safety latch. Remove the
pump.
4. Release the trigger safety latch. Trigger the gun to
force the mineral spirits from the system. DO NOT
run the pump dry for more than 10 seconds to
avoid pump packing damage.
5. Disconnect the hose and gun and store the pump.

14 308069
Maintenance
Pump 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. 12. 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, or (b) the pump requires
more than 35 psi (244 kPa, 2.4 bar) air pressure to
cycle when the gun is triggered, which indicates the
packings are too tight.
1. Relieve the pressure.
2. Remove the six screws (24) using a 1/4” nut driver.
Remove the muffler plate (20).
See Fig. 13.
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. 12.
4. Use a 1/4” diameter rod to tighten the packing nut.
First loosen the nut, then tighten snugly, and finally
tighten 1/4 turn more. See Fig. 14.
5. Replace the muffler cover, and the six screws.
See Fig. 13.
6. Reconnect the air line. After the pump is started, it
should run at 20 psi (1.5 bar) with no load. Startup
may require additional air pressure.
WEEP HOLE LOCATED
OPPOSITE FLUID OUTLET
AND IN BOTTOM OF BASE
Fig. 12
BASE
PISTON
PINCH POINT
FLUID
OUTLET
Fig. 13 24
20
BASE
Fig. 14
1/4” DIA. ROD
PACKING NUT

15308069
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.
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.
NOTE: Check all other possible problems and solutions
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

16 308069
Troubleshooting
PROBLEM CAUSE SOLUTION
Material drips steadily from weep
port in motor base Throat packing nut loose Tighten packing nut
Throat packing worn Replace packings
Pump chattering Packing nut too tight Loosen packing nut
Packing worn/material dried on I.D. of
packing Inspect/replace packings
Material dried on rod Clean or replace rod
Pump fails to prime No material Fill or replace container
Air leak between intake valve and
suction tube (55 gal. unit only) Tighten or replace clamp or hose
Material or other contamination on ball
seats Inspect and clean
Intake ball stuck Inspect, clean or replace
Inlet strainer plugged Clean strainer
* Relieve the pressure. Disconnect the fluid hose. If the pump starts when the air is turned on again, the hose or gun
is clogged.

17308069
Service
Before you start:
1. Have all necessary parts on hand. Always replace
the glands and bearing when replacing the packings.
Use all the parts in the repair kits for the best results
2. Air Motor Repair Kit 206728. Parts included in this
kit are marked with two asterisks, (i.e., 36**), in the
text and drawings.
3. Displacement Pump Repair Kit 235136. Parts in-
cluded in the kit are marked with one asterisk, (i.e.,
6*), in the text and drawings.
4. Always use Padded pliers, p/n 207579 to grip the
trip rod without damaging its surface. Use Gauge,
p/n 171818 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 and relieve the pressure.
2. Disconnect the hoses, remove the pump from its
mounting, and clamp the air motor base in a vise.
3. Use a strap wrench on the riser tube (12) to screw it
out of the air motor base (55).
4. Pull the connecting rod (10) down as far as it will go.
5. Use a hammer and punch to remove the roll pin (4).
Unscrew the connecting rod (10). See Fig. 15.
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, 207579, to grasp the rod.
6. Manually push up on the piston rod (41) to move the
piston assembly (59) up as far as it will go. Unscrew
the cap nut (47). Pull the nut up. Grip the trip rod (54)
with padded pliers and screw the nut off the rod. See
Fig. 15.
CAUTION
To avoid damaging the cylinder wall, lift the cylinder
straight up off of the piston. Never tilt the cylinder as
it is being removed.
7. Remove the six screws (25). See Fig. 15. Pull the cyl-
inder straight up off the piston (59).
8. Use a screwdriver to push down on the trip rod yoke
(28) and snap the toggles down. See Fig. 16.
9. Remove the lockwires (34**) from the adjusting nuts
(33**) of the transfer valves. Screw the top nuts off.
Screw the stems (45**) out of the grommets (32**)
and the bottom nuts (30). Take the valve poppets
(52**) off the stems and squeeze them firmly to
check for cracks. See Fig. 16.
WARNING
To reduce the risk of pinching or amputating your
fingers, always keep fingers clear of the toggle
assemblies (N).
10. Grip the pivot pins (30) with pliers. Compress the
springs (31) and swing the toggle assembly (N) up
and away from the piston lugs (L). Remove the parts.
Check to see that the valve actuator (35) is sup-
ported by the spring clips (58), but slides easily into
them. See Fig. 16.
11. Remove the trip rod yoke (28), actuator (35) and trip
rod (54). See Fig. 16. Check the exhaust valve pop-
pets (53**) for cracks. To remove the exhaust valve
poppets (53**), stretch them out and cut with a sharp
knife.
12. Remove one muffler plate (20 or 40). Pull the piston
(59) up out of the base. Remove the throat packing
nut (42) and packings. See Fig. 15.

18 308069
Service
Reassembly
1. Clean all the parts in a compatible solvent and in-
spect for wear or damage. Check the polished sur-
faces of the piston, piston rod and cylinder wall for
scratches or wear. A scored rod will cause premature
packing wear and leaking. Use all the repair kit parts
and replace other parts as necessary.
2. Lubricate all parts with a light, waterproof grease.
3. One at a time, install these parts in the base (55): the
gland (49*), alternately install three reinforced pack-
ings (48*) and two nitrile packings (72*) with lips fac-
ing 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. 15.
25
59
51
47
55
27
54
4*
10
41
43
*49
42
44*
50*
38
39**
V–PACKINGS:
SEE DETAIL
BELOW
*48
72*
LIPS OF V–PACKINGS
MUST FACE DOWN
Fig. 15

M
PUSH TOGGLES (M) IN
AND THEN UP
(SHOWN IN THE DOWN
POSITION HERE)
TURN WIRES UP
28
54 34**
33**
45**
52**
59 55
30
37
32**
L
53**
58
31
Fig. 16
33**
To remove
toggles,
Push IN,
Swing UP,
Ease OUT
19308069
Service
CUT OFF TOPS OF
POPPETS AS
INDICATED BY
DOTTED LINES
0.145”
(3.7 mm)
CUTAWAY VIEW
54
58
35
Fig. 17
52**
33**
32**
33*
*
45**
53**
59
36*
*
4. Install the poppets (52**) on the valve stems (45**).
Pull the exhaust valve poppets (53**) into the valve
actuator (35) and clip off the top part shown with dot-
ted lines. See Fig. 17.
5. Install the grommets (32**) in the valve actuator (35).
Install the trip rod (54) in the piston (59). Place the trip
rod yoke (28) and valve actuator (35) on the trip rod.
Be sure the o–ring (36*) is in place and that the valve
actuator is supported by the spring clips (58), and
then reassemble the valve mechanism. See Fig. 16.
6. Install the bottom adjusting nuts (33**) on the valve
stems (45**) and screw the stems into the grommets
(32**). Screw the top nuts (33**) on the stems.
Tighten the nuts (33) just enough to slightly
compress the grommet (32). Before installing the
lockwires (34**) in the adjusting nuts, use the special
gauge 171–818 to adjust the transfer valve so there
is 0.145 in. (3.7 mm) clearance between the poppets
(52**) and the seat when it is open. See Fig. 17.
WARNING
To reduce the risk of pinching or amputating your
fingers, always keep your fingers clear of the toggle
assemblies.
7. Install the springs (31) and pivot pins (30) on the
toggle arms (37). Snap the toggles to the up position.
Refer to Fig. 16.
8. Carefully lower the cylinder (51) over the piston (59)
and onto the base (55). Secure with the six screws
(25).
9. Manually push on the piston rod (41) to move the pis-
ton (59) up as far as it will go. Grip the trip rod (54)
with padded pliers and screw the cylinder cap nut
(47) onto the trip rod. Pull the piston rod (41) to move
the piston downward. Be sure the o–ring (27) is in
place at the top of the cylinder (51), and then screw
the cap nut into the cylinder.
10. Screw the connecting rod (10) into the piston rod (41)
and secure with the pin (4*). Screw the riser tube (12)
into the base (55).
11. Install the muffler plates (20,40). Tighten the throat
packing nut (42) just until snug.
12. Connect an air hose and run the pump slowly [about
30 psi (2.1 bar)] to see that it operates smoothly.
13. Remount the pump and reconnect the ground wire.

20 308069
Displacement Pump Service
Before you start:
1. Have all necessary parts on hand. Whenever you re-
place the packings, also replace the glands and
bearing. If you are using a repair kit, use all the parts
for the best results.
2. Displacement Pump Repair Kit 235–136 includes
repair parts for the pump throat and piston. Parts in-
cluded in the kit are marked with one asterisk, for ex-
ample (6*), in the text and drawings.
3. To replace the throat packings, which are included in
Repair Kit 206–924, refer to the Air Motor and
Throat Disassembly on page 17.
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 and relieve the pressure before
proceeding.
2. Disconnect the hoses, remove the pump from its
mounting, and clamp the air motor base in a vise.
3. Unscrew the intake valve body (22) from the riser
tube (12). See Fig. 18. Disassemble the intake
valve.
4. 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. 18.
5. 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 ir-
regular surfaces. Such damage causes premature
packing wear and leaking, so replace the part if dam-
aged.
6. 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 re-
move the press–fit brass bearing (15*). See Fig. 18.
NOTE: If the pressure–fit brass bearing (15*) needs to
be replaced, clamp it in a vise and drive the pis-
ton body (13) out with a plastic hammer. The new
bearing must be started onto the piston body
squarely.
7. Clean and inspect the parts and replace any that are
worn or damaged. Be sure to check the copper gas-
ket (46) in the motor base (55). Lubricate the parts
with a light waterproof grease.
8. 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 reversed, if
needed, to provide a new seat. Screw the piston
body (13) into the piston coupling (14).
9. Screw the riser tube (12) into the air motor base (55).
10. 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).
11. Be sure the ground wire is connected before regular
operation of the pump.