Graco Falcon A Series User manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 2000, Graco Inc. is registered to I.S. EN ISO 9001
50:1 RATIO DOUBLE ACTING
FalcontGrease Pumps
For lubricating products only
7500 psi (52 MPa, 517 bar) Maximum Fluid Working Pressure
150 psi (1.0 MPa, 10 bar) Maximum Air Input Pressure
Model 244044, Series A
35 lb (16 kg) Pail Size
Model 244045, Series A
120 lb (55 kg) Drum Size
Model 244046, Series A
400 lb (180 kg) Drum Size
U.S. Patent No. 5,147,188
309224D
Read warnings and instructions.
See page 2 for table of contents.
8757C
Parts

2 309224
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart 12. . . . . . . . . . . . . . . . . . . . . . . . .
Service 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions and Mounting Hole Layout 29. . . . . . . . . . .
Performance Charts NO TAG. . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 32. . . . . . . . . . . . . . . . . . . . . .
Graco Information 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
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 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 66_C (150_F) or below –40_C (–40_F).
DWear hearing protection when operating this equipment.
DDo not move or lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
DThese pumps are designed to be used only in pumping non-corrosive and non-abrasive lubricants
and greases. Any other use of the pump can cause unsafe operating conditions and component
rupture, which can result in fluid injection or other serious injury, or fire or explosion.

3309224
WARNING
INJECTION HAZARD
Fluid dispensed from the 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.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
DDo not point the valve at anyone or at any part of the body.
DDo not put your hand or fingers over the spray nozzle.
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/valve when dispensing.
DBe sure the valve trigger safety operates before dispensing.
DLock the valve trigger safety when you stop dispensing.
DFollow the Pressure Relief Procedure on page 10 if the nozzle clogs and before cleaning, check-
ing or servicing the equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
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 10 to
prevent the equipment from starting unexpectedly.

4 309224
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and re-
sult in a fire or explosion and serious injury.
DGround the equipment and the object being dispensed to. Refer to Grounding on page 6.
DIf there is any static sparking or you feel an electric shock while using this equipment, stop dis-
pensing 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 dispense area free of debris, including solvent, rags, and gasoline.
DDo not smoke in the dispense area.
DDo not turn on or off any light switch in the dispense area while dispensing or while operating if
fumes are present.
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.
DThe air motor exhausts any fluids added to the input air, such as oil or antifreeze.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

5309224
Introduction
WARNING
These pumps area designed to be used only in
pumping non-corrosive and non-abrasive lubricants
and greases. Any other use of the pump can cause
unsafe operating conditions and component rup-
ture, which can result in fluid injection or other
serious injury, or fire or explosion.
NOTE: Be sure that all operators read and understand
this entire manual and any separate manuals supplied
with components and accessories before using this
equipment.
NOTE: Reference numbers and letters used in the text
refer to the callouts in the figures and the parts dra-
wing.
Terms
WARNING: Alerts the user to avoid or correct condi-
tions that could cause serious injury.
CAUTION: Alerts the user to avoid or correct condi-
tions that could cause damage to or destroy equip-
ment.
NOTE: Identifies helpful procedures and information.
DISPENSE VALVE: Any fluid dispensing device that
can be triggered on and off.
Component Description
This equipment consists of two major components: the
air motor (1) and the displacement pump. See Fig. 1 .
The pump is an in-line design, which means that the
displacement pump screws directly into the motor,
without the use of tie rods or couplers. The displace-
ment pump can be placed directly in the fluid being
pumped.
The pump is available in three different lengths, based
on the size of the fluid container. Refer to the front cov-
er for available sizes. The pumps differ only in length;
operation and packings are the same. All three pumps
use the same Air Motor.
Make sure the muffler (36) is securely installed in the
exhaust port (N) before you operate the pump. See
Fig. 1.
CAUTION
Never run the pump without the muffler installed.
8757C
1
Fig. 1
N
36

6 309224
Installation
NOTE: Always use Genuine Graco Parts and Acces-
sories, available from your Graco distributor.
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE OR EXPLOSION
HAZARD on page 4.
Ground all of this equipment:
DPump: Remove ground screw (Z) and insert
through the eye of the ring terminal at the end of
ground wire (Y). Fasten ground screw back onto
the pump and tighten securely. Connect the other
end of the wire to a true earth ground. See Fig. 2.
Order part number 222011 Grounding Clamp and
Wire.
DFluid hoses: Use only grounded fluid hoses.
DAir hoses: Use only grounded air hoses.
DDispensing Valve: Obtain grounding through
connection to a properly grounded fluid hose and
pump.
DFluid supply container: Follow your local code.
DAir compressor: Follow your local code.
DTo maintain grounding continuity when flushing or
relieving pressure, hold a metal part of the spray
gun firmly to the side of a grounded metal pail, then
trigger the gun.
Fig. 2
Y
Z
TI1052

7309224
Installation
The Typical Installation shown in Fig. 3 is only a guide for selecting and installing system components and
accessories. Contact your Graco distributor for assistance in designing a system to suit your particular needs.
If you supply your own accessories, be sure they are adequately sized and pressure-rated to meet the system’s
requirements. See the Maximum Working Pressure warning on page 8.
Fig. 3
KEY
APump
BBleed-type master air valve (required, Part No. 110224)
CAir regulator
DAir hose
EAir line quick disconnect
FAir line filter
GBleed-type master air valve (for accessories, Part No. 110224))
HMain air line
JGun holder
KFollow plate
LFluid hose
MDispense valve
YGround wire (required, Part No. 222011)
The pump intake
should be no more
than 1/2 in. (13 mm)
off the bottom of the
fluid container.
1
A
BC
8758B
D
E
FG
H
J
K
L
M
Y
1

8 309224
Installation
Mounting the Pump
1. Select a convenient location for the equipment, to
ensure easy operator access to the pump air
controls, sufficient room to change supply contain-
ers, and a secure mounting platform.
2. If using a follow plate (K), remove the fluid contain-
er cover. To prevent air from being trapped under
the follow plate, scoop grease from the center of
the container to the sides, to make the surface
concave. Place the follow plate on the grease and
push down on the plate until grease appears at the
center opening (P). See Fig 4.
02050
K
Concave Surface
Push Down
on Plate
3
P
2
33
2
Fig. 4
3. Guide the pump intake valve through the cover
and follow plate. Secure the cover to the container.
4. Position the pump (A) so its intake valve is no
more than 1/2 in. (13 mm) from the bottom of the
container. Mount the pump to the cover or other
suitable mounting device.
WARNING
Mount the pump securely so that it cannot move
around during operation. Failure to do so could
result in personal injury or equipment damage.
System Accessories
WARNING
Maximum Working Pressure
The maximum working pressure of each compo-
nent in your system may not be the same. To
reduce the risk of overpressurizing any part of your
system, be sure you know the maximum working
pressure rating of each component. Never exceed
the maximum working pressure of the lowest rated
component connected to a pump. Use the following
table to limit the air to the pump so that no air line
or fluid line component or accessory is overpres-
surized.
Approximate
Air Inlet Pressure Fluid Outlet Pressure
psi (MPa, bar) psi (MPa, bar)
40 (0.28, 2.8) 2000 (14, 140)
60 (0.42, 4.2) 3000 (21, 210)
80 (0.56, 5.6) 4000 (28, 280)
100 (0.7, 7.0) 5000 (35, 350)
120 (0.84, 8.4) 6000 (42, 420)
140 (0.98, 9.8) 7000 (49, 490)
150 (0.9, 10) 7500 (52, 517)

9309224
Installation
WARNING
A bleed-type master air valve is required in your
system to help reduce the risk of serious injury,
including splashing in the eyes or on the skin, and
injury from moving parts if you are adjusting or
repairing the pump.
The bleed-type master air valve relieves air trapped
between this valve and the pump after the air is
shut off. Trapped air can cause the pump to cycle
unexpectedly. Locate the valve close to the pump.
1. Install a bleed-type master air valve (B), to relieve
air trapped between the valve and the motor. See
the WARNING above).
2. Install an air regulator (C), to control the pump
speed and pressure.
3. Install an air line filter (F) to remove harmful dirt
and moisture from the compressed air supply.
4. Install a second bleed-type master air valve (G)
upstream from all other accessories, to isolate the
accessories for servicing.
5. Connect the fluid hose (L) to the dispense
valve (M). Use a gun holder (J) to hold the dis-
pense valve when not in use.
6. For ease in connecting the air line to the pump,
use an air line quick disconnect (E) at the pump air
inlet.
7. Connect the air (D) and fluid hoses (L) to the pump
(A). Use only grounded fluid and air hoses. Be
sure all hoses are properly sized and pressure-
rated for your system.
NOTE: Additional air line lubrication is not required to
extend the Falcontgrease pump air motor life. The
air motor is prelubed at the factory and should not
require additional lubrication between maintenance
schedules. No accessory air line lubricator should be
installed.

10 309224
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
Fluid under high pressure can be in-
jected through the skin and cause seri-
ous injury. To reduce the risk of an injury
from injection, splashing fluid, or moving parts, fol-
low the Pressure Relief Procedure whenever you
DAre instructed to relieve the pressure
DStop dispensing
DCheck or service any of the system equipment
DInstall or clean the spray tips/nozzles
1. Close the pump air regulator.
2. Close the bleed-type master air valve (required in
your system).
3. Hold a metal part of the dispensing valve firmly to
the side of a metal waste container, and trigger the
valve to relieve fluid pressure.
If you suspect that the spray tip or hose is completely
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 and relieve
pressure gradually, then loosen completely; then clear
the tip or hose.
Flushing
The pump is tested with lightweight oil, which is left in
to protect the pump parts. If the fluid you are using
may be contaminated by the oil, flush it out with a
compatible solvent before using the pump.
WARNING
For your safety, read the warning section
FIRE AND EXPLOSION HAZARD on
page 4 before flushing, and follow all
the recommendations given there.

11309224
Operation
Starting and Adjusting the Pump
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
1. Close the pump regulator and the bleed-type
master air valve.
2. Point the dispense valve into a grounded metal
waste container, making firm metal-to-metal con-
tact between the valve and the container. Open
the dispense valve.
3. Open the bleed-type master air valve. Open the air
regulator slowly, until the pump just starts running.
4. Run the pump until it is primed and all air has been
pushed out of the fluid line, then close the dis-
pense valve. The pump will stall against the pres-
sure. With the pump and lines primed, and with
adequate air pressure and volume supplied, the
pump will start and stop as the dispensing valve is
opened and closed.
NOTE: If the pump is difficult to prime, relieve the
pressure and remove the hose. Prime the pump
alone, then reconnect the hose and continue to
prime your system.
5. Use the air regulator to control the pump speed
and the fluid pressure. Always use the lowest air
pressure necessary to get the desired results.
Higher pressures cause premature nozzle and
pump wear. Never overpressurize any component
in the system. See the Maximum Working Pres-
sure warning on page 8.
6. Never allow the pump to run dry of the fluid being
pumped.
CAUTION
A dry pump quickly accelerates to a high speed,
possibly damaging itself. 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, refill
the container and prime the pump and the lines with
fluid, or flush and leave it filled with a compatible
solvent. Be sure to eliminate all air from the fluid
system.
7. Read and follow the instructions supplied with
each component in your system.
Shutting Down the Pump
Before you shut down the pump, follow all the steps of
the Pressure Relief Procedure at left.

12 309224
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
Before servicing this equipment, always make sure to
relieve the pressure.
NOTE: Check all possible problems and solutions
before disassembling the pump.
PROBLEM CAUSE SOLUTION
Pump fails to operate. Inadequate air supply pressure or restricted
air line.
Increase air supply (see Technical Data on page
NO TAG).
See Maximum Working Pressure warning on page 8.
Clear line.
Closed or clogged air valves. Open valves; clean.
Obstructed fluid hose or gun/valve;
fluid hose ID is too small.
Open, clear.* Use hose with larger ID, or use shorter
hose.
Dirty, worn, or damaged air motor parts. Clean or repair; see pages 20 to 25. Lubricate with
grease.
Obstructed priming tube. Open, clear.
Pump operates, but out-
put low on both strokes.
Inadequate air supply pressure or restricted
air line.
Increase air supply (see Technical Data on page
NO TAG).
See Maximum Working Pressure Warning on page 8.
Clear line.
Closed or clogged air valves. Open valves; clean.
Obstructed fluid hose or gun/valve;
fluid hose ID is too small.
Open, clear.* Use hose with larger ID, or use shorter
hose.
Exhausted fluid supply. Refill and reprime or flush.
Air leaking into supply container. Check follow plate or inductor plate seal.
Fluid too heavy for pump priming. Use inductor or follow plate.
Worn seals in displacement pump. Replace seals. See page 18.
Pump operates, but out-
put low on downstroke.
Fluid too heavy for pump priming. Use inductor or follow plate.
Held open or worn intake valve or seal (105). Clear valve; replace seal. See page 18.
Pump operates, but out-
put low on upstroke.
Held open or worn piston valve or seal (103). Clear valve; replace seal. See page 18.
Erratic or accelerated
pump speed.
Exhausted fluid supply. Refill and reprime or flush.
Fluid too heavy for pump priming. Use inductor or follow plate.
Held open or worn piston valve or seal (103). Clear valve; replace seal. See page 18.
Held open or worn intake valve or seal (105). Clear valve; replace seal. See page 18.
* Relieve the pressure, and disconnect the fluid hose. Turn on the air. If the pump starts when the air is turned on, the clog is in
the fluid hose or dispense valve.

13309224
Troubleshooting
PROBLEM CAUSE SOLUTION
Continuous air exhaust
from muffler.
Worn or damaged motor piston o-ring (32). Inspect and replace. See page 21.
Air cup (7) not seating properly, or damaged. Inspect; reseat or replace. See page 24.
Continuous air exhaust
from pilot valve vent
holes.
Worn or damaged carriage spool
u-cups (3c).
Inspect and replace. See page 24.
Worn or damaged actuator valve pin o-rings
(23).
Inspect and replace. See page 21.
Air motor not shifting
properly; erratic opera-
tion/stalling.
Worn or damaged actuator valve pin o-rings
(23, top or bottom).
Inspect and replace. See page 21.
Damaged actuator valve springs (16, top or
bottom).
Replace. See page 21.
Worn or damaged carriage spool u-cups
(3c). (Characterized by continuous air leak-
age from actuator valve vents.)
Inspect and replace. See page 24.
Clogged or obstructed valve porting. Clean.
Worn out valve housing (3a). Replace. See page 24.
Improper seating or damaged port or valve
housing o-rings (21, 30).
Inspect o-ring and groove. Clean or replace as neces-
sary.
Air leaking from base vent
hole.
Worn or damaged low pressure u-cup seal
(19).
Inspect and replace. See page 20.
Fluid leaking from base
vent hole.
Worn or damaged high pressure u-cup seal
(20).
Inspect and replace. See page 20.

14 309224
Service
Repair Kit 244159
Repair Kit 244159 is available to service the displace-
ment pump and air motor. Purchase the kit separately.
For the best results, use all new parts in the kit. Parts
included in the kit are denoted with an asterisk, for
example (3*). The kit also contains one tube of sealant
113500. Refer to the text and the notes in the figures
for sealant application instructions.
Required Tools
The following tools are required to service the pump:
DVise, with soft jaws
DPipe wrench
DSnap-ring pliers
DNeedle-nose pliers
DHammer
D3/32 in. punch
DO-ring pick
D9/32 in. or 7 mm socket wrench or nut driver
D3/8 in. or 10 mm box wrench
D7/16 in. or 11 mm box wrench
D1/2 in. or 13 mm box wrench
D5/8 in. or 16 mm box wrench
D1–1/16 in. or 27 mm socket wrench or crow’s foot
DAdjustable wrench
DTorque wrench
DPhillips screwdriver
DThread sealant 113500
(included in Repair Kit 244159)

15309224
Displacement Pump Service
Disconnecting the Air Motor
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
1. Relieve the pressure. Disconnect the fluid hoses
and remove the pump from its mounting.
2. Remove the retaining ring (43) and slide the
mounting plate (44) off the pump. See Fig. 5.
3. Place the pump in a vise with soft jaws, with the
jaws on the cylinder (101). Unscrew the intake
cylinder (110) from the pump cylinder (101). See
Fig. 6.
4. Use a pipe wrench on the lower part of the outlet
housing (18) to loosen the air motor (1) from the
cylinder (101). See Fig. 5.
5. Continue to screw the motor (1) off the cylinder
(101) by hand, until the pin (112) joining the dis-
placement rod (17) with the connecting rod (102) is
accessible. Use a punch to drive the pin (112) out
of the rods (17 and 102) See Fig. 7.
6. Hold the air motor (1) to prevent it from falling
when performing this step. Using a wrench on the
nut (109), unscrew the connecting rod (102) form
the displacement rod (17) to release the motor.
See Fig. 8.
7. To service the displacement pump, refer to pages
18 and 19. To service the air motor, including the
throat packings, refer to pages 20 to 25.
1Apply 113500 sealant
to threads when
reassembling.
Fig. 5
43
44
101
110
1
8763C
1

16 309224
Displacement Pump Service
Fig. 6
Fig. 7
Rotate the cylinder (101) 90 degrees so the hole is up.
Run a punch through the hole in the cylinder to drive the
pin (112) out.
101
18
8762C
101
112
8764C
17
102

17309224
Displacement Pump Service
Reconnecting the Displacement Pump
NOTE: Before connecting the displacement pump to
the motor, check that a new copper gasket (39) is
inserted in the outlet housing (18).
1. Place the displacement pump in a vise, with the
jaws on the pump cylinder (101). Position the air
motor (1) so the displacement rod (18) engages
the threads of the connecting rod (102). Using a
wrench on the nut (109), screw the connecting rod
into the displacement rod until the pin holes align.
See Fig. 8.
2. Install the pin (112*) in the hole to secure the two
rods (17 and 102) together. Make sure the pin is
flush or below the surface of the rod (17). Screw
the motor (1) onto the cylinder (101) by hand. See
Fig. 7.
3. Use a pipe wrench on the lower part of the outlet
housing (18) to securely tighten the motor (1) to
the cylinder (101). See Fig. 6.
4. Apply thread sealant (113500*) and screw the
intake cylinder (110) onto the pump cylinder (101).
See Fig. 5.
5. Remove the pump from the vise. Reinstall the
mounting plate (44) and secure with the retaining
ring (43).
6. Mount the pump. Reconnect the air and fluid
hoses and return the pump to service.
2Check that a new gasket (39) is
inserted in the outlet housing (18)
before connecting the motor to
the displacement pump.
Fig. 8 8765C
109
102 17
1
101
18 2

18 309224
Displacement Pump Service
Disassembly
1. Remove the air motor cover (69)..
2. Disconnect the displacement pump from the air
motor (1), as explained on page 15.
3. Unscrew the packing retainer (106) from the pump
cylinder (101). Pull the entire pump assembly out
of the bottom of the cylinder. See Fig. 9.
4. Drive the pin (112) out of the connecting rod (102)
and piston (104). Unscrew the piston from the rod.
Slide the seal (103) off the piston.
5. Drive the pin (112) out of the piston (104) and
priming piston rod (107). Unscrew the rod.
6. Slide the intake seal (105) off the rod (107). This
may be difficult because there is friction between
the seal and rod.
7. Slide the packing retainer (106) off the rod (107).
Remove the o-ring (111) from the packing retainer.
8. Examine the o-ring (111) and priming piston (108)
for scoring or damage. It is normal for the piston to
show some movement on the rod. If either parts
needs replacement, go to step 9.
9. If the rod (107) or the priming piston (108) needs
to be replaced, insert a punch in the pin hole at the
top of the rod to hold it steady. Unscrew the nut
(109), and remove the priming piston. If 107 or
108 do not need to be replaced, leave
assembled.
Reassembly
1. If the priming piston (108) was removed from the
priming piston rod (107), reinstall it on the bottom
threads of the rod (the end without a pin hole) and
secure with the nut (109). Torque to 35 to 45 in-lb
(4.0 to 5.1 N-m). Lubricate the rod. See Fig. 9.
2. Lubricate the o-ring (111*) and install it on the
packing retainer (106). Slide the retainer onto the
rod (107), with the o-ring at the top. Lubricate the
intake seal (105*) and slide it onto the rod, with the
flat side facing the packing retainer. There should
be friction between the seal and the rod. If there is
very little or no friction, replace the rod or the seal.
It is not necessary to slide the seal all the way
down to the retainer.
3. Screw the piston (104) onto the rod (107) until the
pin holes align. Install the pin (112*). Be sure that
the pin is flush or below the surface of the piston
on both sides.
4. Lubricate the seal (103*) and install it on the piston
(104), with the large bevel facing the piston.
5. Screw the connecting rod (102) onto the piston
(104) until the pin holes align. Install the pin (112*).
Be sure that the pin is flush or below the surface of
the connecting rod on both sides.
6. Lubricate the inside of the cylinder (101). Slide the
rod assembly into the bottom of the cylinder. There
may be a lot of friction, but do not use a hammer
or rubber mallet to drive the assembly, to avoid
damaging the parts.
7. Screw the packing retainer (106) into the cylinder
(101). Using a socket wrench or crow’s foot
wrench, torque to 15 to 20 ft-lb (20 to 27 N-m).
8. Continue to push the rod assembly up as far as
possible. Reconnect the displacement pump to the
air motor (1) as explained on page 15.

19309224
Displacement Pump Service
Fig. 9
101
109
108
107
111*
105*
106
104
*103
102 (REF)
102
107 (REF)
2
3
4
Torque to 15 to 20 ft-lb (20 to 27 N-m).
Lubricate.
Torque to 35 to 45 in-lb (4.0 to 5.1 N-m).
5
Assemble pin (112*) flush or below surface.
Flat side must face retainer (106).
6
Large bevel must face piston (104).
7Lubricate inside diameter.
01971
1
7
25 4
2
2
2
2
6
3
1
112*

20 309224
Air Motor Service
Throat Packing Service
Disassembly
1. Remove the air motor cover (69).
2. Disconnect the air motor (1) from the displacement
pump, as explained on page 15.
3. Remove the three screws (29) holding the outlet
housing (18) to the bottom cylinder cap (4). Pull
the housing off the cap, being careful not to dam-
age the piston rod (17). See Fig. 10.
4. Remove the u-cup packing from the cap (4).
5. Remove the copper gasket (39) and the u-cup
packing (20) from the outlet housing (18).
Reassembly
1. Lubricate the u-cup packing (19*) and install it in
the bottom cylinder cap (4), with the lips facing up
toward the air motor (1). See Fig. 10.
2. Grease and install the u-cup packing (20*) and the
copper gasket (39*) in the outlet housing (18). The
lips of the u-cup must be facing down, toward the
pump.
3. Install the housing (18) on the cap (4).
4. Reconnect the air motor (1) to the displacement
pump, as explained on page 15.
5. Replace the air motor cover (69).
Fig. 10
1
2Lips face up, toward air motor (1).
Lips face down, toward pump.
3
Lubricate.
4
19*
18
20*
39*
17
29
1
2
1
13
8761C
69
70