Graco Fire-Ball H Series Operation manual

INSTRUCTIONS–P ARTS LIST 306–517
Rev. S
Supersedes P
and PCN R
50:1 Ratio Fire-Ball  Pumps
FOR LUBRICA TING PRODUCTS ONL Y
8000 psi (560 bar) Maximum Fluid Working Pressure
160 psi (11 bar) Maximum Air Working Pressure
CHASSIS LUBE PUMPS
With Lifetime Guarantee*
1. This guarantee is of fered to the original purchaser for his
entire lifetime. It covers all Fire-Ball and President Series
lubrication pumps manufactured by Graco Inc., USA,
when used in pumping non-corrosive and non-abrasive
lubricants and greases.
2. Graco will repair or replace such pumps free of charge
when inspection by Graco reveals defective materials or
workmanship. Normal wear of packings and seals is not
considered to be defective workmanship.
3. Graco will repair or replace such pumps at a reasonable
charge if inspection by Graco reveals that damage was
the result, in whole or in part, of causes other than defec -
tive materials or workmanship.
4. Pumps for which guarantee claims are made must be
returned prepaid to the factory , factory branch or service
agency accompanied by proof of purchase, establishing
the owner as the original purchaser .
5.
The foregoing is in lieu of all other warranties, expressed
or implied, and the manufacturer neither assumes nor
authorizes any person to assume for it any other obliga -
tion or liability in connection with said equipment.
*30 years to corporations and purchasers other than natural
persons. See page 6 for available models.
WARNING
These systems are designed to be used only in
pumping non-corrosive and non-abrasive lubricants
and greases. Any other use of the system can
cause unsafe operating conditions and result in
component rupture, fire, or explosion, which can
cause serious injury , including fluid injection.
04188
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1995, GRACO INC.
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE

 
Table of Contents
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional Drawings 6. . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Guide 10. . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Service 11. . . . . . . . . . . . . . . . . . . .
Air Motor and Throat Service 13. . . . . . . . . . . . . . . . . . .
Parts 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Kits 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco W arranty 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco T oll-Free Phone Numbers 20. . . . . . . . . . . . . . . .
Terms
Be sure you read and understand each of these terms
before reading the rest of the manual.
NOTE: Gives additional information or helpful hints.
DISPENSE: T o release fluid through the dispensing
valve, which allows the fluid to flow out in a steady or
metered stream.
DISPENSING V ALVE: Any fluid dispensing device
which can be triggered on and of f.
FLEXIBLE NOZZLE: A flexible rubber hose which ex -
tends from the dispense valve to a non-drip tip. Nor -
mally used for dispensing automatic transmission fluid.
RIGID NOZZLE: A rigid tube which extends from the
dispense valve to a non-drip tip. Normally used for dis -
pensing motor oil, gear oil, etc.
NON-DRIP TIP: A manually operated twist-type valve
tip used to stop flow from the dispense nozzle when
dispensing is completed.



Symbols
Warning Symbol
WARNING
his symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury .
 This equipment is for professional use only .

Read all instruction manuals, tags, and labels before operating the equipment.
 Use the equipment only for its intended purpose. If you are not sure, call Graco T echnical Assis -
tance at 1–800–543–0339.
 Do not alter or modify this equipment.
 Check equipment daily . Repair or replace worn or damaged parts immediately .

Do not exceed the maximum working pressure of the lowest rated component in your system.
This equipment has a 8000 psi (560 bar) maximum working pressure at 160 psi (1 1 bar)
maximum incoming air pressure.
 Use 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 warn -
ings.

Handle hoses carefully . Do not pull on hoses to move equipment.
 Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex -
pose Graco hoses to temperatures above 82  C (180  F) or below –40  C (–40 F).

Do not lift pressurized equipment.
 Comply with all applicable local, state, and national fire, electrical, and safety regulations.
WARNING
WARNING

4 306-517
TOXIC FLUID HAZARD
Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, inhaled, or swallowed.
 Know the specific hazards of the fluid you are using.
 Store hazardous fluid in an approved container . Dispose of hazardous fluid according to all local,
state and national guidelines.
 Always wear protective eyewear , gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer .
INJECTION HAZARD
Spray from the dispensing valve, leaks or ruptured components can inject fluid into your body and
cause extremely serious injury , including the need for amputation. Fluid splashed in the eyes or on
the skin can also cause serious injury .
 Fluid injected into the skin might look like just a cut, but it is a serious injury . Get immediate
medical attention.

Do not point the dispensing valve at anyone or at any part of the body .

Do not put your hand or fingers over the end of the dispensing valve.
 Do not stop or deflect leaks with your hand, body , glove or rag.
 Use only extensions and no-drip tips which are designed for use with your dispensing valve.
 Do not use a low pressure flexible nozzle with this equipment.
 Follow the Pressure Relief Procedure on page 9 if the grease fitting coupler clogs and before
cleaning, checking or servicing the equipment.
T ighten all fluid connections before operating the equipment.
 Check the hoses, tubes, and couplings daily . Replace worn or damaged parts immediately . Do
not repair high pressure couplings; you must replace the entire hose.
 Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
WARNING
WARNING



MOVING P ARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
 Do not operate the pump with the air motor plates removed.
 Keep clear of all moving parts when starting or operating the pump.
 Before servicing the equipment, follow the Pressure Relief Procedure on page 9 to prevent the
equipment from starting unexpectedly .
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury
.

Ground the equipment and the object being sprayed. Refer to Grounding on page 8.
 If there is any static sparking or you feel an electric shock while using this equipment, stop
spraying immediately . Do not use the equipment until you identify and correct the problem.
 Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
 Keep the spray area free of debris, including solvent, rags, and gasoline.
 Before operating this equipment, electrically disconnect all equipment in the spray area.
 Before operating this equipment, extinguish all open flames or pilot lights in the spray area.
 Do not smoke in the spray area.
 Do not turn on or of f any light switch in the spray area while spraying or while there are any
fumes in the air .

Do not operate a gasoline engine in the spray area.
WARNING
WARNING

 
Dimensional Drawings
Model 203–868, Series H
400 lb drum size,
buna-N packings
Model 203–869, Series H
120 lb drum size,
buna-N packings
Model 207–609, Series D
50 lb pail size,
buna-N packings
Model 221–034, Series A
400 lb drum size,
P
TFERpackings
Overall length:
45.4” (1 153.2 mm)
Overall length:
38.4” (975.4 mm)
Overall length:
31” (787.4 mm)
Overall length:
45.4” (1 153.2 mm)
33.6”
(853.4 mm)
26.7”
(678.2 mm)
17.5”
(444.5 mm)
Grndg
Lug
1/4 npt(f)
Fluid
Outlet
Grndg
Lug Grndg Lug
1/4 npt(f)
Fluid
Outlet
1/4
npt(f)
Fluid
Outlet
3/8
npt(f)
Air
Inlet
3/8
npt(f)
Air
Inlet
3/8
npt(f)
Air
Inlet
04190
33.6”
(853.4 mm)
Grndg
Lug
1/4 npt(f)
Fluid
Outlet
3/8
npt(f)
Air
Inlet
0418904190 04188
Mounting Hole
Layout
161–023 Gasket
Two or Four
0.265” (7 mm)
Dia. Holes on 5”
(127 mm) Bolt Circle
3” (76.2 mm) Dia.
04127
2 Hole Mounting
Pattern 4 Hole Mounting Pattern
Technical Data
Maximum W orking Pressure 8000 psi (560 bar) . . . . . .
Fluid pressure ratio 50:1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Air operating range 40 to 160 psi (3 to 1 1 bar). . . . . . . .
Air consumption 19 cfm (0.532 m #/min). . . . . . . . . . . . . .
at 0.25 gpm (0.95 liter/min)
at 100 psi (7 bar)
Pump cycles per gallon 304. . . . . . . . . . . . . . . . . . . . . . .
Pump cycles per liter 80. . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum recommended pump speed 76 cycles/min .
0.25 gpm (0.95 liter/min)
W etted parts Steel, Brass, Aluminum, . . . . . . . . . . . . . . .
Nylon, Nitrile rubber
Approximate weight 22 lb (10 Kg) . . . . . . . . . . . . . . . . . .
TeflonR is a registered trademark of the DuPont Co.
LoctiteR is a registered trademark of the Loctite Corp.



Installation
Fig. 1
For Stationary Mountings
1/2 in.
B
C
D
E
F
G
KEY
A Fluid
dispense line
B Pump ground wire (required)
C Air regulator
D Main air supply line
E Air line filter
F Air line lubricator
G Pump runaway valve
H Follow plate
J Bleed-type Master Air V alve (required)
H
J
A
04191
J
Mounting
1. Plan the mounting layout for easy operator access
to the pump air controls, suf ficient room to change
drums and a secure mounting platform.
2. If using a follow plate (H), remove the drum cover .
Scoop the material to the center of the drum to
make the surface concave. Place the plate on the
material. Guide the pump foot valve through the
plate.
3. Mount the pump to the drum cover or other suit -
able mounting device.
4. For ease in changing drums, install a pump eleva -
tor.
Air and Fluid Line and Accessories
Refer to Figure 1 above.
WARNING
The bleed-type master air valve (J) is required in
your system to help reduce the risk of serious inju -
ry from moving parts if you are adjusting or repair -
ing the pump. Locate the valve close to the pump,
and downstream from the air regulator . The bleed
valve relieves air trapped between it and the air
motor after the air supply is shut of f. T rapped air
can cause the air motor to cycle unexpectedly ,
causing serious injury .
CAUTION
Do not hang the air accessories directly on the air
inlet. The fittings are not strong enough to support
the accessories and may cause one or more to
break. Provide a bracket on which to mount the
accessories.
NOTE:
Install the air line accessories in the order
shown in Figure 1.
1. Install a pump runaway valve (G) to shut of f the air
to the pump if the pump accelerates beyond the
pre-adjusted setting. A pump which runs too fast
can be seriously damaged.
2. Install an air line lubricator (F) for automatic air
motor lubrication.
3. Install a bleed-type master air valve (J) to relieve
air trapped between the valve and the motor (see
WARNING at left). Order Part No. 107–142.
4. Install the air regulator (C) to control pump speed
and pressure.
5. Install an air line filter (E) to remove harmful dirt
and contaminants from your compressed air sup -
ply.
6. Install a second bleed-type master air valve (J)
upstream from all other accessories, to isolate the
accessories for servicing.

8 306-517
Installation
Grounding
Proper grounding is an essential part of maintaining a
safe system.
T o 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:
1. Pump: use a ground wire and clamp as shown in
Fig. 2.
2. Air and fluid hoses: use only electrically conductive
hoses.
3.
Air compressor: follow manufacturer ’ s recommen -
dations.
4.
Fluid supply container: according to local code.
5. T o maintain grounding continuity when flushing or
relieving pressure, always hold a metal part of the
valve firmly to the side of a grounded metal pail,
then trigger the valve.
To ground the pump:
To ground the pump , loosen the grounding lug locknut
(W) and washer (X). Insert one end of a 12 ga (1.5
mm ) minimum ground wire (Y) into the slot in lug (Z)
and tighten the locknut securely . Connect the other
end of the wire to a true earth ground. Order Part No.
222–01 1, Ground Wire and Clamp.
Fig. 2
XW
Y
Z
04111

9
306-517
Operation
Pressure Relief Procedure
INJECTION HAZARD
The equipment stays pressurized until
pressure is manually relieved. T o reduce
the risk of serious injury from pressur -
ized fluid, accidental spray from the valve or
splashing fluid, follow this procedure whenever you:
 are instructed to relieve pressure,
 stop dispensing,
 check, clean or service any system equipment,
 install or clean dispensing devices.
WARNING
1. Close the pump air regulator and the bleed-type
master air valve (required in your system).
2. Hold a metal part of the dispensing valve firmly to
a grounded metal waste container and trigger the
valve to relieve the fluid pressure.
Startup
1. If there are multiple pumps on the air line, close
the air regulators and bleed-type master air valves
to all but one pump. If there is only one pump,
close its air regulator and bleed-type master air
valve.
2.
Open the master air valve from the compressor .
3.
For the pump which is supplied with air , open the
dispensing valve into a grounded metal waste con -
tainer
, making firm metal-to-metal contact between
the container and valve. Open the bleed-type mas -
ter air valve and open the pump air regulator
slowly , just until the pump is running. When the
pump is primed and all air has been pushed out of
the lines, close the dispense valve.
4. If you have more than one pump, repeat this pro -
cedure for each pump.
NOTE: When the pump is primed, and with suf ficient
air supplied, the pump starts when the dispensing
valve is opened and shuts of f when it is closed.
5. Set the air pressure to each pump at the lowest
pressure needed to get the desired results.
COMPONENT RUPTURE HAZARD
The maximum working pressure of each
component in the system may not be the
same. T o reduce the risk of overpressur -
izing any component in the system, be sure you
know the maximum working pressure of each com -
ponent. Never exceed the maximum working pres -
sure of the lowest rated component in the system.
Overpressurizing any component can result in rup -
ture, fire, explosion, property damage, and serious
injury.
T o determine the fluid output pressure using the air
regulator reading, multiply the ratio of the pump by
the air pressure shown on the regulator gauge. For
example:
50 (:1) ratio x 100 psi air =
5000 psi fluid output
[50 (:1) ratio x 7 bar air = 350 bar fluid output]
Limit the air to the pump so that no air line or fluid
line component or accessory is overpressurized.
WARNING
6. Never allow the pump to run dry of the material
being pumped. A dry pump will quickly accelerate
to a high speed, possibly damaging itself. If your
pump accelerates quickly , or is running too fast,
stop it immediately and check the material supply .
If the supply container is empty and air has been
pumped into the lines, prime the pump and lines
with material, or flush it and leave it filled with a
compatible solvent. Be sure to eliminate all air
from the material lines.
NOTE: A pump runaway valve (G) can be installed on
the air line to automatically shut of f the pump if it starts
to run too fast.
7. Read and follow the instructions supplied with
each component in your system.
8. T o shut of f the system, always follow the Pressure
Relief Procedure W arning , at the left.

 
Toubleshooting
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
Relieve pressure before you check or service any sys -
tem equipment.
WARNING
MOVING P ARTS HAZARD
Never operate the pump with the warn -
ing plate or the identification plate re -
moved. These plates protect your fin -
gers from pinching or amputation 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 Inadequate air supply pressure or
restricted air lines
Increase air supply; clear
Closed or clogged valves Open; clean
Clogged fluid lines, hoses, valves,
etc. Clear*
Damaged air motor Service air motor
Exhausted fluid supply Refill and reprime or flush
Continuous air exhaust Worn or damaged air motor
gasket, packing, seal, etc.
Service air motor
Erratic pump operation Exhausted fluid supply Refill and reprime or flush
Held open or worn intake valve or
piston packings
Clear; service
Pump operates, but output low on
up stroke
Held open or worn piston packings Clear; service
Pump operates, but output low on
down stroke Held open or worn intake valve Clear; service
Pump operates, but output low on
both strokes
Inadequate air supply pressure or
restricted air lines
Increase air supply; clear
Closed or clogged valves Open; clean
Exhausted fluid supply Refill and reprime or flush
Clogged fluid lines, hoses, valves,
etc. Clear*
Packing nut too tight Loosen
Loose packing nut or worn packings T ighten; replace
*Follow the Pressure Relief Procedure W arning on page 9 and disconnect the fluid line. If the pump starts when
the air is turned on again, the line, etc., is clogged.



Displacement Pump Service
Before you start:
1. Be sure you have all necessary parts on hand. If
using a repair kit, use all the parts in the kit for the
best results.
2. Displacement Pump Repair Kit 204–164 is
available for Pumps 203–868, 203–869 and
207–609. Displacement Pump Repair Kit
221–036 is available for Pump 221–034. Parts
included in the kits are marked with an asterisk or
a dagger , for example, (10*), in the text and draw -
ings. See page 18 to order these kits.
3. A special Tune–up Kit 221–037 is also available
for Pump 221–034. See page 18 for parts included
in this kit.
4. A 0.25 in. (6.4 mm) diameter rod (K) is required for
disassembling the pump.
Disassembly
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
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 (35) in a
vise.
4.
Screw the priming tube (46) of f of the displace -
ment cylinder (61).
5. Hold the displacement tube (55) with the rod (K)
and screw the priming piston (45) of f the displace -
ment tube. See Fig. 3.
6. See Fig. 4. Use a pipe wrench at the knurled part
of the displacement cylinder (61) to screw it out of
the base. Screw the packing retainer (60) out of
the cyclinder . Remove the seal (59), guides
(56,58) and packing (57). See Fig. 4, Detail A.
Fig. 3
55
45
K
04192
7. Use the rod (K) to screw the displacement tube
(55) out of the check valve packing retainer (54).
Remove the gasket (49), seat (48) and ball (40).
Then screw the packing retainer out of the cou -
pling (47). Remove the upper gasket, seat and
ball, and the guide (50), packing (51), and washer
(52). Do not remove the press-fit brass guide (53)
unless it is damaged. See Fig. 4, Detail B.
8. If the pressed-on brass guide (53) needs replac -
ing, clamp it in a vise and drive the packing re -
tainer (54) out with a plastic hammer . The new
guide must be started onto the retainer squarely .
9.
Clean all the parts in a compatible solvent and in -
spect them for wear or damage. Use all the parts
in the repair kit, and replace other parts as neces -
sary
. The checkball seats (48) can be turned over
to provide new seats.
10. Lubricate all the parts with light waterproof grease
and reassemble the pump. Apply medium-
strength Loctite  to the threads of the intake
packing retainer (60).
11. If the ground wire was disconnected before servic -
ing, be sure to reconnect it before regular opera -
tion of the pump.

 
Displacement Pump Service
Apply medium strength
Loctiter to threads.
Fig. 4
1
2
04193
04194
04195
Detail B:
Piston Packings
47
42
40[
48
49[
50[
51[
52[
53[
54
42
40[
48
49[
61
55
56[
57[
58[
59[
60
45
46
1Torque
to 75–85 ft-lb.
2
Detail A:
Fluid Intake
35
62
See Detail B
See Detail A



Air Motor and Throat Service
Before you start:
1. Be sure you have all necessary parts on hand. Re-
pair Kit 206–728 is available for the motor and
throat. Use all the parts in the kit for the best re -
sults. Parts included in the kit are marked with one
asterisk, for example, (10*), in the text and draw -
ings.
2. T
wo accessory tools should be ordered. Use
Padded Pliers, 207–579, to grip the trip rod with -
out damaging its surface. Use Gauge, 171–818 , to
ensure the proper clearance between the poppets
and seat of the transfer valve.
Disassembly
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
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 (35) in a
vise.
4. Use a pipe wrench on the knurled part of the cylin -
der (61) to screw it out of the base (35). See Fig.
5.
5.
Pull the connecting rod (62) down as far as it will
go.
6.
Use a hammer and punch to remove the roll pin
(42) from the piston rod (18), and then screw the
connecting rod (62) out of the piston rod.
CAUTION
Do not damage the plated surface of the trip rod.
Damaging the surface of the trip rod can result in
erratic air motor operation. Use the special padded
pliers, 207–579, to grasp the rod.
7. Manually push on the piston rod (18) to move the
piston (39) up as far as it will go. Unscrew the cyl -
inder cap nut (24). Pull the nut up. Grip the trip rod
(34) with padded pliers and screw the nut of f the
rod. See Fig. 5.
8. Remove the six screws (3) holding the cylinder
(12) to the base. Carefully pull the cylinder straight
up of f the piston (39).
CAUTION
T o avoid damaging the cylinder wall, lift the cylinder
straight up of f of the piston. Never tilt the cylinder
as it is being removed.

14 306-517
Air Motor and Throat Service
WARNING
To reduce the risk of pinching or amputating your
fingers, always keep fingers clear of the toggle
assemblies (L). See Fig. 6.
9. Use a screwdriver to push down on the trip rod
yoke (7) and snap the toggles down. See Fig. 6.
Remove the lockwires (13) from the adjusting nuts
(1 1) of the transfer valves. Screw the top nuts of f.
Screw the stems (22) out of the grommets (10)
and bottom nuts. T ake the valve poppets (30) of f
the stems and squeeze them firmly to check for
cracks.
10. Grip the toggle rockers (9) with a pliers. Compress
the springs (26) and swing the toggle assembly (L)
up and away from the piston lugs (M), and remove
the parts. Check to see that the valve actuator (33)
is supported by the spring clips (29), but slides
easily into them. See Fig. 6.
11. Remove the trip rod yoke (7), actuator (33), and
trip rod (34). Check the exhaust valve poppets (31)
for cracks.
NOTE: T o remove the exhaust valve poppets (31),
stretch them out and cut them with a sharp knife.
12. Remove one of the air motor plates ( 32 or 64).
Pull the piston (39) up out of the base (35). Re -
move the throat packing nut (19), v-packings (25),
male gland (27), backup washer (20), flat packing
(21) and bearing (28). See the Detail in Fig. 5.
Fig. 5
1
04196
24
34
23
35
44*
18
62
12
*14
*17
1
See Detail below .
04197
Throat Packing Detail
19
21
20
28
25
27
2
2
Lips
of v-packings face down.
42
16
39
61



Air Motor and Throat Service
Reassembly
1. Clean all the parts carefully in a compatible solvent
and inspect for wear or damage. Use all the repair
kit parts during reassembly and replace other parts
as necessary .
2.
Check the polished surfaces of the piston (39),
piston rod (18), and cylinder wall (12) for scratches
or wear . A scored rod will cause premature pack -
ing wear and leaking.
3. Lubricate all parts with a light, waterproof grease.
4. One at a time, install the male gland (27  ), five
v-packings (25 ), bearing (28 ), backup washer
(20), and flat packing (21  ), with the lips of the v-
packings facing down. Screw the packing nut (19)
into the base (35) loosely . See the Detail in Fig. 5.
5. Slide the piston rod (18) down through the pack -
ings and lower the piston (39) into the base (35).
Be sure the o-rings (14*, 16, 17*) are in place.
See Fig. 5.
6. Pull the exhaust valve poppets (31*) into the valve
actuator
(33) and clip of f the top part shown with dot -
ted
lines. See Fig. 6.
7. Install the transfer valve grommets (10*), then reas -
semble the valve mechanism. Before installing the
lockwires (13*) in the adjusting nuts (11*), use the
special
gauge, 171–818, to adjust the transfer valve
so there is 0.145 in. (3.7 mm) clearance between the
poppets (30*) and the seat when it is open. See Fig.
6. Snap the toggles (15) to the up position.
8. Reassemble the air motor and assemble to the dis-
placement pump. Before installing the air motor
plate, tighten the throat packing nut (19) just snug ––
don’t overtighten.
9. Before remounting the pump, connect an air hose
and run the pump slowly [at about 40 psi (3 bar)] to
see that it operates smoothly .
10. Reconnect
the ground wire before regular operation
of the pump.
Fig. 6
13
2
04118 04119
29 31*
13*
11*
22*
10*
11*
30*
39
34 7
M
92615
L
1Turn
wires up.
2
Push toggles (L) in and then up.
33 29
34
0.145”
(3.7 mm)
39
30*
31* 22* 11*
10*
11*
14*
Cutaway V iew
3Cut
of f tops of poppets as indicated by dotted lines.

 
Parts
16
24
*44
61
56
60
45
46
See
Repair Kit information on page 18.
6
12
13*
11
9
26 15
7
10*
11*
31*
8
*14
39
23 30*
22*
18
42
64 2
3
*17
19
21
20
28
25
27
4
5
67
62
47
42
54
40
29
35
32
04198
1
2
1
55
11*
34
48
2
49
57
58
59
Ref No. 69 Piston includes these items & item 55.
T orque to 75–85 ft-lb.
Ref. No. 1 Air Motor includes items 2–39,
64, 67, & 68
42
40
48
49
50
51
52
53
33



Parts
Model 203–868, Series H
400 lb drum size, buna-N packings
Model 203–869, Series H
120 lb drum size, buna-N packings
Model 207–609, Series D
50 lb pail size, buna-N packings
Model 221–034, Series A
400 lb drum size, PTFER packings
Ref.
No. Part No. Description Qty. Ref. No. Part No. Description Qty.
1
203–964 AIR MOTOR ASSY ,
SERIES P (Pump Models 203–868 and 203–869 only)
Includes items 2–39, 64, 67, 68 1
206–404 AIR MOTOR ASSY,
SERIES K (Pump Model 207–609 only)
Includes items 2–39, 64, 67, 68 1
221–060 AIR MOTOR ASSY.,
SERIES B (Pump Model 221–034 only
Includes items 2–39, 64, 67, 68
2 100–078 .SCREW , hex head;
no. 8–32 x 0.38 in. (10 mm) long. 12
3 101–578 .SCREW
, hex head;
no. 8–32 x 0.38 in. (10 mm) long 6
4
104–029 .LUG, grounding 1
5
104–582 .WASHER, tab 1
6 156–698 .O-RING; buna-N 1
7 158–360
.YOKE, rod, trip 1
8 158–362
.PIN, toggle 2
9 158–364 .ROCKER, toggle 2
10* 158–367 .GROMMET
, rubber , air intake 2
11* 160–261 .NUT
, adjusting 4
12 160–613
.CYLINDER, air motor 1
13* 160–618 .LOCKWIRE, transfer valve 2
14* 160–621
.O-RING, nitrile rubber 1
15 160–623
.ARM, toggle 2
16
160–624 .O-RING, buna-N 1
17* 160–625 .O-RING, buna-N 1
18 160–639 .ROD, piston 1
19 160–640 .NUT
, packing 1
20
160–641 .WASHER, back-up 1
21[160–644.PACKING,
flat; leather 1
22* 160–896
.STEM, valve 2
23
160–932 .GASKET ; copper 1
24 161–435 .NUT
, cylinder , cap
(Pump Models 203–868, 203–869,
and 221–034 only) 1
164–704 .NUT,
cylinder cap
(Model 207–609 only) 1
25[162–391
.V-P ACKING; leather (Pump Models
203–868, 203–869, and 207–609 only) 5
164–555 .V-PACKING;
PTFE r
(Pump Model 221–034 only) 5
26 167–585 .SPRING,
helical compression 2
27[
168–851 .GLAND, male 1
28[
168–852 .BEARING, throat 1
29 172–866 .CLIP
, spring 2
30* 170–708 .POPPET
, valve; urethane 2
31* 170–709 .POPPET
, valve; urethane 2
32
222–499 .PLA TE, identification; with muffler 1
33 172–867 .ACTUATOR, valve 1
34 203–965 .ROD, trip 1
35
204–896 .BASE, air motor 1
37 102–975 .SCREW
, rd hd mach;
.no. 6–32 x 0.25” (6.3 mm) 2
39 160–614 .PIST
ON, air motor 1
40[
100–069 BALL, steel; . 0.25” (6.3 mm) dia. 2
42 101–579 PIN, roll 0.12” (3.2 mm) dia.
0.75” (19 mm) long 4
44*[. 150–694 GASKET
; copper 1
45 160–667 PIST
ON, priming 1
46 160–668
TUBE, priming 1
47 160–669 COUPLING, hex 1
48 160–670 SEAT
, valve; reversible 2
49[160–671 GASKET
; copper 2
50[160–672 GUIDE, upper; brass 1
51[160–673 P
ACKING, block, upper piston; buna-N
(Pump Models 203–868, 203–869
and 207–609 only) 1
680–239 P
ACKING, block, upper piston; PTFE R
(Pump Model 221–034 only) 1
52[160–674 WASHER, backup; nylon 1
53[160–675 GUIDE, lower 1
54 160–676 RETAINER, packing 1
55 160–677
TUBE, displacement 1
56[
160–678 GUIDE, displ. tube; brass 1
57[
160–679 P ACKING, block, shovel tube; buna-N
(Pump Models 203–868, 203–869
and 207–609 only) 1
680–277 PACKING,
block, shovel tube; PTFE R
(Pump Model 221–034 only) 1
58[160–680
GUIDE, displ. tube; nylon 1
59[160–681
SEAL, packing retainer; nylon 1
60 160–682 RETAINER, packing 1
61 160–683 CYLINDER; 22”
(55.8 mm) long
(Pump Model 203–869 only) 1
160–685 CYLINDER;
12.75” (323.9 mm) long
(Pump Model 207–609 only) 1
160–687 CYLINDER;
28.94” (735.1 mm) long
(Pump Models 203–868 and 221–034 only) 1
62 160–684 ROD,
connecting;
12” (304.8 mm) long
(Pump Model 203–869 only) 1
160–686 ROD,
connecting; 2.75” (69.9 mm) long
(Pump Model 207–609 only) 1
160–688 ROD, connecting;
18.94” (481.1 mm) long
(Pump Models 203–868and 221–034 only) 1
64 222–501
PLA TE, warning with muffler 1
67
162–718 ADAPTER; 3/8 npt(m) x 1/4 npt(f) 1
68 180–233
LABEL, warning 2
69 207–069 PISTON ASSEMBL
Y (Pump Models
203–868, 203–869, and 207–609 only)
Includes items 40, 42 (qty 2), and 47 to 55 1
221–035 PISTON ASSEMBL Y
(Pump Model 221–034 only)
Includes items 40, 42 (qty 2), and 47 to 55 1
70 172–479 T AG, warning (not shown) 1
* The replacements for these parts are available in Repair Kit
206–728. Purchase the kit separately . See page 18.
[ The replacements for these parts are available in Repair
Kits 204–164 (buna–N) or 221–036 (PTFE) R , as appropri -
ate. Purchase the kits separately . See page 18.
. Replace gasket every time the cylinder is removed for re -
pair.

18 306-517
Repair Kits
206–728 Air Motor Repair Kit
Must be purchased separately
Consists of:
Ref No. Qty
10 2
11 4
13 2
14 1
17 1
22 2
30 2
31 2
44 1
204–164
Displacement Pump Repair Kit
For Pump Models 203–868, 203–869
and 207–609 only
Must be purchased separately
Consists of:
Ref No. Qty Ref Qty
21 1 51 1
25 5 52 1
27 1 53 1
28 1 56 1
40 2 57 1
44 1 58 1
49 2 59 1
50 1
221–036
Displacement Pump Repair Kit
For Pump Model 221–034 only
Must be purchased separately
Consists of:
Ref No. Qty Ref Qty
21 1 51 1
25 5 52 1
27 1 53 1
28 1 56 1
40 2 57 1
44 1 58 1
49 2 59 1
50 1
221–037 Tune-Up Kit
For Pump Models 221–034 only
Must be purchased separately
Consists of:
Ref No. Qty
44 1
50 1
51 1
52 1
53 1
56 1
57 1
58 1
59 1
Manual Change Summary
The manual was revised to add Part Number 150–694 , gasket (Ref. No. 44, Qty . 1), to Repair Kits 204–164,
206–728, 221–036 and 221–037.
Also, a torque requirement of 75–85 ft-lb. was added to the cylinder (Ref. No. 61) on pages 12 and 16.

19
306-517
Notes

 
The Graco Warranty and Disclaimers
WARRANTY
Graco
warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on
the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser ’ s sole remedy for breach of this
warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defec -
tive.
This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’ s written rec-
ommendations.
This warranty does not cover , and Graco shall not be liable for , any malfunction, damage or wear caused by faulty installation,
misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility with Graco
equipment of structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, instal -
lation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor
for verification of the claim. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any
defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts,
labor and transportation.
DISCLAIMERS AND LIMITATIONS
The terms of this warranty constitute purchaser ’ s sole and exclusive remedy and are in lieu of any other warranties (express or
implied), including warranty of merchantability or warranty of fitness for a particular purpose , and of any non–contractual
liabilities, including product liabilities, based on negligence or strict liability . Every form of liability for direct, special or consequen -
tial damages or loss is expressly excluded and denied. In no case shall Graco’ s liability exceed the amount of the purchase price.
Any action for breach of warranty must be brought within two (2) years of the date of sale.
EQUIPMENT NOT COVERED BY GRACO WARRANTY
Graco makes no warranty
, and disclaims all implied warranties of merchantability and fitness for a particular purpose , with
respect to accessories, equipment, materials, or components sold but not manufactured by Graco. These items sold, but not
manufactured by Graco (such as electric motor , switches, hose, etc.) are subject to the warranty , if any , of their manufacturer .
Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
Graco Phone Numbers
TO PLACE AN ORDER , contact your Graco distrib -
utor
, or call this number to identify the distributor
closest to you: 1–800–367–4023 T oll Free
FOR TECHNICAL ASSIST ANCE, service repair
information or assistance regarding the application of
Graco equipment: 1–800–543–0339 T oll Free
Sales Offices: Atlanta, Chicago, Dallas, Detroit, Los Angeles, Mt. Arlington (N.J.)
Foreign Offices: Canada; England; Korea; Switzerland; France; Germany; Hong Kong; Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
PRINTED IN U.S.A. 306–517 7/55 Revised 1/95