Sharp R-963S Troubleshooting guide

INSTRUCTIONS–PARTS LIST
306–518
Rev. R
Supersedes N
and PCN P
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE
5:1 Ratio Fire-Ball Pumps
900 psi (62 bar) Maximum Working Pressure
180 psi (12 bar) Maximum Air Input Pressure
Gear Lube and Motor Oil Pumps
(See page 5 for pump models and descriptions)
MODEL 203–872
MODEL 203–876
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Pumps Models and Dimensional Drawings . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . 10
Air Motor & Throat Service . . . . . . . . . . . . . . . . . . . . 11
Displacement Pump Service . . . . . . . . . . . . . . . . . . 14
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Model 203–857 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Model 203–872 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Model 203–876 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Model 204–254 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Model 222–087 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Graco Phone Numbers . . . . . . . . . . . . . . . . . . . . . . . . . 28
04109
04110
GRACO INC.
P.O. BOX 1441 MINNEAPOLIS, MN
COPYRIGHT 1994, GRACO INC.
55440–1441
Symbols
Warning Symbol
Caution Symbol
WARNING
CAUTION
his symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
D This equipment is for professional use only.
D Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are not sure, call Graco Technical Assistance at 1–800–543–0339.
D Do not alter or modify this equipment.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
D Do not exceed the maximum working pressure of the lowest rated component in your system.
This equipment has a 900 psi (62 bar) maximum working pressure at 180 psi (12 bar) maximum incoming air pressure.
D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
D Handle hoses carefully. Do not pull on hoses to move equipment.
D Route 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).
D Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
WARNING
WARNING
FLUID 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.
If a fluid injection injury occurs, get emergency medical care at once. Do not treat as a simple
cut. Tell the doctor exactly what fluid was injected.
NOTE TO PHYSICIAN: Injection into the skin is a traumatic injury. It is important to treat the
injury surgically as soon as possible. Do not delay treatment to research toxicity. Toxicity is a
concern with some exotic coatings injected directly into the blood stream. Consultation with a
plastic surgeon or reconstructive hand surgeon may be advisable.
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.
Tighten 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.
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.
WARNING
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.
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 off 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.
MOVING PARTS 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.
4 306-518
Pump Models and Dimensional Drawings
MODEL 203–876, Series K
Stubby size, wall mount
MODEL 203–857, Series K
55 gal. (400 lb) drum size,
cover mount
MODEL 203–872, Series K
16 gal. (120 lb) drum size,
cover mount
3/8 npt(f)
Air Inlet
3/8 npt(f)
Air Inlet
Grndg
Lug
Grndg
Lug
3/8 npt(f)
Air Inlet
Grndg
Lug
1/2 npt(f)
Fluid
Outlet
1/2 npt(f)
Fluid
Outlet
11 in.
(279 mm)
33.7 in.
(856 mm)
26.7 in.
(678 mm)
Overall length:
22.8 in. (579 mm)
04109
1/2 npt(f)
Fluid
Outlet
Overall length:
38.5 in. (978 mm)
MODEL 204–254, Series N
55 gal. (400 lb) drum size,
bung mount
04110
Overall length:
45.5 in. (1156 mm)
MODEL 222–087, Series B
275 gal. tank size,
bung mount
3/8 npt(f)
Air Inlet
3/8 npt(f)
Air Inlet
Grndg
Lug
Grndg
Lug
1/2 npt(f)
Fluid
Outlet
1/2 npt(f)
Fluid
Outlet
42 in.
(1067 mm)
40 in.
(1016 mm)
Overall length:
51.8 in. (1316 mm)
04112
04113
Overall length:
53.9 in. (1369 mm)
04114
NOTE: Technical Data and Mounting Hole Layout on page 25.
Installation
G
A
C
A
N
D
F
E
P
H
B
J
DETAIL A
Q
M
L
K
04115
1/2 in.
(13 mm)
KEY
A
B
C
D
E
F
G
Bleed-Type Master Air Valve
Air Line Filter
Air Regulator and Gauge
Pump Runaway Valve (shown for
position – not needed if you use
a low level cut-off valve [K])
Air Inlet
Ground Wire
Pump (Model 204–254 shown)
Fig. 1
H
J
K
L
M
N
P
Q
Drain Valve
Dispensing Valve
Low Level Cut-Off Valve
Male Quick Disconnect Fitting
Female Quick Disconnect Coupler
Air Line Lubricator
Fluid Hose
Weep Hole Drain Tube
Installation
The installation shown in Fig.1 is only a guide to selecting and installing optional and required accessories. For assistance in designing a system to suit your
needs, contact your Graco representative or Graco
Technical Assistance at 1–800–543–0339.
Install the pump on the drum cover so the pump’s fluid
intake is 1/2 in. (13 mm) off the bottom of the drum.
On Models 204–254 and 222–087, screw the bung
adapter tightly into the drum cover’s bung hole, adjust
the position of the pump in the drum, and tighten the
bung adapter screw to hold the pump.
Pump Weep Hole Drain Kit
There is a fluid weep hole (S) in the pump base. See
Fig. 2. The fluid weepage is a necessary function on all
reciprocating type pumps and should not be considered as pump leakage. A Weep Hole Drain Kit, Part
No. 224–907, is available to prevent the fluid from accumulating on the exterior of the pump and surrounding surfaces.
Drive the fitting (R) into the pump base weep hole (S).
Press the tube firmly onto the fitting. Route the tube
(Q) into the drum through the small hole in the cover,
as shown in Fig.1, or route the tube into a separate
container that you have installed for that purpose.
NOTE: Install the accessories in the order shown in
Fig.1 .
1. If you are not using a low level cut-off valve (K) at
the pump fluid intake, install a pump runaway
valve (D) to shut off 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 (N) for automatic air
motor lubrication.
3. Next, install a bleed-type master air valve (A) to
relieve air trapped between it and the motor when
the valve is closed. Order Part No. 107–142. As an
alternative, you can install an air line quick disconnect coupler (M) and fitting (L) to serve as an airbleed device. See Detail A in Fig.1.
WARNING
Two accessories are required in your system: an
air bleed device and a fluid drain valve. These accessories help reduce the risk of serious injury including fluid injection, splashing in the eyes or on
the skin, and injury from moving parts if you are
adjusting or repairing the pump.
The air bleed device relieves air trapped between it
and the air motor after the air supply is shut off.
Trapped air can cause the air motor to cycle unexpectedly, causing serious injury if you are adjusting
or repairing the pump. Use either a bleed-type
master air valve (A) or a quick disconnect coupler
(M) and fitting (L). Install near the pump air inlet,
within easy reach of the pump.
S
The fluid drain valve (H) assists in relieving fluid
pressure in the displacement pump, hoses and
dispensing valve. Triggering the valve to relieve
pressure may not be sufficient.
R
Q
04116
Fig. 2
4. Install the air regulator (C) to control pump speed
and pressure.
System Accessories
CAUTION
Do not hang the air accessories directly on the air
inlet (E). The fittings are not strong enough to support the accessories and may cause one or more
to break. Provide a bracket on which to mount the
accessories.
5. Install an air line filter (B) to remove harmful dirt
and contaminants from your compressed air supply. Install another bleed-type master air valve (A)
to isolate the accessories for servicing.
6. Install a drain valve (H) near the pump fluid outlet.
Order Part No. 210–658.
7. Install a suitable fluid hose (P) and dispensing
valve (J).
306-518
7
Installation
Grounding
To ground the pump:
Proper grounding is an essential part of maintaining a
safe system.
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.
222–011, Ground Wire and Clamp.
To reduce the risk of static sparking, ground the pump.
Check your local electrical code for detailed grounding
instructions for your area and type of equipment. Be
sure to ground all of this equipment:
Z
1. Pump: use a ground wire and clamp as shown to
the right.
2. Air and Fluid hoses: use only grounded hoses.
Y
3. Air compressor: follow manufacturer’s recommendations.
X
4. Fluid supply container: according to local code.
5. To 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.
W
04111
Fig. 3
Operation
Pressure Relief Procedure
WARNING
PRESSURIZED FLUID HAZARD
The equipment stays pressurized until
pressure is manually relieved. to reduce
the risk of serious injury from pressurized 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
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.
WARNING
COMPONENT RUPTURE HAZARD
The maximum working pressure of each
component in the system may not be the
same. To reduce the risk of overpressurizing any component in the system, be sure you
know the maximum working pressure of each component. Never exceed the maximum working pressure of the lowest rated component in the system.
Overpressurizing any component can result in rupture, fire, explosion, property damage, and serious
injury.
To determine the fluid output pressure using the air
regulator reading, multiply the ratio of the pump by
the air pressure shown on the regulator gauge. For
example:
5 (:1) ratio x 100 psi air =
500 psi fluid output
[5 (:1) ratio x 7 bar air = 35 bar fluid output]
Limit the air to the pump so that no air line or fluid
line component or accessory is overpressurized.
WARNING
MOVING PARTS HAZARD
Never operate the pump with the warning plate (17) or the identification plate
(41) removed. These plates protect your
fingers from pinching or amputation by moving
parts in the air motor.
Starting and Adjusting the Pump
1. With the air regulator (C) closed, open the bleedtype master air valves (A) or, if so equipped, join
the quick disconnect coupler (M) to the male fitting
(L).
2. Open the dispensing valve (J) into a grounded
metal waste container, making firm metal-to-metal
contact between the container and valve.
3. Open the pump air regulator (C) slowly, just until
the pump is running. When the pump is primed
and all air has been pushed out of the lines, close
the dispensing valve.
NOTE: When the pump is primed, and with sufficient
air supplied, the pump starts when the dispensing
valve is opened and shuts off when it is closed.
4. Adjust the air regulator until you get sufficient flow
from the dispensing valve. Always run the pump at
the lowest speed necessary to get the desired results. Do not exceed the maximum working pressure of any component in the system.
5. Never allow the pump to run dry of the fluid being
pumped. A dry pump will quickly accelerate to a
high speed, possibly damaging itself. If your pump
accelerates quickly, or is running too fast, stop it
immediately and check the fluid supply. If the supply container is empty and air has been pumped
into the lines, prime the pump and lines with fluid,
or flush it and leave it filled with a compatible solvent. Be sure to eliminate all air from the fluid
lines.
Continued on page 10.
306-518
9
Operation
NOTE: The low level cut-off valve accessory (K)
closes the pump fluid intake when the fluid level is low,
causing the pump to stall, to avoid running dry.
6. Read and follow the instructions supplied with
each component in your system.
A pump runaway valve (D) can be installed on the air
line of pumps not equipped with a low level cut-off
valve, to automatically shut off the pump if it starts to
run too fast.
7. If the pump will be unattended for any period of
time, or to shut off the system at the end of the
work shift, always follow the Pressure Relief Procedure on page 9.
Troubleshooting
NOTE: Check all other possible problems and solutions before disassembling the pump.
Problem
Pump fails to operate
Cause
Solution
Inadequate air supply pressure or
restricted air lines
Increase air supply; clear
Closed or clogged dispensing
valve
Open; clear
Clogged fluid lines, hoses, valves,
etc.
Clear*
Damaged air motor
Service air motor
Exhausted fluid supply
Refill and reprime or flush
Continuous air exhaust
Worn or damaged air motor 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*
*Follow the Pressure Relief Procedure on page 9 and disconnect the fluid line. If the pump starts when the air is
turned on again, the line, etc., is clogged.
Air Motor and Throat Service
Before you start:
1. Be sure you have all necessary parts on hand. Air
Motor Repair Kit 206–728 includes repair parts
for the motor. Use all the parts in the kit for the
best results. Parts included in the kit are marked
with one asterisk, for example (28*), in the t ext
and drawings. See the Parts List for your pump
model number.
2. Displacement Pump Repair Kit 237–498 includes repair parts for the pump throat and piston.
Use all the parts in the kit for the best results.
Parts included in the kit are marked with a symbol,
for example (6), in the text and drawings. See the
Parts List for your pump model number.
7. Remove the six screws (22) holding the cylinder
(31) to the base (52). Carefully pull the cylinder
straight up off the piston (53).
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.
3. Three accessory tools should be used. Padded
Pliers, 207–579, are used to grip the trip rod without damaging its surface. Gauge, 171–818, is
used to ensure the proper clearance between the
poppets and seat of the transfer valve. Guide Collar Tool, 168–085, is used to install the piston in
the displacement pump cylinder during pump servicing.
45
31
Disassembly
1. Flush the pump. Follow the Pressure Relief Procedure on page 9 before proceeding.
51
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 displacement cylinder
(16) to screw it out of the air motor base (52).
53
4. Pull the connecting rod (15) down as far as it will
go.
5. Use a hammer and punch to remove the roll pin
(4) from the piston rod (44), and then screw the
connecting rod (15) out of the piston rod. See
Fig. 4.
CAUTION
52
Do not damage the plated surface of the trip rod
(51). 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.
44
4
16
15
6. Manually push up on the piston rod (44) to move
the piston assembly (53) up as far as it will go. Unscrew the cylinder cap nut (45). Pull the nut up.
Grip the trip rod (51) with padded pliers 207–579
and screw the nut off the rod. See Fig. 4.
04117
Fig. 4
Air Motor and Throat Service
WARNING
MOVING PARTS HAZARD
To reduce the risk of pinching or amputating your fingers, always keep fingers
clear of the toggle assemblies (M).
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, piston
rod and cylinder wall for scratches or wear. A
scored rod will cause premature packing wear and
leaking.
8. Use a screwdriver to push down on the trip rod
yoke (24) and snap the toggles down. See Fig. 5.
Remove the lockwires (32) from the adjusting nuts
(30) of the transfer valves. Screw the top nuts off.
Screw the stems (42) out of the grommets (28)
and bottom nuts (30). Take the valve poppets (49)
off the stems and squeeze them firmly to check for
cracks.
9. Grip the toggle rockers (26) with a pliers. Compress the springs (27) and swing the toggle assembly (M) up and away from the piston lugs (L),
and remove the parts. Check that the valve actuator (33) is supported by the spring clips (55), but
slides easily into them. See Fig. 5.
10. Remove the trip rod yoke (24), actuator (33) and
trip rod (51). Check the exhaust valve poppets (50)
for cracks.
NOTE: To remove the exhaust valve poppets (50),
stretch them out and cut them with a sharp knife.
3. Lubricate all parts with a light, waterproof grease.
4. Install the packing (46), with the lips facing down.
Screw the packing nut (38) into the base (52)
loosely. See Fig. 6.
5. Slide the piston rod (44) down through the packings and lower the piston (56) into the base (52).
Be sure the o-rings (34*,36, 37*) are in place.
6. Pull the exhaust valve poppets (50*) into the valve
actuator (33) and clip off the top part shown with
dotted lines. See Fig. 5.
7. Install the transfer valve grommets (28*), then reassemble the valve mechanism. Before installing
the lockwires (32*) in the adjusting nuts (30*), use
the special gauge 171–818 to adjust the transfer
valve so there is 0.145 in. (3.7 mm) clearance between the poppets (49*) and the seat when it is
open. See Fig. 5. Snap the toggles (35) to the up
position.
8. Reassemble the air motor and assemble to the
displacement pump. Before installing the air motor
plate, tighten the throat packing nut (38) just snug
–– do not 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.
11. Remove one of the air motor muffler plates (17 or
41). Pull the piston up out of the base. Remove the
throat packing nut (38) and packing (46).
10. Reconnect the ground wire before regular operation of the pump.
Air Motor and Throat Service
51 24
M
1
2
35
32*
30*
27
26
51
42*
28*
3
50*
55
42*
33
30*
L
28*
30*
34*
49
4
56
52
49*
56
55
50
30*
Cutaway View
04119
04118
1
Push toggles (M) in and then up.
2
Cut off tops of poppets as indicated by dotted lines.
3
Turn wires up.
0.145 in. (3.7 mm) clearance between
poppets (49*) and seat when it is open.
4
Fig. 5
Displacement Pump Service
Disassembly
NOTE: Displacement Pump Repair Kit 237–498 includes repair parts for the pump piston and throat.
Parts included in the kit are marked with two asterisks,
for example, (6), in the text and drawings.
1. Flush the pump. Follow the Pressure Relief Procedure on page 9, 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 (61 or 65) from the
displacement cylinder (16). Disassemble the intake
valve (see the parts drawing for your model for
parts). Clean and inspect the parts for wear or
damage, and replace parts as needed. Be sure to
check the o-ring (60). Unless further service is
needed, reassemble and reinstall the intake valve,
using liquid sealant on the male threads. See
Fig. 6.
DETAIL A
Throat Packings
45
31
B
38
C
A
34*
56
46
1
36
04121
37*
44
Shows seal being installed.
4
9
52
CAUTION: To avoid seal damage during installation, insert
seal at an angle as shown above, so that side A is below
hole C. Then press side B down until seal bottoms out.
16
15
2
3
5
DETAIL B
Piston Packings
15
2
60
11
61 or 65
3
19
18
12
13
6
12
18
19
04120
1
Lips must face down.
2
3
Torque to 95–105 ft-lb (129–142 N.m).
0.2 in. (5 mm) of ball travel.
4
See Detail A.
5
See Detail B.
Lips must face up.
6
Fig. 6
14306-518
04173
10
6
6
1
1
04122
Displacement Pump Service
NOTE: To replace the throat packing, which is included in Repair Kit 237–498, refer to the Air Motor
and Throat Packing Repair section on page 13.
4. Use a strap wrench on the displacement cylinder
(16) to screw it out of the air motor base (52).
Carefully inspect the smooth inner surface of the
cylinder for scoring or irregular surfaces. Such
damage causes premature packing wear and leaking, so replace the part if damaged.
9. Grease the inside top of the displacement cylinder
(16). Compress the leather cup packings with the
guide collar tool (R) and work the displacement
cylinder onto the lower packing with a turning motion. See Fig. 7. Remove the guide collar tool,
push the displacement cylinder up, and screw it
firmly into the air motor base.
10. If the ground wire was disconnected before servicing, be sure to reconnect it before regular operation of the pump.
5. Loosen the locknut (2), unscrew the piston (11)
from the connecting rod (15), and disassemble the
piston. See Fig. 6.
6. Clean and inspect the parts and replace any that
are worn or damaged. Be sure to check the o-ring
(9) in the motor base (52).
15
11
7. Grease the new piston packings and reassemble
the piston as shown in Fig. 6.
8. Reinstall the piston (11) on the connecting rod
(15), allowing 0.2 in. (5 mm) of free travel between
the steel ball (3) and the end of the connecting rod
before tightening the locknut (2). See Fig. 6.
NOTE: A guide collar is required for installing the piston in the displacement cylinder. Guide Collar Tool,
168–085, is available, or make a collar using shim
stock having a 0.016 in. (0.41 mm) maximum thickness.
R
16
04123
Fig. 7
Parts
Model 203–857, Series K
Ref. No. 20 Air Motor Assy
Includes items 17, 21–56,
67–69
38
46
37*
45
9
41
36
23
16
31
22
68
24
67
60
25
32*
35
52
30*
27
26
17
33
51
28*
50*
54
21
69
15
2
59
64
11
30*
55
63
65
3
19
58
56
*34
18
12
49*
43
13
42*
44
6
12
18
19
4
10
04107
Parts
Model 203–857, Series K
Ref.
No.
Part No.
2
3
4
100–111
100–279
101–579
6
9
10
11
12
13
15
16
17
18
19
20
154–662
156–641
156–989
157–184
158–402
158–857
160–649
160–917
222–501
171–590
171–594
203–963
21
100–078
22
101–578
23
24
25
26
27
28*
30*
31
32*
33
34*
35
156–698
158–360
158–362
158–364
167–585
158–367
160–261
160–613
160–618
172–867
160–621
160–623
Description
Qty.
NUT, hex jam; 1/2–20
1
BALL, steel; 0.88” (22.2 mm) dia
1
PIN, roll; 0.12” (3.2 mm) dia;
0.75” (19 mm) long
1
O-RING; buna-N
1
O-RING; buna-N
1
SEAT, piston
1
HOUSING, piston
1
2
PACKING, cup; leather
SPACER, piston
1
ROD, connecting
1
CYLINDER, displacement
1
1
PLATE, warning (with muffler)
SPREADER, packing
2
WASHER, back-up
2
AIR MOTOR Assy, Series S
Includes items 17, 21–56, 67, 68, 69 1
. SCREW, hex washer hd mach;
no. 8–32 x 0.38”
12
. CAPSCREW, hex hd Nylock;
5/16–18 x 0.88”
6
. O-RING; buna-N
1
. YOKE, rod, trip
1
. PIN, toggle
2
. ROCKER, toggle
2
. SPRING, helical compression
2
. GROMMET; rubber
2
. NUT, adjusting
4
. CYLINDER (white color)
1
. LOCKWIRE, transfer valve
2
. ACTUATOR, valve
1
. O-RING; nitrile rubber
1
2
. ARM, toggle
Ref.
No.
Part No.
36
37*
38
41
42*
43
44
45
46
49*
50*
51
52
53
160–624
160–625
190–024
222–499
160–896
160–932
161–059
161–435
112–843
170–708
170–709
203–965
204–895
214–036
54
102–975
55
56
58
59
60
63
64
65
67
68
69
172–866
100–989
101–190
156–633
157–182
160–914
156–893
104–029
104–582
180–233
Description
Qty.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
O-RING; buna-N
O-RING; buna-N
NUT, packing
PLATE, identification (with muffler)
STEM, valve
GASKET; copper
ROD, piston
NUT, cylinder cap
PACKING, block; polyurethane
POPPET, valve; urethane
POPPET, valve; urethane
ROD, trip
BASE (white color)
PISTON Assy
includes items 54–56 (also includes
repair kit 206–728 when ordered as
a replacement part)
. . SCREW, rd hd mach; no. 6–32 x
0.25”
. . CLIP, spring
. . PISTON, bare; not sold separately
RING, retaining
BALL, steel; 1” (25 mm) dia
O-RING; nitrile rubber
RETAINER, ball
HOUSING, valve
BASE, valve
LUG, grounding
WASHER, tab
LABEL, warning
1
1
1
1
2
1
1
1
1
2
2
1
1
1
2
2
1
1
1
1
1
1
1
1
1
2
* Included in repair kit 206–728.
Included in repair kit 237–498.
306-518
17
Parts
Model 203–872, Series K
Ref. No. 20 Air Motor Assy
Includes items 17, 21–56, 65, 66, 68
38
46
37*
45
9
41
36
23
16
31
22
66
24
65
60
25
35
27
52
32*
30*
17
26
33
21
68
15
2
51
57
59
28*
50*
54
58
30*
11
61
55
3
56
*34
19
62
18
12
49*
43
13
42*
44
6
12
18
19
4
10
04107
Parts
Model 203–872, Series K
Ref.
No.
Part No.
2
3
4
100–111
100–279
101–579
6
9
10
11
12
13
15
16
17
18
19
20
154–662
156–641
156–989
157–184
158–402
158–857
160–647
160–915
222–501
171–590
171–594
203–963
21
100–078
22
101–578
23
24
25
26
27
28*
30*
31
32*
33
34*
35
156–698
158–360
158–362
158–364
167–585
158–367
160–261
160–613
160–618
172–867
160–621
160–623
Description
Qty.
1
NUT, hex jam; 1/2–20
BALL, steel; 0.88” (22.2 mm) dia
1
PIN, roll; 0.12” (3.2 mm) dia;
0.75” (19 mm) long
1
O-RING; buna-N
1
O-RING; buna-N
1
SEAT, piston
1
HOUSING, piston
1
2
PACKING, cup; leather
SPACER, piston
1
ROD, connecting
1
CYLINDER, displacement
1
1
PLATE, warning (with muffler)
SPREADER, packing
2
WASHER, back-up
2
AIR MOTOR Assy, Series S
Includes items 17, 21–56, 65, 66, 68 1
. SCREW, hex washer hd mach;
no. 8–32 x 0.38”
12
. CAPSCREW, hex hd Nylock;
5/16–18 x 0.88”
6
. O-RING; buna-N
1
. YOKE, rod, trip
1
. PIN, toggle
2
. ROCKER, toggle
2
. SPRING, helical compression
2
. GROMMET; rubber
2
. NUT, adjusting
4
. CYLINDER (white color)
1
. LOCKWIRE, transfer valve
2
. ACTUATOR, valve
1
. O-RING; nitrile rubber
1
2
. ARM, toggle
Ref.
No.
Part No.
36
37*
38
41
42*
43
44
45
46
49*
50*
51
52
53
160–624
160–625
190–024
222–499
160–896
160–932
161–059
161–435
112–84
170–708
170–709
203–965
204–895
214–036
54
102–975
55
56
57
58
59
60
61
62
65
66
68
172–866
101–190
157–182
160–914
156–633
156–893
100–989
104–029
104–582
180–233
Description
Qty.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
O-RING; buna-N
O-RING; buna-N
NUT, packing
PLATE, identification (with muffler)
STEM, valve
GASKET; copper
ROD, piston
NUT, cylinder cap
PACKING, block; polyurethane
POPPET, valve; urethane
POPPET, valve; urethane
ROD, trip
BASE (white color)
PISTON Assy
includes items 54–56 (also includes
repair kit 206–728 when ordered as
a replacement part)
. . SCREW, rd hd mach; no. 6–32 x
0.25”
. . CLIP, spring
. . PISTON, bare; not sold separately
BALL, steel; 1” (25 mm) dia
RETAINER, ball
HOUSING, valve
O-RING; nitrile rubber
BASE, valve
RING, retaining
LUG, grounding
WASHER, tab
LABEL, warning
1
1
1
1
2
1
1
1
1
2
2
1
1
1
2
2
1
1
1
1
1
1
1
1
1
2
* Included in repair kit 206–728.
Included in repair kit 237–498.
306-518
19
Parts
Model 203–876, Series K
Ref. No. 20 Air Motor Assy
Includes items 17, 21–56, 62–64
38
46
37*
45
36
41
23
31
22
63
24
62
25
35
27
64
32*
30*
26
33
51
54
50*
28*
30*
55
17
15
2
21
52
9
11
3
19
16
18
56
12
*34
60
13
43
49*
42*
44
6
59
57
12
18
65
19
10
4
04124
Parts
Model 203–876, Series K
Ref.
No.
Part No.
2
3
4
100–111
100–279
101–579
6
9
10
11
12
13
15
16
17
18
19
20
154–662
156–641
156–989
157–184
158–402
158–857
160–697
183–010
222–501
171–590
171–594
203–963
21
100–078
22
101–578
23
24
25
26
27
28*
30*
31
32*
33
34*
35
156–698
158–360
158–362
158–364
167–585
158–367
160–261
160–613
160–618
172–867
160–621
160–623
Description
NUT, hex jam; 1/2–20
BALL, steel; 0.88” (22.2 mm) dia
PIN, roll; 0.12” (3.2 mm) dia;
0.75” (19 mm) long
O-RING; buna-N
O-RING; buna-N
SEAT, piston
HOUSING, piston
PACKING, cup; leather
SPACER, piston
ROD, connecting
CYLINDER, displacement
PLATE, warning (with muffler)
SPREADER, packing
WASHER, back-up
AIR MOTOR Assy, Series S
Includes items 17, 21–56, 62–64
. SCREW, hex washer hd mach;
no. 8–32 x 0.38”
. CAPSCREW, hex hd Nylock;
5/16–18 x 0.88”
. O-RING; buna-N
. YOKE, rod, trip
. PIN, toggle
. ROCKER, toggle
. SPRING, helical compression
. GROMMET; rubber
. NUT, adjusting
. CYLINDER (white color)
. LOCKWIRE, transfer valve
. ACTUATOR, valve
. O-RING; nitrile rubber
. ARM, toggle
Qty.
1
1
1
1
1
1
1
2
1
1
1
1
2
2
Ref.
No.
Part No.
36
37*
38
41
42*
43
44
45
46
49*
50*
51
52
53
160–624
160–625
190–024
222–499
160–896
160–932
161–059
161–435
112–843
170–708
170–709
203–965
204–895
214–036
54
102–975
55
56
57
59
60
62
63
64
65
172–866
1
12
6
1
1
2
2
2
2
4
1
2
1
1
2
101–190
157–182
156–633
104–029
104–582
180–233
183–009
Description
Qty.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
O-RING; buna-N
O-RING; buna-N
NUT, packing
PLATE, identification (with muffler)
STEM, valve
GASKET; copper
ROD, piston
NUT, cylinder cap
PACKING, block; polyurethane
POPPET, valve; urethane
POPPET, valve; urethane
ROD, trip
BASE (white color)
PISTON Assy
includes items 54–56 (also includes
repair kit 206–728 when ordered as
a replacement part)
. . SCREW, rd hd mach; no. 6–32 x
0.25”
. . CLIP, spring
. . PISTON, bare; not sold separately
BALL, steel; 1” (25 mm) dia
RETAINER, ball
O-RING; buna-N
LUG, grounding
WASHER, tab
LABEL, warning
BODY, intake valve
*
Included in repair kit 206–728.
Included in repair kit 237–498.
1
1
1
1
2
1
1
1
1
2
2
1
1
1
2
2
1
1
1
1
1
1
2
1
Parts
Model 204–254, Series N
Ref. No. 20 Air Motor Assy
Includes items 17, 21–56, 70–72
38
46
37*
45
36
23
41
9
22
31
16
71
70
24
25
35
52
32*
30*
27
26
33
51
50*
17
21
15
72
2
28*
30*
54
11
68
67
60
63
55
3
19
56
18
*34
72
43
59
12
49*
13
42*
6
64
65
58
12
44
18
19
10
4
04125
Parts
Model 204–254, Series N
Ref.
No.
Part No.
2
3
4
100–111
100–279
101–579
6
9
10
11
12
13
15
16
17
18
19
20
154–662
156–641
156–989
157–184
158–402
158–857
161–815
161–816
222–501
171–590
171–594
203–963
21
100–078
22
101–578
23
24
25
26
27
28*
30*
31
32*
33
34*
35
36
37*
38
156–698
158–360
158–362
158–364
167–585
158–367
160–261
160–613
160–618
172–867
160–621
160–623
160–624
160–625
190–024
Description
NUT, hex jam; 1/2–20
BALL, steel; 0.88” (22.2 mm) dia
PIN, roll; 0.12” (3.2 mm) dia;
0.75” (19 mm) long
O-RING; buna-N
O-RING; buna-N
SEAT, piston
HOUSING, piston
PACKING, cup; leather
SPACER, piston
ROD, connecting
CYLINDER, displacement
PLATE, warning (with muffler)
SPREADER, packing
WASHER, back-up
AIR MOTOR Assy, Series S
Includes items 17, 21–56, 70–72
. SCREW, hex washer hd mach;
no. 8–32 x 0.38”
. CAPSCREW, hex hd Nylock;
5/16–18 x 0.88”
. O-RING; buna-N
. YOKE, rod, trip
. PIN, toggle
. ROCKER, toggle
. SPRING, helical compression
. GROMMET; rubber
. NUT, adjusting
. CYLINDER (white color)
. LOCKWIRE, transfer valve
. ACTUATOR, valve
. O-RING; nitrile rubber
. ARM, toggle
. O-RING; buna-N
. O-RING; buna-N
. NUT, packing
Qty.
1
1
1
1
1
1
1
2
1
1
1
1
2
2
1
12
6
1
1
2
2
2
2
4
1
2
1
1
2
1
1
1
Ref.
No.
Part No.
41
42*
43
44
45
46
49*
50*
51
52
53
222–499
160–896
160–932
161–059
161–435
112–843
170–708
170–709
203–965
204–895
214–036
54
102–975
55
56
58
59
60
63
64
65
66
172–866
100–989
101–190
156–633
157–182
160–914
156–893
222–308
67
68
70
71
72
104–542
210–834
104–029
104–582
180–233
Description
Qty.
PLATE, identification (with muffler)
STEM, valve
GASKET; copper
ROD, piston
NUT, cylinder cap
PACKING, block; polyurethane
POPPET, valve; urethane
POPPET, valve; urethane
ROD, trip
BASE (white color)
PISTON Assy
includes items 54–56 (also includes
repair kit 206–728 when ordered as
a replacement part)
. . SCREW, rd hd mach; no. 6–32 x
0.25”
. . CLIP, spring
. . PISTON, bare; not sold separately
RING, retaining
BALL, steel; 1” (25 mm) dia
O-RING; nitrile rubber
RETAINER, ball
HOUSING, valve
BASE, valve
BUNG ADAPTER Assy
includes items 67 and 68
. SCREW, cap, hex hd; M8 x 1.25”
. ADAPTER, bung, bare
LUG, grounding
WASHER, tab
LABEL, warning
.
.
.
.
.
.
.
.
.
.
.
*
Included in repair kit 206–728.
Included in repair kit 237–498.
1
2
1
1
1
1
2
2
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
2
Parts
Model 222–087, Series B
Ref. No. 20 Air Motor Assy
Includes items 17, 21–56,
62–64
38
46
37*
36
45
41
9
23
31
16
22
63
24
62
25
35
32*
52
27
30*
15
26
33
17
21
64
51
50*
2
30*
60
59
3
57
19
55
67
11
28*
54
68
65
18
56
*34
12
13
49*
42*
43
69
6
12
18
44
19
10
4
04126
Parts
Model 222–087, Series B
Ref.
No.
Part No.
2
3
4
100–111
100–279
101–579
6
9
10
11
12
13
15
16
17
18
19
20
154–662
156–641
156–989
157–184
158–402
158–857
160–697
183–010
222–501
171–590
171–594
203–963
21
100–078
22
101–578
23
24
25
26
27
28*
30*
31
32*
33
34*
35
36
37*
38
156–698
158–360
158–362
158–364
167–585
158–367
160–261
160–613
160–618
172–867
160–621
160–623
160–624
160–625
190–024
Description
NUT, hex jam; 1/2–20
BALL, steel; 0.88” (22.2 mm) dia
PIN, roll; 0.12” (3.2 mm) dia;
0.75” (19 mm) long
O-RING; buna-N
O-RING; buna-N
SEAT, piston
HOUSING, piston
PACKING, cup; leather
SPACER, piston
ROD, connecting
CYLINDER, displacement
PLATE, warning (with muffler)
SPREADER, packing
WASHER, back-up
AIR MOTOR Assy, Series S
Includes items 17, 21–56, 62–64
. SCREW, hex washer hd mach;
no. 8–32 x 0.38”
. CAPSCREW, hex hd Nylock;
5/16–18 x 0.88”
. O-RING; buna-N
. YOKE, rod, trip
. PIN, toggle
. ROCKER, toggle
. SPRING, helical compression
. GROMMET; rubber
. NUT, adjusting
. CYLINDER (white color)
. LOCKWIRE, transfer valve
. ACTUATOR, valve
. O-RING; nitrile rubber
. ARM, toggle
. O-RING; buna-N
. O-RING; buna-N
. NUT, packing
Qty.
1
1
1
1
1
1
1
2
1
1
1
1
2
2
1
12
6
1
1
2
2
2
2
4
1
2
1
1
2
1
1
1
Ref.
No.
55
56
57
59
60
62
63
64
65
66
67
68
69
*
Description
Qty.
PLATE, identification (with muffler)
STEM, valve
GASKET; copper
ROD, piston
NUT, cylinder cap
PACKING, block; polyurethane
POPPET, valve; urethane
POPPET, valve; urethane
ROD, trip
BASE (white color)
PISTON Assy
includes items 54–56 (also includes
repair kit 206–728 when ordered as
a replacement part)
102–975
. . SCREW, rd hd mach; no. 6–32 x
0.25”
172–866
. . CLIP, spring
. . PISTON, bare; not sold separately
101–190
BALL, steel; 1” (25 mm) dia
157–182
RETAINER, ball
O-RING; nitrile rubber
156–633
104–029
LUG, grounding
104–582
WASHER, tab
180–233
LABEL, warning
183–009
BODY, intake valve
222–308
BUNG ADAPTER Assy
includes items 67 and 68
104–542
. SCREW, cap, hex hd; M8 x 1.25”
210–834
. ADAPTER, bung, bare
220–691
SUCTION TUBE Assy
Included in repair kit 206–728.
Included in repair kit 237–498.
41
42*
43
44
45
46
49*
50*
51
52
53
54
Part No.
222–499
160–896
160–932
161–059
161–435
112–843
170–708
170–709
203–965
204–895
214–036
.
.
.
.
.
.
.
.
.
.
.
1
2
1
1
1
1
2
2
1
1
1
2
2
1
1
1
1
1
1
2
1
1
1
1
1
Mounting Hole
Layout
161–023 Gasket
Four 0.265 in. (7 mm)
dia. holes on 5 in.
(127 mm) bolt circle
3 in. (76.2 mm) dia.
04127
Technical Data
Pump cycles per gallon . . . . . . . . . . . . . . . . . . . . . . . . 28
Maximum working pressure . . . . . . . . . 900 psi (62 bar)
Fluid pressure ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5:1
Air operating range . . . . . . . . 40 to 180 psi (3 to 12 bar)
Air consumption . . . . . . . . . . . 3 cfm per gallon pumped
(1.35 m/liter) at 100 psi (7 bar);
up to 8 cfm with pump operated
within recommended range
Maximum recommended pump speed . 66 cycles/min;
2.5 gpm (9.56 liter/min)
Pump cycles per liter . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
Recommended speed for
optimum pump life . . . . . . . . . . . 15 to 25 cycles per min
Wetted parts . . . . . . . . . Steel, Copper, Leather, Buna-N
Approximate weight . . . . . . . . . . . . . . . . . . 22 lb (10 kg)
Notes
Manual Change Summary
This manual was revised to update the drawings and
include the following changes:
Assembly
Changed
Part
Status
Ref
No.
Part No.
Name
Page 27: Under Mounting Hole Layout, Part
Number 161–023, Gasket, was changed to have four
holes. This will allow either a two hole or four hole
mounting configuration.
203–857,
203–872,
203–876,
204–254 &
222–087
Deleted
Deleted
Deleted
Deleted
29
39
40
47
159–312
160–632
160–634
169–133
Male Gland
Washer
Flat Packing
Female Gland
Old
New
38
38
160–631
190–024
Packing Nut
Packing Nut
Old
New
46
46
159–314
112–843
V-Packing
Block Packing
Series Change: Model 203–857 to Series K; Model
203–872 to Series K; Model 203–876 to Series K;
Model 204–254 to Series N; and Model 222–087 to
Series B. Air Motor 203–963 to Series S.
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 defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.
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, installation, 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 consequential 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 distributor, or call this number to identify the distributor
closest to you: 1–800–367–4023 Toll Free
FOR TECHNICAL ASSISTANCE, service repair
information or assistance regarding the application of
Graco equipment: 1–800–543–0339 Toll 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
PRINTED IN U.S.A.
306–518 7/55 Revised 11/94
55440–1441