INSTRUCTIONS–PARTS LIST 306–517

Rev. N
Supersedes M
This manual contains IMPORTANT
WARNINGS AND INSTRUCTIONS
READ AND RETAIN FOR REFERENCE

50:1 RATIO FIRE–BALL
PUMPS

8000 psi (560 bar) Maximum Working Pressure
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 operat-
ing conditions and result in component rup-
ture, fire or explosion which can cause seri-
ous bodily injury, including fluid injection.

CHASSIS LUBE PUMPS

With Lifetime Guarantee*
1. This guarantee is offered to the original purchaser for
his Entire Lifetime. It covers all Fire–Ball and Presi-
dent Series lubrication pumps manufactured by
Graco Inc., USA, when used in pumping non–corro-
sive 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 workman-
ship.
3. Graco will repair or replace such pumps at a Reason-
able Charge if inspection by Graco reveals that dam-
age was the result, in whole or in part, of causes other
than defective materials or workmanship.
4. Pumps for which guarantee claims are made must be
returned prepaid to the factory, factory branch or serv-
ice agency accompanied by proof of purchase, estab-
lishing the owner as the original purchaser.
5. The foregoing is in lieu of all other warranties, ex-
pressed or implied, and the manufacturer neither as-
sumes nor authorizes any person to assume for it any
other obligation or liability in connection with said
equipment.
*30 years to corporations and purchasers other than
natural persons. See page 3 for available models.

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441

 TABLE OF CONTENTS

Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . 8

Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . 3 Displacement Pump Repair . . . . . . . . . . . . . . . . . . . . 9
Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . . . . 3 Air Motor and Throat Packing Repair . . . . . . . . . . 10
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Parts Lists & Drawings . . . . . . . . . . . . . . . . . . . . . . . 12
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Graco Warranty . . . . . . . . . . . . . . . . . . . . . . Back Cover
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

TERMS

Be sure you read and understand each of these terms DISPENSING V ALVE: Any fluid dispensing device
before reading the rest of the manual. which can be triggered on and off.
WARNING: Alerts user to avoid or correct conditions FLEXIBLE NOZZLE: A flexible rubber hose which ex-
which could cause bodily injury. tends from the dispense valve to a non–drip tip. Normally
CAUTION: Alerts user to avoid or correct conditions used for dispensing automatic transmission fluid.
which could cause damage to or destruction of equip- RIGID NOZZLE: A rigid tube which extends from the dis-
ment. pense valve to a non–drip tip. Normally used for dispens-
NOTE: Gives additional information or helpful hints. ing motor oil, gear oil, etc.

DISPENSE: To release fluid through the dispensing NON–DRIP TIP: A manually operated twist–type valve
valve, which allows the fluid to flow out in a steady or me- tip used to stop flow from the dispense nozzle when dis-
tered stream. pensing is completed.

 

 DIMENSIONAL DRAWING

MODEL 203–868, Series H MODEL 221–034, Series A MODEL 203–869, Series H MODEL 207–609, Series D
400 lb drum size 400 lb drum size 120 lb drum size 50 lb pail size

Grndg Grndg Grndg

Lug Lug Lug
Grndg
Fluid Fluid Fluid Lug
Outlet Outlet Outlet
Fluid
Outlet

33.6” 33.6”
(654 mm) 2.67” 17.5”
(654 mm) (678 mm) (444 mm)

Overall length: Overall length: Overall length: Overall length:

45.4” (1153.9 mm) 45.4” (1153.9 mm) 38.4” (115.9 mm) 31” (787 mm)

MOUNTING HOLE LAYOUT TECHNICAL DATA

Maximum working pressure . . . . . . . 8000 psi (560 bar)
Fluid pressure ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . 50:1
Air operating range . . . . . . . . 40 to 160 psi (3 to 11 bar)
Air consumption . . . . . . . . . . . 3 cfm per gallon pumped
(1.35 m3/liter) at 100 psi (7 bar)
up to 8 cfm with pump operated
within recommended ranged
Pump cycles per gallon . . . . . . . . . . . . . . . . . . . . . . . 310
161–023 GASKET
Pump cycles per liter . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Maximum recommended pump speed . 76 cycles/min
TWO 0.31” (7.9 mm) 1/4 gpm (1 liter/min)
DIA. HOLES ON 5” Wetted parts . . . . . . . . . . . . . . . Steel, Brass, Aluminum,
(127 mm) BOLT CIRCLE Nylon, Nitrile rubber
Approximate weight . . . . . . . . . . . . . . . . . . 22 lb (10 Kg)
3.25” (82.6 mm) DIA


 
 SAFETY WARNINGS
HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY.
FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS
Read and understand all instruction manuals before operating equipment.

FLUID INJECTION HAZARD

General Safety Pressure Relief Procedure
This equipment generates fluid pressure high enough to To reduce the risk of serious bodily injury, including fluid
cause an injection injury. Spray from the dispense valve injection or splashing in the eyes or on the skin, always
or fluid emitted under high pressure from leaks or rup- follow this procedure whenever you shut of f the pump,
tured components can inject fluid through your skin and when checking or servicing any part of the system, when
into your body and cause extremely serious bodily injury, installing or changing dispensing devices, and whenever
including the need for amputation. Also, fluid injected or you stop dispensing.
splashed into the eyes or on the skin can cause serious
damage. 1. Close the pump air regulator.
2. Hold a metal part of the valve firmly to a grounded
NEVER point the dispensing valve at anyone or at any
metal waste container and trigger the valve to relieve
part of the body. NEVER put hand or fingers over the end
the fluid pressure.
of the dispensing valve.
Dispensing Valve Safety (if applicable)
ALWAYS follow the Pressure Relief Procedure , right, Do not modify any part of the dispensing valve. Only use
before cleaning or removing the nozzle or servicing any extensions and no–drip tips which are designed for use
system equipment. with your dispensing valve. Modifying parts can cause a
malfunction and result in serious bodily injury, including
NEVER try to stop or deflect leaks with your hand or
fluid injection and splashing in the eyes or on the skin.
body.
Flexible Nozzle Safety
Be sure equipment safety devices are operating properly Be sure you know the maximum working pressure of the
before each use. flexible nozzle you are using. Never exceed that pres-
sure, even if your dispensing valve and/or pump is rated
Medical Alert––Injection Wounds
for higher working pressures.
If any fluid appears to penetrate your skin, get EMER-
GENCY MEDICAL CARE AT ONCE. DO NOT TREAT Never use a low pressure flexible nozzle, designed for
AS A SIMPLE CUT. Tell the doctor exactly what fluid was low pressure dispensing valves or hand–powered lubri-
injected. cating equipment, on a high pressure dispensing valve.
Note to Physician: Injection in the skin is a traumatic in- Grease Fitting Coupler Safety
jury. It is important to treat the injury surgically as soon Use extreme caution when cleaning or changing grease
as possible. Do not delay treatment to research toxic- fitting couplers. If the coupler clogs while dispensing,
ity. Toxicity is a concern with most lubricants injected STOP DISPENSING IMMEDIA TELY. Follow the Pres-
directly into the blood stream. Consultation with a sure Relief Procedure , above. Then remove the cou-
plastic surgeon or reconstructive hand surgeon may pler to clean it. Never wipe off buildup around the coupler
be advisable. until pressure is fully relieved.

HOSE SAFETY

High pressure fluid in the hoses can be very dangerous. If damage or movement of the hose couplings. If any of
the hose develops a leak, split or rupture due to any kind these conditions exist, replace the hose immediately. DO
of wear , damage or misuse, the high pressure spray NOT try to recouple high pressure hose or mend it with
emitted from it can cause a fluid injection injury or other tape or any other device. A repaired hose cannot contain
serious bodily injury or property damage. the high pressure fluid.
TIGHTEN all fluid connections securely before each use. HANDLE AND ROUTE HOSES CAREFULL Y. Do not
High pressure fluid can dislodge a loose coupling or allow pull on hoses to move equipment. Do not use fluids or sol-
high pressure spray to be emitted from the coupling. vents which are not compatible with the inner tube and
cover of the hose. DO NOT expose Graco hose to tem-
NEVER use a damaged hose. Before each use, check peratures above 180_ F (82_ C) or below –40_ F (–40_
entire hose for cuts, leaks, abrasion, bulging cover , or C).

4 306-517
EQUIPMENT MISUSE HAZARD
General Safety Fluid Compatibility
Any misuse of the dispensing equipment or accessories, BE SURE that all lubricants or fluids used are chemically
such as overpressurizing, modifying parts, using incom- compatible with the wetted parts shown in the Technical
patible chemicals and fluids, or using worn or damaged Data. Always read the fluid and solvent manufacturer ’s
parts, can cause them to rupture and result in fluid injec- literature before using them in this system.
tion or other serious bodily injury, fire, explosion or prop-
erty damage. System Pressure
To reduce the risk of overpressurizing any part of your
NEVER alter or modify any part of this equipment; doing system, be sure you know the maximum working pres-
so could cause it to malfunction. sure rating of each pump and its connected components.
The MAXIMUM WORKING PRESSURE of the
CHECK all dispense equipment regularly and repair or 50:1 Ratio Fire–Ball Pumps is 8000 psi (560 bar).
replace worn or damaged parts immediately. at a maximum air operating pressure of 160 psi (11 bar).
Reduce the air pressure to reduce the fluid pressure. See
ALWAYS read and follow the lubricant or fluid manufac- the Maximum Working Pressure Warning on page 7.
turer’s recommendations regarding the use of protective Never exceed the maximum working pressure of the low-
clothing and equipment. est rated component in each system.

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers or other KEEP CLEAR of moving parts when starting or operating
body parts. The piston in the air motor, located behind the the pump. Before checking or servicing the pump, follow
air motor plates, moves when air is supplied to the motor. the Pressure Relief Procedure on page 4 to prevent the
Therefore, NEVER operate the pump with the air motor pump from starting accidentally.
plates removed.

FIRE OR EXPLOSION HAZARD

Static electricity is created by the flow of fluid through the 5. To maintain grounding continuity when flushing or re-
pump and hose. If the pump is not properly grounded, lieving pressure, always hold a metal part of the valve
sparking may occur, and the system may become haz- firmly to the side of a grounded metal pail, then trig-
ardous. Sparking may also occur when plugging in or un- ger the valve.
plugging a power supply cord. Sparks can ignite fumes
from solvents, dust particles and other flammable sub-
stances, whether you are operating indoors or outdoors, To ground the pump, loosen the grounding lug
and can cause a fire or explosion and serious bodily injury locknut (W) and washer (X). Insert one end of a 12
and property damage. ga (1.5 mm2) minimum ground wire (Y) into the slot
in lug (Z) and tighten locknut securely. Connect the
If you experience any static sparking or even a slight other end of the wire to a true earth ground. Refer to
shock while using this equipment, STOP SPRAYING IM- page 15 to order a ground wire and clamp.
MEDIATELY. Check for proper grounding. Do not use the
system again until the problem has been identified and Z
corrected.
Grounding
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 Y
SURE to ground all of this spray equipment:
1. Pump: use a ground wire and clamp as shown to the X
W
right.
2. Air and Fluid hoses: use only grounded hoses.
3. Air compressor: follow manufacturer ’s recommen-
dations.
4. Fluid supply container: according to local code.

IMPORTANT

United States Government safety standards have been adopted under the Occupational Safety and Health Act. These
standards––particularly the General Standards, Part 1910––should be consulted.

 
 TYPICAL INSTALLATION

For Stationary Mountings

C D
B

E
G F

KEY
A Fluid dispense line
B Pump ground wire
C Air regulator
1/2 in. D Main air supply line
E Air filter
F Pump lubricator
G Pump runaway valve
H Follow plate

INSTALLATION
1. Mounting NOTE: Install the air line accessories in the order shown
in the TYPICAL INSTALLATION.
a. Plan the mounting layout for easy operator ac-
cess to the pump air controls, sufficient room to
change drums and a secure mounting platform. a. Install a pump runaway valve (G) to shut off the
air to the pump if the pump accelerates beyond
b. If using a follow plate (H), remove the drum the pre–adjusted setting. A pump which runs too
cover. Scoop the material to the center of the fast can be seriously damaged.
drum to make the surface concave. Place the
plate on the material. Guide the pump foot valve
b. Install an air line lubricator (F) for automatic air
through the plate.
motor lubrication.
c. Mount the pump to the drum cover or other suit-
able mounting device. c. Install the air regulator (C) to control pump speed
d. For ease in changing drums, install a pump ele- and pressure.
vator.
d. On the main air supply line from the compressor,
install an air line filter (E) to remove harmful dirt
2. Air and Fluid Line and Accessories and contaminants from your compressed air
Refer to The Typical Installation above. supply.

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 ac-
cessories.

GROUNDING
Proper grounding is an essential part of maintaining a
safe system. Read and follow the grounding instructions
in FIRE OR EXPLOSION HAZARD on page 5.
 

 OPERATION
WARNING WARNING
Pressure Relief Procedure Maximum Working Pressure
To reduce the risk of serious bodily injury, including The maximum working pressure of each compo-
fluid injection or splashing in the eyes or on the skin, nent in your system may not be the same. T o re-
always follow this procedure whenever you shut off duce the risk of overpressurizing any part of your
the pump, when checking or servicing any part of the system, be sure you know the maximum working
system, when installing or changing grease fitting pressure rating of each component. Never exceed
couplers, and whenever you stop dispensing. the maximum working pressure of the lowest rated
1. Close the pump air regulator. component connected to a pump.
2. Hold a metal part of the dispense valve firmly to To determine the fluid output pressure using the air
a grounded metal waste container and trigger to regulator reading, multiply the ratio of the pump by
relieve the fluid pressure. the air pressure shown on the regulator gauge. For
example:
50 (:1) ratio x 100 psi air =
Startup 5000 psi fluid output
[50:(1) ratio x 7 bar air = 350 bar fluid output]
1. If there are multiple pumps on the air line, close the
air regulators and bleed–type master air valves to all Limit the air to the pump so that no air line or fluid
but one pump. If there is only one pump, close its air line component or accessory is overpressurized.
regulator and bleed–type master air valve.
2. Open the master air valve from the compressor.
6. Never allow the pump to run dry of the material being
3. For the pump which is supplied with air, open the dis- pumped. A dry pump will quickly accelerate to a high
pensing valve into a grounded metal waste con- speed, possibly damaging itself. If your pump accel-
tainer, making firm metal–to–metal contact between erates quickly, or is running too fast, stop it immedi-
the container and valve. Open the bleed–type mas- ately and check the material supply . If the supply
ter air valve and open the pump air regulator slowly, container is empty and air has been pumped into the
just until the pump is running. When the pump is lines, prime the pump and lines with material, or flush
primed and all air has been pushed out of the lines, it and leave it filled with a compatible solvent. Be sure
close the dispense valve. to eliminate all air from the material lines.
4. If you have more than one pump, repeat this proce- NOTE: A pump runaway valve (G) can be installed on
dure for each pump. the air line to automatically shut off the pump if it
starts to run too fast.
NOTE: When the pump is primed, and with sufficient air
supplied, the pump starts when the dispensing 7. Read and follow the instructions supplied with each
valve is opened and shuts off when it is closed. component in your system.
5. Set the air pressure to each pump at the lowest pres- 8. To shut off the system, always follow the Pressure
sure needed to get the desired results. Relief Procedure Warning, at the left.


 
 TROUBLESHOOTING GUIDE
WARNING WARNING
Pressure Relief Procedure NEVER operate the pump with the air motor warning
To reduce the risk of serious bodily injury , including plate or the identification plate removed as these
injection, always follow this procedure whenever you plates enclose the piston and help protect your fin-
shut off the pump, and before inspecting, removing, gers from serious injury, including amputation.
cleaning or repairing any part of the pump or system.
(1) Close the bleed–type master air valve (required
in the system).
NOTE: Check all other possible problems and solutions
(2) Open the dispensing valve until pressure is fully before disassembling the pump.
relieved.
If you suspect that the nozzle or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, VER Y SLOWL Y
loosen the nozzle or hose end coupling and relieve
pressure gradually , then loosen completely . Now
clear the nozzle or hose.

PROBLEM CAUSE SOLUTION

Pump fails to operate Inadequate air supply pressure or re- Increase air supply; clear
stricted air lines

Closed or clogged valves Open; clean

Clogged material lines, hoses, Clear*

valves, etc.

Damaged air motor Service air motor

Exhausted material supply Refill and reprime or flush

Continuous air exhaust Worn or damaged air motor gasket, Service air motor
packing, seal, etc.

Erratic pump operation Exhausted material supply Refill and reprime or flush

Held open or worn intake valve or pis- Clear; service

ton packings

Pump operates, but output low on Held open or worn piston packings Clear; service
up stroke

Pump operates, but output low on Held open or worn intake valve Clear; service
down stroke

Pump operates, but output low on Inadequate air supply pressure or re- Increase air supply; clear
both strokes stricted air lines

Closed or clogged valves Open; clean

Exhausted material supply Refill and reprime or flush

Clogged material lines, hoses, Clear*

valves, etc.

Packing nut too tight Loosen

Loose packing nut or worn packings Tighten; replace

*Follow the Pressure Relief Procedure Warning, above, and disconnect the material line. If the pump
start when the air is turned on again, the line, etc., is clogged.

8 306-517
 DISPLACEMENT PUMP SERVICE
Before you start: 8. If the pressed–on brass guide (53) needs replacing,
clamp it in a vise and drive the packing retainer (54)
1. Be sure you have all necessary parts on hand. If us- out with a plastic hammer . The new guide must be
ing a repair kit, use all the parts in the kit for the best started onto the retainer squarely.
results.
Displacement Pump Repair Kit 204–164 is avail- 9. Lubricate all the parts with light waterproof grease
able for Pumps 203–868, 203–869 and 207–609. and reassemble the pump. Apply medium–strength
Displacement Pump Repair Kit 221–036 is avail- Loctite to the threads of the packing retainer (60).
able for Pump 221–034. Parts included in the kit are
marked with two asterisks, for example, (22**), in the 10. If the ground wire was disconnected before servic-
text and drawings. See page 14 for ordering these ing, be sure to reconnect it before regular operation
kits. of the pump.
A special Tune–up Kit 221–037 is also available for
Pump 221–034. See page 14 for parts included in
that kit.
24
2. A 0.25 in. (6.4 mm) diameter rod (K) is required for
disassembling the pump.
Disassembly 34

1. Flush the pump. Follow the Pressure Relief Proce- 12

dure Warning, page 8, before proceeding.
2. Disconnect the hoses, remove the pump from its
mounting, and clamp the air motor base in a vise.
3. Clamp the pump base (35) in a vise. Screw the prim- 19
ing tube (46) off of the displacement cylinder (61).
25
4. Hold the displacement tube (55) with the rod (K) and LIPS OF
screw the priming plunger (45) off the displacement V–PACKING
FACE DOWN
tube.
5. Use a pipe wrench at the knurled part of the displace-
ment cylinder (61) to screw it out of the base. Screw
the packing retainer (60) out of the tube. Remove the
seal (59), guides (56,58) and packing (57). See Fig
9–1.

18
35
62
55
47

42

62
K
54
45

Fig 9–1

6. Use the rod (K) to screw the displacement tube (55)

out of the check valve packing retainer (54). Remove 60
the gasket (49), seat (48) and ball (40). Then screw APPLY MEDIUM–
the packing retainer out of the coupling (47). Remove STRENGTH LOCTITE
TO THREADS
the upper gasket, seat and ball, and the guide (50), 46
packing (51), and washer (52). Do not remove the
press–fit brass guide (53).
7. 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 necessary. Fig 9–2
The checkball seats (48) can be turned over to pro-
vide new seats.
306-517 9
 AIR MOTOR and THROAT SERVICE
Before you start: 8. Use a screwdriver to push down on the trip rod yoke
(7) and snap the toggles down. See Fig 10–1. Re-
1. Be sure you have all necessary parts on hand. Re- move the lockwires (13) from the adjusting nuts (11)
pair kit 206–728 is available for the motor and throat. of the transfer valves. Screw the top nuts off. Screw
Use all the parts in the kit for the best results. Parts the stems (22) out of the grommets (10) and bottom
included in the kit are marked with one asterisk, for nuts. Take the valve poppets (30) off the stems and
example, (10*), in the text and drawings. squeeze them firmly to check for cracks.

2. Two accessory tools should be used. Padded pli-

ers, 207–579. is used to grip the trip rod without dam-
PUSH IN
aging its surface. Gauge, 171–818, is used to as- 7
34 13
sure the proper clearance between the poppets and EASE OUT
seat of the transfer valve. See ACCESSORIES for
ordering.
15
Disassembly
11
1. Flush the pump. Follow the Pressure Relief Proce-
dure Warning, page 8, before proceeding.
22
2. Disconnect the hoses, remove the pump from its
mounting, and clamp the air motor base in a vise. 9
3. Use a pipe wrench on the knurled part of the cylinder
(61) to screw it out of the base (35).
J
4. Pull the connecting rod (62) down as far as it will go.

5. Use a hammer and punch to remove the roll pin (42) Fig 10–1
from the piston rod (18), and then screw the connect-
ing rod (62) out of the piston rod.
9. Grip the toggle rockers (9) with a pliers. Compress
the springs up, away from the piston lugs, and re-
CAUTION move the parts. Check to see that the valve actuator
DO NOT damage the plated surface of the trip rod. (33) is supported by the spring clips (38), but slides
Damaging the surface of the trip rod can result in er- easily into them.
ratic air motor operation. Use the special padded pli- 10. Remove the trip rod yoke, actuator and trip rod (4).
ers, 207–579, to grasp the rod. Check the exhaust valve poppets (31) for cracks.
11. Remove one of the air motor plates ( 32 or 64). Pull
6. Manually push on the piston rod (18) to move the pis- the piston up out of the base. Remove the throat
ton (39) up as far as it will go. Unscrew the cylinder packing nut (10), packings (25), gland (27), backup
cap nut (24). Pull the nut up. Grip the trip rod (34) with washer (20), flat packing (21) and bearing (28).
padded pliers and screw the nut off the rod.
NOTE: To remove the exhaust valve poppets (31),
7. Remove the six screws (3) holding the cylinder (12) stretch them out and cut with a sharp knife.
to the base. Carefully pull the cylinder straight up off Reassembly
the piston (39).
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.
CAUTION
To avoid damaging the cylinder wall, lift the cylinder 2. Check the polished surfaces of the piston, piston rod
STRAIGHT UP off of the piston. NEVER tilt the cyl- and cylinder wall for scratches or wear. A scored rod
inder as it is being removed. will cause premature packing wear and leaking.
3. Lubricate all parts with a light, waterproof grease.
4. Install the v–packings (25), bearing and washer one
WARNING at a time, with the lips of the v–packings facing down.
To reduce the risk of pinching or amputating your fin- Screw the packing nut(10) into the base loosely.
gers, ALWAYS keep fingers clear of the toggle as- 5. Slide the piston rod (18) down through the packings
semblies (J). and lower the piston into the base. Be sure the o–
rings are in place.

 

 AIR MOTOR and THROAT SERVICE
6. Pull the exhaust valve poppets (31) into the valve ac- 7. Install the transfer valve grommets (10), then reas-
tuator (33) and clip off the top part shown with dotted semble the valve mechanism. Before installing the
lines. See Fig 11–1. lockwires (13) in the adjusting nuts (11), use the spe-
cial 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
11–1. Snap the toggles (15) to the up position.
8. Reassemble the air motor and assemble to the dis-
33 placement pump. Before installing the air motor
31 plate, tighten the throat packing nut (19) just snug ––
10
don’t over tighten.
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
30 0.145”
of the pump.
(3.7 mm)

Fig 11–1


 
 PARTS DRAWING

See Repair Kit information on page 14.

24

12

13
9
11 26 19
15
9 21
26 20
15 7
8
10 28
11
31 44
29 25
14 16
27 2 32 61
17

39 71
23 221–034
ONLY
30 3
22

5
4

18 35 67
203–869
203–869
62 207–609 55
64 2 ONLY
47
42
42 56

40 57
49 58
50 59
Ref No. 69
Piston 51 60
Includes these items 52
53 45
54
42 46
40
48
49

 

 PARTS LISTS
Model 203–868, Series H Model 207–609, Series D
400 lb drum size 50 lb pail size
Includes items 1 – 65, 67–70 Includes items 1–65, 67–70

Model 203–869, Series H Model 221–034, Series A

120 lb drum size 400 lb drum size
Includes items 1 – 65, 67–70 Includes items 1 – 65, 68–71
REF REF
NO PART NO. DESCRIPTION QTY NO PART NO. DESCRIPTION QTY
1 203–964 AIR MOTOR ASSY, 45 160–667 PISTON, PRIMING 1
SERIES P (MODEL 203–868, 203–869 ONLY) 46 160–668 CYLINDER, INTAKE 1
INCLUDES ITEMS 2–39, 64, 68 1 47 160–669 COUPLING, HEX 1
206–404 AIR MOTOR ASSY, 48 160–670 SEAT, VALVE; REVERSIBLE 2
SERIES K (MODEL 207–609 ONLY) 49 160–671** GASKET, COPPER 2
INCLUDES ITEMS 2–39, 64, 67, 68 1 50 160–672** GUIDE, UPPER, BRASS 1
221–060 AIR MOTOR ASSY., 51 160–673** PACKING, UPPER PISTON
SERIES B (MODEL 221–034 ONLY BLOCK, BUNA–N 1
INCLUDES ITEMS 2–39, 64, 68 680–239 PACKING, UPPER PISTON
2 100–078 .SCREW , HEX HEAD, BLOCK, BUNA–N 1
NO. 8–32 X 0.38 IN. LG. 12 52 160–674** WASHER, BACKUP, NYLON 1
3 101–578 .SCREW , HEX HEAD , 53 160–675** GUIDE, LOWER 1
NO. 8–32 X 0.38 IN. LG. 6 54 160–676 RETAINER, PACKING 1
4 104–029 .LUG, GROUNDING 1 55 160–677 TUBE, DISPLACEMENT 1
5 104–582 .WASHER, TAB 1 56 160–678** GUIDE, DISPL. TUBE, BRASS 1
6 156–698 .O–RING, BUNA–N 1 57 160–679** PACKING, SHOVEL TUBE
7 158–360 .YOKE, ROD, TRIP 1 BLOCK, BUNA–N
8 158–362 .PIN, TOGGLE 2 (MODELS 203–868, 203–869
9 158–364 .ROCKER, TOGGLE 2 AND 207–609 ONLY) 1
10 158–367* .GROMMET, RUBBER, AIR INTAKE 2 680–277 PACKING, SHOVEL TUBE
11 160–261* .NUT, ADJUSTING 4 BLOCK, BUNA–N
12 160–613 .CYLINDER AIR MOTOR 1 (MODEL 221–034 ONLY) 1
13 160–618* .LOCKWIRE, TRANSFER VALVE 2 58 160–680** GUIDE, DISPL. TUBE, NYLON 1
14 160–621* .O–RING, NITRILE RUBBER 1 59 160–681** SEAL, PACKING RETAINER;
15 160–623 .ARM, TOGGLE 2 NYLON 1
16 160–624 .O–RING, BUNA–N 1 60 160–682 RETAINER, PACKING 1
17 160–625 * .O–RING, BUNA–N 1 61 160–683 CYLINDER (MODEL 203–869 ONLY) 1
18 160–639 .ROD, PISTON 1 160–685 CYLINDER (MODEL 207–609 ONLY) 1
19 160–640 .NUT, PACKING 1 160–687 CYLINDER (MODEL 203–868 ONLY) 1
20 160–641 .WASHER, BACK–UP 1 62 160–684 ROD, CONNECTING; 12”
21 160–644** .PACKING; FLAT LEATHER 1 (304.8 MM) LONG
(MODEL 203–869 ONLY) 1
22 160–896* .STEM, VALVE 2
160–686 ROD, CONNECTING;
23 160–932 .GASKET, COPPER 1
12” (304.8 MM) LONG
24 161–435 .NUT, CYLINDER, CAP
(MODEL 207–609 ONLY) 1
(MODEL 203–868, 203–869 ONLY) 1
160–688 ROD, CONNECTING;
164–704 .NUT, CYLINDER CAP
12” (304.8 MM) LONG
(MODEL 207–609 ONLY) 1 (MODEL 203–868 ONLY) 1
25 162–391** .V–PACKING; LEATHER 64 222–501 PLATE, WARNING
(MODELS 203–868, 203–869, WITH MUFFLER 1
207–609 ONLY) 5 67 162–718 ADAPTER,3/8 NPT(M)
164–555** .V–PACKING; PTFE
X 1/4 NPT(F)
(MODEL 221–034 ONLY) 5 MODELS 203–868, 203–869, 207–609 1
26 167–585 .SPRING, HELICAL COMPRESSION 2 68 180–233 LABEL, WARNING 2
27 168–851 ** .GLAND, MALE 1 69 207–069 PISTON ASSEMBLY (MODELS
28 168–852 ** .BEARING, THROAT 1 203–868, 203–869, 207–609 ONLY)
29 172–866 CLIP, SPRING 2 INCLUDES ITEMS 40, 42 (QTY 2),
30 170–708 * .POPPET, VALVE, URETHANE 2 & 47 TO 55 1
31 170–709* .POPPET, VALVE, URETHANE 2 221–035 PISTON ASSEMBLY
32 222–499 .PLATE, IDENTIFICATION (MODELS 221–034 ONLY)
WITH MUFFLER 1 INCLUDES ITEMS 40, 42 (QTY 2),
33 172–867 .ACTUATOR, VALVE 1 & 47 TO 55 1
34 203–965 .ROD, TRIP 1 70 172–479 TAG, WARNING 1
35 204–896 .BASE, AIR MOTOR 1 71 169–971 FITTING, AIR LINE
37 102–975 .SCREW, RD HD MACH; MODEL 221–034 ONLY 1
.NO. 6–32 X 0.25” 2
39 160–614 .PISTON, AIR MOTOR NOTE: See page 14 for ordering repair kits.
40 100–069** .BALL, STEEL; 1/4” DIA. 2 *Included in Repair Kit 206–728.
42 101–579 .PIN, ROLL 0.12” (3.2 MM) DIA **Included in Repair Kit 204–164 or 221–036 as appropriate.
0.75” (19 MM) LG 2
44 150–694 GASKET: COPPER 1

 
 REPAIR KITS SERVICE INFORMATION
206–728 Air Motor Repair Kit Listed below by the assembly changed are OLD and
Must be purchased separately NEW parts.
Consists of:
Ref No. Qty Assembly Ref
10 2 Changed Status No. Part No. Description
11 4
13 2 203–964 OLD 172–464 Plate
14 1 Air Motor NEW 32 222–499 Plate with
17 1 to Series P, muffler
22 1 206–404 OLD 172–457 Plate
22 2 Air Motor NEW 64 222–501 Plate with
30 2 to Series K, muffler
31 2 221–060
Air Motor
to Series B
204–164 Displacement Pump Repair Kit
FOR PUMP MODELS 203–868, 203–869
AND 207–609 ONLY INTERCHANGEABILITY NOTE: NEW parts replace the
Must be purchased separately OLD parts listed directly above them.

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
49 2 58 1
50 1 59 1

221–036 Displacement Pump Repair Kit

FOR PUMP MODELS 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
49 2 58 1
50 1 59 1

221–037 Tune–Up Kit

FOR PUMP MODELS 221–034 ONLY
Must be purchased separately

Consists of:
Ref No. Qty
50 1
51 1
52 1
53 1
56 1
58 1
59 1

14 306-517
 ACCESSORIES

Air Line Lubricator Bleed–type Master Air Valve 107–142

250 psi (127.5 bar) Maximum Working Pressure 300 psi (21 bar) Maximum Working Pressure
214–847 3/8” npt
Relieves air trapped in the air line between the
214–848 1/2” npt pump air inlet and this valve when closed.
1/2” npt

Air Regulator
300 psi Maximum Working Pressure
109–075 3/8” npt
104–266 1/2” npt Grounding Clamp & Wire 222–011
12 ga, 25 ft (7.6 m) wire

Pump Runaway Valve 215–362

180 psi (12 bar) Maximum Working Pressure

Shuts off air suppy to the pump if the pump ac-

celerates beyond the pre–adjusted setting due
to an empty supply container, interrupted fluid
supply to the pump or excessive cavitation. Air Line Filter
3/4” npt(f) 250 psi (127.5 bar) Maximum Working Pressure
106–148 3/8” npt
106–149 1/2” npt


 
 THE GRACO WARRANTY AND DISCLAIMERS
WARRANTY

Graco warrants all equipment manufactured by it and bearing its name to be free from defects in mate-
rial 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 ap-
plies 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 mainte-
nance, 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, manu-
facture, 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 re-
pair or replace free of charge any defective parts. The equipment will be returned to the original pur-
chaser 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 LI-
ABILITIES, BASED ON NEGLIGENCE OR STRICT LIABILITY. EVERY FORM OF LIABILITY FOR DIRECT, SPECIAL OR CON-
SEQUENTIAL DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND DENIED. IN NO CASE SHALL GRACO’S LIABILITY EX-
CEED THE AMOUNT OF THE PURCHASE PRICE. ANY ACTION FOR BREACH OF W ARRANTY 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 mo-
tor, 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.

Factory Branches: Atlanta, Chicago, Dallas, Detroit, Los Angeles, West Caldwell (N.J.)
Subsidiary and Affiliate Companies: Canada; England; 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 10–89