Graco Marine Sanitation System 206405 User Manual

Instructions–Parts List  
15:1 Fire-BallR 300 Pumps  
306531Z1  
For pumping petroleum–based undercoating material.  
2700 psi (18.6 MPa, 186 bar) Maximum Working Pressure  
180 psi (1.2 Ma, 12 bar) Maximum Air Input Pressure  
Model No. 206405, Series K  
35 lb. pail size  
Model No. 206699, Series J  
120 lb. drum size  
Model No. 206700, Series J  
400 lb. drum size  
Important Safety Instructions  
Read all warnings and instructions in this manual.  
Save these instructions.  
WARNING  
This product is designed to be used for pumping  
non-corrosive and non-abrasive fluids only. Any  
other use can cause unsafe operating conditions  
and result in component rupture, fire, or explosion,  
which can cause serious injury, including skin  
injection.  
Table of Contents  
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10  
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . 12  
Air Motor Service . . . . . . . . . . . . . . . . . . . . . . . . 13  
Displacement Pump Service . . . . . . . . . . . . . . 16  
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18  
Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . 23  
Dimensional Drawings . . . . . . . . . . . . . . . . . . . 23  
Model 206405 Shown  
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . 23  
Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . 24  
Graco Phone Numbers . . . . . . . . . . . . . . . . . . . 24  
04208B  
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WARNING  
SKIN INJECTION HAZARD  
Spray from the gun, 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.  
D Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate  
surgical treatment..  
D Do not point the gun at anyone or at any part of the body.  
D Do not put your hand or fingers over the spray tip.  
D Do not stop or deflect leaks with your hand, body, glove or rag.  
D Do not “blow back” fluid; this is not an air spray system.  
D Always have the tip guard and the trigger guard on the gun when spraying.  
D Check the gun diffuser operation weekly. Refer to the gun manual.  
D Be sure the gun trigger safety operates before spraying.  
D Close the gun ball valves when you stop spraying.  
D Lock the gun trigger safety when you stop spraying.  
D Follow the Pressure Relief Procedure on page 8 if the spray tip clogs and before cleaning,  
checking or servicing the equipment.  
D Tighten all fluid connections before operating the equipment.  
D 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.  
D Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by  
kinks or bends near the couplings.  
MOVING PARTS HAZARD  
Moving parts can pinch or amputate your fingers.  
D Keep clear of all moving parts when starting or operating the pump.  
D Before checking or servicing the equipment, follow the Pressure Relief Procedure on page 8 to  
prevent the equipment from starting unexpectedly.  
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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.  
D Ground the equipment and the object being sprayed. Refer to Grounding on page 7.  
D If there is any static sparking or you feel an electric shock while using this equipment, stop spray-  
ing immediately. Do not use the equipment until you identify and correct the problem.  
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid  
being sprayed.  
D Keep the spray area free of debris, including solvent, rags, and gasoline.  
D Before operating this equipment, electrically disconnect all equipment in the spray area.  
D Before operating this equipment, extinguish all open flames or pilot lights in the spray area.  
D Do not smoke in the spray area.  
D Do not turn on or off any light switch in the spray area while operating or if fumes are present.  
D Do not operate a gasoline engine in the spray area.  
TOXIC FLUID HAZARD  
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,  
inhaled, or swallowed.  
D Know the specific hazards of the fluid you are using.  
D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,  
state and national guidelines.  
D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and  
solvent manufacturer.  
4
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Notes  
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Installation  
F G  
E
H
J
K
L
A
B
M
C
D
KEY  
A
B
C
D
E
F
G
H
J
Electrically Conductive Air Hose  
Female Quick Disconnect Coupler  
Male Quick Disconnect Fitting  
Air Line Filter  
Air Regulator and Gauge  
Bleed-Type Master Air Valve  
Air Line Lubricator  
N
Pump Runaway Valve  
Pump Air Inlet  
K
L
M
N
Ground Wire  
1/2 in.  
(13 mm)  
Pressure Drain Valve  
Electrically Conductive Fluid Hose  
Spray Gun  
04209  
Fig. 1  
NOTE: Reference numbers and letters in parentheses  
in the text refer to the callouts in the figures and the  
parts drawings.  
System Accessories  
WARNING  
Figure 1 is only a guide to selecting and installing  
optional and required accessories. For help in design-  
ing a system to suit your needs, contact your Graco  
distributor.  
To reduce the risk of serious injury including skin  
injection, splashing in the eyes or on the skin, and  
injury from moving parts, if you are adjusting or  
repairing the pump, two accessories are required  
in your system: a bleed-type master air valve (F)  
and a pressure drain valve (L).  
Mount the pump to suit the type of installation planned.  
See page 23 for dimensions and mounting hole layout.  
The bleed-type master air valve (F) 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 if you are adjusting or  
repairing the pump. Install the valve near the pump  
air inlet, within easy reach of the pump.  
The pressure drain valve (L) assists in relieving  
fluid pressure in the displacement pump, hoses  
and gun. Triggering the spray gun to relieve pres-  
sure may not be sufficient.  
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Installation  
D Pump: use a ground wire and clamp as shown  
below.  
CAUTION  
Provide a bracket for mounting the air accessories.  
The fittings are not strong enough to support the  
accessories and may cause one or more to break.  
D Truck bed or platform: according to your local code.  
D Fluid hoses: use only electrically conductive hoses.  
D Air compressor: follow manufacturer’s recommen-  
NOTE: Install the accessories in the order shown in  
Figure 1.  
dations.  
D Spray gun: grounding is obtained through connec-  
D A pump runaway valve (H) shuts off the air to the  
pump if the pump accelerates beyond the pre-ad-  
justed setting. A pump which runs too fast can be  
seriously damaged.  
tion to a properly grounded fluid hose and pump.  
D Object being sprayed: according to local code.  
D Fluid supply container: according to local code.  
D All solvent pails used when flushing or relieving  
pressure, always hold a metal part of the gun firmly  
to the side of a grounded metal pail, then trigger the  
gun.  
D An air line lubricator (G) provides automatic air  
motor lubrication.  
D A bleed-type master air valve (F) relieves air  
trapped between it and the motor when the valve is  
closed. Order Part No. 107142.  
To ground the pump:  
D The air regulator (E) controls pump speed and  
pressure.  
To ground the pump, use a ground wire and clamp as  
shown below. Remove the ground screw (Z) and insert  
through the eye of ring terminal at end of ground wire  
(Y). Fasten the ground screw back onto the pump and  
tighten securely. Connect the other end of the ground  
wire to a true earth ground. See Fig. 2. To order a  
ground wire and clamp, order Part No. 222011.  
D An air line filter (D) removes harmful dirt and  
contaminants from your compressed air supply.  
D A drain valve (L) is required near the pump fluid  
outlet to relieve fluid pressure in the pump, hose  
and gun. Order Part No. 210657.  
D Install an electrically conductive fluid hose (M) and  
spray gun (N).  
Grounding  
Z
Y
Proper grounding is an essential part of maintaining a  
safe system.  
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:  
TI1052  
Fig. 2  
306531Z1  
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Operation  
Pressure Relief Procedure  
WARNING  
Never operate the pump with the warning plate  
(20) or the identification plate (40) removed. These  
plates protect your fingers from pinching or am-  
putation by moving parts in the air motor.  
WARNING  
SKIN INJECTION HAZARD  
The system pressure must be manually  
relieved to prevent the system from  
starting or spraying accidentally. Fluid  
under high pressure can be injected through the  
skin and cause serious injury. To reduce the risk of  
an injury from injection, splashing fluid, or moving  
parts, follow the Pressure Relief Procedure  
whenever you:  
Starting and Adjusting the Pump  
1. With the air regulator (E) closed, open the bleed-  
type master air valve (F).  
D are instructed to relieve the pressure,  
D stop spraying,  
2. Connect the air hose.  
D check or service any of the system equipment,  
D or install or clean the spray tips.  
1. Lock the spray gun trigger safety.  
3. Trigger the spray gun (N) into a grounded metal  
pail, making firm metal-to-metal contact.  
2. Close the pump air regulator. Close the bleed-type  
master air valve (required in your system).  
4. Open the pump air regulator (E) slowly, just until  
the pump is running. When the pump is primed  
and all air has been pushed out of the lines, re-  
lease the spray gun trigger. With sufficient air  
supplied, the pump starts when the spray gun is  
triggered and shuts off when the trigger is re-  
leased.  
3. Unlock the gun trigger safety.  
4. Hold a metal part of the spray gun firmly to a  
grounded metal waste container and trigger the  
gun to relieve the fluid pressure.  
5. Lock the gun trigger safety.  
6. Open the pump drain valve (required with your  
system) and leave it open until you are ready to  
spray again.  
5. Adjust the air regulator just until you get adequate  
flow from the spray gun. Always run the pump at  
the lowest speed necessary.  
If you suspect that the spray tip or hose is clogged or  
that fluid pressure is not fully relieved after following  
the steps above, very slowly loosen the tip guard  
retaining nut or hose end coupling and relieve pressure  
gradually. Clear the tip or hose obstruction.  
CAUTION  
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 acceler-  
ates 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. Use a pump runaway valve (K) to  
automatically shut off the pump if it starts to run too fast.  
WARNING  
COMPONENT RUPTURE HAZARD  
Overpressurizing any component can  
result in rupture, fire, explosion, property  
damage, and serious injury. To reduce  
the risk of overpressurizing, know the Maximum  
Working Pressure of the lowest rated component in  
your system, and limit the air to the pump so that  
you never exceed that pressure.  
6. Read and follow the instructions supplied with  
each component in your system.  
To determine the fluid output pressure using the air  
regulator reading, multiply the pump ratio by the air  
pressure you set on the regulator gauge. Example:  
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, at the left.  
15 (:1) ratio x 100 psi air = 1500 psi fluid output  
[15 (:1) ratio x 7 bar air = 105 bar fluid output]  
8
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Notes  
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Maintenance  
Shutdown and General Care  
Flushing  
WARNING  
To reduce the risk of serious injury whenever you  
are instructed to relieve pressure, always follow the  
Pressure Relief Procedure on page 8.  
WARNING  
To reduce the risk of serious injury whenever you  
are instructed to relieve pressure, always follow the  
Pressure Relief Procedure on page 8.  
1. To reduce the risk of skin injection, static sparking  
or splashing, Relieve the Pressure before flush-  
ing.  
D Always relieve the pressure when you shut down  
the pump.  
2. Remove the spray tip.  
D If you are pumping fluid that dries or sets up, flush  
with a compatible solvent as often as necessary to  
prevent buildup in the pump and hoses.  
3. Hold a metal part of the gun firmly to the side of a  
grounded metal pail. Use the lowest possible fluid  
pressure when flushing.  
D After every 40 hours of operation, adjust the pack-  
Lubrication  
ing nut (42) as described on page 11.  
The accessory air line lubricator (G) provides automat-  
ic air motor lubrication. For daily, manual lubrication  
follow this procedure:  
1. Disconnect the regulator.  
2. Place about 15 drops of light machine oil in the  
pump air inlet.  
3. Reconnect the regulator.  
4. Turn on the air supply to blow oil into the motor.  
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Maintenance  
Packing Nut Adjustment  
WARNING  
To reduce the risk of serious injury whenever you  
are instructed to relieve pressure, always follow the  
Pressure Relief Procedure on page 8.  
PISTON  
WARNING  
Keep your hand and fingers away from the piston  
when it is moving. As the piston moves into the  
pump base it can amputate fingers or break tools  
caught between the moving parts. Note the pinch  
point shown in Fig. 3. Be sure all air and fluid  
pressure is fully relieved before adjusting the piston  
or packing nut to reduce the risk of amputation.  
PINCH POINT  
BASE  
FLUID  
OUTLET  
NOTE: Perform this adjustment if: (a) material drips  
steadily from the air motor weep hole, which indicates  
the packings are too loose, (b) the pump requires more  
than 50 psi (.345 MPa, 3.4 bar) air pressure to cycle  
when the gun is triggered, which indicates the pack-  
ings are too tight, or (c) the pump has been in opera-  
tion for 40 hours.  
WEEP HOLE LOCATED  
OPPOSITE FLUID OUTLET  
AND IN BOTTOM OF BASE  
Fig. 3  
1. Relieve the pressure. Follow the Pressure Relief  
Procedure on page 8.  
BASE  
2. Using a 1/4” nut driver, remove the six screws (24)  
from one of the muffler plates (20 or 40) and  
remove the muffler plate. See Fig. 4.  
3. Check to see that the air motor piston is at the top  
of the stroke. If it is not, first read the warning  
above. Then, while keeping your fingers away  
from moving parts, apply very low pressure air to  
the air inlet to move the piston up. Close the air  
regulator and disconnect the air supply hose.  
Refer to Fig. 3.  
20  
24  
Fig. 4  
PACKING NUT  
1/4” DIA. ROD  
4. Use a 1/4” diameter rod, spanner wrench, or  
torque wrench to tighten the packing nut. First  
loosen the nut, then tighten snugly, and finally  
tighten an additional 1/2 turn (20–25 ft–lbs). See  
Fig. 5.  
5. Replace the muffler cover, and the six screws.  
See Fig. 4.  
6. Reconnect the air line. After the pump is started, it  
should run at 40 psi (.276 MPa, 2.8 bar) with no  
load. Startup may require additional air pressure.  
Fig. 5  
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Troubleshooting  
WARNING  
To reduce the risk of serious injury whenever you  
are instructed to relieve pressure, always follow the  
Pressure Relief Procedure on page 8.  
WARNING  
Never operate the pump with the warning plate  
(20) or the identification plate (40) removed. These  
plates protect your fingers from pinching or ampu-  
tation by moving parts in the air motor.  
Relieve the Pressure before you check or service any  
system equipment.  
NOTE: Check all other possible problems and solu-  
tions before disassembling the pump.  
Problem  
Cause  
Solution  
Pump fails to operate  
Low air supply pressure or restricted air Increase air supply; clear*  
lines  
Closed valves  
Open  
Clogged fluid lines, hoses, valves, etc. Clear*  
Damaged air motor  
Service air motor  
Refill and reprime, or flush  
Empty fluid supply container  
Continuous air exhaust  
Erratic pump operation  
Worn or damaged air motor gasket, Service air motor  
packing, seal, etc.  
Empty fluid supply container  
Refill and reprime, or flush  
Held open or worn intake valve or  
piston packings  
Clear; service  
Pump operates, but output is low Held open or worn piston  
on the up stroke or packings  
Clear; service  
Pump operates, but output is low Held open or worn intake valve  
on the down stroke  
Clear; service  
Pump operates, but output is low Low air supply pressure or  
Increase air supply; clear*  
on both strokes  
restricted air lines  
Closed valves  
Open  
Empty fluid supply container  
Refill and reprime, or flush  
Clogged fluid lines, hoses, valves, etc. Clear*  
Packing nut too tight  
Loosen  
Loose packing nut or worn packings  
Tighten; replace  
*Follow the Pressure Relief Procedure on page 8. Disconnect the fluid hose. If the pump starts when the air is  
turned on again, the hose or gun is clogged.  
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Air Motor Service  
Before you start:  
CAUTION  
To avoid damaging the cylinder wall, lift the  
cylinder (51) straight up off the piston (59). Never tilt the  
cylinder as it is being removed.  
D Have all necessary parts on hand. Always replace  
the glands and bearing when replacing the pack-  
ings. Use all the parts in the repair kits for the best  
results. See page 18 to order the kits.  
D Air Motor Repair Kit 206728. Parts included in  
this kit are marked with a dagger, (for example,  
36), in the text and drawings.  
8. Remove the six screws (25). See Fig. 6. Pull the  
cylinder (51) straight up off the piston (59).  
D Displacement Pump Repair Kit 206925. Parts  
included in this kit are marked with one asterisk,  
(i.e., 6*), in the text and drawings.  
9. Use a screwdriver to push down on the trip rod  
yoke (28), and snap the toggles down. See Fig. 7.  
D Two accessory tools should be ordered. Use  
Padded Pliers, 207579, to grip the trip rod without  
damaging its surface. Use Gauge, 171818, to  
ensure the proper clearance between the poppets  
and seat of the transfer valve.  
47  
27  
Air Motor & Throat Disassembly  
51  
54  
WARNING  
To reduce the risk of serious injury whenever you  
are instructed to relieve pressure, always follow the  
Pressure Relief Procedure on page 8.  
38  
1. Flush the pump.  
39†  
2. Relieve the pressure before proceeding.  
42  
3. Disconnect the hoses, remove the pump from its  
mounting, and clamp the air motor base (55) in a  
vise.  
25  
59  
44*  
1
55  
43  
4. Use a strap wrench on the riser tube (12) to screw  
it out of the air motor base (55).  
5. Pull the connecting rod (10) down as far as it will  
go.  
6. Use a hammer and punch to remove the roll pin  
(4). Unscrew the connecting rod (10). See Fig. 6.  
4*  
41  
10  
12  
1
See detail below.  
CAUTION  
Do not damage the plated surface of the trip rod (54).  
Damaging the surface of the trip rod can result in erratic  
air motor operation. Use the special Padded Pliers,  
Part Number 207579, to grasp the rod.  
50*  
2
48*  
49*  
7. Manually push up on the piston rod (41) to move  
the piston assembly (59) up as far as it will go.  
Unscrew the cap nut (47). Pull the nut up. Grip the  
trip rod (54) with padded pliers, and screw the nut  
off the rod. See Fig. 6.  
2
Lips of v-packings must face down.  
04210B  
Fig. 6  
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Air Motor Service  
M
2
54  
1
30 31 37  
28  
54  
53†  
34†  
58  
3
45†  
33†  
35  
L
33†  
45†  
32†  
32†  
33†  
1
36†  
0.145”  
(3.7 mm)  
59  
55  
45†  
59  
58  
533345†  
Cutaway View  
1
To remove toggles: push in, swing up, ease out.  
Push toggles (M) in and then up (shown in down position).  
Turn wires up.  
2
Cut off tops of poppets as indicated by dotted lines.  
1
3
04119  
04118  
Fig. 8  
Fig. 7  
10. Remove the lockwires (34) from the adjusting  
nuts (33) of the transfer valves. Screw the top  
nuts off. Screw the poppet valve stems (45) out of  
the grommets (32) and the bottom nuts (30). Take  
the valve poppets off the stems and squeeze them  
firmly to check for cracks. See Fig. 7.  
Reassembly  
1. Clean all the parts in a compatible solvent and  
inspect for wear or damage. Check the polished  
surfaces of the piston (59), piston rod (41), and  
cylinder wall (51) for scratches or wear. A scored  
rod will cause premature packing wear and leak-  
ing. Use all the repair kit parts and replace other  
parts as necessary.  
WARNING  
To reduce the risk of pinching or amputating your  
fingers, always keep fingers clear of the toggle  
assemblies (M).  
2. Lubricate all parts with a light, waterproof grease.  
3. One at a time, install these parts in the base (55):  
the gland (49*), five v-packings (48*) with lips  
facing down, bearing (50*), backup washer (43),  
flat packing (44*), and loosely screw in the packing  
nut (42). Be sure the o-rings (38 & 39) are in  
place. See Fig. 6.  
11. Grip the pivot pins (30) with pliers. Compress the  
springs (31), and swing the toggle assembly (M)  
up and away from the piston lugs (L). Remove the  
parts. Check to see that the valve actuator (35) is  
supported by the spring clips (58) but slides easily  
into them. See Fig. 7.  
4. Pull the exhaust valve poppets (53) into the valve  
actuator (35) and clip off the top part shown with  
dotted lines. See Fig. 8.  
12. Remove the trip rod yoke (28), actuator (35) and  
trip rod (54). See Fig. 7. Check the exhaust valve  
poppets (53) for cracks. To remove the exhaust  
valve poppets (53), stretch them out and cut them  
with a sharp knife.  
5. Install the grommets (32) in the valve actuator  
(35). Install the trip rod (54) in the piston (59).  
Place the trip rod yoke (28) and valve actuator (35)  
on the trip rod. Be sure the o-ring (36*) is in place  
and that the valve actuator is supported by the  
spring clips (58), and reassemble the valve  
mechanism. See Fig. 7.  
13. Remove one muffler plate (20 or 40). Pull the  
piston (59) up out of the base. Remove the throat  
packing nut (42) and packings. See Fig. 6.  
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Air Motor Service  
6. Install the bottom adjusting nuts (33) on the poppet  
9. Manually push on the piston rod (41) to move the  
piston (59) up as far as it will go. Grip the trip rod  
(54) with padded pliers and screw the cylinder cap  
nut (47) onto the trip rod. Pull the piston rod (41) to  
move the piston down. Be sure the o-ring (27) is in  
place at the top of the cylinder (51), and screw the  
cap nut into the cylinder.  
valve stems (45) and screw the stems into the  
grommets (32). Screw the top nuts (33) on the  
stems. Before installing the lockwires (34) in the  
adjusting nuts, use the gauge 171818 to adjust  
the transfer valve so there is 0.145 in. (3.7 mm)  
clearance between the poppets and the seat when  
it is open. See Fig. 8.  
10. Screw the connecting rod (10) into the piston rod  
(41) and secure with the pin (4*). Manually push  
on the piston rod (41) to move the piston (59) up  
as far as it will go. Screw the riser tube (12) into  
the base (55).  
WARNING  
To reduce the risk of pinching or amputating your  
fingers, always keep fingers clear of the toggle  
assemblies (M).  
11. Use a 1/4” diameter rod, spanner wrench, or  
torque wrench to tighten the packing nut (42).  
Tighten snugly and then tighten an additional 1/2  
turn (20–25 ft–lbs).  
7. Install the springs (31) and pivot pins (30) on the  
toggle arms (37). Snap the toggles to the up  
position. Refer to Fig. 7.  
12. Install the muffler plate (20 or 40) using the six  
screws (24).  
13. Connect an air hose and run the pump slowly  
[about 30 psi (2.1 bar)] to see that it operates  
smoothly.  
8. Carefully lower the cylinder (51) over the piston  
(59) and onto the base (55). Secure with the six  
screws (25).  
14. Remount the pump and reconnect the ground wire.  
306531Z1  
15  
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Displacement Pump Service  
Before you start:  
1. Have all necessary parts on hand. Whenever you  
replace the packings, also replace the glands and  
bearing. If you are using a repair kit, use all the  
parts for the best results. See the parts pages to  
order the kits.  
2. Displacement Pump Repair Kit 206925 includes  
repair parts for the pump throat and piston. Parts  
included in the kit are marked with one asterisk, for  
example (6*), in the text and drawings.  
3. To replace the throat packings, which are included  
in Repair Kit 206728, refer to the Air  
Motor and Throat Disassembly on page 13.  
46  
Displacement Pump Disassembly  
WARNING  
To reduce the risk of serious injury whenever you  
are instructed to relieve pressure, always follow the  
Pressure Relief Procedure on page 8.  
7  
1. Flush the pump.  
2. Relieve the Pressure  
55  
3. Disconnect the hoses, remove the pump from its  
mounting, and clamp the air motor base in a vise.  
*4  
4. Unscrew the intake valve body (22) from the riser  
tube (12). See Fig. 9. Disassemble the intake  
valve.  
10  
12  
14  
2*  
*4  
5. Clean and inspect the parts for wear or damage,  
and replace parts as needed. Unless further  
service is needed, reassemble and reinstall the  
intake valve, using liquid sealant on the male  
threads. See Fig. 9.  
*19  
*6  
*17  
*15  
18*  
16*  
6. Use a strap wrench on the riser tube (12) to screw  
it out of the air motor base (55). Carefully inspect  
the smooth inner surface of the cylinder for scoring  
or irregular surfaces. Such damage causes prema-  
ture packing wear and leaking, so replace the part  
if damaged.  
13  
22  
21  
7
7. Unscrew the piston body (13) from the piston  
coupling (14). Remove the ball (2*), seat (19*),  
gasket (6*), bearing (18*), packing (17*), and seal  
(16). Do not remove the press-fit brass bearing  
(15*). See Fig. 9.  
3*  
04212B  
Fig. 9  
16 306531Z1  
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Displacement Pump Service  
NOTE: If the pressure-fit brass bearing (15*) needs to  
10. Install the gasket (7*[). Screw the riser tube (12)  
be replaced, clamp it in a vise and drive the piston  
body (13) out with a plastic hammer. The new bearing  
must be started onto the piston body squarely.  
into the air motor base (55).  
11. Reinstall the ball (3*), gasket (7), ball stop (21) and  
other gasket (7) in the intake valve housing (22).  
Screw the housing onto the riser tube (12).  
8. Clean and inspect the parts and replace any that  
are worn or damaged. Be sure to check the copper  
gasket (46) in the motor base (55). Lubricate the  
parts with a light waterproof grease.  
12. Be sure the ground wire is connected before  
regular operation of the pump.  
9. Install the seal (16*), packing (17*), bearing (18*),  
gasket (6*), seat (19*) and ball (2*) on the piston  
body (13). The check ball seat (19*) may be re-  
versed to provide a new seat. Screw the piston  
body (13) into the piston coupling (14).  
306531Z1  
17  
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Parts  
Model 206405, Series K  
35 lb. pail size  
39†  
38  
47  
27  
40  
55  
25  
51  
60  
63  
28  
34†  
35  
29  
10  
14  
33†  
53†  
37  
31  
20  
24  
30  
32†  
33†  
54  
57  
2*  
*4  
19*  
58  
59  
6*  
18*  
36  
17*  
16*  
46  
45†  
15*  
13  
41  
7*†  
*4  
12  
42  
44*  
43  
50*  
7
21  
7
48*  
49*  
3*  
22  
04213B  
18 306531Z1  
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Parts  
Model 206405, Series K  
35 lb. pail size  
Ref  
Ref  
No.  
Part No.  
Description  
Qty.  
No.  
Part No.  
Description  
Qty.  
2*  
3*  
4*  
100114  
100400  
101579  
BALL, steel, 0.44” (11.2 mm) dia. 1  
37 160623  
38 160624  
39160625  
40** 234577  
. ARM, toggle  
2
1
1
BALL, steel, 0.75” (19 mm) dia.  
PIN, roll, 0.12” (3.2 mm) dia.,  
0.75” (19 mm) long  
1
. O-RING, nitrile rubber  
. O-RING, nitrile rubber  
. PLATE, identification,  
with muffler  
. ROD, piston  
. NUT, packing  
. WASHER, backup  
. PACKING, flat leather  
. VALVE, poppet  
. GASKET, copper  
. NUT, cylinder cap  
. V-PACKING, leather  
. GLAND, male  
. BEARING, throat  
. CYLINDER, air motor  
. POPPET, valve, urethane  
. ROD, trip  
. BASE, air motor  
. SCREW, rd hd mach,  
6–32 x 1/4”  
3
1
6*  
150451  
GASKET, copper  
1
1
1
1
1
2
1
1
5
1
1
1
2
1
1
7*150694  
10 165970  
12 165971  
GASKET, copper  
(qty 1 in kits 206925 and 206728) 3  
ROD, connecting,  
41 160639  
42 160640  
43 160641  
44* 160644  
45236079  
46 160932  
47 164704  
48* 162391  
49* 168851  
50* 168852  
51 160613  
53170709  
54 203965  
55 204896  
57 102975  
5 1/4” (133 mm) long  
1
TUBE, riser,  
11–11/16” (297 mm) long  
BODY, piston  
1
1
1
1
1
1
1
1
1
1
1
13 160939  
14 160940  
15* 160941  
16* 160942  
17* 160943  
18* 160944  
19* 160945  
20** 234578  
21 183326  
22 191080  
24** 100078  
COUPLING, piston  
BEARING, press fit, brass  
SEAL, piston; PTFE  
PACKING, block, nitrile rubber  
BEARING, piston, brass  
SEAT, piston, reversible  
PLATE, warning (with muffler)  
STOP, ball  
HOUSING, intake valve  
. SCREW, hex washer hd, mach,  
8–32 x 3/8”  
2
2
1
1
58 172866  
59 15K534  
60 116343  
63 162718  
. CLIP, spring  
12  
. PISTON, air motor  
. SCREW, ground  
. ADAPTER, 3/8 npt (m) x  
1/4 npt(f)  
25 101578  
. CAPSCREW, hex hd Nylockr,  
. O-RING, nitrile rubber  
. YOKE, rod, trip  
. PIN, toggle  
. PIN, pivot  
. SPRING, helical compression  
. GROMMET; rubber  
. NUT, adjusting  
. WIRE, lock  
. ACTUATOR, valve  
. O-RING, nitrile rubber  
5/16–18 x 7/8”  
6
1
1
2
2
2
2
4
2
1
1
27 156698  
28 158360  
29 158362  
30 158364  
31 167585  
32158367  
33160261  
34160618  
35 172867  
36160621  
1
*
These parts are included in Pump Repair Kit 206925,  
which may be purchased separately.  
** These parts are included in Muffler Repair Kit 222559,  
which may be purchased separately.  
These parts are included in Air Motor Repair Kit 206728,  
which may be purchased separately.  
306531Z1  
19  
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Parts  
Model 206699, Series J  
120 lb. drum size  
39†  
40  
47  
27  
38  
Model 206700, Series J  
400 lb. drum size  
55  
25  
51  
60  
63  
35  
28  
29  
37  
34†  
33†  
53†  
10  
31  
30  
20  
24  
*4  
14  
32†  
33†  
57  
58  
2*  
19*  
6*  
54  
59  
18*  
17*  
16*  
36  
45†  
15*  
13  
46  
*4  
41  
7*†  
42  
44*  
43  
12  
50*  
7
21  
7
48*  
49*  
3*  
22  
04214B  
20 306531Z1  
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Parts  
Model 206699, Series J  
120 lb. drum size  
Model 206700, Series J  
400 lb. drum size  
Ref.  
Ref.  
No.  
Part No.  
Description  
Qty.  
No.  
Part No.  
Description  
Qty.  
2*  
3*  
4*  
100114  
100400  
101579  
BALL, steel, 0.44” (11.2 mm) dia. 1  
33160261  
34160618  
35 172867  
36160621  
37 160623  
38 160624  
39160625  
40** 234577  
. NUT, adjusting  
. WIRE, lock  
4
2
1
1
2
1
1
BALL, steel, 0.75” (19 mm) dia.  
PIN, roll, 0.12” (3.2 mm) dia.,  
0.75” (19 mm) long  
1
. ACTUATOR, valve  
. O-RING, nitrile rubber  
. ARM, toggle  
. O-RING, nitrile rubber  
. O-RING, nitrile rubber  
. PLATE, identification,  
with muffler  
3
1
6*  
150451  
GASKET, copper  
7*150694  
GASKET, copper  
(qty 1 in kits 206925 and 206728) 3  
ROD, connecting,  
10 160688  
18–15/16” (481 mm) long  
(For Model 206699)  
ROD, connecting,  
25 7/8” (657 mm) long  
(For Model 206700)  
TUBE, riser,  
25–3/8” (645 mm) long  
(For Model 206699)  
TUBE, riser,  
32 5/16” (821 mm) long  
(For Model 206700)  
BODY, piston  
COUPLING, piston  
BEARING, press fit, brass  
SEAL, piston; PTFE  
PACKING, block, nitrile rubber  
BEARING, piston, brass  
SEAT, piston, reversible  
PLATE, warning (with muffler)  
STOP, ball  
1
1
1
1
1
1
1
1
1
2
1
1
5
1
1
1
2
1
1
41 160639  
42 160640  
43 160641  
44* 160644  
45236079  
46 160932  
47 161435  
48* 162391  
49* 168851  
50* 168852  
51 160613  
53170709  
54 203965  
55 204896  
57 102975  
. ROD, piston  
. NUT, packing  
161050  
12 160938  
161051  
. WASHER, backup  
. PACKING, flat leather  
. VALVE, poppet  
. GASKET, copper  
. NUT, cylinder cap  
. V-PACKING, leather  
. GLAND, male  
. BEARING, throat  
. CYLINDER, air motor  
. POPPET, valve, urethane  
. ROD, trip  
. BASE, air motor  
. SCREW, rd hd mach,  
6–32 x 1/4”  
13 160939  
14 160940  
15* 160941  
16* 160942  
17* 160943  
18* 160944  
19* 160945  
20** 234578  
21 183326  
22 191080  
24** 100078  
1
1
1
1
1
1
1
1
1
1
2
2
1
1
58 172866  
59 15K534  
60 116343  
63 162718  
. CLIP, spring  
. PISTON, air motor  
. SCREW, ground  
. ADAPTER, 3/8 npt (m) x  
1/4 npt(f)  
HOUSING, intake valve  
. SCREW, hex washer hd, mach,  
8–32 x 3/8”  
1
12  
25 101578  
. CAPSCREW, hex hd Nylock,  
5/16–18 x 7/8”  
. O-RING, nitrile rubber  
. YOKE, rod, trip  
. PIN, toggle  
. PIN, pivot  
*
These parts are included in Pump Repair Kit 206925,  
which may be purchased separately.  
6
1
1
2
2
2
2
27 156698  
28 158360  
29 158362  
30 158364  
31 167585  
32158367  
** These parts are included in Muffler Repair Kit 222559,  
which may be purchased separately.  
. SPRING, helical compression  
. GROMMET; rubber  
These parts are included in Air Motor Repair Kit 206728,  
which may be purchased separately.  
306531Z1  
21  
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Notes  
22 306531Z1  
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Dimensions  
Technical Data  
Maximum Working Pressure . . . . . . 2700 psi (186 bar)  
Fluid pressure ratio . . . . . . . . . . . . . . . . . . . . . . . . . . 15:1  
Air operating range . . . . . . . 40 to 180 psi (3 to 12 bar)  
Air motor effective diameter . . . . . . . . . . . 3 in. (76 mm)  
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 in. (76 mm)  
Air consumption . . . . 17 cfm/gallon pumped at 100 psi  
3/8 npt(f)  
Air Inlet  
3
1/4 npt(f)  
Fluid Outlet  
(0.476 m /liter at 7 bar);  
up to 30 cfm with pump operated  
at 180 psi and 66 cycles/min.  
3
(up to 0.84 m /min with pump operated  
at 12 bar and 66 cycles/min.)  
Pump cycles per gallon (liter) . . . . . . . . . . . . . . . 90 (24)  
Delivery . . . . . . . . 0.66 gallons/minute (3 liters/minute)  
Maximum recommended  
pump speed . . . . . . . . . . . . . . . . . . . . . . . 66 cycles/min;  
0.7 gpm (32 liter/min)  
Recommended speed  
for optimum pump life . . . . . . . 15 to 25 cycles per min  
Model  
206405  
13 inches  
(330 mm)  
Wetted parts . . . . . . . . . . . . . . . . . . Carbon Steel, Brass,  
Copper, Aluminum,  
Model  
PTFE, Nitrile Rubber, Leather  
206699  
Approximate weight . . . . . . . . . . . . . . . . . . . 22 lb (10 kg)  
26.69 inches  
(677.7 mm)  
Model  
206700  
33.62 inches  
(854 mm)  
04217B  
Mounting Hole Layout  
2 Hole Mounting  
Pattern  
4 Hole Mounting  
Pattern  
161023 Gasket  
Two or Four  
0.265” (7 mm)  
Dia. Holes on 5”  
(127 mm) Bolt Circle  
04127  
3” (76.2 mm) Dia.  
306531Z1  
23  
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Graco Standard Warranty  
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the  
date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco,  
Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be  
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 general wear and tear, or any malfunction, damage or wear caused by  
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub-  
stitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of  
Graco equipment with 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 claimed defect. 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.  
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT  
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.  
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other  
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any  
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the  
date of sale.  
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection  
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured  
by Graco (such as electric motors, 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.  
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment  
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,  
breach of warranty, the negligence of Graco, or otherwise.  
FOR GRACO CANADA CUSTOMERS  
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings  
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnais-  
sent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires  
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.  
Graco Phone Numbers  
TO PLACE AN ORDER, contact your Graco distributor, or call one of the following numbers  
to identify the distributor closest to you:  
1–800–533–9655 Toll Free  
612–623–6928  
612–378–3590 Fax  
All written and visual data contained in this document reflects the latest product information available at the time of publication.  
Graco reserves the right to make changes at any time without notice.  
This manual contains English. MM 306531  
Graco Headquarters: Minneapolis  
International Offices: Belgium, China, Japan, Korea  
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441  
Copyright 1996, Graco Inc. is registered to ISO 9001  
Revised 05/2009  
24 306531Z1  
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