Instructions – Parts List
10:1 Fire–Ballr425 Pump
For pumping non–corrosive and
non–abrasive oils and lubricants only.
180 psi (12.4 bar) Maximum Incoming Air Pressure
1800 psi (124 bar) Maximum Fluid Working Pressure
Model 205626, Series K
Universal Pump
Model 222065, Series C
55-Gallon Drum Cover-Mount Pump
Model 222095, Series C
55-Gallon Drum Bung-Mount Pump
Important Safety Instructions.
Read all warnings and instructions in this manual.
Save these instructions.
308655J
Model 205626 shown
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1996, Graco Inc. is registered to I.S. EN ISO 9001
TI1071
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Motor and Throat Service 9. . . . . . . . . . . . . . . . . . . . .
Displacement Pump Service 13. . . . . . . . . . . . . . . . . . . .
Parts List 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
WARNINGWARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
Parts Drawing 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 16. . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance Chart 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 18. . . . . . . . . . . . . . . . . . . . . . . . . .
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
D This equipment is for professional use only.
D Read all instruction manuals, tags, and labels before you operate this equipment.
D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
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 stated on the equipment or in the Technical Data
for your equipment. Do not exceed the maximum working pressure of the lowest rated component in your system.
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 Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids that contain such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
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.
2 308655J
WARNINGWARNING
SKIN INJECTION HAZARD
Fluid 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.
D Fluid injected into the skin may look like just a cut, but it is a serious injury. Get immediate
surgical treatment.
D Do not point the dispensing valve at anyone or at any part of the body.
D Do not put your hand or fingers over the end of the dispensing valve.
D Do not stop or deflect leaks with your hand, body, glove or rag.
D Use only extensions and no-drip tips that are designed for use with your dispensing valve.
D Tighten all fluid connections before you operate this 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.
HAZARDOUS FLUIDS
Improper handling of hazardous fluids or inhaling toxic fumes can cause extremely serious injury,
even death, due to splashing in the eyes, ingestion, or bodily contamination.
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.
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. Refer to Grounding on page 6.
D If there is any static sparking or you feel an electric shock while you use this equipment, stop
dispensing 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 dispensed.
D Do not smoke in the dispensing area.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
D Keep clear of all moving parts when you start or operate the pump.
D Before you service this equipment, follow the Pressure Relief Procedure on page 7 to prevent
the equipment from starting unexpectedly.
308655J 3
Installation
The typical installation shown in Fig.1 is only a guide to
help you select and install a pump; it is not an actual
system design. Contact your Graco distributor for
assistance in designing a system to suit your needs.
CAUTION
Always mount the pump firmly to a bracket or a
tank cover. Never operate the pump while it is not
mounted. Such use could damage the pump and
fittings.
G
C
DNA
A
B
F
A
E
R
H
K
P
J
Z
Y
DETAIL A
L
S
TI0890
T
M
For Portable Applications
KEY
A Bleed-type master air valve
(required, Part No. 107142)
B Air line filter
C Air regulator and gauge
D Pump runaway valve
E Air inlet
F Ball valve (for releasing collected moisture)
G Pump
H Drain valve (required, Part No. 210658)
J Dispensing valve (model 222411 shown)
K Thermal relief kit (required, Part No. 240429)
Fig. 1
4 308655J
L Male quick-disconnect fitting
M Female quick-disconnect coupler
N Air line lubricator
P Fluid hose
R Electrically conductive air hose (218093 shown)
Use at least 1/2 in. (13 mm) ID to supply an adequate volume
of air to the air motor.
S Fluid inlet
T Wall-mounting bracket (Part No. 238245)
Y Ground wire (required, Part No. 222011)
Z Muffler
06038
Installation
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.
NOTE: Install the following accessories in the order
shown in Fig. 1.
WARNING
Four accessories are required in your system: an
air shut-off valve/air bleed device, fluid drain valve,
thermal relief kit, and ground wire. These accessories help reduce the risk of serious bodily injury
including fluid injection, splashing in the eyes or on
the skin, injury from moving parts if you are adjusting or repairing the pump, and explosion from
static sparking.
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 bodily 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.
D Install an air line filter (B) to remove harmful dirt
and contaminants from your compressed air supply.
D Install a bleed-type master air valve (A) to isolate
the accessories for servicing. See Fig. 1. To order
a bleed-type master air valve, order Part No.
107142.
As an alternative to a bleed-type master air valve,
you can install an air line quick disconnect coupler
(M) and fitting (L) to serve as an air-bleed device.
See Detail A in Fig. 1.
D Install a ball valve (F), at the end of a line drop, as
shown in Fig. 1, for releasing moisture that collects
in the line.
D Install a drain valve (H) near the pump fluid outlet to
relieve fluid pressure in the hoses and gun when
opened. To order a fluid drain valve, order Part No.
210658.
D Install a pump runaway valve (D) to shut off the air
to the pump if the pump accelerates beyond the
pre-adjusted setting, which can be caused by a
depleted fluid supply. A pump that runs too fast
can be seriously damaged. To order a 3/4-in. npt(f)
inlet and outlet pump runaway valve, order Part No.
215362.
D Install a thermal relief kit (K) on the dispensing
valve side of the pump. To order a 1600 psi
(110 bar) thermal relief kit, order Part No. 240429.
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.
The thermal relief kit assists in relieving pressure in
the pump, hose, and dispensing valve due to heat
expansion.
The ground wire reduces the risk of static sparking.
D Screw the muffler (5) into the 3/4-in. npt muffler
port, and tighten it using a wrench on the flats of
the muffler near the male threads.
D Install an air line lubricator (N) for automatic air
motor lubrication.
D Install the air regulator (C) to control pump speed
and pressure.
D Install a suitable fluid hose (P) and dispensing
valve (J).
Wall Mount
The pump shown in Fig. 1 is a wall-mounted universal
pump, Model 205626. To order the wall-mounting
bracket shown, order Part No. 238245.
Cover Mount
Pump Model 222065 is designed for mounting directly
on a 55-gallon drum cover. When the pump is
mounted to a closed-head drum, be sure you loosen
the vent plug on the drum cover to prevent a vacuum
in the drum. For cover mounting, see the Mounting
Hole Layout on page 16.
Bung Mount
Pump model 222095 is designed for bung mounting on
a 55-gallon drum. The bung adapter (153) is shown in
the Parts Drawing on page 15.
308655J 5
Installation
Grounding
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 this equipment:
D Pump: Use a ground wire and clamp as shown in
Fig. 2.
D Air and Fluid hoses: Use only electrically conduc-
tive hoses.
D Air compressor: Follow the manufacturer’s recom-
mendations.
D Fluid supply container: Follow the local code.
D Object being lubricated: Follow the local code.
D 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.
To ground the pump, remove the ground screw (Z)
and insert through the eye of the ring terminal at end of
the 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.
Y
Z
Fig. 2
TI1052
6 308655J
Pressure Relief Procedure
Operation
WARNING
WARNING
SKIN INJECTION HAZARD
To reduce the risk of serious bodily
injury, including fluid injection or
splashing in the eyes or on the skin,
always follow this procedure whenever you shut off
the pump, check or service any part of the system,
install or change dispensing devices, and when you
stop dispensing.
1. Close 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, or open the
drain valve (H).
If you suspect that the nozzle or hose is completely
clogged, or that pressure has not been fully relieved
after you have followed the steps above, do the following: Wrap a rag around the hose end coupling, and
relieve pressure gradually by very slowly partially
loosening the fitting. Then loosen completely, then
clear the obstruction.
Startup and Adjustment
HAZARDOUS VAPORS
The air motor exhaust coming out of the
muffler could contain harmful materials,
such as oil, antifreeze, or some of the
material being pumped.
WARNING
MOVING PARTS HAZARD
Do not operate the pump without the
muffler installed. When the muffler is not
installed, the air motor is exposed, and it
could cut your fingers if they are pushed into the
muffler opening.
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.
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, including the air motor and pump.
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:
10 (:1) ratio x 180 psi air =
1800 psi fluid output
[10 (:1) ratio x 12.4 bar air = 124 bar fluid output]
Limit the air to the pump so that no air line or fluid
line component or accessory is overpressurized.
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. If your system is equipped with a runaway valve (D
in Fig. 1), set it for your system configuration. See
manual 308201 for instructions on setting the
pump runaway valve.
5. 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.
6. 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. If your system has a runaway
valve, reset it according to the instructions in
manual 308201.
308655J 7
Operation
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, and it may
get very hot.
8. If the pump will be unattended for any period of
time, if there is an air supply interruption, or to shut
off the system at the end of the work shift, always
relieve the pressure.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
7. Read and follow the instructions supplied with
each component in your system.
9. Check periodically to ensure that the pump’s
mounting is secure.
Troubleshooting
WARNING
SKIN INJECTION HAZARD
To reduce the risk of serious bodily injury, including fluid injection or splashing in the eyes or on the
skin, always follow the Pressure Relief Procedure on page 7 when you shut off the pump, check or
service any part of the system, install or change dispensing devices, and when you stop dispensing.
NOTE: Check all other possible problems and solutions before you disassemble the pump.
Problem Cause Solution
Pump fails to operate, or there is
no fluid flow.
Continuous air exhaust Worn or damaged air motor gas-
Erratic pump operation Exhausted fluid supply Refill and reprime or flush
Pump operates, but output low on
up stroke
Pump operates, but output low on
down stroke
Pump operates, but output low on
both strokes
Fluid is coming out of the muffler. Worn or damaged throat seal Service
Inadequate air supply pressure or
restricted air lines
Closed or clogged dispensing
valve
Clogged fluid lines, hoses, valves,
etc.
Damaged air motor Service air motor
Exhausted fluid supply Refill and reprime or flush
ket, packing, seal, etc.
Held open or worn intake valve or
piston packings
Held open or worn piston packings Clear; service
Held open or worn intake valve Clear; service
Inadequate air supply pressure or
restricted air lines
Closed or clogged valves Open; clear
Increase air supply; clear
Open; clear
Clear*
Service air motor
Clear; service
Increase air supply; clear
* Follow the Pressure Relief Procedure on page 7, and disconnect the fluid line. If the pump starts when
the air is turned on again, the line, hose, valve, etc., is clogged.
8 308655J
Air Motor and Throat Service
Before You Start
D Be sure you have all necessary parts on hand.
Repair Kit 238751 includes repair parts for the air
motor and pump. Use all parts in the kit for the
best results. Parts included in the kit are marked
with one asterisk, for example (19*), in the text and
drawings. See the Parts List on page 14.
D Two accessory tools should be used: Padded
Pliers, 207579, are used to grip the trip rod without
damaging its surface, and a 0.125-in. (3.18 mm)
Gauge, 171818, is used to assure the proper
clearance between the poppets and seat of the
piston.
Disassembly
1. Flush the pump.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
2. Relieve the pressure.
CAUTION
Do not damage the plated surface of the trip rod
(31). Damaging the surface of the trip rod can
result in erratic air motor operation. Use the
special padded pliers, 207579, to grasp the rod.
9. Remove the eight screws (3) that hold the cylinder
(30) to the base (28). Carefully pull the cylinder
straight up off of the piston assembly (27).
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.
24
30
31
3. Disconnect the hoses, remove the pump from its
mounting, and clamp the air motor base (28) in a
vise horizontally by closing the vise jaws on the
flange.
4. Use a strap wrench on the displacement pump
cylinder (110) to screw it out of the air motor base
(28). See Fig. 3.
5. Remove the piston/valve seat (109) from the
displacement rod (29) with wrenches or with the
vise and a wrench.
6. Remove the piston ball (103), seal (107*), and
seal retainer washer (113).
7. Remove the air motor base from the vise, and
place the displacement rod (29) flats in the vise
with the air motor up.
8. Loosen the lift ring (24). Pull up the lift ring, grip
the trip rod (31) with the padded pliers, and screw
the lift ring off of the rod.
27
3
28
103
113
flange
109
110
Fig. 3
* Included in Pump Repair Kit 238751,
which may be purchased separately.
29
2*
lips face
down
108*
107*
lips face up
105*
TI1072
308655J 9
Air Motor and Throat Service
10. Pull the piston assembly (27) from the air motor
base (28), and set it aside.
11. Remove the throat bearing (36) with a 1 5/8-in.
socket, remove the seal (2*), and wipe the seat
clean with a cloth.
12. Remove the piston/base assembly from the vise,
and set it upright on the workbench.
13. Inspect the air motor for damaged or worn lower
valve grommets (17*), o-rings (19*, 20*), valve
nuts (21*), lock wires (22*), exhaust valve poppets
(26*), and inlet valve poppets (32*). If any of these
parts need to be replaced, continue with steps 14
to 20. Otherwise, see Reassembly on page 11.
14. Use a screwdriver to push down on the trip rod
yoke (13), and snap the toggles down. See Fig. 4.
WARNING
15. In this step, while you are prying with the screwdriver with one hand, cover the toggle assemblies
with your other hand so as to catch the springloaded toggle assemblies when they snap out of
the lugs. Place the tip of a screwdriver into the
piston between the piston lugs (L) below the pivot
pins (16) on the toggles, pry up with the screwdriver handle to compress the springs on the
toggle assembly (M) up and away from the piston
lugs, and remove the parts. See Fig. 4.
16. Straighten the lockwires (22*), and remove them
from the valve nuts (21*). Screw the top nuts off.
Remove the trip rod yoke (13), actuator (12), and
trip rod (31). Unscrew the bottom valve nuts (21*),
and remove the poppets inlet valve poppets (32*).
Make sure the valve bar spring clips (14) are not
worn or damaged and that they properly guide the
actuator.
17. Remove the exhaust valve poppets (26) by cutting
them with a side cutter, then pull them out of the
actuator (12).
18. Clean all the parts carefully in a compatible solvent, and inspect them for wear or damage. Use
all the repair kit parts during reassembly, and
replace other parts as necessary.
MOVING PARTS HAZARD
To reduce the risk of pinching or
amputating your fingers, keep your
fingers clear of the toggle assemblies
when you are snapping the toggles
(M in Fig. 4 ) up or down.
19. Check the surfaces of the air motor piston (27),
displacement rod (29), and the wall of the air motor
cylinder (30) for scoring or scratches. Scored or
scratched surfaces cause premature packing wear
and leaking.
20. Lubricate all parts with a light, waterproof grease.
10 308655J
Turn
lockwires
up.
Air Motor and Throat Service
13
15
23
M
25
16
L
31
15
22*
21*
32*
17*
32*
27
12
14
31
13
Cut off tops
of poppets as
indicated by
dotted lines.
26*
32*
21*
17*
21*
19*
0.125”
(3.18 mm)
04422
Fig. 4
21*
26*14
Reassembly
1. Place the piston rod (29) flats in the vise with the
air motor up.
2. Pull the exhaust valve poppets (26*) into the valve
actuator (12), and clip off the top parts of the
poppets (shown with dotted lines in the Cutaway
View in Fig. 4).
3. Install the lower valve grommets (17*) in the
actuator (12), place the inlet valve poppets (32*) in
the piston, and thread the bottom valve nuts (21*)
onto the inlet valve poppets until there are a few
threads left before the threads run out.
NOTE: If you thread the valve nuts too far down
onto the poppets, they will run off of the
threaded part of the poppets.
4. Grease heavily and place the trip rod (31) in the
piston, place the actuator (12) in the yoke (13),
and place the well-greased actuator/yoke assembly in the piston, with the trip rod going through the
center holes of the actuator and yoke and the inlet
valve poppets (32*) going through the lower valve
grommets (17*).
5. Thread the top valve nuts (21*) onto the inlet valve
poppets (32*) until one thread of the inlet valve
poppets is exposed above the valve nuts.
6. Install the toggle pins (15) in the yoke (13), place
the toggle arm (23) ends of the toggle assembly
(M) onto the toggle pins, and snap the pivot pin
(16) ends of the toggle assembly into the lugs (L).
28
Cutaway View
7. Measuring with the gauge (Part No.171818),
create 0.125-in. (3.18 mm) of clearance between
the inlet valve poppets (32*) and the piston seat
when the inlet valve is open. See the Cutaway
View Fig. 4.
NOTE: Adjust the distance between the inlet valve
poppets and the piston seat by turning the
top valve nuts (21*).
8. Tighten the bottom valve nuts (21*) securely by
hand.
9. Align the holes in the valve nuts (21*) and the slots
on the tops of the inlet valve poppets (32*), and
drop the lock wires (22*) through the holes in the
valve nuts and into the slots in the inlet valve
poppets. Pull the lock wires down tightly, and
bend the ends with pliers so that they cannot be
pulled back out of the holes.
32*
05612
CAUTION
Never re-use the old lock wires. They will get
brittle and break easily from too much bending.
When you install new lock wires, do not bend them
too severely, or they may break. See Fig. 4.
10. Grease and install the new o-rings (19* and 20*)
on the piston assembly (27) and in the groove in
the air motor base (28).
11. Clamp the air motor base (28) in a vise horizontally
by closing the vise jaws on the flange.
27
308655J 11
Air Motor and Throat Service
12. Grease and reinstall the seal (2*) with the lips
down, thread the throat bearing (36) into the air
motor base (28), and torque the throat bearing to
30 to 40 ft-lb (41 to 54 N.m) using a 1 5/8-in.
socket.
13. Slide the piston rod (29) down through the packing, and lower the piston assembly (27) into the air
motor base (28).
14. Carefully lower the cylinder (30) straight down onto
the piston assembly (27). Tighten the eight screws
(3) that hold the cylinder to the base (28).
CAUTION
To avoid damaging the cylinder wall, lower the
cylinder straight down onto the piston. Do not tilt
the cylinder while you lower it.
15. Grip the trip rod (31) with padded pliers, screw the
lift ring (24) onto the trip rod, push the lift ring
down, and screw it into the top of the cylinder.
16. Install the seal (107*) with the lips up, and place
the seal retainer washer (113) on the piston/valve
seat (109). Make sure the lips of the seal face up.
See Fig. 3.
18. Clean the threads of the piston/valve seat (109),
Apply Loctiter to the threads, and thread the
assembly from Step 16 onto the displacement
rod (29).
19. Clamp the flats of the piston/valve seat (109) in a
vise, and torque the displacement rod (29) to the
piston valve seat to 45 to 55 ft-lb (61 to 75 N.m).
20. Clamp the air motor base (28) in a vise horizontally
by closing the vise jaws on the flange
21. Thread piston assembly tool (A) (included in repair
kit 238751) onto the threads of the displacement
pump cylinder (110). See Fig. 5.
22. Insert the piston assembly (B) into the displacement pump cylinder.
23. Unscrew the piston assembly tool from the displacement pump cylinder. Clip the piston assembly tool with a diagonal cutter (C), and discard it.
NOTE: Be careful that you do not scratch the rod.
24. Use a strap wrench to screw the displacement
pump cylinder (110) to the air motor base (28).
See Fig. 3.
25. Before you remount the pump, connect an air hose
and run the air motor slowly, starting with just
enough air pressure to make the air motor run, and
make sure that it operates smoothly.
17. Place the piston ball (103) in the displacement
rod (29).
A
110
Fig. 5
26. Reconnect the ground wire before regular operation of the pump.
rod
B
C
7221A
12 308655J
Displacement Pump Service
Disassembly
NOTE: Be sure you have all necessary parts on hand.
Repair Kit 238751 includes repair parts for the
air motor and pump. Use all parts in the kit for
the best results. Parts included in the kit are
marked with one asterisk, for example (19*), in
the text and drawings. See the Parts List on
page 14.
1. Flush the pump.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
2. Relieve the pressure.
3. Disconnect the hoses, remove the pump from its
mounting, and clamp the air motor base (28) in a
vise horizontally by closing the vise jaws on the
flange.
Intake Valve. See Fig 6.
Displacement Pump. See Fig 6.
NOTE: Clean and inspect all parts for wear or damage
as you disassemble them. Replace parts as
needed. For best results, always replace all
the o-rings and packings when you disassemble the pump.
1. Relieve the pressure.
2. Follow steps 1 to 7 of Disassembly on page 9.
3. Carefully inspect the smooth inner surface of the
fluid cylinder (110) for scoring or scratches. Such
damage causes premature seal wear and leaking.
Replace the cylinder as needed.
Reassembly
Do steps 16 through 26 in Air Motor and Throat
Service on page 12.
110
1. Relieve the pressure.
2. Unscrew the valve housing (111). Remove the
o-ring (105*), retainer (112), and ball (104).
3. Inspect the parts for wear or damage. If the ball is
nicked, replace it. Put grease on the male
threads, and reassemble.
112
105*
111
Fig. 6
* Included in Pump Repair Kit 238751, which may
be purchased separately. The Parts List on page
14 includes all parts in kit.
104
06039
308655J 13
Parts List
Model 205626, Series K Model 222065, Series C Model 222095, Series C
Wall-Mount Universal Pump 55-Gallon Drum Cover-Mount Pump 55-Gallon Drum Bung-Mount Pump
Includes items 1 to 113 Includes items 1 to 113, 150, and 151 Includes items 1 to 113, 150,152, and 153
Ref
No. Part No. Description Qty.
1 AIR MOTOR (items 2 to 36) 1
2* 110247 SEAL; polyurethane, nitrile 1
3 101578 SCREW, cap, hex hd 8
5 102656 MUFFLER, air exhaust 1
7 116343 SCREW, ground 1
11 156698 PACKING, o-ring 1
12 158359 ACTUATOR, air valve 1
13 158360 YOKE, trip rod 1
15 158362 PIN, toggle 2
16 158364 PIN, pivot 2
17* 158367 GROMMET, lower valve 2
18 158377 PACKING, ring seal 1
19* 158378 PACKING, o-ring 1
20* 158379 PACKING, o-ring 1
21* 160261 NUT, valve 4
22* 160618 WIRE, lock 2
23 160623 ARM, toggle 2
24 190929 RING, lift 1
25 167585 SPRING, helical compression 2
26* 170709 POPPET, exhaust valve 2
27 207391 PISTON, includes items 27a to
27c, (also includes 207385 repair kit
when ordered as a replacement
part) 1
27a 102975 SCREW, rd hd mach; 6–32 X 1/4” 2
27b 158361 CLIP, spring 2
27c BARE PISTON (not sold separately) 1
28 191544 BASE, air motor 1
29 191545 ROD, displacement 1
Ref
No. Part No. Description Qty.
30 15E954 CYLINDER, air motor 1
31 207150 ROD, trip 1
32* 236079 POPPET, inlet valve 2
33 119344 LABEL, designation 1
35Y 290259 LABEL, warning 1
36 191546 BEARING, throat 1
103 100279 BALL; sst 1
104 101190 BALL; sst 1
105* 156633 PACKING, o-ring 1
107* 113564 SEAL, block, vee 1
108* 156641 PACKING, o-ring 1
109 191547 PISTON/VALVE SEAT 1
110 191548 CYLINDER, fluid 1
111 183009 VALVE HOUSING 1
112 157182 RETAINER, ball 1
113 191123 RETAINER, seal 1
150 110127 SPACER, foot 1
151 191128 TUBE, extension; 21.75” (553 mm) 1
152 191130 TUBE, extension; 26.0” (661 mm) 1
153 222308 BUNG ADAPTER 1
* Included in Repair Kit 238751, which may be
purchased separately.
Y Extra warning labels are available at no cost.
14 308655J
Parts Drawing
Torque to 30 to 40 ft-lb
1
(41 to 54 N.m)
Torque to 45 to 55 ft-lb
2
(61 to 75 N.m)
3
Lips face down
4
Lips face up
When assembling the fluid cylinder
5
(110) over the assembled fluid
piston (107, 109, 113), use the
piston assembly tool included in
repair kit 238751 and steps 21
through 23 on page 12 .
31
27a
27b
27
16
25
15
23
26*
24
11
30
18
13
22*
21*
12
17*
21*
2*
3
28
5
3
7
113
107*
4
103
109
2
108*
27c
*19
1
29
36
*20
32*
153
110
5
105*
112
104
111
151, 152
150
06036
308655J 15
Dimensions
Mounting Hole
1/2-in.
npt air
inlet
3/4-in.
npt fluid
outlet
3/4-in.
npt
muffler
port
MODEL 205626, Series K
18.4 in.
(467 mm)
06035
7.4 in.
(188 mm)
Model
205626
25.8 in.
(655 mm)
45_
Layout
2.25-in. (57.2 mm) diameter
clearance hole
Four 0.406-in. (10.3
mm) holes on 7-in.
(177.8 mm) bolt
circle
Four threaded
holes on bottom of
air motor base are
1/4–20 UNC on
4.25-in. (108 mm)
bolt circle.
8.0 in.
(203.2 mm)
diameter of
flange
Note: For
sealed tank
mounting use
gasket
192658.
16 308655J
Model
222065
32.3 in.
(820 mm)
Model
222095
36.6 in.
(929 mm)
Technical Data
Maximum working pressure 1800 psi (124 bar). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid pressure ratio 10:1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air operating range 40 to 180 psi (2.8 to 12.4 bar). . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air consumption Approximately 13 ft3/min per gallon pumped,. . . . . . . . . . . . . . . . . .
(6 m3/hour per liter pumped)
at 100 psi (6.9 bar)
Pump cycles per gallon (liter) 20 (5.3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum recommended continuous pump speed 60 cycles/min;. . . . . . . . . . . . . . .
3 gpm (11.4 liter/min)
Recommended speed for optimum pump life 15 to 25 cycles per min. . . . . . . . . . . .
Sound data 78.0 dBA sound power at 100 psi air, 40 cycles per minute. . . . . . . . . . .
Piston seals polyurethane with nitrile spreader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rod seals polyurethane with nitrile spreader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wetted parts aluminum, steel, polyurethane, nitrile. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight (Model 205626, Universal Pump) 28.7 lb (13.0 kg). . . . . . . . . . . . . . . . . . . . . .
Loctiter is a registered trademark of the Loctite Corporation.
1400
(96.6)
1300
(89.7)
1200
(82.8)
Performance Chart
KEY black curves=fluid outlet pressure
gray curves=air consumption
A 40 psi (2.8 bar) air pressure
B 70 psi (4.8 bar) air pressure
C 100 psi (6.9 bar) air pressure
D 150 psi (10.4 bar) air pressure
1100
(75.9)
1000
(69.0)
900
(62.1)
800
(55.2)
700
(48.3)
600
(41.4)
B
500
(34.5)
FLUID OUTLET PRESSURE––psi (bar)
400
(27.6)
A
300
(20.7)
200
(13.8)
100
(6.9)
D
C
B
A
Air
Consumption
––scfm
(m
D
#/min)
90
(2.52)
80
C
(2.24)
70
(1.96)
60
(1.68)
50
(1.40)
40
(1.12)
30
(0.84)
20
(0.56)
10
(0.28)
0
0123456
(3.8) (7.6) (11.4) (15.1) (18.9) (22.7)
FLUID FLOW––gpm (lpm)
Test Fluid: 10-weight oil at 75_ F (23.9_ C)
To find fluid outlet pressure at a specific fluid flow
and operating air pressure:
1. Locate desired fluid flow along bottom of chart.
2. Follow vertical line up to intersection with
selected fluid outlet pressure curve (black).
3. Follow left to scale to read fluid outlet pressure.
To find pump air consumption at a specific fluid
flow and air pressure:
1. Locate desired flow along bottom of chart.
2. Read vertical line up to intersection with selected
air consumption curve (gray).
2. Follow right to scale to read air consumption.
308655J 17
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 substitution 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 reconnaissent 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 Number
TO PLACE AN ORDER, contact your Graco distributor, or call this number 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 308655
International Offices: Belgium, Korea, China Japan
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Graco Headquarters: Minneapolis
308655 06/1996 Revised 3/2007
18 308655J
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