Graco Heat Pump 306518ZAC User Manual

Instructions  
®
5:1 Fire-Ball 300  
Pump  
306518ZAC  
EN  
For pumping non-corrosive and non-abrasive greases and lubricants only.For professional  
use only.  
Model No. 203872, 203857, 204254,  
222087, 203876  
900 psi (6.2 MPa, 62 bar) Maximum Working Pressure  
180 psi (1.2 MPa, 12 bar) Maximum Air Input Pressure  
Important Safety Instructions  
Read all warnings and instructions in this  
manual. Save these instructions.  
 
Warnings  
Warnings  
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-  
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When  
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific  
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where  
applicable.  
WARNING  
EQUIPMENT MISUSE HAZARD  
Misuse can cause death or serious injury.  
Do not operate the unit when fatigued or under the influence of drugs or alcohol.  
Do not exceed the maximum working pressure or temperature rating of the lowest rated system com-  
ponent. See Technical Data in all equipment manuals.  
Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all  
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information  
about your material, request MSDS from distributor or retailer.  
Do not leave the work area while equipment is energized or under pressure.  
Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.  
Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-  
facturer’s replacement parts only.  
Do not alter or modify equipment. Alterations or modifications may void agency approvals and create  
safety hazards.  
Make sure all equipment is rated and approved for the environment in which you are using it.  
Use equipment only for its intended purpose. Call your distributor for information.  
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.  
Do not kink or over bend hoses or use hoses to pull equipment.  
Keep children and animals away from work area.  
Comply with all applicable safety regulations.  
TOXIC FLUID OR FUMES HAZARD  
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or  
swallowed.  
Read MSDSs to know the specific hazards of the fluids you are using.  
Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.  
Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.  
MOVING PARTS HAZARD  
Moving parts can pinch, cut or amputate fingers and other body parts.  
Keep clear of moving parts.  
Do not operate equipment with protective guards or covers removed.  
Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,  
follow the Pressure Relief Procedure and disconnect all power sources.  
PERSONAL PROTECTIVE EQUIPMENT  
Wear appropriate protective equipment when in the work area to help prevent serious injury, including  
eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is  
not limited to:  
Protective eyewear, and hearing protection.  
Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer  
306518ZAC  
3
 
 
Installation  
Installation  
To maintain grounding continuity when flushing or  
relieving pressure: hold metal part of the valve firmly to  
the side of a grounded metal pail, then trigger the  
gun/valve.  
Grounding  
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. To order a  
ground wire clamp, order Part. No. 222011.  
The equipment must be grounded to reduce the risk  
of static sparking and electric shock. Electric or static  
sparking can cause fumes to ignite or explode.  
Improper grounding can cause electric shock.  
Grounding provides an escape wire for the electric  
current.  
Be sure to ground all this equipment:  
Pump: Use a ground wire and clamp as shown in FIG. 1.  
Fluid hoses: Use only electrically conductive hoses.  
Z
Y
Air compressor: Follow manufacturer’s recommenda-  
tions.  
FIG. 1  
Fluid supply container: Follow the local code.  
G
F
A
C
A
N
D
A
S
E
P
J
B
R
H
DETAIL A  
L
M
K
1/2 in. (13 mm) between  
foot spacer and bottom of  
drum  
FIG. 2: Typical Installation  
Key:  
A
Bleed-type master air valve (required if quick-disconnect  
fitting [L] and coupler [M] are not installed) Order Part No.  
107142  
Air line filter  
Air regulator and gauge  
Pump runaway valve  
Air inlet  
Ground wire (required) Order Part No. 222011  
Pump (model 204254 shown)  
H
J
K
L
M
N
P
R
S
Drain valve (required) Order Part No. 210658  
Dispensing valve  
Low-level cut-off valve  
Male quick-disconnect fitting  
Female quick-disconnect coupler  
Air line lubricator  
B
C
D
E
F
Fluid hose  
Thermal relief kit (required) Order Part No. 237893  
Bung adapter, models 204254 and 222087  
G
4
306518ZAC  
 
       
Installation  
1. Install the pump on the drum cover so that the  
pump’s fluid intake is 1/2 inch. (13 mm) off the bot-  
tom of the drum. (FIG. 2)  
1. Install a pump runaway valve (D) to shut off the air  
to the pump if the pump accelerates beyond the  
pre-adjusted setting. A pump that runs too fast can  
be seriously damaged.  
2. On Models 204254 and 222087, screw the bung  
adapter tightly into the drum cover’s bung hole,  
adjust the position of the pump in the drum, and  
tighten the bung adapter screw to hold the pump,  
NOTICE  
Never allow the pump to run dry of fluid being  
pumped. A dry pump will quickly accelerate to a high  
speed, possibly damaging itself, and it may get very  
hot.  
System Accessories  
Refer to FIG. 2 for the following instructions.  
2. Install an air line lubricator (N) for automatic air  
motor lubrication.  
3. Install a bleed-type master air valve (A) to relieve air  
trapped between the valve and the motor. As an  
alternative, you can install an air line quick-discon-  
nect coupler (M) and fitting (L) to serve as an  
air-bleed device. See FIG. 2.  
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 yes or on the skin,  
injury from moving parts if you are adjusting or repair  
the pump, and explosion from static sparking.  
4. Install a Thermal Relief Kit (K) on the dispensing  
valve side of the pump.  
5. Install the air regulator (C) to control pump speed  
and pressure.  
• The air bleed device relieves air trapped between it  
and air motor after the air supply is shut off.  
Trapped air can cause the motor to cycle  
unexpectedly, causing serious injury if you are  
adjusting or repairing the pump. Use either a  
bleed-type master air valve (A) or a  
6. Install an air line filter (B) to remove harmful dirt and  
contaminants from the compressed air supply.  
Install another bleed-type master air valve (A) to iso-  
late the accessories for servicing.  
quick-disconnect coupler (M) and fitting (L). Install  
them near the pump air inlet within easy reach from  
the pump.  
7. Install a drain valve (H) near the pump fluid outlet.  
8. Install a suitable fluid hose (P) and dispensing valve  
(J).  
• The fluid drain (H) assists in relieve fluid pressure  
in the displacement pump, hoses, and dispensing  
valve. Triggering the valve to relieve pressure may  
not be sufficient.  
• The thermal relief kit (R) assists in relieving  
pressure in the pump, hose, and dispensing valve  
due to heat and expansion.  
• The ground wire (F) reduces the risk of static  
sparking.  
NOTICE  
Do not hang the air accessories directly on the air  
inlet (E). The fittings are not strong enough to support  
the accessories and may break. Provide a bracket on  
which to mount the accessories.  
NOTE: Install the air line accessories in the order shown  
306518ZAC  
5
 
 
Operation  
Operation  
5. 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 compat-  
ible solvent. Be sure to eliminate all air from the fluid  
lines.  
Pressure Relief Procedure  
Follow the Pressure Relief Procedure whenever  
you see this symbol.  
This equipment stays pressurized until pressure is  
manually relieved. To help prevent serious injury from  
pressurized fluid, such as skin injection, splashing  
fluid and moving parts, follow the Pressure Relief  
Procedure when you stop spraying and before  
cleaning, checking, or servicing the equipment.  
NOTICE  
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.  
NOTE:  
1. Close the pump air regulator and bleed-type master  
air valve (required in the system).  
The low-level cut-off valve accessory (K) closes  
the pump fluid intake when the fluid level is low,  
which prevents air from entering the system.  
A pump runaway valve (D) should be installed  
on the air line to automatically shut off the pump  
if it starts to run too fast.  
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.  
Start and Adjusting the Pump  
6. Read and follow the instructions supplied with each  
component in the system.  
7. If the pump will be unattended for any period of  
time, if there is an air supply interruption, or at the  
end of the work shift, shut off the system and always  
relieve the pressure. (See Pressure Relief Proce-  
dure)  
1. With the air regulator (C) closed, open the  
bleed-type master air valves (A), or, if so equipped,  
join the quick-disconnect coupler (M) to the male fit-  
ting (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 dis-  
pensing valve.  
NOTE: When the pump is, and with sufficient air sup-  
plied, the pump starts when the dispensing valve is  
opened and shuts off when closed.  
4. Adjust the air regulator until you get sufficient flow  
from the dispensing valve. Always run the pump at  
the lowest pressure necessary to get the desired  
results. Do not exceed the maximum working pres-  
sure of any component in the system.  
6
306518ZAC  
 
     
Troubleshooting  
Troubleshooting  
1. Follow Pressure Relief Procedure, page 6, before  
checking or repairing gun.  
2. Check all possible problems and causes before dis-  
assembling gun.  
Problem  
Cause  
Solution  
Inadequate air supply pressure or  
restricted air lines  
Increase air supply and/or clear  
restriction  
Closed or clogged valves  
Open and/or clear  
Clogged fluid lines, hoses, valves,  
etc.  
Pump fails to operate  
Relieve pressure. Clear obstruction  
Assess damage and service air  
motor  
Damaged air motor  
Exhausted fluid supply  
Refill and reprime or flush  
Worn or damaged air motor gasket  
or seal  
Asses wear or damage and service  
air motor  
Continuous air exhaust  
Erratic pump operation  
Exhausted fluid supply  
Refill and reprime or flush  
Clear and service  
Held open or worn intake valve or  
piston packings  
Pump operates, but output low on  
upstroke  
Held open or worn piston packings  
Held open or worn intake valve  
Clear and service  
Clear and service  
Pump operates, but output low on  
downstroke  
Inadequate air supply or restricted  
air line  
Increase air supply and /or clear  
restriction  
Closed or clogged valves  
Exhausted fluid supply  
Open and/or clear  
Pump operates, but output low on  
both strokes  
Refill fluid supply and reprime pump  
or flush  
Clogged fluid lines, hoses, valves,  
etc.  
Relieve pressure. Clear obstruction  
306518ZAC  
7
 
 
Service  
Service  
11. Clamp the flats of the fluid piston (110) in a vise,  
and torque the displacement rod (8) to the piston to  
40 to 60 ft-lbs (54 to 81 N.m).  
Displacement Pump Service  
12. Clamp the air motor base (5) in a vise horizontally  
by closing the vise jaws on the flange.  
Pump Repair Kit 238286 is available and includes repair  
parts for the pump and air motor. Use all parts in the kit  
for best results.  
13. Use a strap wrench to screw the displacement  
pump cylinder (105) to the air motor base (5), and  
torque to 95 to 105 ft-lbs (129 to 142 N.m).  
1. Flush the pump.  
14. If the ground wire was disconnected before servic-  
ing, be sure to reconnect it before you operate the  
pump.  
2. Relieve the pressure before proceeding, page 6.  
3. Disconnect the hoses, remove the pump from its  
mounting, and clamp the air motor base (5) in a vise  
horizontally by closing the vise jaws on the flange.  
Air Motor and Throat Service  
4. Unscrew the intake valve body (107) from the fluid  
cylinder (105). Disassemble the intake valve. (See  
Parts Drawing Page 12.) Clean and inspect the  
parts for wear or damage, and replace parts as  
needed. be sure to check the o-ring (108). Unless  
further intake valve service is needed, reassemble  
and reinstall, using liquid sealant on the male  
threads.  
Refer to FIG. 3 and FIG. 4 for the following instructions.  
Pump Repair Kit 238286 is available and includes repair  
parts for the pump and air motor. Use all parts in the kit  
for best results.  
5. Use strap wrench on the fluid cylinder (105) to  
screw it out of the air motor base (5). Carefully  
inspect the smooth inner surface on the cylinder for  
scoring or irregular surfaces. Such damage causes  
premature packing wear and leaking, so replace the  
part if it is damaged.  
Two accessory tools should be used: Padded Pliers,  
207579, are used to grip the trip rod without damaging  
its surface; Gauge, 171818, is used to ensure the proper  
clearance between the poppets and seat of the transfer  
valve.  
6. Using wrenches on the flats of the displacement rod  
(8) and on the flats of the fluid piston (11), unscrew  
the fluid piston from the displacement rod.  
Disassembly  
1. Flush the pump.  
7. Take the ball (111) out of the displacement rod (8),  
and take the packing o-ring (104) off of the fluid pis-  
ton.  
2. Relieve the pressure, see page 6.  
3. Disconnect the ground wire from the grounding  
screw (5a), disconnect the hoses, remove the pump  
from its mounting, and clamp the air motor base in a  
vise horizontally by closing the vise jaws on the  
flange.  
8. Clean and inspect all parts. Use all the repair kit  
parts during reassembly and replace other parts as  
necessary.  
9. Place the piston ball (109) in the displacement rod  
(8).  
4. Use a strap wrench on the fluid cylinder (105) to  
screw it out of the air motor base (5).  
10. Install the new packing o-ring (104) on the fluid pis-  
ton (110).  
5. Pull the displacement rod (8) down as far as it will  
8
306518ZAC  
 
     
Service  
6. Using wrenches on the flats of the displacement rod  
(8) and on the flats of the fluid piston (110), unscrew  
the fluid piston from the displacement rod. Remove  
the ball (111) from the end of the displacement rod,  
and remove the packing o-ring (104) from the fluid  
piston.  
29  
17  
11  
7. Clamp the air motor upright in the vise by closing  
the vise jaws below the flange.  
24  
10  
1
2
8. Unscrew the cylinder cap nut (29) from the top of  
the air motor cylinder (17).  
5a  
9
21  
9. Pull up on the cylinder cap nut (29) to expose the  
trip rod, grasp the trip rod with padded pliers, and  
unscrew the cylinder cap nut from the trip rod.  
6
5
flange  
8
NOTICE  
Do not damage the plated surface of the trip rod (11).  
Damaging the surface of the trip rod can result in  
erratic air motor operation. Use the special padded  
pliers to grasp the rod.  
FIG. 3  
13. Remove the o-ring (24) from the air motor piston (2).  
10. Remove the six screws (21) holding the air motor  
cylinder (17) to the air motor base (5), and carefully  
pull the cylinder straight up off the piston (2).  
14. Clamp the displacement rod upright in the vise by  
closing the vise jaws on the flats of the displace-  
ment rod.  
NOTICE  
15. Use a screw driver to push down on the trip rod  
yoke (22) to snap the toggles (M) down. (FIG. 4)  
To avoid damaging the cylinder wall, lift the cylinder  
straight up off the piston. Never tilt the cylinder while  
you are removing it.  
16. Remove the lockwires (31) from the adjusting nuts  
(30) of the transfer valves. Screw the top nuts off.  
Screw the valve poppet (1) stems out of the grom-  
mets (12) and bottom nuts (30). Take the valve pop-  
pets off the stems and squeeze them firmly to check  
for cracks.  
11. Pull the air motor piston/displacement rod assembly  
(2, 8) clear of the air motor base (5) by pulling up on  
the air motor piston.  
12. Remove the o-rings (9, 112) and u-cup packing (6)  
from the air motor base (5). Use needle-nose pliers  
to remove the u-cup packing from the bottom of the  
air motor base.  
17. Grip the toggle rockers (26) with pliers. Compress  
the springs (27) and swing the toggle assembly (M)  
up and away from the piston lugs (L), and remove  
the assembly. Check that the valve, actuator (13) is  
support by the spring clips (14), but slides easily into  
them. (FIG. 4)  
18. Remove the trip rod yoke (22), actuator (13), and  
trip rod (11). Check the exhaust valve poppets (16)  
for cracks.  
19. To remove the exhaust valve poppets (16), stretch  
them out and cut them with a sharp knife.  
306518ZAC  
9
 
 
Service  
NOTE: Adjust the distance between the inlet valve pop-  
pets and the piston seat by turning the top valve nuts  
(30).  
Reassembly  
1. Clean all the parts carefully in a compatible solvent,  
and inspect for wear or damage. Use all the repair  
kit parts during reassembly, and replace other parts  
as needed.  
11. Tighten the bottom valve nuts (30) by hand. The  
grommets (12) should be slightly compressed.  
2. Check the polished surfaces of the piston (2), dis-  
placement rod (8), and cylinder (17) wall for  
scratches or wear. A scored rod causes premature  
throat seal wear and leaking.  
12. Align the holes in the valve nuts (30) and the slots  
on the stems of the inlet valve poppets (1), and drop  
the lock wires (31) through the holes in the valve  
nuts and into the slots in the stems of 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.  
3. Lubricate all parts with a light, water-resistant  
grease.  
4. Clamp the displacement rod (8) upright in the vise  
by closing the vise jaws on the flats of the displace-  
ment rod.  
NOTICE  
Never re-use the old lock wires. They will get brittle  
and break easily from too much bending.  
5. Pull the exhaust valve poppets (16) into the value  
actuator (13), and clip off the top part shown with  
dotted lines in FIG. 4.  
13. Take the assembly out of the vise so that you can  
move it around for the next two steps.  
6. Install the new grommets (12) in the actuator (22),  
place the inlet valve poppets (1) in the piston, and  
thread the bottom valve nuts (30) onto the stems of  
the inlet valve poppets until there are a few threads  
left before the threads run out.  
14. Grease and install the new o-rings (9, 24, 112).  
15. Install the new u-cup packing (6) through the bottom  
of the air motor base, with the lips facing toward the  
bottom of the pump.  
NOTE: If you thread the valve nuts too far down onto the  
poppets, they will run off of the threaded part of the pop-  
pets.  
16. Slide the displacement rod (8) down through the  
packings, and lower the air motor piston (2) into the  
air motor base (5).  
7. Grease heavily and place the trip rod (11) in the air  
motor piston (2), place the actuator (13) in the yoke  
(22), 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 stems of the inlet valve poppets (1) going  
through the grommets (12).  
17. Clamp the air motor upright in the vise by closing  
the vise jaws below the flange.  
18. Carefully lower the air motor cylinder (17) straight  
down onto the piston assembly (2). Tighten the six  
screws (21) holding the air motor cylinder to the air  
motor base (5).  
8. Thread the top of valve nuts (30) onto the stems of  
the inlet valve poppets (1) until one thread of the  
inlet valve poppets is exposed above the valve nuts.  
NOTICE  
To avoid damaging the cylinder wall, lower the cylin-  
der straight down onto the piston. Never tilt the cylin-  
der as it is being lowered.  
9. Install the pins (23) in the yoke (22), place the toggle  
arm (25) ends of the toggle assembly (M) onto the  
toggle pins, and snap the pivot pin (26) ends of the  
toggle assembly into the piston lugs (L).  
19. Pull the trip rod (11) so it is sticking up out of the air  
motor cylinder (17).  
10. Measuring with the gauge create 0.145 inch (3.7  
mm) of clearance between the inlet valve poppets  
(1) and the piston seat when the inlet valve is open.  
See the Cutaway View, FIG. 4.  
NOTE: You may have to hold the unit upside down to  
shake the trip rod loose.  
10  
306518ZAC  
 
Service  
20. Grip the trip rod (11) with padded pliers, screw the  
cylinder cap (29) onto the trip rod, push the cylinder  
cap nut down, and screw it into the top of the cylin-  
der.  
23. Clamp the flats of the fluid piston (11) in a vise, and  
torque the displacement rod (8) to the piston to 40 to  
60 ft-lbs (54 to 81 N.m).  
24. Clamp the air motor base (5) in a vise horizontally  
by closing the vise jaws on the flange.  
NOTICE  
Do not damage the plated surface of the trip rod (11).  
Damaging the surface of the trip rod can result in  
erratic air motor operation. Use the special padded  
pliers to grasp the rod.  
25. Use a strap wrench to screw the displacement  
pump cylinder (105) to the air motor base (5), and  
torque to 95 to 105 ft-lbs (129 to 142 N.m).  
26. Before remounting 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 it operates smoothly.  
21. Place the piston ball (109) in the displacement rod  
(8).  
22. Clean the threads of the fluid piston (110), apply  
27. Reconnect the ground wire before you resume regu-  
lar pump operation.  
®
Loctite to the threads, install the new packing  
o-ring (104) on the fluid piston, and thread the fluid  
piston onto the displacement rod (8).  
11 22  
25  
27  
26  
2
M
31*  
30*  
1*  
11  
1
16*  
14  
1*  
12*  
13  
30*  
3
L
12*  
30*  
24*  
1*  
2
4
5
1*  
2
14  
30*  
16*  
Push toggles (M) in and then up.  
Cut off tops of poppets as indicated by dotted lines.  
Turn wires up.  
1
2
3
0.145 in (3.7 mm) clearance between poppets (1) and seat when it is open.  
4
FIG. 4  
306518ZAC  
11  
 
 
Parts  
Parts  
Air Motor  
Pump  
29  
28  
112*  
17  
105  
118b  
22  
118a  
23  
25  
27  
26  
111  
110  
31*  
30*  
13  
104*  
108*  
106  
11  
15  
14  
16*  
12*  
30*  
109  
2
24*  
107  
1*  
33  
8
114, 115,  
116, or 117  
9*  
10  
18**  
113  
21  
5a  
5
6*  
1
**20  
**19  
1
Lips face down.  
12  
306518ZAC  
 
 
Parts  
Model 203857, Series N, 55 gal.  
Includes items 101 to 114  
Model 203872, Series N, 16 gal.  
Includes items 101 to 113 and 115  
Model 203876, Series N, Universal  
Includes items 101 to 112  
Model 204254, Series S, 55 gal. Bung Mount  
Includes items 101 to 113, 116, and 118  
Model 222087, Series E, 275 gal. Bung  
Mount  
Ref.  
Part Description  
158360 YOKE, rod, trip  
158362 PIN, toggle  
Qty.  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
33  
1
2
1
2
2
2
1
1
4
2
1
O-RING, nitrile rubber  
160623 ARM, toggle  
158364 ROCKER, toggle  
167585 SPRING, helical compression  
156698 O-RING, buna-N  
161435 NUT, cylinder, cap  
NUT, adjusting  
LOCK WIRE, transfer valve  
160932 GASKET, copper  
Pumps  
Includes items 101 to 113, 117, and 118  
Ref.  
104  
Part Description  
PACKING, o-ring  
Qty.  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Air Motor  
105  
106  
107  
108  
109  
110  
111  
112  
113  
114  
115  
116  
117  
118  
191125 CYLINDER, fluid  
157182 RETAINER, ball  
183009 BODY, intake valve  
Ref.  
1
Part Description  
VALVE, poppet  
Qty.  
2
1
1
1
1
1
1
1
1
1
2
1
2
2
O-RING, buna-N  
2
4
5
5a  
6
8
9
160614 PISTON, air motor  
101190 BALL, steel, 1” (25 mm) dia  
191122 PISTON, fluid  
100279 BALL, steel, 0.88” (22.2 mm) dia  
116343 SCREW, grounding1  
238278 BASE, air motor, includes 5a  
116343 SCREW, grounding  
O-RING, buna-N  
PACKING, u-cup  
15H889 ROD, displacement  
O-RING, buna-N  
110127 SPACER, foot  
191128 TUBE, extension, 21.75” (553 mm)  
191126 TUBE, extension, 14.25” (362 mm)  
191130 TUBE, extension, 26.0” (661 mm)  
191131 TUBE, extension, 36.0” (915 mm)  
222308 BUNG ADAPTER ASSEMBLY,  
includes items 118a and 118b  
10  
11  
12  
13  
14  
15  
160624 O-RING, buna-N  
203965 ROD, trip  
GROMMET, rubber  
172867 ACTUATOR, valve  
172866 CLIP, spring  
102975 SCREW, rd hd mach, no. 6-32 x  
1/4” (6.3mm)  
118a 104542 SCREW, cap, hex hd, M8 x 1.25”  
118b 210834 ADAPTER, bung, bare  
1
1
16  
17  
18  
19  
POPPET, valve  
2
1
1
Parts included in Kit 238286 (purchase separately).  
160613 CYLINDER, air motor  
‡ Parts included in Kit 222559 (purchase separately).  
PLATE, identification, with muffler  
SCREW, hex head, no. 8-32 x 0.38 12  
inches (10 mm) long  
NOTE: Two accessory tools are required for air motor  
and throat services: Padded Pliers, 207579, and Gauge,  
17181.  
20  
21  
PLATE, warning, with muffler  
1
6
101578 SCREW, hex head, 5/16-18 x 0.88”  
306518ZAC  
13  
 
Technical Data  
Technical Data  
.
®
5:1 Fire-Ball 300 Pumps  
US  
Metric  
6.2 MPa, 62 bar  
5:1  
Maximum fluid working pressure  
Fluid pressure ratio  
900 psi  
Air pressure operating range*  
Maximum air consumption  
40 to 180 psi  
0.28 to 1.2 MPa, 2.8 to 12 bar  
3
3
13 ft /minute for first gpm  
0.096 m /minute for first lpm  
pumped at 100 psi up to 8 addi- pumped at 0.7 MPa, 7 bar up to  
3
3
tional ft /min for each additional 0.058 additional m /min for each  
gpm with pump operated within additional lpm with pump oper-  
recommended range  
ated within recommended range  
Pump cycles per gallon (liters)  
7.9  
30  
Recommended speed for optimum pump life  
70 cycles per minute  
Maximum recommended pump speed  
Wetted Parts  
130 cycles per minute 5 gpm  
130 cycles per minute 19 lpm  
Steel, aluminum, buna-N, urethane  
Sound pressure level (measured at 1 meter  
from unit)  
77.8 dB(A)  
85.6 dB(A)  
7.7 kg  
Sound power level (tested in accordance with  
ISO 9614-2)  
Approximate weight  
17 lb  
®
Loctite is a registered trademark of the Loctite Corporation.  
(m3/min)  
14  
306518ZAC  
 
 
Dimensions  
Dimensions  
Model 203876, Series N, Overall length 20.7 in (526 mm)  
Model 203857, Series N, Overall length 45.6 in (1158 mm)  
Model 203872, Series N, Overall length 38.1 in (968 mm)  
Model 204254, Series S, Overall length 49.9 in (1267 mm)  
Model 222087, Series E, Overall length 59.9 in (1521 mm)  
grounding  
screw  
3/8 in.  
npt(f) air  
inlet  
3/8 in.  
1/2 in. npt(f)  
npt(f) air  
fluid outlet  
8.9 in.  
inlet  
grounding  
screw  
(226 mm)  
Model 203857  
1/2 in.  
npt(f)  
fluid  
33.8 in. (859 mm)  
Overall Length: 20.7 in. (526 mm)  
outlet  
Model 203872  
26.3 in. (668 mm)  
Mounting Hole Layout  
Model 204254  
38.1 in. (968 mm)  
Gasket,  
Part No.  
161023  
Model 222087  
48.1 in. (1222 mm)  
Two 0.265-in. (6.73  
mm) diameter holes  
on 5-in. (127 mm) bolt  
circle  
Four 0.265-in. (6.73  
mm) diameter holes on  
5-in. (127 mm) bolt  
circle  
3-in. (76.2 mm)  
diameter hole  
2-Hole Mounting Pattern  
4-Hole Mounting Pattern  
306518ZAC  
15  
 
 
Graco Standard Warranty  
Graco warrants all equipment referenced in this document which is 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 procédures concernées.  
Graco Information  
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.  
Phone: 612-623-6928 or Toll Free: 1-800-533-9655, Fax: 612-378-3590.  
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.  
Original instructions. This manual contains English. MM 306518  
Graco Headquarters: Minneapolis  
International Offices: Belgium, China, Japan, Korea  
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA  
Copyright 1994, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.  
Revised February 2014  
 
 

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