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Obstructed fluid hose or gun/valve Fluid dried on the displacement rod Dirty or worn air motor parts Refill and reprime or flush. Clear; see TECHNICAL DATA on back cover. Open, clear. Clear.* Clean. See SERVICE. Clean, service. See air motor manual, supplied. Pump operates but outputlow on both strokes Exhausted fluid supply Restricted line or inadequate air supply Insufficient air pressure, closed or clogged airvalves, etc. Obstructed fluid hose or gun/valve Bleeder valve open or worn Air leaking into supply drum Fluid too heavy for pump priming Worn throat packings in displacement pump Refill and reprime or flush. Clear. See TECHNICAL DATA on back cover. Open, clear. Clear.* Close; replace. Check inductor or ram plate seal. Use pump bleeder valve (see page 5). Use inductor or ram unit. Replace gland/packing stack. Pump operates but outputlow on downstroke Fluid too heavy for pump priming Held open or worn intake valve or packings Use pump bleeder valve (see page 5). Use inductor or ram unit. Clear valve; replace gland/packing stack. Pump operates but outputlow on upstroke Held open or worn piston valve or packings Clear valve; replace gland/packing stack. Erratic or accelerated Exhausted fluid supply Refill and reprime or flush. pump speed Fluid too heavy for pump priming Held open or worn piston valve or packings Held open or worn intake valve or packings Worn throat packings in displacement pump Use pump bleeder valve (see page 5). Use inductor or ram unit. Clear valve; replace packings. Clear valve; replace gland/packing stack. Replace gland/packing stack. * To clear the pump, follow the Pressure Relief Procedure Warning, above. Disconnect the fluid line. If the pump starts when theair is turn on, then the fluid hose or gun/valve is obstructed. 306–646 . DISPLACEMENT PUMP SERVICE WARNING Moving parts can pinch or amputate your fingers or other body parts. When the pump is operating, the priming piston (located at the pump intake) and the air motor piston (located behind the air motor shield) move. Therefore, NEVER operate the pump with the air motor shield removed, and keep your fingers and hands away from the priming piston. Before attempting to clear an obstruction from the priming piston or service the pump, follow the Pressure Relief Procedure Warning on page 7 to prevent the pump from starting accidentally. Before You Start (All Models) 1. Repair Kit 220–861 is available. See pages 13 and 15. For the best results, use all the new parts in thekit, even if the old ones look good. Repair kit parts areindicated in the text and the parts list with an asterisk, for example (27*). 2. To reduce down time, keep spare parts on hand. Recommended spare parts are indicated in the partslist with a double asterisk, for example (41**). 3. The gland/packing stacks (64*, 65*) are preassembled. Do not disassemble the stacks when installing them in the pump. 4. For air motor service and parts information, refer tomanual 307–049 for motor Model 208–356, manual 306–968 for motor Model 206–647, manual 307–304 for motor Model 215–255, or manual 307–741 for motor Model 220–106. 5. If possible, flush the pump before service with a compatible solvent. Follow the Pressure Relief Procedure Warning on page 7. Stop the pump at the bottom of its stroke. 6. Disconnect all the hoses. Remove the pump from itsmounting and clamp it in a vise. Model 204–641 Displacement Pump (Used onModels 204–287, 215–873 and 222–248) Disassembly NOTE: Refer to Fig 2 and the parts drawing. 1. Remove the cotter pin (41). Unscrew the couplingnut (50) and the three tie rod locknuts (44). Pull thedisplacement pump (2) off the air motor (1). 2. Remove the cotter pin (42). Loosen the locknut (45). Unscrew the connecting rod (53) from the upper cap(33). 3. Insert a 1/4 in. (6 mm) diameter rod in the holes of the packing nut/wet–cup (21), and loosen it. Push thedisplacement rod (18) down until the priming piston (37) clears the intake valve housing (28). Removethe nut (6), priming piston (37), valve plate (36) and plate guide (31). 4. Unscrew the four tie bolts (8) and pull the intake valvehousing (28) off the pump. Pull the priming rod (32) and displacement rod (18) out of the bottom of thecylinder (39). Remove the pin (7) and unscrew thepriming rod (32) from the connecting rod (20). . 306–646 5. Pull the cylinder (39) down out of the outlet housing(26). Inspect the inner surface of the cylinder and the outer surface of the displacement rod (18) forscratches or scoring, which can cause prematurepacking wear and leaking. To check, run a finger overthe surface or hold the part up to the light at an angle. 6. Disassemble the intake valve (3). Clean and inspectall parts, replacing as necessary . Check the intakevalve seat (30) for nicks or damage. 7. Unscrew the upper cap (33) from the connecting rod(20). Pull the displacement rod (18) off the lower cap(19), and remove the piston assembly from the connecting rod. Disassemble the piston. 8. Unscrew the packing n...

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