Graco Camping Equipment 222800 Series C User Manual

Instructions–Parts List

321 MM (12.625 IN.)

308213V

Premier™ Air Motor

100 psi (0.7 MPa, 7 bar) Maximum Air Input Pressure

Part No. 222800, Series C

Standard Motor

United States Patent Nos. 5,189,943; Des. 345,138; 2,032,617; 5,363,739

Taiwan Patent No. 050264

Canada Patent No. D75390

Korea Patent No. 152224

Other US and Foreign Patents Pending

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

See page 2 for Table of Contents.

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Symbols

Warning Symbol

Caution Symbol

WARNING

CAUTION

This symbol alerts you to the possibility of serious

injury or death if you do not follow the instructions.

This symbol alerts you to the possibility of damage to

or destruction of equipment if you do not follow the

instructions.

WARNING

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

D This equipment is for professional use only.

INSTRUCTIONS

D Read all instruction manuals, tags, and labels before operating the equipment.

D Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco

distributor.

D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

D Check equipment daily. Repair or replace worn or damaged parts immediately.

D Do not exceed the maximum working pressure of the lowest rated system component. Refer to the

Technical Data on page 26 for the maximum working pressure of this equipment.

D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-

nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

D Do not kink or overbend hoses or use hoses to pull equipment.

D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose

Graco hoses to temperatures above 180_F (82_C) or below –40_F (–40_C).

D Wear hearing protection when operating this equipment.

D Do not lift pressurized equipment.

D Do not lift the equipment by the Premier air motor lift ring if the total weight of the equipment ex-

ceeds 550 lb (250 kg).

D Comply with all applicable local, state, and national fire, electrical, and safety regulations.

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WARNING

SKIN INJECTION HAZARD

Spray from the gun, hose 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 Lock the gun trigger safety when you stop spraying.

D Follow the Pressure Relief Procedure on page 10 whenever you: are instructed to relieve pres-

sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.

D Tighten all fluid connections before operating the equipment.

D Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.

Permanently coupled hoses cannot be repaired; replace the entire hose.

D Use only Graco approved hoses. Do not remove the spring guard that is used to help protect the

hose from rupture caused by kinks or bends near the couplings.

MOVING PARTS HAZARD

Moving parts, such as the air motor piston, can pinch or amputate your fingers.

D Keep clear of all moving parts when starting or operating the pump.

D Before servicing the equipment, follow the Pressure Relief Procedure on page 10 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 Electrically disconnect all equipment in the spray area.

D 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.

D Keep a fire extinguisher in the work 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.

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Installation/Operation

Mounting Accessories

CAUTION

Mount the motor to suit the type of installation planned.

Motor dimensions and the mounting hole layout are

shown on page 27.

The Premier air motor is designed for intermittent

duty cycle applications, such as spraying of corrosion

control materials, or adhesive and sealant applica-

tions. It is not recommended for continuous duty

circulating systems. Contact your Graco distributor

for further application information.

If you are mounting the motor on an elevator or a cart,

refer to the separate manuals supplied with those

components for installation and operation instructions.

Air Line Accessories

NOTE: Reference numbers and letters in parentheses

in the text refer to the callouts in the figures and the

parts drawings.

The following air line accessories are available from

Graco. Contact your Graco distributor for help in

designing a system to suit your particular needs.

NOTE: Always use Genuine Graco Parts and Acces-

sories, available from your Graco distributor. If you

supply your own accessories, be sure they are ade-

quately sized and pressure rated for your system.

D A bleed-type master air valve is required in your

system to relieve air trapped between it and the air

motor when the valve is closed (see the WARNING

at left). Be sure the bleed valve is easily accessible

from the motor, and is located downstream from

the air regulator. Order Part No. 113163.

System Accessories

WARNING

D An air regulator controls pump speed and outlet

pressure by adjusting the air pressure to the motor.

Locate the regulator close to the motor, but up-

stream from the bleed-type master air valve.

A bleed-type master air valve and a fluid drain

valve are required in your system. These accesso-

ries help reduce the risk of serious injury, including

fluid injection and splashing of fluid in the eyes or

on the skin, and injury from moving parts if you are

adjusting or repairing the pump.

D An air line filter removes harmful dirt and moisture

from the compressed air supply.

D An air line lubricator adds oil to the compressed

air supply at an adjustable rate, to automatically

lubricate the air motor.

The bleed-type master air valve relieves air trapped

between this valve and the pump after the air is

shut off. Trapped air can cause the pump to cycle

unexpectedly. Locate the valve close to the pump.

D A pump runaway valve senses when the pump is

running too fast and automatically shuts off the air

to the motor. A pump which runs too fast can be

seriously damaged. Install closest to the motor air

inlet.

The fluid drain valve assists in relieving fluid pres-

sure in the displacement pump, hose, and gun.

Triggering the gun to relieve pressure may not be

sufficient.

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Installation/Operation

2. Air and fluid hoses: use only electrically conductive

Grounding

hoses.

WARNING

3. Air compressor: follow manufacturer’s recommen-

FIRE AND EXPLOSION HAZARD

Before operating the pump, ground the

system as explained below. Also read

the section FIRE AND EXPLOSION

HAZARD on page 5.

dations.

4. Spray gun: ground through connection to a prop-

erly grounded fluid hose and pump.

1. Pump: use a ground wire and clamp (supplied).

See Fig. 1. Loosen the grounding lug locknut (W)

and washer (X). Insert one end of a 1.5 mm@ (12

ga) minimum ground wire (Y) into the slot in lug (Z)

and tighten the locknut securely. Connect the other

end of the wire to a true earth ground. Order Part

No. 237569 Ground Wire and Clamp.

5. Fluid supply container: follow your local code.

6. Object being sprayed: follow your local code.

7. Solvent pails used when flushing: follow your local

code. Use only metal pails, which are conductive,

placed on a grounded surface. Do not place the

pail on a nonconductive surface, such as paper or

cardboard, which interrupts the grounding continu-

ity.

8. To maintain grounding continuity when flushing or

relieving pressure, hold a metal part of the spray

gun firmly to the side of a grounded metal pail,

then trigger the gun.

0864

Fig. 1

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Troubleshooting the Air Motor

3. Reinstall the air inlet fitting (22). Reconnect the air

Preventive Maintenance Schedule

line.

The operating conditions of your particular system

determine how often maintenance is required. Estab-

lish a preventive maintenance schedule by recording

when and what kind of maintenance is needed, and

then determine a regular schedule for checking your

system.

4. Open the bleed-type master air valve and set the

air regulator to about 0.1 MPa, 1 bar (14 psi).

Observe the rocker arms and trip rods for smooth

operation. Check at points A through E in Fig. 2 by

listening or feeling for escaping air, or squirting a

small amount of oil around the suspected leak.

The oil will bubble if air is leaking. Refer to the

sections noted in the Check Chart for detailed

service procedures.

Air Motor Cylinder

Premier motors require lubrication and continuous

maintenance including the replacement of the air motor

cylinder casting at least every 15,000,000 cycles of

use. Use Premier cylinder repair kit 16P239.

Check Chart

NOTE: Service the air valve every 3 million cycles. If

the air motor stalls, service the air valve immediately.

Repair or replace the Air Valve assembly (222799)

whenever motor stalling or hesitation occurs. This

ensures the motor does not overtravel and cause

added stress to the cylinder casting.

Ref.

Letter

Problem

Refer to:

Rocker assemblies Service rocker arms

(29) not operating.

(see pages 17 and

18).

WARNING

EXPLOSION HAZARD

Without proper maintenance, the cylin-

der casting (120026) may fracture

Air escaping around Service trip rod

trip rod or push rods. and air valve

(see pages 11–16).

unexpectedly due to metal fatigue. This

is a potentially hazardous condition and

may result in serious injury. The precise

life of this casting is difficult to predict

and is affected by the operating pressure, number

of cycles, lubrication and air valve maintenance.

Service push rod

seals (see pages 17

and 18).

Air escaping around Service air valve

air valve (25).

and air valve gaskets

(see pages 11–16).

Air escaping around Service slide blocks

Checking the Air Motor for Leaks

or Damaged Parts

or out of exhaust

manifold (45).

and air valve seals

(see pages 11–16).

Air escaping around Service piston and

If the pump is not performing well, the problem could

be in the air motor. To check the air motor, perform the

following steps.

piston rod (4).

rod seals (see pages

19 and 20).

Air motor stalls.

Service air valve (see

the NOTE above, and

refer to pages 11–16).

Install the detent, trip

rod, and air valve kits

(see pages 21–24).

1. Close the bleed-type master air valve. Disconnect

the air line.

2. Remove the shroud. Refer to page 11.

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29 (under the cover)

C (25), F

A, B

(4) E

(45) D

06547A

A, B

Fig. 2

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Service

Pressure Relief Procedure

Required Service Tools

D Phillips screwdriver

D Flat blade screwdriver

D 16 mm box wrench

D Set of metric socket wrenches

D Set of metric allen wrenches

D Set of adjustable wrenches

D Torque wrench

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:

D are instructed to relieve the pressure,

D stop spraying/dispensing,

D check or service any of the system equipment,

D or install or clean the spray tips/nozzles.

1. Lock the gun/valve trigger safety.

2. Shut off the air supply to the pump.

D Pliers

3. Close the bleed-type master air valve (required in

your system).

D Rubber mallet

4. Unlock the gun/valve trigger safety.

5. Hold a metal part of the gun/valve firmly to the side

of a grounded metal pail, and trigger the gun/valve

to relieve pressure.

D O-ring pick

D Soft brush (for cleaning)

D Large vise, with soft jaws

D Thread sealant

6. Lock the gun/valve trigger safety.

7. Open the drain valve (required in your system)

and/or pump bleeder valve, having a container

ready to catch the drainage.

8. Leave the drain valve open until you are ready to

spray/dispense again.

D Thread lubricant

If you suspect that the spray tip/nozzle or hose is

completely clogged, or that pressure has not been fully

relieved after following the steps above, very slowly

loosen the tip guard retaining nut or hose end coupling

and relieve pressure gradually, then loosen completely.

Now clear the tip/nozzle or hose.

D Multi-purpose grease

D Heavy-duty lithium grease (for air valve)

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Service

Air Valve Replacement

WARNING

NOTE: Service the air valve every 3 million cycles. If

the air motor stalls, service the air valve immediately.

To avoid serious injury and equipment

damage, do not lift the equipment by the

Premier air motor lift ring if the total

weight of the equipment exceeds 550 lb

(250 kg). The lift ring cannot support that

weight.

To replace the entire air valve assembly, order Part

No. 222799 and perform the following procedure. To

service the air valve, refer to pages 13–16.

Air Motor Shroud

NOTE: Air Valve Repair Kit 222959 includes the sub-

plate seals (27{) and gasket (26{).

NOTE: Reference numbers and letters in parentheses

in the text refer to the callouts in the figures and the

parts drawing.

Disassembly

WARNING

To reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 10.

WARNING

To reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 10.

1. Stop the pump at the middle of its stroke. Relieve

the pressure before performing any service.

1. Stop the pump at the middle of its stroke. Relieve

the pressure before performing any service.

2. Remove the air motor shroud as described under

2. Disconnect the air supply and the ground wire.

Air Motor Shroud Disassembly, at left.

3. If necessary, disconnect the displacement pump

from the air motor, as explained in your separate

pump manual.

3. Use a 6 mm allen wrench to remove the six socket

screws (28) holding the air valve (25) to the motor.

Remove the air valve.

4. Unscrew the air inlet swivel (22). See Fig. 3.

5. Remove the three screws (13) and washers (51).

Lift the shroud (53) off the motor.

4. Inspect the subplate gasket (26{) and seals (27{)

for wear or damage. Always replace the gasket

(26{) when replacing the air valve. Grease the

grooves of the slide plates (G), then install the

seals (27{) in the grooves with the curved sides

facing out (see the Detail in Fig. 3).

Reassembly

1. Make sure the rocker arm cover pad (63) and

cover plug (57) are in place.

2. Place the shroud (53) on the motor so the three

notches in the top center align with the outer holes

in the lift ring (3). Apply sealant to the three screws

(13) and attach the shroud to the lift ring with the

screws and washers (51).

5. Grease the ends of the trip rod (106).

6. Install the new air valve (25), using a 6 mm allen

wrench and the six socket screws (28). Torque to

22–23 NSm (195–205 in-lb).

3. Install the air inlet swivel (22).

4. If the displacement pump was removed, reconnect

it as explained in your separate pump manual.

7. Reinstall the air motor shroud as described under

5. Reconnect the air supply and the ground wire.

Air Motor Shroud Reassembly, at left.

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Service

Torque to 22–23 NSm (195–205 in-lb)

Apply sealant.

Grease ends of trip rod.

{

These parts are included in Air Valve Repair Kit

222959, which may be purchased separately.

Detail of Slide Plate Seals

Grease the grooves of

the slide plates (G).

Install the seals (27{) in

the grooves of the slide

plates (G) with the

curved sides facing out.

27{

02301

27{

26{

106{

06549A

Fig. 3

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Service

2. Remove the air motor shroud as described under

Air Valve Service

Air Motor Shroud Disassembly, on page 11.

NOTE: Service the air valve every 3 million cycles. If

3. Follow steps 3 and 4 under Air Valve Replace-

ment on page 11.

the air motor stalls, service the air valve immediately.

NOTE: Air Valve Repair Kit 222959 is available. Parts

included in the kit are marked with a symbol ({). For

the best results, use all the parts in the kit.

4. Using a 4 mm allen wrench, remove the socket

screws (104) holding the two slide plates (124) to

the valve housing (101). Lift the slide plates off the

housing, being careful not to scratch the polished

surfaces. Clean the slide plate surfaces and edges

and inspect for damage. See Fig. 4.

NOTE: Trip Rod Kit 222981 and Detent Kit 222982 are

available to replace these complete assemblies. Parts

included in Kit 222981 are marked with a symbol (})

and parts included in Kit 222982 are marked with a

checkmark (n).

5. Lift the valve carriage (111) out of the valve hous-

ing (101). The detent assemblies (J) will slide out

of the carriage; be careful not to drop them. Set

them aside.

Disassembly

WARNING

To reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 10.

6. Remove the screws (104) holding the top rod

fitting (103) to the valve housing (101). Turn the

fitting 90_ and remove it. Using an o-ring pick,

remove the seal (102). Repeat for the bottom rod

fitting.

1. Stop the pump at the middle of its stroke. Relieve

the pressure before performing any service.

7. Remove the trip rod assembly (T) from the hous-

ing (101). Set it aside.

104

103}

102}

104

124

111

101

Lubricate.

Apply thread sealant.

Grease ends of trip rod (T).

}107

104

Torque to 9 NSm (75 in-lb) and unscrew as need-

ed for plate (124) to be flush with housing (101)

Torque to 2–3 NSm (20–30 in-lb)

Lips must face into housing (101).

102}

103}

104

}

These parts are included in Trip Rod Kit

222981, which may be purchased separately.

n These parts are included in Detent Kit 222982,

which may be purchased separately.

02271

Fig. 4

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Service

8. With your fingers, snap the slide blocks (119) off of

a. Place the flats of one trip rod (106) in a vise

with soft jaws and unscrew the other trip rod

(106) with a wrench. Be careful not to scratch

the trip rods (106). See Fig. 8.

the valve carriage (111) to free the o-rings (120).

Clean and inspect the slide blocks. See Fig. 8.

9. Remove the screws (104) and disassemble the

bearing retainers (122), bearing rollers (121), and

pins (123). Clean and inspect these parts.

b. Disassemble the trip rod assembly. Inspect the

press-fit bearings (129) in place in the spring

guides (108). Clean and inspect all parts.

10. Clean and inspect the valve carriage (111). Re-

move and replace the bearings (107}).

13. Inspect the two detent plates (105) in place on the

valve housing (101). Remove if worn or damaged.

11. To disassemble the detents:

NOTE: If you are using Detent Kit 222982, it is not

necessary to disassemble the detents. Just replace the

old detents with the new ones provided in the kit (see

Reassembly, step 9).

14. Inspect the carriage bumpers (128) and replace if

worn or damaged.

Reassembly

a. Hold the detent roller (115) with a pliers while

turning the plunger guide (113) slightly with a

wrench, until the locking tabs of the guide

disengage from the windows in the plunger

(114). See Fig. 5.

1. Install the detent plates (105) on the valve housing

(101). Apply thread sealant and torque the screws

(104) to 9 N.m (75 in-lb). Lubricate the plates with

heavy-duty lithium grease. See Fig. 8.

2. Assemble the trip rod.

b. Use a flatblade screwdriver to pry out the

detent roller (115) and pin (117). See Fig. 8.

NOTE: If you are using Trip Rod Kit 222981, it is not

necessary to assemble the trip rod. Skip steps a

through c, and go to step 3.

113

115

a. Press fit the bearings (129) flush with the

inside surface of the spring guides (108).

Apply thread sealant to one of the trip rods

(106) and screw the shaft (109) onto the rod.

b. Install the spring guides (108) in the spring

(110), with the flanges facing out. Apply thread

sealant to the second trip rod and slide both

trip rods into the spring guides.

02249

Fig. 5

c. Compress the spring so the shaft (109) and

trip rod engage two or three threads. Place the

flats of one trip rod in a vise with soft jaws.

Use a wrench on the flats of the other rod and

torque to 17–23 NSm (150–200 in-lb).

12. To disassemble the trip rod:

NOTE: If you are using Trip Rod Kit 222981, it is not

necessary to disassemble the trip rod. Just replace the

old trip rod with the new one provided in the kit (see

Reassembly, step 3).

3. Install the trip rod assembly (T}) in the housing

(101). Grease the ends of the trip rod. See Fig. 4.

WARNING

4. Lubricate the seal (102{}) and slide it onto the trip

rod (T}) and into the top hole of the housing (101)

with the lips facing into the housing. Lubricate

the rod fitting (103{}) and install in the housing

(see Fig. 4). Apply thread sealant and torque the

screws (104) to 2–3 NSm (20–30 in-lb). Repeat for

the bottom of the housing.

MOVING PARTS HAZARD

Use caution when disassembling the trip

rod. The trip rod spring (110) is under

tension. When the trip rod is unscrewed

tension is released, and parts may be projected

through the air with considerable force.

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Service

5. Install the bearings (107}) on the valve carriage

9. Insert the detent assemblies into the valve carriage

(111) so the detent rollers (115) face out of the

carriage. Set the carriage into the valve housing

(101) so the detent rollers engage the detent

plates (105) on the housing. See Fig. 7.

(111). Apply thread sealant and torque the screws

(104) to 2–3 NSm (20–30 in-lb).

6. Install the bearing retainers (122) in the recesses

of the valve carriage (111). Apply thread sealant

and torque the screws (104) to 9 NSm (75 in-lb).

Lubricate the pins (123n) and install them in the

bearing rollers (121n). Lubricate the retainers

(122) and install the bearing rollers (121n).

124

111

7. Lubricate the o-rings (120{) and install them on

the valve carriage (111). Snap the slide blocks

(119) in place with the lip (K) facing toward the

nearest end of the carriage. Be sure the o-rings do

not roll out or twist. Lubricate the slide blocks.

104

8. Assemble the detents.

115

101

NOTE: If you are using Detent Kit 222982, it is not

necessary to assemble the detents. Skip steps a and

b, and go to step 9.

a. Lubricate the roller pin (117) and install it in the

detent roller (115). Lubricate the spring (112)

and install in the plunger guide (113). Lubricate

the plunger (114). Push the detent roller and

pin assembly into the plunger.

Apply thread sealant.

Torque to 9 NSm (75 in-lb) and unscrew as need-

ed for plate (124) to be flush with housing (101).

n These parts are included in Detent Kit 222982,

which may be purchased separately.

02269

b. Align the windows in the plunger (114) with the

tabs of the plunger guide (113). Stand the

detent assembly on the workbench and push

down on the plunger guide to seat the roller

(115) in the plunger. Make sure the plunger

tabs lock in the windows. See Fig. 6. Repeat

for the other detent assembly.

Fig. 7

10. Grease the slide plates (124) and install them in

the valve housing (101), with the o-ring grooves

facing out of the housing. Apply thread sealant and

torque the screws (104) evenly to 9 NSm (75 in-lb),

then unscrew as needed for plates (124) to be

flush with housing (101). See Fig. 7

11. Replace the subplate gasket (26{) and seals

(27{). Grease the o-ring grooves of the slide

plates (G), then install the seals (27{) in the

grooves with the curved sides facing out (see the

Detail in Fig. 3 on page 12).

114

113

12. Install the air valve (25), using a 6 mm allen

wrench and the six socket screws (28). Torque to

22–23 NSm (195–205 in-lb). See Fig. 3.

115

02249

13. Reinstall the air motor shroud as described under

Fig. 6

Air Motor Shroud Reassembly, on page 11.

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Service

WARNING

128

MOVING PARTS HAZARD

Use caution when disassembling the trip

rod. The trip rod spring (110) is under

tension. When the trip rod is unscrewed

tension is released, and parts may be projected

through the air with considerable force.

106}

108}

104

129}

104

113n

103{}

102{}

112n

124

114n

110}

117n

104

115n

101

129}

105

108}

119

{120

109}

107}

106}

104

102{}

123n

103{}

111

121n122

104

Lubricate with heavy-duty lithium grease.

Apply thread sealant.

Grease ends of trip rods (106).

128

01346

Torque to 9 NSm (75 in-lb).

Torque to 2–3 NSm (20–30 in-lb).

Lips must face into the housing (101).

{

These parts are included in Air Valve Repair Kit 222959,

which may be purchased separately.

Press fit flush with the inside surface of the guide (108).

Lip (K) must face toward the nearest end of the carriage (111).

}

These parts are included in Trip Rod Kit 222981, which

may be purchased separately. The kit also includes the

assembled trip rod.

Torque to 17–23 NSm (150–200 in-lb).

Torque to 9 NSm (75 in–lb) and unscrew as needed for

plates (124) to be flush with housing (101).

n These parts are included in Detent Kit 222982, which may

be purchased separately.

Fig. 8

308213

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Service

10. Remove the two screws (42), the top rod fitting

Subplate and Rocker Assemblies

(20), and the push rod (19) from the motor cap (2).

Using an o-ring pick, pull out the seal (21). Inspect

these parts for wear. Repeat for the bottom push

rod assembly.

NOTE: Air Valve Repair Kit 222959 is available. Parts

included in the kit are marked with a symbol ({). For

the best results, use all the parts in the kit.

Disassembly

Reassembly

1. Lubricate the seal (21{) and insert it in the motor

cap (2) with the lips facing into the cap. Install

the rod fitting (20{). Grease the end of the push

rod (19) and insert it in the fitting. Apply thread

sealant and torque the screws (42) to 2–3 NSm

(20–30 in-lb). Repeat for the bottom push rod

assembly. See Fig. 9.

WARNING

To reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 10.

1. Stop the pump at the middle of its stroke. Relieve

the pressure before performing any service.

2. Place the gasket (24) on the back side of the

subplate (23), aligning the holes in both parts. With

the air inlet port (P) facing up, install the subplate

on the cylinder (1) with the eight socket screws

(41). Torque to 10–12 NSm (90–110 in-lb).

2. Follow the steps under Air Motor Shroud Disas-

sembly on page 11.

3. Use an allen wrench to remove the six socket

screws (28) holding the air valve (25) to the sub-

plate (23). See Fig. 3 on page 12. Remove the air

valve.

3. Install the two liners (44) in the cavities of the

exhaust manifold (45). Attach the manifold to the

subplate with the gasket (47) and capscrew (43),

using a 17 mm box wrench. Torque to 24–27 NSm

(18–20 ft-lb).

NOTE: To replace or service the air valve, refer to

pages 11–16.

4. Remove the gasket (26) and the two seals (27).

Inspect these parts for wear or damage.

4. Lubricate the sleeve (31) and two bearings (32)

and install them in the rocker arm (29). Position

the rocker arm between the top flanges of the

subplate (23).

5. Remove the two screws (13) and washers (51)

holding the bottom cover (61) to the bottom rocker

arm cover (62). See Fig. 9.

5. Note that the rocker arm cover (62) has two tabs

that are off-center. Install the cover so the end with

the two tabs is toward the outside of the subplate

(see Fig. 9). Insert the stud (30) through the cover

and rocker arm, then install the nut (33). Torque to

22–23 NSm (195–205 in-lb). Replace the rocker

arm cover pad (63, see Fig. 3 on page 12).

6. Remove the pad (63, see Fig. 3 on page 12) from

the top rocker assembly. Hold the stud (30) with a

wrench while unscrewing the nut (33). Pull the stud

(30) out and disassemble the rocker assembly.

Push the sleeve (31) out of the rocker arm (29).

Inspect the rocker arm, sleeve, and bearings (32)

for wear.

6. Assemble the bottom rocker assembly as ex-

plained in steps 4 and 5. Install the bottom cover

(61) and secure to the rocker arm cover with the

two screws (13) and washers (51).

7. Disassemble the bottom rocker assembly as

explained in step 6.

8. Using a 17 mm box wrench, remove the capscrew

(43) and gasket (47) holding the exhaust manifold

(45) to the subplate (23). Remove the two liners

(44) from the cavities in the manifold. Check that

the vertical slot (V) in the manifold is clear of dirt or

blockage; clean with a brush or compressed air.

See Fig. 9.

7. Install the two seals (27{) and the gasket (26{).

See the Detail in Fig. 3 on page 12.

8. Install the air valve (25), using a 6 mm allen

wrench and six socket screws (28). Torque to

22–23 NSm (195–205 in-lb).

9. Using an allen wrench, unscrew the eight socket

screws (41) holding the subplate (23) to the cylin-

der (1). Remove the subplate and the gasket (24).

Inspect these parts for wear or damage.

9. Follow the steps under Air Motor Shroud Reas-

sembly on page 11.

308213 17

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Service

{

These parts are included in Air Valve Repair Kit

222959, which may be purchased separately.

z These parts are included in Premier Cylinder

Rebuild Kit 16P239, which may be purchased

separately.

20{

21{

32z

29z

30z

1 32z

31z

33z

24z

Lubricate.

Apply sealant.

Torque to 22–23 NSm (195–205 in-lb).

Torque to 10–12 NSm (90–110 in-lb).

Torque to 2–3 NSm (20–30 in-lb).

Torque to 24–27 NSm (18–20 ft-lb).

Lips must face into motor cap (2).

Grease the end of push rods (19).

06550A

Fig. 9

308213

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Service

11. Check the inner surface of the cylinder (1) for

scoring or other damage.

Piston and Piston Rod Seals

NOTE: Air Motor Repair Kit 222958 is available. Parts

included in the kit are marked with an asterisk (*). For

the best results, use all the parts in the kit.

Reassembly

1. Lubricate the ID of the cylinder (1), using a rag

soaked in grease. See Fig. 10.

Disassembly

2. Lubricate the seals and o-ring (7*, 8*, 11*). The

bottom of the bearing (6) has a narrow o-ring

groove on the outer surface. Install the o-ring (11*)

in this groove. Install the wiper (8*) in the bearing,

so the notch of the wiper faces down, out of the

bearing. At the top of the bearing, install the seal

(7*) so the lips face up, toward the cylinder (1).

WARNING

To reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 10.

1. Stop the pump at the middle of its stroke. Relieve

the pressure before performing any service.

3. Press the bearing assembly into the neck of the

cylinder (1) from the bottom until it is seated.

2. Follow the steps under Air Motor Shroud Disas-

sembly on page 11.

4. Install the bottom support bracket (35). Apply

thread sealant to the screws (14) and torque to

6–7 NSm (55–65 in-lb).

3. Disassemble the subplate and rocker assemblies,

as explained on page 17.

5. If the adapter (R) was disassembled, screw the

piston rod onto the adapter (R). Using adjustable

wrenches on the flats of the piston rod, torque to

318–349 NSm (234–257 ft-lb).

4. Remove the six screws (13), the lift ring (3), and

the o-ring (11*). See Fig. 10.

5. Using a 17 mm socket wrench, remove the fifteen

capscrews (12) holding the motor cap (2) to the

cylinder (1). Lift the motor cap off the cylinder.

Remove and inspect the o-ring (10).

6. Lubricate the o-ring (9*) and install it on the piston

(5).

7. Lubricate the piston rod. Lower the piston assem-

bly into the cylinder (1), carefully sliding the adapt-

er and rod down through the bearing (6).

6. Disconnect the air motor from the displacement

pump (see your separate pump manual). Leave

the adapter (R) attached to the piston rod.

8. Reconnect the air motor to the displacement pump

(see your separate pump manual).

7. Using a rubber mallet, drive the piston assembly

(5) out of the cylinder (1). Do not use a hammer.

9. Lubricate the o-ring (10) and install it on the motor

cap (2). Place the motor cap on the cylinder (1) so

the push rod hole (M) is aligned with the flat sur-

face (F) of the cylinder. Attach the cap with the

fifteen capscrews (12), using a 17 mm socket

wrench. Torque to 39–43 NSm (29–32 ft-lb).

8. Remove and inspect the piston o-ring (9*). Check

the piston and piston rod for scoring or damage.

Leave the piston rod and adapter (R) assembled

unless any of these parts requires replacement.

10. Lubricate the o-ring (11*) and install it on the

underside of the lift ring (3). Align the lift ring with

the six inner holes in the motor cap, with the

grounding lug (49) positioned as shown. Apply

thread sealant and install the six screws (13).

9. If it is necessary to disassemble the adapter (R)

from the piston rod, be careful not to scratch the

piston rod. Using adjustable wrenches on the flats

of the piston rod, unscrew it from the adapter (R).

10. Remove the screws (14) and the bottom support

bracket (35). Press the bearing (6), o-ring (11*),

seal (7*) and wiper (8*) out the bottom of the

cylinder (1). Inspect these parts for wear or dam-

age.

11. Reassemble the subplate and rocker assemblies,

as explained on page 17.

12. Follow the steps under Air Motor Shroud Reas-

sembly on page 11.

308213 19

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Service

11*z

10z

9*z

Lubricate.

Apply sealant.

Notch faces down, out of bearing (6).

Torque to 6–7 NSm (55–65 in-lb).

Torque to 39–43 NSm (29–32 ft-lb).

Lips must face up, toward cylinder (1).

7*z

Lubricate inside diameter with rag soaked in grease.

Torque to 318–349 NSm (234–257 ft-lb).

8*z

These parts are included in Air Motor Repair Kit

222958, which may be purchased separately.

11*z

z These parts are included in Premier Cylinder

Rebuild Kit 16P239, which may be purchased

separately.

06551A

Fig. 10

308213

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Parts

Ref.

Model 222800 Premier Air Motor, Series C

No.

Part No. Description

Qty.

NOTE: Some parts of this assembly are listed and

pictured on page 22.

184353

RING, lift

11*z 109484

O-RING; buna-N

107558

SCREW, cap, hex hd; M8 x 1.25;

25 mm (0.98 in.) long

SCREW, cap, hex hd; M6 x 1;

12 mm (0.47 in.) long

MOUNT; 3/8–16 unc–2A

SWIVEL, air inlet, 90_;

1 in. npt(f) x 1 in. npsm(f)

BRACKET, support

WASHER, grounding

LUG, grounding

GASKET; polyethylene

WASHER, flat; 8 mm

SHROUD, motor

PAD, top

PLUG, button

105468

189977

112955

191989

104582

104029

190072

108788

276457

113918

111909

158585

120027

192881

192883

192882

100132

NIPPLE; 1 in. npt

COVER, bottom

PAD, rocker arm cover

PAD, front

PAD, bottom

WASHER, flat

These parts are included in Air Motor Repair Kit

222958, which may be purchased separately.

11*z

z These parts are included in Premier Cylinder Re-

See page 22

build Kit 16P239, which may be purchased separa-

tely.

Y Foreign language warning labels are available at no

cost. Order Part No. 290396 (German), 290397

(French), or 290398 (Spanish).

See page 24

06548B

308213 21

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Parts

NOTE: Some parts of this assembly are listed and pictured on page 21.

20{

21{

10z

9*z

32z

30z

31z

24z

33z

27z{n

26z{n

z*7

z*8

z*11

01345B

45 47

308213

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Parts

Model 222800 Premier Air Motor, Series C (shown)

NOTE: Some parts of this assembly are listed and pictured on page 21.

Ref.

No.

Ref.

No.

Part No. Description

Qty.

Part No. Description

Qty.

120026

184374

15B959

184351

109492

109493

109485

CYLINDER, motor

CAP, motor

33z 105329

NUT, lock, with nylon insert;

M8 x 1.25

SCREW, cap, socket hd; M6 x 1.0;

20 mm (0.79 in.) long

SCREW, cap, socket hd; M5 x 0.8;

12 mm (0.47 in.) long

SCREW, cap, hex hd; M10 x 1.5;

50 mm (1.97 in.) long

LINER; polyurethane

MANIFOLD, exhaust

PLUG, pipe, socket hd; 1/4–18 npt 3

GASKET, copper

PISTON ASSEMBLY

BEARING; acetal

SEAL, bearing; polyurethane

WIPER; polyurethane

O-RING; buna-N

SCREW, cap, hex hd; M10 x 1.5;

30 mm (1.18 in.) long

ROD, push

FITTING, rod

SEAL, rod; polyurethane

SUBPLATE

GASKET; cork/rubber

VALVE, air motor;

see page 24

GASKET; cork/rubber

SEAL; buna-N

109489

107100

109491

7*z

8*z

9*z

10z 109486

11*z 109484

276076

186264

100721

167730

192686

109487

184357

276066

109494

184463

20{

21{

24z 184376

25 222799

COVER, rocker arm

These parts are included in Air Motor Repair Kit

222958, which may be purchased separately.

{

These parts are included in Air Valve Repair Kit

222959, which may be purchased separately.

26{nz184377

27{nz184467

109490

SCREW, cap, socket hd; M8 x 1.25;

n These parts are included in Detent Kit 222982,

50 mm (1.97 in.) long

ARM, rocker

STUD

SLEEVE, rocker arm

BEARING, rocker; acetal

which may be purchased separately.

29z 184359

30z 110036

31z 184607

32z 184360

z These parts are included in Premier Cylinder Re-

build Kit 16P239, which may be purchased separa-

tely.

NOTE: Remote Exhaust Manifold (184559) is available with a 1 in. npt(f) outlet

308213 23

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Parts

Part No. 222799 Air Valve, Series A

128

106}

108}

129}

104

n113

n112

103{}

102{}

124

n114

110}

129}

104

n117

n115

101

127Y

105

108}

109}

119

{120

107}

104

106}

104

102{}

n123

103{}

111

n121 122

104

128

01346

308213

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Parts

Part No. 222799 Air Valve, Series A

Ref.

No.

Part No. Description

184375 HOUSING, valve

Qty.

No.

Part No. Description

Qty.

101

102{} 109494

103{} 276067

121n 109513

122 276068

123n 184605

124 184362

127Y 184614

128 184615

129} 184603

ROLLER, bearing

RETAINER, bearing

PIN, roller

PLATE, slide

LABEL, caution

BUMPER

SEAL, rod; polyurethane

FITTING, rod; acetal

104

107100

SCREW, cap, socket hd; M5 x 0.8;

12 mm (0.47 in.) long

PLATE, detent

105

276060

106} 184358

107} 276083

108} 184361

109} 184465

110} 184485

ROD, trip

BEARING; acetal

GUIDE, spring

BEARING, guide; acetal

{

These parts are included in Air Valve Repair Kit

222959, which may be purchased separately.

SHAFT

SPRING, compression

CARRIAGE, valve

SPRING, compression

GUIDE, plunger; acetal

PLUNGER

111

184372

}

These parts are included in Trip Rod Kit 222981,

which may be purchased separately.

112n 184484

113n 276064

114n 184370

115n 184619

117n 184369

n These parts are included in Detent Kit 222982,

ROLLER, detent

PIN, roller

which may be purchased separately.

119

184363

BLOCK, slide

Y Replacement Danger and Warning labels, tags and

120{ 109514

O-RING; urethane

cards are available at no cost.

308213 25

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Technical Data