REPAIR INSTRUCTIONS

X/T 68:1 Displacement Pump

Korean Spray Technology Co., Ltd.

#6036, Daejeo-2ong, Gangseo-Gu,
Busan, S. Korea. (618-817)
Tel: 82-70-7600-9630
Fax: 82-51-312-0991
This manual contains important warning and e-mail : kst0991@naver.com
information. http://www.kstspray.com
Read and keep reference.
 ! WARNING
EQUIPMENT MISUSE HAZARD INJECTION HAZARD
Equipment misuse can cause the equipment to rupture Spray from the gun/valve, hose leaks, or ruptured components
or malfunction and result in serious injury. can inject fluid into your body and cause extremely serious
injury, including the need for amputation. Fluid splashed in the
_ This equipment is for professional use only. eyes or on the skin can also cause serious injury.

_ Read all instruction manuals, tags, and labels before _ Fluid injected into the skin might look like just a cut, but it is a
operating the equipment. serious injury. Get immediate medical attention.

_ Use the equipment only for its intended purpose. If _ Do not point the gun at anyone or at any part of the body.
you are uncertain about usage, call your KST
distributor. _ Do not put your hand or fingers over the spray tip.

_ Do not alter or modify this equipment. Use only _ Do not stop or deflect leaks with your hand, body, glove or
genuine KST parts and accessories. rag.

_ Check equipment daily. Repair or replace worn or _ Do not “blow back” fluid; this is not an air spray system.
damaged parts immediately.
_ Always have the tip guard and the trigger guard on he gun
_ Do not exceed the maximum working pressure of the when spraying.
lowest rated system component.
_ Do not use hoses to pull equipment. _ Be sure the gun trigger safety operates before spraying.

_ Route hoses away from traffic areas, sharp edges, _ Lock the gun trigger safety when you stop spraying.
moving parts, and hot surfaces. Do not expose
KST hoses to temperatures above 82_C (180_F) or _ Tighten all fluid connections before operating the equipment.
below –40_C (–40_F).
_ Check the hoses, tubes, and couplings daily. Replace worn,
_ Wear hearing protection when operating this damaged, or loose parts immediately.
equipment. Permanently coupled hoses cannot be repaired; replace the
entire hose.
_ Do not lift pressurized equipment.
_ Use only KST approved hoses. Do not remove any spring
_ Comply with all applicable local, state, and national guard that is used to help protect the hose from rupture
fire, electrical, and safety regulations. caused by kinks or bends near the couplings.

TOXIC FLUID HAZARD FIRE AND EXPLOSION HAZARD

Hazardous fluid or toxic fumes can cause serious Improper grounding, poor ventilation, open flames or sparks
injury or death if splashed in the eyes or on the can cause a hazardous condition and
skin,inhaled, or swallowed. result in a fire or explosion and serious injury.

_ Know the specific hazards of the fluid you are using. _ If there is any static sparking or you feel an electric shock
while using this equipment, stop spraying immediately.
_ Store hazardous fluid in an approved container. Do not use the equipment until you identify and correct the
Dispose of hazardous fluid according to all local, problem.
state and national guidelines.
_ Provide fresh air ventilation to avoid the buildup of flammable
_ Always wear protective eyewear, gloves, clothing fumes from solvents or the fluid being sprayed.
and respirator as recommended by the fluid and
solvent manufacturer. _ Keep the spray area free of debris, including solvent, rags,
and gasoline.

_ Electrically disconnect all equipment in the spray area.

MOVING PARTS HAZARD _ Extinguish all open flames or pilot lights in the spray area.

Moving parts, such as the air motor piston, can pinch _ Do not smoke in the spray area.
or amputate your fingers.
_ Do not turn on or off any light switch in the spray area while
_ Keep clear of all moving parts when starting or operating or if fumes are present.
operating the pump.
_ Do not operate a gasoline engine in the spray area.
Operation
1. Lock the spray gun trigger safety.
2. Close the red-handed bleed-type master air valve
3. Unlock the gun trigger safety.
4. Hold a metal part of the gun firmly to the side of a grounded metal pail, and trigger the gun to relieve pressure.
5. Lock the gun trigger safety.
6. Open the drain valve having a container ready to catch the drainage.
7. Leave the drain valve open until you are ready to spray again.

If you suspect that the spray tip 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 or hose.
Packing nut / wet-cup
Before starting, fill the packing nut 1/3 full with TSL or compatible solvent. To reduce
the risk of serious injury whenever you are instructed to relieve pressure, always follow
the pressure relief procedure. The packing nut is torqued at the factory and is ready for
operation If is becomes loose and there is leaking form the throat packings, relieve
pressure, then torque the nut to 136-149N.m using a wrench. Do this whenever
necessary. Do not over tighten the packing nut.

Flush the Pump Before first Using

The pump is tested with lightweight motor oil, which is left in to protect the pump parts.
If the fluid you are using may be contaminated by the oil, flush it out with a compatible solvent before using the pump. If the pump is being
used to supply a circulating system, allow the solvent to circulate until the pump is thoroughly flushed.
Flush the pump.
- Before the first use.
- When changing colors or fluids.
- Before fluid can dry or settle out in a dormant pump(check the pot life of catalysed fluids)
- Before storing the pump
Flush whit a fluid that is compatible whit fluid you are pumping and whit the wetted parts in your system.
Check whit a fluid manufacturer or supplier for recommended flushing fluids and flushing frequency .

Troubleshooting
PROBLEM CAUSE SOLUTION
Valve closed or clogged. Clear air line: increase air supply. Check valve open.
Doesn’t operate Fluid hose or gun obstructed. Clear hose or gun: use hose with larger ID.
Dried fluid on displacement rod. Clean rod: always stop pump at bottom of stroke:
Keep wet-cup filled with compatible solvent.
Air motor parts dirty, worm, or damaged. Clean or repair air motor: see motor manual.
Air line restricted or air supply inadequate. Clear air line: increase air supply, Check valve open.
Output low on both Valves closed or clogged.
strokes. Fluid hose/gun obstructed: hose ID too small. Clear hose or gun: use hose with larger ID.
Worn packings in displacement pump. Replace packings.
Air motor parts dirty, worm, or damaged. Clean or repair air motor: see separate motor manual.
Open or worm intake valve. Clear or service intake valve.
Open or worm intake valve. Clear or service intake valve.
Output low in down
stroke High viscosity fluid. Adjust intake spacers.
Output low on up Open or worn fluid piston valve or packings. Clear piston valve: replace packings.
stroke
Fluid supply exhausted, clogged suction line. Refill supply and prime pump. Clean suction tube.
Erratic or accelerated High viscosity fluid. Reduce viscosity, Adjust intake spacers
speed Open or worm piston valve or packings. Clear piston valve: replace packings.
Open or intake valve Clear or service intake valve.
Runs sluggishly. Possible icing. Stop pump. Let ice melt
Cycles, or fails to Worm check valves or seals. Service pump
hold pressure at stall.
Audible air leak Check air connections. Service pump
Loose suction line. Tighten. Use a compatible liquid thread sealant or
Air bubbles in fluid. PTFE tape on connections.
Parts drawing and Parts List
NO. KST-code G-code Description Q'ty
101 K254-100 AIR MOTOR 1
102 KS-X002 197-329 ROD, Tie 3
103 KS-X003 197-341 ADAPTER 1
104 KS-X004 197-340 COVER 1
105 KS-X005 244-819 COUPLING 1
106 X451-200 244-416 DIS. PUMP 1
107 KS-X007 101-712 NUT 3
108 KS-X008 244-820 CLIP, HAIRPIN 1

DISCONNECTING THE DISPLACEMENT PUMP

1. Flush the pump if possible. Stop the pump at the bottom of
its stroke. Relieve the pressure.

2. Disconnect the air and fluid hoses. Remove the pump from
its mounting.

3. Unscrew the coupling nut off of the air motor piston rod .
Be Carefully not to loss the two couplers as you lower the
nut. Unscrew the tie rod locknuts from the tie rods.
Carefully pull the displacement pump away from the air
motor.

4. To service the displacement pump, refer to displacement

pump service.

RECONNECTING THE DISPLACEMENT PUMP

1. Align the pump’s fluid outlet to the optional fluid outlet of the
air motor. Position the displacement pump on the tie rod.

2. Make sure the couplers are in place inside the coupling nut.
Screw the coupling nut up onto the air motor piston rod
snugly. Screw the locknut onto the tie rods loosely.

3. Mount the pump and reconnect all hoses. Reconnect the

ground wire if it was disconnected during repair.

4. Tighten the tie rod locknuts evenly, and torque to 40-50ft–lb

(54-68 N.m). Torque the coupling nut to 145-155 ft-lb(195-
210 N. m)

5. Start the pump and run it slowly, at about 40 psi (280

kPa,2.8 bar) air pressure, to check the tie rods for signs of
binding. Adjust the tie rods as necessary to eliminate
binding. Tighten the packing nut/wet-cup whit the wrench
supplied. Fill the wet-cup half full whit throat seal liquid or
compatible solvent.
 DISASSEMBLY
1. Use only non-sparking 2. 3.
tools

4. Service on cart Remove for service 5.

6. 7. 8.

9.
 REASSEMBLY
1. 2. Use only non-sparking tools

3. 4. Assemble cylinder counter clockwise

into outlet housing until cylinder bottoms
out in outlet housing

Max of 0.125 in

Gap for cylinder

should be max.
of 0.125 in

5.
Rotate clockwise until hole in outlet housing lines up flat
cylinder, and insert locking pin into cylinder
 REASSEMBLY
6. Torque to 25-30 ft-lb(34-41Nm) 7.

8.

9. Reattach to air motor

 BALL ADJUSTMENT
1. 2.

3. 4.

Shortest Longest
ball travel ball travel
2

4
5

1
 PISTON ROD DISASSEMBLY
Always use a plastic or wooden block to drive the rod out of the cylinder. Damage to rod end will shorten pump life,

1. 2. Torque to 190-210 3. 4.
Ft-lb(258-285 Nm)

Piston
Packing
Stack

NOTE: Clean all parts with a compatible solvent and inspect them for wear or damage

PISTON ROD DISASSEMBLY

Note: Soak packings in oil before assembly

1. 2. 3. 4.

For assembly
Anti sieze lubricate all
Lips lubricant piston packings
Face and o-rings
Up

.Packing Repair Kits are available. For the best results, use all the new parts in the kit.

INLET HOUSING REASSEMBLY

1. 2.

Packing Repair Kits are available. For the best results,

use all the new parts in the kit.
For assembly lubricate o-rings.
 CARTRIDGE REASSEMBLY

Packing Repair Kits are available.

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

NOTE: Only the 45:1 pumps have

shims placed on top of the female
gland.

Throat Packing Stack

For assembly lubricate all o-rings,
inside of cartridge, and outside
threads of wet cup. Note: Soak leather packings in oil
before assembly.
Service
Parts drawing and Parts List
250cc (1045)Pump
244416
Note : part marked in color are the spare parts

These parts are included in repair kit which may

be purchased separately.

Always use genuine parts

No KST-code G-code Description Qty

1 X681-01 197304 HOUSING , Inlet 1
2 X681-02 244856 SHIM 3 3
3 X681-03 197308 BALL GUIDE 1 1
4 X681-04 245129 BALL 1 111
5 X681-05 244894 PACKING ,O-RING 4 4
6 X681-06 197344 SEAT 1 1
7 X681-07 197318 CYLINDER 1 1
8 X681-08 197322 DISPLACEMENT ROD 1 1
9 X681-09 197312 PISTON VALVE 1 1
10 X681-10 244898 BALL 1 1
11 X681-11 245232 GLAND-M 1 1
12 X681-12 245229 PACKING-V 3 3
13 X681-13 245230 PACKING-V(L) 2 2
14 X681-14 245233 GLAND-F 1 1
15 X681-15 244999 SEAL 1 1
16 X681-16 197331 PACKING NUT 1 1
17 X681-17 197327 CARTRIDGE 1 1
18 X681-18 244891 PACKING, O-RING 1 1
19 X681-19 244893 PACKING, O-RING 1 1
20 X681-20 197335 HOUSING 1 1
21 KS-X021 244826 PIN 1 11
22 KS-X026 TUBE 1
23 KS-X027 NIPPL,pt1*pf1 1
24 KS-X028 NIPPLE, pt1*pf3/4 1
REPAIR KIT No : 244851
With 4,5,10,11,12,13,14,15,18,19
Technical Data
Data
Category K-TYPE AIR MOTOR B-TYPE AIR MOTOR
244414 244412 244414 244412
245120(A) 245121(A) 245167(A) 245117(A)

Maximum fluid 38.6 MPa 46.9 MPa 19.3 MPa 22.8 MPa
working pressure 386 bar 468 bar 193 bar 228 bar

Maximum air input 0.7 MPa

pressure page
7 bar

Ratio 56:1 68:1 28:1 33:1

Air inlet size 3/4 in. npt(f)

Fluid inlet size 1 -1/4 in npt

Displacement per 220cc 180cc 220cc 180cc

cycle

Fluid flow at 60 3.4 / 13 Gal. / Ltr. 2.9 / 11 Gal. / Ltr. 3.4 / 13 Gal. / Ltr. 2.9 / 11 Gal. /

cycles per minute Ltr.

Maximum operating 82_C (180_F)

temperature

Wetted parts Carbon Steel; Alloy Steel; S45C, 415,440: Zinc and Nickel Plating; Ductile
Iron; Tungsten Carbide; PTFE; Leather
KST Standard Warranty
KST warrants all equipment referenced in this document which is manufactured by KST 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 KST, KST will, for a period of twelve months from the date of sale, repair or replace any part of the
equipment determined by KST to be defective. This warranty applies only when the equipment is installed, operated and maintained in
accordance with KST written recommendations.

This warranty does not cover, and KST 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–KST component parts. Nor shall KST be liable for malfunction, damage or wear caused by the incompatibility of KST equipment with
structures, accessories, equipment or materials not supplied by KST, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by KST.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized KST distributor for
verification of the claimed defect. If the claimed defect is verified, KST 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.

KST 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 one (1) years of the
date of sale.

KST 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 KST. These items sold, but not manufactured by KST (such as electric motors, switches,
hose, etc.), are subject to the warranty, if any, of their manufacturer. KST will provide purchaser with reasonable assistance in making any
claim for breach of these warranties.
In no event will KST be liable for indirect, incidental, special or consequential damages resulting from KST 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 KST or otherwise.

KST Information
TO PLACE AN ORDER OR FOR SERVICE, contact your KST distributor, or call these numbers to identify the nearest
distributor.

Korean Spray Technology Co., Ltd.

#6036, Daejeo-2dong, Gangseo-Gu,
Busan, S. Korea. (618-812)
Tel: 82-70-7600-9630
Fax: 82-51-312-0991
e-mail : kst0991@naver.com
http://www.kstspray.com