Graco Heat Pump 238108 User Manual

Instructions – Parts List  
6:1 Fire–Ballr 425 Pump  
308608K  
For pumping non–corrosive and  
non–abrasive oils and lubricants only.  
Model 238108, Series D  
1100 psi (7.6MPa, 76 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.  
06031  
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441  
Copyright 1995, Graco Inc. is registered to I.S. EN ISO 9001  
 
WARNING  
SKIN INJECTION HAZARD  
Fluid from the dispensing valve, leaks or ruptured components can inject fluid into your body and  
cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on  
the skin can also cause serious injury.  
D Fluid injected into the skin may look like just a cut, but it is a serious injury. Get immediate  
surgical treatment.  
D Do not point the dispensing valve at anyone or at any part of the body.  
D Do not put your hand or fingers over the end of the dispensing valve.  
D Do not stop or deflect leaks with your hand, body, glove or rag.  
D Use only extensions and no-drip tips which are designed for use with your dispensing valve.  
D Tighten all fluid connections before operating the equipment.  
D Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do  
not repair high pressure couplings; you must replace the entire hose.  
HAZARDOUS FLUIDS  
Improper handling of hazardous fluids or inhaling toxic fumes can cause extremely serious injury,  
even death, due to splashing in the eyes, ingestion, or bodily contamination.  
D Know the specific hazards of the fluid you are using.  
D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,  
state and national guidelines.  
D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid  
and solvent manufacturer.  
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3
 
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. Refer to Grounding on page 7.  
D If there is any static sparking or you feel an electric shock while using this equipment, stop  
dispensing immediately. Do not use the equipment until you identify and correct the problem.  
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid  
being dispensed.  
D Do not smoke in the dispensing area.  
MOVING PARTS HAZARD  
Moving parts can pinch or amputate your fingers.  
D Keep clear of all moving parts when starting or operating the pump.  
D Before servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the  
equipment from starting unexpectedly.  
4
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Installation  
The typical installation shown in Fig.1 is only a guide  
CAUTION  
Always mount the pump firmly to a bracket or a  
tank cover. Never operate the pump while it is not  
mounted. Such use could damage the pump and  
fittings.  
for selecting and installing a pump; it is not an actual  
system design. Contact your Graco representative or  
your Graco distributor for assistance in designing a  
system to suit your needs.  
G
N
D
A
A
C
A
R
J
K H  
P
E
Z
B
Y
F
DETAIL A  
L
TI0890  
T
S
M
For Portable Applications  
KEY  
A
B
C
D
Bleed-type master air valve (required)  
Air line filter  
J
Dispensing valve (model 222411 shown)  
K
L
M
N
P
R
S
T
Y
Z
Thermal relief kit (required), Part No. 240429  
Male quick-disconnect fitting  
Female quick-disconnect coupler  
Air line lubricator  
Air regulator and gauge  
Pump runaway valve (shown for  
position) – not needed if you use  
a low level cut-off valve  
Air inlet  
Ball valve (for releasing collected moisture)  
Pump  
Drain valve (required)  
Fluid hose  
E
F
G
H
Electrically conductive air hose (218093 shown)  
Fluid inlet  
Wall-mounting bracket  
Ground wire (required)  
Muffler  
05610  
Fig. 1  
308608K  
5
 
Installation  
1. Screw the muffler (5) into the 3/4-in. npt muffler  
System Accessories  
port, and tighten it using a wrench on the flats of  
the muffler near the male threads.  
CAUTION  
2. Install an air line lubricator (N) for automatic air  
motor lubrication.  
Do not hang the air accessories directly on the air  
inlet (E). The fittings are not strong enough to  
support the accessories and may cause one or  
more to break. Provide a bracket on which to  
mount the accessories.  
3. Install the air regulator (C) to control pump speed  
and pressure.  
4. Install an air line filter (B) to remove harmful dirt  
and contaminants from your compressed air  
supply.  
NOTE: Install the accessories in the order shown in  
Fig. 1.  
5. Install a bleed-type master air valve (A) to isolate  
the accessories for servicing. See Fig. 1. To  
order a bleed-type master air valve, order Part No.  
107142.  
WARNING  
Four accessories are required in your system: an  
air shut-off valve/air bleed device, fluid drain valve,  
thermal relief kit, and ground wire. These accesso-  
ries help reduce the risk of serious bodily injury  
including fluid injection, splashing in the eyes or on  
the skin, injury from moving parts if you are adjust-  
ing or repairing the pump, and explosion from  
static sparking.  
As an alternative to a bleed-type master air valve,  
you can install an air line quick disconnect coupler  
(M) and fitting (L) to serve as an air-bleed device.  
See Detail A in Fig. 1.  
6. Install a drain valve (H) near the pump fluid outlet  
to relieve fluid pressure in the hoses and gun when  
opened. To order a fluid drain valve, order Part  
No. 210658.  
The air bleed device relieves air trapped between it  
and the air motor after the air supply is shut off.  
Trapped air can cause the air motor to cycle unex-  
pectedly, causing serious bodily injury if you are  
adjusting or repairing the pump. Use either a  
bleed-type master air valve (A) or a quick-discon-  
nect coupler (M) and fitting (L). Install near the  
pump air inlet, within easy reach of the pump.  
7. Install a thermal relief kit (K) on the dispensing  
valve side of the pump. To order a 1600 psi  
(110 bar, 11 MPa) thermal relief kit, order Part No.  
240429.  
The fluid drain valve (H) assists in relieving fluid  
pressure in the displacement pump, hoses and  
dispensing valve. Triggering the valve to relieve  
pressure may not be sufficient.  
8. Install a suitable fluid hose (P) and dispensing  
valve (J).  
Cover Mount  
For cover mounting, see the Mounting Hole Layout  
on page 18.  
The thermal relief kit assists in relieving pressure in  
the pump, hose, and dispensing valve due to heat  
expansion.  
Wall Mount  
The ground wire reduces the risk of static sparking.  
The pump shown in Fig. 1 is wall mounted. To order  
the wall-mounting bracket, order Part No. 238245.  
6
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Installation  
To ground the pump, remove the ground screw (Z)  
Grounding  
and insert through the eye of the ring terminal at end of  
the ground wire (Y). Fasten the ground screw back onto  
the pump and tighten securely. Connect the other end of  
the ground wire to a true earth ground. See Fig. 2. To  
order a ground wire and clamp, order Part No. 222011.  
Proper grounding is an essential part of maintaining a  
safe system.  
To reduce the risk of static sparking, ground the pump.  
Check your local electrical code for detailed grounding  
instructions for your area and type of equipment. Be  
sure to ground this equipment:  
1. Pump: Use a ground wire and clamp as shown in  
Fig. 2.  
2. Air and Fluid hoses: Use only electrically conduc-  
tive hoses.  
3. Air compressor: Follow manufacturer’s recom-  
mendations.  
Y
4. Fluid supply container: Follow the local code.  
Z
5. To maintain grounding continuity when flushing or  
relieving pressure, always hold a metal part of the  
valve firmly to the side of a grounded metal pail,  
then trigger the valve.  
TI1052  
Fig. 2  
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7
 
Operation  
Pressure Relief Procedure  
WARNING  
HAZARDOUS VAPORS  
The air motor exhaust coming out of the  
muffler could contain harmful materials,  
such as oil, antifreeze, or some of the  
material being pumped.  
WARNING  
SKIN INJECTION HAZARD  
To reduce the risk of serious bodily  
injury, including fluid injection or splash-  
ing in the eyes or on the skin, always  
follow this procedure whenever you shut off the  
pump, when checking or servicing any part of the  
system, when installing or changing dispensing  
devices, and whenever you stop dispensing.  
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 fitting  
(L).  
1. Close the bleed-type master air valve (required in  
your system).  
2. Open the dispensing valve (J) into a grounded  
metal waste container, making firm metal-to-metal  
contact between the container and valve.  
2. Hold a metal part of the dispensing valve firmly to  
a grounded metal waste container and trigger the  
valve to relieve the fluid pressure, or open the  
drain valve (H).  
3. Open the pump air regulator (C) slowly, just until  
the pump is running. When the pump is primed  
and all air has been pushed out of the lines, close  
the dispensing valve.  
If you suspect that the dispensing valve or hose is  
completely clogged, or that pressure has not been fully  
relieved after following the steps above, very slowly  
loosen the hose end coupling and relieve pressure  
gradually, then loosen completely, then clear the valve  
or hose.  
NOTE: When the pump is primed, and with sufficient  
air supplied, the pump starts when the dis-  
pensing valve is opened and shuts off when it  
is closed.  
4. If your system is equipped with a runaway valve (D  
in Fig. 1), set it for your system configuration. See  
manual 308201 for instructions on setting the  
pump runaway valve.  
Startup and Adjustment  
WARNING  
COMPONENT RUPTURE HAZARD  
The maximum working pressure of each  
component in the system may not be the  
same. To reduce the risk of overpres-  
5. Adjust the air regulator until you get sufficient flow  
from the dispensing valve. Always run the pump  
at the lowest speed necessary to get the desired  
results. Do not exceed the maximum working  
pressure of any component in the system.  
surizing any component in the system, be sure you  
know the maximum working pressure of each  
component, including the air motor and pump.  
Never exceed the maximum working pressure of  
the lowest rated component in the system. Over-  
pressurizing any component can result in rupture,  
fire, explosion, property damage, and serious  
injury.  
6. If your pump accelerates quickly or is running too  
fast, stop it immediately and check the fluid supply.  
If the supply container is empty and air has been  
pumped into the lines, prime the pump and lines  
with fluid, or flush it and leave it filled with a com-  
patible solvent. Be sure to eliminate all air from  
the fluid lines. If your system has a runaway  
valve, reset it according to the instructions in  
manual 308201.  
To determine the fluid output pressure using the air  
regulator reading, multiply the ratio of the pump by  
the air pressure shown on the regulator gauge. For  
example:  
6 (:1) ratio x 180 psi air =  
1080 psi fluid output  
CAUTION  
Never allow the pump to run dry of the fluid being  
pumped. A dry pump will quickly accelerate to a  
high speed, possibly damaging itself, and it may  
get very hot.  
6 (:1) ratio x 7 bar air = 42 bar fluid output  
6 (:1) ratio x 0.7 MPa air = 4.2 MPa fluid output  
Limit the air to the pump so that no air line or fluid  
line component or accessory is overpressurized.  
8
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Operation  
7. Read and follow the instructions supplied with  
8. If the pump will be unattended for any period of  
time, if there is an air supply interruption, or to shut  
off the system at the end of the work shift, always  
relieve the pressure.  
each component in your system.  
WARNING  
To reduce the risk of serious injury whenever you  
are instructed to relieve pressure, always follow the  
Pressure Relief Procedure on page 8.  
9. Check periodically to ensure that the pump’s  
mounting is secure.  
Troubleshooting  
NOTE: Check all other possible problems and solu-  
WARNING  
SKIN INJECTION HAZARD  
To reduce the risk of serious bodily  
tions before disassembling the pump.  
injury, including fluid injection or splash-  
ing in the eyes or on the skin, always  
follow the Pressure Relief Procedure on page 8  
whenever you shut off the pump, when checking or  
servicing any part of the system, when installing or  
changing dispensing devices, and whenever you  
stop dispensing.  
Problem  
Cause  
Inadequate air supply pressure or  
Solution  
Pump fails to operate  
Increase air supply; clear  
restricted air lines  
Closed or clogged dispensing  
valve  
Open; clear  
Clear*  
Clogged fluid lines, hoses, valves,  
etc.  
Damaged air motor  
Service air motor  
Exhausted fluid supply  
Refill and reprime or flush  
Service air motor  
Continuous air exhaust  
Erratic pump operation  
Worn or damaged air motor gas-  
ket, packing, seal, etc.  
Exhausted fluid supply  
Refill and reprime or flush  
Clear; service  
Held open or worn intake valve or  
piston packings  
Pump operates, but output low on  
up stroke  
Held open or worn piston packings  
Clear; service  
Pump operates, but output low on  
down stroke  
Held open or worn intake valve  
Clear; service  
Pump operates, but output low on  
both strokes  
Inadequate air supply pressure or  
restricted air lines  
Increase air supply; clear  
Closed or clogged valves  
Open; clear  
Service  
Fluid is coming out of the muffler.  
Worn or damaged throat seal  
* Follow the Pressure Relief Procedure on page 8 and disconnect the fluid line. If the pump starts when  
the air is turned on again, the line, hose, valve, etc., is clogged.  
308608K  
9
 
Air Motor and Throat Service  
9. Remove the eight screws (3) holding the cylinder  
Before You Start  
(30) to the base (28). Carefully pull the cylinder  
D Be sure you have all necessary parts on hand.  
Air Motor Repair Kit 207385 includes repair parts  
for the motor. Use all the parts in the kit for the  
best results. Parts included in the kit are marked  
with one asterisk, for example (19*), in the text and  
drawings. See the Parts List on page17.  
straight up off of the piston assembly (27).  
CAUTION  
To avoid damaging the cylinder wall, lift the cylinder  
straight up off of the piston. Never tilt the cylinder  
as it is being removed.  
D Two accessory tools should be used: Padded  
Pliers, 207579, are used to grip the trip rod without  
damaging its surface, and a 0.125-in. (3.18 mm)  
Gauge, 171818, is used to assure the proper  
clearance between the poppets and seat of the  
piston.  
24  
30  
Disassembly  
1. Flush the pump.  
WARNING  
To reduce the risk of serious injury whenever you  
are instructed to relieve pressure, always follow the  
Pressure Relief Procedure on page 8.  
31  
27  
2. Relieve the pressure.  
3. Disconnect the hoses, remove the pump from its  
mounting, and clamp the air motor base (28) in a  
vise horizontally by closing the vice jaws on the  
flange.  
3
4. Use a strap wrench on the displacement pump  
cylinder (110) to screw it out of the air motor base  
(28). See Fig. 3.  
29  
28  
10{  
5. Remove the piston/valve seat (109) from the rod  
(29) with wrenches or with the vice and a wrench.  
103  
113  
108{  
6. Remove the piston ball (103), u-cup packing  
flange  
(107{), and piston washer (113).  
109  
110  
107{  
105{  
7. Remove the air motor base from the vice, and  
place the piston rod (29) flats in the vice with the  
air motor up.  
8. Loosen the lift ring (24). Pull up the lift ring, grip  
the trip rod (31) with the padded pliers, and screw  
the lift ring off of the rod.  
TI1076  
06033  
Fig. 3  
CAUTION  
Do not damage the plated surface of the trip rod  
(31). Damaging the surface of the trip rod can  
result in erratic air motor operation. Use the  
special padded pliers, 207579, to grasp the rod.  
{ Included in Pump Repair Kit 238225,  
which may be purchased separately.  
10  
308608K  
 
Air Motor and Throat Service  
10. Pull the piston assembly from the air motor base  
15. In this step, while you are prying with the screw-  
driver with one hand, cover the toggle assemblies  
with your other hand so as to catch the spring-  
loaded toggle assemblies when they snap out of  
the lugs. Place the tip of a screwdriver into the  
piston between the piston lugs (L) below the pivot  
pins (16) on the toggles, pry up with the screw-  
driver handle to compress the springs on the  
toggle assembly (M) up and away from the piston  
lugs, and remove the parts. See Fig. 4.  
(28), and set it aside.  
11. Remove the throat bearing (36) with a 2-in. socket,  
remove the u-cup seal (10{), and wipe the seat  
clean with a cloth.  
12. Remove the piston/base from the vise, and set it  
upright on the workbench.  
16. Straighten the lockwires (22*) and remove them  
from the valve nuts (21*). Screw the top nuts off.  
Remove the trip rod yoke (13), actuator (12), and  
trip rod (31). Unscrew the bottom nuts (21*), and  
remove the poppets. Make sure the valve bar  
spring clips (14) are not worn or damaged and that  
they properly guide the actuator (12).  
13. Inspect the air motor for damaged or worn inlet  
valve grommets (17*), o-rings (19*, 20*), valve  
nuts (21*), lock wires (22*), exhaust valve poppets  
(26*), or inlet valve poppets (32*). If any of these  
parts need to be replaced, continue with steps 14  
to 20. Otherwise, see Reassembly on page 12.  
17. Remove the exhaust valve poppets (26) by cutting  
them with a side cutter, then pull them out of the  
actuator (12).  
14. Use a screwdriver to push down on the trip rod  
yoke (13), and snap the toggles down. See Fig. 4.  
18. Clean all the parts carefully in a compatible solvent  
and inspect them for wear or damage. Use all the  
repair kit parts during reassembly, and replace  
other parts as necessary.  
WARNING  
MOVING PARTS HAZARD  
To reduce the risk of pinching or  
amputating your fingers, keep your  
fingers clear of the toggle assemblies  
when you are snapping the toggles  
(M in Fig. 4 ) up or down.  
19. Check the surfaces of the piston, piston rod, and  
cylinder wall for scratches or wear. A scored rod  
will cause premature packing wear and leaking.  
20. Lubricate all parts with a light, waterproof grease.  
308608K  
11  
 
Air Motor and Throat Service  
13  
31  
Cut off tops  
of poppets as  
indicated by  
dotted lines.  
15  
23  
25  
16  
15  
22*  
M
31  
21*  
32*  
17*  
13  
26*  
14  
32*  
21*  
12  
Turn  
lock-  
wires  
up.  
L
17*  
21*  
19*  
32*  
0.125”  
(3.18 mm)  
27  
28  
32*  
27  
04422  
14  
26* 21*  
05612  
Cutaway View  
Fig. 4  
Reassembly  
1. Place the piston rod (29) flats in the vice with the  
air motor up.  
7. Measuring with the gauge (Part No.171818),  
create 0.125-in. (3.18 mm) of clearance between  
the inlet valve poppets (32*) and the piston seat  
when the inlet valve is open. See the Cutaway  
View Fig. 4.  
2. Pull the exhaust valve poppets (26*) into the valve  
actuator (12), and clip off the top parts of the  
poppets (shown with dotted lines in the Cutaway  
View in Fig. 4).  
NOTE: Adjust the distance between the inlet valve  
poppets and the piston seat by turning the  
top valve nuts (21*).  
3. Install the grommets (17*) in the actuator (12),  
place the inlet valve poppets (32*) in the piston,  
and thread the bottom valve nuts (21*) onto the  
8. Tighten the bottom valve nuts (21*) securely by  
hand.  
inlet valve poppets until there are a few threads left  
before the threads run out.  
9. Align the holes in the valve nuts (21*) and the slots  
on the tops of the inlet valve poppets (32*), and  
drop the lock wires (22*) through the holes in the  
valve nuts and into the slots in the inlet valve  
poppets. Pull the lock wires down tightly, and  
bend the ends with pliers so that they cannot be  
pulled back out of the holes.  
NOTE: If you thread the valve nuts too far down  
onto the poppets, they will run off of the  
threaded part of the poppets.  
4. Grease heavily and place the trip rod (31) in the  
piston, place the actuator (12) in the yoke (13),  
and place the well-greased actuator/yoke assem-  
bly in the piston, with the trip rod going through the  
center holes of the actuator and yoke and the inlet  
valve poppets (32*) going through the grommets  
(17*).  
CAUTION  
Never re-use the old lock wires. They will get  
brittle and break easily from too much bending.  
5. Thread the top valve nuts (21*) onto the inlet valve  
poppets (32*) until one thread of the inlet valve  
poppets is exposed above the valve nuts.  
10. Grease and install the new o-rings (19* and 20*)  
on the piston assembly (27) and in the groove in  
the air motor base (28).  
6. Install the toggle pins (15) in the yoke (13), place  
the toggle arm (23) ends of the toggle assembly  
(M) onto the toggle pins, and snap the pivot pin  
(16) ends of the toggle assembly into the lugs (L).  
11. Clamp the air motor base (28) in a vise horizontally  
by closing the vice jaws on the flange.  
12  
308608K  
 
Air Motor and Throat Service  
12. Grease and reinstall the u-cup seal (10{), thread  
16. Install the u-cup packing (107{) with the lips up,  
and place the piston washer (113) on the piston/  
valve seat (109). Make sure the lips of the u-cup  
packing face up. See Fig. 3.  
the throat bearing (36) into the air motor base (28),  
and torque the throat bearing to 30 to 40 ft-lb  
(41 to 54 N.m) using a 2-in. socket.  
17. Place the piston ball (103) in the piston rod (29).  
13. Slide the piston rod (29) down through the pack-  
ing, and lower the piston assembly (27) into the air  
motor base (28).  
18. Clean the threads of the piston/valve seat, Apply  
Loctiter to the threads, (109), and thread the  
assembly from Step 16 onto the piston rod (29).  
14. Carefully lower the cylinder (30) straight down onto  
the piston assembly (27). Tighten the eight screws  
(3) holding the cylinder to the base (28).  
19. Clamp the flats of the piston/valve seat (109) in a  
vice, and torque the piston rod (29) to the piston  
valve seat to 40 to 60 ft-lb (54 to 81 N.m).  
20. Clamp the air motor base (28) in a vise horizontally  
by closing the vice jaws on the flange  
CAUTION  
To avoid damaging the cylinder wall, lower the  
cylinder straight down onto the piston. Never tilt  
the cylinder as it is being lowered.  
21. Use a strap wrench to screw the displacement  
pump cylinder (110) to the air motor base (28), and  
torque to 95 to 105 ft-lb (129 to 142 N.m).  
22. 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 that it operates smoothly.  
15. Grip the trip rod (31) with padded pliers, screw the  
lift ring (24) onto the trip rod, push the lift ring  
down, and screw it into the top of the cylinder.  
23. Reconnect the ground wire before regular opera-  
tion of the pump.  
308608K  
13  
 
Displacement Pump Service  
Displacement Pump. See Fig 5.  
Disassembly  
NOTE: Clean and inspect all parts for wear or damage  
as you disassemble them. Replace parts as  
needed. For best results, always replace all  
the o-rings and packings when you disassem-  
ble the pump.  
NOTE: Displacement Pump Repair Kit 238225  
includes repair parts for the pump throat and  
piston. Use all the parts in the kit for the best  
results. Parts included in the kit are marked  
with a dagger, for example (7{), in the text and  
drawings. See the Parts List on page 15.  
1. Relieve the pressure.  
1. Flush the pump.  
2. Follow steps 1 to 7 of Disassembly on page 10.  
3. Carefully inspect the smooth inner surface of the  
cylinder (110) for scoring or irregular surfaces.  
Such damage causes premature seal wear and  
leaking. Replace the cylinder as needed.  
WARNING  
To reduce the risk of serious injury whenever you  
are instructed to relieve pressure, always follow the  
Pressure Relief Procedure on page 8.  
Reassembly  
Do steps 16 through 23 in Air Motor and Throat  
Service on page 13.  
2. Relieve the pressure.  
3. Disconnect the hoses, remove the pump from its  
mounting, and clamp the air motor base (28) in a  
vise horizontally by closing the vice jaws on the  
flange.  
110  
112  
Intake Valve. See Fig 5.  
1. Relieve the pressure.  
104  
105{  
2. Unscrew the valve housing (111). Remove the  
111  
o-ring (105{), retainer (112), and ball (104).  
05617  
Fig. 5  
{ Included in Pump Repair Kit 238225, which may  
be purchased separately. The Parts List on page  
15 includes all parts in kit.  
3. Inspect the parts for wear or damage. If the ball is  
nicked, replace it. Reassemble, using grease on  
the male threads.  
14  
308608K  
 
Displacement Pump Parts Drawing and List  
Model 238108, Series D  
Air motor not listed or shown here. See pages 16 and 17.  
Ref  
No.  
Ref  
No.  
Part No. Description  
Qty.  
Part No. Description  
Qty.  
109  
110  
111  
112  
113  
194016  
190922  
190926  
190928  
190924  
PISTON  
1
1
1
1
1
10{ 113345  
SEAL, u-cup (shown on page 16) 1  
CYLINDER, pump  
VALVE HOUSING  
RETAINER, ball  
WASHER, piston  
103  
104  
101190  
101178  
BALL, piston; metallic  
BALL; sst  
1
1
1
1
1
105{ 113347  
107{ 113346  
108{ 112349  
PACKING, o-ring  
PACKING, u-cup  
PACKING, o-ring  
{ Included in Pump Repair Kit 238225,  
which may be purchased separately.  
113  
107{  
3
103  
109 1  
108{  
110  
2
105{  
112  
104  
111  
1
1
2
3
Torque to 40 to 60 ft-lb (54 to 81 N.m)  
Torque to 95 to 105 ft-lb (129 to 142 N.m)  
Lips face up  
03846  
308608K  
15  
 
Air Motor Parts Drawing  
24  
1
36  
11  
30  
20*  
10{  
2
28  
18  
13  
15  
5
3
22*  
21*  
23  
25  
16  
12  
17*  
21*  
31  
26*  
7
27a  
27b  
27  
27c  
*19  
See Displacement  
Pump Parts Drawing  
and List on page 15.  
32*  
29  
06032  
1
2
Torque to 30 to 40 ft-lb (41 to 54 N.m).  
Lips must face down.  
16  
308608K  
 
Air Motor Parts List  
Ref  
No.  
Ref  
Part No. Description  
Qty.  
No.  
Part No. Description  
Qty.  
24  
25  
26*  
27  
190929  
167585  
170709  
207391  
RING, lift  
SPRING, helical compression  
POPPET, exhaust valve  
PISTON, includes items 27a to 27c  
(also includes 207385 repair kit when  
ordered as a replacement part)  
SCREW, rd hd mach; 6–32 x 1/4” 2  
CLIP, Spring  
BARE PISTON (not sold separately) 1  
BASE, air motor  
ROD, piston  
CYLINDER, air motor  
ROD, trip  
POPPET, inlet valve  
LABEL, designation  
LABEL, warning  
BEARING, throat  
1
2
2
3
5
7
101578  
102656  
116343  
SCREW, cap, hex hd  
8
1
1
1
1
1
1
2
2
2
1
1
1
4
2
2
MUFFLER, air exhaust  
SCREW, ground  
SEAL, u-cup  
PACKING, o-ring  
ACTUATOR, air valve  
YOKE, trip rod  
PIN, toggle  
10{ 113345  
11  
12  
13  
15  
16  
17*  
18  
19*  
20*  
21*  
22*  
23  
156698  
158359  
158360  
158362  
158364  
158367  
158377  
158378  
158379  
160261  
160618  
160623  
1
27a  
27b  
27c  
28  
29  
30  
31  
32*  
33  
102975  
158361  
2
PIN, pivot  
190927  
193799  
15E954  
207150  
236079  
119344  
1
1
1
1
2
1
1
1
GROMMET, inlet valve  
PACKING, ring seal  
PACKING, o-ring  
PACKING, o-ring  
NUT, valve  
WIRE, lock  
ARM, toggle  
35Y 290259  
36 190930  
{ Included in Pump Repair Kit 238225,  
which may be purchased separately.  
*
Included in Air Motor Repair Kit 207385,  
which may be purchased separately.  
Y Extra warning labels are available at no cost.  
308608K  
17  
 
Dimensions  
Mounting Hole  
Layout  
MODEL 238108 Pump, Series D  
3.0-in. (76.2-mm)  
diameter clearance  
45_  
hole  
Four 1/4–20  
UNC-2B tapped  
depth 1.25-in  
(31.7-mm) on  
4.25-in (108-mm)  
diameter bolt  
circle  
3/4-in.  
npt fluid  
outlet  
1/2-in.  
npt air  
inlet  
Four 0.406-in.  
(10.3-mm)  
diameter  
holes on 7-in.  
(177.8-mm)  
diameter bolt  
circle  
26.4 in.  
(670 mm)  
3/4-in.  
npt  
muffler  
port  
8.0 in.  
(203.2 mm)  
diameter of flange  
8.0 in.  
(203 mm)  
Note: For sealed  
tank mounting,  
use gasket  
06031  
192658.  
Technical Data  
Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . . . 1100 psi (76 bar, 7.6 MPa)  
Fluid pressure ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6:1  
Air operating range . . . . . . . . . . . . . . . . . . 40 to 180 psi (3 to 12 bar, 0.3 to 1.2 MPa)  
3
Air consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ft /min per gallon pumped,  
3
(0.051 m /min per liter pumped)  
at 100 psi (7 bar, 0.7 MPa)  
Pump cycles per gallon (liter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5 (3.8)  
Maximum recommended pump speed . . . . . . . . 78 cycles/min; 6 gpm (23 liter/min)  
Recommended speed for optimum pump life . . . . . . . . . . . . 15 to 25 cycles per min  
Piston seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . polyurethane with nitrile spreader  
Rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . polyurethane with nitrile spreader  
Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . aluminum, steel, polyurethane, nitrile  
Approximate weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 lb (21 kg)  
* Sound pressure level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.5 dB(A)  
* Sound pressure measured at 30 cycles per minute at 100 psi (7 bar, 0.7 MPa)  
air inlet pressure per ISO Standard 3744.  
Loctiter is a registered trademark of the Loctite Corporation.  
18  
308608K  
 
Performance Charts  
To find Fluid Outlet Pressure (psi/bar) at a specific fluid flow (gpm/lpm) and operating air pressure (psi/bar):  
1. Locate desired fluid flow along bottom of chart.  
2. Follow vertical line up to point of intersection with selected fluid outlet pressure curve.  
2. Align point on curve with vertical scale on left side of chart to read fluid outlet pressure.  
Test Conditions: Pump tested with AW-32 oil at 75_ F (24_ C)  
Fluid Outlet Pressure  
900  
A 150 psi (10.3 bar) inlet air pressure  
B 100 psi (6.9 bar) inlet air pressure  
C 70 psi (4.8 bar) inlet air pressure  
D 40 psi (2.8 bar) inlet air pressure  
(62.1)  
A
800  
(55.2)  
700  
(48.3)  
600  
(41.4)  
B
500  
(34.5)  
400  
C
D
(27.6)  
300  
(20.7)  
200  
(13.8)  
100  
(6.90)  
0
0
2
4
6
8
(7.57)  
(15.14)  
(22.71)  
(30.28)  
Fluid Flow – gpm (lpm)  
3
To find Pump Air Consumption (scfm or m /min) at a specific fluid flow (gpm/lpm) and operating air pressure (bar/psi):  
1. Locate desired fluid flow along bottom of chart.  
2. Follow vertical line up to point of intersection with selected air consumption curve.  
2. Align point on curve with vertical scale on left side of chart to read air consumption.  
Test Conditions: Pump tested with AW-32 oil at 75_ F (24_ C)  
Inlet Air Consumption  
90  
(2.52)  
80  
A 150 psi (10.3 bar) inlet air pressure  
B 100 psi (6.9 bar) inlet air pressure  
C 70 psi (4.8 bar) inlet air pressure  
D 40 psi (2.8 bar) inlet air pressure  
(2.24)  
A
70  
(1.96)  
60  
(1.68)  
50  
(1.40)  
B
40  
(1.12)  
C
D
30  
(0.84)  
20  
(0.56)  
10  
(0.28)  
0
0
2
4
6
8
(7.57)  
(15.14)  
(22.71)  
(30.28)  
Fluid Flow – gpm (lpm)  
308608K  
19  
 
Graco Standard Warranty  
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the  
date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco,  
Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be  
defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written  
recommendations.  
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by  
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or sub-  
stitution 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 reconnais-  
sent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires  
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.  
Graco Phone Number  
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:  
1–800–533–9655 Toll Free  
612–623–6928  
612–378–3590 Fax  
All written and visual data contained in this document reflects the latest product information available at the time of publication.  
Graco reserves the right to make changes at any time without notice.  
This manual contains English. MM 308608  
Graco Headquarters: Minneapolis  
International Offices: Belgium, Korea, China, Japan  
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441  
308608 10/1995, Revised 03/2007  
20  
308608K  
 

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