Graco Fire-Ball 425 E Series Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
50:1 Fire-Ballr425 Pumps
For pumping non–corrosive and non–abrasive
greases and lubricants only.
7500 psi (51.7 MPa, 517 bar) Maximum Working Pressure
150 psi (1.0 MPa, 10 bar) Maximum Air Input Pressure
Model 205394, Series E
Model 205395, Series N
306674U
WARNING
This pump is designed to be used only in pumping
non-corrosive and non-abrasive oils and lubricants.
Any other use of the pump can cause unsafe operat-
ing conditions and component rupture, which can re-
sult in fluid injection or other serious injury or fire or
explosion.
06306B
Important Safety instructions
Read all warnings and instructions in this manual.
Save these instructions.

2 306674U
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Service 10. . . . . . . . . . . . . . . . . . . .
Air Motor and Throat Service 12. . . . . . . . . . . . . . . . . . . .
Parts Drawing 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 20. . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 20. . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
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.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
DDo not alter or modify this equipment.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure stated on the equipment or in the Technical Data
for your equipment. Do not exceed the maximum working pressure of the lowest rated component
in your system.
DUse 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.
DHandle hoses carefully. Do not pull on hoses to move equipment.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 66_C (150_F) or below –40_C (–40_F).
DWear hearing protection when operating this equipment.
DDo not move or lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.

306674U 3
WARNING
SKIN INJECTION HAZARD
Fluid from the gun, 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.
DFluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious
injury. Get immediate surgical treatment.
DDo not point the dispensing valve at anyone or any part of the body.
DDo not put your hand or fingers over the end of the dispensing valve.
DDo not stop or deflect leaks with your hand, body, glove, or rag.
DDo not “blow back” fluid; this is not an air spray system.
DUse only extensions and couplings that are designed for use with your dispensing valve.
DFollow the Pressure Relief Procedure on page 7 before you clean, check, or service the
equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not
repair high pressure couplings; you must replace the entire hose.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
DKeep clear of all moving parts when starting or operating the pump.
DBefore checking or servicing the equipment, follow the Pressure Relief Procedure on page 7 to
prevent the equipment from starting unexpectedly.

4 306674U
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.
DGround the equipment and the object being dispensed to. Refer to Grounding on page 5.
DIf there is any static sparking or you feel an electric shock while using this equipment, stop dis-
pensing immediately. Do not use the equipment until you identify and correct the problem.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being dispensed.
DKeep the dispensing area free of debris, including solvent, rags, and gasoline.
DDo not smoke in the dispensing area.
DDo not turn on or off any light switch in the area while dispensing if fumes are present.
DNever use 1.1.1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents, or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
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.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state, and national guidelines.
DAlways wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid and
solvent manufacturer.
DThe air motor exhausts any fluids added to the input air.
DGraco does not manufacture or supply the reactive chemical components that may be used in this
equipment and is not responsible for injury or property loss, damage, expense, or claims (direct or
consequential) that arise from the use of such chemical components.

306674U 5
Installation
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
NOTE: Always use Genuine Graco Parts and Acces-
sories, available from your Graco distributor.
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE OR EXPLOSION HAZ-
ARD on page 4.
DPump: Use a ground wire and clamp as shown
below.
Fig. 1 TI1052
Y
Z
DAir and fluid hoses: Use only electrically conductive
hoses.
DAir compressor: Follow manufacturer’s recommen-
dations.
DDispensing valve: Ground through connection to a
properly grounded fluid hose and pump.
DObject being dispensed to: Follow your local code.
DSolvent 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.
DTo maintain grounding continuity when flushing or
relieving pressure, hold a metal part of the dispens-
ing gun firmly to the side of a grounded metal pail,
then trigger the gun.
To ground the pump, remove the ground screw (Z)
and insert through the eye of the ring terminal at end of
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. 1.
To order a ground wire and clamp, order Part No.
222011.
Mounting the Pump
WARNING
Mount the pump securely so that it cannot move
around during operation. Failure to do so could
result in personal injury or equipment damage.
DSelect a convenient location for the equipment to
ensure easy operator access to the pump air
controls, sufficient room to change supply contain-
ers, and a secure mounting platform.
DIf you are mounting the pump directly on the supply
tank, position the pump so its intake valve is no
more than 1 in. (25 mm) from the bottom of the
container. Mount the pump to the cover or other
suitable mounting device.

6 306674U
Installation
Mount the pump to suit the type of installation planned.
Very heavy lubricants may require an inductor plate.
See page 18 for the mounting hole layout and dimen-
sions
Install the air line accessories in the approximate order
shown in the Typical Installation. Install a bleed-type
master air valve (B) within easy reach of the pump,
upstream from the air regulator. Install an air filter (C)
to remove harmful dirt and moisture from your com-
pressed air supply. For automatic air motor lubrication,
install an air line oiler (D) close to the pump air inlet.
Install an air regulator (E) to control pump speed.
WARNING
A bleed-type master air valve (B) is required to
shut off and relieve air pressure that may be
trapped in the air motor. Trapped air could cause
the pump to cycle unexpectedly and cause serious
bodily injury, including amputation.
Be sure the air hose is properly sized to deliver an
adequate supply of air to the motor. Refer to the
Technical Data on page 19.
Connect a dispensing hose to the 3/8 npt(f) pump
outlet. Install an appropriate gun or dispensing valve to
the hose.
Ground the pump as explained on page 5.
Fig. 2
Key
A
B
C
D
E
F
G
H
J
Grounded Air Line
Bleed-type Master Air Valve
Air Filter
Air Line Oiler
Air Regulator
Grounded Dispensing Hose
Dispensing Valve
Elevator Assy. With Inductors
Ground Wire
Typical Installation
06309
A
B
CD
E
H
J
F
G

306674U 7
Operation
WARNING
DThis pump is designed to be used ONLY in
pumping non-corrosive and non-abrasive lubri-
cants and greases. Any other use of this pump
can cause unsafe operating conditions and
result in component rupture, fire, or explosion,
which can can cause serious bodily injury,
including injection.
DMoving parts can pinch or amputate your fin-
gers or other body parts. When the pump is
operating, the priming piston (located at the
pump intake) and the air motor piston (located
behind the air motor plates) move. NEVER
Operate the pump with the air motor plates
removed, and keep your fingers and hands
away from the priming piston.
Pressure Relief Procedure
WARNING
SKIN INJECTION HAZARD
Fluid under high pressure can be in-
jected 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
DAre instructed to relieve the pressure
DStop dispensing
DCheck or service any of the system equipment
DInstall or clean the dispensing nozzles
1. Close the air regulators.
2. Close the supply pump’s bleed-type master air
valve (required in this system).
3. Open the dispensing valve until pressure is fully
relieved.
If you suspect that the dispensing valve, extension, or
grease fitting coupler is clogged, or that pressure has
not been fully relieved after following the steps above,
VERY SLOWLY loosen the coupler or hose end cou-
pling and relieve pressure gradually, then loosen
completely, then clear the clog.
Startup and Adjustment
Open the bleed-type master air valve. Open the dis-
pensing valve, and slowly open the air regulator until
the pump is running smoothly. After all the air is
purged, close the dispensing valve. The pump will
start and stop as the valve is opened and closed.
CAUTION
Never allow the pump to run dry of the fluid being
pumped. A dry pump quickly accelerates to a high
speed and may damage itself. If your pump acceler-
ates 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 the pump and
leave it filled with a compatible solvent. Be sure to
eliminate all air from the fluid system.
Use the air regulator (E) to control the pump speed
and fluid pressure. See Fig. 2. Always use the lowest
pressure necessary to obtain the desired results.
When you are finished using the pump for the day,
always follow the Pressure Relief Procedure at left.
Maintenance
The Accessory air line oiler (D) provides automatic air
motor lubrication. For daily manual lubrication, discon-
nect the air hose, place about 15 drops of light ma-
chine oil in the air inlet, reconnect the hose, and turn
on the air supply to blow oil into the motor.

8 306674U
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
Before servicing this equipment always make sure to
Relieve the Pressure.
Note: Check all possible problems and solutions
before disassembling the pump.
Problem Cause Solution
Pump fails to operate. Inadequate air supply pressure or
restricted air lines
Increase air supply; clear
Closed or clogged valves Open; clean
Clogged fluid lines, hoses, valves,
etc.
Clear*
Damaged air motor Service air motor
Exhausted fluid supply Refill and reprime, or flush
Continuous air exhaust Worn or damaged air motor gasket,
packing, seal, etc.
Service air motor
Erratic pump operation Exhausted fluid supply Refill and reprime, or flush
ppp
Held open or worn intake valve or
piston packings
Clear; service
Pump operates, but output low on
upstroke
Held open or worn piston or packings Clear; service
Pump operates, but output low on
downstroke
Held open or worn intake valve Clear; service
Pump operates, but output low on
both strokes
Inadequate air supply or restricted air
lines
Increase air supply; clear
Closed or clogged valves Open; clean
Exhausted fluid supply Refill and reprime, or flush
Clogged fluid lines, hoses, valves,
etc.
Clear*
Packing nut too tight Loosen
Loose packing nut or worn packings Tighten; replace
* Follow the Pressure Relief Procedure, and disconnect the fluid line. If the pump starts when the air is turned
back on, the fluid line, hose, valve, etc. was clogged.

306674U 9
Notes

10 306674U
Displacement Pump Service
Fig. 3
06308
1
2
77
64
68
}65
}74
}59
}75
}76
70
78
73}1
}69
72
79 2
66}
80n
59}
62}
61n
67
}62 68
Lips of v-packings
must face up
Torque to 50 to 70
ft-lb (68 to 95 N-m).
06336
72
1/4” ROD
71
}Included in Repair Kit 239320,
which may be purchased separately.
Ref. 63 (copper gasket) and
Ref. 60}(cotter pin),
see Parts Drawing on page 16.
1

306674U 11
Displacement Pump Service
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
Before you start:
DTo reduce down time, be sure you have all neces-
sary repair parts available. Recommended spare
parts are listed in the parts list with a check mark,
for example ( 80n)
DThe balls (59) in the intake and piston valves can-
not be reseated on the hardened seats (68).
DRepair Kit 239320 is available. If you have a repair
kit, use all the new parts for the best results. Throat
seal parts included in the kit are marked with a
dagger ({) and pump lower parts are marked with a
double dagger (}).
DWhenever you replace the packings, also replace
the glands and bearing.
DWhen cleaning parts, use a compatible solvent.
Inspect parts for wear or damage and replace as
necessary. Scoring or irregular surfaces on the
priming tube (72) or polished inner wall of the riser
tube (79) causes premature packing wear and
leaking. Check these parts by rubbing a finger on
the surface and by holding the parts up to the light
at a slight angle.
Use light, waterproof grease wherever grease is
mentioned.
Disassembly
1. Flush the pump if possible. Follow the Pressure
Relief Procedure on page 7. Disconnect all air
and fluid hoses.
2. Clamp the motor base in a vise. Unscrew the
priming cylinder (78).
3. Hold the priming tube (72) with a 1/4 in (6mm)
diameter rod through the holes in the tube. Grip
the flats of the priming piston (71) with a wrench,
and unscrew the piston.
4. Loosen the packing housing (70). Unscrew the
riser tube (79) from the air motor.
5. Remove the packing housing (70) from the riser
tube (79), and remove the packings from the
housing.
6. Hold the intake valve housing (67) with a wrench,
and unscrew the priming tube (72) by inserting a
1/4 in (6 mm) diameter rod through the holes in the
tube. Handle the tube carefully to avoid marring
the surface. Remove the ball, seat, and gasket.
7. Unscrew the intake valve housing (67) from the
piston valve housing (64). Remove the ball and
packings.
8. Clean all parts thoroughly. Grease all parts except
threads when reassembling.
Reassembly
1. One at a time, place the female gland (74}), five
leather v-packings (66}) with the lips of the pack-
ings facing up, and the male gland (65}) on the
intake housing (67). Place the gasket (62}),
seat (68), and ball (59}) on the housing (67).
2. If the pins (80) were removed from the piston valve
housing (64), replace them. Hold the piston valve
housing with a wrench and screw in the intake
valve housing.
3. Place a gasket (62}), seat (68), and ball (59}) on
the priming tube (72). Holding the piston valve
housing (67) with a wrench, screw the priming tube
into it, using a 1/4 in. diameter rod through the
tube for leverage.
4. Guide the riser tube (79) over the priming tube and
screw it into the motor base, making sure the
gasket (63) is in place. Torque to 50 to 70 ft-lb
(68 to 95 N-m).
5. One at a time, place the female gland (76}), five
leather v-packings (73}) with lips of packings
facing up, a male gland (75}), and a bearing (69})
in the packing housing (70). Screw the housing
firmly into the riser tube (79).
6. Screw the priming piston (71) firmly onto the
priming tube (72). Screw the intake cylinder (78)
firmly onto the riser tube.
7. Reconnect the ground wire if it was disconnected
during repair.

12 306674U
Air Motor and Throat Service
Before you Start
DBe sure you have all necessary parts on hand. Air
Motor Repair Kit 207385 includes repair parts for
the motor. Pump Repair Kit 239320 includes repair
parts for the pump and the air motor throat area.
Use all the parts in the kits for the best results.
Parts included in the kits are marked with an aster-
isk (*), a dagger ({), or a double dagger (}) in text
and drawings. See the parts drawing and list
(pages 16 and 17) for further information.
DTwo accessory tools should be used. Padded
pliers, 207579 is used to grip the trip rod without
damaging its surface. Gauge, 171818, is used to
ensure the proper clearance between the poppets
and seat of the transfer valve.
Disassembly
1. Flush the pump. Follow the Pressure Relief
Procedure Warning, at left, before proceeding.
2. Disconnect the air hose from the motor. If neces-
sary, disconnect the motor from the pump. Clamp
the air motor base in a vise.
3. Manually push up on the piston rod to move the
piston assembly to the top of its stroke. Unscrew
the cylinder cap nut (31) from the cylinder (32).
Pull up on the cap nut. Grip the trip rod (1) with
padded pliers 207579 and screw the cap nut off
the trip rod. See Fig. 4.
CAUTION
Do not damage the plated surface of the trip rod.
Damaging the surface of the trip rod can result in
erratic air motor operation. Use the special padded
pliers, 207579, to grasp the rod.
4. Remove the eight screws (7) holding the cylinder
(32) to the base (56). Carefully pull the cylinder
straight up off the piston. See Fig. 4.
CAUTION
To avoid damaging the cylinder wall, ALWAYS lift the
cylinder straight up off of the piston. Never tilt the
cylinder as it is being removed.
Always keep fingers clear of the toggle assemblies
(K), to avoid pinching or amputating them. See
Fig. 5.
WARNING
5. Use a screwdriver to push down on the trip rod
yoke (14) and snap the toggle assemblies (K)
down. See Fig. 5. Remove the lockwires (28*)
from the adjusting nuts (27*) of the transfer valves
(M). Screw the top adjusting nuts (27*) off. Screw
the valve stems (30*) out of the grommets (18*)
and lower adjusting nuts (27*). Take the valve
poppets (37*) off the stems and squeeze them
firmly to check for cracks.
Fig. 4
32
7
56
36
1
Hold trip rod with
padded pliers
207579, to prevent
damage to rod
31

306674U 13
Air Motor and Throat Service
6. Grip the toggle rockers (16) with a pliers. Com-
press the springs (17) and swing the toggle
assembly (K) up and away from the piston lugs
(L), and remove the parts. Check that the valve
actuator (13) is supported by the spring clips (4),
but slides easily into them. See Fig. 5.
7. Remove the trip rod yoke (14), valve actuator (13)
and trip rod (1). Check the exhaust valve poppets
(38*) for cracks.
NOTE: To remove the exhaust valve poppets
(38*), stretch them out and cut with a sharp knife.
8. Pull the piston (5) up out of the base (56) and
inspect the piston o-ring (20*) and the o-ring in the
base casting.
Fig. 5
K
Push toggles (K) in
and then up.
Turn wires up.
L
11428*
27*
30*
18*
5
56
17
16
4 38*13
27*
37*
Cut off tops of
poppets (x) as
indicated by dotted
lines
0.125 in.
(3.18 mm)
CUTAWAY VIEW
1
4
13
38* 30* 27*
18*
27*
20*
5
37*
M

14 306674U
Air Motor and Throat Service
Reassembly
1. Clean all the parts carefully in a compatible solvent
and inspect for wear or damage. Use all the repair
kit parts during reassembly and replace other parts
as necessary.
2. Check the polished surfaces of the piston, piston
rod and cylinder wall for scratches or wear. A
scored rod will cause premature packing wear and
leaking.
3. Lubricate all parts with a light, waterproof grease.
4. Be sure the o-rings are in place. Slide the piston
rod down through the throat bearing and lower the
piston (5) into the air motor base (56).
5. Pull the exhaust valve poppets (38*) into the valve
actuator (13) and clip off the top part shown with
dotted lines. See Fig. 5.
6. Install the transfer valve poppets (37*) onto the
valve stems (30*), then reassemble the valve
stems (30*), bottom adjusting nuts (27*), grom-
mets (18*), and top adjusting nuts (27*) on the
piston (5). Assemble the trip rod (1), valve actuator
(13), trip rod yoke (14) and toggle assemblies (K)
on the piston. See Fig. 5.
7. Before installing the lockwires (28*) in the adjusting
nuts (27*), use the special gauge 171818 to adjust
the transfer valve (M) so there is 0.125 in.
(3.68 mm) clearance between the poppets (37*)
and the piston (5) when the toggle assemblies are
in the down position. See Fig. 5.
8. Snap the toggle assemblies (K) to the up position.
Reinstall the cylinder (32) and cap nut (31). Reas-
semble the air motor to the displacement pump.
9. Before remounting the pump, connect an air hose
and run the pump slowly, at about 40 psi
(0.28 MPa, 2.8 bar) to ensure that it operates
smoothly.
10. Reconnect the ground wire before regular opera-
tion of the pump.
Throat Packing Service
The piston in the air motor, located behind the air
motor plates, moves when air is supplied to the
motor. Moving parts can pinch or amputate your
fingers or other body parts. Therefore, never
operate the pump with the air motor plates
removed.
WARNING
See Fig. 6 on page 15 and the parts drawing and list
(pages 16 and 17) for further information.
1. Clamp the pump in a vise and unscrew the riser
tube (80) from the air motor base (56). Pull the
riser tube away from the air motor until the cotter
pin (60}) which secures the displacement pump
connecting rod to the air motor piston rod (52) is
visible. See Fig. 6.
2. Remove the cotter pin (60}) and unscrew the
pump connecting rod (79) from the air motor piston
rod (52). See Fig. 6. Remove the cylinder (32)
from the air motor base (56) as described under
Disassembly on page 12.
3. Remove one louvered air exhaust plate (36) and
unscrew the throat packing nut (45{), using a
spanner wrench or a 0.22 in. (5.6 mm) diameter
rod. See Fig. 6.
4. Remove the packing nut (45{), male and female
glands (47{, 48{), v-packings (49{), washer
(44{), bearing (46{), retainer (24{), wiper (22{),
o-ring (23{), u-cup (25{), and washer (26{) from
the base.
5. Clean the throat packing area in the base and the
packing nut. Clean and inspect all parts, and
replace as necessary.
6. Lubricate the packings, piston rod and piston
flange with a light waterproof grease.
7. Install the washer (26{) into the base. Assemble
the packing (25{) and the wiper (22{) into the
retainer (24{). Install the o-ring (23{) onto the
retainer, and insert the retainer assembly into the
base.
NOTE: Make sure the packing (25{) lips face
down, and make sure the wiper (22{) lips face up.
8. Insert the bearing (46{) and the washer (44{) into
the base. Assemble the female gland (48{),
v-packings (49{), and the male gland (47{) into
the packing nut (45{).

306674U 15
Air Motor and Throat Service
9. Reinstall the spacer and packing in the base and
packing nut (45{). Screw the packing nut into the
base, and tighten it securely. Carefully slide the
piston rod (52) down through the throat packing,
and lower the piston into the base. Reinstall the
plate (36) and cylinder (32). Reassemble the air
motor to the displacement pump.
10. Torque the outlet adapter (42) to 45 to 55 ft-lb (61
to 75 N-m).
CAUTION
When reinstalling cotter pin (60}), always spread
and flatten the pin (both the head and prongs)
around the rod to within a 1 in. (25 mm) total diame-
ter. See Detail A of Fig. 6.
Fig. 6
45{
36
80
56
32
SEE DETAIL A
52
60}
79
1 in.
(25 mm)
DETAIL A

16 306674U
Parts Drawing
Model 205394, Series E 120 lb (55 kg) drum length
Model 205395, Series N 400 lb (180 kg) drum length
1
2
3
4
5
6
7
8
9
62
75
13 14
15
16
17
18*
19
*20
21*
22
23
24
25
26
27*
28*
29
*30
31
32
58
36
*37
38*
40
42
44
46
48
49
52
53
56
57
33
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
76
77
78
79
80
27*
{
45
{
{
{
{
{
{
n
{
{
47
{
{
33
}
}
}
}
}
}
n
}
}
}
}
59}
68
n
n
1Torque to 45–55 ft–lb (61–75 N–m)
1

306674U 17
Parts List
Model 205394, Series E 120 lb (55 kg) drum length
Model 205395, Series N 400 lb (180 kg) drum length
Air Motor
Ref
No. Part No. Description Qty.
1 207150 TRIP ROD 1
2 207391 PISTON
includes items 3 to 5 (also includes
207385 repair kit (** items) when
ordered as a replacement part) 1
3 102975 .SCREW, rd hd mach; 6–32 x 1/4 in. 2
4n158361 .CLIP, spring 2
5 .BARE PISTON (not sold separately) 1
6 100078 SCREW, hex head; 8–32 x 3/8 in. 20
7 101578 SCREW, hex head Nylock;
8–32 x 3/8 in. 8
8 150647 GASKET; copper 1
9n156698 O-RING; Buna–N 1
13 158359 ACTUATOR, valve 1
14 158360 YOKE, rod, trip 1
15 158362 PIN, toggle 2
16 158364 ROCKER, toggle 2
17 167585 SPRING, helical compression 2
18* 158367 GROMMET; rubber 2
19 158377 SEAL, flat ring; nitrile rubber 1
20* 158378 SEAL, o-ring; nitrile rubber 1
21* 158379 SEAL, o-ring; nitrile rubber 1
22{113935 WIPER, rod 1
23{113944 PACKING, o-ring 1
24{192172 RETAINER, packing 1
25{113936 PACKING, u-cup 1
26{192173 WASHER, packing 1
27* 160261 NUT, adjusting 4
28* 160618 LOCKWIRE, transfer valve 2
29 160623 ARM, toggle 2
30* 160896 STEM, valve 2
31 161435 NUT, cylinder cap 1
32 15E954 CYLINDER, motor, air 1
33 178270 PLATE, muffler 2
36 15E555 PLATE, identification 1
37* 170708 POPPET, valve; urethane 2
38* 170709 POPPET, valve; urethane 2
40 150461 GASKET; copper 1
42 158409 ADAPTER, outlet 1
44{158697 WASHER, thrust 1
45{159047 NUT, packing 1
46{159048 BEARING, brass 1
47{159306 GLAND, male 1
48{159307 GLAND, female 1
49{159308 V-PACKING; nitrile rubber 4
52 162553 ROD, piston 1
53 116343 SCREW, grounding 1
56 165362 BASE, motor, air 1
58 177843 PLATE, warning 1
Pump
Ref
No. Part No. Description Qty.
59}100170 BALL, steel; 3/8” dia. 2
60}100579 PIN, cotter; 7/64” dia.; 1” long 1
61n108513 PIN, roll; 0.135” dia.; 7/8” long 1
62}150451 GASKET, copper 2
63 158314 GASKET, copper 1
64 162555 HOUSING, piston valve 1
65}162556 GLAND, male 1
66}162557 V-PACKING, leather 5
67 162558 HOUSING, intake valve 1
68 162559 SEAT, valve 2
69}162560 BEARING, brass 1
70 162561 HOUSING, packing 1
71 162562 PISTON, priming 1
72 162564 TUBE, priming 1
73}162566 V-PACKING, leather 5
74}162568 GLAND, female 1
75}162602 GLAND, male 1
76}162603 GLAND, female 1
77 164234 ROD, connecting; 12.47”
(317 mm) long
for Model 205394 1
164231 ROD, connecting; 19–13/32”
(493 mm) long
for Model 205395 1
78 164233 CYLINDER, intake primer 1
79 165381 TUBE, riser; 21.31” (541 mm long)
for Model 205394 1
165382 TUBE, riser; 28–1/4” (718 mm long)
for Model 205395 1
80n102180 PIN, spring; 0.135” dia.; 1” long 2
* Included in Air Motor Repair Kit 207385, which
may be purchased separately.
Repair Kit 239320, which may be purchased
separately, includes parts to service the air motor
throat area and the pump lower.
{Parts marked with a dagger are for the air motor
throat area.
}Parts marked with a double dagger are for the
pump lower.
nRecommended “tool box” spare parts. Keep on
hand to reduce down time.

18 306674U
Dimensions
Model 205395, Series N
Weight 36 lb (16 kg)
Model 205394, Series E
Weight 36 lb (16 kg)
Priming Piston
6–1/2”
(165.1 mm)
Diameter
3/8 npt
Fluid
Outlet
41–1/4”
26–11/16”
(1048 mm)
(678 mm)
14–9/16”
(369.9 mm)
Priming Piston
6–1/2”
(165.1 mm)
Diameter
3/8 npt
Fluid
Outlet
48–3/16”
33–5/8”
(1224 mm)
(854.1 mm)
14–9/16”
(369.9 mm)
1/2 npt(f)
Air Inlet
1/2 npt(f)
Air Inlet
06306B
Mounting Hole Layout
06337
3 1/4” (82.6 mm) DIA. TWO 5/16” (7.94 mm)
DIAMETER HOLES ON
4 1/4” (108 mm)
BOLT CIRCLE
7/8” (22.2 mm) DIA.
2–3/32” (53.18 mm) 45o

306674U 19
Technical Data
Fluid pressure ratio 50:1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air pressure operating range 40 to 150 psi (0.3 to 1.0 MPa, 3 to 10 bar). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum working pressure 7500 psi (51.7 MPa, 517 bar). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum delivery 0.5 gpm (1.9 lpm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cycles per gallon (per liter) 110 (28). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. recommended pump speed 60 cycles per minute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air motor effective diameter 4.25 in (108 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke 4 in. (102 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air consumption approx. 19 cfm (0.53 m#/min). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
at 1 gpm (3.8 lpm) at 70 psi (0.48 MPa, 4.8 bar)
Wetted parts steel, brass, aluminum, leather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight Model No. 205394: 34 lb (15 kg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model No. 205395: 37 lb (17 kg)
Sound Pressure Level
(measured at 1 meter from unit)
Input Air Pressures at 15 cycles per minute
40 psi (0.28 MPa, 2.8 bar) 70 psi (0.48 MPa, 4.8 bar) 100 psi (0.7 MPa, 7 bar)
73.6 dB(A) 78.34 dB(A) 80.85 dB(A)
Sound Power Level
(tested in accordance with ISO 9614–2)
Input Air Pressures at 15 cycles per minute
40 psi (0.28 MPa, 2.8 bar) 70 psi (0.48 MPa, 4.8 bar) 100 psi (0.7 MPa, 7 bar)
87.4 dB(A) 92.09 dB(A) 94.62 dB(A)

20 306674U
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 user. 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 Numbers
TO PLACE AN ORDER, contact your Graco distributor, or call one of the following numbers
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 306674
Graco Headquarters: Minneapolis
International Offices: Belgium, Korea, China, Japan
www.graco.com
01/1961, Revised 04/2007