Graco Fire-Ball D Series Operation manual

Instructions – Parts List
GRACO INC.P.O. BOX 1441MINNEAPOLIS, MN55440-1441
Copyright 1995, Graco Inc. is registered to I.S. EN ISO 9001
6:1 Fire–Ballr425 Pump
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
308608K
06031
Important Safety instructions
Read all warnings and instructions in this manual.
Save these instructions.

2 308608K
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Motor and Throat Service 10. . . . . . . . . . . . . . . . . . . .
Displacement Pump Service 14. . . . . . . . . . . . . . . . . . . .
Displacement Pump Parts Drawing and List 15. . . . . . .
Air Motor Parts Drawing 16. . . . . . . . . . . . . . . . . . . . . . . .
Air Motor Parts List 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 18. . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance Charts 19. . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 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.
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 compo-
nent in your system.
DUse fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s
warnings.
DDo not 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.
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 82_C (180_F) or below –40_C (–40_F).
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
WARNINGWARNING

308608K 3
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.
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.
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.
DFluid injected into the skin 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 at 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.
DUse only extensions and no-drip tips which are designed for use with your dispensing valve.
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.
WARNINGWARNING

4 308608K
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
DKeep clear of all moving parts when starting or operating the pump.
DBefore servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the
equipment from starting unexpectedly.
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. Refer to Grounding on page 7.
DIf 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.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being dispensed.
DDo not smoke in the dispensing area.
WARNINGWARNING

308608K 5
Installation
The typical installation shown in Fig.1 is only a guide
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.
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.
CAUTION
D
N
A
C
A
KEY
ABleed-type master air valve (required)
BAir line filter
CAir regulator and gauge
DPump runaway valve (shown for
position) – not needed if you use
a low level cut-off valve
EAir inlet
F Ball valve (for releasing collected moisture)
GPump
HDrain valve (required)
JDispensing valve (model 222411 shown)
KThermal relief kit (required), Part No. 240429
LMale quick-disconnect fitting
MFemale quick-disconnect coupler
NAir line lubricator
PFluid hose
RElectrically conductive air hose (218093 shown)
SFluid inlet
TWall-mounting bracket
YGround wire (required)
ZMuffler
Fig. 1
BE
G
Y
HPJ
L
M
DETAIL A
For Portable Applications
R
ST
K
05610
A
F
Z
TI0890

6 308608K
Installation
System Accessories
CAUTION
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.
NOTE: Install the accessories in the order shown in
Fig. 1.
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.
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.
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.
The thermal relief kit assists in relieving pressure in
the pump, hose, and dispensing valve due to heat
expansion.
The ground wire reduces the risk of static sparking.
WARNING
1. Screw the muffler (5) into the 3/4-in. npt muffler
port, and tighten it using a wrench on the flats of
the muffler near the male threads.
2. Install an air line lubricator (N) for automatic air
motor lubrication.
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.
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.
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.
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.
8. Install a suitable fluid hose (P) and dispensing
valve (J).
Cover Mount
For cover mounting, see the Mounting Hole Layout
on page 18.
Wall Mount
The pump shown in Fig. 1 is wall mounted. To order
the wall-mounting bracket, order Part No. 238245.

308608K 7
Installation
Grounding
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.
4. Fluid supply container: Follow the local code.
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.
To ground the pump, remove the ground screw (Z)
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.
TI1052
Z
Y
Fig. 2

8 308608K
Operation
Pressure Relief Procedure
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.
WARNING
1. Close the bleed-type master air valve (required in
your system).
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).
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.
Startup and Adjustment
COMPONENT RUPTURE HAZARD
The maximum working pressure of each
component in the system may not be the
same. To reduce the risk of overpres-
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.
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
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.
WARNING
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.
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).
2. Open the dispensing valve (J) into a grounded
metal waste container, making firm metal-to-metal
contact between the container and valve.
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.
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.
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.
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.
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.
CAUTION

308608K 9
Operation
7. Read and follow the instructions supplied with
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.
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.
9. Check periodically to ensure that the pump’s
mounting is secure.
Troubleshooting
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 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.
WARNING NOTE: Check all other possible problems and solu-
tions 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 dispensing
valve
Open; clear
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 gas-
ket, packing, seal, etc.
Service air motor
Erratic pump operation Exhausted fluid supply Refill and reprime or flush
Held open or worn intake valve or
piston packings
Clear; service
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
Fluid is coming out of the muffler. Worn or damaged throat seal Service
* 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.

10 308608K
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. 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.
DTwo 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.
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.
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.
4. Use a strap wrench on the displacement pump
cylinder (110) to screw it out of the air motor base
(28). See Fig. 3.
5. Remove the piston/valve seat (109) from the rod
(29) with wrenches or with the vice and a wrench.
6. Remove the piston ball (103), u-cup packing
(107{), and piston washer (113).
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.
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.
9. Remove the eight screws (3) holding the cylinder
(30) to the base (28). Carefully pull the cylinder
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.
TI1076
Fig. 3
28
110
29
31
27
24
30
3
113
107{
109
103
flange
10{
108{
105{
06033
{Included in Pump Repair Kit 238225,
which may be purchased separately.

308608K 11
Air Motor and Throat Service
10. Pull the piston assembly from the air motor base
(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.
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.
14. Use a screwdriver to push down on the trip rod
yoke (13), and snap the toggles down. See Fig. 4.
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.
WARNING
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.
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).
17. Remove the exhaust valve poppets (26) by cutting
them with a side cutter, then pull them out of the
actuator (12).
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.
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.

12 308608K
Air Motor and Throat Service
L
05612
25
16
23
15
Turn
lock-
wires
up.
Fig. 4
Cut off tops
of poppets as
indicated by
dotted lines.
0.125”
(3.18 mm)
Cutaway View
M
13
31
22*
21*
32*
21*
32*
27
28 32*
21*
17*
31
14
17*
21*
32*
26*
27
26*14
19*
04422
12
13
15
Reassembly
1. Place the piston rod (29) flats in the vice with the
air motor up.
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).
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
inlet valve poppets until there are a few threads left
before the threads run out.
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*).
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.
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).
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.
NOTE: Adjust the distance between the inlet valve
poppets and the piston seat by turning the
top valve nuts (21*).
8. Tighten the bottom valve nuts (21*) securely by
hand.
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.
Never re-use the old lock wires. They will get
brittle and break easily from too much bending.
CAUTION
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).
11. Clamp the air motor base (28) in a vise horizontally
by closing the vice jaws on the flange.

308608K 13
Air Motor and Throat Service
12. Grease and reinstall the u-cup seal (10{), thread
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.
13. Slide the piston rod (29) down through the pack-
ing, and lower the piston assembly (27) into the air
motor base (28).
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).
CAUTION
To avoid damaging the cylinder wall, lower the
cylinder straight down onto the piston. Never tilt
the cylinder as it is being lowered.
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.
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.
17. Place the piston ball (103) in the piston rod (29).
18. Clean the threads of the piston/valve seat, Apply
Loctiterto the threads, (109), and thread the
assembly from Step 16 onto the piston rod (29).
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
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.
23. Reconnect the ground wire before regular opera-
tion of the pump.

14 308608K
Displacement Pump Service
Disassembly
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. 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.
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.
Intake Valve. See Fig 5.
1. Relieve the pressure.
2. Unscrew the valve housing (111). Remove the
o-ring (105{), retainer (112), and ball (104).
3. Inspect the parts for wear or damage. If the ball is
nicked, replace it. Reassemble, using grease on
the male threads.
Displacement Pump. See Fig 5.
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.
1. Relieve the pressure.
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.
Reassembly
Do steps 16 through 23 in Air Motor and Throat
Service on page 13.
Fig. 5
104
111
105{
110
112
05617
{Included in Pump Repair Kit 238225, which may
be purchased separately. The Parts List on page
15 includes all parts in kit.

03846
113
107{
103
108{
110
112
104
105{
109
111
1
2
1
2
Torque to 40 to 60 ft-lb (54 to 81 N.m)
Torque to 95 to 105 ft-lb (129 to 142 N.m)
3Lips face up
3
1
308608K 15
Displacement Pump Parts Drawing and List
Model 238108, Series D
Air motor not listed or shown here. See pages 16 and 17.
Ref
No. Part No. Description Qty.
10{113345 SEAL, u-cup (shown on page 16) 1
103 101190 BALL, piston; metallic 1
104 101178 BALL; sst 1
105{113347 PACKING, o-ring 1
107{113346 PACKING, u-cup 1
108{112349 PACKING, o-ring 1
Ref
No. Part No. Description Qty.
109 194016 PISTON 1
110 190922 CYLINDER, pump 1
111 190926 VALVE HOUSING 1
112 190928 RETAINER, ball 1
113 190924 WASHER, piston 1
{Included in Pump Repair Kit 238225,
which may be purchased separately.

16 308608K
Air Motor Parts Drawing
16
24
11
30
22*
21*
25
23
12
21*
17*
26*
*19
27b
27a
31
15
13
27c
32*
29
3
10{
7
18
2
See Displacement
Pump Parts Drawing
and List on page 15.
36 1
2
1
Lips must face down.
Torque to 30 to 40 ft-lb (41 to 54 N.m).
06032
20*
5
28
27

308608K 17
Air Motor Parts List
Ref
No. Part No. Description Qty.
3 101578 SCREW, cap, hex hd 8
5 102656 MUFFLER, air exhaust 1
7 116343 SCREW, ground 1
10{113345 SEAL, u-cup 1
11 156698 PACKING, o-ring 1
12 158359 ACTUATOR, air valve 1
13 158360 YOKE, trip rod 1
15 158362 PIN, toggle 2
16 158364 PIN, pivot 2
17* 158367 GROMMET, inlet valve 2
18 158377 PACKING, ring seal 1
19* 158378 PACKING, o-ring 1
20* 158379 PACKING, o-ring 1
21* 160261 NUT, valve 4
22* 160618 WIRE, lock 2
23 160623 ARM, toggle 2
Ref
No. Part No. Description Qty.
24 190929 RING, lift 1
25 167585 SPRING, helical compression 2
26* 170709 POPPET, exhaust valve 2
27 207391 PISTON, includes items 27a to 27c
(also includes 207385 repair kit when
ordered as a replacement part) 1
27a 102975 SCREW, rd hd mach; 6–32 x 1/4” 2
27b 158361 CLIP, Spring 2
27c BARE PISTON (not sold separately) 1
28 190927 BASE, air motor 1
29 193799 ROD, piston 1
30 15E954 CYLINDER, air motor 1
31 207150 ROD, trip 1
32* 236079 POPPET, inlet valve 2
33 119344 LABEL, designation 1
35Y290259 LABEL, warning 1
36 190930 BEARING, throat 1
{Included in Pump Repair Kit 238225,
which may be purchased separately.
*Included in Air Motor Repair Kit 207385,
which may be purchased separately.
YExtra warning labels are available at no cost.

18 308608K
Dimensions
1/2-in.
npt air
inlet
8.0 in.
(203 mm)
3/4-in.
npt
muffler
port
26.4 in.
(670 mm)
MODEL 238108 Pump, Series D
3/4-in.
npt fluid
outlet
06031
Note: For sealed
tank mounting,
use gasket
192658.
Mounting Hole
Layout
3.0-in. (76.2-mm)
diameter clearance
hole
45_
Four 1/4–20
UNC-2B tapped
depth 1.25-in
(31.7-mm) on
4.25-in (108-mm)
diameter bolt
circle
Four 0.406-in.
(10.3-mm)
diameter
holes on 7-in.
(177.8-mm)
diameter bolt
circle
8.0 in.
(203.2 mm)
diameter of flange
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). . . . . . . . . . . . . . . . . .
Air consumption 7 ft3/min per gallon pumped,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(0.051 m3/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.
Loctiteris a registered trademark of the Loctite Corporation.

308608K 19
Test Conditions: Pump tested with AW-32 oil at 75_F (24_C)
Fluid Outlet Pressure
Performance Charts
(7.57) (15.14)
Fluid Flow – gpm (lpm)
(22.71)
(62.1)
(30.28)
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.
0
100
200
300
400
500
600
700
800
900
02468
A
B
C
D
A150 psi (10.3 bar) inlet air pressure
B100 psi (6.9 bar) inlet air pressure
C70 psi (4.8 bar) inlet air pressure
D40 psi (2.8 bar) inlet air pressure
(55.2)
(48.3)
(41.4)
(34.5)
(27.6)
(20.7)
(13.8)
(6.90)
To find Pump Air Consumption (scfm or m3/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
Fluid Flow – gpm (lpm)
0
10
20
30
40
50
60
70
80
90
0 2 4 6 8
A
B
C
D
A150 psi (10.3 bar) inlet air pressure
B100 psi (6.9 bar) inlet air pressure
C70 psi (4.8 bar) inlet air pressure
D40 psi (2.8 bar) inlet air pressure
Inlet Air Flow – scfm (m
3/min) Outlet Pressure – psi (bar)
(7.57) (15.14) (22.71) (30.28)
(2.52)
(2.24)
(1.96)
(1.68)
(1.40)
(1.12)
(0.84)
(0.56)
(0.28)

20 308608K
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.P.O. BOX 1441MINNEAPOLIS, MN55440-1441
308608 10/1995, Revised 03/2007