INSTRUCTIONSPARTS LIST

This manual contains IMPORTANT WARNINGS AND INSTRUCTIONS READ AND RETAIN FOR REFERENCE

307049
Rev K Supersedes J

7 inch (178 mm)

BULLDOGr AIR MOTOR

For Driving Bulldog Pumps

100 psi (7 bar) MAXIMUM WORKING PRESSURE

Model 208356, Series J Standard Air Motor for most Bulldog Pumps Model 223905, Series A For Bulldog Pumps using Riser Tube 206793 Model 208360, Series J For Bulldog Sanitary Pumps Model 208357, Series J For Bulldog Transfer Pumps

TABLE OF CONTENTS
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Parts Drawings and Lists Models 208356 and 223905 . . . . . . . . . . . 8, 9 Model 208357 . . . . . . . . . . . . . . . . . . . . . . 10, 11 Model 208360 . . . . . . . . . . . . . . . . . . . . . . 12, 13 How to Order Replacement Parts . . . . . 9, 11, 13 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . . 15 Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . 15 Technical Data . . . . . . . . . . . . . . . . . . . . . Back Cover Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover Graco TollFree Phone Numbers . . . . . Back Cover

Model 208356 Shown

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 554401441

SAFETY WARNINGS
HIGH PRESSURE FLUID CAN CAUSE SERIOUS INJURY. FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS. Read And Understand All Instruction Manuals Before Operating Equipment.

FLUID INJECTION HAZARD General Safety

This equipment generates very high fluid pressure. Spray from the spray gun/dispensing valve, leaks or ruptured components can inject fluid through your skin and into your body and cause extremely serious bodily injury, including the need for amputation. Also, fluid injected or splashed into the eyes or on the skin can cause serious damage. NEVER point the spray gun/dispensing valve at anyone or at any part of the body. NEVER put hand or fingers over the spray tip/nozzle. ALWAYS have the tip guard in place on the spray gun when spraying. ALWAYS follow the Pressure Relief Procedure, at right, before cleaning or removing the spray tip/nozzle or servicing any system equipment. NEVER try to stop or deflect leaks with your hand or body. Be sure equipment safety devices are operating properly before each use.

Tip Guard (Spray Guns Only)

ALWAYS have the tip guard in place on the spray gun while spraying. The tip guard alerts you to the fluid injection hazard and helps reduce, but does not prevent, the risk of placing your fingers or any part of your body close to the spray tip.

Trigger Guard
NEVER operate the gun/valve with the trigger guard removed. This guard helps prevent the gun/valve from triggering accidentally if it is dropped.

Spray Tip/Nozzle Safety

Use extreme caution when cleaning or changing spray tips/nozzles. If the tip/nozzle clogs while spraying, engage the gun/valve safety latch immediately. ALWAYS follow the Pressure Relief Procedure and then remove the tip/nozzle to clean it. NEVER wipe off buildup around the spray tip/nozzle until pressure is fully relieved and the gun/valve safety latch is engaged.

Medical AlertAirless Spray Wounds

If any fluid appears to penetrate your skin, get EMERGENCY MEDICAL CARE AT ONCE. DO NOT TREAT AS A SIMPLE CUT. Tell the doctor exactly what fluid was injected. Note to Physician: Injection in the skin is a traumatic injury. It is important to treat the injury surgically as soon as possible. Do not delay treatment to research toxicity. Toxicity is a concern with some exotic coatings injected directly into the blood stream. Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable.

Pressure Relief Procedure

To reduce the risk of serious bodily injury, including fluid injection, splashing in the eyes or on the skin, or injury from moving parts, always follow this procedure whenever you shut off the pump, when checking or servicing any part of the spray/dispensing system, when installing, cleaning or changing spray tips/nozzles, and whenever you stop spraying/dispensing. 1. Engage the gun/valve safety latch. 2. Turn off the air to the motor. 3. Close the bleedtype master air valve (required in your system). 4. Disengage the gun/valve safety latch. 5. Hold a metal part of the gun/valve firmly to the side of a grounded metal pail, and trigger the gun/valve to relieve pressure. 6. Engage the gun/valve safety latch. 7. Open the drain valve (required in your system), having a container ready to catch the drainage. 8. Leave the drain valve open until you are ready to spray/dispense again. If you suspect that the spray tip/nozzle or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen the tip guard or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip/nozzle or hose.

Spray Gun/Dispensing Valve Safety Devices

Be sure all gun/valve safety devices are operating properly before each use. Do not remove or modify any part of the gun/valve; this can cause a malfunction and result in serious bodily injury.

Safety Latch
Whenever you stop spraying, even for a moment, always set the gun/ valve safety latch in the closed or safe position, making the gun/valve inoperative. Failure to set the safety latch can result in accidental triggering of the gun/valve.

Diffuser (Spray Guns Only)

The gun diffuser breaks up spray and reduces the risk of fluid injection when the tip is not installed. Check diffuser operation regularly. Follow the Pressure Relief Procedure, to the right, then remove the spray tip. Aim the gun into a metal pail, holding the gun firmly to the pail. Using the lowest possible pressure, trigger the gun. If the fluid emitted is not diffused into an irregular stream, replace the diffuser immediately.

EQUIPMENT MISUSE HAZARD General Safety

Any misuse of the spray/dispensing equipment or accessories, such as overpressurizing, modifying parts, using incompatible chemicals and fluids, or using worn or damaged parts, can cause them to rupture and result in fluid injection, splashing in the eyes or on the skin, or other serious bodily injury, or fire, explosion or property damage. NEVER alter or modify any part of this equipment; doing so could cause it to malfunction. CHECK all spray/dispensing equipment regularly and repair or replace worn or damaged parts immediately. Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.

System Pressure
NEVER exceed 100 psi (7 bar) air pressure to the motor, and NEVER exceed the maximum working pressure of the complete pump, as stated in your separate pump manual. Be sure that all accessories are rated to withstand the maximum air and fluid working pressures of this system.

Fluid Compatibility
BE SURE that all fluids and solvents used are chemically compatible with the wetted parts shown in the TECHNICAL DATA in your separate pump manual. Always read the fluid and solvent manufacturers literature before using them in the pump.

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HOSE SAFETY
High pressure fluid in the hoses can be very dangerous. If the hose develops a leak, split or rupture due to any kind of wear, damage or misuse, the high pressure spray emitted from it can cause a fluid injection injury or other serious bodily injury or property damage. ALL FLUID HOSES MUST HAVE SPRING GUARDS ON BOTH ENDS! The spring guards help protect the hose from kinks or bends at or close to the coupling which can result in hose rupture. TIGHTEN all fluid connections securely before each use. High pressure fluid can dislodge a loose coupling or allow high pressure spray to be emitted from the coupling. NEVER use a damaged hose. Before each use, check the entire hose for cuts, leaks, abrasion, bulging cover, or damage or movement of the hose couplings. If any of these conditions exist, replace the hose immediately. DO NOT try to recouple high pressure hose or mend it with tape or any other device. A repaired hose cannot safely contain the high pressure fluid. HANDLE AND ROUTE HOSES CAREFULLY. Do not pull on hoses to move equipment. Do not use fluids which are not compatible with the inner tube and cover of the hose. DO NOT expose Graco hoses to temperatures above 180) F (82) C) or below 40) F (40) C).

Hose Grounding Continuity

Proper hose grounding continuity is essential to maintaining a grounded spray/dispensing system. Check the electrical resistance of your air and fluid hoses at least once a week. If your hose does not have a tag on it which specifies the maximum electrical resistance, contact the hose supplier or manufacturer for the maximum resistance limits. Use a resistance meter in the appropriate range for your hose to check the resistance. If the resistance exceeds the recommended limits, replace it immediately. An ungrounded or poorly grounded hose can make your system hazardous. Also, read FIRE OR EXPLOSION HAZARD, below.

MOVING PARTS HAZARD

The piston in the air motor (located behind the air motor shield) 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 or air motor with the air motor shield or any other parts removed. KEEP CLEAR of moving parts when starting or operating the pump. Before checking or servicing the pump or any system component, follow the Pressure Relief Procedure on page 2, to prevent the pump from starting accidentally.

FIRE OR EXPLOSION HAZARD

Static electricity is created by the flow of fluid through the pump and hose. If every part of the spray/dispensing equipment is not properly grounded, sparking may occur, and the system may become hazardous. Sparking may also occur when plugging in or unplugging a power supply cord. Sparks can ignite fumes from solvents and the fluid being sprayed, dust particles and other flammable substances, whether you are spraying/dispensing indoors or outdoors, and can cause a fire or explosion and serious bodily injury and property damage. Do not plug in or unplug any power supply cords in the spray/dispensing area when there is any chance of igniting fumes still in the air. If you experience any static sparking or even a slight shock while using this equipment, STOP SPRAYING/DISPENSING IMMEDIATELY. Check the entire system for proper grounding. Do not use the system again until the problem has been identified and corrected. 8.

To maintain grounding continuity when flushing or relieving pressure, always hold a metal part of the gun/valve firmly to the side of a grounded metal pail, then trigger the gun/valve.

To ground the pump:

To ground the pump, loosen the grounding lug locknut (W) and washer (X). Insert one end of a 1.5 mm@ (12 ga) minimum ground wire (Y) into the slot in lug (Z) and tighten the locknut securely. See Fig 1. Connect the other end of the wire to a true earth ground. See page 14 to order a ground wire and clamp.

Y W X Z

Grounding
To reduce the risk of static sparking, ground the pump, object being sprayed, and all other spray/dispensing equipment used or located in the spray/dispensing area. CHECK your local electrical code for detailed grounding instructions for your area and type of equipment. BE SURE to ground all of this spray/dispensing equipment: 1. 2.

Pump: use a ground wire and clamp as shown in Fig 1. Air and fluid hoses: use only grounded hoses with a maximum of 500 ft (150 m) combined hose length to ensure grounding continuity. Refer to Hose Grounding Continuity, above.
Air compressor: follow manufacturers recommendations.

Fig 1

3. 4. 5. 6. 7.

Spray gun/dispensing valve: grounding is obtained through connection to a properly grounded fluid hose and pump.
Fluid supply container: according to your local code.

Flushing Safety
To reduce the risk of fluid injection injury, static sparking and splashing, always follow the specific flushing procedure given in your separate pump manual. Before flushing, be sure the entire system and flushing pails are properly grounded. Refer to Grounding, at the left. Follow the Pressure Relief Procedure on page 2, and remove the spray tip (spray guns only). Always use the lowest possible fluid pressure, and maintain firm metaltometal contact between the gun/valve and the pail during flushing.

Object being sprayed: according to your local code.

All solvent pails used when flushing, according to 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 continuity.

IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards particularly the General Standards, Part 1910, and the Construction Standards, Part 1926 should be consulted.

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TROUBLESHOOTING THE AIR MOTOR

Grounding WARNING Before operating the pump, ground the system as explained under FIRE OR EXPLOSION HAZARD and Grounding on page 3. WARNING Moving parts can pinch or amputate your fingers or other body parts. To reduce the risk of serious bodily injury, be sure to keep your fingers out of the detent housing (45) and exhaust openings. Locating Air Leaks To locate where air is leaking, shut off the air supply and disconnect the air hose. Screw the inlet union (3) out of the air manifold (41), remove the shield (51), then screw the union back into the manifold. See Fig 2. Connect the air hose and turn the air on. DO NOT exceed 40 psi (2.8 bar) incoming air pressure. Use the checking methods listed in the Check Chart below to find where air is leaking.

Stalled Motor To restart a stalled motor, remove the lift ring (18) from the detent housing (45), and use a screwdriver to push the air valve housing (30) down. See Fig 2.
0.031 (0.79 mm) 0.031 (0.79 mm)

H (37, 17)

41 18 30 A or D (38)

CHECK CHART
Letter Ref. Stroke Position Points UP only (air valve housing down) A B C Check Method By feel By feel Squirt oil around wiper seal (25) By feel By feel Squirt oil around bearing (1) Squirt oil around bearing (1) Squirt oil around air valve (30) I Hold paper strip over exhaust holes Cause of Leakage Blown air manifold gaskets (38) Blown air cylinder gasket (19) Worn throat packings (23 or 61)

45

3 1

51

F (21)

DOWN only (air valve housing up)

D E F

Blown air manifold gaskets (38) Damaged connecting tube seal (25) Worn trip rod packing (21) Damaged trip rod bearing gasket (16)

(16) G

I (29)

BOTH or

Worn air valves (37) their packings (17)

(19) B C (23, 61)

Worn air piston packing (29)

E (25) Fig 2

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SERVICE
WARNING Pressure Relief Procedure To reduce the risk of serious bodily injury, including fluid injection, splashing in the eyes or on the skin, or injury from moving parts, always follow this procedure whenever you shut off the pump, when checking or servicing any part of the spray/dispensing system, when installing, cleaning or changing spray tips/ nozzles, and whenever you stop spraying/dispensing. 1. Engage the gun/valve safety latch. 2. Turn off the air to the motor. 3. Close the bleedtype master air valve (required in your system). 4. Disengage the gun/valve safety latch. 5. Hold a metal part of the gun/valve firmly to the side of a grounded metal pail, and trigger the gun/valve to relieve pressure. 6. Engage the gun/valve safety latch. 7. Open the drain valve (required in your system), having a container ready to catch the drainage. 8. Leave the drain valve open until you are ready to spray again. If you suspect that the spray tip/nozzle or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen the tip guard or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip or hose.

WARNING The piston in the air motor moves when air is supplied to the motor. Moving parts can pinch or amputate your fingers or other body parts. To reduce the risk of serious bodily injury, be sure to follow the Pressure Relief Procedure Warning above before servicing the motor. 1. Disconnect all hoses, rods, tubes, controls, etc. from the air motor as necessary to provide ease in servicing. 2. Remove the air inlet union (3), disconnect the ground wire, and remove the lift ring (18). See Fig 2. NOTE: Repair Kit 206734 is available.For best results, use all the new parts in the kit, even if the old ones look good. Parts included in the kit are marked with an asterisk, for example (16*). 3. Remove the screws (10), washers (5), air motor shield (51), and grommet (40). Air Valve Repair (See Fig 3) 1. Unscrew each detent spring retainer (32), and remove the spring (34), guide (33) and plunger (46) from each side of the detent housing (45). CAUTION HANDLE SPRINGS CAREFULLY. Scratches or nicks may cause the springs to break during use. 2. Remove the four screws (13) and washers (7) from the detent housing (45). Carefully lift the housing, making sure you dont drop the detent rollers (4) and axles (52). 3. Push the motor piston (2) up from the bottom of the base (50 or 66). Turn the air valve housing (30) so it rests on the manifolds (41). Remove the spring (26), oring (17), and air director valve (37) from each side of the housing. 4. Pull the trip rod (22) up as far as possible, and grasp it with the special padded pliers 207579 (see ACCESSORIES on page 14). Hold the flats of the hub (35) with a wrench. Screw off the trip rod nut (31), and

remove the lockwasher (9). Remove the air valve housing. Screw off the hub (35), and release the pliers. CAUTION Take special care to avoid damaging the plated surface of the trip rod (22), which would restrict its free movement. 5. Remove the two screws (8) and lockwashers (9) from each air manifold (41). Remove the manifold gaskets (38) from the cylinder (44). WARNING The openings in the valve plates (47) are razor sharp! Be careful not to cut yourself when handling the plates. 6. Check the valve plates (47) and seals (39). Replace them if they are worn or damaged. 7. Clean the mating surfaces of the valve plates and manifolds, then reassemble using the screws (14). 8. If no further service is needed, continue on with Reassembly, step 13.

If the piston needs servicing, continue as follows.

Piston Repair (See Fig 3) 1. Remove the trip rod bearing (1), using a 1 in. socket wrench. Remove the gasket (16), washer (20), and vpacking (21) from the bearing. 2. Remove the screws (11) and lockwashers (6). Pull the cylinder (44) straight up off the piston. CAUTION DO NOT tilt or force the cylinder as doing so could damage the smooth inner cylinder wall. If the cylinder is stuck to the base, use a plastic hammer to break it loose. 3. Pull the piston and connecting tube assembly (2) and the trip rod (22) up out of the base (50 or 66). Remove the oring (29) from the piston. Remove the packings and seals from the base. 307049 5

32 13 18 45 7 34 33 4 52 46

4. Place a wrench on the turned down portion at the bottom of the connecting tube (2), and screw out the stud (36). CAUTION Be careful not to damage the polished surface of the connecting tube. 5. Remove the trip rod (22) from the connecting tube (2). Whenever the trip rod is removed from the connecting tube or a new trip rod is being installed, check to make sure the distance between the inside shoulders of the spring guides (J) is EXACTLY 5.5 in. (139.7 mm). See Fig 4. If the spring guide(s) (J) is removed or the setting is not exactly 5.5 in. (139.7 mm), or if any part of the trip rod is damaged, the entire trip rod assembly must be replaced. CAUTION DO NOT attempt to readjust the spring guides (J)! Readjustment could cause air motor failure. NOTE: If the trip rod is broken, use a 9/16 in. hex key wrench to remove it.

28 31 9 30 27

26

17* 37 47

40

35

27 14 28 1 39 41 *38 16* 20* 21* 8 9 29 2 22

44

22 *23

2 29* J
5.5 in. (139.7 mm)

50 or 66 50 or 66

11 *24

Fig 4

Fig 3 6 307049

36

Reassembly (See Fig 3) 1. Clean all the parts thoroughly, and inspect for wear or damage. Replace parts as necessary. 2. Grease the cavity in the base (50 or 66). Install a washer (24*) and a vpacking (23*) so the lips of the vpacking face up in the base. Install the wiper seal (25*) in the base. On Model 208357, install the throat packings in the base as shown in the parts drawing, with the lips of the vpackings facing down. 3. Grease the piston (2), oring (29*), and cylinder (44). Place the cylinder upside down on a flat surface. Place the oring around the piston; the oring is larger than the piston groove. Install the piston in the cylinder so the excess of the oring fits into one of the notches on the flange of the cylinder. Use a screwdriver to push the oring out of the notch and seat it in the piston groove. Push the piston into the cylinder to hold the oring in place. CAUTION DO NOT tilt or force the piston into the cylinder as this could damage the smooth inner cylinder wall. 4. Regrease the inside of the cylinder (44), the trip rod (22) and the piston stud (36). Be sure the gasket (19) is properly located on the base (50 or 66). CAUTION When reassembling the sanitary air motor, Model 208360, apply sealant to the cylinder flange to seal out exhaust air that could contaminate the material. Use silicone sealant GE No. SCS 1300 or equivalent. 5. Guide the piston assembly (2) and cylinder (44) into the base (50 or 66), aligning the cylinder and base correctly. Install the lockwashers (6) and screws (11) snugly. 6. Install a washer (20*) and vpacking (21*) in the bearing (1) so the lips of the vpacking face out of the bearing. Install the gasket (16*) on the bearing. 7. install the bearing (1) in the cylinder (44) throat. 8. Push the piston (2) up, and thread the trip rod nut (31) loosely onto the trip rod (22). Use a 1 in. socket wrench to tighten the bearing (1) into the cylinder (44).

9. Install the dampener pad (28) and washer (27) into the cylinder throat. 10. Place the air valve alignment tool 168513 (see ACCESSORIES, page 14) on the cylinder. Position the gaskets (38) and manifolds (41) on the cylinder. Install the screws (8) and washers (9). Remove the tool. NOTE: The air valve alignment tool ensures a proper clearance and makes reassembly easier. 11. Push the piston (2) up as far as possible. Remove the trip rod nut (31). Slide the hub (35) onto the rod, then grasp the rod below the hub with the special padded pliers. Screw the hub down as far as possible. 12. Install the air valve housing (30), washer (9), and trip rod nut (31). Screw the trip rod nut down so there is a 0.031 in. (0.79 mm) clearance (about the thickness of a dime) between the top of the rod and the top of the nut. See Fig 3. Holding the trip rod nut in this position with a wrench, tighten the hub up to the trip rod nut and washer. Turn the valve housing so it rests on the manifolds, then release the pliers. 13. Install the orings (17*) on the director valves (37). Grease the director valves and springs (26), and place them in each side of the air valve housing. Hold the parts in at the top, and carefully rotate the valve housing until it slides down between the manifolds. Be very careful not to pinch your fingers. 14. Hold the air valve alignment tool up to the manifolds to be sure the proper clearance has been maintained. 15. Install the plunger (46), guide (33), and spring (34). Loosely screw the retainer (32) into each side of the detent housing (45). 16. Install the dampener pad (28) and washer (27) in the bottom of the detent housing. Grease the axles (52) and rollers (4), and install them in the housing. 17. Position the detent housing (45) on the manifolds (41). Install the washers (7) and screws (13) firmly. Tighten each detent spring retainer (32) firmly to the side of the detent housing (45). The spring guide (33) should pass through the hole in the end of the retainer (32) in this position. 18. Replace the grommet (40). Install the air motor shield (51), washers (5), screws (10), and the air inlet union (3). Reconnect the ground wire.

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PARTS DRAWING
Model 208356, Series J Includes items 154 Model 223905, Series A Includes items 154

53 54 18 10 5 51 11 33 34** 32 6 3 44 36 *24 19** 29* 2** 23*

LIPS OF VPACKING MUST FACE UP

46 13 8 9 41 39 *38 47 37 *17 **26 30 15 7 14 45

4** 52 28 27 31 9 40

12, 42

**22 50 *25 35 1** 16* 20*

21*
LIPS OF VPACKING MUST FACE DOWN

307049

PARTS LIST
Model 208356, Series J Includes items 154 Model 223905, Series A Includes items 154
REF NO. PART NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 204649** 206710** 207648 169585** 100016 100018 100052 100101 100133 100333 100424 101845 101713 101716 102726 150647* 156698* 180952 161556** 161559* 161560* 214852** 161562* 161563* 161569* DESCRIPTION QTY 1 1 1 2 8 8 4 4 5 8 8 8 4 8 1 1 2 1 1 1 1 1 1 1 1 REF NO. PART NO. 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 44 45 46 47 50 51 52 53 54 161575** 161576 161577 161578* 161585 161586 161587 161588 161589** 161590 168180 168182 168183* 168184 168185 168187 172476 169372 177664 169583 169584 206782 223904 169588 169586 104029 104582 DESCRIPTION QTY 2 2 2 1 1 1 2 2 2 1 1 2 2 2 1 2 1 1 1 2 2 1 1 1 2 1 1

BEARING AIR PISTON & CONNECTING TUBE UNION, 90_ adapter; 3/4 npt(m) x 3/4 npsm(f) swivel ROLLER, axle LOCKWASHER, spring; 1/4 LOCKWASHER, spring; 1/2 LOCKWASHER, spring; 7/16 SCREW, hex hd cap; 3/816 x 1 long LOCKWASHER, spring; 3/8 SCREW, hex hd cap; 1/420 x 1/2 long SCREW, hex hd cap; 1/213 x 11/4 long SCREW, type f self tapping; no. 632 x 3/8 long SCREW, hex hd cap; 7/1614 x 31/2 long SCREW, flat hd machine; no. 1024 x 1/2 long PLUG, pipe; socket hd; 3/4 npt GASKET ORING; bunaN RING, lift GASKET WASHER, backup VPACKING; polyurethane ROD, trip VPACKING; bunaN WASHER, backup SEAL, felt wiper

SPRING, compression WASHER, flat PAD, dampening ORING; bunaN HOUSING, air valve NUT; 3/824 RETAINER, detent spring GUIDE, spring SPRING, compression HUB, valve housing STUD, connecting rod VALVE, air director GASKET, air manifold SEAL, valve plate; bunaN GROMMET MANIFOLD, air PLATE, instruction CYLINDER, air motor HOUSING, detent PLUNGER, detent PLATE, valve BASE, air motor (For Model 208356) BASE, air motor (For Model 223905) SHIELD, air motor AXLE, detent LUG, grounding WASHER, tab

Included in repair kit 206734.

** Recommended spare parts. Keep on hand to reduce downtime.

206734 Repair Kit Purchase kit separately. Kit includes: Ref. No. Qty 16 1 17 2 20 1 21 1 23 1 24 1 25 1 29 1 38 2

HOW TO ORDER PARTS

1 To be sure you receive the correct replacement parts, kits or accessories, always give all of the information requested in the chart below. 2. Check the parts list to identify the correct part number; do not use the ref. no. when ordering. 3. Order all parts from your nearest Graco distributor. 6 digit Part Number Qty Part Description

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PARTS DRAWING
Model 208357, Series J Includes items 166

53 54 18 10 5 51 59 55 56 11 33 34** 32 6 44 36 *24 19** 29* 2** 65** 64** 57**

LIPS OF VPACKINGS MUST FACE DOWN

23*
LIPS OF VPACKING MUST FACE UP

46 13 8 9 41 39 *38 47 37 *17 **26 30 15 7 14 45

66

4** 52 28 27 31 9 40

**22

61 58** 60 63

35 1** 16* 20* 21*

LIPS OF VPACKING MUST FACE DOWN

10

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PARTS LIST
Model 208357, Series J Includes items 166
REF NO. PART NO. 1 2 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 204649** 206710** 169585** 100016 100018 100052 100101 100133 100333 100424 101713 101716 102726 150647* 156698* 180952 161556** 161559* 161560* 214852** 161562* 161563* 161569* 161575** 161576 161577 161578* 161585 161586 161587 DESCRIPTION QTY 1 1 2 8 8 4 4 5 8 8 4 8 1 1 2 1 1 1 1 1 1 1 1 2 2 2 1 1 1 2 REF NO. PART NO. 33 34 35 36 37 38 39 40 41 44 45 46 47 51 52 53 54 55 56 57 58 59 60 61 63 64 65 66 161588 161589** 161590 168180 168182 168183* 168184 168185 168187 169372 177664 169583 169584 169588 169586 104029 104582 107141 101407 157636** 157638** 156172 158388 159314** 162847 162848** 162849** 162935 DESCRIPTION QTY 2 2 1 1 2 2 2 1 2 1 1 2 2 1 2 1 1 1 1 1 1 1 1 4 1 1 1 1

BEARING AIR PISTON & CONNECTING TUBE ROLLER, axle LOCKWASHER, spring; 1/4 LOCKWASHER, spring; 1/2 LOCKWASHER, spring; 7/16 SCREW, hex hd cap; 3/816 x 1 long LOCKWASHER, spring; 3/8 SCREW, hex hd cap; 1/420 x 1/2 long SCREW, hex hd cap; 1/213 x 11/4 long SCREW, hex hd cap; 7/1614 x 31/2 long SCREW, flat hd machine; no. 1024 x 1/2 long PLUG, pipe; socket hd; 3/4 npt GASKET ORING; bunaN RING, lift GASKET WASHER, backup VPACKING; polyurethane ROD, trip VPACKING; bunaN WASHER, backup SEAL, felt wiper SPRING, compression WASHER, flat PAD, dampening ORING; bunaN HOUSING, air valve NUT; 3/824 RETAINER, detent spring

GUIDE, spring SPRING, compression HUB, valve housing STUD, connecting rod VALVE, air director GASKET, air manifold SEAL, valve plate; bunaN GROMMET MANIFOLD, air CYLINDER, air motor HOUSING, detent PLUNGER, detent PLATE, valve SHIELD, air motor AXLE, detent LUG, grounding WASHER, tab VALVE, shutoff; 3/4 npt NIPPLE, pipe; 3/4 npt x 3 long GLAND, female GLAND, male UNION, straight adapter; 3/4 npt(f) x 3/4 nps(f) swivel SPRING, compression VPACKING; neoprene RETAINER, packing BEARING, throat WASHER, flat BASE, air motor

Included in repair kit 206734.

** Recommended spare parts. Keep on hand to reduce downtime.

206734 Repair Kit (Must be purchased separately) Consists of: Ref. No. Qty 16 1 17 2 20 1 21 1 23 1 24 1 25 1 29 1 38 2

HOW TO ORDER PARTS

1 To be sure you receive the correct replacement parts, kits or accessories, always give all of the information requested in the chart below. 2. Check the parts list to identify the correct part number; do not use the ref. no. when ordering. 3. Order all parts from your nearest Graco distributor. 6 digit Part Number Qty Part Description

307049

11

PARTS DRAWING
Model 208360, Series J Includes items 154

53 54 18 10 5 51 11 33 34** 32 6 3 44 36 *24 19** 29* 2** 48 7 14 28 27 31 9 47 37 *17 **26 30 35 1** 16* 20* 21*
LIPS OF VPACKING MUST FACE DOWN

23*
LIPS OF VPACKING MUST FACE UP

46 13 8 9 41 39 *38 15 45

4** 52

42

**22 40 50 *25

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PARTS LIST
Model 208360, Series J Includes items 154
REF NO. PART NO. 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 204649** 206710** 207648 169585** 100016 100018 100052 100101 100133 100333 100424 101713 101716 102726 150647* 156698* 180952 161556** 161559* 161560* 214852** 161562* 161563* 161569* 161575** 161576 161577 DESCRIPTION QTY 1 1 1 2 8 8 4 4 5 8 8 4 8 1 1 2 1 1 1 1 1 1 1 1 2 2 2 REF NO. PART NO. 29 30 31 32 33 34 35 36 37 38 39 40 41 42 44 45 46 47 48 50 51 52 53 54 161578* 161585 161586 161587 161588 161589** 161590 168180 168182 168183* 168184 168185 168187 172476 169372 177664 169583 169584 100933 207250 208388 169586 104029 104582 DESCRIPTION ORING; bunaN HOUSING, air valve NUT; 3/824 RETAINER, detent spring GUIDE, spring SPRING, compression HUB, valve housing STUD, connecting rod VALVE, air director GASKET, air manifold SEAL, valve plate; bunaN GROMMET MANIFOLD, air PLATE, instruction CYLINDER, air motor HOUSING, detent PLUNGER, detent PLATE, valve SCREW, type f selftapping; no. 832 x 3/8 long BASE, air motor SHIELD, air motor; 1 npt(f) exhaust connection AXLE, detent LUG, grounding WASHER, tab QTY 1 1 1 2 2 2 1 1 2 2 2 1 2 1 1 1 2 2 16 1 1 2 1 1

BEARING AIR PISTON & CONNECTING TUBE UNION, 90_ adapter; 3/4 npt(m) x 3/4 npsm(f) swivel ROLLER, axle LOCKWASHER, spring; 1/4 LOCKWASHER, spring; 1/2 LOCKWASHER, spring; 7/16 SCREW, hex hd cap; 3/816 x 1 long LOCKWASHER, spring; 3/8 SCREW, hex hd cap; 1/420 x 1/2 long SCREW, hex hd cap; 1/213 x 11/4 long SCREW, hex hd cap; 7/1614 x 31/2 long SCREW, flat hd machine; no. 1024 x 1/2 long PLUG, pipe; socket hd; 3/4 npt GASKET ORING; bunaN RING, lift GASKET WASHER, backup VPACKING; polyurethane ROD, trip VPACKING; bunaN WASHER, backup SEAL, felt wiper SPRING, compression WASHER, flat PAD, dampening

Included in repair kit 206734.

** Recommended spare parts. Keep on hand to reduce downtime.

206734 Repair Kit (Must be purchased separately) Consists of: Ref. No. Qty 16 1 17 2 20 1 21 1 23 1 24 1 25 1 29 1 38 2

HOW TO ORDER PARTS

1 To be sure you receive the correct replacement parts, kits or accessories, always give all of the information requested in the chart below. 2. Check the parts list to identify the correct part number; do not use the ref. no. when ordering. 3. Order all parts from your nearest Graco distributor. 6 digit Part Number Qty Part Description

307049

13

USE GENUINE GRACO PARTS AND ACCESSORIES

Must be purchased separately. GROUNDING CLAMP 103538 GROUND WIRE 208950 25 ft (7.6 m) long, 12 gauge (1.5 mm@)
BLEEDTYPE MASTER AIR VALVE 107141 300 psi (21 bar) MAXIMUM WORKING PRESSURE Relieves air trapped in the air line between the pump air inlet and this valve when closed. 3/4 npt (m x f) inlet and outlet.

ACCESSORIES

AIR REGULATOR 207755 300 psi (21 bar) MAXIMUM WORKING PRESSURE 10125 psi (19 bar) REGULATED PRESSURE RANGE 3/4 npt(f) inlet and outlet ports; 1/4 npt(f) pressure gauge ports. See instruction manual 306972.

AIR LINE FILTER 106150 250 psi (18 bar) MAXIMUM WORKING PRESSURE 3/4 npt(f) inlet and outlet.

AIR LINE LUBRICATOR 214849 250 psi (18 bar) MAXIMUM WORKING PRESSURE 3/4 npt(f) inlet and outlet. AIR REGULATOR KIT 207651 Includes air regulator 207755 (see above), gauge, air inlet manifold, bleedtype master air valve, hose, and mounting hardware. 3/4 npt(f) inlet and outlet. See instruction manual 306972.

ALIGNMENT TOOL 168513 For correctly aligning and spacing air manifolds. Position tool on trip rod as shown. Install manifolds loosely. Hold manifolds against block and tighten. Remove block and complete assembly of motor.

TRIP ROD PLIERS 207579 Use to hold trip rod without damaging the trip rods plated surface. 14 307049

MOUNTING HOLE LAYOUT

Models 208356, 223905, and 208360
USE GASKET 161806

4 (102 mm) 1.375 (34.9 mm) R 45_ 9.75 (247.7 mm) dia. 90_ Four 0.437 (11.1 mm) dia. holes on 10.5 (267 mm) bolt circle

Model 208357
4.75 (121 mm) dia.

Four 0.406 (10.3 mm) dia. holes on 5.75 (146 mm) bolt circle

DIMENSIONAL DRAWINGS

3/4 npt(f) AIR INLET 3.5 (88.9 mm) 3.5 (88.9 mm) 1.75 (44.45 mm) 3/4 npt(f) AIR INLET

21.25 (540 mm)

19 (483 mm)

22.38 (568.2 mm)

Models 208356, 223905, and 208360

Model 208357

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SERVICE INFORMATION
Model 223905, for Bulldog Pumps using Riser Tube 206793, has been added to the manual.

TECHNICAL DATA
Maximum incoming air pressure . . . . . . . 100 psi (7 bar) Effective piston area . . . . . . . . . . . . 38 sq. in. (248 cm@) Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 in. (178 mm) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . 4.75 in. (121 mm) Air valves . . . . . . . . . . . . . . . . . . . . . . . . . Dual, slide type Valve housing . . . . . . . . . Balanced, opposing seals and detent rollers Shipping weight Models 208356, 223905, and 208357 . . . . . . . . . . . . . . . . . . . . 74 lb (33.3 kg) Model 208360 . . . . . . . . . . . . . . . . . . 78 lb (35.1 kg)

THE GRACO WARRANTY AND DISCLAIMERS

WARRANTY Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchasers sole remedy for breach of this warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Gracos written recommendations. This warranty does not cover, and Graco shall not be liable for, any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of nonGraco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility with Graco equipment of 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 claim. 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. DISCLAIMERS AND LIMITATIONS
THE TERMS OF THIS WARRANTY CONSTITUTE PURCHASERS SOLE AND EXCLUSIVE REMEDY AND ARE IN LIEU OF ANY OTHER WARRANTIES (EXPRESS OR IMPLIED), INCLUDING WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, AND OF ANY NONCONTRACTUAL LIABILITIES, INCLUDING PRODUCT LIABILITIES, BASED ON NEGLIGENCE OR STRICT LIABILITY. EVERY FORM OF LIABILITY FOR DIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND DENIED. IN NO CASE SHALL GRACOS LIABILITY EXCEED THE AMOUNT OF THE PURCHASE PRICE. ANY ACTION FOR BREACH OF WARRANTY MUST BE BROUGHT WITHIN TWO (2) YEARS OF THE DATE OF SALE.

EQUIPMENT NOT COVERED BY GRACO WARRANTY

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WITH RESPECT TO ACCESSORIES, EQUIPMENT, MATERIALS, OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO.

These items sold, but not manufactured by Graco (such as electric motor, 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.

IMPORTANT PHONE NUMBERS

TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you: 18003280211 Toll Free FOR TECHNICAL ASSISTANCE, service repair information or assistance regarding the application of Graco equipment: 18005430339 Toll Free

Factory Branches: Atlanta, Chicago, Dallas, Detroit, Los Angeles, West Caldwell (N.J.) Subsidiary and Affiliate Companies: Canada; England; Switzerland; France; Germany; Hong Kong; Japan; Korea GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 554401441
PRINTED IN U.S.A. 307049 871 Revised 491

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