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Installation 

6

308608L

Installation

System Accessories

Install the accessories shown in F

IG

. 1.

1. Insert the muffler (5) into the 3/4 in. npt muffler port 

and tighten 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 an air regulator (C) to control the pump 

speed and pressure.

4. Install an air line filter (B) to remove harmful dirt and 

contaminants from the compressed air supply.

5. Install a bleed-type master air valve (A) to isolate 

the accessories for servicing. See F

IG

. 1. To order a 

bleed-type master air valve, order Part No. 107142.

As an alternative to a bleed-type master air valve, 

installation of an air line female quick-disconnect 

coupler (M) and male quick-disconnect pin fitting 

(L) (see F

IG

. 1) can serve as an air-bleed device. 

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 (11 MPa, 110 

bar) thermal relief kit, order Part No. 240429.

8. Install a suitable fluid hose (P) and dispensing valve 

(J).

Four accessories are required in the system: an air 

shut-off valve’s bleed device, fluid drain valve, 

thermal relief kit, and ground wire. These accessories 

help reduce the risk of serious bodily injury including 

fluid injection, splashing in the eyes or on the skin, 

injury from moving parts if adjusting 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 

unexpectedly, causing serious bodily injury when 

adjusting or repairing the pump. Use either a 

bleed-type master air valve (A) or a quick-disconnect 

coupler with male quick-disconnect pin 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 dispensing valve (J) 

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.

Summary of Contents for Series D

Page 1: ...use in European explosive atmosphere locations Model 238108 Series D 1100 psi 7 6MPa 76 bar Maximum Working Pressure 180 psi 1 2 MPa 12 bar Maximum Air Input Pressure Related Manuals Important Safety...

Page 2: ...Product Life 10 Troubleshooting 11 Repair 12 Air Motor and Throat 12 Disassembly 12 Reassembly 15 Displacement Pump 16 Disassembly 16 Intake Valve 16 Displacement Pump 16 Reassembly 16 Parts 17 Displ...

Page 3: ...equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only Do not alter or modify equipment Alterations or mo...

Page 4: ...quipment only in well ventilated area Eliminate all ignition sources such as cigarettes and portable electric lamps Ground all equipment in the work area Keep work area free of debris including rags a...

Page 5: ...off valve E Air inlet F Ball valve for releasing collected moisture G Pump H Drain valve required J Dispensing valve model 222411 shown K Thermal relief kit required Part No 240429 L Male quick discon...

Page 6: ...ump To order a 1600 psi 11 MPa 110 bar thermal relief kit order Part No 240429 8 Install a suitable fluid hose P and dispensing valve J Four accessories are required in the system an air shut off valv...

Page 7: ...easy operator access to the pump air controls The pump must be mounted in a ver tical position See Technical Specifications page 22 for pump weight information and the Dimensions and Mounting Hole La...

Page 8: ...container and valve 3 Open the pump air regulator C slowly just until the pump is running When the pump is primed and all This equipment stays pressurized until pressure is manually relieved To help p...

Page 9: ...running too fast 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 filled with a compatible...

Page 10: ...roduct s useful life dismantle and recycle it in a responsible manner Perform the Pressure Relief Procedure in your pump manual Drain and dispose of fluids according to applicable regulations Refer to...

Page 11: ...hoses valves etc Clear Damaged air motor Service air motor Exhausted fluid supply Refill and re prime or flush Continuous air exhaust Worn or damaged air motor gasket packing seal etc Service air moto...

Page 12: ...ton washer 113 7 Remove the air motor base from the vise and place the piston rod 29 flats in the vise with the air motor facing up 8 Loosen the lift ring 24 Pull up the lift ring grip the trip rod 31...

Page 13: ...the piston lugs L below the pivot pins 16 on the toggles pry up using the screwdriver handle to compress the springs on the toggle assembly M up and away from the piston lugs and remove the parts FIG...

Page 14: ...Repair 14 308608L FIG 4 Air Motor and Throat...

Page 15: ...G 4 NOTE Adjust the distance between the inlet valve poppets and the piston seat by turning the top valve nuts 21 8 Hand tighten the bottom valve nuts 21 securely 9 Align the holes in the valve nuts 2...

Page 16: ...e page 8 3 Disconnect the hoses remove the pump from its mounting and clamp the air motor base 28 in a vise horizontally by closing the vise jaws on the flange Intake Valve Refer to FIG 5 for the foll...

Page 17: ...chase separately Ref Part Description Qty 10 113345 SEAL u cup shown on page 18 1 103 101190 BALL piston metallic 1 104 101178 BALL sst 1 105 113347 PACKING o ring 1 107 113346 PACKING u cup 1 108 112...

Page 18: ...Parts 18 308608L Air Motor...

Page 19: ...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 24 190929 RING lift 1 25 167585 SP...

Page 20: ...vertical scale on left side of the chart to read air consumption Test Conditions Pump tested with AW 32 oil at 75 F 24 C To find Fluid Outlet Pressure psi bar at a specific fluid flow gpm lpm and ope...

Page 21: ...Dimensions 308608L 21 Dimensions Model 238108 Pump Series D Mounting Hole Layout...

Page 22: ...4 5 per gallon 3 8 per liter Maximum recommended pump speed 78 cycles min 6 gpm 23 l min Recommended speed for optimum pump life 15 to 25 cycles per min Wetted Parts Piston seals polyurethane with nit...

Page 23: ...California Proposition 65 308608L 23 California Proposition 65 CALIFORNIA RESIDENTS WARNING Cancer and reproductive harm www P65warnings ca gov...

Page 24: ...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 WARR...

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