Graco 205394 Operation manual

306674W
EN
Instructions - Parts List
50:1 Fire-Ball®
425 Pumps
For pumping non-corrosive and non-abrasive greases and lubricants only. For
professional use only.
Model 205394, Series E
Model 205395, Series N
7500 psi (51.7 MPa, 517 bar) Maximum Working
Pressure
150 psi (1.0 MPa, 10 bar) Maximum Air Input Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
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
operating conditions and component rupture, which
can result in fluid injection or other serious injury or
fire or explosion.

Warnings
2306674W
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
WARNING
FIRE AND EXPLOSION HAZARD
When flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be
aware that flammable fumes can ignite or explode. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources, such as cigarettes and portable electric lamps.
• Keep work area free of debris, including rags and spilled or open containers of solvent and gasoline.
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Ground all equipment in the work area.
• Use only grounded hoses.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.

Warnings
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EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system com-
ponent. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is
not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer
WARNING

Installation
4306674W
Installation
Grounding
Pump: Use a ground wire and clamp as shown in FIG. 1.
Air and fluid hoses: Use only electrically conductive
hoses.
Air compressor: Follow manufacturer’s recommenda-
tions.
Dispense valve: Ground through connection to a prop-
erly grounded fluid hose and pump.
Object being dispensed: follow local code.
Solvent pails used when flushing: Follow local code.
Use only conductive metal pails, placed on a grounded
surface. Do not place the pail on a nonconductive sur-
face, such as paper or cardboard, which interrupts
grounding continuity.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the spray
gun/dispense valve firmly to the side of a grounded
metal pail, then trigger the gun/valve.
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 and wire clamp, order Part No. 222011.
Mounting the Pump
• Select a convenient location for the equipment to
ensure easy operator access to the pump air con-
trols, sufficient room to change supply containers,
and a secure mounting platform.
• If you are mounting the pump directly on the supply
tank, position the pump so its intake valve is no
more than 1 inch (25 mm) from the bottom of the
container. Mount the pump to the cover or other suit-
able mounting device.
Typical Installation
Mount the pump to suit the type of installation planned.
Very heavy lubricant may require an inductor plate. See
page 17 for the mounting hole layout and dimensions.
Install the airline accessories in the approximate order
shown in FIG. 2. 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 compressed 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.
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.
FIG. 1
Y
Z
Mount the pump securely so that it cannot move
around during operation. Failure to do so could result
in personal injury or equipment damage.

Installation
306674W 5
Be sure the air hose is properly sized to deliver an ade-
quate supply of air to the motor. Refer to the Technical
Data on page 16.
Connect a dispensing hose to the 3/8 npt(f) pump outlet.
Install an appropriate gun or dispense valve to the hose.
Ground the pump as explained on page 4.
Key:
A Grounded air line
B Bleed-type master air valve
CAirfilter
D Air line oiler
E Air regulator
F Grounded dispensing hose
G Dispensing valve
H Elevator assembly with inductors
J Ground wire
A bleed-type master air valve (B) is required to shut
off an 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.
FIG. 2: Typical Installation
A
B
CD
E
H
J
F
G

Operation
6306674W
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Close the air regulators (E).
2. Close the supply pump’s bleed-type air master valve
(B, required in system).
3. Open the dispensing valve (G) until pressure is fully
relieved.
NOTE: If you suspect that the dispensing valve, exten-
sion, or grease fitting coupler is clogged, or that pres-
sure has not been fully relieved after following the steps
above, VERY SLOWLY loosen the coupler or hose end
coupling and relieve pressure gradually, then loosen
completely and clear the clog.
Startup and Adjustment
Open the bleed-type air master valve (B). Open the dis-
pensing valve (G), and slowly open the air regulator (E)
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.
Use the air regulator (E) to control the pump speed and
fluid pressure. See FIG. 2. Always use the lowest pres-
sure necessary to obtain the desired results.
When you are finished using the pump for the day
always follow the Pressure Relief Procedure.
Maintenance
The accessory air line oiler (D) provides automatic air
motor lubrication. Four daily manual lubrication, discon-
nect the air hose, place about 15 drops of light machine
oil in the air inlet, reconnect the hose, and turn on the air
supply to blow oil into the motor.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.
NOTICE
Never allow the pump to run dry of the fluid being
pumped. A dry pump quickly accelerates to a high
sped 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 the 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.

Troubleshooting
306674W 7
Troubleshooting
1. Follow Pressure Relief Procedure, page 6, before
checking or repairing gun.
2. Check all possible problems and causes before dis-
assembling gun.
* Follow the Pressure Relief Procedure (see page 6), and disconnect the fluid line. If the pump starts when the air is
turned back on, the fluid line, hose, valve, etc. was clogged.
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, valve,
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
Held open or worn intake valve or
piston packings Clear; service
Pump operates, but output low on
upstroke
Held open or worn piston or pack-
ings 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

Service
8306674W
Service
FIG. 3
77
64
68
65
74
59
75
76
70
78
73 1
69
72
79 2
66
80
59
62
61
67
62 68
72
1/4” ROD
71
Ref. 63 (copper gasket) and
Ref. 60 (cotter pin),
see Parts Drawing on page 16.
1
15

Service
306674W 9
Displacement Pump
Before starting:
• To reduce down time, be sure you have all neces-
sary repair parts available. Recommended spare
parts are listed in the parts list on page 15.
• The balls (59) in the intake and piston valves cannot
be reseated on the hardened seats (68).
• Repair Kit 239320 is available. If you have a repair
kit, use all the new parts for the best results.
• Whenever replacing packings, also replace the
glands and bearing.
• When 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 leak-
ing. 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 whenever grease is
mentioned.
Disassembly
1. Flush the pump if possible. Follow the Pressure
Relief Procedure on page 6. Disconnect all air and
fluid hoses.
2. Clamp the motor base in a vise. Unscrew the prim-
ing cylinder (78).
3. Hold the priming tube (72) with a 1/4 in (6 mm)
diameter rod through the holes in the tube. Grip the
flats of the priming position (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 hous-
ing.
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 pis-
ton valve housing (64). Remove the ball and pack-
ings.
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 packings
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 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.
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.

Service
10 306674W
Air Motor and Throat Service
Before starting:
• Be sure to 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.
• Two accessory tools should be used. Padded Pliers,
207579, is used to grip the trip rod without damag-
ing 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 Proce-
dure, page 6.
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 on the piston rod to move the piston
assembly to the top of its stroke. Unscrew the cylin-
der cap nut (31) from the cylinder (32). Pull up on
the cap nut. Grip the trip rod (1) with a padded pli-
ers, 207579, and screw the cap nut off the trip rod.
(FIG. 4)
4. Remove the eight screws (7) holding the cylinder
(32) to the base (56). Carefully pull the cylinder
straight up off the piston. (FIG. 4)
5. Use a screw driver to push down on the trip rod
yoke (14) and snap the toggle assemblies (k) down.
Remove the lockwires (28) from the adjusting nuts
(27) of the transfer valves (M). Screw the top adjust-
ing 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. 5)
6. Grip the toggle rockers (16) with a pliers. Compress
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 sup-
ported by the spring clips (4), but slides easily into
them. (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 and out of the base (56) and
inspect the piston o-ring (20) and the o-ring base
casting.
FIG. 4
32
7
56
36
1
Hold trip rod with
padded pliers
207579, to prevent
damage to rod
31
NOTICE
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.