Graco BLUE DEVIL 260000 Operation manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001
311304 rev.C
Instructions - Parts List
Fuel Transfer Pump
For pumping gasoline, diesel fuel, and kerosene. Do not use to pump other fluids
including water.
Models 260000 through 260017, 260019 and 260024,
10 gpm (38 lpm), 12 VDC (CSA C/US listed motor)
Models 260020 and 260021, 10 gpm (38 lpm), 24 VDC
Models 260022 and 260023, 12 gpm (45 lpm), 230 VAC
Models 260025 through 260028, 12 gpm (45 lpm), 115 VAC
10 psi (0.07 MPa, 0.7 bar) Maximum Working Pressure
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Mounting Pump . . . . . . . . . . . . . . . . . . . . . . . . . .5
Mounting Hose and Nozzle . . . . . . . . . . . . . . . . .5
Electrical Installation 12 VDC and 24 VDC . . . . . 5
Electrical Installation 115 VAC and 230 VAC . . . . 6
Priming Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Performance Chart . . . . . . . . . . . . . . . . . . . . . . . 13
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 14
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 14
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
CSA mark applies only to 12 VDC motors
for Class I, Div I, Group D Hazardous
Locations

Models
2311304C
Models
Part No. Hose Nozzle
12 VDC, 10 gpm (38 lpm), 12.5 amps
260000 260069 - 12 ft (3.66 m) grounded 260079 - manual, leaded/diesel
260001 260069 - 12 ft (3.66 m) grounded 260082 - automatic, regular
260002 260069 - 12 ft (3.66 m) grounded 260078 - manual, unleaded
260003 260069 - 12 ft (3.66 m) grounded 260083 - automatic, unleaded
260004 260526 - 4 ft (1.22 m) UL listed assembly
260523 - 8 ft (2.44 m) UL listed assembly 260078 - manual, unleaded
260005 260525 - 5 ft (1.52 m) UL listed assembly 260078 - manual, unleaded
260006 260525 - 5 ft (1.52 m) UL listed assembly 260078 - manual, unleaded
260007 260524 - 6 ft (1.83 m) UL listed assembly 260078 - manual, unleaded
260008 260524 - 6 ft (1.83 m) UL listed assembly 260078 - manual, unleaded
260009 260525 - 5 ft (1.52 m) UL listed assembly 260078 - manual, unleaded
260010 260522 - 10 ft (3.05 m) UL listed assembly 260078 - manual, unleaded
260011 260525 - 5 ft (1.52 m) UL listed assembly 260078 - manual, unleaded
260012 260523 - 8 ft (2.44 m) UL listed assembly 260078 - manual, unleaded
260013 260525 - 5 ft (1.52 m) UL listed assembly 260078 - manual, unleaded
260014 260525 - 5 ft (1.52 m) UL listed assembly 260078 - manual, unleaded
260015 260523 - 8 ft (2.44 m) UL listed assembly 260078 - manual, unleaded
260016 270521 - 12 ft (3.66 m) UL listed assembly
260525 - 5 ft (1.52 m) UL listed,assembly 260078 - manual, unleaded
260017 260525 - 5 ft (1.52 m) UL listed assembly 260078 - manual, unleaded
260019 None None
260024 None None
24 VDC, 10 gpm (38 lpm), 7 amps
260020 260069 - 12 ft (3.66 m) grounded 260079 - manual, leaded/diesel
260021 260069 - 12 ft (3.66 m) grounded 260082 - automatic, regular
230 VAC, 12 gpm (45 lpm), 1 amps
260022 260069 - 12 ft (3.66 m) grounded 260078 - manual, unleaded
260023 260069 - 12 ft (3.66 m) grounded 260083 - automatic, unleaded
115 VAC, 12 gpm (45 lpm), 2 amps
260025 260069 - 12 ft (3.66 m) grounded 260079 - manual, leaded/diesel
260026 260069 - 12 ft (3.66 m) grounded 260082 - automatic, regular
260027 260069 - 12 ft (3.66 m) grounded 260078 - manual, unleaded
260028 260069 - 12 ft (3.66 m) grounded 260083 - automatic, unleaded

Warnings
311304C 3
Warnings
The following general warnings are for the setup, use, grounding, maintenance, and repair of this equipment. Addi-
tional, more specific warnings may be found throughout the body of this manual where applicable. Symbols appear-
ing in the body of the manual refer to these general warnings. When these symbols appear throughout the manual,
refer back to these pages for a description of the specific hazard.
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.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
• Follow Pressure Relief Procedure in this manual, when you stop dispensing and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

Warnings
4311304C
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
component. 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 forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco
replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your Graco 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.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
WARNING

Installation
311304C 5
Installation
When unpacking pump, check for shipping damage.
Report any shipping damage to delivering carrier imme-
diately.
Mounting Pump
1. Apply fuel compatible sealant to large thread on
bung adapter (9) (2 in. x 1-1/2 in. reducer fitting).
Install bung adapter on fuel tank.
2. Assemble suction tube sections by applying PVC
cement (supplied with your pump) to the inside
diameter of the PVC couplers. Make sure PVC
cement is applied to the complete inside diameter
and slide the pipe sections into the coupler with a
twisting motion.
3. Cut the suction tube so that it is 2 in. (55 mm) from
the bottom of the tank when installed in the tank.
4. Insert inlet gasket (7f) into union nut (1k). Apply a
fuel compatible sealant to the threads on the suction
tube assembly (5c) and screw the suction tube into
the pump inlet (1j).
5. Insert suction tube attached to pump through bung
adapter (9) into tank. Position pump as desired and
tighten union nut (1k) on bung adapter (9).
Mounting Hose and Nozzle
1. Apply fuel compatible sealant to male threads on
the street elbow fitting (1e) and screw fitting into the
3/4 in. npt outlet port on the top of pump. Do not
over tighten.
2. Apply fuel compatible sealant to threads on both
ends of the hose assembly. Screw one end of hose
into the female thread on the fitting (1e) and tighten.
3. Screw nozzle onto the other end of hose and
tighten.
Electrical Installation
12 VDC and 24 VDC
To install wiring for a negative ground system:
1. Ensure pump switch is OFF.
2. To remove electrical cover (2a), remove four bolts
(2c).
3. Strip 3 in. (76 mm) of outside insulation from power
cable (6c) from end opposite of fuse.
4. Strip 3/8 in. (10 mm) of insulation from red and black
wires.
5. Slide strain relief (6b) over end of power cable (6c)
on the end just stripped. Male thread of strain relief
should be toward stripped end.
6. Insert power cable through conduit thread in electri-
cal cover (2a). Connect wires from power cable to
wires from the motor using wire nuts (2e): red to red
and black to black.
7. Screw strain relief (6b) into electrical cover (2a).
CAUTION
Do not use a curb pump automatic shut-off nozzle
with this pump. Use of a curb pump automatic nozzle
may cause priming problems, reduced output flow,
and motor overheating. If an automatic shut-off nozzle
is required, use Graco part number 260082 (regular)
or 260083 (unleaded) or Catlow, Inc. part number
NCLF-1 (regular) or NCNLF-1 (unleaded).
CAUTION
• Ensure tank being used is clean and free of welding
slag.
• Ensure the tank has a vent to allow air into the tank
as the fuel is being pumped out. Failure to vent tank
will cause priming problems.
For tanks deeper than 36 in. (914 mm) you will
need a standard 1 in. (25 mm) pipe with 1 in. npt
threads on one end. Suction tubes longer than 60
in. (1.52 m) require a foot valve (Graco Part No.
260217) at the bottom of the tube to prevent loss of
prime.
Power cable can be cut to shorter length if 18 feet
(5.5 m) is not required. Cut to proper length and
proceed with steps 3 and 4.

Installation
6311304C
8. Position power cable (6c) so the large diameter of
power cable extends through strain relief (6b).
9. Tighten nut on strain relief to form a seal around the
power cable.
10. Reinstall electrical cover (2a) on the pump.
11. Remove 1/2 in. (13 mm) of insulation from wires on
the fuse holder end of the power cable.
12. Attach battery clamps (6a) with red sleeve to red
wire and black sleeve to black wire. Wire must be
crimped to the battery clamp firmly to get a good
electrical connection.
13. Connect red wire with fuse holder inline to positive
battery terminal. Connect black wire to negative bat-
tery terminal.
Electrical Installation
115 VAC and 230 VAC
1. Ensure pump switch is OFF and electrical power is
disconnected.
2. Install conduit and user-supplied power cord to
pump.
3. Strip 3 in. (76 mm) from power cord jacket and 1/2
in. (13 mm) from individual conductor insulation.
4. To remove electrical cover (2a), remove four bolts
(2c).
5. Remove 1/2 in. (13 mm) of insulation from power
wires inside pump electrical terminal cavity.
6. Insert electrical power wire through conduit opening
in back of pump.
7. Using wire nuts (2e), connect wires: green to green,
white to white, and black to black.
8. Replace electrical cover.
Priming Pump
1. All pump models will prime with no fluid in the
pumping chamber to a height of 5 ft (1.52 m). If
pump fails to prime, remove hose from street elbow-
fitting on pump outlet and pour 8 oz (0.24 liter) of
motor oil into the pump outlet port.
2. If suction height is too great, the pump may lose its
prime if the nozzle is opened with the pump turned
off.
3. To hold fluid in the suction tube, a check valve
(Graco Part No. 260217) may be required on the
bottom of tanks with a suction height over 5 ft (1.52
m).
4. The tank must be vented or the pump may not prime
or may lose its prime due to a vacuum in the tank.
On 115 VAC and 230 VAC pumps, electrical connec-
tions must be made by a licensed electrician per
requirements of local, state, and national codes
regarding class 1, group D installations. Only rigid
conduit with threaded connections should be used.
Conduit opening in pump must be sealed with
waterproof, fuel-resistant sealant. Failure to comply
with this warning could result in injury from electrical
shock.

Operation
311304C 7
Operation
On/Off switch lever (8d) is located under nozzle holder.
Remove nozzle before turning pump on.
1. Move switch lever (8d) on.
2. Insert nozzle into tank and actuate nozzle lever to
dispense fuel.
3. Immediately after fueling turn switch lever (8d) off.
Maintenance
1. Clean inlet strainer (3b) after every 50 hours of
operation.
2. To remove inlet strainer (3b), remove four screws
(3c) and strainer cover (3a). Remove and clean
strainer.
3. If strainer is excessively dirty, clean tank to protect
pump and the equipment being fueled.
4. After cleaning strainer, replace strainer and cover.
Make sure cover seal (3d/7e) is in place.
Before servicing, turn pump off and open the
nozzle to relieve pressure.
CAUTION
Do not operate pump dry. Do not run pump for more
than 5 minutes with nozzle closed. Do not operate
pump for more than 30 minutes continuously in 1 hour.

Troubleshooting
8311304C
Troubleshooting
Problem Cause Solution
Motor runs but pump will not prime. Motor rotation wrong. (12 VDC and
24 VDC units only.)
Check wiring instructions for possible
problems.
Missing relief valve o-ring seal
(4c/7a).
Remove gear cover (1b) inspect seal
(4c/7a), replace if missing or
damaged.
Sheared drive key (1g/7c). Remove cover (1b) and inspect key
(1g/7c/10b), replace if worn or
sheared.
Dirt under relief poppet (4a) or seal
(4c/7a).
Remove cover (1b) and inspect,
clean or replace if damaged.
Strainer seal (3d/7e) leaking. Inspect and replace if damaged.
Suction height too high to prime. See Priming Pump, page 6.
Worn or damaged gears. Remove cover (1b) and inspect
gears. Replace if worn or damaged.
Fuel level low. Refill tank.
Cover seal (1f/7b/10c) damaged. Replace if worn or damaged.
Inlet strainer (3b) clogged. Remove and clean or replace.
Air leak in suction tube. Inspect all joints in suction tube,
make sure all joints have sealant
applied.
Air lock in system. This may occur if filter or meter or
automatic shut-off nozzle is used. If
this occurs, fill pump and meter with
fuel through top of pump.
Motor does not run at proper speed. Check electric connections. Check
supply voltage for proper voltage
level.
Unit pumps but output flow is low. Clogged inlet strainer (3b). Clean or replace.
Air leak in suction tube. Check to make sure all joints in suc-
tion tube are sealed.
Suction tube too close to tank
bottom.
Suction tube must have a 2 in.
(51 mm) minimum clearance.
Tank empty. Refill tank.
Tank not vented. Tank must be vented to atmosphere.
Worn or damaged gears. Remove cover (1b) and inspect
gears. Replace if worn or damaged.
Damaged motor. Replace motor.
Clogged suction tube, hose, or
nozzle.
Inspect and clean.

Troubleshooting
311304C 9
Motor stalls when nozzle is closed. Bypass relief valve (4a) stuck. Inspect relief valve, making sure
poppet is free. Replace if damaged.
Low supply voltage. Check supply voltage.
Gears (1c/10a) damaged and
binding.
Inspect gears. Gears should turn
freely. Replace if damaged.
Faulty motor. Replace motor.
Fuel leaking in motor mount. Faulty or damaged motor shaft seal
(1h/7d).
Replace shaft seal
Operating pump extended time with
nozzle closed.
Do not exceed 5 minutes of operation
with nozzle closed.
Motor shaft worn. Replace motor if shaft has groove
worn in seal area.
Motor overheating. Gears (1c/10a) binding. Check to make sure gears turn freely
on shaft.
Operating pump extended time with
nozzle closed.
Do not exceed 5 minutes of operation
with nozzle closed.
Clogged inlet strainer (3b). Clean or replace, see Maintenance,
page 7.
Clogged suction tube, hose, or
nozzle.
Inspect and clean if required.
Operating pump more than 30 min-
utes continuous duty.
Limit operation to 30 minutes per
hour.
Switch will not turn pump on. Blown fuse. Replace fuse. 20 amp automotive
fuse (Littelfuse ATO 257020 or
Bussman ATC-20).
Electrical problem. Check that supply voltage is proper
and getting to pump.
Defective switch (8e). Check and replace if defective.
Mechanical problem. Check switch actuator cam (8c). Cam
should be actuating the switch (8e).
Damaged or defective motor. Check motor, replace if damaged or
defective.
Problem Cause Solution

Parts Drawing
10 311304C
Parts Drawing
3a 3c
3d/7e
1a
8e
8b
8f
8g
1i
1f/7b/10c
1g/7c/10b
2e
2f
3b
1b
1c/ 10a
1d
4b
4a
2h
2i
8c
8a
8d
4c/
9
7f 1k 1h/7d
2g
2c
2b
2d
5c
5a
2a
2c
6b
6c
6a
Models 260000 through 260017, 260019,
and 260024, 12 VDC
Models 260020 and 260021, 24 VDC
Models 260022 and 260023, 230 VAC
Models 260025 through 260028, 115 VAC
1j
260450
260451
260452
260453
260457
260454
260456
260459
260458
260433
7a
Packing Kit 260434 includes items 7a-7f
which are also included in other kits.
260300
5a
5b
253723
253724
253719
253720
253721
253722
253718