Graco Fast-Ball 222103 User manual

307906ZAA
EN
Instructions
1:1 Ratio
Fast-Ball™Pumps
For dispensing non-abrasive oils and lubricants only.
Model No. 222051, Series E
Universal Pump
Model No. 222103, Series E
55 Gallon Drum, Bung-Mount Pump
Model No. 222104, Series E
275 Gallon Tank, Bung-Mount Pump
Model No. 685438, Series E
Universal Pump, PTFE Cup
180 psi (1.2MPa, 12.4 bar) Maximum Air and Fluid
Working Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
Model 222051
Models 222103 and
222104

Warnings
2307906ZAA
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation 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.
• Ground all equipment in the work area.
• 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.
• 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
307906ZAA 3
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 Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifica-
tions in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete infor-
mation about your material, request Safety Data Sheets (SDSs) 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 manufac-
turer’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 Safety Data Sheets (SDSs) to know the specific hazards of the fluids you are using.
• Route exhaust away from work area. If diaphragm ruptures, fluid may be exhausted into the air.
• 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. 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
4307906ZAA
Installation
Typical Installation
Install the accessories in order shown in the typical installation in FIG. 1. The 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 distributor for assis-
tance in designing a system to suit your needs.
NOTE: Blow out all lines with compressed air before you connect the pumps.
KEY
A Air shutoff valve
BAirfilter
C Air regulator and gauge
D Air motor lubricator
E Bleed-type master air valve (required, Part No. 110223)
F Air and fluid hose kits
G Ground wire (required Part No. 222011)
H Fluid shutoff valve
J Wall bracket
K Universal pump (Model 222051)
L Suction kit
M 55 gallon drum bung-mount pump (Model 222103)
N Fluid drain valve (required Part No. 210658)
P Air inlet
Q Ball valve (fore releasing collected moisture)
R Thermal relief kit (required for permanent installations,
Part No. 237601)
28 Bung adapter
NOTICE
Always mount the pump firmly to a wall bracket or a
bung on a drum. Never operate pump while it is not
mounted. Such use could damage the pump and fit-
tings.
NOTICE
Do not hang the air accessories directly on the air
inlet (P). The fittings are not strong enough to support
the accessories and may break. Provide a bracket on
which to mount the accessories.
FIG. 1

Installation
307906ZAA 5
Grounding
Proper grounding is an essential part of maintaining a
safe system.
Pump: use ground wire and clamp (supplied) as shown
in FIG. 2.
Air compressor: follow manufacturer’s
recommendations.
Object being dispensed to: follow local code.
Fluid supply container: follow local code.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of thedispense
valve firmly to the side of a grounded metal container,
then trigger the valve.
To ground the pump, remove the ground screw (Z) and
insert through eye of the ring terminal at the end of the
ground wire (Y). Fasten the ground screw back onto the
pump and tighten securely. Connect the other end of the
wire to a true earth ground. To order a ground wire and
clamp, order Part No. 222011.
System Accessories
Refer to FIG. 1, page 4.
Required Accessories
•Bleed-type master air valve (E): required in your
system to relieve 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 injury if you are adjusting or repairing the
pump. As an alternative, use a quick-disconnect
couple fitting. Install them near the pump air inlet
within easy reach from the pump.
•Fluid drain valve (N): assists in relieving fluid
pressure in the displacement pump, hoses and
dispensing valve. Triggering the valve to relieve
pressure may not be sufficient.
•Grounding wire (G): reduces the risk of static
sparking.
Additionally, for permanent installations, a thermal relief
kit is required.
•Thermal Relief Kit (R): assists in relieving pressure
in the pump, hose and dispensing valve due to heat
expansion.
Other Accessories
•Extension Tubes: Pump models 222103 and
222104 have extension tubes. An extension tube
may be added to the Universal pump for use in sub-
merged applications. To install, apply PTFE tape to
the female threads at the top of the tube. Thread the
tube tightly into the intake housing of the Universal
pump. Also install a bung adapter. To order a stan-
dard 2-inch bung adapter, order Part No. 222308.
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. 2
Three accessories are required in your system to help
reduce the risk of serious bodily injury, including fluid
injection, splashing of fluid in eyes or on skin, injury
from moving parts when you are adjusting or repairing
the pump, and explosion from static sparking.

Installation
6307906ZAA
•Air and Fluid Hose Kits (F): An 18-inch kit for wall
mounted pumps and a 6-foot kit for drum-mounted
pumps are available. Use a minimum 1/4-inch ID air
supply hose between the pump air inlet and the air
accessories. To order a kit with a 1/4-inch air hose,
1/4-inch swivel elbow, 3/4-inch fluid hose, and
3/4-inch swivel elbow, order one of the following kits:
- 222118 - 18-inch (0.4 m) hose kit for wall
mounted pump.
- 222119 - 6-foot (1.8 m) hose kit for drum
mounted pump.
•Wall Bracket (J): The wall bracket is used for
mounting the Universal pump. The wall bracket is
sized to fit any Graco pump designed to use a
2-inch bung adapter. Order Part No. 203987.
•Runaway Valve: Install a pump runaway valve to
shut off the air to the pump when the pump acceler-
ates beyond the pre-adjusted setting. A pump that is
in a runaway condition can be seriously damaged.
•Bleed-Type Master Air Valve (E): Install a
bleed-type master air valve to relieve air trapped
between it and the motor when the valve is closed.
A 300 psi (2.1 Mpa, 21 bar), 1/4-inch npt(f) bleed
type master air valve is available from Graco. Order
Part No. 110223.
•Suction Kit (L): The suction kit is for use with the
wall-mounted Universal pump. It includes a drum
tube and hose. Order Part No. 213099.
•Air Motor Lubricator (D): The air motor lubricator
provides automatic air motor lubrication. A 250 psi
(1.7 MPa, 17.4 bar), 1/4-inch npt(f) air motor lubrica-
tor is available from Graco. Order Part No. 110148.
•Air Regulator and Gauge (C): The air regulator
and gauge are used to control air pressure and
pump speed. A 0-200 psi (0-1.4 MPa, 0-14 bar) reg-
ulated pressure range 300 psi (2.1 MPa, 21 bar)
maximum, 1/4-inch npt(f) air regulator and gauge
are available from Graco. Order Part No. 110147.
•Air Filter (B): The air filter removes harmful dirt and
moisture from the compressed air supply. A 300 psi
(2.1 MPa, 21 bar), 1/4-inch npt(f) air filter (20
micron) is available from Graco. Order Part No.
110146.
•Air and Fluid Shutoff Valves (A and H): Install air
shutoff valve (A) and fluid shutoff valve (H) as
shown in FIG. 1, page 4, to isolate the pump while
you are servicing it.
•Quick-Disconnect Coupler and Nipple: The
quick-disconnect coupler and nipple (not shown) are
used to quickly disconnect the air supply. Attach the
coupler (Part No. 208536) to the pump air inlet
hose, and install the nipple (Part No. 169970) to the
pump air inlet (P).
•Thermal Relief Kit: Install the thermal relief kit on
the dispensing valve side of the pump to assist in
relieving pressure in the pump, hose and dispensing
valve due to heat expansion. A 600 psi (4.2 MPa, 41
bar) thermal relief kit is available from Graco. Order
Part No. 237601.
NOTICE
Never allow the pump to run dry of the fluid being
pumped. A dry pump quickly accelerates to a high
speed, possibly damaging itself, and it may get very
hot.

Operation
307906ZAA 7
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Turn off power supply to the pump.
2. Close the bleed-type master air valve (E) (required
in your system).
3. Hold a metal part of the dispensing valve firmly to a
grounded metal container and trigger the dispense
valve to relieve pressure.
If you suspect that the nozzle or hose is completely
clogged, or that pressure has not been fully relieved
after you have followed the steps (above), wrap a rag
around the hose end coupling and relieve pressure
gradually by very slowly partially loosening the fitting.
Then loosen it completely. Then clear the obstruction.
Starting the Pump
1. Turn the air regulator (C) to the minimum setting.
2. Direct the outlet hose into a waste container.
3. Open the bleed-type master air valve (E).
4. Slowly adjust the air regulator (C) until the pump is
running smoothly and all air has been pumped out
of the pump and hoses. If the pump contains sol-
vent, be sure to pump it all into the waste container.
5. Use the air regulator (C) to control the pump speed
and cycle rate. Always use the lowest pressure
needed to obtain the desired results. This results in
optimum system efficiency and reduces pump wear.
NOTE:
• The pump only takes a few strokes to prime. How-
ever, in a large system, it may take several minutes
to completely prime the fluid lines.
• To prevent air from being sucked into the pump and
fluid lines, if the supply container runs dry, use a
low-level cutoff valve at the pump intake. A 1-1/2
inch npt(f) thread connection low level cutoff valve is
available from Graco. Order Part No. 203688.
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 dispensing and before
cleaning, checking, or servicing the equipment.
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.
NOTICE
Never allow the pump to run dry of the fluid being
pumped. A dry pump quickly accelerates to a high
speed, possibly damaging itself, and it may get very
hot.

Troubleshooting
8307906ZAA
Troubleshooting
Problem Cause Solution
Pump does not run. There is no fluid demand. In a closed-end system, the pump
runs only when there is demand for
fluid.
Air supply is insufficient. Check air supply. Increase air
pressure or volume.
Fluid outlet line or intake valve is
clogged.
Relieve the pressure, page 7.
Check and clear obstacles.
Air motor parts are worn or
damaged.
Check the piston o-rings (15a*,
15b*) and exhaust plate (15c*) for
swelling. Replace if necessary. See
Service instructions beginning on
page 9.
Check the piston assembly (15). Be
sure its screws are properly torqued
(10 to 14 in-lb [1.3 to 1.6 N•m]) and
that the assembly is hand-tightened
onto the piston rod.
Check the springs (8, 17) for wear or
damage and replace as needed.
Pump speeds up or runs erratically. Material viscosity is too high. Reduce viscosity. Reduce pump
speed when running viscous
materials.
Pump throat packings, piston or
piston packings, or intake valve is
worn.
Relieve the pressure, page 7.
Check and repair. See Service
instructions beginning on page 9.
Pump slows down or runs erratically. Air motor is icing. Shut off pump and allow to warm up.
Run pump at a lower air pressure.
Pump runs, but output is low on up
or down stroke.
Pump piston and/or intake valve is
worn.
Relieve the pressure, page 7.
Check and repair. See Service
instructions beginning on page 9.
Pump runs, but output is low on both
strokes.
Air supply is insufficient. Check air supply. Increase air
pressure or volume.
Fluid outlet line, intake valve, or
dispense valve is clogged.
Relieve the pressure, page 7.
Check and repair.

Service
307906ZAA 9
Service
NOTE:
• Clean and inspect all parts for wear or damage
when disassembled. Replace parts as needed.
Fast-Ball Repair Kit 247431 is available. For best
results, use all the parts in the kit.
• In the following instructions, the parts included in the
kit are marked with an asterisk in the text, figures,
Parts Drawing and Parts List.
• Cup Packing, Part No. 162871 and Packing O-Ring
Part No. 154662 are required for servicing pump
Model 685438.
• Piston Cup, Part No. 116152 (included in Fast-Ball
Repair Kit 247431) can be discarded when servicing
pump 685438.
Intake Valve
See the Parts Drawing, page 12.
1. Relieve the pressure, page 7.
2. Unscrew the valve housing (2). Remove the o-ring
(22*), ball (23), and retainer (20).
3. Inspect the parts for wear or damage. If the ball in
nicked, replace it. Apply liquid sealant to the male
threads and reassemble.
Air Motor
See FIG. 3, page 11.
1. Relieve the pressure, page 7.
2. Remove the air hose and fluid hoses.
3. Place the air motor base (5) in a vise.
4. Remove the air cap (2). Gently pry the coils of the
spring (17) to remove the spring. Check the spring
for wear or damage and replace if needed.
5. Use a strap wrench to unscrew the air cylinder (4)
from the base (5).
6. Unscrew the air piston assembly (15) from the pis-
ton rod (10). Use pliers on the air exhaust plate
(15c*) and a wrench on the piston rod. See the Pis-
ton Detail in FIG. 3, page 11.
NOTE: Old, cured thread sealant on the piston rod
threads make it necessary to use tools to remove the air
piston assembly from the piston rod. Do not use these
tools when you screw the air piston assembly onto
the piston rod.
7. Disassemble the air piston assembly (15). See the
Piston Detail in FIG. 3, page 11. Clean all parts and
inspect them for wear or damage. If any valve plate
spacers are damaged, replace all three in order to
maintain the correct clearance between the valve
plates and seals.
8. Check the spring (8) for wear or damage and
replace as needed.
9. Apply sealant such as Loctite®green to the threads
of the screws. Assemble the parts as shown in the
Piston Detail in FIG. 3, page 11. Torque the screws
to 10 to 14 in.-lbs (1.3 to 1.6 N•m).
To reduce the risk of injury from trapped air pressure
when servicing the air motor, always remove the air
cap (2) from the air cylinder (4) before removing the
air cylinder from the base (5).

Service
10 307906ZAA
Pump Lower Repair
See FIG. 3, page 11.
1. Use a strap wrench on the fluid cylinder (24) to
unscrew it from the motor base (5). Pull down on the
piston rod (10) until you have access to the fluid pis-
ton assembly (19).
2. Remove the fluid piston (19) from the piston rod (10)
by holding the piston rod stationary while turning the
fluid piston out. Be careful to not drop the check ball
(18).
3. Use a strap wrench to unscrew the air cylinder (4)
from the pump base (5). Carefully lift the air cylinder
off the air valve.
4. Carefully remove the piston rod (10) from the pump
base (5) by pulling upward on the air valve (15).
5. Remove the shaft seal (16*), wiper ring (11*), and
the gasket (9*) from the top of the motor base (5).
6. Reach inside the opening of the air motor base (5)
to remove the o-ring (26*). Carefully remove the
wiper ring (11*) and the seal (12*) from the motor
base.
7. Lubricate and install the new shaft seal (16*), upper
wiper ring (11*), gasket (9*), seal (12*), lower wiper
ring (11*), and o-ring (26*) into the base (5).
8.
For pumps 222051, 222103, or 222104
a. Remove the washer (19c) and piston seal
(19b*) from the fluid piston (19a).
b. Lubricate the new piston seal (19b*) and install
it on the fluid piston (19a).
c. Install washer (19c) onto fluid piston (19a).
For pump 685438
a. Remove the washer (19c), piston seal (19b),
and piston spacer (19d) from the fluid piston
b. Remove the spacer o-ring (19e) from inside the
piston spacer (19d)
c. Lubricate and install the new spacer o-ring
(19e) inside the piston spacer (19d)
d. Carefully slide the piston spacer (19d) and
o-ring (19e) assembly onto the fluid piston
(19a).
e. Lubricate the new piston seal (19b) and install it
on the fluid piston (19a).
f. Install washer (19c) onto fluid piston (19a).
For all pumps
9. Install the air motor rod assembly by inserting it
down through the pump base (5) from the top.
10. Carefully install air cylinder (4) onto the base (5),
making sure the gasket (9*) is in place. Screw the
cylinder and base together until hand tight.
11. Place the check ball (18) on the fluid piston (19)
12. Apply thread sealant to the threads of the fluid pis-
ton (19), screw the fluid piston onto the piston rod
(10), and tighten to proper torque. For 222051,
222103, and 222104 the proper torque is 23 ft-lbs
(31.2 N-m). For 685438, the proper torque is 50
ft-lbs (68 N-m).
13. Heavily lubricate the top inside diameter of the fluid
cylinder (24) and the outside threads. Carefully
guide the fluid piston assembly into the fluid cylin-
der. Push the fluid cylinder up, and screw it into the
pump base. Use strap wrench on the knurled part of
the intake valve housing (21) to tighten the fluid cyl-
inder and the intake valve to the pump base.
Do not cycle pump with any parts disassembled.