Graco Fire-Ball 300 D Series User manual

308883S
EN
Instructions
50:1 Fire-Ball®300
Pump
For pumping non-corrosive and non-abrasive greases and lubricants only.For
professional use only.
Model No. 239877, Series D
pail length
Model No. 239887, Series D
120 lb drum length
Model No. 239888, Series D
400 lb drum length
8400 psi (58 MPa, 580 bar) Maximum Working Pressure
140 psi (0.97 MPa, 9.7 bar) Maximum Air Input Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
This product is designed to be used only in pumping
non-corrosive and non-abrasive lubricants and
greases. Any other use can cause unsafe operating
conditions and result in component rupture, fire, or
explosion, which can cause serious injury including
fluid injection.

Warnings
2308883S
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
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 from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• 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.
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.
• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
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.
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

Installation
308883S 3
Installation
Grounding
Pump: Use a ground wire and clamp as shown in FIG.
1.
Fluid hoses: Use only electrically conductive hoses.
Air compressor: Follow manufacturer’s recommenda-
tions.
Fluid supply container: Follow the local code.
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
the 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. To
order a ground wire clamp, order Part. No. 222011.
Key:
A Fluid dispense line
B Pump ground wire (required)
C Air regulator with gauge
D Main air supply line
E Air line filter
F Air line lubricator
G Pump runaway valve
H Follower plate
J Bleed-type master air valve (required)
K Fluid drain valve
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
FIG. 2: Typical Installation
Recommended air line
configuration to reduce
moisture in pump
1/2 in.
B
C
D
E
F
G
H
J
A
J
K

Installation
4308883S
Mounting
1. Plan the mounting layout for easy operator access
to the pump air controls, sufficient room to change
drums and a secure mounting platform.
2. If using a follow plate (H), remove the drum cover.
Scoop the material to the center of the drum. Place
the plate on the material. Guide the pump foot valve
through the plate.
3. Mount the pump to the drum cover or other suitable
mounting device.
4. For ease in changing drums, install a pump eleva-
tor.
Air and Fluid Line Accessories
Refer to FIG. 2 for the following instructions.
Three accessories are required in your system: an air
shut-off valve/air bleed device, fluid drain valve, and
ground wire. These accessories help reduce the risk of
serious bodily injury, including fluid injection, splashing
in the yes or on the skin, injury from moving parts if
you are adjusting or repair the pump, and explosion
from static sparking.
• The air bleed device relieves air trapped between it
and air motor after the air supply is shut off.
Trapped air can cause the motor to cycle
unexpectedly, causing serious injury if you are
adjusting or repairing the pump. Use a bleed-type
master air valve (J). Install them near the pump air
inlet within easy reach from the pump.
• The fluid drain (K) assists in relieve fluid pressure
in the displacement pump, hoses, and dispensing
valve. Triggering the valve to relieve pressure may
not be sufficient.
• The ground wire (B) reduces the risk of static
sparking.
NOTE: Install the air line accessories in the order shown
in Fig.
1. Install a pump runaway valve (G) to shut off the air
to the pump if the pump accelerates beyond the
pre-adjusted setting. A pump that runs too fast can
be seriously damaged.
2. Install an air line lubricator (F) for automatic air
motor lubrication.
3. Install a bleed-type master air valve (J) to relieve air
trapped between the valve and the motor.
4. Install the air regulator (C) to control pump speed
and pressure.
5. Install an air line filter (E) to remove harmful dirt and
contaminants from the compressed air supply.
6. Install a second bleed-type master air valve (J)
upstream from all other accessories, to isolate the
accessories for servicing.
Mount the pump securely so that it cannot move
around during operation. Failure to do so could result
in personal injury or equipment damage.
NOTICE
Do not hand the air accessories directly on the air
inlet. The fittings are not strong enough to support the
accessories and may cause one or more to break.
Provides a bracket on which to mount the accesso-
ries.

Operation
308883S 5
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Close the pump air regulator and bleed-type master
air valve (required in the system).
2. Hold a metal part of the dispensing valve firmly to a
grounded metal waste container and trigger the
valve to relieve the fluid pressure.
Start Up
1. If there are multiple pumps on the air line, close the
air regulators and bleed-type master air valves to all
but one pump. If there is only one pump, close its air
regulator and bleed-type master air valve.
2. Open the master air valve from the compressor.
3. Open the dispensing valve into the grounded metal
waste container, making firm metal-to-metal contact
between the container and valve. Open the
bleed-type master air valve and open the pump air
regulator slowly, just until the pump is running.
When the pump is primed and all air has been
pushed out of the lines, close the dispense valve.
4. If there is more than one pump, repeat this proce-
dure for each pump.
NOTE: When the pump is, and with sufficient air sup-
plied, the pump starts when the dispensing valve is
opened and shuts off when closed.
5. Set the air pressure to each pump at the lowest
pressure needed to get the desired results.
6. Never allow the pump to run dry of the material
being pumped.
NOTE: A pump runaway valve (G) can be installed on
the air line to automatically shut off the pump if it starts
to run too fast.
7. Read and follow the instructions supplied with each
components in the system.
8. To shut off the system always follow the Pressure
Relief Procedure.
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
The pump has a rated ratio of 50:1. However, it is
capable of reaching stall pressures equal to 60
times the air input pressure. Calculate the fluid
output pressure using the air regulator reading.
Multiply the air pressure shown on the regulator
gauge by 60. For example:
140 psi air x 60 = 8400 psi fluid output
0.97 MPa air x 60 = 58.2 MPa fluid output
9.7 bar air x 60 = 582 bar fluid output
Regulate air to the pump so that no air line or fluid
line component or accessory is over pressurized.
NOTICE
A dry pump will quickly accelerate to a high speed,
possibly damaging itself. If your pump accelerates
quickly, or is running too fast, stop it immediately and
check the material supply. If the supply container is
empty and air has been pumped into the lines, prime
the pump and lines with material, or flush it and leave
it filled with a compatible solvent. Be sure to eliminate
all air from the material lines.

Repair
6308883S
Repair
Displacement Pump Service
Refer to FIG. 3 for the following instructions.
Be sure you have all necessary parts on hand before
starting. Use all parts in the repair kit for best results.
Displacement Pump Repair Kit 241623 is available.
1. Flush the pump.
2. Relieve the pressure before proceeding, page 5.
3. Disconnect the hoses, remove the pump from its
mounting, and clamp the air motor base (5) in a
vise.
4. Use strap wrench to screw shovel tube (67) off of
pump cylinder (59).
5. Use strap wrench to screw shovel (66) off of shovel
rod (58).
6. se strap wrench on pump cylinder (59) to screw it
out of extension tube (64). Screw tube connector
(63) out of pump cylinder. Remove bearing (61) and
seal (62).
7. Screw the shovel rod (58) out of the piston (52).
Remove the lower ball (56). Screw the piston out of
the extension rod (57). Remove the upper ball (56),
retaining washer (53), and seal (54).
8. Clean all the parts in a compatible solvent and
inspect them for wear or damage. Use all the parts
in the repair kit, and replace other parts as neces-
sary.
9. Generously lubricate all the parts with light
water-resistant grease and reassemble the pump.
NOTE: Torque the shovel tube (67) to the pump cylinder
(59) at 45 to 55 ft-lbs (61 to 75 N.m).
Torque the pump cylinder (59) to the extension tube (64)
at 45 to 55 ft-lbs (61 to 75 N.m).
Torque the shovel rod (58) to the piston (52) at 25 to 30
ft-lbs (34 to 41 N.m).
Torque the piston (52) to the extension rod (57) at 25 to
30 ft-lbs (34 to 41 N.m).
10. If the ground wire was disconnected before servic-
ing, be sure to reconnect it before you operate the
pump.
NOTICE
To avoid damaging the shovel tube, do not use slots
in the tube to tighten or loosen tube.

Repair
308883S 7
FIG. 3
1
3
4
Using nut (63), torque the
pump cylinder (59) to the ex-
tension tube (64) at 45–55 ft-lb
(61–75 N m).
Torque the shovel rod (58)
to the piston (52) at 25–30
ft-lb (34–41 N m).
Torque the piston (52) to the
extension rod (57) at 25–30
ft-lb (34–41 N m).
5
60
64
59
56
52
62
61
63
58
57
53
54 67
66
4
3
1
Caution: Do not use
slots in shovel tube to
tighten or loosen tube.

Repair
8308883S
Air Motor and Throat Service
Refer to FIG. 4 for the following instructions.
Before starting, be sure to have all necessary parts on
hand. Repair kit 206728 is available for the motor.
Two accessory tools should be ordered. Use Padded
Pliers, 207579, to grip the trip rod without damaging its
surface. Use Gauge, 171818, to ensure the proper
clearance between the poppets and seat of the transfer
valve.
1. Flush the pump.
2. Relieve the pressure, see page 5.
3. Disconnect the hoses, remove the pump from its
mounting, and clamp the air motor base (5) in a
vise.
4. Use a strap wrench or pipe wrench on the extension
tube (64) to screw it out of the base (5). See FIG. 4.
5. Pull the extension rod (57) down as far as it will go,
exposing the displacement rod (8).
6. Use a hammer and punch to remove the roll pin (74)
from the displacement rod (8), and unscrew the
extension rod (57) out of the displacement rod.
7. Manually push on the displacement rod (8) to move
the air motor piston (2) up as far as it will go.
Unscrew the cylinder cap nut (29a or 29b). Pull the
nut up. Grip the trip rod (11) with padded pliers, and
screw the nut off the rod. (FIG. 4)
8. Remove the six screws (21) that hold the cylinder
(17) to the base. Carefully pull the cylinder straight
up off the piston (2).
9. Use a screw driver to push down on the trip rod
yoke (22), and snap the toggles down. Remove the
lockwires (31) from the adjusting nut (30) of the
transfer valves. Screw the top nuts off. Screw the
stems (1a) out of the grommets (12) and bottom
nuts. Take the valve poppets (1b) off the stems and
squeeze them firmly to check for cracks. (FIG. 5)
10. Grip the toggle rockers (26) with a pliers. Compress
the springs (27), and swing the toggle assembly (L)
up and away from the piston lugs (M), and remove
the parts. Check to see that the valve actuator (13)
is supported by the spring clips (14), but slides eas-
ily into them. (FIG. 5)
11. Remove the trip rod yoke (22), actuator (13), and
trip rod (11). Check the exhaust valve poppets (16)
for cracks.
NOTE: To remove cracked exhaust valve poppets (16),
stretch them out, and cut them with a sharp knife.
12. Remove one of the air motor plates (18 or 20). Pull
the piston (2) up out of the base (5). Remove the
throat packing nut (38) and throat seal (6).
NOTICE
In step 7, do not damage the plated surface of the trip
rod (11). A damaged trip rod could cause erratic air
motor operation. Use the special padded pliers,
207579, to grasp the rod.
NOTICE
To avoid damaging the cylinder wall, lift the cylinder
straight off of the piston. Never tilt the cylinder while
you are removing it.

Repair
308883S 9
FIG. 4
5
8
57
64
74
2
11
21
17
38
6

Repair
10 308883S
Air Motor and Throat Seals
Reassembly
1. Clean all the parts carefully in a compatible solvent,
and inspect for wear or damage. Use all the repair
kit parts during reassembly, and replace other parts
as needed.
2. Check the polished surfaces of the piston (2), dis-
placement rod (8), and cylinder (17) wall for
scratches or wear. A scored rod causes premature
throat seal wear and leaking.
3. Lubricate all parts with a light, water-resistant
grease.
4. Install the new throat seal (6), lips facing down.
Screw the packing nut (38) into the base (5).
5. Slide the displacement rod (8) down through the
throat, and lower the piston (2) into the base (5). Be
sure the o-rings (9, 10, and 24) are in place. (FIG. 4)
6. Pull the exhaust valve poppets (16) into the value
actuator (13), and clip off the top part shown with
dotted lines in FIG. 5.
7. Install the transfer valve grommets (12), and reas-
semble the valve mechanism. Before you install the
lockwires (31) in the adjusting nuts (30), use the
special gauges, 171818, to adjust the transfer valve
so there is 0.145 inches (3.7 mm) clearance
between the poppets (1b) and the seat when it is
open. Snap the toggles (25) to the up position. (FIG.
5)
8. Reassemble the air motor, and assemble to the dis-
placement pump. Torque the extensions tube (64)
to the base (5) at 45 to 55 ft-lbs (61 to 75 N.m).
Before you install the air motor plate, tighten the
throat packing nut (38) snugly; do not overtighten it.
9. Before you remount the pump, connect an air hose,
and run the pump slowly, at about 40 psi (.028 MPa,
2.8 bar), to see that it operates smoothly.
10. Reconnect the ground wire before regular operation
of the pump.
FIG. 5
1
14
16
31
30
1b
12
1b
2
11 22
M
26 27 25
L2
13 14
11
0.145 in.
(3.7 mm)
2
1b
16 1a
30
12
30
24
Cutaway View
30
3