Graco Fire-Ball 425 E Series Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
50:1 Fire-Ballr425 Pumps
For pumping non–corrosive and non–abrasive
greases and lubricants only.
7500 psi (51.7 MPa, 517 bar) Maximum Working Pressure
150 psi (1.0 MPa, 10 bar) Maximum Air Input Pressure
Model 205394, Series E
Model 205395, Series N
306674U
WARNING
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 operat-
ing conditions and component rupture, which can re-
sult in fluid injection or other serious injury or fire or
explosion.
06306B
Important Safety instructions
Read all warnings and instructions in this manual.
Save these instructions.

2 306674U
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Service 10. . . . . . . . . . . . . . . . . . . .
Air Motor and Throat Service 12. . . . . . . . . . . . . . . . . . . .
Parts Drawing 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 20. . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 20. . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
DDo not alter or modify this equipment.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure stated on the equipment or in the Technical Data
for your equipment. Do not exceed the maximum working pressure of the lowest rated component
in your system.
DUse fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
DHandle hoses carefully. Do not pull on hoses to move equipment.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 66_C (150_F) or below –40_C (–40_F).
DWear hearing protection when operating this equipment.
DDo not move or lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.

306674U 3
WARNING
SKIN INJECTION HAZARD
Fluid from the gun, leaks, or ruptured components can inject fluid into your body and cause extremely
serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also
cause serious injury.
DFluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious
injury. Get immediate surgical treatment.
DDo not point the dispensing valve at anyone or any part of the body.
DDo not put your hand or fingers over the end of the dispensing valve.
DDo not stop or deflect leaks with your hand, body, glove, or rag.
DDo not “blow back” fluid; this is not an air spray system.
DUse only extensions and couplings that are designed for use with your dispensing valve.
DFollow the Pressure Relief Procedure on page 7 before you clean, check, or service the
equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not
repair high pressure couplings; you must replace the entire hose.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
DKeep clear of all moving parts when starting or operating the pump.
DBefore checking or servicing the equipment, follow the Pressure Relief Procedure on page 7 to
prevent the equipment from starting unexpectedly.

4 306674U
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames, or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
DGround the equipment and the object being dispensed to. Refer to Grounding on page 5.
DIf there is any static sparking or you feel an electric shock while using this equipment, stop dis-
pensing immediately. Do not use the equipment until you identify and correct the problem.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being dispensed.
DKeep the dispensing area free of debris, including solvent, rags, and gasoline.
DDo not smoke in the dispensing area.
DDo not turn on or off any light switch in the area while dispensing if fumes are present.
DNever use 1.1.1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents, or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state, and national guidelines.
DAlways wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid and
solvent manufacturer.
DThe air motor exhausts any fluids added to the input air.
DGraco does not manufacture or supply the reactive chemical components that may be used in this
equipment and is not responsible for injury or property loss, damage, expense, or claims (direct or
consequential) that arise from the use of such chemical components.

306674U 5
Installation
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
NOTE: Always use Genuine Graco Parts and Acces-
sories, available from your Graco distributor.
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE OR EXPLOSION HAZ-
ARD on page 4.
DPump: Use a ground wire and clamp as shown
below.
Fig. 1 TI1052
Y
Z
DAir and fluid hoses: Use only electrically conductive
hoses.
DAir compressor: Follow manufacturer’s recommen-
dations.
DDispensing valve: Ground through connection to a
properly grounded fluid hose and pump.
DObject being dispensed to: Follow your local code.
DSolvent pails used when flushing: Follow your local
code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place the pail
on a nonconductive surface, such as paper or
cardboard, which interrupts the grounding continu-
ity.
DTo maintain grounding continuity when flushing or
relieving pressure, hold a metal part of the dispens-
ing gun firmly to the side of a grounded metal pail,
then trigger the gun.
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 wire and clamp, order Part No.
222011.
Mounting the Pump
WARNING
Mount the pump securely so that it cannot move
around during operation. Failure to do so could
result in personal injury or equipment damage.
DSelect a convenient location for the equipment to
ensure easy operator access to the pump air
controls, sufficient room to change supply contain-
ers, and a secure mounting platform.
DIf you are mounting the pump directly on the supply
tank, position the pump so its intake valve is no
more than 1 in. (25 mm) from the bottom of the
container. Mount the pump to the cover or other
suitable mounting device.

6 306674U
Installation
Mount the pump to suit the type of installation planned.
Very heavy lubricants may require an inductor plate.
See page 18 for the mounting hole layout and dimen-
sions
Install the air line accessories in the approximate order
shown in the Typical Installation. 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 com-
pressed 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.
WARNING
A bleed-type master air valve (B) is required to
shut off and 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.
Be sure the air hose is properly sized to deliver an
adequate supply of air to the motor. Refer to the
Technical Data on page 19.
Connect a dispensing hose to the 3/8 npt(f) pump
outlet. Install an appropriate gun or dispensing valve to
the hose.
Ground the pump as explained on page 5.
Fig. 2
Key
A
B
C
D
E
F
G
H
J
Grounded Air Line
Bleed-type Master Air Valve
Air Filter
Air Line Oiler
Air Regulator
Grounded Dispensing Hose
Dispensing Valve
Elevator Assy. With Inductors
Ground Wire
Typical Installation
06309
A
B
CD
E
H
J
F
G

306674U 7
Operation
WARNING
DThis pump is designed to be used ONLY in
pumping non-corrosive and non-abrasive lubri-
cants and greases. Any other use of this pump
can cause unsafe operating conditions and
result in component rupture, fire, or explosion,
which can can cause serious bodily injury,
including injection.
DMoving parts can pinch or amputate your fin-
gers or other body parts. When the pump is
operating, the priming piston (located at the
pump intake) and the air motor piston (located
behind the air motor plates) move. NEVER
Operate the pump with the air motor plates
removed, and keep your fingers and hands
away from the priming piston.
Pressure Relief Procedure
WARNING
SKIN INJECTION HAZARD
Fluid under high pressure can be in-
jected through the skin and cause
serious injury. To reduce the risk of an
injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you
DAre instructed to relieve the pressure
DStop dispensing
DCheck or service any of the system equipment
DInstall or clean the dispensing nozzles
1. Close the air regulators.
2. Close the supply pump’s bleed-type master air
valve (required in this system).
3. Open the dispensing valve until pressure is fully
relieved.
If you suspect that the dispensing valve, extension, or
grease fitting coupler is clogged, or that pressure has
not been fully relieved after following the steps above,
VERY SLOWLY loosen the coupler or hose end cou-
pling and relieve pressure gradually, then loosen
completely, then clear the clog.
Startup and Adjustment
Open the bleed-type master air valve. Open the dis-
pensing valve, and slowly open the air regulator 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.
CAUTION
Never allow the pump to run dry of the fluid being
pumped. A dry pump quickly accelerates to a high
speed 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 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.
Use the air regulator (E) to control the pump speed
and fluid pressure. See Fig. 2. Always use the lowest
pressure necessary to obtain the desired results.
When you are finished using the pump for the day,
always follow the Pressure Relief Procedure at left.
Maintenance
The Accessory air line oiler (D) provides automatic air
motor lubrication. For daily manual lubrication, discon-
nect the air hose, place about 15 drops of light ma-
chine oil in the air inlet, reconnect the hose, and turn
on the air supply to blow oil into the motor.

8 306674U
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
Before servicing this equipment always make sure to
Relieve the Pressure.
Note: Check all possible problems and solutions
before disassembling the pump.
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, valves,
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
ppp
Held open or worn intake valve or
piston packings
Clear; service
Pump operates, but output low on
upstroke
Held open or worn piston or packings 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
* Follow the Pressure Relief Procedure, and disconnect the fluid line. If the pump starts when the air is turned
back on, the fluid line, hose, valve, etc. was clogged.

306674U 9
Notes

10 306674U
Displacement Pump Service
Fig. 3
06308
1
2
77
64
68
}65
}74
}59
}75
}76
70
78
73}1
}69
72
79 2
66}
80n
59}
62}
61n
67
}62 68
Lips of v-packings
must face up
Torque to 50 to 70
ft-lb (68 to 95 N-m).
06336
72
1/4” ROD
71
}Included in Repair Kit 239320,
which may be purchased separately.
Ref. 63 (copper gasket) and
Ref. 60}(cotter pin),
see Parts Drawing on page 16.
1