Graco fire-ball 425 Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1996, Graco Inc. is registered to I.S. EN ISO 9001
10:1 Fire–Ballr425 Pump
For pumping petroleum–based lubricating fluids only.
180 psi (12.4 bar) Maximum Incoming Air Pressure
1800 psi (124 bar) Maximum Fluid Working Pressure
Model 205626, Series J
Universal Pump
Model 222065, Series B
55-Gallon Drum Cover-Mount Pump
Model 222095, Series B
55-Gallon Drum Bung-Mount Pump
308655H
Important Safety Instructions.
Read all warnings and instructions in this manual.
Save these instructions.
Model 205626 shown
TI1071
Parts
Mascott Equipment Co
Portland Seattle Pasco
[phone] [phone] [phone]

2 308655
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Motor and Throat Service 9. . . . . . . . . . . . . . . . . . . . .
Displacement Pump Service 13. . . . . . . . . . . . . . . . . . . .
Parts List 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 16. . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance Chart 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 18. . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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 you operate this 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 compo-
nent in your system.
DUse fluids and solvents which are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s
warnings.
DDo not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids that contain such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
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 82_C (180_F) or below –40_C (–40_F).
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
WARNINGWARNING

3
308655
HAZARDOUS FLUIDS
Improper handling of hazardous fluids or inhaling toxic fumes can cause extremely serious injury,
even death, due to splashing in the eyes, ingestion, or bodily contamination.
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.
INJECTION HAZARD
Fluid from the dispensing valve, 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 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 at 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.
DUse only extensions and no-drip tips that are designed for use with your dispensing valve.
DTighten all fluid connections before you operate this 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.
WARNINGWARNING
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
DKeep clear of all moving parts when you start or operate the pump.
DBefore you service this equipment, follow the Pressure Relief Procedure on page 7 to prevent
the equipment from starting unexpectedly.
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. Refer to Grounding on page 6.
DIf there is any static sparking or you feel an electric shock while you use this equipment, stop
dispensing 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.
DDo not smoke in the dispensing area.

4 308655
Installation
The typical installation shown in Fig.1 is only a guide to
help you select and install a pump; it is not an actual
system design. Contact your Graco distributor for
assistance in designing a system to suit your needs. Always mount the pump firmly to a bracket or a
tank cover. Never operate the pump while it is not
mounted. Such use could damage the pump and
fittings.
CAUTION
DNA
C
A
KEY
ABleed-type master air valve
(required, Part No. 107142)
BAir line filter
CAir regulator and gauge
DPump runaway valve
EAir inlet
FBall valve (for releasing collected moisture)
GPump
HDrain valve (required, Part No. 210658)
JDispensing valve (model 222411 shown)
KThermal relief kit (required, Part No. 240429)
LMale quick-disconnect fitting
MFemale quick-disconnect coupler
NAir line lubricator
PFluid hose
RElectrically conductive air hose (218093 shown)
Use at least 1/2 in. (13 mm) ID to supply an adequate volume
of air to the air motor.
SFluid inlet
TWall-mounting bracket (Part No. 238245)
YGround wire (required, Part No. 222011)
ZMuffler
Fig. 1
B
E
G
Y
HPJ
L
M
DETAIL A
For Portable Applications
R
S
K
A
F
Z
06038
T
TI0890

5
308655
Installation
System Accessories
CAUTION
Do not hang the air accessories directly on the air
inlet (E). The fittings are not strong enough to
support the accessories and may cause one or
more to break. Provide a bracket on which to
mount the accessories.
NOTE: Install the following accessories in the order
shown in Fig. 1.
Four accessories are required in your system: an
air shut-off valve/air bleed device, fluid drain valve,
thermal relief kit, and ground wire. These accesso-
ries help reduce the risk of serious bodily injury
including fluid injection, splashing in the eyes or on
the skin, injury from moving parts if you are adjust-
ing or repairing the pump, and explosion from
static sparking.
The air bleed device relieves air trapped between it
and the air motor after the air supply is shut off.
Trapped air can cause the air motor to cycle unex-
pectedly, causing serious bodily injury if you are
adjusting or repairing the pump. Use either a
bleed-type master air valve (A) or a quick-discon-
nect coupler (M) and fitting (L). Install near the
pump air inlet, within easy reach of the pump.
The fluid drain valve (H) assists in relieving fluid
pressure in the displacement pump, hoses, and
dispensing valve. Triggering the valve to relieve
pressure may not be sufficient.
The thermal relief kit assists in relieving pressure in
the pump, hose, and dispensing valve due to heat
expansion.
The ground wire reduces the risk of static sparking.
WARNING
DScrew the muffler (5) into the 3/4-in. npt muffler
port, and tighten it using a wrench on the flats of
the muffler near the male threads.
DInstall an air line lubricator (N) for automatic air
motor lubrication.
DInstall the air regulator (C) to control pump speed
and pressure.
DInstall an air line filter (B) to remove harmful dirt
and contaminants from your compressed air supply.
DInstall a bleed-type master air valve (A) to isolate
the accessories for servicing. See Fig. 1. To order
a bleed-type master air valve, order Part No.
107142.
As an alternative to a bleed-type master air valve,
you can install an air line quick disconnect coupler
(M) and fitting (L) to serve as an air-bleed device.
See Detail A in Fig. 1.
DInstall a ball valve (F), at the end of a line drop, as
shown in Fig. 1, for releasing moisture that collects
in the line.
DInstall a drain valve (H) near the pump fluid outlet to
relieve fluid pressure in the hoses and gun when
opened. To order a fluid drain valve, order Part No.
210658.
DInstall a pump runaway valve (D) to shut off the air
to the pump if the pump accelerates beyond the
pre-adjusted setting, which can be caused by a
depleted fluid supply. A pump that runs too fast
can be seriously damaged. To order a 3/4-in. npt(f)
inlet and outlet pump runaway valve, order Part No.
215362.
DInstall a thermal relief kit (K) on the dispensing
valve side of the pump. To order a 1600 psi
(110 bar) thermal relief kit, order Part No. 240429.
DInstall a suitable fluid hose (P) and dispensing
valve (J).
Wall Mount
The pump shown in Fig. 1 is a wall-mounted universal
pump, Model 205626. To order the wall-mounting
bracket shown, order Part No. 238245.
Cover Mount
Pump Model 222065 is designed for mounting directly
on a 55-gallon drum cover. When the pump is
mounted to a closed-head drum, be sure you loosen
the vent plug on the drum cover to prevent a vacuum
in the drum. For cover mounting, see the Mounting
Hole Layout on page 16.
Bung Mount
Pump model 222095 is designed for bung mounting on
a 55-gallon drum. The bung adapter (153) is shown in
the Parts Drawing on page 15.

6 308655
Installation
Grounding
Proper grounding is an essential part of maintaining a
safe system.
To reduce the risk of static sparking, ground the pump.
Check your local electrical code for detailed grounding
instructions for your area and type of equipment. Be
sure to ground this equipment:
DPump: Use a ground wire and clamp as shown in
Fig. 2.
DAir and Fluid hoses: Use only electrically conduc-
tive hoses.
DAir compressor: Follow the manufacturer’s recom-
mendations.
DFluid supply container: Follow the local code.
DObject being lubricated: Follow the local code.
DTo maintain grounding continuity when flushing or
relieving pressure, always hold a metal part of the
valve firmly to the side of a grounded metal pail,
then trigger the 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. 2. To
order a ground wire and clamp, order Part No. 222011.
Fig. 2 TI1052
Z
Y

7
308655
Operation
Pressure Relief Procedure
INJECTION HAZARD
To reduce the risk of serious bodily
injury, including fluid injection or
splashing in the eyes or on the skin,
always follow this procedure whenever you shut off
the pump, check or service any part of the system,
install or change dispensing devices, and when you
stop dispensing.
WARNING
1. Close the bleed-type master air valve (required in
your 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, or open the
drain valve (H).
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, do the follow-
ing: Wrap a rag around the hose end coupling, and
relieve pressure gradually by very slowly partially
loosening the fitting. Then loosen completely, then
clear the obstruction.
Startup and Adjustment
COMPONENT RUPTURE HAZARD
The maximum working pressure of each
component in the system may not be the
same. To reduce the risk of overpres-
surizing any component in the system, be sure you
know the maximum working pressure of each
component, including the air motor and pump.
Never exceed the maximum working pressure of
the lowest rated component in the system. Over-
pressurizing any component can result in rupture,
fire, explosion, property damage, and serious
injury.
To determine the fluid output pressure using the air
regulator reading, multiply the ratio of the pump by
the air pressure shown on the regulator gauge. For
example:
10 (:1) ratio x 180 psi air =
1800 psi fluid output
[10 (:1) ratio x 12.4 bar air = 124 bar fluid output]
Limit the air to the pump so that no air line or fluid
line component or accessory is overpressurized.
WARNING
WARNING
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.
WARNING
MOVING PARTS HAZARD
Do not operate the pump without the
muffler installed. When the muffler is not
installed, the air motor is exposed, and it
could cut your fingers if they are pushed into the
muffler opening.
1. With the air regulator (C) closed, open the bleed-
type master air valves (A) or, if so equipped, join
the quick disconnect coupler (M) to the male fitting
(L).
2. Open the dispensing valve (J) into a grounded
metal waste container, making firm metal-to-metal
contact between the container and valve.
3. Open the pump air regulator (C) slowly, just until
the pump is running. When the pump is primed
and all air has been pushed out of the lines, close
the dispensing valve.
NOTE: When the pump is primed, and with sufficient
air supplied, the pump starts when the dis-
pensing valve is opened and shuts off when it
is closed.
4. If your system is equipped with a runaway valve (D
in Fig. 1), set it for your system configuration. See
manual 308201 for instructions on setting the
pump runaway valve.
5. Adjust the air regulator until you get sufficient flow
from the dispensing valve. Always run the pump
at the lowest speed necessary to get the desired
results. Do not exceed the maximum working
pressure of any component in the system.
6. If your pump accelerates quickly or is running too
fast, stop it immediately, and check the fluid sup-
ply. If the supply container is empty and air has
been pumped into the lines, prime the pump and
lines with fluid, or flush it and leave it filled with a
compatible solvent. Be sure to eliminate all air
from the fluid lines. If your system has a runaway
valve, reset it according to the instructions in
manual 308201.

8 308655
Operation
Never allow the pump to run dry of the fluid being
pumped. A dry pump will quickly accelerate to a
high speed, possibly damaging itself, and it may
get very hot.
CAUTION
7. Read and follow the instructions supplied with
each component in your system.
8. If the pump will be unattended for any period of
time, if there is an air supply interruption, or to shut
off the system at the end of the work shift, always
relieve the pressure.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
9. Check periodically to ensure that the pump’s
mounting is secure.
Troubleshooting
INJECTION HAZARD
To reduce the risk of serious bodily injury, including fluid injection or splashing in the eyes or on the
skin, always follow the Pressure Relief Procedure on page 7 when you shut off the pump, check or
service any part of the system, install or change dispensing devices, and when you stop dispensing.
WARNING
NOTE: Check all other possible problems and solutions before you disassemble the pump.
Problem Cause Solution
Pump fails to operate, or there is
no fluid flow.
Inadequate air supply pressure or
restricted air lines
Increase air supply; clear
Closed or clogged dispensing
valve
Open; clear
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 gas-
ket, 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
up stroke
Held open or worn piston packings Clear; service
Pump operates, but output low on
down stroke
Held open or worn intake valve Clear; service
Pump operates, but output low on
both strokes
Inadequate air supply pressure or
restricted air lines
Increase air supply; clear
Closed or clogged valves Open; clear
Fluid is coming out of the muffler. Worn or damaged throat seal Service
* Follow the Pressure Relief Procedure on page 7, and disconnect the fluid line. If the pump starts when
the air is turned on again, the line, hose, valve, etc., is clogged.

9
308655
Air Motor and Throat Service
Before You Start
DBe sure you have all necessary parts on hand.
Repair Kit 238751 includes repair parts for the air
motor and pump. Use all parts in the kit for the
best results. Parts included in the kit are marked
with one asterisk, for example (19*), in the text and
drawings. See the Parts List on page 14.
DTwo accessory tools should be used: Padded
Pliers, 207579, are used to grip the trip rod without
damaging its surface, and a 0.125-in. (3.18 mm)
Gauge, 171818, is used to assure the proper
clearance between the poppets and seat of the
piston.
Disassembly
1. Flush the pump.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
2. Relieve the pressure.
3. Disconnect the hoses, remove the pump from its
mounting, and clamp the air motor base (28) in a
vise horizontally by closing the vise jaws on the
flange.
4. Use a strap wrench on the displacement pump
cylinder (110) to screw it out of the air motor base
(28). See Fig. 3.
5. Remove the piston/valve seat (109) from the
displacement rod (29) with wrenches or with the
vise and a wrench.
6. Remove the piston ball (103), seal (107*), and
seal retainer washer (113).
7. Remove the air motor base from the vise, and
place the displacement rod (29) flats in the vise
with the air motor up.
8. Loosen the lift ring (24). Pull up the lift ring, grip
the trip rod (31) with the padded pliers, and screw
the lift ring off of the rod.
CAUTION
Do not damage the plated surface of the trip rod
(31). Damaging the surface of the trip rod can
result in erratic air motor operation. Use the
special padded pliers, 207579, to grasp the rod.
9. Remove the eight screws (3) that hold the cylinder
(30) to the base (28). Carefully pull the cylinder
straight up off of the piston assembly (27).
CAUTION
To avoid damaging the cylinder wall, lift the cylinder
straight up off of the piston. Never tilt the cylinder
as it is being removed.
TI1072
Fig. 3
28
110
29
31
27
24
30
3
113
107*
lips face up
109
103
flange
2*
lips face
down
108*
105*
*Included in Pump Repair Kit 238751,
which may be purchased separately.

10 308655
Air Motor and Throat Service
10. Pull the piston assembly (27) from the air motor
base (28), and set it aside.
11. Remove the throat bearing (36) with a 1 5/8-in.
socket, remove the seal (2*), and wipe the seat
clean with a cloth.
12. Remove the piston/base assembly from the vise,
and set it upright on the workbench.
13. Inspect the air motor for damaged or worn lower
valve grommets (17*), o-rings (19*, 20*), valve
nuts (21*), lock wires (22*), exhaust valve poppets
(26*), and inlet valve poppets (32*). If any of these
parts need to be replaced, continue with steps 14
to 20. Otherwise, see Reassembly on page 11.
14. Use a screwdriver to push down on the trip rod
yoke (13), and snap the toggles down. See Fig. 4.
MOVING PARTS HAZARD
To reduce the risk of pinching or
amputating your fingers, keep your
fingers clear of the toggle assemblies
when you are snapping the toggles
(M in Fig. 4 ) up or down.
WARNING
15. In this step, while you are prying with the screw-
driver with one hand, cover the toggle assemblies
with your other hand so as to catch the spring-
loaded toggle assemblies when they snap out of
the lugs. Place the tip of a screwdriver into the
piston between the piston lugs (L) below the pivot
pins (16) on the toggles, pry up with the screw-
driver handle to compress the springs on the
toggle assembly (M) up and away from the piston
lugs, and remove the parts. See Fig. 4.
16. Straighten the lockwires (22*), and remove them
from the valve nuts (21*). Screw the top nuts off.
Remove the trip rod yoke (13), actuator (12), and
trip rod (31). Unscrew the bottom valve nuts (21*),
and remove the poppets inlet valve poppets (32*).
Make sure the valve bar spring clips (14) are not
worn or damaged and that they properly guide the
actuator.
17. Remove the exhaust valve poppets (26) by cutting
them with a side cutter, then pull them out of the
actuator (12).
18. Clean all the parts carefully in a compatible sol-
vent, and inspect them for wear or damage. Use
all the repair kit parts during reassembly, and
replace other parts as necessary.
19. Check the surfaces of the air motor piston (27),
displacement rod (29), and the wall of the air motor
cylinder (30) for scoring or scratches. Scored or
scratched surfaces cause premature packing wear
and leaking.
20. Lubricate all parts with a light, waterproof grease.