Graco FIRE-BALL User manual

308–879
Rev. B
Supercedes Rev. A
First choice when
quality counts. 
8428B
Model No. 240–857 shown
INSTRUCTIONS–PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
Fire-Balland President
Lubrication Pumps for
Automatic Lubrication Systems
Units for Heavy Grease
50:1 Ratio Fire-Ball Pumps: 5000 psi (35 MPa, 350 bar) Maximum Working Pressure
75:1 Ratio President Pumps: 7500 psi (52 MPa, 517 bar) Maximum Working Pressure
Part No. Pump For Type of
Container Vent Valve Kit Cover Follow Plate* Hold-down Kit
240–848
240–854
240–857
75:1 President
50:1 Fire-Ball
50:1 Fire-Ball
400 lb
120 lb
70 lb 
240–763
240–761
240–760
240–666
240–668
240–668
240–459
240–457
240–457 222–061 240–671
*Follow plate is an option for all units and must be ordered separately.
 Includes container .
WARNING
These systems are designed to be used only in
pumping non-corrosive and non-abrasive
lubricants. Any other use of the system can cause
unsafe operating conditions and result in
component rupture, fire, or explosion which can
cause serious bodily injury , including fluid injection.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1998, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

 
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Lists and Drawings
Vent V alve Kits 240–760, 240–761, 240–763 11. . . .
Fire-Ball Packages 240–854, 240–857 12. . . . . . . . . .
President Package 240–848 13. . . . . . . . . . . . . . . . . . .
Hold-Down Kits 222–061 and 240–671 14. . . . . . . . . .
Graco Standard Warranty 16. . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 16. . . . . . . . . . . . . . . . . . . . . . . . . .
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.
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
 Check equipment daily . Repair or replace worn or damaged parts immediately.
Do 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.
Use 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.
 Handle hoses carefully . Do not pull on hoses to move equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 150F (66C) or below –40F (–40C).
Wear hearing protection when operating this equipment.
Do not move or lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.


WARNING
INJECTION HAZARD
Fluid from the injector, leaks, or ruptured components can inject fluid into your body and cause ex-
tremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can
also cause serious injury .
Fluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious
injury. Get immediate medical attention.
Do not put your hand or fingers over any grease outlet.
Do not stop or deflect leaks with your hand, body, glove or rag.
Do not “blow back” fluid; this is not an air spray system.
Follow the Pressure Relief Procedure on page 10 before you clean, check, or service the
equipment.
Use only fittings, hoses, and tubing that are designed to meet the system pressure requirements.
Tighten all fluid connections before operating the equipment.
Check 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 P ARTS HAZARD
Moving parts can pinch or amputate your fingers.
Keep clear of all moving parts when starting or operating the pump.
Before checking or servicing the equipment, follow the Pressure Relief Procedure on page 10 to
prevent the equipment from starting unexpectedly.

4 308-879
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.
Ground the equipment and the object being dispensed to. See Grounding on page 6.
If 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.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being dispensed.
Keep the dispensing area free of debris, including solvent, rags, and gasoline.
Do not smoke in the dispensing area.
Never 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.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
The air motor exhausts any fluids added to the input air.
Graco 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.

5308-879
Notes

6 308-879
Installation
Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawing.
Always use genuine Graco parts and accessories, 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.
Ground all of this equipment:
 Air and fluid hoses: Use only electrically conductive
hoses.
 Air compressor: Follow the manufacturer’s
recommendations.
 Injectors: Ground through connection to a properly
grounded fluid hose and pump or to the mounting
manifold.
 Object being dispensed to: Follow the local code.
 Pump: Use a ground wire and clamp as shown in
Fig. 1. Loosen the grounding lug locknut (W) and
washer (X). Insert one end of a 12 ga (1.5 mm)
minimum ground wire (Y) into the slot in lug (Z) and
tighten the locknut securely. Connect the other end
of the wire to a true earth ground.

Fig. 1
Y
W
X
Z
Air Line and Accessories
Note: Install the air line accessories in the order
shown in the Typical Installation on page 7.
CAUTION
Do not hang air accessories directly on the air inlet.
The fittings are not strong enough to support acces-
sories and may cause one or more to break. Provide
a bracket on which to mount accessories.
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.
Install an air line lubricator (F) for automatic air
motor lubrication.
Install an air regulator (C) to control pump speed
and pressure.
On the main air supply line from the compressor,
install an air filter (E) to remove harmful dirt and
contaminants from the compressed air supply.
Install a bleed-type master air valve (M) within easy
reach of the pump, upstream from the air regulator
(C).


Installation
Typical Installation
The typical installation shown below is only a guide for selecting and installing system components and
accessories. Contact your Graco distributor for assistance in designing a system to suit your particular needs.
vent
valve (J)
Key
AFluid dispense line
B Pump ground wire (required; included)
C Air regulator
D Main air supply line
E Air filter
F Air line lubricator
G Pump runaway valve
H Follow plate (optional)
JV ent valve
KV ent return line
L Safety relief valve (required; included with V ent V alve Kit)
(See Detail A)
M Bleed-type master air valve (required; included with V ent V alve Kit)
A
D
H
BC EFG
J
K
DET AIL A
safety
relief
valve (L)
M
8429B

 
Installation
Stationary Mounting Layout
Plan the layout for easy operator access to the
pump air controls, leave sufficient room to change
drums, and mount on a secure platform.
For ease in changing drums, install a pump
elevator.
Open Drum, Cover-Mounted Pumps
See Fig. 2.
1. Remove the original drum cover.
2. Place the new drum cover on the drum. Carefully
guide the pump riser tube through the mounting
gasket, and fasten the pump to the drum cover
such that the outlet of the pump is 90counter-
clockwise from the hole with the grommet.
3. For Models 240–854 and 240–857, install the
Hold-Down Kit according to the instruction in the
Drum Mounting With Hold-down Kit section on
page 9.
4. Install and tighten the bolts that secure the pump
to the drum cover.
Fig. 2
vent tube
8449B
Model No. 240–857 shown
hold-down bracket
vent hose
(high-pressure
grease hose)
follow plate
(optional)
high-pressure grease hose
vent valve
air hose
air hose coupling
hold-down rod
tee
Hold-Down Kit Part Numbers:
For 120# barrel: 222–061
For 70# barrel: 240–671
V ent V alve Kit Part Numbers:
For Fire-Ball Model 240–857: 240–760
For Fire-Ball Model 240–854: 240–761
For President Model 240–848: 240–763
Optional Follow Plate Part Numbers:
For 70# and 120# barrel: 240–457
For 400# barrel: 240–459
Drum Cover Part Numbers:
For Fire-Ball Models: 240–668
For President Model: 240–666
drum cover
hold-down lug
air hose


Installation
Drum Mounting With Hold-down Kit
Models 240–857 and 240–854
See Fig 3.
1. Place the drum in the desired location.
2. Lay out the mounting locations for the hold-down
lugs (R) to achieve the desired drum cover
orientation. The drum cover orientation dictates
the location of the tie downs and the vent valve.
3. Place the hold-down lugs (R) around the drum
base, and bolt directly to the truck bed or mounting
platform.
4. Assemble the hold-down bracket (P), rod (J), and
wing nut (N) as shown, and tighten the wing nut to
hold the cover securely on the container.
Fig. 3 8431A
P
R
N
J
Mobile Mounting Layout
Plan the layout for easy operator access to the pump
air controls, sufficient room to change drums, and a
secure truck bed or mounting platform.
Installing the Vent Valve Kit
For pumps using Vent Valve Kits 240–760,
240–761, or 240–763 See Fig 4.
Note: The Vent Valve Kit is shipped only partially
assembled. This is to facilitate proper alignment of
hoses and fittings when you put together the
unassembled parts and install the kit on your system.
1. Insert the vent tube (14 or 15) through the
off-center hole in the container cover.
2. Apply anaerobic sealant to all male threads,
except at swivel adapter joints.
3. Loosely assemble the remaining hoses, fittings,
and vent valve on your system. Do not tighten any
fittings until all parts are in place.
4. When all parts are in place and properly aligned,
tighten all fittings.
WARNING
INJECTION HAZARD
Be certain that all grease hoses and air
hoses are properly installed in their cor-
rect location, as shown in Fig. 4 and in
the Vent Valve Kits Parts drawings on page 1 1.
Hose part numbers are stamped on the metal hose
couplings. If you have doubts about the installa-
tion, do not operate the system; contact your
Graco distributor or the factory to confirm the
proper installation. Installing an air hose where a
high-pressure grease hose is required could cause
serious injury , including fluid injection.
Fig. 4
vent tube
to container
to pump
outlet
grease line to system
to air
solenoid
to air inlet
on pump
8430A
air hose
air hose
high-pressure
grease hose

10 308-879
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, in-
cluding fluid injection or splashing in the
eyes or on the skin, always follow the
Pressure Relief Procedure whenever you
Are instructed to relieve the pressure
Shut off the pump
Check or service any of the system equipment
Install or clean the grease fitting couplers
1. Disconnect power from the timer control.
2. Close the pump air regulator and/or bleed-type
master air valve.
3. Disconnect the air coupler (3) from the tee (6) on
the vent valve. See drawings on page 11.
Start-up
1. Close the air regulators and bleed-type master air
valves to all but one pump.
2. Open the master air valve from the compressor.
3. Disconnect the supply lines from the injector
manifolds, open the bleed-type master air valve,
and open the pump air regulator slowly, until the
pump is running and all air has been purged out of
the lines. Reconnect the supply lines, remove the
zerk cap from the injector, and use a standard
grease gun to prime the feed lines to the bearings.
Note: When the pump is primed, and with
sufficient air supplied, the pump starts when the
timer activates the air line solenoid valve, and it
shuts off when the timer deactivates the air valve.
4. Set the air pressure to the pump at the lowest
pressure needed to get the desired results.
5. Read and follow the instructions supplied with
each component in your system.
6. To shut off the system, disconnect power to the
central timer, and turn off the air supply.
In an emergency situation, any of the following
methods can be used to shut down the
system:
Turn off the electrical power to the system.
Shut off the air supply with the bleed-type
master air valve (M).
Disconnect the air line quick coupler (3)
from the air line fitting (4) on the vent valve
tee (6).
WARNING
The maximum working pressure of each pump in
your system may not be the same. To reduce the
risk of over-pressurizing any part of your system,
be sure you know the maximum working pressure
rating of each pump and its connected compo-
nents. Never exceed the maximum working pres-
sure of the lowest rated component connected to a
particular pump.
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:
50:(1) ratio x 70 psi air = 3500 psi fluid output
50:(1) ratio x 0.48 MPa air = 24 MPa fluid output
50:(1) ratio x 4.8 bar air = 240 bar fluid output
Limit the air to the pump so that no air line or fluid
line component or accessory is over-pressurized.
CAUTION
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. If your pump accel-
erates quickly, or is running too fast, stop it immedi-
ately and check the fluid supply. If the supply con-
tainer 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 system.
Note: A pump runaway valve, Part No. 224–040, can
be installed on the air line to automatically shut off the
pump if it starts to run too fast.