Graco Mini Fire-Ball 246775 User manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2004, Graco Inc. is registered to I.S. EN ISO 9001
Fire-Ball® Oil Pumps
For non-corrosive and non-abrasive oils
and lubricants only.
Mini Fire-Ball 225, 3:1 Bare Oil Pump, Part 246775
540 psi (3.7 MPa, 37 bar) Maximum Working Pressure
180 psi (1.24 MPa, 12.4 bar) Maximum Air Input Pressure
Fire-Ball 300, 5:1, Bare Oil Pump, Part 203876
900 psi (6.2 MPa, 62 bar) Maximum Working Pressure
180 psi (1.24 MPa, 12.4 bar) Maximum Air Input Pressure
Fire-Ball 425, 3:1, Bare Oil Pump, Part 237526
540 psi (3.7 MPa, 37 bar) Maximum Working Pressure
180 psi (1.24 MPa, 12.4 bar) Maximum Air Input Pressure
Fire-Ball 425, 6:1, Bare Oil Pump, Part 238108
1100 psi (7.6 MPa, 76 bar) Maximum Working Pressure
180 psi (1.24 MPa, 12.4 bar) Maximum Air Input Pressure
Fire-Ball 425, 10:1, Bare Oil Pump, Part 205626
1800 psi (12.4 MPa, 124 bar) Maximum Working Pressure
180 psi (1.24 MPa, 12.4 bar) Maximum Air Input Pressure
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Parts/Materials required See page 5
Time required to rebuild pump 1 hour
Service, Repair, and Parts
309869C

Contents
2309869C
Contents
Interactive Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 3
Before you start . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 6
Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning and Servicing . . . . . . . . . . . . . . . . . . . . . 21
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Reinstalling the Fire-Ball Pump . . . . . . . . . . . . . . 34
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Air Motor and Pump Lower . . . . . . . . . . . . . . . . . . 38
Part 246775, 225 Mini-Fire-Ball Pump Parts . . . . 39
Part 203876, 300 Pump Parts List . . . . . . . . . . . . 40
Part 237526, 425 (3:1) Pump Parts List . . . . . . . . 41
Part 238108, 425 (6:1) Pump Parts List . . . . . . . . 42
Part 205626, 425 (10:1) Pump Parts List . . . . . . . 43
225 (3:1) Technical Data . . . . . . . . . . . . . . . . . . . . 44
225 (3:1) Performance Chart . . . . . . . . . . . . . . . . . 44
300 (5:1) Technical Data . . . . . . . . . . . . . . . . . . . . 45
300 (5:1) Performance Chart . . . . . . . . . . . . . . . . . 45
425 (3:1) Technical Data . . . . . . . . . . . . . . . . . . . . 46
425 (3:1) Performance Chart . . . . . . . . . . . . . . . . . 46
425 (6:1) Technical Data . . . . . . . . . . . . . . . . . . . . 47
425 (6:1) Performance Chart Flow . . . . . . . . . . . . 47
425 (10:1) Performance Chart . . . . . . . . . . . . . . . . 48
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 50
Interactive Manual
This manual was designed to be viewed on a computer. The computer version has short videos and animations built
into the repair steps to provide you with a better understanding of how the Fire-Ball pump operates and demonstrates
some of the repair steps. Click on this movie projector symbol in the instruction manual to see a short video or anima-
tion.
When using Adobe Acrobat, use the arrows circled in red to individually page through the manual or return directly to
the beginning or end page. See FIG. 1. Use the arrows circled in blue when using the navigational links found in the
manual. The arrow pointing left returns the reader to the previous page containing the link. Please install Windows
Media Player to view the videos and animations.
Please contact your Graco distributor to obtain a CD that has the interactive additional reference materials Movie
icons do not appear in the printed manual.A printed copy of this manual can be obtained from the interactive CD,
Graco’s web site at www.graco.com, or by calling the 1-800 toll free number on the back of any instruction manual.
Additional Reference Materials
This manual was designed for those that have previous experience with Graco Fire-Ball pumps. If more detailed infor-
mation is required please contact your local Graco distributor or visit Graco’s web site at www.graco.com.
FIG. 1
309868 Installation, Operation Instructions, and Model Information

Manual Conventions
309869C 3
Manual Conventions
Warning Caution
Note
WARNING
A warning alerts you to possible serious injury or
death if you do not follow instructions.
Symbols, such as fire and explosion (shown), alert you
to a specific hazard and direct you to read the indi-
cated hazard warnings beginning on page 3.
CAUTION
A caution alerts you to possible equipment damage or
destruction if you do not follow instructions.
A note indicates additional helpful information.
WARNINGS
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• 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.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your Graco distributor for information.
• For professional use only.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not use hoses to pull equipment.
• Comply with all applicable safety regulations.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin
and cause serious injury.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

Warning
4309869C
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from gun, 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 gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
MOVING PARTS HAZARD
Moving parts can pinch 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 in this manual. Disconnect power or air supply.
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 MSDS’s 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.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Ground equipment and conductive objects. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.

Before you start
309869C 5
Before you start
If you are unfamiliar with the Fire-Ball pump there are several resources that can be reviewed prior to rebuilding this
pump. They include the training guides which provide theory and understanding of how the Fire-Ball pumps work.
Refer to www.graco.com for additional information.
You must have the following tools and repair kit prior to rebuilding or repairing the Fire-Ball pump. Order repair kits
and special tools from Graco Inc.
• Utility Knife • 1 Gallon Bucket
• Straight Blade Screwdriver or nut driver • Large Vise
• Crescent Wrench
Model 225
Use adjustment tool, part# 15E796.
15E796 is also included in Repair Kit 246918.
Models 300 and 425
Use adjustment tool, part# 171818.
Model 225
Use pliers tool, part# 248198.
Models 300 and 425
Use pliers tool, part# 207579.
Repair Kits
Model 225 (3:1)
Repair Kit #246918 for both motor and lower repair.
Model 300 (5:1)
Repair Kit #238286 for both motor and lower repair.
Model 425 (3:1)
Repair Kit #207385 for air motor repair
Repair Kit #237602 for lower repair
Model 425 (6:1)
Repair Kit #207385 for air motor repair
Repair Kit #238225 for lower repair
Model 425 (10:1)
Repair Kit #238751 for both motor and lower repair.

Pressure Relief Procedure
6309869C
Pressure Relief Procedure
WARNING
This equipment stays pressurized until pressure is
manually relieved. Read PRESURIZED EQUIPMENT
HAZARD warnings beginning on page 3.
1. Close the pump air regulator (C)
and the bleed-type master air
valve (A) (required in your sys-
tem).
2. Hold a metal part of the dispens-
ing valve (J) firmly to a grounded
metal waste container, and trigger
the valve to relieve the fluid pres-
sure.
C
A
J

Service and Repair
309869C 7
Service and Repair
Prior to rebuilding the pump remove it from production. To do this:
1. Flush the pump, and relieve the pressure. Follow the pressure relief procedure on page 6.
2. Disconnect the ground wire from the ground screw (14) if equipped.
3. Disconnect any hoses.
4. Remove the pump from its mounting.
Disassembly
1. Vertically clamp the valve hous-
ing (42) in a vise and use a strap
wrench or chain wrench to loosen
the valve housing by turning the
fluid cylinder (41).
2. Horizontally clamp the air motor
base (28) in a vise by closing the
vise jaws on the air motor flange.
WARNING
Read warnings beginning on page 3.
CAUTION
Do not remove the valve housing
(42). It is needed to support the
removal of the fluid cylinder.

Service and Repair
8309869C
3. Use a strap wrench or chain
wrench on the fluid cylinder (41)
to screw it out of the air motor
base (28).
4. Pull the fluid cylinder (41) off.
5. Remove the valve housing (42).

Service and Repair
309869C 9
6. Remove ball retainer and inspect
the metallic ball (8), ball retainer
(44), and seat of valve housing
(42) for damage.
7. Remove and replace the o-ring
packing (21*).
8. Screw the valve housing (42) into
the fluid cylinder (41) and hand
tighten.

Service and Repair
10 309869C
9. Pull the displacement rod (29)
down.
10. Using wrenches on the flats of the
displacement rod (29) and on the
flats of the fluid piston (43),
unscrew the fluid piston from the
displacement rod.
11. Remove the metallic ball (6) from
the end of the displacement rod
(29).

Service and Repair
309869C 11
12. Remove the packing o-ring (11*)
from the fluid piston (43).
13. Unscrew the cylinder cap nut (39)
from the top of the air motor cylin-
der (35).
14. Pull up on the cylinder cap nut
(39) to expose the trip rod (40).

Service and Repair
12 309869C
15. Grasp the trip rod (40) with pad-
ded pliers. See page 5 for part
numbers.
16. Unscrew the cylinder cap nut (39)
from the trip rod (40).
17. Thread the service nut (A) (not
supplied) onto the top of the trip
rod (40).
CAUTION
Do not damage the plated surface of
the trip rod (40). Damaging the sur-
face of the trip rod can result in
erratic motor operation.
A

Service and Repair
309869C 13
18. Remove the six hex head screws
(7) holding the air motor plate
identification (46) to the air motor
base (28).
19. Remove the six hex head screws
(7) holding the warning plate (47)
to the air motor base (28).
20. Remove the six hex head cap
screws (9) holding the air motor
cylinder (35) to the air motor base
(28).

Service and Repair
14 309869C
21. Carefully pull the air motor cylin-
der (35) straight off of the air
motor piston (34).
22. Pull the air motor piston/displace-
ment rod assembly (34, 29) clear
of the air motor base (28).
23. Remove o-ring packing (12*).
CAUTION
To avoid damaging the cylinder wall,
pull the cylinder straight off of the pis-
ton. Never tilt the cylinder while you
are removing it.

Service and Repair
309869C 15
24. Remove the block packing (16*)
from the bottom of the air motor
base (28).
25. Remove the o-ring packing (13*)
from the air motor base.
26. Clamp the air motor piston (34) in
an upright position.
XXXX

Service and Repair
16 309869C
27. Remove the o-ring packing (18*)
from the air motor piston (34).
28. Use a screwdriver handle to push
down the trip rod yoke (23) to
snap the toggle arms (38) down.
29. Place an adjustable wrench on
top of the toggle arms (38) and
push down to compress the
spring and release from the piston
lug.
WARNING
To reduce the risk of pinching or
amputating your fingers, always keep
fingers clear of the toggle assem-
blies. Read warnings beginning on
page 3.

Service and Repair
309869C 17
30. Swing the toggle assembly up and
away from the piston lugs, and
remove the assembly.
31. Remove the toggle pins (36) from
the trip rod yoke (23).
32. Straighten the lockwires (25*).

Service and Repair
18 309869C
33. Remove the lockwires (25*) from
the valve nuts (24*).
34. Screw the top valve nuts off (24*).
35. Pull the valve assembly out of the
piston.

Service and Repair
309869C 19
36. Remove the trip rod (40), trip rod
yoke (23), and valve actuator (27).
37. To remove the valve poppets (31*)
cut them with a sharp knife or side
cutter.
38. To remove the lower valve grom-
mets (17*) cut them off with a
sharp knife or cutter.

Service and Repair
20 309869C
39. Unscrew and remove the bottom
valve nuts (24*) and the poppet
valve (32).
Disassembly is complete.