Graco 203857 User Manual

Instructions

5:1 Fire-Ball Pump

For pumping non-corrosive and non-abrasive greases and lubricants only.For professional use only.

Model No. 203872, 203857, 204254, 222087, 203876

900 psi (6.2 MPa, 62 bar) Maximum Working Pressure 180 psi (1.2 MPa, 12 bar) Maximum Air Input Pressure

300

306518ZAE

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

System Accessories . . . . . . . . . . . . . . . . . . . . . . 5

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Pressure Relief Procedure . . . . . . . . . . . . . . . . . 6

Start and Adjusting the Pump . . . . . . . . . . . . . . . 6

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Displacement Pump Service . . . . . . . . . . . . . . . . 8

Air Motor and Throat Service . . . . . . . . . . . . . . . 8

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 16

2 306518ZAE

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation 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 manufacturer’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

306518ZAE 3

Installation

CDE

DETAIL A

1/2 in. (13 mm) between foot spacer and bottom of drum

N A

Installation

Grounding

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.

Be sure to ground all this equipment:

Pump: Use a ground wire and clamp as shown in F

Fluid hoses: Use only electrically conductive hoses.

Air compressor: Follow manufacturer’s recommenda-

tions.

Fluid supply container: Follow the local code.

IG. 1.

To maintain grounding continuity when flushing or relieving pressure: hold metal part of the 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.

FIG. 1

FIG. 2: Typical Installation

Key:

A Bleed-type master air valve (required if quick-disconnect

fitting [L] and coupler [M] are not installed) Order Part No.

107142

B Air line filter C Air regulator and gauge D Pump runaway valve E Air inlet F Ground wire (required) Order Part No. 222011 G Pump (model 204254 shown)

4 306518ZAE

H Drain valve (required) Order Part No. 210658 J Dispensing valve K Low-level cut-off valve L Male quick-disconnect fitting M Female quick-disconnect coupler N Air line lubricator PFluid hose R Thermal relief kit (required) Order Part No. 237893 S Bung adapter, models 204254 and 222087

Installation

1. Install the pump on the drum cover so that the pump’s fluid intake is 1/2 inch. (13 mm) off the bottom of the drum. (F

IG. 2)

2. On Models 204254 and 222087, screw the bung adapter tightly into the drum cover’s bung hole, adjust the position of the pump in the drum, and tighten the bung adapter screw to hold the pump,

System Accessories

Refer to FIG. 2 for the following instructions.

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 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 either a bleed-type master air valve (A) or a quick-disconnect coupler (M) and fitting (L). Install them near the pump air inlet within easy reach from the pump.

• The fluid drain (H) assists in relieve fluid pressure in the displacement pump, hoses, and dispensing valve. Triggering the valve to relieve pressure may not be sufficient.

• The thermal relief kit (R) assists in relieving pressure in the pump, hose, and dispensing valve due to heat and expansion.

• The ground wire (F) reduces the risk of static sparking.

NOTICE

Do not hang the air accessories directly on the air inlet (E). The fittings are not strong enough to support the accessories and may break. Provide a bracket on which to mount the accessories.

1. Install a pump runaway valve (D) 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.

NOTICE

Never allow the pump to run dry of fluid being pumped. A dry pump will quickly accelerate to a high speed, possibly damaging itself, and it may get very hot.

2. Install an air line lubricator (N) for automatic air motor lubrication.

3. Install a bleed-type master air valve (A) to relieve air trapped between the valve and the motor. As an alternative, you can install an air line quick-disconnect coupler (M) and fitting (L) to serve as an air-bleed device. See F

IG. 2.

4. Install a Thermal Relief Kit (K) on the dispensing valve side of the pump.

5. Install the air regulator (C) to control pump speed and pressure.

6. Install an air line filter (B) to remove harmful dirt and contaminants from the compressed air supply. Install another bleed-type master air valve (A) to isolate the accessories for servicing.

7. Install a drain valve (H) near the pump fluid outlet.

8. Install a suitable fluid hose (P) and dispensing valve (J).

NOTE: Install the air line accessories in the order shown in F

IG. 2.

306518ZAE 5

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