Graco 205394, 205395 Instruction Manual

Instructions - Parts List

50:1 Fire-Ball 425 Pumps

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

Model 205394, Series E Model 205395, Series N

7500 psi (51.7 MPa, 517 bar) Maximum Working Pressure 150 psi (1.0 MPa, 10 bar) Maximum Air Input Pressure

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Important Safety Instructions

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

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 operating conditions and component rupture, which can result in fluid injection or other serious injury or fire or explosion.

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

FIRE AND EXPLOSION HAZARD

When flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be aware that flammable fumes can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources, such as cigarettes and portable electric lamps.

• Keep work area free of debris, including rags and spilled or open containers of solvent and gasoline.

• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

• Ground all equipment in the work area.

• Use only grounded hoses.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, 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 dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

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Warnings

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.

• 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.

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.

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.

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

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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.

Pump: Use a ground wire and clamp as shown in FIG.

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 and wire clamp, order Part No. 222011.

Mounting the Pump

Mount the pump securely so that it cannot move around during operation. Failure to do so could result in personal injury or equipment damage.

• Select a convenient location for the equipment to ensure easy operator access to the pump air controls, sufficient room to change supply containers, and a secure mounting platform.

• If you are mounting the pump directly on the supply tank, position the pump so its intake valve is no more than 1 inch (25 mm) from the bottom of the container. Mount the pump to the cover or other suitable mounting device.

FIG. 1

Air and fluid hoses: Use only electrically conductive

hoses.

Air compressor: Follow manufacturer’s recommendations.

Dispense valve: Ground through connection to a properly grounded fluid hose and pump.

Object being dispensed: follow local code.

Solvent pails used when flushing: Follow local code.

Use only conductive metal pails, placed on a grounded surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

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

gun/dispense valve firmly to the side of a grounded metal pail, then trigger the gun/valve.

Typical Installation

Mount the pump to suit the type of installation planned. Very heavy lubricant may require an inductor plate. See page 17 for the mounting hole layout and dimensions.

Install the airline accessories in the approximate order shown in FIG. 2. 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 compressed 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.

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A bleed-type master air valve (B) is required to shut off an 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.

Installation

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 16.

Connect a dispensing hose to the 3/8 npt(f) pump outlet. Install an appropriate gun or dispense valve to the hose.

Ground the pump as explained on page 4.

FIG. 2: Typical Installation

Key:

A Grounded air line B Bleed-type master air valve C Air filter D Air line oiler E Air regulator F Grounded dispensing hose G Dispensing valve H Elevator assembly with inductors J Ground wire

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Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1. Close the air regulators (E).

2. Close the supply pump’s bleed-type air master valve (B, required in system).

3. Open the dispensing valve (G) until pressure is fully relieved.

NOTE: 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 coupling and relieve pressure gradually, then loosen completely and clear the clog.

Startup and Adjustment

Open the bleed-type air master valve (B). Open the dispensing valve (G), and slowly open the air regulator (E) 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.

NOTICE

Never allow the pump to run dry of the fluid being pumped. A dry pump quickly accelerates to a high sped and may damage itself. If your pump accelerates 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 the 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.

Maintenance

The accessory air line oiler (D) provides automatic air motor lubrication. Four daily manual lubrication, disconnect the air hose, place about 15 drops of light machine oil in the air inlet, reconnect the hose, and turn on the air supply to blow oil into the motor.

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