Graco 3900, 246909C, 235534D, 224854D User Manual

Instructions - Parts List

9038B

50:1 Mini Fire-Ball
225 Grease Pump

309966H

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

Not for use in explosive atmospheres.

Model No. 246909, Series C, Pail Length
Model No. 246780, Series C, 120-lb Drum Length
Model No. 246781, Series C, 400-lb Drum Length
Model No. 253361, Series C, Pail Length Without Handle

8400 psi (58 MPa, 580 bar) Maximum Working Pressure
140 psi (1.0 MPa, 10 bar) Maximum Air Working Pressure

Important Safety Instructions

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

EN

Table of Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

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

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

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

Air Motor and Throat Service . . . . . . . . . . . . . . . . 11

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . 16

Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . . . 16

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 18

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 18

Model No. 246780 shown

Warnings

Warnings

The following general warnings are for the setup, use, grounding, maintenance, and repair of this equipment. Addi­tional, more specific warnings may be found throughout the body of this manual where applicable. Symbols appear-

ing in the body of the manual refer to these general warnings. When these symbols appear throughout the manual,
refer back to these pages for a description of the specific hazard.

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 forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco
replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your Graco 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.

SKIN INJECTION HAZARD

High-pressure fluid from dispense valve, 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 dispense valve at anyone or at any part of the body.

• Do not put your hand over the end of the dispense nozzle.

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

• Follow Pressure Relief Procedure in this manual, when you stop dispensing 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.

2 309966H

Warnings

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.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

• Gloves

• Hearing protection

309966H 3

Installation

TI1052

Z

Y

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.

Ground the following equipment:

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

IG. 1.

• Fluid hoses: Use only electrically conductive hoses.

• Air compressor: Follow the manufacturer’s recom­mendations.

• Fluid supply container: Follow the local code.

• To 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 F

order a ground wire and clamp, order Part No. 222011.

IG. 1. To

Mounting

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

1. Plan the mounting layout for easy operator access
to the pump air controls, sufficient room to change
drums and a secure mounting platform.

2. If using a follow plate (H), remove the drum cover.
Scoop the material to the center of the drum to
make the surface convex. Place the plate on the
material. Guide the pump foot valve through the
plate.

3. Mount the pump to the drum cover or other suitable
mounting device.

4. Install a pump elevator for easier changing of
drums,

F

IG. 1

4 309966H

Installation

04191C

A

B

C

D

E

F

G

H

J

K

J

Recommended air line
configuration to reduce
moisture in pump

KEY

A Fluid dispense line
B Pump ground wire (required)
C Air regulator with gauge
D Main air supply line
E Air line filter
F Air line lubricator
G Pump runaway valve
H Follower plate
J Bleed-type master air valves

(required)

K Fluid drain valve

1/2 in.

Air and Fluid Line and Accessories

See FIG. 2.

Three accessories are required in your system: an air
shut-off valve/air bleed device, fluid drain valve, and
ground wire. These accessories help reduce the risk of
serious bodily injury, including skin injection, splashing
in the eyes or on the skin, injury from moving parts if you
are adjusting 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 unex­pectedly, causing serious injury if you are adjusting
or repairing the pump. Use a bleed-type master air
valve (J), installed near the pump air inlet within
easy reach from the pump.

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

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

CAUTION

Do not hang the air accessories directly on the air
inlet. 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.

Install the air line accessories in the order shown in
F

IG. 2.

1. 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.

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

3. Install a bleed-type master air valve (J) to relieve air
trapped between the valve and the motor. Order
Part No. 107142.

4. Install an air regulator (C) to control pump speed
and pressure.

5. Install an air line filter (E) to remove harmful dirt and
contaminants from your compressed air supply.

6. Install a second bleed-type master air valve (J)
upstream from all other accessories, to isolate the
accessories for servicing.

Typical Installation for Stationary Mountings

FIG. 2

309966H 5

Operation

Operation

Pressure Relief Procedure

The equipment stays pressurized until pressure is man­ually relieved. To reduce the risk of serious injury from
pressurized fluid, fluid from the valve, or splashing fluid,
follow this procedure whenever you:

• are instructed to relieve pressure

• stop dispensing

• check, clean, or service any system equipment

• install or clean dispensing devices.

1. Close the pump air regulator and 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.

The pump has a rated ratio of 50:1. However, it is
capable of reaching stall pressures equal to 60
times the air input pressure. Calculate the fluid out­put pressure using the air regulator reading. Multi­ply the air pressure shown on the regulator gauge
by 60. For example:

140 psi air x 60 = 8400 psi fluid output)

(0.97 MPa air = 58.2 MPa fluid output

99.7 bar air x 60 = 582 bar fluid output

Regulate air to the pump so that no air line or fluid
line component or accessory is overpressurized.

6. Never allow the pump to run dry of the material
being pumped.

Startup

1. If there are multiple pumps on the air line, close the
air regulators and bleed–type master air valves to all
but one pump. If there is only one pump, close its air
regulator and bleed–type master air valve.

2. Open the master air valve from the compressor.

3. Open the dispensing valve into a grounded metal
waste container, making firm metal–to–metal con­tact between the container and valve. Open the
bleed–type master air valve and open the pump air
regulator slowly, just until the pump is running.
When the pump is primed and all air has been
pushed out of the lines, close the dispense valve.

4. If you have more than one pump, repeat this proce­dure for each pump.

When the pump is primed, and with sufficient air
supplied, the pump starts when the dispensing
valve is opened and shuts off when it is closed.

CAUTION

A dry pump will quickly accelerate to a high speed,
possibly damaging itself. If your pump accelerates
quickly, or is running too fast, stop it immediately and
check the material supply. If the supply container is
empty and air has been pumped into the lines, prime
the pump and lines with material, or flush it and leave
it filled with a compatible solvent. Be sure to eliminate
all air from the material lines.

A pump runaway valve can be installed on the air
line to automatically shut off the pump if it starts to
run too fast.

7. Read and follow the instructions supplied with each
component in your system.

8. To shut off the system, always follow the Pressure
Relief Procedure.

5. Set the air pressure to each pump at the lowest
pressure needed to get the desired results.

6 309966H