Graco Series D Datasheet

308608L

Instructions - Parts List

6:1 Fire-Ball® 425 Pump

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

only.

Not approved for use in European explosive atmosphere locations.

Model 238108, Series D

1100 psi (7.6MPa, 76 bar) Maximum Working Pressure

180 psi (1.2 MPa, 12 bar) Maximum Air Input Pressure

Related Manuals

Important Safety Instructions

Read all warnings and instructions in this

manual before using the equipment.

Save these instructions.

Manual in

English Description

308201 Pump Runaway Valve

2 308608L

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

System Accessories. . . . . . . . . . . . . . . . . . . . . . . 6

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cover Mount . . . . . . . . . . . . . . . . . . . . . . . . . 7

Wall Mount . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 8

Start Up and Adjustment . . . . . . . . . . . . . . . . . . . 8

Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . 10

End of Product Life . . . . . . . . . . . . . . . . . . . . . . 10

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Air Motor and Throat . . . . . . . . . . . . . . . . . . . . . 12

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 12

Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . 15

Displacement Pump. . . . . . . . . . . . . . . . . . . . . . 16

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 16

Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . 16

Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . 16

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Displacement Pump. . . . . . . . . . . . . . . . . . . . . . 17

Model 238108, Series D . . . . . . . . . . . . . . . 17

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Performance Charts. . . . . . . . . . . . . . . . . . . . . . . . 20

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Model 238108 Pump, Series D . . . . . . . . . . . . . 21

Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . 21

Technical Specifications . . . . . . . . . . . . . . . . . . . . 22

California Proposition 65 . . . . . . . . . . . . . . . . . . . . 23

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 24

Warnings

308608L 3

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 Specifications in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical

Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For

complete information about your material, request Safety Data Sheets (SDSs) 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.

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.

Warnings

4 308608L

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 Safety Data Sheets (SDSs) 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.

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious

chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious

injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or

fluids containing such solvents.

• Do not use chlorine bleach.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material

supplier for compatibility.

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.

• Ground all equipment in the work area.

• 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.

• 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.

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.

• 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. 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.

WARNING

Typical Installation

308608L 5

Typical Installation

The typical installation shown in FIG. 1 is only a guide for selection and installation of a pump. It is not an actual

system design. Contact your Graco representative or Graco distributor for assistance in the design of a suitable

system.

Key:

A Bleed-type master air valve (required)

B Air line filter

C Air regulator and gauge

D Pump runaway valve (shown for position) - not needed if

using a low-level cut-off valve

E Air inlet

F Ball valve (for releasing collected moisture)

G Pump

H Drain valve (required)

J Dispensing valve (model 222411 shown)

K Thermal relief kit (required) Part No. 240429

L Male quick-disconnect pin fitting (alternative to A)

M Female quick-disconnect coupler (alternative to A)

N Air line lubricator

P Fluid hose

R Electrically conductive air hose (218093 shown)

S Fluid inlet

T Wall mounting bracket

Y Ground wire (required)

Z Muffler

FIG. 1: Typical Installation

Alternate Air Bleed Device

NOTICE

Always mount the pump firmly to a bracket or a tank

cover. Do not operate the pump if it is not mounted,

doing so could damage the pump and the fittings.

Installation

6 308608L

Installation

System Accessories

Install the accessories shown in FIG. 1.

1. Insert the muffler (5) into the 3/4 in. npt muffler port

and tighten using a wrench on the flats of the

muffler near the male threads.

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

motor lubrication.

3. Install an air regulator (C) to control the pump

speed and pressure.

4. Install an air line filter (B) to remove harmful dirt and

contaminants from the compressed air supply.

5. Install a bleed-type master air valve (A) to isolate

the accessories for servicing. See FIG. 1. To order a

bleed-type master air valve, order Part No. 107142.

As an alternative to a bleed-type master air valve,

installation of an air line female quick-disconnect

coupler (M) and male quick-disconnect pin fitting

(L) (see FIG. 1) can serve as an air-bleed device.

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

relieve fluid pressure in the hoses and gun when

opened. To order a fluid drain valve, order Part No.

210658.

7. Install a thermal relief kit (K) on the dispensing valve

side of the pump. To order a 1600 psi (11 MPa, 110

bar) thermal relief kit, order Part No. 240429.

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

(J).

Four accessories are required in the system: an air

shut-off valve’s 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 eyes or on the skin,

injury from moving parts if 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 bodily injury when

adjusting or repairing the pump. Use either a

bleed-type master air valve (A) or a quick-disconnect

coupler with male quick-disconnect pin fitting (L).

Install near the pump air inlet, within easy reach of

the pump.

The fluid drain valve (H) assists in relieving fluid

pressure in the displacement pump, hoses and

dispensing valve. Triggering the dispensing valve (J)

to relieve pressure may not be sufficient.

The thermal relief kit assists in relieving pressure in

the pump, hose, and dispensing valve due to heat

expansion.

The ground wire reduces the risk of static sparking.

Installation

308608L 7

Grounding

1. Remove the ground screw (Z) located on the side of

the pump base.

2. Insert the ground screw (Z) through the eye of the

ring terminal (W) located at the end of the ground

wire (Y).

3. Fasten the ground screw (Z) back onto the back of

the pump and tighten the screw securely.

4. Connect the other end of the ground wire (Y) to a

true earth ground.

Mounting

Install the pump in a location that will adequately sup-

port the weight of the pump when it is filled with lubri-

cant and also provides easy operator access to the

pump air controls. The pump must be mounted in a ver-

tical position. See Technical Specifications, page 22

for pump weight information and the Dimensions and

Mounting Hole Layout, page 21.

Cover Mount

For cover mounting, see the Mounting Hole Layout,

page 21.

Wall Mount

The pump shown in FIG. 1 is wall mounted. To oder the

wall mounting bracket, order Part No. 238425.

The equipment must be grounded to reduce the risk

of static sparking. Static sparking can cause fumes

to ignite or explode. Grounding provides an escape

wire for the electric current.

FIG. 2

Mount the pump securely so that it cannot move

around during operation. Failure to do so could result

in injury or equipment damage.

Operation

8 308608L

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever

you see this symbol.

1. Close the bleed-type master air valve (A) (required

in the system) or female quick-disconnect coupler

(M).

2. Hold a metal part of the dispensing valve (J) firmly

to a grounded metal waste container and trigger

the valve to relieve the fluid pressure.

3. Open the drain valve (H).

Start Up and Adjustment

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:

6 (:1) ratio x 180 psi air = 1080 psi fluid output

6 (:1) ratio x 7 bar air = 42 bar fluid output

6 (:1) ratio x 0.7 MPa air = 4.2 MPa fluid output

1. With the air regulator (C) closed, open the

bleed-type master air valves (A), or, if so equipped,

join the female quick-disconnect coupler (M) to the

male quick-disconnect pin fitting (L).

2. Open the dispensing valve (J) into a grounded

metal waste container, making firm metal-to-metal

contact between the container and valve,

3. Open the pump air regulator (C) slowly, just until the

pump is running. When the pump is primed and all

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 dispensing and before

cleaning, checking, or servicing the equipment.

COMPONENT RUPTURE HAZARD

The maximum working pressure of each component

in the system may not be the same. To reduce the

risk of over-pressurizing any component in the

system, be sure you know the maximum working

pressure of each component. Never exceed the

maximum working pressure of the lowest rated

component in the system. Over-pressurizing can

result in rupture, fire, explosion, property damage,

and serious injury.

Limit the air to the pump so that no air line or fluid line

component or accessory is over-pressurized.

The air motor exhaust coming out of the muffler

could contain harmful materials, such as oil,

anti-freeze, or some of the material being pumped.

Wear appropriate protective equipment when in the

work area to help prevent serious injury, including

inhalation of toxic fumes.

Operation

308608L 9

of the air has been pushed out of the lines, close

the dispensing valve.

NOTE: 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.

4. If the system is equipped with a runaway valve (D),

set it for the system configuration. See Pump

Runaway Valve manual for setting instructions.

5. Adjust the air regulator until there is sufficient flow

from the dispensing valve. Always run the pump at

the lowest speed necessary for the desired results,

making sure not to exceed the maximum working

pressure of any component in the system.

NOTE: Stop the pump if it is accelerating too quickly or

is running too fast, and check the fluid supply. If the

supply container is empty and air has been pumped

into the lines, prime the pump and lines with fluid, or

flush it and leave filled with a compatible solvent.

Ensure that all air is eliminated from the fluid lines. If the

system has a runaway valve, reset it according to the

instructions in the Pump Runaway Valve manual.

6. Read and follow the instructions supplied with each

of your system components.

7. If the pump will be unattended for any period of

time, if there is an air supply interruption, or to shut

off the system at the end of the work shift, relieve

pressure following the Pressure Relief Procedure,

page 8.

8. Periodically check that the pump’s mounting is

secure.

Do not allow the pump to run dry of the fluid being

pumped. A dry pump will quickly accelerate to a high

speed, possibly damaging itself, and it may become

very hot.

Recycling and Disposal

10 308608L

Recycling and Disposal

End of Product Life

At the end of the product’s useful life, dismantle and

recycle it in a responsible manner.

• Perform the Pressure Relief Procedure in your

pump manual.

• Drain and dispose of fluids according to applicable

regulations. Refer to the material manufacturer’s

Safety Data Sheet.

• Deliver remaining product to a recycling facility.

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