3:1 Mini Fire-Ball??

225 Oil Pump

309868D

ENG

Installation

Installation

The typical stationary installation shown in FIG. 1 is only a guide for selecting and installing a pump. It is not an

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F

M

B

P

actual system design. Contact your Graco distributor for assistance in designing a system to meet your needs.

E

J H

N

K G

Mounting the Pump

Mount the pump securely so that it cannot move dur- ing operation. Failure to do so could result in per- sonal injury or equipment damage.

???Select a location that allows the operator easy access to the pump and air controls, sufficient room to change supply containers, and a secure mounting platform.

???If you are mounting the pump directly on the supply container, be sure it is positioned so the pump???s intake tube is no more than 1 in. (25 mm) from the bottom of the container. Mount the pump to the cover or other suitable mounting device.

To prevent damage to the pump, remove sedi- ment from the bottom of the container before installing a pump in an existing container.

Grounding

Proper grounding is essential to maintaining a safe system.

To reduce the risk of static sparking, ground the pump. Check local electrical codes for detailed grounding instructions for your area and equipment type. Be sure the following equipment is properly grounded:

???Pump: See FIG. 2.

???Air and fluid hoses: Use only electrically conductive hoses.

???Air compressor: Follow manufacturer???s recommendations.

???Dispensing valve: Obtain grounding through con- nection to a properly grounded fluid hose and pump.

???Fluid supply container: Follow your local code.

???Object being lubricated: Follow your local code.

Installation

???Any pails used when flushing: Use only metal, grounded pails when flushing. Make firm metal-to-metal contact between a metal part of the dispensing valve and the pail. Use the lowest possi- ble pressure.

To maintain grounding continuity when flushing or reliev- ing 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 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. 2. To order a ground wire and clamp order Part No. 222011.

Y

Z

TI1052

FIG. 2

Operation

Operation

See FIG. 1 to identify references shown in parentheses, i.e., (A).

This equipment stays pressurized until pressure is manually relieved. Read PRESSURIZED EQUIP- MENT HAZARD warnings on page 2.

Maximum working pressure of all components in the system may not be the same. To reduce risk of over- pressurizing any component, 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. Overpressur- izing any component can result in rupture, fire, explo- sion, property damage, and serious injury.

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:

3:1 ratio x 100 psi air = 300 psi fluid output

Limit the air pressure to the pump so that no air line or fluid line component is overpressurized.

Pressure Relief Procedure

1.Close the pump air regulator (C) and the bleed-type master air valve (A), required in your system.

2.Hold a metal part of the dispensing valve (H) firmly to a grounded metal waste container, and trigger the valve to relieve fluid pressure.

Starting and Adjusting the Pump

1.With the air regulator (C) closed, open the bleed-type master air valve (A).

2.Open the dispensing valve (H) 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 air has been pushed out of the lines, close the dis- pensing valve (H).

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

4.Adjust the air regulator (C) until you get sufficient flow from dispensing valve (H). Always run the pump at the lowest pressure necessary to get the desired results. Do not exceed the maximum work- ing pressure of any component in the system.

CAUTION

Never allow the pump to run dry of the fluid being pumped. A dry pump will quickly accelerate to a high speed, possibly causing pump damage. It may also get very hot.

5.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 lines with fluid, or flush it and leave it filled with a compat- ible solvent. Be sure to eliminate all air from the fluid lines.

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

7.If the pump will be unattended for any period of time, if there is an air supply interruption, or at the end of the work shift, shut off the system and always relieve the pressure.

Before You Start

???Be sure you have all necessary parts on hand. Pump Repair Kit 246918 includes repair parts for the pump and air motor. Use all the parts in the kit for the best results. Parts included in the kit are marked with one asterisk, for example (17*), in the text and drawings. See Parts, page 14.

???Two accessory tools should be used: Padded Pliers, 248198, are used to grip the trip rod without damaging its surface. Gauge, 15E796, is used to ensure the proper clearance between the poppets and seat of the transfer valve.

Disassembly

1. Flush the pump, and relieve the pressure.

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 6.

2.Disconnect the ground wire from the grounding screw (28a), disconnect the hoses, remove the pump from its mounting, and clamp the air motor base in a vise horizontally by closing the vice jaws on the flange.

3.Use a strap wrench on the fluid cylinder (105) to screw it out of the air motor base (28). See Parts, page 14.

4.Pull the displacement rod (29) down as far as it will go. See FIG. 3.

5.Using wrenches on the flats of the displacement rod (29) and on the flats of the fluid piston (107), unscrew the fluid piston from the displacement rod. Remove the ball (100) from the end of the displace- ment rod, and remove the packing o???ring (102*) from the fluid piston. See Parts, page 14.

6.Clamp the air motor upright in the vice by closing the vice jaws below the flange.

7.Unscrew the cylinder cap nut (39) from the top of the air motor cylinder (35).

8.Pull up on the cylinder cap nut (39) to expose the trip rod, grasp the trip rod with padded pliers (Part No. 248198), and unscrew the cylinder cap nut from the trip rod.

CAUTION

Do not damage the plated surface of the trip rod (40). Damaging the surface of the trip rod can result in erratic air motor operation. Use the special padded pliers to grasp the rod.

9.Remove the six screws (9) holding the air motor cylinder (35) to the air motor base (28), and care- fully pull the cylinder straight up off of the

piston (34).

CAUTION

To avoid damaging the cylinder wall, lift the cylinder straight up off of the piston. Never tilt the cylinder while you are removing it.

10.Pull the air motor piston/displacement rod assembly (29, 34) clear of the air motor base (28) by pulling up on the air motor piston.

11.Remove the o???rings (13*, 103*) and u???cup

packing (16*) from the air motor base (28). Use nee- dle???nose pliers to remove the u???cup packing from the bottom of the air motor base.

39

35

40

9

16*

flange

12.Remove the o???ring (18*) from the air motor piston (34).

13.Clamp the displacement rod upright in the vice by closing the vice jaws on the flats of the displace- ment rod.

14.Use a screwdriver to push down on the trip rod yoke (23) to snap the toggle assemblies (L) down. See FIG. 4.

15.Remove the lockwires (25*) from the adjusting nuts (24*) of the transfer valves. Screw the top nuts off. Screw the valve poppet (32*) stems out of the grommets (17*) and bottom nuts (24*). Take the valve poppets off of the stems, and squeeze them firmly to check for cracks.

16.Grip the toggle arms (38) with pliers. Compress the springs (20) and swing the toggle assembly (L) up and away from the piston lugs (M), and remove the assembly. Check that the valve actuator (27) is sup- ported by the spring clips (26), but slides easily into them. See Fig. 4.

To reduce the risk of pinching or amputating your fin- gers, always keep fingers clear of the toggle assemblies (L).

17.Remove the trip rod yoke (23), actuator (27), and trip rod (40). Check the exhaust valve poppets (31*) for cracks.

To remove the exhaust valve poppets (31*), stretch them out and cut the end off with a sharp knife.

Clean and Service

1.Clean all the parts carefully in a compatible solvent and inspect for wear or damage. Use all the repair kit parts during reassembly, and replace other parts as necessary.

2.Check the polished surfaces of the air motor piston (34), displacement rod (29), and cylinder wall (35) for scratches or wear. A scored rod will cause premature packing wear and leaking.

3.Lubricate all parts with a light weight, water-resis- tant grease.

Air Motor and Throat Service

Reassembly

1.Clamp the displacement rod (29) upright in the vice by closing the vice jaws on the flats of the displace- ment rod.

2.Pull the new exhaust valve poppets (31*) into the valve actuator (27), and clip off the top parts of the poppets (shown with dotted lines in the Cutaway View in Fig. 4).

3.Install the new grommets (17*) in the actuator (27), place the inlet valve poppets (32*) in the piston, and thread the bottom valve nuts (24*) onto the stems of the inlet valve poppets until there are a few threads left before the threads run out.

If you thread the valve nuts too far down onto the poppets, they will run off the threaded part of the

poppets.

4.Grease heavily and place the trip rod (40) in the air motor piston (34), place the actuator (27) in the yoke (23), and place the well???greased actuator/yoke assembly in the piston, with the trip rod going through the center holes of the actuator and yoke and the stems of the inlet valve poppets (32*) going through the grommets (17*).

5.Thread the top valve nuts (24*) onto the stems of the inlet valve poppets (32*) until one thread of the inlet valve poppets is exposed above the valve nuts.

6.Install the toggle pins (36) in the yoke (23), place the toggle arm (38) ends of the toggle assembly (L) onto the toggle pins, and snap the pivot pin (37) ends of the toggle assembly into the piston lugs (M).

7.Measuring with the gauge (Part No.15E796), create 0.105 in. (2.7 mm) of clearance between the inlet valve poppets (32*) and the piston seat when the inlet valve is open. See the Cutaway View in Fig. 4.

Adjust the distance between the inlet valve poppets and the piston seat by turning the top valve

nuts (24*).

8.Tighten the bottom valve nuts (24*) by hand. The grommets (17*) should be slightly compressed.

25*

1

M

24*

32*

17*

24*

26

34

1Turn wires up.

2Push toggles (L) in and then up.

3Cut off tops of poppets as indicated by dotted lines.

FIG. 4

40 3

24*

17*

24*

18*

0.105 in.

(2.7 mm)

32*

04119 34

Cutaway View

CAUTION

Never re-use the old lock wires. They will get brittle and break easily from too much bending.

9.Align the holes in the valve nuts (24*) and the slots on the stems of the inlet valve poppets (32*). Drop the lock wires (25*) through the holes in the valve nuts and into the slots in the stems of the inlet valve poppets. Pull the lock wires down tightly, and bend the ends with pliers so that they cannot be pulled back out of the holes.

10.Take the assembly out of the vice so that you can move it around for steps 11 and 12.

11.Grease and install the new o???rings (13*, 18*, 103*).

12.Install the new u???cup packing (16*) through the bot- tom of the air motor base, with the lips facing toward the bottom of the pump.

13.Slide the displacement rod (29) down through the packings, and lower the air motor piston (34) into the air motor base (28).

14.Clamp the air motor upright in the vice by closing the vice jaws below the flange.

15.Carefully lower the air motor cylinder (35) straight down onto the piston assembly (34). Tighten the six screws (9) holding the air motor cylinder to the air motor base (28).

CAUTION

To avoid damaging the cylinder wall, lower the cylinder straight down onto the piston. Never tilt the cylinder as it is being lowered.

16.Pull the trip rod (40) so it is sticking up out of the air motor cylinder (35).

You may have to hold the unit upside down to shake the trip rod loose.

17.Grip the trip rod (40) with padded pliers, screw the cylinder cap nut (39) onto the trip rod, push the cyl- inder cap nut down, and screw it into the top of the cylinder.

CAUTION

Do not damage the plated surface of the trip rod (40). Damaging the surface of the trip rod can result in erratic air motor operation. Use the special padded pliers to grasp the rod.

18.Place the piston ball (100) in the displacement rod (29).

19.Clean the threads of the fluid piston (107), apply Loctite?? to the threads, install the new packing o???ring (102*) on the fluid piston, and thread the fluid piston onto the displacement rod (29).

Air Motor and Throat Service

20.Clamp the flats of the fluid piston (107) in a vice, and torque the displacement rod (29) to the piston to 40 to 60 ft???lb (54 to 81 N???m).

21.Clamp the air motor base (28) in a vise horizontally by closing the vice jaws on the flange.

22.Use a strap wrench to screw the displacement pump cylinder (105) to the air motor base (28), and torque to 40 to 60 ft???lb (54 to 81 N???m).

23.Before remounting the pump, connect an air hose and run the air motor slowly, starting with just enough air pressure to make the air motor run, and make sure that it operates smoothly.

Never operate the pump with the warning plate (47) or the identification plate (46) removed. These plates protect your fingers from getting pinched or ampu- tated by moving parts in the air motor.

24.Reconnect the ground wire before you resume regu- lar pump operation.

Be sure you have all necessary parts on hand. Pump Repair Kit 246918 includes repair parts for the pump and air motor. Use all of the parts in the kit for the best results. Parts included in the kit are marked with one asterisk, for example (13*), in the text and drawings. See Parts, page 14.

1. Flush the pump and relieve the pressure.

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 6.

2.Disconnect the hoses, remove the pump from its mounting, and clamp the air motor base in a vise horizontally by closing the vice jaws on the flange.

3.Unscrew the intake valve housing (106) from the fluid cylinder (105). Disassemble the intake valve (see Parts, page 14). Clean and inspect the parts for wear or damage, and replace parts as needed. Be sure to check the o-ring (104*). Unless further intake valve service is needed, reassemble and reinstall, using liquid sealant on the male threads.

4.Use a strap wrench on the fluid cylinder (105) to screw it out of the air motor base (28). Carefully inspect the smooth inner surface of the cylinder for scoring or irregular surfaces. Such damage causes premature packing wear and leaking, so replace the part if it is damaged.

5.Using wrenches on the flats of the displacement rod (29) and on the flats of the fluid piston (107), unscrew the fluid piston from the displacement rod.

6.Take the piston ball (100) out of the displacement rod (29), and take the packing o-ring (102*) off of the fluid piston (107).

7.Clean and inspect the parts. Use all the repair kit parts during reassembly, and replace other parts as necessary.

8.Place the piston ball (100) in the displacement rod (29).

9.Install the new packing o-ring (102*) on the fluid piston (107).

10.Clamp the flats of the fluid piston (107) in a vice and torque the displacement rod (29) to the piston to 40 to 60 ft-lb (54 to 81 N???m).

11.Clamp the air motor base (28) in a vise horizontally by closing the vice jaws on the flange.

12.Use a strap wrench to screw the fluid cylinder (105) to the air motor base (28), and torque to

40 to 60 ft-lb (54 to 81 N???m).

13.If you disconnected the ground wire, reconnect it before you resume regular pump operation.

Air Motor

Pump

*Included in Pump Repair Kit 246918.

** Use gap adjustment tool 15E796 (also included in Repair Kit 246918) to ensure correct gap setting for poppets.

Technical Data

Technical Data

(Data measured with 10 weight oil at 70??F (21??C)

Flow Rate

TEST FLUID: No 10 Weight Oil

A= 100 psi (6.9 bar)

B= 70 psi (4.8 bar)

C= 40 psi (2.8 bar)

8.9 in.

1/2 in. npt(f) fluid outlet

8.9 in.

(20 cm)

(20 cm)

1-1/2 in. npt

05750

Mounting Hole Layout

Pump Base

4.250 in. (10.8 cm) bolt circle

0.281 in. (7.1 mm) diameter clearance holes

40.68 in. (103.33 cm) drop tube is cut to length

Order gasket 15R881 for sealed tank/drum mounting.

2.518 in.

(6.4 cm) dia.

4.250 in. (10.8 cm) bolt circle

0.266 in. (6.7 mm) diameter clearance holes