Hitachi 308996J User's Manual
Contents
1. Instructions Parts List GRACO STAINLESS STEEL Falcon and Falcon Il Pumps 308996J With Severe Duty Rod and Cylinder Part No 241594 Pump Series B 10 1 Ratio with Falcon Air Motor 1500 psi 10 3 MPa 103 5 bar Maximum Fluid Working Pressure 150 psi 1 0 MPa 10 4 bar Maximum Air Input Pressure Part No 241595 Pump Series B 20 1 Ratio with Falcon Il Air Motor 2200 psi 15 MPa 152 bar Maximum Fluid Working Pressure 100 psi 0 7 MPa 7 bar Maximum Air Input Pressure Chinese Patent No ZL00808468 8 Taiwan Patent R O C New Invention Patent No 163401 U S Patent No 7 168 856 France Brevet No 1192362 Germany DBP No 1192362 Italy Patent No 1192362 United Kingdom Patent No 1192362 Korean Patent No 10 0689946 Important Safety Instructions TL Y Read all warnings and instructions this manual Be Save these instructions LA 9092B PROVEN QUALITY LEADING TECHNOLOGY GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 1999 Graco Inc is registered to I S EN ISO 9001 12G Table of Contents Symbols VVa IOS iii ent ar ela Delta Lang RE 2 y A O IA 5 Warning Symbol Operation Maintenance u e La 8 Troubleshooting Chart as ia ta as ex 11 WARNING SEIGE watts mites Sale ree tended hes 12 Required Tools ee ee ee ee ee ee ee ee 12 This symbol alerts you to the possibility of serious Disconnecting the Displacement Pu2. 5 Turn on air supply Run pump slowly to ensure proper operation 44 WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 8 Model 241594 Shown 107 1 Se a 2 106 a ee o A SA O 4 Peal E 108 N U el ee i e VAN Torque to 120 130 in lb 10 11 Nem NA Fig 3 9094B 308996 13 Service Disassembly When disassembling the pump lay out all removed parts in sequence to ease reassembly NOTE U cup Repair Kits are available For the best results use all the new parts in the kit Kit parts are marked with an asterisk for example 8 1 Fig 4 Place outlet housing 7 in vise 2 Apply adjustable wrench to flats of intake valve 19 Unscrew intake valve from cylinder 9 Remove seal 8 from intake valve Remove ball stop 3 and ball 17 Inspect ball and seat D of intake valve for wear or damage 3 Unscrew cylinder 9 Gently pull cylinder straight out of outlet housing Displacement rod 1 and piston assembly may come out with cylinder If not pull displacement rod out 14 308996 a Fig 5 Unscrew wet cup 2 from outlet hous ing 7 Remove u cup 4 bearing 5 and seal 8 b Fig 4 Remove seal 8 from cylinder 9 Shine light into cylinder to inspect inner sur face for scoring or wear Fig 6 Place flats of piston housing 16 in vise
3. Using adjustable wrench unscrew displacement rod 1 from piston housing Examine displacement rod for scratches or other damage Fig 7 Remove nut 13 lockwasher 12 u cup seals 14 and spacers 15 from piston housing 16 Inspect seals for wear or damage Clean all parts with compatible solvent and inspect for wear or damage Remove piston housing from vise Remove ball 11 and examine it and piston seat A Service A Torque to 30 40 ft lb 41 54 N m Lubricate 9095A Fig 4 OU Cd MN Torque to 30 40 ft lb 41 54 N m Lubricate 9099B Fig 5 308996 15 Service AX Torque to 5 20 ft lb 120 27 Nem ES 4 Lubricate A 13 ag L 9096A Fig 6 16 308996 Service Reassembly 1 Fig 6 Clean threads of displacement rod 1 and piston housing 16 Replace u cup seals 14 and spacers 15 Reassemble piston nut 13 and lockwasher 12 Place flats of piston seat housing 16 in vise Tighten displacement rod and piston nut from 20 to 27 Nem 15 to 20 ft lb Install seal 8 on cylinder 9 Lubricate seal and threads Fig 5 Install throat bearing 5 and u cup seal 4 into wet cup 2 Install seal 8 onto wet cup Lubricate seals and threads Install wet cup into outlet housing 7 hand tight Fig 6 Lubricate u cup seals 14 and insert piston displacement rod into cylinder 9 7 10 12 Install cylinder
4. 1 800 328 0211 Toll Free 612 623 6921 612 378 3505 Fax All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice This manual contains English MM 308996 Graco Headquarters Minneapolis International Offices Belgium Korea China Japan www graco com 308996 06 1999 Revised 04 2007 26 308996
5. first by sliding displacement rod 1 up through outlet housing 7 and wet cup 2 then engage cylinder threads into outlet housing and hand tighten Replace intake ball 17 and ball stop 3 into intake valve 19 Install seal 8 on intake valve Lubricate seal and threads Install intake valve into cylinder and hand tighten Place outlet housing into vise Using an adjustable wrench tighten the wet cup from 41 to 54 Nem 30 to 40 ft lb Tighten the cylinder from 41 to 54 Nem 30 to 40 ft lb and the intake valve from 41 to 54 Nem 30 to 40 ft lb Reconnect the displacement pump to the air motor as detailed in Reconnecting the Displacement Pump on page 12 308996 17 Service I AN Torque to 20 27 N m 15 20 ft lb A Torque to 41 54 N m 30 40 ft Ib ZA Lubricate Y us 2 A Lips face up A Lips face down See Throat Seal Detail at left See Piston Seal Detail at left Throat Packing Stack Detail Displacement Pump 241516 Shown see page 21 for options Piston Packing Stack Detail Displacement Pump 241516 Shown see page 21 for options 15 Er N A So A U ONTZA V 3 9097A Fig 7 18 308996 Parts Part No 241594 Pump Series B 10 1 Ratio vvith Falcon Air Motor These parts are included with Lower Repair Kit 241597 9094B Ref No PartNo Description Qty 101 241504 AIR M
6. ISO 9614 2 Model 241595 Falcon Il Pump Rat A r ED A RA DR 20 1 Maximum fluid working pressure u e ua eee 152 bar 2200 psi Maximum air input pressure u e au ea a ena 7 bar 100 psi Cycle rates et ee cites aera peda et gen aa a aa aa Wan 60 cycles min maximum Pump cycles per 3 8 liters 1 gal 2 0 2 cece eee eee 200 Fluid flow at 60 cycles min 0 cece eee es 0 29 gpm Air motor piston effective area 2 0 keene 6 665 in 2 Stroke length Les shee ele Dels a a nls wed Gad a E 57 mm 2 25 in Displacement pump effective area Le eee ees 0 307 in 2 Maximum pump operating temperature au ea eee 66 C 120 F Noise level at 100 psi 30 cycles min 0 cece eee 74 6 dB A Sound power level at 100 psi 30 cycles min 77 4 dB A Air inlet Size use ii ia 3 8 npsm f Eluiciinietsize sre aeto n Lt A i ama Ee 3 8 npt f Fluid outlet Size ici ii de mt ie om ria Dant 1 4 npt f A A ta ade a ne 20 lb Wetted paritaria as stainless steel PTFE uhmvvpe Tested in accordance with ISO 9614 2 308996 23 Technical Data Performance Charts To find Fluid Outlet Pressure psi MPa bar at a specific fluid flow Ipm gpm and operating air pressure psi MPa bar 1 Locate fluid flow rate along bottom of chart 2 Follow vertical line up to intersection with selected fluid outlet pressure curve 3 Follow left to scale to
7. Parts Displacement Pump Series B Description ROD displacement stainless steel chrome HOUSING throat stainless steel STOP ball stainless steel HOUSING outlet stainless steel SEAL PTFE CYLINDER stainless steel chrome BALL piston stainless steel 0 375 9 5 mm dia HOUSING seat piston valve stainless steel BALL intake stainless steel 0 5 12 7 mm dia VALVE intake stainless steel TAG warning not shown Part No 241516 Ref Part No No 1 194756 2 194757 3 115148 7 194759 8 103341 9 194760 11 101947 16 194761 17 105445 19 195003 254 172479 A e ES ES S 16 Piston Packing Stack see page 21 9099B Qty aq gt 2 Repair Rits Repair Kit 241597 for Falcon Pump 241516 Ref Part No No Description Qty 4 115251 SEAL u cup uhmwpe 5 194758 BEARING throat acetal 8 103341 O RING PTFE 11 101947 BALL piston 14 115146 SEAL u cup carbon filled PTFE 15 194880 SPACER seal Nylon 17 105445 BALL intake 106 115218 PIN clevis 107 111609 PIN cotter 115146 is a PTFE seal An uhmwpe seal 115408 is avail able and sold separately La a NN ga a THROAT PACRINGS LIPS FACE DOWN 2 107 es 106 es LIPS DOWN O 15 5 LIPS UP Sd LIPS DOWN S ue 4 LIPS UP So 15 Om Ow LUBRICATE PACKINGS 17 8 Throat Seal Repair Kit 241827 for Falcon Pump 241516 1 1 Ref Part No No Description Qty 4 115251 SEAL u
8. exceed the specified Maximum Incoming Air Pres sure to the pump see the Front page of this manual 12 Use air regulator F to control pump speed and fluid pressure Always use lowest air pressure necessary to get desired results Higher pressures cause premature tip and pump wear 44 WARNING SKIN INJECTION HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying accidentally Fluid under high pressure can be injected through the skin and cause serious injury To reduce the risk of an injury from injection splashing fluid or moving parts follow the Pressure Relief Procedure whenever you are instructed to relieve the pressure stop spraying check or service any of the system equipment or install or clean the spray tips Install the Spray Tip 44 WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 8 Relieve the pressure by shutting off air valve and then trigger the gun Install the spray tip and tip guard as explained in your separate gun manual 308996 9 Operation Maintenance Shutdown and Care of the Pump 44 WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 8 Always flush the pump before the fluid dries on the displacement rod See Flushing belo
9. pump 109 from motor 101 as follows Note relative position of pump s fluid outlet U to air inlet V of motor If motor does not require servicing leave it attached to its mounting 44 CAUTION If you are disconnecting the displacement pump from a motor which is still mounted for example on a wall bracket be sure to support the displacement pump while it is being disconnected to prevent it from falling and causing injury or property damage 12 308996 5 Using needle nose pliers remove cotter pin 107 from clevis pin 106 Remove clevis pin from displacement rod 1 6 Hold tie rod flats with wrench to keep rods from turning Unscrew nuts 108 from tie rods 105 Carefully remove displacement pump 109 from motor 101 7 Refer to page 14 for displacement pump service To service air motor refer to separate motor manual 308995 Reconnecting the Displacement Pump 1 Fig 3 Reconnect displacement pump 109 to motor 101 see CAUTION at left Orient pump s fluid outlet U to air inlet V as noted in step 4 under Disconnecting the Displacement Pump Position displacement pump 109 on tie rods 105 2 Insert clevis pin 106 through piston rod VV and displacement rod 1 Install cotter pin 107 3 Screw nuts 108 onto tie rods 105 and tighten 4 Reconnect all hoses Reconnect ground wire if disconnected Fill wet cup 2 1 3 full of Graco Throat Seal Liquid or compatible solvent
10. such as paper or cardboard which interrupts the grounding continu ity 8 To maintain grounding continuity when flushing or relieving pressure hold a metal part of the spray gun firmly to the side of a grounded metal pail then trigger the gun System Accessories Fig 2 is only a guide for selecting and installing sys tem components and accessories Contact your Graco distributor for assistance in designing a system to suit your particular needs Air and Fluid Hoses Ensure that you have an adequate compressed air supply Bring a compressed air supply line from the air compressor to the pump location Be sure all air hoses H and D and fluid hose N are properly sized and pressure rated for your system Use only electrically conductive hoses Fluid hoses must have spring guards on both ends The air hose H should have a 3 8 npt m thread A quick disconnect coupling is recommended Mounting Accessories Mount the pump A to suit the type of installation planned Fig 2 illustrates a wall mount system Pump dimensions and the mounting hole layout are shown on page 25 308996 5 Installation System Accessories continued 44 WARNING A bleed type master air valve E is required in your system This accessory helps reduce the risk of serious injury including fluid injection and splashing of fluid in the eyes or on the skin and injury from moving parts if you are adjusting or repairing the pump The bl
11. EIGHT OIL FALCON Il 20 1 scfm Air Consumption m3 min 10 0 Zz 0 28 o E 7 5 0 21 B50 A 0 14 B oO a 2 5 c lt 0 07 0 0 gpm 0 0 0 1 0 2 0 3 0 4 0 5 liters minute 0 4 0 8 1 1 1 5 1 9 FLUID FLOW TEST FLUID NO 10 WEIGHT OIL Dimensions Mounting Hole Layout Model 241595 Shown Gao gt 1 4 A 0653 9092B 241594 513 qua a mm 209 yi 159 a 3 8 in npt f 1 4 in npt f 3 8 npt f 241595 20 2 in 11 97 in 8 23 in 6 25 in 308996 25 Graco Standard Warranty Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or sub stitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompa
12. OTOR Falcon See 308995 for parts 1024 190867 LABEL warning 105 194909 ROD tie 127 mm 5 shoulder to shoulder 106 115218 PIN clevis 107 111609 PIN cotter 108 111040 NUT hex 109 241516 PUMP displacement See page 20 for parts 1 These parts are included with Lower Repair Kit 241597 A Replacement Danger and Warning labels tags and cards are available at no cost gt 00 Part No 241595 Pump Series B 20 1 Ratio with Falcon Il Air Motor These parts are included with Lower Repair Kit 241597 9094B Ref No PartNo Description Qty 101 241505 AIR MOTOR Falcon II See 308995 for parts 1 1024 190867 LABEL warning 105 194909 ROD tie 127 mm 5 shoulder to shoulder 106 115218 PIN clevis 107 111609 PIN cotter 108 111040 NUT hex 109 241516 PUMP displacement See page 20 for parts 1 These parts are included with Lower Repair Kit 241597 A Replacement Danger and Warning labels tags and cards are available at no cost 00 308996 19 NOTE The parts listed on this page are common to all displacement pumps covered in this manual Refer to page 21 for the different packing configurations available These parts are included in Lower Repair Kit 241597 A Replacement Danger and Warning labels tags and cards which may be purchased separately are available at no cost 20 Throat Packing Stack see page 21 308996
13. cup uhmwpe 5 194758 BEARING throat acetal THROAT PACKINGS LIPS FACE DOWN 5 lt S LUBRICATE PACKINGS Piston Repair Kit 241828 for Falcon Pump 241516 2NNAa a Ref Part No No Description Qty 11 101947 BALL bearing 0 375 in 12 103780 WASHER lock 13 103777 NUT hex full 14 115146 SEAL u cup carbon filled PTFE 15 194880 SPACER seal Nylon 16 194761 VALVE piston 115146 is a PTFE seal An uhmwpe seal 115408 is avail able and sold separately LIPS UP LIPS wa 15 SO 14 LUBRICATE PACKINGS Intake Repair Kit 241829 for Falcon Pump 241516 Ref Part No No Description Qty 3 115148 STOP intake ball 8 103341 O RING packing 17 105445 BALL 0 5000 in 19 195003 VALVE intake OD 3 QS A SS 17 19 9104A 308996 21 Repair Rits Piston Repair Rit 241830 for Falcon Pump 241516 Ref No 14 15 115146 is a PTFE seal An uhmwpe seal 115408 is avail able and sold separately Part LIPS DOWN No Description Qty 15 LIPS UP 115146 SEAL u cup carbon filled PTFE 2 194880 SPACER seal Nylon 2 14 LIPS DOWN LIPS UP 15 LUBRICATE PACKINGS Piston SST Conversion Kit 15B327 for Falcon Pump 241516 Ref No 14 15 115146 is a PTFE seal An uhmwpe seal 115408 is avail Part LIPS DOVVN No Description Qty 15 LIPS UP 115146 SEAL u cup carbon filled PTFE 2 15B328 SPACER seal sst 2 14 O able and sold s
14. eed type master air valve relieves air trapped between this valve and the pump after the air is shut off Trapped air can cause the pump to cycle unexpectedly Locate the valve close to the pump Order Part No 114362 Air Line Accessories Install the following accessories in the locations shown in Fig 2 using adapters as necessary e A bleed type master air valve E is required in your system to relieve air trapped between it and the air motor when the valve is closed see the WARNING above Be sure the bleed valve is eas ily accessible from the pump and is located upstream from the air regulator e An air regulator F controls pump speed and out let pressure by adjusting the air pressure to the pump Locate the regulator close to the pump but downstream from the bleed type master air valve 6 308996 e An air regulator Z adjusts air pressure to the air assisted gun e An air line filter J removes harmful dirt and moisture from the compressed air supply Also install a drain valve W at the bottom of each air line drop to drain off moisture e A second bleed type air valve K isolates the air line accessories for servicing Locate upstream from all other air line accessories e An Air Relief Valve G Falcon Il Packages only opens automatically to prevent over pressurization of the pump Fluid Line Accessories Install the following accessories in the locations shown in Fig 2 using adapters as nec
15. em until clear solvent flows from gun 8 Stop pump with displacement rod at bottom of its stroke 9 Relieve the pressure 10 Clean tip guard spray tip and fluid filter element separately then reinstall them 11 Clean inside and outside of suction hose Troubleshooting Chart 1 Relieve the pressure 44 WARNING 2 Check all possible causes and problems before To reduce the risk of serious injury whenever you disassembling the pump are instructed to relieve pressure always follow the Pressure Relief Procedure on page 8 PROBLEM CAUSE SOLUTION The pump fails to oper Restricted air line or an inadequate air Clear the line increase the air supply ate supply closed or clogged valves Check that the valves are open Obstructed fluid hose or gun Open clear use a hose with a larger ID the fluid hose ID is too small Fluid has dried on the displacement rod Clean the rod always stop the pump at the bottom of its stroke keep the wet cup 1 3 filled with a compatible sol vent Dirty worn or damaged motor parts Clean or repair see the separate motor manual 308995 The pump operates Restricted air line or an inadequate air Clear the line increase the air supply but the output is low on supply closed or clogged valves Check that the valves are open both strokes Obstructed fluid hose or gun Open clear use a hose with a larger ID the fluid hose ID is too small Worn u cup seals
16. eparately 15 LIPS UP 22 LUBRICATE PACKINGS 308996 Technical Data 44 WARNING Be sure that all fluids and solvents used are chemically compatible with the Wetted Parts listed below Always read the manufacturers literature before using fluid or solvent in these pumps Model 241594 Falcon Pump Rat Oi 2 nas a Da A A A id 10 1 Maximum fluid working pressure 0c eee ee 104 bar 1500 psi Maximum air input pressure u au ea na 10 4 bar 150 psi Cycle mate citen ida ES SI HS DGE CIA 60 cycles min maximum Pump cycles per 3 8 liters 1 gal u e ea a aa LL LL 200 Fluid flow at 60 cycles min u Lu ue teenies 0 29 gpm Air motor piston effective area 4 ua Luna aa na 3 142 in 2 SU ORe On gi citi ii de sitat neS 57 mm 2 25 in Displacement pump effective area 4 44 una Lena 0 307 in 2 Maximum pump operating temperature au ee 66 C 120 F Noise level at 100 psi 30 cycles min 0 cece eee 70 8 dB A Sound power level at 100 psi 30 cycles min 74 8 dB A Alt MOU SIZ Cis a ccc ces plan Esc etat sae kate na eal idea tt 3 8 npsm f Eluidiniet Size sens ec head fetter a oC EE ada wg bed 3 8 npt f Eluid outl tsize 0 A a 1 4 npt f Weight ca a O ed 20 Ib Wetted parts cien acti Rat ee ac Aedes stainless steel PTFE uhmvvpe Tested in accordance with
17. essary e A fluid filter not shown with a 60 mesh 250 micron stainless steel element to filter particles from the fluid as it leaves the pump e A gun S dispenses the fluid The gun shown in Fig 2 is an air assisted spray gun for light to me dium viscosity fluids e A gun swivel R allows freer gun movement e A suction hose T allows the pump to draw fluid from a supply container Installation TYPICAL INSTALLATION KEY A Pump J Air Line Filter S Air Assisted Spray Gun B Wall Bracket K Bleed Type Master Air Valve T Suction Hose D Gun Air Hose for accessories U Strainer E Bleed Type Master Air Valve L Pump Outlet Y Ground Wire and Clamp required for pump M Wet Cup required see page 5 F Pump Air Regulator N Electrically Conductive for installation instructions H Electrically Conductive Air Supply Hose Fluid Supply Hose W Air Line Drain Valve G Air Relief Valve Falcon ll packages only R Gun Swivel Z Gun Air Regulator shown in exploded view Main Air Line ee U w 9140B A Do not stretch hose tight let it hang as shovvn to assist fluid flovv into the pump Adjust suction tube so it s about a 1 2 inch off bottom of the pail Fig 2 308996 7 Operation Maintenance Pressure Relief Procedure 1 8 44 WARNING SKIN INJECTION HAZARD The system pressure must be manually relieved to prevent the system from starting or spraying accidentally Fluid under high pressure can be
18. gger safety when you stop spraying Follow the Pressure Relief Procedure on page 8 whenever you are instructed to relieve pres sure stop spraying clean check or service the equipment and install or clean the spray tip Tighten all fluid connections before operating the equipment Check the hoses tubes and couplings daily Replace worn loose or damaged parts immediately Permanently coupled hoses cannot be repaired you must replace the entire hose Fluid hoses must have spring guards on both ends to help protect them from rupture caused by kinks or bends near the couplings MOVING PARTS HAZARD S7 Moving parts such as the air motor piston can pinch or amputate your fingers e Keep clear of all moving parts when you start or operate the pump e Before you service this equipment follow the Pressure Relief Procedure on page 8 to prevent the equipment from starting unexpectedly 308996 3 44 WARNING FIRE AND EXPLOSION HAZARD Improper grounding poor ventilation open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury Ground the equipment and the object being sprayed Refer to Grounding on page 5 If there is any static sparking or you feel an electric shock while using this equipment stop spray ing immediately Do not use the equipment until you identify and correct the problem Provide fresh air ventilation to avoid the buildup of flammable fumes from so
19. in the displacement Replace the u cup seals pump The pump operates Held open or worn intake valve Clear the valve service but the output is low on the downstroke The pump operates Held open or worn piston valve or u cup Clear the valve replace the u cup seals but the output is low on the upstroke Erratic or accelerated Exhausted fluid supply Refill the supply and prime the pump pump speed Held open or worn piston valve or u cup Clear the valve replace the u cup seals seals Held open or worn intake valve Clear the valve service To determine if the fluid hose or gun is obstructed follow the Pressure Relief Procedure on page 8 Discon nect the fluid hose and place a container at the pump fluid outlet to catch any fluid Turn on the air just enough to start the pump If the pump starts when the air is turned on the obstruction is in the fluid hose or gun NOTE If you experience air motor icing call your Graco distributor 308996 11 Service Required Tools Set of adjustable vvrenches Torque wrench Vise Thread lubricant Disconnecting Displacement Pump 1 Fig 3 Flush pump if possible Stop pump at bottom of its stroke 44 WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 8 2 Relieve the pressure 3 Disconnect air hose and fluid hose 4 Disconnect displacement
20. injected through the skin and cause serious injury To reduce the risk of an injury from injection splashing fluid or moving parts follow the Pressure Relief Procedure whenever you are instructed to relieve the pressure stop spraying check or service any of the system equipment or install or clean the spray tips Lock the gun trigger safety 308996 Shut off the air supply to the pump Close the bleed type master air valve E required in your system Unlock the gun trigger safety Hold a metal part of the gun firmly to the side of a grounded metal pail and trigger the gun to relieve pressure Lock the gun trigger safety 44 WARNING If you suspect that the spray tip or hose is com pletely clogged or that pressure has not been fully relieved after following the steps above very slowly loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually then loosen completely Now clear the tip or hose Operation Maintenance Flush Pump Before First Use The pump is tested with lightweight oil which is left in to protect the pump parts If the fluid you are using may be contaminated by the oil flush it out with a compatible solvent See Flushing on page 10 Starting and Adjusting Pump Before starting fill wet cup 1 3 full with TSL or compat ble solvent 1 Remove tip guard and spray tip from gun Refer to gun manual 2 Close air regulator F 3 Close bleed
21. l implied warranties of merchantability and fitness for a particular purpose in connection with accessories equipment materials or components sold but not manufactured by Graco These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnais sent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les procedures concern es Graco Information TO PLACE AN ORDER contact your Graco distributor or call one of the following numbers to identify the distributor closest to you
22. lvents or the fluid being sprayed Keep the spray area free of debris including solvent rags and gasoline Electrically disconnect all equipment in the spray area Extinguish all open flames or pilot lights in the spray area Do not smoke in the spray area Do not turn on or off any light switch in the spray area while operating or if fumes are present Do not operate a gasoline engine in the spray area TOXIC FLUID HAZARD Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin inhaled or swallowed Know the specific hazards of the fluid you are using Store hazardous fluid in an approved container Dispose of hazardous fluid according to all local state and national guidelines Always wear protective eyewear gloves clothing and respirator as recommended by the fluid and solvent manufacturer 4 308996 Installation General Information NOTE Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawing NOTE Always use Genuine Graco Parts and Acces sories available from your Graco distributor If you supply your own accessories be sure they are ade quately sized and pressure rated for your system Prepare the Operator All persons who operate the equipment must be trained in the safe efficient operation of all system components as well as the proper handling of all fluids All operators must thoroughl
23. mp 12 injury or death if you do not follow the instructions Reconnecting the Displacement Pump 12 Displacement Pump Service 14 Parts Drawings and Parts Lists 19 Pump Assemblies u e 19 Caution Symbol Displacement PUMP 20 Technical Data 23 A CAUTION DIMENSIONS es Sisk te ee he NE EO es 25 Mounting Hole Layout u e 25 This symbol alerts you to the possibility of damage to Graco Standard Warranty 26 or destruction of equipment if you do not follow the Graco Information o 26 instructions 44 WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury 84 NA INSTRUCTIONS This equipment is for professional use only Read all instruction manuals tags and labels before operating the equipment Use the equipment only for its intended purpose If you are not sure contact your Graco distributor Do not alter or modify this equipment Use only genuine Graco parts and accessories Check equipment daily Repair or replace worn or damaged parts immediately Do not exceed the maximum working pressure of the lowest rated system component Refer to the Technical Data on pages 23 24 for the maximum working pressure of this equipment Use fluids and solvents which a
24. re compatible with the equipment wetted parts Refer to the Tech nical Data section of all equipment manuals Read the fluid and solvent manufacturer s warnings Wear hearing protection when operating this equipment Do not lift pressurized equipment Comply with all applicable local state and national fire electrical and safety regulations Keep hands and clothing away from moving parts Route hoses away from traffic areas sharp edges moving parts and hot surfaces Do not expose Graco hoses to temperatures above 180 F 82 C or below 0 F 18 C 2 308996 44 WARNING SKIN INJECTION HAZARD Spray from the gun leaks or ruptured components can inject fluid into your body and cause extremely serious injury including the need for amputation Fluid splashed in the eyes or on the skin can also cause serious injury Fluid injected into the skin might look like just a cut but it is a serious injury Get immediate surgical treatment Do not point the gun at anyone or at any part of the body Do not put your hand or fingers over the spray tip Do not stop or deflect leaks with your hand body glove or rag Do not blow back fluid this is not an air spray system Always have the tip guard and the trigger guard on the gun when spraying Check the gun diffuser operation weekly Refer to the gun manual Be sure the gun trigger safety operates before spraying Do not allow children to use this equipment Lock the gun tri
25. read fluid outlet pressure A 100 psi 0 7 MPa 7 bar air pressure B 70 psi 0 49 MPa 4 9 bar air pressure C 40 psi 0 28 MPa 2 8 bar air pressure FALCON 10 1 psi Fluid Outlet Pressure ii MPa bar Es 1000 Dn 6 6 68 A die il or 750 a 500 E 3 4 34 o 250 e 1 7 17 L 0 gpm 0 0 0 1 0 2 0 3 0 4 0 5 liters minute 0 4 0 8 1 1 1 5 1 9 FLUID FLOW TEST FLUID NO 10 WEIGHT OIL FALCON II 20 1 psi Fluid Outlet Pressure w MPa bar Lc Es 2400 o 16 6 166 A a 1800 a 12 4 124 E Ww g a 8 3 83 o 600 C AA A AAA E 4 2 41 L 0 gpm 0 0 0 1 0 2 0 3 0 4 0 5 liters minute 0 4 0 8 1 1 1 5 1 9 FLUID FLOW TEST FLUID NO 10 WEIGHT OIL 24 308996 To find Pump Air Consumption m3 min or scfm at a specific fluid flow Ipm gpm and air pressure psi MPa bar 1 Locate fluid flow rate along bottom of chart 2 Read vertical line up to intersection with selected air consump tion curve 3 Follow left to scale to read air consumption A 100 psi 0 7 MPa 7 bar air pressure B 70 psi 0 49 MPa 4 9 bar air pressure C 40 psi 0 28 MPa 2 8 bar air pressure FALCON 10 1 scfm Air Consumption m3 min 10 0 zZ 0 28 o E 7 5 0 21 2 S 5 0 O 0 14 A Oo ac 2 5 Be lt 0 07 c 0 0 gpm 0 0 0 1 0 2 0 3 0 4 0 5 liters minute 0 4 0 8 1 1 1 5 1 9 FLUID FLOW TEST FLUID NO 10 W
26. tibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale Graco makes no warranty and disclaims al
27. type air valves E and K Connect airline H to bleed type air valve E 4 Check that all fittings throughout the system are tightened securely 5 See Fig 2 Connect the suction hose T to pump s fluid inlet Place tube into fluid supply Do not stretch hose tight let it hang as shown in Fig 2 to assist fluid flow into pump 6 Hold metal part of gun S firmly to side of grounded metal pail and hold trigger open 7 Open pump s bleed type master air valve E 8 Slowly turn regulator knob clockwise increasing pressure until pump starts 9 Cycle pump slowly until all air is pushed out and pump and hoses are fully primed 10 Release gun trigger and engage safety latch Pump should stall against pressure 44 CAUTION Do not allow the pump to run dry It will quickly accelerate to a high speed causing damage If your pump is running too fast stop it immediately and check the fluid supply If the container is empty and air has been pumped into the lines refill the con tainer and prime the pump and the lines or flush and leave it filled with a compatible solvent Eliminate all air from the fluid system 11 With pump and lines primed and with adequate air pressure and volume supplied pump will start and stop as you open and close gun 44 WARNING COMPONENT RUPTURE HAZARD To reduce the risk of overpressurizing uH Mell your system which could cause compo nent rupture and serious injury never
28. w Preventive Maintenance Schedule The operating conditions of your particular system determine how often maintenance is required Estab lish a preventive maintenance schedule by recording when and what kind of maintenance is needed and then determine a regular schedule for checking your system Flushing 44 WARNING FIRE AND EXPLOSION HAZARD Before flushing read the section FIRE AND EXPLOSION HAZARD on page 4 Be sure the entire system and flush ing pails are properly grounded Refer to Grounding on page 5 Flush the pump e Before first use e When changing colors or fluids e Before fluid drys or settles out in a dormant pump check the pot life of catalyzed fluids e Before storing the pump 10 308996 Flush with a fluid that is compatible with the fluid you are pumping and with the wetted parts in your system Check with your fluid manufacturer or supplier for recommended flushing fluids and flushing frequency Always flush the pump before fluid dries on the dis placement rod 44 WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure always follow the Pressure Relief Procedure on page 8 1 Relieve the pressure 2 Remove spray tip from gun 3 Place suction hose in a container of solvent 4 Hold metal part of gun firmly to side of grounded metal pail 5 Start pump Always use lowest possible fluid pressure when flushing 6 Trigger gun 7 Flush syst
29. y read all instruction manuals tags and labels before operating the equip ment Grounding A WARNING FIRE AND EXPLOSION HAZARD Before operating the pump ground the system as explained below Also read the section FIRE AND EXPLOSION HAZARD on page 4 1 Pump use a ground wire and clamp See Fig 1 Loosen the grounding lug locknut W and washer X Insert one end of a 1 5 mm 12 ga minimum ground wire Y into the slot in lug Z and tighten the locknut securely Connect the other end of the wire to a true earth ground Order Part No 238909 Ground Wire and Clamp VV 0864 Fig 1 2 Pump air supply and fluid hoses Use only electri cally conductive hoses with a maximum of 500 feet 150 m combined hose length to ensure ground ing continuity Check the electrical resistance of your air and fluid hoses at least once a week If the total resistance to ground exceeds 29 megohms replace the hose immediately NOTE Use a meter that is capable of measuring resistance at this level 3 Air compressor follow manufacturer s recommen dations 4 Spray gun ground through connection to a prop erly grounded fluid hose and pump 5 Fluid supply container follow your local code 6 Object being sprayed follow your local code 7 Solvent pails used when flushing follow your local code Use only metal pails which are conductive placed on a grounded surface Do not place the pail on a nonconductive surface
Download Pdf Manuals
Related Search