Graco Falcon C Series Instructions-Parts List Manual page 9

Disassembly
NOTE: Falcon cylinder, base, and piston repair parts
are available in Repair Kit 241833.
1. Fig. 3. Remove three screws (29) holding motor
base (17) to bottom cylinder cap (3). Pull base off
cap.
2. Remove u–cup packing (18) from bottom cylinder
cap.
3. Remove retaining ring (51) and bearing (50) from
motor base. Inspect. Replace if worn or damaged.
4. Remove six screws (24 and 53) holding bottom
cylinder cap to motor cylinder (1). Lift motor cylin-
der off bottom cylinder cap to expose piston (13).
5. Pull piston and piston rod (16) out of motor
cylinder.
6. Remove trip plate (49) from bottom of piston.
7. Remove piston o-ring (32). Use wrench on flats at
end of piston rod to hold it steady, and unscrew
nut (35) from rod. Remove piston and o-ring (30)
from rod.
8. Remove two screws (45) and motor cover (41)
from top cylinder cap (2).
9. Remove six screws (24 and 53) and lift off top
cylinder cap.
10. Remove trip plate (49) from top of cylinder.
11. Examine inner surface of cylinder for scoring or
damage.
12. Remove large o-ring (21) and two small o-rings
(34) from inside of top cylinder cap. Repeat for
bottom cylinder cap.
Falcon Air Motor Service
Cylinder, Base and Piston Service
Reassembly
1. Fig. 3. Grease large o-ring (21) and two small
o-rings (34) and install on top cylinder cap (2).
Repeat for bottom cylinder cap (3).
2. Install trip plate (49) into bottom of motor
cylinder (1).
3. Install bottom cylinder cap on cylinder. Be sure
that large o-ring (21) does not roll out of groove.
Install two M4 screws (24) in square section of
bottom cylinder cap. Install four M5 screws (53) in
tabs. Torque two M4 screws in square section from
14 to 17 in-lb (1.6 to 1.9 NSm) and four M5 screws
in tabs from 35 to 45 in-lb (4.0 to 5.1 NSm).
4. Lubricate u–cup packing (18). Install it in bottom
cylinder cap with lips facing up toward cylinder
5. Install bearing (50) and retaining ring (51) into
motor base (17).
6. Install motor base on bottom cylinder cap.
7. Install o-ring (30) and piston (13, with chamfer
facing down toward o-ring) on piston rod (16).
Screw self-locking nut (35) onto piston rod. Install
o-ring (32) on piston, and lubricate o-ring.
8. Grease piston rod and inner wall of motor cylinder.
9. Insert piston rod through motor cylinder into bot-
tom cylinder cap and motor base. Be careful not to
damage u-cup packing inside bottom cap.
10. Install trip plate (49) into top of motor cylinder.
11. Install top cylinder cap on motor cylinder. Be sure
that large o–ring does not roll out of groove. Install
two M4 screws (24) in square section of top cylin-
der cap. Install four M5 screws (53) in tabs. Torque
two M4 screws in square section from 14 to 17
in-lb (1.6 to 1.9 NSm) and four M5 screws in tabs
from 35 to 45 in-lb (4.0 to 5.1 NSm).
12. Install motor cover (41) using two screws (45).
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