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Instructions – Parts List
STAINLESS STEEL
Falcon and Falcon II Pumps
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 II 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
Read all warnings and instructions this manual.
Save these instructions.
308996J
9092B
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Summary of Contents for Graco 308996J
- Page 1 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 Read all warnings and instructions this manual. Save these instructions. 308996J 9092B...
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Page 2: Table Of Contents
Table of Contents Warnings ........Installation . - Page 3 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. D Fluid injected into the skin might look like just a cut, but it is a serious injury.
- Page 4 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. D Ground the equipment and the object being sprayed. Refer to Grounding on page 5. D If there is any static sparking or you feel an electric shock while using this equipment, stop spray- ing immediately.
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Page 5: 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. - Page 6 System Accessories (continued) 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.
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Page 7: Typical Installation
Pump Wall Bracket Gun Air Hose Bleed-Type Master Air Valve (required, for pump) Pump Air Regulator Electrically Conductive Air Supply Hose G Air Relief Valve (Falcon II packages only) (shown in exploded view) Main Air Line Fig. 2 Installation TYPICAL INSTALLATION Air Line Filter Bleed-Type Master Air Valve (for accessories) -
Page 8: Operation/Maintenance
Operation/Maintenance Pressure Relief Procedure 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:... - Page 9 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- ible solvent.
- Page 10 Operation/Maintenance Shutdown and Care of the Pump 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.
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Page 11: Troubleshooting Chart
Troubleshooting Chart WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 8. PROBLEM CAUSE The pump fails to oper- Restricted air line or an inadequate air ate. -
Page 12: Service
Required Tools Set of adjustable wrenches Torque wrench Vise Thread lubricant Disconnecting Displacement Pump 1. Fig. 3. Flush pump, if possible. Stop pump at bottom of its stroke. WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 8. - Page 13 Service Model 241594 Shown Torque to 120–130 in-lb (10–11 NSm). 9094B Fig. 3 308996...
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Page 14: Displacement Pump 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*). Fig. - Page 15 Fig. 4 Fig. 5 Service Torque to 30–40 ft-lb (41–54 N.m). Lubricate. Torque to 30–40 ft-lb (41–54 N.m). Lubricate. 9095A 9099B 308996...
- Page 16 Torque to 5–20 ft-lb (120–27 NSm). Lubricate. Fig. 6 308996 Service 9096A...
- Page 17 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). 2. Place flats of piston seat housing (16) in vise. Tighten displacement rod and piston nut from 20 to 27 NSm (15 to 20 ft–lb).
- Page 18 Torque to 20–27 N.m (15–20 ft-lb). Torque to 41–54 N.m (30–40 ft-lb). Lubricate. Lips face up 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;...
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Page 19: Parts Drawings And Parts Lists
Part No. 241594 Pump, Series B 10:1 Ratio, with Falcon Air Motor *106 107* These parts are included with Lower Repair Kit 241597. Ref. Part No. Description 241504 AIR MOTOR, Falcon See 308995 for parts 102Y 190867 LABEL, warning 194909 ROD, tie;... -
Page 20: Displacement Pump
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, which may be purchased separately. Y Replacement Danger and Warning labels, tags and cards are available at no cost. - Page 21 Repair Kit 241597, for Falcon Pump 241516 Part Description 115251 SEAL, u–cup; uhmwpe 194758 BEARING, throat; acetal 103341 O–RING; PTFE 101947 BALL, piston 115146 SEAL, u–cup; carbon–filled PTFE 194880 SPACER, seal; Nylon 105445 BALL, intake 115218 PIN, clevis 111609 PIN, cotter * 115146 is a PTFE seal.
- Page 22 Piston Repair Kit 241830, for Falcon Pump 241516 Part Description 115146 SEAL, u–cup; carbon–filled PTFE 194880 SPACER, seal; Nylon * 115146 is a PTFE seal. An uhmwpe seal, 115408 is avail- able and sold separately Piston SST Conversion Kit 15B327, for Falcon Pump 241516 Part Description 115146...
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Page 23: Technical Data
Technical Data Be sure that all fluids and solvents used are chemically compatible with the Wetted Parts listed below. Always read the manufacturer’s literature before using fluid or solvent in these pumps. (Model 241594 Falcon Pump) Ratio ..............Maximum fluid working pressure . - Page 24 To find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow (lpm/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 read fluid outlet pressure. 100 psi (0.7 MPa, 7 bar) air pressure 70 psi (0.49 MPa, 4.9 bar) air pressure 40 psi (0.28 MPa, 2.8 bar) air pressure...
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Page 25: Dimensions
Dimensions Model 241595 Shown Pump Model 241594, 513 mm 304 mm 241595 (20.2 in.) (11.97in.) 35.6 mm (1.40”) 2x 7mm 0.28” 9092B 209 mm 159 mm (8.23 in.) (6.25 in.) Mounting Hole Layout 35.6 mm (1.40”) 89 mm (3.50”) 35.6 mm (1.40”) 3/8 in. -
Page 26: Graco Standard Warranty
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.