Graco 308996J Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1999, Graco Inc. is registered to I.S. EN ISO 9001
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
308996J
9092B
Important Safety Instructions
Read all warnings and instructions this manual.
Save these instructions.

2 308996
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation/Maintenance 8. . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart 11. . . . . . . . . . . . . . . . . . . . . . . . .
Service 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnecting the Displacement Pump 12. . . . . . .
Reconnecting the Displacement Pump 12. . . . . . . .
Displacement Pump Service 14. . . . . . . . . . . . . . . .
Parts Drawings and Parts Lists 19. . . . . . . . . . . . . . . . . .
Pump Assemblies 19. . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 20. . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 25. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 26. . . . . . . . . . . . . . . . . . . . . .
Graco Information 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are not sure, contact your Graco distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo 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.
DUse fluids and solvents which are 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.
DWear hearing protection when operating this equipment.
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
DKeep hands and clothing away from moving parts.
DRoute 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).

308996 3
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.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate
surgical treatment.
DDo not point the gun at anyone or at any part of the body.
DDo not put your hand or fingers over the spray tip.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DDo not “blow back” fluid; this is not an air spray system.
DAlways have the tip guard and the trigger guard on the gun when spraying.
DCheck the gun diffuser operation weekly. Refer to the gun manual.
DBe sure the gun trigger safety operates before spraying.
DDo not allow children to use this equipment.
DLock the gun trigger safety when you stop spraying.
DFollow 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.
DTighten all fluid connections before operating the equipment.
DCheck 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.
DFluid 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
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
DKeep clear of all moving parts when you start or operate the pump.
DBefore you service this equipment, follow the Pressure Relief Procedure on page 8 to prevent
the equipment from starting unexpectedly.

4 308996
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.
DGround the equipment and the object being sprayed. Refer to Grounding on page 5.
DIf 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.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
DKeep the spray area free of debris, including solvent, rags, and gasoline.
DElectrically disconnect all equipment in the spray area.
DExtinguish all open flames or pilot lights in the spray area.
DDo not smoke in the spray area.
DDo not turn on or off any light switch in the spray area while operating or if fumes are present.
DDo 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.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

308996 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.
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 thoroughly read all instruction
manuals, tags, and labels before operating the equip-
ment.
Grounding
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.
Fig. 1
W
X
Y
Z
0864
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, 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.

6 308996
Installation
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.
The bleed-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:
DAbleed-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.
DAn 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.
DAn air regulator (Z) adjusts air pressure to the
air–assisted gun.
DAn 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.
DA second bleed-type air valve (K) isolates the air
line accessories for servicing. Locate upstream
from all other air line accessories.
DAn Air Relief Valve (G) (Falcon II 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 necessary:
DA fluid filter (not shown) with a 60 mesh (250
micron) stainless steel element, to filter particles
from the fluid as it leaves the pump.
DA gun (S) dispenses the fluid. The gun shown in
Fig. 2 is an air–assisted spray gun for light to me-
dium viscosity fluids.
DA gun swivel (R) allows freer gun movement.
DA suction hose (T) allows the pump to draw fluid
from a supply container.

308996 7
Installation
Fig. 2
KEY
APump
BWall Bracket
DGun Air Hose
EBleed-Type Master Air Valve
(required, for pump)
FPump Air Regulator
HElectrically Conductive Air Supply Hose
GAir Relief Valve (Falcon II packages only)
(shown in exploded view)
JAir Line Filter
KBleed-Type Master Air Valve
(for accessories)
LPump Outlet
MWet Cup
NElectrically Conductive
Fluid Supply Hose
RGun Swivel
SAir–Assisted Spray Gun
TSuction Hose
UStrainer
YGround Wire and Clamp
(required; see page 5
for installation instructions)
WAir Line Drain Valve
ZGun Air Regulator
TYPICAL INSTALLATION
1Do not stretch hose tight; let it hang as shown, to
assist fluid flow into the pump. Adjust suction tube
so it’s about a 1/2 inch off bottom of the pail.
B
S
R
Y
W
H
J
K
G
A
U
T
Z
E
F
1
D
D
N
9140B
N
L
M
Main Air Line
(G) Air Relief Valve
F
E
G

8 308996
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:
Dare instructed to relieve the pressure,
Dstop spraying,
Dcheck or service any of the system equipment,
Dor install or clean the spray tips.
1. Lock the gun trigger safety.
2. Shut off the air supply to the pump.
3. Close the bleed-type master air valve (E) (required
in your system).
4. Unlock the gun trigger safety.
5. Hold a metal part of the gun firmly to the side of a
grounded metal pail, and trigger the gun to relieve
pressure.
6. Lock the gun trigger safety.
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.

308996 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.
1. Remove tip guard and spray tip from gun. Refer to
gun manual.
2. Close air regulator (F).
3. Close bleed–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.
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.
WARNING
COMPONENT RUPTURE HAZARD
To reduce the risk of overpressurizing
your system, which could cause compo-
nent rupture and serious injury, never
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.
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:
Dare instructed to relieve the pressure,
Dstop spraying,
Dcheck or service any of the system equipment,
Dor install or clean the spray tips.
Install the Spray Tip
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.

10 308996
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. See Flushing below.
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
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:
DBefore first use
DWhen changing colors or fluids
DBefore fluid drys or settles out in a dormant pump
(check the pot life of catalyzed fluids)
DBefore storing the pump.
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.
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 system 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.