Graco Falcon A Series User manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 2000, Graco Inc. is registered to I.S. EN ISO 9001
50:1 RATIO DOUBLE ACTING
FalcontGrease Pumps
For lubricating products only
7500 psi (52 MPa, 517 bar) Maximum Fluid Working Pressure
150 psi (1.0 MPa, 10 bar) Maximum Air Input Pressure
Model 244044, Series A
35 lb (16 kg) Pail Size
Model 244045, Series A
120 lb (55 kg) Drum Size
Model 244046, Series A
400 lb (180 kg) Drum Size
U.S. Patent No. 5,147,188
309224D
Read warnings and instructions.
See page 2 for table of contents.
8757C
Parts

2 309224
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart 12. . . . . . . . . . . . . . . . . . . . . . . . .
Service 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions and Mounting Hole Layout 29. . . . . . . . . . .
Performance Charts NO TAG. . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 32. . . . . . . . . . . . . . . . . . . . . .
Graco Information 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
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, call 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 stated on the equipment or in the Technical Data
for your equipment. Do not exceed the maximum working pressure of the lowest rated component
in your system.
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.
DHandle hoses carefully. Do not pull on hoses to move equipment.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 66_C (150_F) or below –40_C (–40_F).
DWear hearing protection when operating this equipment.
DDo not move or lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
DThese pumps are designed to be used only in pumping non-corrosive and non-abrasive lubricants
and greases. Any other use of the pump can cause unsafe operating conditions and component
rupture, which can result in fluid injection or other serious injury, or fire or explosion.

3309224
WARNING
INJECTION HAZARD
Fluid dispensed from the valve, 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 medi-
cal attention.
DDo not point the valve at anyone or at any part of the body.
DDo not put your hand or fingers over the spray nozzle.
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/valve when dispensing.
DBe sure the valve trigger safety operates before dispensing.
DLock the valve trigger safety when you stop dispensing.
DFollow the Pressure Relief Procedure on page 10 if the nozzle clogs and before cleaning, check-
ing or servicing the equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
DKeep clear of all moving parts when starting or operating the pump.
DBefore checking or servicing the equipment, follow the Pressure Relief Procedure on page 10 to
prevent the equipment from starting unexpectedly.

4 309224
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and re-
sult in a fire or explosion and serious injury.
DGround the equipment and the object being dispensed to. Refer to Grounding on page 6.
DIf there is any static sparking or you feel an electric shock while using this equipment, stop dis-
pensing 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 dispensed.
DKeep the dispense area free of debris, including solvent, rags, and gasoline.
DDo not smoke in the dispense area.
DDo not turn on or off any light switch in the dispense area while dispensing or while operating if
fumes are present.
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.
DThe air motor exhausts any fluids added to the input air, such as oil or antifreeze.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

5309224
Introduction
WARNING
These pumps area designed to be used only in
pumping non-corrosive and non-abrasive lubricants
and greases. Any other use of the pump can cause
unsafe operating conditions and component rup-
ture, which can result in fluid injection or other
serious injury, or fire or explosion.
NOTE: Be sure that all operators read and understand
this entire manual and any separate manuals supplied
with components and accessories before using this
equipment.
NOTE: Reference numbers and letters used in the text
refer to the callouts in the figures and the parts dra-
wing.
Terms
WARNING: Alerts the user to avoid or correct condi-
tions that could cause serious injury.
CAUTION: Alerts the user to avoid or correct condi-
tions that could cause damage to or destroy equip-
ment.
NOTE: Identifies helpful procedures and information.
DISPENSE VALVE: Any fluid dispensing device that
can be triggered on and off.
Component Description
This equipment consists of two major components: the
air motor (1) and the displacement pump. See Fig. 1 .
The pump is an in-line design, which means that the
displacement pump screws directly into the motor,
without the use of tie rods or couplers. The displace-
ment pump can be placed directly in the fluid being
pumped.
The pump is available in three different lengths, based
on the size of the fluid container. Refer to the front cov-
er for available sizes. The pumps differ only in length;
operation and packings are the same. All three pumps
use the same Air Motor.
Make sure the muffler (36) is securely installed in the
exhaust port (N) before you operate the pump. See
Fig. 1.
CAUTION
Never run the pump without the muffler installed.
8757C
1
Fig. 1
N
36

6 309224
Installation
NOTE: Always use Genuine Graco Parts and Acces-
sories, available from your Graco distributor.
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE OR EXPLOSION
HAZARD on page 4.
Ground all of this equipment:
DPump: Remove ground screw (Z) and insert
through the eye of the ring terminal at the end of
ground wire (Y). Fasten ground screw back onto
the pump and tighten securely. Connect the other
end of the wire to a true earth ground. See Fig. 2.
Order part number 222011 Grounding Clamp and
Wire.
DFluid hoses: Use only grounded fluid hoses.
DAir hoses: Use only grounded air hoses.
DDispensing Valve: Obtain grounding through
connection to a properly grounded fluid hose and
pump.
DFluid supply container: Follow your local code.
DAir compressor: Follow your local code.
DTo 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.
Fig. 2
Y
Z
TI1052

7309224
Installation
The Typical Installation shown in Fig. 3 is only a guide for selecting and installing system components and
accessories. Contact your Graco distributor for assistance in designing a system to suit your particular needs.
If you supply your own accessories, be sure they are adequately sized and pressure-rated to meet the system’s
requirements. See the Maximum Working Pressure warning on page 8.
Fig. 3
KEY
APump
BBleed-type master air valve (required, Part No. 110224)
CAir regulator
DAir hose
EAir line quick disconnect
FAir line filter
GBleed-type master air valve (for accessories, Part No. 110224))
HMain air line
JGun holder
KFollow plate
LFluid hose
MDispense valve
YGround wire (required, Part No. 222011)
The pump intake
should be no more
than 1/2 in. (13 mm)
off the bottom of the
fluid container.
1
A
BC
8758B
D
E
FG
H
J
K
L
M
Y
1

8 309224
Installation
Mounting the Pump
1. Select a convenient location for the equipment, to
ensure easy operator access to the pump air
controls, sufficient room to change supply contain-
ers, and a secure mounting platform.
2. If using a follow plate (K), remove the fluid contain-
er cover. To prevent air from being trapped under
the follow plate, scoop grease from the center of
the container to the sides, to make the surface
concave. Place the follow plate on the grease and
push down on the plate until grease appears at the
center opening (P). See Fig 4.
02050
K
Concave Surface
Push Down
on Plate
3
P
2
33
2
Fig. 4
3. Guide the pump intake valve through the cover
and follow plate. Secure the cover to the container.
4. Position the pump (A) so its intake valve is no
more than 1/2 in. (13 mm) from the bottom of the
container. Mount the pump to the cover or other
suitable mounting device.
WARNING
Mount the pump securely so that it cannot move
around during operation. Failure to do so could
result in personal injury or equipment damage.
System Accessories
WARNING
Maximum Working Pressure
The maximum working pressure of each compo-
nent in your system may not be the same. To
reduce the risk of overpressurizing any part of your
system, be sure you know the maximum working
pressure rating of each component. Never exceed
the maximum working pressure of the lowest rated
component connected to a pump. Use the following
table to limit the air to the pump so that no air line
or fluid line component or accessory is overpres-
surized.
Approximate
Air Inlet Pressure Fluid Outlet Pressure
psi (MPa, bar) psi (MPa, bar)
40 (0.28, 2.8) 2000 (14, 140)
60 (0.42, 4.2) 3000 (21, 210)
80 (0.56, 5.6) 4000 (28, 280)
100 (0.7, 7.0) 5000 (35, 350)
120 (0.84, 8.4) 6000 (42, 420)
140 (0.98, 9.8) 7000 (49, 490)
150 (0.9, 10) 7500 (52, 517)

9309224
Installation
WARNING
A bleed-type master air valve is required in your
system to help reduce the risk of serious injury,
including splashing 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.
1. Install a bleed-type master air valve (B), to relieve
air trapped between the valve and the motor. See
the WARNING above).
2. Install an air regulator (C), to control the pump
speed and pressure.
3. Install an air line filter (F) to remove harmful dirt
and moisture from the compressed air supply.
4. Install a second bleed-type master air valve (G)
upstream from all other accessories, to isolate the
accessories for servicing.
5. Connect the fluid hose (L) to the dispense
valve (M). Use a gun holder (J) to hold the dis-
pense valve when not in use.
6. For ease in connecting the air line to the pump,
use an air line quick disconnect (E) at the pump air
inlet.
7. Connect the air (D) and fluid hoses (L) to the pump
(A). Use only grounded fluid and air hoses. Be
sure all hoses are properly sized and pressure-
rated for your system.
NOTE: Additional air line lubrication is not required to
extend the Falcontgrease pump air motor life. The
air motor is prelubed at the factory and should not
require additional lubrication between maintenance
schedules. No accessory air line lubricator should be
installed.

10 309224
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
Fluid under high pressure can be in-
jected through the skin and cause seri-
ous injury. To reduce the risk of an injury
from injection, splashing fluid, or moving parts, fol-
low the Pressure Relief Procedure whenever you
DAre instructed to relieve the pressure
DStop dispensing
DCheck or service any of the system equipment
DInstall or clean the spray tips/nozzles
1. Close the pump air regulator.
2. Close the bleed-type master air valve (required in
your system).
3. Hold a metal part of the dispensing valve firmly to
the side of a metal waste container, and trigger the
valve to relieve fluid pressure.
If you suspect that the spray tip or hose is completely
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; then clear
the tip or hose.
Flushing
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 before using the pump.
WARNING
For your safety, read the warning section
FIRE AND EXPLOSION HAZARD on
page 4 before flushing, and follow all
the recommendations given there.