Graco Falcon A Series Manual de usuario

Instructions – Parts List

GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441

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

Fig. 1

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

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.

8758B

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

Concave Surface

Push Down

on Plate

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.

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