Hitachi 308996J User Manual
Instructions – Parts List
STAINLESS STEEL
Falcon and Falcon II Pumps
308996J
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.
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1999, Graco Inc. is registered to I.S. EN ISO 9001
9092B
Table of Contents
Symbols
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS
D This equipment is for professional use only.
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.
D Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are not sure, contact your Graco distributor.
D Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
D Do 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.
D Use 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.
D Wear hearing protection when operating this equipment.
D Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
D Keep hands and clothing away from moving parts.
D Route 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).
2 308996
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.
D Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate
surgical treatment.
D Do not point the gun at anyone or at any part of the body.
D Do not put your hand or fingers over the spray tip.
D Do not stop or deflect leaks with your hand, body, glove or rag.
D Do not “blow back” fluid; this is not an air spray system.
D Always have the tip guard and the trigger guard on the gun when spraying.
D Check the gun diffuser operation weekly. Refer to the gun manual.
D Be sure the gun trigger safety operates before spraying.
D Do not allow children to use this equipment.
D Lock the gun trigger safety when you stop spraying.
D Follow 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.
D Tighten all fluid connections before operating the equipment.
D Check 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.
D Fluid 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.
D Keep clear of all moving parts when you start or operate the pump.
D Before you service this equipment, follow the Pressure Relief Procedure on page 8 to prevent
the equipment from starting unexpectedly.
308996 3
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.
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. Do not use the equipment until you identify and correct the problem.
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
D Keep the spray area free of debris, including solvent, rags, and gasoline.
D Electrically disconnect all equipment in the spray area.
D Extinguish all open flames or pilot lights in the spray area.
D Do not smoke in the spray area.
D Do not turn on or off any light switch in the spray area while operating or if fumes are present.
D Do 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.
D Know the specific hazards of the fluid you are using.
D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
4 308996
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 Accessories, available from your Graco distributor. If you
supply your own accessories, be sure they are adequately 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 equipment.
Grounding
WARNING
2. Pump air supply and fluid hoses: Use only electrically conductive hoses with a maximum of 500 feet
(150 m) combined hose length to ensure grounding 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 recommendations.
4. Spray gun: ground through connection to a properly 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 continuity.
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.
W
X
Y
Z
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 system 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.
Fig. 1
0864
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.
308996 5
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:
D A bleed-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 easily accessible from the pump, and is located
upstream from the air regulator.
D An air regulator (Z) adjusts air pressure to the
air–assisted gun.
D An 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.
D A second bleed-type air valve (K) isolates the air
line accessories for servicing. Locate upstream
from all other air line accessories.
D An 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:
D A fluid filter (not shown) with a 60 mesh (250
micron) stainless steel element, to filter particles
from the fluid as it leaves the pump.
D A gun (S) dispenses the fluid. The gun shown in
Fig. 2 is an air–assisted spray gun for light to medium viscosity fluids.
D An 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.
D A gun swivel (R) allows freer gun movement.
D A suction hose (T) allows the pump to draw fluid
from a supply container.
6 308996
Installation
KEY
A Pump
B Wall Bracket
D Gun Air Hose
E Bleed-Type Master Air Valve
(required, for pump)
F Pump Air Regulator
H Electrically Conductive Air Supply Hose
G Air Relief Valve (Falcon II packages only)
(shown in exploded view)
J
K
Main Air Line
H
S
D
TYPICAL INSTALLATION
J Air Line Filter
K Bleed-Type Master Air Valve
(for accessories)
L Pump Outlet
M Wet Cup
N Electrically Conductive
Fluid Supply Hose
R Gun Swivel
W
B
Y
M
D
L
N
S Air–Assisted Spray Gun
T Suction Hose
U Strainer
Y Ground Wire and Clamp
(required; see page 5
for installation instructions)
W Air Line Drain Valve
Z Gun Air Regulator
(G) Air Relief Valve
A
F
F
G
Z
E
E
G
Fig. 2
R
T
1
N
U
9140B
Do not stretch hose tight; let it hang as shown, to
1
assist fluid flow into the pump. Adjust suction tube
so it’s about a 1/2 inch off bottom of the pail.
308996 7
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:
D are instructed to relieve the pressure,
D stop spraying,
D check or service any of the system equipment,
D or 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 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. Now clear the tip or hose.
8 308996
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