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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. ZL0080
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Table of Contents Symbols Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Warning Symbol Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Operation/Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 8 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . 11 WARNING Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Required Tools . . . . . . . . . . . .
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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. Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgical treatment. Do not point the gun at anyone or at any part of the body. Do not put your hand or fingers over the spray tip. Do not
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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. Ground the equipment and the object being sprayed. Refer to Grounding on page 5. 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. Provide fresh air ventilation to avoid the bu
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Installation 2. Pump air supply and fluid hoses: Use only electri- General Information cally conductive hoses with a maximum of 500 feet (150 m) combined hose length to ensure ground- NOTE: Reference numbers and letters in parentheses ing continuity. Check the electrical resistance of in the text refer to the callouts in the figures and the your air and fluid hoses at least once a week. If the parts drawing. total resistance to ground exceeds 29 megohms, replace the hose immediately. NOTE: Alway
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Installation An air regulator (Z) adjusts air pressure to the System Accessories (continued) air–assisted gun. WARNING An air line filter (J) removes harmful dirt and moisture from the compressed air supply. Also, A bleed-type master air valve (E) is required in your install a drain valve (W) at the bottom of each air system. This accessory helps reduce the risk of line drop, to drain off moisture. serious injury, including fluid injection and splashing of fluid in the eyes or on the skin, a
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Installation TYPICAL INSTALLATION KEY A Pump J Air Line Filter S Air–Assisted Spray Gun B Wall Bracket K Bleed-Type Master Air Valve T Suction Hose D Gun Air Hose (for accessories) U Strainer E Bleed-Type Master Air Valve L Pump Outlet Y Ground Wire and Clamp (required, for pump) M Wet Cup (required; see page 5 F Pump Air Regulator N Electrically Conductive for installation instructions) H Electrically Conductive Air Supply Hose Fluid Supply Hose W Air Line Drain Valve G Air Relief Valve (Falcon
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Operation/Maintenance 2. Shut off the air supply to the pump. Pressure Relief Procedure 3. Close the bleed-type master air valve (E) (required in your system). WARNING 4. Unlock the gun trigger safety. SKIN INJECTION HAZARD The system pressure must be manually 5. Hold a metal part of the gun firmly to the side of a relieved to prevent the system from grounded metal pail, and trigger the gun to relieve starting or spraying accidentally. Fluid pressure. under high pressure can be injected through
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Operation/Maintenance 11. With pump and lines primed, and with adequate air Flush Pump Before First Use pressure and volume supplied, pump will start and The pump is tested with lightweight oil, which is left in stop as you open and close gun. 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. WARNING Starting and Adjusting Pump COMPONENT RUPTURE HAZARD To reduce the risk of overpressurizing Befor
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Operation/Maintenance Flush with a fluid that is compatible with the fluid you Shutdown and Care of the Pump are pumping and with the wetted parts in your system. Check with your fluid manufacturer or supplier for WARNING recommended flushing fluids and flushing frequency. Always flush the pump before fluid dries on the dis- To reduce the risk of serious injury whenever you placement rod. are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 8. WARNING Always fl
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Troubleshooting Chart 1. Relieve the pressure. WARNING 2. Check all possible causes and problems before To reduce the risk of serious injury whenever you disassembling the pump. are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 8. PROBLEM CAUSE SOLUTION The pump fails to oper- Restricted air line or an inadequate air Clear the line; increase the air supply. ate. supply; closed or clogged valves. Check that the valves are open. Obstructed fluid hose or gun; O
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Service 5. Using needle nose pliers, remove cotter pin (107) Required Tools from clevis pin (106). Remove clevis pin from displacement rod (1). Set of adjustable wrenches Torque wrench 6. Hold tie rod flats with wrench to keep rods from Vise turning. Unscrew nuts (108) from tie rods (105). Thread lubricant Carefully remove displacement pump (109) from Disconnecting Displacement Pump motor (101). 1. Fig. 3. Flush pump, if possible. Stop pump at 7. Refer to page 14 for displacement pump se
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Service Model 241594 Shown V 101 W 105 1 107 1 2 106 109 108 1 U Torque to 120–130 in-lb (10–11 Nm). 1 9094B Fig. 3 308996 13
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Service a. Fig. 5. Unscrew wet cup (2) from outlet hous- Disassembly ing (7). Remove u–cup (4), bearing (5), and seal (8). When disassembling the pump, lay out all removed parts in sequence, to ease reassembly. b. Fig. 4. Remove seal (8) from cylinder (9). Shine light into cylinder to inspect inner sur- NOTE: U–cup Repair Kits are available. For the best face for scoring or wear. results, use all the new parts in the kit. Kit parts are marked with an asterisk, for example (8*). 4. Fig. 6. Place
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Service 1 7 2 9 1 *8 2 *17 3 D 1 Torque to 30–40 ft-lb (41–54 N.m). 2 2 Lubricate. 19 1 9095A Fig. 4 2 1 2 5* 4* 2 8* 2 7 1 Torque to 30–40 ft-lb (41–54 N.m). 2 Lubricate. 9099B Fig. 5 308996 15
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Service 1 1 11* A *16 *15 *14 2 *15 *12 1 Torque to 5–20 ft-lb (120–27 Nm). *13 1 2 Lubricate. 9096A Fig. 6 16 308996
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Service 7. Install cylinder, first by sliding displacement rod (1) Reassembly up through outlet housing (7) and wet cup (2), then 1. Fig. 6. Clean threads of displacement rod (1) and engage cylinder threads into outlet housing and piston housing (16). Replace u–cup seals (14) and hand tighten. spacers (15). Reassemble piston nut (13) and lockwasher (12). 8. Replace intake ball (17) and ball stop (3) into intake valve (19). Install seal (8) on intake valve. 2. Place flats of piston seat housing (
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Service 1 1 Torque to 20–27 N.m (15–20 ft-lb). 2 Torque to 41–54 N.m (30–40 ft-lb). 2 2 3 Lubricate. 4 Lips face up. 5 Lips face down. 6 See Throat Seal Detail at left. 7 See Piston Seal Detail at left. 7 Throat Packing Stack Detail (Displacement Pump 241516 Shown; see page 21 for options.) 5* 3 *8 T 6 4* 5 Piston Packing Stack Detail (Displacement Pump 241516 Shown; see page 21 for options.) 11* 9 2 P 7 15* 16* 1 12* 14* 4 13* 17* 14* 5 D *8 3 19 15* 2 3 9097A Fig. 7 18 308996
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Parts Part No. 241594 Pump, Series B Part No. 241595 Pump, Series B 10:1 Ratio, with Falcon Air Motor 20:1 Ratio, with Falcon ll Air Motor 102 102 101 101 105 105 *106 *106 107* 107* 109 109 108 108 * These parts are included * These parts are included with Lower Repair Kit with Lower Repair Kit 241597. 241597. 9094B 9094B Ref. Ref. No. Part No. Description Qty. No. Part No. Description Qty. 101 241504 AIR MOTOR, Falcon 101 241505 AIR MOTOR, Falcon ll See 308995 for parts 1 See 308995 for par
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Parts NOTE: The parts listed on this page are common to all Part No. 241516 displacement pumps covered in this manual. Refer to page Displacement Pump, Series B 21 for the different packing configurations available. Ref Part * These parts are included in Lower Repair Kit 241597, No. No. Description Qty which may be purchased separately. 1 194756 ROD, displacement; stainless steel, chrome 1 Replacement Danger and Warning labels, tags and cards 2 194757 HOUSING, throat; stainless steel 1 are a
