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Hitachi 308996J manual

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Table of contents for the manual

  • Page 1

    Instructions – Parts List GRACO INC.ąP .O. BOX 1441ąMINNEAPOLIS, MNą55440-1441 Copyright 1999, Graco Inc. is registered to I.S. EN ISO 9001 ST AINLESS 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[...]

  • Page 2

    2 308996 T able of Contents W arnings 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation/Maintenance 8 . . . . . . . . . . . . . . . . . . . . . . . . . T roubleshooting Chart 1 1 . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 3

    308996 3 W ARNING 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 inju[...]

  • Page 4

    4 308996 W ARNING 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 [...]

  • Page 5

    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 rate[...]

  • Page 6

    6 308996 Installation System Accessories (continued) W ARNING 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 mast[...]

  • Page 7

    308996 7 Installation Fig. 2 KEY A Pump B W all Bracket D Gun Air Hose E Bleed-T ype M aster Air V alve (required, for pump) F Pump Air Regulator H Electrically Conductive Air Supply Hose G Air Relief V alve (Falcon II packages only) (shown in exploded view) J Air Line Filter K Bleed-T ype M aster Air V alve (for accessories) L Pump Outlet M W et C[...]

  • Page 8

    8 308996 Operation/Maintenance Pressure Relief Procedure W ARNING 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 . T o reduce the risk of an injury from injection, splashing fluid, o[...]

  • Page 9

    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 com[...]

  • Page 10

    10 308996 Operation/Maintenance Shutdown and Care of the Pump W ARNING T o 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 [...]

  • Page 11

    308996 1 1 T roubleshooting Chart W ARNING T o 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. Check all possible causes and problems before disassembling the pump. PROBLEM CAUSE SOLUTION The pump fails to oper- ate. Restricted air [...]

  • Page 12

    12 308996 Service Required T ools D Set of adjustable wrenches D T orque wrench D Vis e D Thread lubricant Disconnecting Displacement Pump 1. Fig. 3. Flush pump, if possible. Stop pump at bottom of its stroke. W ARNING T o reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure [...]

  • Page 13

    308996 13 Service 9094B 1 Fig. 3 101 109 108 107 105 106 2 1 V U W T orque to 120–130 in-lb (10–1 1 N S m). 1 1 Model 241594 Shown[...]

  • Page 14

    14 308996 Service Disassembly When disassembling the pump, lay out all removed parts in sequence, to ease reassembly . NOTE: U–cup Repair Kits are available. For the best results, use all the new parts in the kit. Kit parts are marked with an asterisk, for example (8*). 1. Fig. 4. Place outlet housing (7) in vise. 2. Apply adjustable wrench to fl[...]

  • Page 15

    308996 15 Service Fig. 4 1 2 7 9 19 1 T orque to 30–40 ft-lb (41–54 N.m). 1 D *17 *8 2 Lubricate. 2 2 9095A 1 3 Fig. 5 2 5* 9099B 4* 8* 7 1 T orque to 30–40 ft-lb (41–54 N.m). 2 Lubricate. 1 2 2 2[...]

  • Page 16

    16 308996 Service Fig. 6 1 *13 T orque to 5–20 ft-lb (120–27 N S m). 1 11 * *16 1 1 9096A *12 *15 *15 *14 A Lubricate. 2 2[...]

  • Page 17

    308996 17 Service Reassembly 1. Fig. 6. Clean threads of displacement rod (1) and piston housing (16). Replace u–cup seals (14) and spacers (15). Reassemble piston nut (13) and lockwasher (12). 2. Place flats of piston seat housing (16) in vise. T ighten displacement rod and piston nut from 20 to 27 N S m (15 to 20 ft–lb). 3. Install seal (8) o[...]

  • Page 18

    18 308996 Service Fig. 7 1 2 3 4 T orque to 20–27 N.m (15–20 ft-lb). T orque to 41–54 N.m (30–40 ft-lb). Lubricate. 5 6 7 1 *8 19 17* 16* D T P 2 7 9 *8 11 * Lips face up . Lips face down. 4* 15* See Throat Seal Detail at left. See Piston Seal Detail at left. Throat Packing Stack Detail (Displacement Pump 241516 Shown; see page 21 for optio[...]

  • Page 19

    308996 19 Parts Part No. 241594 Pump, Series B 10:1 Ratio, with Falcon Air Motor Ref. No. Part N o. Description Qty . 101 241504 AIR MOT OR, Falcon See 308995 for parts 1 102 Y 190867 LABEL, warning 1 105 194909 ROD, ti e; 127 mm (5”) shoulder to shoulder 3 106* 1 15218 PIN, clevis 1 107* 1 1 1609 PIN, cotter 1 108 1 1 1040 NUT , hex 3 109 241516[...]

  • Page 20

    19 9 17* 3 8* 16 8* Throat Packing Stack* (see page 21) Piston Packing Stack* (see page 21) 9099B 2 7 1 *1 1 8* 20 308996 Parts NOTE: The parts listed on this page are common to all displacement pumps covered in this manual. Refer to page 21 for the dif ferent packing configurations available. * These parts are included in Lower Repair Kit 241597, [...]

  • Page 21

    308996 21 Repair Kits Repair Kit 241597, for Falcon Pump 241516 Ref Part No. No. Description Qty 4 1 15251 SEAL, u–cup; uhmwpe 1 5 194758 BEARING, throat; acetal 1 8 103341 O–RING; PTFE 3 1 1 101947 BALL, piston 1 14* 1 15146 SEAL, u–cup; carbon–filled PTFE 2 15 194880 SP ACER, seal; Nylon 2 17 105445 BALL, intake 1 106 1 15218 PIN, clevis [...]

  • Page 22

    22 308996 Repair Kits Piston Repair Kit 241830, for Falcon Pump 241516 Ref Part No. No. Description Qty 14* 1 15146 SEAL, u–cup; carbon–filled PTFE 2 15 194880 SP ACER, seal; Nylon 2 * 1 15146 is a PTFE seal. An uhmwpe seal, 1 15408 is avail- able and sold separately LUBRICA TE P ACKINGS 15 14 15 LIPS UP LIPS DOWN LIPS UP LIPS DOWN Piston SST C[...]

  • Page 23

    308996 23 T echnical Data W ARNING Be sure that all fluids and solvents used are chemically compatible with the Wetted Parts listed below . Always read the manufacturer ’s literature before using fluid or solvent in these pumps. (Model 241594 Falcon Pump) Ratio 10:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 24

    24 308996 T echnical Data T o find Fluid Outlet Pressure (psi/MPa/bar) at a specific fluid flow (lpm/gpm) and operating air pressure (psi/MPa/bar): 1. Locate fluid flow rate along bottom of chart. 2. Follow vertical line up to intersection with selected fluid outlet pressure curve. 3. Follow left to scale to read fluid outlet pressure. T o find Pum[...]

  • Page 25

    308996 25 Dimensions Model 241595 Shown A B C D E F G 9092B Mounting Hole Layout 35.6 mm (1.40”) 89 mm (3.50”) DIA 0653 2x 7mm 0.28” DIA 35.6 mm (1.40”) 35.6 mm (1.40”) 35.6 mm (1.40”) Pump Model A B C D E F G 241594, 241595 513 mm (20.2 in.) 304 mm (1 1.97in.) 209 mm (8.23 in.) 159 mm (6.25 in.) 3/8 in. npt(f) 1/4 in. npt(f) 3/8 npt(f)[...]

  • Page 26

    26 308996 Graco Standard W arranty Graco w arrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco w ill, for a period of twelve months from th[...]