Graco 3000cc, 4000cc User Manual

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Page 1

Instructions - Parts List

Repair Kits

Accessory Kits

Related Manuals

See page 22

4-Ball Lowers

3A0540L

3000cc and 4000cc Models

Designed for low pressure, high volume circulation of finishing materials. Do not use for flushing or purging lines with caustics, acids, abrasive line strippers, and other similar fluids. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual and in your separate pump manual. Save these instructions.

See page 2 for model information, including maximum working pressure.

TI15603a

Page 2

Models

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4-Ball Lowers Cross Reference Chart . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Changing the TSL . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Replace the Throat Packings Without Disconnecting

the Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3000cc Lowers . . . . . . . . . . . . . . . . . . . . . . . . . 18

4000cc Lowers . . . . . . . . . . . . . . . . . . . . . . . . . 20

Repair Kits, Related Manuals, and Accessories . 22

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 24

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 24

TSL Pump Repair (if present) . . . . . . . . . . . . . . . 8

Shield Disassembly/Reassembly . . . . . . . . . . . . 8

Lower Disassembly . . . . . . . . . . . . . . . . . . . . . . . 9

Lower Reassembly . . . . . . . . . . . . . . . . . . . . . . 13

Models

3000cc Lowers

Maximum Pump

Model

No. Series Material

24F448 A SST 440 (3.0, 30) Chromex/Chrome UHMWPE/Leather Inlet: 2 in. npt

24F450 A CST 440 (3.0, 30) Chromex/Chrome UHMWPE/Leather Inlet: 2 in. npt

24F449 A SST 440 (3.0, 30) Chromex/MaxLife UHMWPE/Leather Inlet: 2 in. npt

Working Pressure

psi (MPa, bar)

Rod/Cylinder

Material Packings

Inlet/Outlet Fitting

Size and Type

Outlet: 2 in. npt

Parts Page

4000cc Lowers

Maximum Pump

Model

No. Series Material

24F451 A SST 330 (2.3, 23) Chromex/Chrome UHMWPE/Leather Inlet: 2 in. npt

24F453 A CST 330 (2.3, 23) Chromex/Chrome UHMWPE/Leather Inlet: 2 in. npt

24F452 A SST 330 (2.3, 23) Chromex/MaxLife UHMWPE/Leather Inlet: 2 in. npt

24J888 A SST 330 (2.3, 23) Chromex/Chrome UHMWPE/Leather Inlet: 2 in. BSPP

Working Pressure

psi (MPa, bar)

Rod/Cylinder

Material Packings

Inlet/Outlet Fitting

Size and Type

Outlet: 2 in. npt

Outlet: 2 in. BSPP

Parts Page

2 3A0540L

Page 3

4-Ball Lowers Cross Reference Chart

This chart cross references earlier styles of 4-ball lowers to the current lowers, which include the TSL pump and spring loaded packings.

Earlier Lower

Part No.

218523 24F286

218524 24F448

218530 24F453

218531 24F451

235526 24F448

239813 24F448

240588 24F451

240589 24F451

Lower Part

Current

No.

Earlier Lower

Part No.

240590 24F451

240591 24F448

240592 24F448

240593 24F448

243732 24F450

243733 24F453

243735 24F448

243736 24F451

Lower Part

Current

No.

Earlier Lower

Part No.

243772 24F448

243773 24F451

248330 24F448

248331 24F451

248333 24F448

248334 24F451

Lower Part

Current

No.

3A0540L 3

Page 4

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

WARNINGWARNINGWARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable vapors. To help prevent fire and explosion:

• Clean plastic parts only in a well ventilated area.

• Do not clean with a dry cloth.

• Do not operate electrostatic guns in equipment work area.

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

4 3A0540L

Page 5

Warnings

WARNING

WARNINGWARNINGWARNING

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

3A0540L 5

Page 6

Changing the TSL

Check the condition of the TSL and the level in the reservoir every week, minimum. TSL should be changed at least every month.

Part No. 206995 Throat Seal Liquid (TSL) carries residue from the pump rod into the reservoir. Discoloration of the TSL fluid is to be expected during normal operation. After some time the TSL will thicken and darken, and must be replaced. Thick, dirty TSL will not pump through the lines and will harden in the pump wet-cup.

How long TSL lasts depends on which chemicals are used, how much is used, what pressure, and condition of the pump seal and rod.

To avoid the buildup of static charge, do not rub the plastic bottle with a dry cloth while it is attached to the pump. Remove the bottle to clean, if needed.

2. Remove and empty the reservoir bottle. Clean any residue.

3. Clean screen (Z) of inlet check valve (53c

‡

). If check valves are not sealing and dirty TSL is getting into the wet-cup, replace the check valves (53c, 53d). See F

. 1.

A drop in the level of TSL in the reservoir indicates that the throat packings are starting to wear. Add TSL to the reservoir and keep the level above the Minimum fill line. Monitor the usage and condition of the TSL. If pumped material bypasses the throat packings and enters the TSL reservoir, replace the packings.

To change the TSL:

1. Shut off the pump.

Outlet Check Valve (53d

53b

Inlet Check Valve

(53c

‡)

NOTE: Order Check Valve Repair Kit 24F404. Kit parts are marked with a symbol, for example (53b‡).

4. Fill the reservoir to the Maximum fill line with Throat Seal Liquid (TSL).

5. Run pump. Each time pump rod reaches bottom of stroke, check that some TSL is pumped from reservoir through wet-cup and back to reservoir.

Maximum Fill Line

‡)

‡

Minimum Fill Line

TI15853b

TI15857

FIG. 1. Cutaway of TSL Reservoir, and Fill Lines

6 3A0540L

Page 7

Repair

Replace the Throat Packings Without Disconnecting the Lower

NOTE: Throat packing kits are available. See page 22.

Kit parts are marked with a symbol, for example (30†). For best results, install the TSL Pump Repair Kit 24F618 each time the throat packings are changed.

NOTE: To replace the throat packings as part of a complete service of the lower, see page 9.

NOTE: Tool Kit 24F494 is available as an accessory. The kit includes two wrenches for use with the wet-cup (34) and throat cartridge (27).

1. Flush the pump, if possible.

2. Stop the pump at the middle of its stroke.

3. Relieve the pressure. See your separate pump manual.

4. Following the instructions in your separate pump manual, remove the 2-piece shield covering the coupling assembly. Unscrew the coupling nut from the motor shaft. Lift the motor shaft and remove the coupling nut and collars.

5. See F

. 5. Remove the collar (41) and screws (56),

cap (40), and manifold and bottle assembly (53).

8. Lubricate the throat packings and glands. Install the spring (28) and one male gland (31†) in the throat cartridge (27), then seven v-packings with the lips facing down: one UHMWPE (30†), one leather (31†), UHMWPE, leather, UHMWPE, leather, UHMWPE. Install the female gland (32†). Install three v-packings with the lips facing up: UHMWPE, leather, UHMWPE. Install the other male gland (33†).

9. Lubricate the o-ring (52†) and install it on the wet-cup (34). Install the wet-cup finger-tight.

10. Install the o-ring (52†) on the throat cartridge (27). Apply lubricant to the throat cartridge threads then screw the cartridge into the outlet housing (1).

11. Torque the cartridge (27) to 95-100 ft-lb (129-135 N•m).

12. Torque the wet-cup (34) to 70-75 ft-lb (95-102 N•m).

13. Reassemble the spring (35), TSL pump piston seal (36), and o-rings (51).

14. Reassemble the manifold and bottle assembly (53), cap (40), collar (41) and screws (56). Torque the cap (40) to 34-40 N•m (25-30 ft-lb).

15. Reinstall the coupling nut and collars on the piston rod (19).

16. Reconnect the coupling nut to the motor shaft. See your separate pump assembly manual for correct torque specifications for your model. Reinstall the shield.

6. Remove the wet-cup (34) and o-ring (52). Remove

the TSL pump piston seal (36), spring (35), and o-rings (51).

7. Remove the throat cartridge (27). Remove the o-ring (52), glands (32, 33), packings (30, 31), and spring (28).

NOTE: Inspect the surface of the piston rod (19). If it is scratched, replace the piston rod.

3A0540L 7

Page 8

Repair

TSL Pump Repair (if present)

Table 1: TSL Pump Troubleshooting

Problem Cause Solution

TSL pump not pumping TSL fluid. Plugged manifold (53a). Clear the manifold. Verify that the mani-

fold is clear by blowing compressed air through the opening.

Plugged check valves (53c, 53d). Clear obstruction in check valves.

Plugged inlet strainer (53c). Clear strainer mesh.

Damaged TSL pump piston (36). Replace TSL pump piston.

NOTE: TSL Pump Repair Kit 24F618 is available. See page 22. Install the TSL Pump Repair Kit 24F618 each time the throat packings are changed. Kit parts are marked with a symbol, for example (36).

Shield Disassembly/Reassembly

The lowers include two shield kits. The correct size is determined by your lower and motor. See manual 406876 to select the correct size kit for your lower and motor.

Shield Disassembly

1. Follow steps 1-6 under Replace the Throat Packings Without Disconnecting the Lower, page 7.

2. Clean all parts and inspect for damage.

3. Follow steps 11-16 under Replace the Throat Packings Without Disconnecting the Lower.

See F

. 2. Remove the 2-piece shield (57) by inserting a screwdriver straight into the slot, and using it as a lever to release the tab. Repeat for all tabs. Do not use the screwdriver to pry the shields apart.

Install the shields (57) by engaging the bottom lips with the groove in the wet-cup cap (40). Snap the two shields together.

Shield Reassembly

ti15759a

ti15770a

ti15758a

ti15757a

40 57

FIG. 2. Disassembly and Reassembly of the Shields

8 3A0540L

Page 9

Repair

Lower Disassembly

NOTE: This pump is easiest to repair when left in the

Part No. 218742 accessory pump stand and disassembled as instructed. For repair at a remote location, have another pump stand available.

NOTE: Seal kits are available for each lower size. See page 22. Kit parts are marked with an asterisk in the text and drawings, for example (3*).

NOTE: Throat packing kits are available. See page 22. Kit parts are marked with a symbol, for example (30†). For best results, install the TSL Pump Repair Kit 24F618 each time the throat packings are changed.

NOTE: Tool Kit 24F494 is available as an accessory. The kit includes two wrenches for use with the wet-cup (34) and throat cartridge (27).

NOTE: Complete pump repair kits are also available. The kits include all seal kit parts, throat packing kit parts, and TSL pump repair kit parts. See page 22.

1. Flush the pump, if possible.

2. Stop the pump at the middle of its stroke.

6. Use a 13 mm socket wrench to loosen and remove the twelve capscrews (9) and lockwashers (8) on the outlet manifold (1).

7. Lift the manifold (1) off the outlet valve housing (2) and remove the ball guides (16), balls (18), seats (13) and seals (17). Remove the o-ring (15) from the seats (13).

NOTE: See F

. 3. Seat Puller Kit 220384 is available to

make removal of the seats from the manifolds easier.

NOTICE

Be careful not to drop or damage the balls (18) or seats (13). A damaged ball or seat cannot seal properly and the pump will leak. The outlet valve seats (13) can be reversed to provide longer use of the seat.

Seat Puller Kit 220384

Screw bolt (X, Part 108481) into Seat Puller (Y, Part 181630).

Position Seat Puller (Y) under the seat (S) by slipping it through at an angle.

3. Relieve the pressure. See your separate pump manual.

4. Remove the lower from the motor as described in your separate pump manual.

NOTE: See F lower. See F

. 5 for an exploded view of the entire

. 6 for a cutaway view of the lower and an

exploded view of the throat packings.

5. Remove the collar (41) and screws (56), cap (40), and manifold and bottle assembly (53).

NOTE: To replace the check valves in the TSL bottle, order Check Valve Repair Kit 24F404. Kit parts are marked with a symbol, for example (53b‡). To replace the bottle only, order Bottle Replacement Kit 24F405. Kit parts are marked with a symbol, for example (48e). The kit includes 5 bottles and 5 labels. See F 5, and F

. 6.

. 1, FIG.

Place Seat Puller (Z, Part 181629) on top of seat. Turn bolt (X) to pull the seat out.

. 3. Removing Seats from Manifold

01414

3A0540L 9

Page 10

Repair

8. Remove the wet-cup (34) and o-ring (52). Remove the TSL pump piston seal (36), spring (35), and o-rings (51).

9. Remove the throat cartridge (27). Remove the o-ring (52), glands (32, 33), packings (30, 31), and spring (28).

10. Remove the nuts (12), lockwashers (11), and six cylinder capscrews (10). Lift off the outlet valve housing (2).

11. Lift the riser tubes (6) and cylinder (4) off the inlet valve housing (7). The piston assembly may stay in the cylinder. Remove the seals (3 and 5) from the inlet and outlet housings (2, 7). See F

. 5.

NOTE: Tap on the valve housings with a plastic mallet and use a slight rocking motion to help loosen and remove the cylinder and tubes.

12. If Part No. 218742 accessory pump stand is used, unscrew and remove the three pump stand bolts. Lift the inlet valve assembly off the stand. Place the inlet valve housing (7) face down on a protected surface.

13. Use a 13 mm socket wrench to loosen and remove the twelve capscrews (9) and lockwashers (8) from the inlet manifold (1). See F

. 5.

15. Inspect the pressure relief valve in the fluid inlet seat (14) to make sure it is not clogged. Press down on the valve's ball to see if the ball and spring are free to move. See F

. 4.

ball

spring

pressure relief valve

TI15631a

FIG. 4. Inlet Seat with Pressure Relief Valve

NOTICE

If the pressure relief valve in the inlet seat (14) is clogged or filled with material, soak the seat in a compatible solvent. Make sure all material residue is cleaned from the ball and seat area.

14. Lift the manifold (1) off the inlet valve housing (7) and remove the seats (13 and 14). Remove the o-ring (15) from the seats. Remove the balls (18),

ball guides (16) and seals (17).

NOTICE

Be careful not to drop or damage the balls (18) or seats (13 or 14). A damaged ball or seat cannot seal properly and the pump will leak. One inlet valve seat (13) can be reversed to provide longer use of the seat. However, the fluid inlet seat (14) contains a pressure relief valve and is not reversible. See F

. 5 for proper

orientation.

If the relief valve cannot be thoroughly cleaned so that the ball and spring are free to move, replace the seat (14).

16. Push the piston assembly through the cylinder just enough to expose the piston (26) flats. Secure the piston flats in a vise. Use a plastic mallet to tap the cylinder (4) up and off the piston assembly.

17. Loosen the piston nut (21). Use Tool Kit 220385 (to remove the piston shaft (19) and piston nut (21). Remove the piston nut o-ring (22) and o-ring retainer (20) from the shaft. Remove the plate (24) and the seal (25) from the piston (26).

18. Inspect the piston shaft (19). If it is damaged or the surface is scored, replace it.

19. Clean all piston parts and the cylinder thoroughly in a compatible solvent. Inspect the inner surface of the cylinder for scoring, and replace it if necessary. A scored cylinder will quickly damage the packings.

10 3A0540L

Page 11

36

53a

53b

‡

53c



53e

53f

Repair

*22

17*

15*

23*

25*

17*

15*

53d

35

51

52†

‡

*17

*15

See Throat Packing Detail on pages 18 and 20.

7104

†52

Apply lubricant to all packings and seals.

Apply removable (blue) Loctite entire length of threads.

Torque to 200-210 ft-lb (270-285 N•m).

Apply thread lubricant.

243 to

FIG. 5. Exploded View of Lower

Torque to 18-20 ft-lb (24-27 N•m).

Tighten uniformly until cylinder is seated then torque to 60-65 ft-lb (81-88 N•m).

Torque to 95-100 ft-lb (129-135 N•m).

Apply high strength (red) Loctite or 2760 to entire length of threads. Sealant must be allowed to cure for a minimum of 12 hours before use.

Torque to 70-75 ft-lb (95-102 N•m).

Torque to 25-30 ft-lb (34-40 N•m).

TI15572c

263

3A0540L 11

Page 12

Repair

*15

*25

36

53a

53f

35

51

53b 53d

53c

‡ ‡

‡

16 18

17*

15*

†52

†33

†30

†32

31†

53e



†30

†33

31†

†52

*15

TI15858c

17*

15 14

TI15604a

FIG. 6. Cutaway View of Lower

12 3A0540L

Page 13

Repair

Lower Reassembly

1. Lubricate the new piston seal (25*) and install it on the piston.

2. Install the piston plate (24) with the beveled edge facing away from the piston seal. See F

*22

Apply lubricant.

Torque to 200-210 ft-lb (270-285 N•m).

Apply lubricant to face of piston nut.

Apply high strength (red) Loctite length of threads. Sealant must be allowed to cure for a minimum of 12 hours before use.

263 or 2760 to entire

. 7.

23*

25*

TI0219

3. Install o-ring retainer (20). Lubricate o-ring (22*) and slide it on over the threads of piston shaft. Apply

high strength (red) Loctite

263 or 2760 to entire length of the piston rod (19) threads. Sealant must be allowed to cure for a minimum of 12 hours before use. Screw the piston nut (21) snugly against the o-ring retainer (20). Apply lubricant to the bottom face of the piston nut (21). Assemble o-ring (23*) and install in the groove on the piston nut. Screw rod (19) into piston (26) until snug. Tighten piston nut (21) to 270-285 N•m. (200-210 ft-lb).

4. Remove the piston assembly from the vise, but do

not lay it down on its side; doing so may damage the seal.

5. Carefully and evenly guide the seal and the piston into the cylinder. The piston seal and piston may need to be tipped at an angle and the exposed, leading lip of the seal tapped into the cylinder with a plastic mallet. After the seal lip has entered the cylinder use an arbor press or tap the bottom of the piston assembly lightly with a plastic mallet to slide the piston assembly into the cylinder. Before pressing, ensure the piston seal lips are started into the cylinder. See F

. 9.

6. Clean the remaining pump parts in a compatible solvent.

. 7. Piston Assembly

Tighten the tool on the widest part of the shaft (19). Grip the tool with a wrench and unscrew the shaft.

. 8. Tool Kit 220385

01413

Do not damage edges of seal.

. 9. Install Piston in Cylinder

TI0221

3A0540L 13

Page 14

Repair

7. Lubricate and install the new o-rings (15*) around each of the four ball seats (13 and 14).

NOTICE

The orientation of the ball valves in the inlet and outlet valve housings is critical. Install the parts of the ball valve exactly as instructed and refer to F

. 5. If

installed incorrectly, the pump will not operate.

8. Place the inlet valve housing (7) on a flat surface with the ball valve openings facing up. Lubricate the seals (17*) and set them into each side of the inlet valve housing.

9. Place the ball guides (16) and balls (18) in the inlet valve housing.

COMPONENT RUPTURE HAZARD

The relief valve seat (14) must be installed at the fluid inlet, as shown in F

. 5 and FIG. 6. The relief valve reduces the risk of pump overpressurization. The seat cannot relieve pressure if installed on the other side of the inlet housing.

10. Press the seat (14) with the pressure relief valve into the fluid inlet side of the inlet manifold (1). This seat is not reversible. Orient as shown in F F

. 6. Press the other seat (13), with the unworn

. 5 and

side facing out, into the other side of the inlet manifold.

11. Apply removable (blue) Loctite

243 to entire length of the screw (9) threads. Position the inlet manifold (1) on the inlet valve housing (1). Install the twelve capscrews (9) and lockwashers (8) loosely.

12. Tighten the four inside screws (9) oppositely and evenly to 3 N•m (27 in-lb) to balance the load on the valves. Then tighten all twelve screws oppositely

and evenly to 24-27 N•m (18-20 ft-lb). See F

Torque oppositely and evenly to 81-88 N•m (60-65 ft-lb).

Apply removable (blue) Loctite threads on all 12 screws (9). Torque 4 inside screws oppositely and evenly to 3 N•m (27 in-lb), then tighten all 12 screws oppositely and evenly to 24-27 N•m (18-20 ft-lb).

243 to entire length of

01410

. 10.

NOTE: The pressure relief seat kit (14) includes two

FIG. 10. Manifold Screws Torque Values

seals (17) and two o-rings (15). When installing a new pressure relief seat, also install the seals and o-rings on both sides of the fluid inlet manifold (1).

14 3A0540L

Page 15

Repair

13. If Part No. 218742 accessory pump stand is used, place the inlet valve housing and manifold assembly on the pump stand. Install and tightly screw in the three pump stand bolts.

14. Lubricate and install the new seals (3*, 5*) in the inlet and outlet housings (2, 7). Set the cylinder (4) and riser tubes (6) into place in the inlet valve housing (7). Set the outlet housing (2) onto the cylinder and riser tubes.

15. Install the six cylinder capscrews (10), lockwashers (11) and nuts (12). Tighten the capscrews oppositely and evenly to 81-88 N•m (60-65 ft-lb). See F

. 10.

16. Lubricate the seals (17*) and press one into each side of the outlet valve housing (2). Press the seats (13), with the unworn sides facing the balls, into the outlet valve housing. Then install the balls (18) and ball guides (16).

17. Apply removable (blue) Loctite

243 to entire length of the screw (9) threads. Place the outlet manifold (1) on the outlet valve housing (2) and install the twelve screws (9) and lockwashers (8) loosely.

18. Tighten the inside four screws (9) oppositely and evenly to 3 N•m (27 in-lb) to balance the load on the valves. Then tighten all twelve screws oppositely and evenly to 24-27 N•m (18-20 ft-lb). See F

. 10.

19. Lubricate the throat packings and glands. Install the spring (28) and one male gland (33†) in the throat cartridge (27), then seven v-packings with the lips facing down: one UHMWPE (30†), one leather (31†), UHMWPE, leather, UHMWPE, leather, UHMWPE. Install the female gland (32†). Install three v-packings with the lips facing up: UHMWPE, leather, UHMWPE. Install the other male gland (33†).

20. Lubricate the o-ring (52†) and install it on the wet-cup (34). Install the wet-cup finger-tight.

21. Install the o-ring (52†) on the throat cartridge (27). Apply lubricant to the throat cartridge threads then screw the cartridge into the outlet housing (2).

22. Torque the cartridge (27) to 129-135 N•m (95-100 ft-lb).

23. Torque the wet-cup (34) to 95-102 N•m (70-75 ft-lb).

24. Reassemble the spring (35), TSL pump piston seal (36), and o-rings (51).

25. Reassemble the manifold and bottle assembly (53), cap (40), collar (41) and screws (56). Torque the cap (40) to 34-40 N•m (25-30 ft-lb).

26. Reinstall the coupling nut and collars on the piston rod (19).

27. Fill the cavity in the bottom of the motor shaft with grease. Reconnect the lower to the motor as described in your separate pump manual.

3A0540L 15

Page 16

Repair

16 3A0540L

Page 17

Parts

See Parts Lists:

3000cc, pages 18-19 4000cc, pages 20-21

Parts

36

53a

‡

53b

‡

53c



53e

53f

*22

17*

15*

23*

25*

17*

15*

53d

35

51

‡

*17

52†

*15

See Throat Packing Detail on pages 18 and 20.

TI15572c

Shields (shipped loose)

†52

3A0540L 17

ti15757a

Page 18

Parts

3000cc Lowers

Part No. 24F448, Series A, Stainless Steel Part No. 24F450, Series A, Carbon Steel Part No. 24F449, Series A, Stainless Steel

Ref. No. Description

1 MANIFOLD; sst 16E965 16E965 2

MANIFOLD; cst

2 HOUSING, outlet; sst 16E084

HOUSING, outlet; cst 3* GASKET, cylinder; UHMWPE n/a n/a n/a 2 4 CYLINDER, pump; sst/chrome 180498 180498 1

CYLINDER, pump; sst/MaxLife 5* O-RING; PTFE n/a n/a n/a 4 6 TUBE, fluid; sst 180530 180530 180530 2 7 HOUSING, inlet; sst 180523

HOUSING, inlet; cst 8 WASHER, flat; 8.4 mm; sst 111003 111003 111003 24 9 CAPSCREW, hex hd; M8 x 1.25 x 25; sst 107554 107554 107554 24 10 CAPSCREW, hex hd; 9/16-12 unc x 7.5 in.; sst 107553 107553 107553 6 11 LOCKWASHER, spring; 9/16 in.; sst 108792 108792 108792 6 12 NUT, hex 107538 107538 107538 6 13 SEAT, valve; sst 180529 180529 180529 3 14 SEAT, intake valve, with relief valve; sst 237572 237572 237572 1 15* O-RING; PTFE n/a n/a n/a 4 16 GUIDE, ball; sst 180509 180509 180509 4 17 SEAL; UHMWPE 180761 180761 180761 4 18 BALL; 2 in. (51 mm) dia.; sst 110294 110294 110294 4 19 ROD, piston; sst 16A677 16A677 16A677 1 20 RETAINER, o-ring, piston 196356 196356 196356 1 21 NUT, piston 196243 196243 196243 1 22* O-RING; PTFE encapsulated fluoroelastomer n/a n/a n/a 1 23* O-RING; PTFE n/a n/a n/a 1 24 PLATE, retaining, piston 196264 196264 196264 1 25* PACKING, piston; UHMWPE n/a n/a n/a 1 26 PISTON 196263 196263 196263 1 27 CARTRIDGE, packing, throat 16A679 16A679 16A679 1 28 SPRING 16A545 16A545 16A545 1 30† V-PACKING, throat; UHMWPE n/a n/a n/a 6 31† V-PACKING, throat; leather n/a n/a n/a 4 32† GLAND, female; sst n/a n/a n/a 1 33† GLAND, male; sst n/a n/a n/a 2

Lower

Qty24F448 24F450 24F449

180520 2

16E084 1

16E085 1

24A345 1

180523 1

180521 1

Throat Packing Detail

33†

30†

31†

30†

32†

30†

31† 30†

31†

30†

31†

30†

33†

TI15573a

18 3A0540L

Page 19

Parts

Ref. No. Description

34 WET CUP 16A678 16A678 16A678 1 35 SPRING n/a n/a n/a 1 36 SEAL, piston, TSL pump n/a n/a n/a 1 39 SPACER, open wet-cup (not shown; shipped loose) 16E536 16E536 16E536 1 40 CAP, wet-cup 16F051 16A682 16F051 1 41 COLLAR, rod, piston 16E416 16E416 16E416 2 43 PLATE, warning 183460 183460 183460 1 48 TAG, warning (not shown) 172479 172479 172479 1 51 O-RING; fluoroelastomer 108657 108657 108657 2 52† O-RING; PTFE n/a n/a n/a 2 53 MANIFOLD/BOTTLE; includes 53a-53f 24T075 24T075 24T075 1 53a MANIFOLD; nylon n/a n/a n/a 1 53b‡ NIPPLE; sst n/a n/a n/a 1 53c‡ INLET CHECK; nylon, sst, fluoroelastomer n/a n/a n/a 1 53d‡ OUTLET CHECK; nylon, sst, pvc, fluoroelastomer n/a n/a n/a 1 53e BOTTLE; hdpe n/a n/a n/a 1 53f O-RING 16G290 16G290 16G290 1 56 SCREW; M4 x 12 115263 115263 115263 1 57 SHIELD KITS; lowers include two shield kits; see

manual 406876 to select the correct size kit for your lower and motor

Click here to return to repair kit page.



Replacement Danger and Warning labels, tags, and cards are available at no cost.

Parts included in Seal Repair Kit 243728 (purchase separately).

24F254 24F254 24F254 1 24F255 24F255 24F255

Lower

Qty24F448 24F450 24F449

† Parts included in Throat Packing Repair Kit 24F247 (purchase separately).



Parts included in TSL Pump Repair Kit 24F618 (purchase separately).



Order TSL Bottle Replacement Kit 24F405 (purchase separately). Includes 5 bottles.

‡

Parts included in TSL Check Valve Repair Kit 24F404 (purchase separately).

Complete Pump Repair Kit 24F664 is available (purchase separately).

Parts labeled n/a are not available separately.

3A0540L 19

Page 20

Parts

4000cc Lowers

Part No. 24F451, Series A, Stainless Steel Part No. 24F453, Series A, Carbon Steel Part No. 24F452, Series A, Stainless Steel Part No. 24J888, Series A, Stainless Steel

Ref. No. Description

1 MANIFOLD; sst; npt 16E965 16E965 2

MANIFOLD; cst; npt

MANIFOLD; sst; BSPP 2 HOUSING, outlet; sst 16E084

HOUSING, outlet; cst 3* GASKET, cylinder; UHMWPE n/a n/a n/a n/a 2 4 CYLINDER, pump; sst/chrome 180497 180497 180497 1

CYLINDER, pump; sst/MaxLife 5* PACKING, o-ring; PTFE n/a n/a n/a n/a 4 6 TUBE, fluid; sst 180530 180530 180530 180530 2 7 HOUSING, inlet; sst 180523

HOUSING, inlet; cst 8 WASHER, flat; 8.4 mm; sst 111003 111003 111003 111003 24 9 CAPSCREW, hex hd; M8 x 1.25 x 25; sst 107554 107554 107554 107554 24 10 CAPSCREW, hex hd; 9/16-12 unc x 7.5 in.;

sst 11 LOCKWASHER, spring; 9/16 in.; sst 108792 108792 108792 108792 6 12 NUT, hex 107538 107538 107538 107538 6 13 SEAT, valve; sst 180529 180529 180529 180529 3 14 SEAT, intake valve, with relief valve; sst 237572 237572 237572 237572 1 15* O-RING; PTFE n/a n/a n/a n/a 4 16 GUIDE, ball; sst 180509 180509 180509 180509 4 17 SEAL; UHMWPE 180761 180761 180761 180761 4 18 BALL; 2 in. (51 mm) dia.; sst 110294 110294 110294 110294 4 19 ROD, piston; sst 16A677 16A677 16A677 16A677 1 20 RETAINER, o-ring, piston 196356 196356 196356 196356 1 21 NUT, piston 196243 196243 196243 196243 1 22* O-RING; PTFE encapsulated fluoroelasto-

mer 23* O-RING; PTFE n/a n/a n/a n/a 1 24 PLATE, retaining, piston 196266 196266 196266 196266 1 25* PACKING, piston; UHMWPE n/a n/a n/a n/a 1 26 PISTON 196265 196265 196265 196265 1 27 CARTRIDGE, packing, throat 16A679 16A679 16A679 16A679 1 28 SPRING 16A545 16A545 16A545 16A545 1 30† V-PACKING, throat; UHMWPE n/a n/a n/a n/a 6 31† V-PACKING, throat; leather n/a n/a n/a n/a 4 32† GLAND, female; sst n/a n/a n/a n/a 1 33† GLAND, male; sst n/a n/a n/a n/a 2

107553 107553 107553 107553 6

n/a n/a n/a n/a 1

Lower

Qty24F451 24F453 24F452 24J888

180520 2

193203 2

16E084 16E084 1

16E085 1

24A346 1

180523 180523 1

180521 1

Throat Packing Detail

33†

30†

31†

30†

32†

30†

31† 30†

31†

30†

31†

30†

33†

TI15573a

20 3A0540L

Page 21

Parts

Ref. No. Description

34 WET CUP 16A678 16A678 16A678 16A678 1 35 SPRING n/a n/a n/a n/a 1 36 SEAL, piston, TSL pump n/a n/a n/a n/a 1 39 SPACER, open wet-cup (not shown;

shipped loose) 40 CAP, wet-cup 16F051 16A682 16F051 16F051 1 41 COLLAR, piston rod 16E416 16E416 16E416 16E416 2 43 PLATE, warning 183460 183460 183460 183460 1 48 TAG, warning (not shown) 172479 172479 172479 172479 1 51 O-RING; fluoroelastomer 108657 108657 108657 108657 2 52† O-RING; PTFE n/a n/a n/a n/a 2 53 MANIFOLD/BOTTLE; includes 53a-53f 24T075 24T075 24T075 24T075 1 53a MANIFOLD; nylon n/a n/a n/a n/a 1 53b‡ NIPPLE; sst n/a n/a n/a n/a 1 53c‡ INLET CHECK; nylon, sst, fluoroelastomer n/a n/a n/a n/a 1 53d‡ OUTLET CHECK; nylon, sst, pvc, fluoro-

elastomer 53e BOTTLE; hdpe n/a n/a n/a n/a 1 53f O-RING 16G290 16G290 16G290 16G290 1 56 SCREW; M4 x 12 115263 115263 115263 115263 1 57 SHIELD KITS; lowers include two shield

kits; see manual 406876 to select the cor-

rect size kit for your lower and motor

16E536 16E536 16E536 16E536 1

n/a n/a n/a n/a 1

24F254 24F254 24F254 24F254 1 24F255 24F255 24F255 24F255

Lower

Qty24F451 24F453 24F452 24J888

Click here to return to repair kit page.



Replacement Danger and Warning labels, tags, and cards are available at no cost.

Parts included in Seal Repair Kit 243729 (purchase separately).

† Parts included in Throat Packing Repair Kit 24F247 (purchase separately).



Parts included in TSL Pump Repair Kit 24F618 (purchase separately).



Order TSL Bottle Replacement Kit 24F405 (purchase separately). Includes 5 bottles.

‡

Parts included in TSL Check Valve Repair Kit 24F404 (purchase separately).

Complete Pump Repair Kit 24F665 is available (purchase separately).

Parts labeled n/a are not available separately.

3A0540L 21

Page 22

Repair Kits, Related Manuals, and Accessories

NOTE: The lowers listed in this manual must use the throat packing kits and the complete pump repair kits listed in

the following table. Do not use kits for older-style lowers (see manual 311832) with these lowers. The throat packing gland height has changed.

NOTE: For best results, install the TSL Pump Repair Kit 24F618 each time the throat packings are changed.

Part No. Description

All lowers in this manual.

24F448

24F449

24F450

3000 cc and 4000 cc Lowers

3000 cc Lower

Related Manuals

3A0540 4-Ball Lower

Manual Description

Instructions-Parts

Repair Kits

24F247 Standard Throat Packing Kit, 4 Leather and

24F248 Throat Packing Conversion Kit, 10 PTFE

24J442 Throat Packing Conversion Kit, 6 PTFE and

24F618 TSL Pump Repair Kit. Includes items 35,

24F404 TSL Check Valve Repair Kit. Includes items

24F405 TSL Bottle Replacement Kit. Includes five

243728 Piston Seal Repair Kit. Includes items 3, 5,

235855 Piston Seal Conversion Kit. Includes items

Repair Kit Description

6 UHMWPE Packings. Includes items 30, 31, 32, 33, 52.

Packings. Includes items 30, 32, 33, 52.

4 Leather Packings. Includes items 30, 31, 32, 33, 52.

36, and 51. For best results, install each time the throat packings are changed.

53b, 53c, 53d.

of item 53e.

15, 17, 22, 23, 25 (UHMWPE).

3, 5, 15, 17, 22, 23, 25 (PTFE).

24F664 Complete Pump Repair Kit. Includes items

3, 5, 15, 17, 22, 23, 25, 30, 31, 32, 33, 35, 36, 51, 52.

24F451

24F452

24F453

24J888

22 3A0540L

4000 cc Lower

3A0540 4-Ball Lower

Instructions-Parts

243729 Piston Seal Repair Kit. Includes items 3, 5,

15, 17, 22, 23, 25 (UHMWPE).

235854 Piston Seal Conversion Kit. Includes items

3, 5, 15, 17, 22, 23, 25 (PTFE).

24F665 Complete Pump Repair Kit. Includes items

3, 5, 15, 17, 22, 23, 25, 30, 31, 32, 33, 35, 36, 51, 52.

Page 23

Technical Data

4-Ball Pump Lowers (3000 and 4000 cc Sizes)

U.S. Metric

Maximum Fluid Working Pressure

3000 cc Lowers 440 psi 3.0 MPa, 30 bar

4000 cc Lowers 330 psi 2.3 MPa, 23 bar

Displacement per Cycle

3000 cc Lowers 3000 cc

4000 cc Lowers 4000 cc

Technical Data

Maximum Fluid Temperature Rating

Fluid Inlet and Outlet Sizes See Models, page 2.

Weight

3000 cc Lowers 103 lb 46.7 kg

4000 cc Lowers 105 lb 47.6 kg

Wetted Parts (main pump) Stainless Steel, PTFE, Leather, Ultra-High Molecular Weight Polyethylene,

Wetted Parts (enclosed wet-cup) Stainless Steel, Ultra-High Molecular Weight Polyethylene, High-density

Loctite® is a registered trademark of the Loctite Corporation.

150°F 66°C

Carbon Steel

Polyethylene, Nylon, Fluoroelastomer

(Models 24F450 and 24F453 only)

3A0540L 23

Page 24

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is 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 will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissen rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

t avoir convenu que la

Graco Information

For the latest information about Graco products, visit www.graco.com. For patent information, see

www.graco.com/patents.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Graco reserves the right to make changes at any time without notice.

Original instructions.

This manual contains English. MM 3A0540

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revision L, January 2015

Graco 3000cc, 4000cc User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Models

4-Ball Lowers Cross Reference Chart

Warnings

Changing the TSL

Repair

Replace the Throat Packings Without Disconnecting the Lower

TSL Pump Repair (if present)

Shield Disassembly/Reassembly

Lower Disassembly

Lower Reassembly

Parts

3000cc Lowers

4000cc Lowers

Repair Kits, Related Manuals, and Accessories

Technical Data

Graco Standard Warranty

Graco Information