Graco 3000cc, 4000cc User Manual

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

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

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

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

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

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

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

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

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