Accessory Kits
See page 22
Instructions - Parts List
4-Ball Lowers
3A0540L
EN
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.
working pressure.
TI15603a
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4-Ball Lowers Cross Reference Chart
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.
Current
Lower Part
No.
Current
Lower Part
No.
Current
Lower Part
No.
Earlier Lower
Part No.
Earlier Lower
Part No.
Earlier Lower
Part No.
240590
240591
240592
240593
243732
243733
243735
243736
24F451
24F448
24F448
24F448
24F450
24F453
24F448
24F451
243772
243773
248330
248331
248333
248334
24F448
24F451
24F448
24F451
24F448
24F451
218523
218524
218530
218531
235526
239813
240588
240589
24F286
24F448
24F453
24F451
24F448
24F448
24F451
24F451
3A0540L
3
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Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion 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
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
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Warnings
WARNING
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
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Changing the TSL
Changing the TSL
Check the condition of the TSL and the level in the res-
ervoir every week, minimum. TSL should be changed at
least every month.
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.
Part No. 206995 Throat Seal Liquid (TSL) carries resi-
due from the pump rod into the reservoir. Discoloration
of the TSL fluid is to be expected during normal opera-
tion. 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.
2. Remove and empty the reservoir bottle. Clean any
residue.
3. Clean screen (Z) of inlet check valve (53c‡). If
How long TSL lasts depends on which chemicals are
used, how much is used, what pressure, and condition
of the pump seal and rod.
check valves are not sealing and dirty TSL is getting
into the wet-cup, replace the check valves (53c,
53d). See FIG. 1.
NOTE: Order Check Valve Repair Kit 24F404. Kit parts
are marked with a symbol, for example (53b‡).
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.
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 reser-
voir through wet-cup and back to reservoir.
To change the TSL:
1. Shut off the pump.
Maximum Fill Line
Outlet Check Valve
(53d‡)
53b
‡
Minimum Fill Line
Inlet Check Valve
(53c‡)
Z
TI15857
TI15853b
FIG. 1. Cutaway of TSL Reservoir, and Fill Lines
6
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Repair
Repair
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, UHM-
WPE. Install the female gland (32†). Install three
v-packings with the lips facing up: UHMWPE,
leather, UHMWPE. Install the other male gland
(33†).
Replace the Throat Packings
Without Disconnecting the
Lower
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.
9. Lubricate the o-ring (52†) and install it on the
wet-cup (34). Install the wet-cup finger-tight.
NOTE: To replace the throat packings as part of a com-
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).
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).
11. Torque the cartridge (27) to 95-100 ft-lb (129-135
N•m).
1. Flush the pump, if possible.
2. Stop the pump at the middle of its stroke.
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).
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.
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.
5. See FIG. 5. Remove the collar (41) and screws (56),
cap (40), and manifold and bottle assembly (53).
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
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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).
Plugged inlet strainer (53c).
Clear obstruction in check valves.
Clear strainer mesh.
Damaged TSL pump piston (36).
Replace TSL pump piston.
NOTE: TSL Pump Repair Kit 24F618 is available. See
time the throat packings are changed. Kit parts are
marked with a symbol, for example (36).
2. Clean all parts and inspect for damage.
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.
See FIG. 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 Disassembly
Shield Reassembly
ti15758a
ti15759a
ti15757a
ti15770a
40
57
FIG. 2. Disassembly and Reassembly of the Shields
8
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Repair
6. Use a 13 mm socket wrench to loosen and remove
the twelve capscrews (9) and lockwashers (8) on
the outlet manifold (1).
Lower Disassembly
NOTE: This pump is easiest to repair when left in the
Part No. 218742 accessory pump stand and disassem-
bled as instructed. For repair at a remote location, have
another pump stand available.
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: Seal kits are available for each lower size. See
and drawings, for example (3*).
NOTE: See FIG. 3. Seat Puller Kit 220384 is available to
make removal of the seats from the manifolds easier.
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.
NOTICE
Be careful not to drop or damage the balls (18) or
seats (13). A damaged ball or seat cannot seal prop-
erly and the pump will leak. The outlet valve seats (13)
can be reversed to provide longer use of the seat.
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).
X
NOTE: Complete pump repair kits are also available.
The kits include all seal kit parts, throat packing kit parts,
Seat Puller Kit
220384
Y
1. Flush the pump, if possible.
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.
2. Stop the pump at the middle of its stroke.
S
3. Relieve the pressure. See your separate pump
manual.
4. Remove the lower from the motor as described in
your separate pump manual.
Y
NOTE: See FIG. 5 for an exploded view of the entire
lower. See FIG. 6 for a cutaway view of the lower and an
exploded view of the throat packings.
Place Seat Puller (Z, Part 181629) on top of
seat. Turn bolt (X) to pull the seat out.
5. Remove the collar (41) and screws (56), cap (40),
and manifold and bottle assembly (53).
X
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 FIG. 1, FIG.
5, and FIG. 6.
Z
01414
FIG. 3. Removing Seats from Manifold
3A0540L
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Repair
8. Remove the wet-cup (34) and o-ring (52). Remove
the TSL pump piston seal (36), spring (35), and
o-rings (51).
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 FIG. 4.
9. Remove the throat cartridge (27). Remove the
o-ring (52), glands (32, 33), packings (30, 31), and
spring (28).
ball
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 FIG. 5.
15
spring
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.
14
pressure relief valve
TI15631a
FIG. 4. Inlet Seat with Pressure Relief Valve
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.
NOTICE
If the pressure relief valve in the inlet seat (14) is
clogged or filled with material, soak the seat in a com-
patible solvent. Make sure all material residue is
cleaned from the ball and seat area.
13. Use a 13 mm socket wrench to loosen and remove
the twelve capscrews (9) and lockwashers (8) from
the inlet manifold (1). See FIG. 5.
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).
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.
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 FIG. 5 for proper
orientation.
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
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Repair
20
21
3
16
23*
2
5
*22
9
1
10
1
17*
18
4
24
8
1
25* 1
13
56
15*1
26
10
43
40
7
2
36
1
41
11
12
16
18
1
5*
53a
1
*3
4
53f
53d
‡
6
‡
53b
16
6
17*
35
51
1
‡
53c
18
14
1
*17
15*
1
5*
1
34
4
*3
1
1
53e
13
9
1
8
52†
*15
1
19
9
2
1
5
28
27
8
4
7
†52
TI15572c
1
®
1
5
8
Apply lubricant to all packings and
seals.
Torque to 18-20 ft-lb (24-27 N•m).
Tighten uniformly until cylinder is
Apply high strength (red) Loctite 263
or 2760 to entire length of threads.
Sealant must be allowed to cure for a
minimum of 12 hours before use.
6
®
2
Apply removable (blue) Loctite 243 to
entire length of threads.
seated then torque to 60-65 ft-lb (81-88
N•m).
9
Torque to 70-75 ft-lb (95-102 N•m).
Torque to 25-30 ft-lb (34-40 N•m).
3
4
7
Torque to 200-210 ft-lb (270-285 N•m).
Apply thread lubricant.
Torque to 95-100 ft-lb (129-135 N•m).
10
FIG. 5. Exploded View of Lower
3A0540L
11
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