Graco Yard Vacuum 3000cc User Manual

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.  
See page 2 for model information, including maximum  
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
3A0540L  
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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  
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.  
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-  
plete service of the lower, see page 9.  
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  
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).  
2. Clean all parts and inspect for damage.  
3. Follow steps 11-16 under Replace the Throat  
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
3A0540L  
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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  
page 22. Kit parts are marked with an asterisk in the text  
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.  
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.  
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,  
and TSL pump repair kit parts. See page 22.  
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  
9
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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  
3A0540L  
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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
on pages 18 and 20.  
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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