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
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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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Repair  
41  
40  
40  
19  
36  
1
53a  
53f  
35  
53b  
53d  
16  
18  
9
53c‡  
51  
16  
18  
34  
*15  
†52  
†33  
53e  
13  
*3  
17*  
2
†30  
†32  
15*  
31†  
31†  
14  
5*  
21  
24  
4
†30  
*25  
26  
†33  
28  
6
*3  
27  
7
16  
18  
†52  
5*  
*15  
TI15858c  
16  
13  
17*  
15  
14  
1
18  
TI15604a  
FIG. 6. Cutaway View of Lower  
12  
3A0540L  
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Repair  
3. Install o-ring retainer (20). Lubricate o-ring (22*) and  
slide it on over the threads of piston shaft. Apply  
Lower Reassembly  
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).  
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 FIG. 7.  
19  
20  
21  
3
4
8
4. Remove the piston assembly from the vise, but do  
not lay it down on its side; doing so may dam-  
age the seal.  
23*  
24  
*22  
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 cyl-  
inder 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 press-  
ing, ensure the piston seal lips are started into the  
cylinder. See FIG. 9.  
25*  
1
1
26  
TI0219  
1
3
4
8
Apply lubricant.  
Torque to 200-210 ft-lb (270-285 N•m).  
6. Clean the remaining pump parts in a compatible sol-  
vent.  
Apply lubricant to face of piston nut.  
®
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.  
26  
25  
FIG. 7. Piston Assembly  
Tighten the tool on the  
widest part of the shaft  
(19). Grip the tool with  
a wrench and unscrew  
the shaft.  
19  
4
19  
TI0221  
1 Do not damage edges of seal.  
01413  
FIG. 9. Install Piston in Cylinder  
FIG. 8. Tool Kit 220385  
3A0540L  
13  
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Repair  
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.  
7. Lubricate and install the new o-rings (15*) around  
each of the four ball seats (13 and 14).  
NOTICE  
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 FIG. 10.  
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 FIG. 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.  
10  
1
9. Place the ball guides (16) and balls (18) in the inlet  
valve housing.  
COMPONENT RUPTURE HAZARD  
01410  
The relief valve seat (14) must be installed at the fluid  
inlet, as shown in FIG. 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.  
9
2
Torque oppositely and evenly to 81-88 N•m (60-65 ft-lb).  
1
2
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 FIG. 5 and  
FIG. 6. Press the other seat (13), with the unworn  
side facing out, into the other side of the inlet mani-  
fold.  
Apply removable (blue) Loctite® 243 to entire length of  
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).  
NOTE: The pressure relief seat kit (14) includes two  
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).  
FIG. 10. Manifold Screws Torque Values  
14  
3A0540L  
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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.  
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, 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†).  
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 hous-  
ing (7). Set the outlet housing (2) onto the cylinder  
and riser tubes.  
20. Lubricate the o-ring (52†) and install it on the  
wet-cup (34). Install the wet-cup finger-tight.  
15. Install the six cylinder capscrews (10), lockwashers  
(11) and nuts (12). Tighten the capscrews oppo-  
sitely and evenly to 81-88 N•m (60-65 ft-lb). See  
FIG. 10.  
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).  
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).  
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).  
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.  
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).  
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 FIG. 10.  
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  
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Repair  
16  
3A0540L  
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Parts  
Parts  
See Parts Lists:  
20  
21  
16  
23*  
*22  
43  
9
10  
17*  
18  
24  
8
1
25*  
13  
56  
15*  
26  
40  
7
2
36  
41  
11  
16  
18  
53a  
53f  
5*  
6
*3  
4
12  
16  
53d  
53b  
53c  
17*  
14  
35  
51  
18  
*17  
13  
15*  
5*  
34  
*3  
53e  
1
8
52†  
*15  
on pages 18 and 20.  
19  
9
28  
27  
TI15572c  
Shields (shipped loose)  
†52  
57  
ti15757a  
3A0540L  
17  
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Parts  
3000cc Lowers  
Part No. 24F448, Series A, Stainless Steel  
Part No. 24F450, Series A, Carbon Steel  
Part No. 24F449, Series A, Stainless Steel  
Lower  
Ref.  
No.  
Description  
24F448 24F450 24F449  
Qty  
1
MANIFOLD; sst  
MANIFOLD; cst  
16E965  
16E965  
16E084  
n/a  
2
2
1
1
2
1
1
4
2
1
1
24  
24  
6
6
6
3
1
4
4
4
4
1
1
1
1
1
1
1
1
1
1
6
4
1
2
180520  
2
HOUSING, outlet; sst  
HOUSING, outlet; cst  
GASKET, cylinder; UHMWPE  
CYLINDER, pump; sst/chrome  
CYLINDER, pump; sst/MaxLife  
O-RING; PTFE  
TUBE, fluid; sst  
HOUSING, inlet; sst  
HOUSING, inlet; cst  
WASHER, flat; 8.4 mm; sst  
CAPSCREW, hex hd; M8 x 1.25 x 25; sst  
CAPSCREW, hex hd; 9/16-12 unc x 7.5 in.; sst  
LOCKWASHER, spring; 9/16 in.; sst  
NUT, hex  
SEAT, valve; sst  
SEAT, intake valve, with relief valve; sst  
O-RING; PTFE  
GUIDE, ball; sst  
SEAL; UHMWPE  
BALL; 2 in. (51 mm) dia.; sst  
ROD, piston; sst  
RETAINER, o-ring, piston  
NUT, piston  
O-RING; PTFE encapsulated fluoroelastomer  
O-RING; PTFE  
PLATE, retaining, piston  
PACKING, piston; UHMWPE  
PISTON  
CARTRIDGE, packing, throat  
SPRING  
V-PACKING, throat; UHMWPE  
V-PACKING, throat; leather  
GLAND, female; sst  
16E084  
Throat Packing Detail  
16E085  
n/a  
180498  
3*  
4
n/a  
180498  
33†  
30†  
31†  
30†  
24A345  
n/a  
180530  
180523  
5*  
6
7
n/a  
180530  
180523  
n/a  
180530  
180521  
111003  
107554  
107553  
108792  
107538  
180529  
237572  
n/a  
8
9
111003  
107554  
107553  
108792  
107538  
180529  
237572  
n/a  
111003  
107554  
107553  
108792  
107538  
180529  
237572  
n/a  
10  
11  
12  
13  
14  
15*  
16  
17  
18  
19  
20  
21  
22*  
23*  
24  
25*  
26  
27  
28  
30†  
31†  
32†  
33†  
32†  
30†  
31†  
30†  
180509  
180761  
110294  
180509  
180761  
110294  
180509  
180761  
110294  
31†  
30†  
16A677 16A677 16A677  
196356  
196243  
n/a  
n/a  
196264  
n/a  
196263  
16A679 16A679 16A679  
16A545 16A545 16A545  
n/a  
n/a  
n/a  
n/a  
196356  
196243  
n/a  
n/a  
196264  
n/a  
196356  
196243  
n/a  
n/a  
196264  
n/a  
31†  
30†  
33†  
196263  
196263  
TI15573a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
GLAND, male; sst  
18  
3A0540L  
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Parts  
Lower  
Ref.  
No.  
Description  
24F448 24F450 24F449  
Qty  
34  
WET CUP  
16A678 16A678 16A678  
1
1
1
1
1
2
1
1
2
2
1
1
1
1
1
1
1
1
1
35SPRING  
36SEAL, piston, TSL pump  
39  
40  
41  
43PLATE, warning  
48TAG, warning (not shown)  
51O-RING; fluoroelastomer  
52†  
53  
53a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
SPACER, open wet-cup (not shown; shipped loose) 16E536 16E536 16E536  
CAP, wet-cup  
COLLAR, rod, piston  
16F051 16A682 16F051  
16E416 16E416 16E416  
183460  
172479  
108657  
n/a  
183460  
172479  
108657  
n/a  
183460  
172479  
108657  
n/a  
O-RING; PTFE  
MANIFOLD/BOTTLE; includes 53a-53f  
MANIFOLD; nylon  
24T075 24T075 24T075  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
53b‡ NIPPLE; sst  
53c‡ INLET CHECK; nylon, sst, fluoroelastomer  
53d‡ OUTLET CHECK; nylon, sst, pvc, fluoroelastomer  
53eBOTTLE; hdpe  
53f  
56  
57  
O-RING  
SCREW; M4 x 12  
SHIELD KITS; lowers include two shield kits; see  
16G290 16G290 16G290  
115263 115263 115263  
24F254 24F254 24F254  
manual 406876 to select the correct size kit for your 24F255 24F255 24F255  
lower and motor  
Replacement Danger and Warning labels, tags, and cards are available at no cost.  
*
Parts included in Seal Repair Kit 243728 (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 24F664 is available (purchase separately).  
Parts labeled n/a are not available separately.  
3A0540L  
19  
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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  
Lower  
Ref.  
No.  
Description  
24F451 24F453 24F452 24J888  
Qty  
1
MANIFOLD; sst; npt  
MANIFOLD; cst; npt  
16E965  
16E965  
2
2
180520  
MANIFOLD; sst; BSPP  
HOUSING, outlet; sst  
HOUSING, outlet; cst  
GASKET, cylinder; UHMWPE  
CYLINDER, pump; sst/chrome  
CYLINDER, pump; sst/MaxLife  
PACKING, o-ring; PTFE  
TUBE, fluid; sst  
193203  
16E084 16E084  
2
1
1
2
1
1
4
2
Throat Packing Detail  
2
16E084  
16E085  
n/a  
180497  
33†  
30†  
31†  
30†  
3*  
4
n/a  
180497  
n/a  
n/a  
180497  
24A346  
n/a  
5*  
6
7
n/a  
180530  
180523  
n/a  
180530  
n/a  
180530  
180523  
180530  
180523  
HOUSING, inlet; sst  
1
HOUSING, inlet; cst  
WASHER, flat; 8.4 mm; sst  
CAPSCREW, hex hd; M8 x 1.25 x 25; sst 107554  
CAPSCREW, hex hd; 9/16-12 unc x 7.5 in.; 107553  
sst  
180521  
111003  
107554  
107553  
1
8
111003  
111003  
107554  
107553  
111003  
107554  
107553  
24  
24  
6
9
10  
32†  
30†  
11  
12  
13  
14  
15*  
16  
17  
18  
19  
20  
21  
22*  
LOCKWASHER, spring; 9/16 in.; sst  
NUT, hex  
SEAT, valve; sst  
SEAT, intake valve, with relief valve; sst  
O-RING; PTFE  
GUIDE, ball; sst  
SEAL; UHMWPE  
BALL; 2 in. (51 mm) dia.; sst  
ROD, piston; sst  
RETAINER, o-ring, piston  
NUT, piston  
O-RING; PTFE encapsulated fluoroelasto- n/a  
mer  
108792  
107538  
180529  
237572  
n/a  
180509  
180761  
110294  
108792  
107538  
180529  
237572  
n/a  
180509  
180761  
110294  
108792  
107538  
180529  
237572  
n/a  
180509  
180761  
110294  
108792  
107538  
180529  
237572  
n/a  
180509  
180761  
110294  
6
6
3
1
4
4
4
4
1
1
1
1
31†  
30†  
31†  
30†  
16A677 16A677 16A677 16A677  
196356  
196243  
196356  
196243  
n/a  
196356  
196243  
n/a  
196356  
196243  
n/a  
31†  
30†  
33†  
23*  
24  
25*  
26  
27  
28  
30†  
31†  
32†  
33†  
O-RING; PTFE  
n/a  
196266  
n/a  
n/a  
196266  
n/a  
n/a  
196266  
n/a  
n/a  
196266  
n/a  
1
1
1
1
1
1
6
4
1
2
PLATE, retaining, piston  
PACKING, piston; UHMWPE  
PISTON  
CARTRIDGE, packing, throat  
SPRING  
V-PACKING, throat; UHMWPE  
V-PACKING, throat; leather  
GLAND, female; sst  
GLAND, male; sst  
TI15573a  
196265  
196265  
196265  
196265  
16A679 16A679 16A679 16A679  
16A545 16A545 16A545 16A545  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
20  
3A0540L  
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Parts  
Lower  
Ref.  
No.  
Description  
24F451 24F453 24F452 24J888  
Qty  
34  
WET CUP  
16A678 16A678 16A678 16A678  
1
1
1
1
35SPRING  
36SEAL, piston, TSL pump  
39  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
SPACER, open wet-cup (not shown;  
shipped loose)  
16E536 16E536 16E536 16E536  
40  
41  
CAP, wet-cup  
COLLAR, piston rod  
16F051 16A682 16F051 16F051  
16E416 16E416 16E416 16E416  
1
2
1
1
2
2
1
1
1
1
1
43PLATE, warning  
48TAG, warning (not shown)  
51O-RING; fluoroelastomer  
52†  
53  
53a  
183460  
172479  
108657  
n/a  
183460  
172479  
108657  
n/a  
183460  
172479  
108657  
n/a  
183460  
172479  
108657  
n/a  
O-RING; PTFE  
MANIFOLD/BOTTLE; includes 53a-53f  
MANIFOLD; nylon  
24T075 24T075 24T075 24T075  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
n/a  
53b‡ NIPPLE; sst  
53c‡ INLET CHECK; nylon, sst, fluoroelastomer n/a  
53d‡ OUTLET CHECK; nylon, sst, pvc, fluoro- n/a  
elastomer  
53eBOTTLE; hdpe  
n/a  
n/a  
n/a  
n/a  
1
1
1
1
53f  
56  
57  
O-RING  
SCREW; M4 x 12  
16G290 16G290 16G290 16G290  
115263 115263 115263 115263  
SHIELD KITS; lowers include two shield 24F254 24F254 24F254 24F254  
kits; see manual 406876 to select the cor- 24F255 24F255 24F255 24F255  
rect size kit for your lower and motor  
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  
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Repair Kits, Related Manuals, and Accessories  
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.  
Related  
Manual  
Repair  
Kits  
Part No.  
All lowers 3000 cc and 3A0540  
Description Manuals Description  
Repair Kit Description  
4-Ball Lower  
Standard Throat Packing Kit, 4 Leather and  
31, 32, 33, 52.  
in this  
manual.  
4000 cc Low-  
ers  
Instructions-Parts  
Throat Packing Conversion Kit, 10 PTFE  
Throat Packing Conversion Kit, 6 PTFE and  
32, 33, 52.  
TSL Pump Repair Kit. Includes items 35,  
time the throat packings are changed.  
TSL Check Valve Repair Kit. Includes items  
TSL Bottle Replacement Kit. Includes five  
24F448  
24F449  
24F450  
3000 cc  
Lower  
3A0540  
3A0540  
4-Ball Lower  
Instructions-Parts  
Piston Seal Repair Kit. Includes items 3, 5,  
Piston Seal Conversion Kit. Includes items  
Complete Pump Repair Kit. Includes items  
36, 51, 52.  
24F451  
24F452  
24F453  
24J888  
4000 cc  
Lower  
4-Ball Lower  
Instructions-Parts  
Piston Seal Repair Kit. Includes items 3, 5,  
Piston Seal Conversion Kit. Includes items  
Complete Pump Repair Kit. Includes items  
36, 51, 52.  
22  
3A0540L  
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Technical Data  
Technical Data  
4-Ball Pump Lowers (3000 and 4000 cc Sizes)  
U.S.  
Metric  
Maximum Fluid Working Pressure  
3000 cc Lowers  
440 psi  
330 psi  
3.0 MPa, 30 bar  
2.3 MPa, 23 bar  
4000 cc Lowers  
Displacement per Cycle  
3000 cc Lowers  
3000 cc  
4000 cc  
4000 cc Lowers  
Maximum Fluid Temperature  
Rating  
150°F  
66°C  
Fluid Inlet and Outlet Sizes  
Weight  
See Models, page 2.  
3000 cc Lowers  
4000 cc Lowers  
103 lb  
105 lb  
46.7 kg  
47.6 kg  
Wetted Parts (main pump)  
Stainless Steel, PTFE, Leather, Ultra-High Molecular Weight Polyethylene,  
Carbon Steel (Models 24F450 and 24F453 only)  
Wetted Parts (enclosed wet-cup)  
Stainless Steel, Ultra-High Molecular Weight Polyethylene, High-density  
Polyethylene, Nylon, Fluoroelastomer  
Loctite® is a registered trademark of the Loctite Corporation.  
3A0540L  
23  
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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 reconnaissent avoir convenu que la  
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.  
Graco Information  
For the latest information about Graco products, visit www.graco.com. For patent information, see  
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 reserves the right to make changes at any time without notice.  
This manual contains English. MM 3A0540  
Graco Headquarters: Minneapolis  
International Offices: Belgium, China, Japan, Korea  
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA  
Copyright 2010, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.  
Revision L, January 2015  
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