Graco Yard Vacuum 3000cc User Manual

Repair Kits

Accessory Kits

Related Manuals

See page 22

Instructions - Parts List

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

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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

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

24F451

3A0540L

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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.

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

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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‡)

TI15857

TI15853b

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

3A0540L

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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

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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).

1. Follow steps 1-6 under Replace the Throat Pack-

ings 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.

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

FIG. 2. Disassembly and Reassembly of the Shields

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).

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

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.

3. Relieve the pressure. See your separate pump

manual.

4. Remove the lower from the motor as described in

your separate pump manual.

NOTE: See 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).

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.

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.

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.

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.

3A0540L

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Repair

23*

*22

17*

25* ₁

15*₁

36

53a

53f

53d

‡

53b

17*

35

51

‡

53c

*17

15*

53e

52†

*15

See Throat Packing Detail

on pages 18 and 20.

†52

TI15572c

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.

Apply removable (blue) Loctite 243 to

entire length of threads.

seated then torque to 60-65 ft-lb (81-88

N•m).

Torque to 70-75 ft-lb (95-102 N•m).

Torque to 25-30 ft-lb (34-40 N•m).

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

Apply thread lubricant.

Torque to 95-100 ft-lb (129-135 N•m).

FIG. 5. Exploded View of Lower

3A0540L

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