Graco 3A0540L User's Manual
Contents
1. ES YLINDER pump sst chrome 180498 180498 1 YLINDER pump sst MaxLife 24A34 BORING PIE fa ma 1 4 5 TUBE fus 180530 180530 180530 2 OUSING inlet ssl 780528 180528 1 OUSING inlet cst Emm NEN B WASHER fat84mm sst 11008 111008 111003 24 9 CAPSCREW hexhd M8 x 125 x25 ss 107564 107554 107554 24 T0 CAPSCREW hex hd 9 16 12 uncx 7 5 in sst 107668 107553 107553 6 17 LOCKWASHEH spring 9 16 isst 108702 108792 108792 6 T2 NOT Rex 07538 107538 107538 6 73 SEAT valve st 180529 180529 180529 3 74 SEAT intake valve with relief valve sst 297672 297572 257572 1 m JORINGPTE pa ma ma 4 75 GUDE pass fre0s09 180509 180509 4 17 BEALUHMWPE 180761 180761 180761 4 BALL Zin 5T mm dia ssi 110294 170294 110204 4 TS MOD piston sr eer rene EN 1 20 RETAINER o ring piston 196356 196856 196356 1 21 NUT piston 196248 196243 196243 1 va Ya 24 PLATE retaining piston 196264 106264 196264 96263 6A679 6A545 ve SIT V PACKING throat eather ma ma ma 4 324 GLAND female st ma ma ma 1 BST JGLAND male st ma ma pa 2 a B AY B A co 5 gt A NO 18 Throat Packing Detail 33T 30T 31T 30T 32Tt 307 311 30T 31T 30T 31T 30T 33T Tr m T T115573a 3A0540L Daris Sr WETCUP LL WORST 1 Wa Lt PRIN 89 SPAGER open wet2. 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 WWW graco com Revision L January 2015
3. 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 Repair _ eT CES CS 8 9 See Throat Packing Detail on pages 18 and 20 I AN L I 7 7 P NES en T115572c A Apply lubricant to all packings and A Torque to 18 20 ft Ib 24 27 Nem Apply high strength red Loctite 263 seals A a or 2760 to entire length of threads A 2 8 Tighten uniformly until cylinder is Sealant must be allowed to cure for a Apply removable blue Loctite 243 to seated then torque to 60 65 ft lb 81 88 minimum of 12 hours before use entire length of threads Nem A Torque to 70 75 ft Ib 95 102 Nem A Torque to 200 210 ft lb 270 285 Nem AN Torque to 95 100 ft lb 129 135 Nem A Torque to 25 30 ft lb 34 40 Nem A Apply thread lubricant FIG 5 Exploded View of Lower 3A0540L 11 Repair 53dt 53ct 53ex as Q M M oo LO LO 10 ve H RAI reinen Tt Kel T115858c 5 S Niz nn V D EE WELL fe S 15 13 T115604a FiG 6 Cutaway View of Lower 3A0540L 12 Lower Reassembly 1 Lubricate the new piston seal 25 and install it on the piston Install the piston plate 24 w
4. MANIFOLD st BSPP f 198208 Throat Packing Detail OUSING outlet ssi 16E084 166084 6E0684 T HOUSING ouiet er 3 peos 1 1 1 33t ASKET cylinder UHMWPE CYLINDER pump sst chrome 80497 180497 180497 1 30t CYLINDER pump sst MaxLife T 24A346 L ACKING o ring PTFE n a na ma ja 4 P om TUBE fluid sst 180830 180530 180530 180530 2 OUSING inlet sst 180528 feos23 180523 T i OUSING inlet cst qe Pay 8 WASHER flat 8 4mm sst 111003 111008 111008 111008 24 amp CAPSCREW hex hd M8 x 1 25 x25 sst 07554 07554 107554 107554 24 Dy set 0 CAPSCHEW hex hd 9 16 12 unc x 7 5 1n 107553 1107553 107553 107553 LE e eme omm ON 11 LOCKWASHER spring 9 16 in sst 108792 108792 108792 1087922 6 30t m2 NoT hes 107838 107588 107538 107538 6 7 13 BEATvave sst 180529 180529 180529 180828 3 31t 14 SEAT intake valve with relief valve sst 287572 237572 287572 207572 1 Me 5 JO RING PTE na ma ma wma 4 76 GUIDE ball st 180809 180509 180509 180509 4 311 7 BEALUHMWPE 3 3 180761 180761 180761 180761 4 X ALL 2 in 51 mm dia ssi T0294 110294 110294 10294 4 oy 30t 9 ROD pistonsst 1 1 1 116677 fieaer7 T6A677 16467 1 ES 20 RETAINER o ring piston 1 1 196356 196356 196356 190356 1 31t md mer Pe O RING PTE 1 wa ma ma ma T i 24 PLATE retaining piston 3 1196266 196266 196266 196
5. 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
6. 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 speci
7. e Do not clean with a dry cloth e 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 e Follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment e Tighten all fluid connections before operating the equipment e 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 e Read MSDSs to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines 4 3A0540L Warnings 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 e Protective eyewear and hearing protection e 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
8. 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 9 Parts labeled n a are not available separately 3A0540L Parts 21 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 Description Manuals Description Kits Repair Kit Description 4 Ball Lower 24F247 Standard Throat Packing Kit 4 Leather and 6 UHMWPE Packings Includes items 30 4000 cc Low Instructions Parts 31 32 33 52 24F248 Throat Packing Conversion Kit 10 PTFE Packings Includes items 30 32 33 52 24J442 Throat Packing Conversion Kit 6 PTFE and 4 Leather Packings Includes items 30 31 32 33 52 TSL Pump Repair Kit Includes items 35 36 and 51 For best results install each time the throat packings are changed 24F404 TSL Check Valve Repair Kit Includes items 53b 530 53d 24F405 TSL Bottle Replacement Kit Includes five of item 53e 243728 Piston Seal Repair Kit Includ
9. up UHMWPE leather UHMWPE Install the other male gland 33t Lubricate the o ring 527 and install it on the wet cup 34 Install the wet cup finger tight Install the o ring 527 on the throat cartridge 27 Apply lubricant to the throat cartridge threads then screw the cartridge into the outlet housing 2 Torque the cartridge 27 to 129 135 Nem 95 100 ft Ib Torque the wet cup 34 to 95 102 Nem 70 75 ft lb Reassemble the spring 35 TSL pump piston seal 36 and o rings 51 Reassemble the manifold and bottle assembly 53 cap 40 collar 41 and screws 56 Torque the cap 40 to 34 40 Nem 25 30 ft Ib Reinstall the coupling nut and collars on the piston rod 19 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 15 Repair 16 3A0540L Parts Parts See Parts Lists 3000cc pages 18 19 4000cc pages 20 21 m rT 8 See Throat Packing Detail on pages 18 and 20 3A0540L 17 Parts 3000cc Lowers Part No 24F448 Series A Stainless Steel Part No 24F450 Series A Carbon Steel Part No 24F449 Series A Stainless Steel Description 24F448 24F450 24F449 WE ee sst 16E965 16E965 MANIFOED cst MANIFOLD est h80520 FOUSING oe QE NME 1 HOUSING out est
10. 266 1 26 PISTON I96265 190265 196265 196268 T 27 CARTRIDGE packing throat f16A679 16A679 16A679 16A679 1 28 SPRING I6AB45 16A545 16A545 16A545 I GOT V PACKING hroa UHMWPE ma pma ma va Srt V PACKING throat leather wa ma ma wa 4 354 GLAND male st ma pma ma a 2 20 3A0540L Lower E ume SA pus pour o SPRING canal SEAL piston TSLpump si SEAL pistor TEL gumg SEAL piston TSLpump ae a E na a9 SPACER open wet cup not shown Taan Taan Taan aan shipped loose 40 CAP wetcup 16F051 16A682 16F051 167051 47 COLLAR piston ra SEAT TEATS EATS TEATS 2 va BoE NIPPLE st eH OUTLET CHECK nylon ast pvc fluoro n a n a n a n a 1 S ma ma ma Wa 1 c RNG RI NG 1 Tana 6G290 166290 3166290 1 B SCREW Max M4 x 12 115263 115263 1115263 115263 S SHIELD SHIELD KITS Toners include two SHI lowers include two shield D S 24F254 24F254 kits see manual 406876 to select the cor 24F255 24F255 2AF255 Saree rect size kit for your lower and motor Click here to return to repair kit page Replacement Danger and Warning labels tags and cards are available at no cost gt 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
11. 3A0540L 5 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 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 How long TSL lasts depends on which chemicals are used how much is used what pressure and condition of the pump seal and rod A drop in the level of TSL in the reservoir indicates that the throat packings are starting to wear Add TSL to the reservoir and keep the level above the Minimum fill line Monitor the usage and condition of the TSL If pumped material bypasses the throat packings and enters the TSL reservoir replace the packings To change the TSL 1 Shut off the pump Inlet Check Valve 53ct FIG 1 Cutaway of TSL Reservoir and Fill Lines Awe 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 Outlet Check Valve 53d 53bt TI15853b 2 Remove and empty the reservoir bottle Clean any residue 3 Clean screen Z of inlet check valve 53ct If check valves are not seali
12. Accessory Kits Instructions Parts List diues b Y Related Manuals 7 See page 22 GRACO 4 Ball Lowe rs 3A0540L 3000cc and 4000cc Models EN 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 e 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 d M U a L Lond TI15603a PROVEN QUALITY LEADING TECHNOLOGY Models Contents ae T M Pee GATENE 2 PATES rar yc DR ACC Rub i C Ee 17 4 Ball Lowers Cross Reference Chart 3 300066 LOWETS 24 55 xc ode Sra eR ede es 18 Warnings ess sus Uri o at es dents d 400066 Lowers sus du Ee tais 20 Changing the TSL 3a she vn raw nente 6 Repair Kits Related Manuals and Accessories 22 REP ossetere S r 7 Technical Data vovit bos 23 Heplace the Throat Packings Without Disconnecting Graco Standard Warranty 24 ME LOWGIS Jis saco a beer een 7 Graco Information 24 TSL Pump Repair if present 8 Shield Disassembly Reassembly 8 Lower Disassembly 9 Lower Reassembly 13 Models 3000cc Lowers Maximum Pump Mod
13. al 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com For patent information see www graco com patents 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 Original instructions This manual contains English MM 3A0540 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea
14. 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 Ve MOVING PARTS HAZARD M Moving parts can pinch cut or amputate fingers and other body parts 3 e Keep clear of moving parts vrz Peres s Do not operate equipment with protective guards or covers removed e Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all power sources
15. and bolts 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 Install the six cylinder capscrews 10 lockwashers 11 and nuts 12 Tighten the capscrews oppo sitely and evenly to 81 88 Nem 60 65 ft lb See FiG 10 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 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 Tighten the inside four screws 9 oppositely and evenly to 3 Nem 27 in lb to balance the load on the valves Then tighten all twelve screws oppositely and evenly to 24 27 Nem 18 20 ft lb See FIG 10 3A0540L 19 20 21 22 23 24 25 26 27 Repair Lubricate the throat packings and glands Install the spring 28 and one male gland 331 in the throat cartridge 27 then seven v packings with the lips facing down one UHMWPE 301 one leather 317 UHMWPE leather UHMWPE leather UHM WPE Install the female gland 321 Install three v packings with the lips facing
16. ase the tab Repeat for all tabs Do not use motor 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 ST ti15758a 7 ti15757a ti15770a 40 57 ti15759a Fic 2 Disassembly and Reassembly of the Shields 8 3A0540L 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 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 Throat packing kits are available See page 22 Kit parts are marked with a symbol for example 301 For best results install the TSL Pump Repair Kit 24F618 each time the throat packings are changed 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 1 Flush the pump if possible 2 Stop the pump at the middle of its stroke de 4 3 Helieve the pressure See your separate pump manual 4 Remove the lower f
17. bricate the seals 17 and set them into each side of the inlet valve housing 9 Place the ball guides 16 and balls 18 in the inlet valve housing 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 N Torque oppositely and evenly to 81 88 Nem 60 65 ft lb 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 Apply removable blue Loctite 243 to entire length of threads on all 12 screws 9 Torque 4 inside screws oppositely and evenly to 3 Nem 27 in lb then tighten all 12 screws oppositely and evenly to 24 27 Nem 18 20 side facing out into the other side of the inlet mani ft Ib fold NOTE The pressure relief seat kit 14 includes two Fic 10 Manifold Screws Torque Values 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 14 3A0540L 13 14 15 16 17 18 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 st
18. cup not shown shipped loose 166836 IGESSS 16 536 T 40 CaP weep frerost 16A682 16r0st I 41 COLAR od pison 6E416 feens TOE 2 48A TAG warning not shown 172479 172479 172479 51e O HiNG fuoroastome I06687 08657 108657 2 2 527_ O RING PTFE Wa p va 2 53a MANFOLD nylon fa ma a O RING T be CREW Max M4 x 12 115263 d KITS lowers include two shield kits see DST apan F manual 406876 to select the correct size kit for your SIFE CSA S lower and motor Click here to return to repair kit page A Heplacement 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 9 Parts labeled n a are not available separately 3A0540L 19 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 249888 Series A Stainless Steel Boc 24F453 24F452 24J888 Qty WE Oe MERS Teos fj s 1 2 MANIFOLD cstinpt 80 1 2
19. el Working Pressure Rod Cylinder Inlet Outlet Fitting No psi MPa bar Material Size and Type 24F448 SST 440 3 0 30 Chromex Chrome UHMWPE Leather Inlet 2 in npt Outlet 2 in npt CST 440 3 0 30 Chromex Chrome UHMWPE Leather Inlet 2 in npt 18 Outlet 2 in npt 24F449 SST 440 3 0 30 Chromex MaxLife UHMWPE Leather Inlet 2 in npt 18 Outlet 2 in npt 4000cc Lowers Maximum Pump Model Working Pressure Rod Cylinder Inlet Outlet Fitting No psi MPa bar Material Size and Type SST 330 2 3 23 Chromex Chrome UHMWPE Leather Inlet 2 in npt Outlet 2 in npt CST 330 2 3 23 Chromex Chrome UHMWPE Leather Inlet 2 in npt Outlet 2 in npt SST 330 2 3 23 Chromex MaxLife UHMWPE Leather Inlet 2 in npt Outlet 2 in npt 24J888 SST 330 2 3 23 Chromex Chrome UHMWPE Leather Inlet 2 in BSPP Outlet 2 in BSPP 2 3A0540L 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 Current Current Earlier Lower Lower Part Earlier Lower Lower Part Earlier Lower Lower Part Part No No Part No No Part No No 218523 24F286 240590 24F451 243772 24F448 218524 24F448 240591 24F448 243773 24F451 218530 24F453 240592 24F448 248330 24F448 3A0540L 3 Warnings Warnings The following warnings are for the setup use grounding ma
20. es items 3 5 15 17 22 23 25 UHMWPE 235855 Piston Seal Conversion Kit Includes items 3 5 15 17 22 20 25 FIFE ers 24F618 3000 cc 3A0540 4 Ball Lower Lower Instructions Parts 24F664 Complete Pump Repair Kit Includes items 3 5 15 17 22 23 75 30 91 32 Da 95 36 51 52 243729 Piston Seal Repair Kit Includes items 3 5 15 17 22 23 25 UHMWPE 235854 Piston Seal Conversion Kit Includes items 3 5 15 17 22 23 25 FIFE 4000 cc 3A0540 4 Ball Lower Lower Instructions Parts 24F665 Complete Pump Repair Kit Includes items 3 5 19 17 2 23 25 30 91 32 39 35 36 51 52 22 3A0540L Technical Data Technical Data 4 Ball Pump Lowers 3000 and 4000 cc Sizes Maximum Fluid Working Pressure 3000 cc Lowers 440 psi 3 0 MPa 30 bar 4000 cc Lowers 330 psi 2 3 MPa 23 bar Displacement per Cycle 3000 cc Lowers 3000 cc 4000 cc Lowers 4000 cc Maximum Fluid Temperature Rating Fluid Inlet and Outlet Sizes See Models page 2 3000 cc Lowers 103 Ib 46 7 kg 4000 cc Lowers 105 Ib 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 Graco Standard
21. intenance 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 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 e Clean plastic parts only in a well ventilated area
22. ith the beveled edge facing away from the piston seal See FIG 7 S PE 1 mm AA m M aa p 22 Ce Z 26 N Apply lubricant A Torque to 200 210 ft lb 270 285 Nem ZA 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 FIG 7 Piston Assembly Tighten the tool on the widest part of the shaft 19 Grip the tool with 19 a wrench and unscrew the shaft Lg L f FIG 8 Tool Kit 220385 3A0540L Repair Install o ring retainer 20 Lubricate o ring 22 and slide it on over the threads of piston shaft Apply 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 Nem 200 210 ft lb Remove the piston assembly from the vise but do not lay it down on its side doing so may dam age the seal 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
23. ls 17 NOTICE Be careful not to drop or damage the balls 18 or seats 13 or 14 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 10 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 pressure relief valve TI15631a FIG 4 Inlet Seat with Pressure Relief Valve 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 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 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
24. motor shaft Lift the motor shaft and remove the coupling nut and collars See FIG 5 Remove the collar 41 and screws 56 cap 40 and manifold and bottle assembly 53 Remove the wet cup 34 and o ring 52 Remove the TSL pump piston seal 369 spring 35 and o rings 51 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 Repair Lubricate the throat packings and glands Install the spring 28 and one male gland 311 in the throat cartridge 27 then seven v packings with the lips facing down one UHMWPE 301 one leather 317 UHMWPE leather UHMWPE leather UHM WPE Install the female gland 321 Install three v packings with the lips facing up UHMWPE leather UHMWPE Install the other male gland 33t Lubricate the o ring 527 and install it on the wet cup 34 Install the wet cup finger tight Install the o ring 52t on the throat cartridge 27 Apply lubricant to the throat cartridge threads then screw the cartridge into the outlet housing 1 Torque the cartridge 27 to 95 100 ft Ib 129 135 Nem Torque the wet cup 34 to 70 75 ft Ib 95 102 Nem Reassemble the spring 35 TSL pump piston seal 36 and o rings 519 Reassemble the manifold and bottle assembly 53 cap 40 collar 41 and
25. ng 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 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 Maximum Fill Line Label No 16E333 Rev E Fill with Graco TSL 206994 MAXIMUM Minimum Fill Line GRACO MINIMUM 1115857 3A0540L Repair Replace the Throat Packings Without Disconnecting the Lower NOTE Throat packing kits are available See page 22 Kit parts are marked with a symbol for example 301 For best results install the TSL Pump Repair Kit 24F618 each time the throat packings are changed NOTE To replace the throat packings as part of a com plete service of the lower see page 9 NOTE Tool Kit 24F494 is available as an accessory The kit includes two wrenches for use with the wet cup 34 and throat cartridge 27 1 Flush the pump if possible 2 Stop the pump at the middle of its stroke 0 I MPa bar PSI PIT Y 3 Helieve the pressure See your separate pump manual Following the instructions in your separate pump manual remove the 2 piece shield covering the coupling assembly Unscrew the coupling nut from the
26. 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 Clean the remaining pump parts in a compatible sol vent 26 im dy 25 4 19 La Pl TI0221 A Do not damage edges of seal FIG 9 Install Piston in Cylinder 13 Repair 7 Lubricate and install the new o rings 15 around 11 Apply removable blue Loctite 243 to entire length each of the four ball seats 13 and 14 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 NOTICE The orientation of the ball valves in the inlet and outlet 12 Tighten the four inside screws 9 oppositely and valve housings is critical Install the parts of the ball evenly to 3 Nem 27 in lb to balance the load on the valve exactly as instructed and refer to FIG 5 If valves Then tighten all twelve screws oppositely installed incorrectly the pump will not operate and evenly to 24 27 Nem 18 20 ft Ib See FiG 10 8 Place the inlet valve housing 7 on a flat surface with the ball valve openings facing up Lu
27. rom 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 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 3A0540L Repair 6 Use a 13 mm socket wrench to loosen and remove the twelve capscrews 9 and lockwashers 8 on the outlet manifold 1 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 See FIG 3 Seat Puller Kit 220384 is available to make removal of the seats from the manifolds easier NOTICE Be careful not to drop or damage the balls 18 or seats 13 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 Seat Puller Kit 220384 M Screw bolt X Part 108481 into Seat Puller Y Part 181630 Position Seat Puller Y under the seat S by slipping it thro
28. screws 56 Torque the cap 40 to 34 40 Nem 25 30 ft Ib Reinstall the coupling nut and collars on the piston rod 19 Reconnect the coupling nut to the motor shaft See your separate pump assembly manual for correct torque specifications for your model Reinstall the shield Repair TSL Pump Repair if present Table 1 TSL Pump Troubleshooting Problem TSL pump not pumping TSL fluid Plugged manifold 53a Clear the manifold Verify that the mani fold is clear by blowing compressed air through the opening Plugged check valves 53c 53d Clear obstruction in check valves Plugged inlet strainer 530 Clear strainer mesh Damaged TSL pump piston 36 Replace TSL pump piston NOTE TSL Pump Repair Kit 24F618 is available See 1 Follow steps 1 6 under Replace the Throat Pack page 22 Install the TSL Pump Repair Kit 24F618 each ings Without Disconnecting the Lower page 7 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 Packings Without Disconnecting the Lower Shield Disassembly Reassembly The lowers include two shield kits The correct size is oee Fic 2 Remove the 2 piece shield 57 by inserting determined by your lower and motor See manual a screwdriver straight into the slot and using it as a 406876 to select the correct size kit for your lower and lever to rele
29. ugh at an angle C 4 seb L X qu ue EN Y Place Seat Puller Z Part 181629 on top of seat Turn bolt X to pull the seat out 01414 FIG 3 Removing Seats from Manifold Repair 8 Remove the wet cup 34 and o ring 52 Remove the TSL pump piston seal 36 spring 35 and o rings 51 9 Remove the throat cartridge 27 Remove the o ring 52 glands 32 33 packings 30 31 and spring 28 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 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 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 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 sea
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