Accessory Kits
See page 22
Instructions - Parts List
4-Ball Lowers
3A0540L
EN
3000cc and 4000cc Models
Designed for low pressure, high volume circulation of finishing materials.
Do not use for flushing or purging lines with caustics, acids, abrasive line strippers, and
other similar fluids. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this
manual and in your separate pump
manual. Save these instructions.
working pressure.
TI15603a
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4-Ball Lowers Cross Reference Chart
4-Ball Lowers Cross Reference Chart
This chart cross references earlier styles of 4-ball lowers to the current lowers, which include the TSL pump and
spring loaded packings.
Current
Lower Part
No.
Current
Lower Part
No.
Current
Lower Part
No.
Earlier Lower
Part No.
Earlier Lower
Part No.
Earlier Lower
Part No.
240590
240591
240592
240593
243732
243733
243735
243736
24F451
24F448
24F448
24F448
24F450
24F453
24F448
24F451
243772
243773
248330
248331
248333
248334
24F448
24F451
24F448
24F451
24F448
24F451
218523
218524
218530
218531
235526
239813
240588
240589
24F286
24F448
24F453
24F451
24F448
24F448
24F451
24F451
3A0540L
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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
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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
Changing the TSL
Check the condition of the TSL and the level in the res-
ervoir every week, minimum. TSL should be changed at
least every month.
To avoid the buildup of static charge, do not rub the
plastic bottle with a dry cloth while it is attached to the
pump. Remove the bottle to clean, if needed.
Part No. 206995 Throat Seal Liquid (TSL) carries resi-
due from the pump rod into the reservoir. Discoloration
of the TSL fluid is to be expected during normal opera-
tion. After some time the TSL will thicken and darken,
and must be replaced. Thick, dirty TSL will not pump
through the lines and will harden in the pump wet-cup.
2. Remove and empty the reservoir bottle. Clean any
residue.
3. Clean screen (Z) of inlet check valve (53c‡). If
How long TSL lasts depends on which chemicals are
used, how much is used, what pressure, and condition
of the pump seal and rod.
check valves are not sealing and dirty TSL is getting
into the wet-cup, replace the check valves (53c,
53d). See FIG. 1.
NOTE: Order Check Valve Repair Kit 24F404. Kit parts
are marked with a symbol, for example (53b‡).
A drop in the level of TSL in the reservoir indicates that
the throat packings are starting to wear. Add TSL to the
reservoir and keep the level above the Minimum fill line.
Monitor the usage and condition of the TSL. If pumped
material bypasses the throat packings and enters the
TSL reservoir, replace the packings.
4. Fill the reservoir to the Maximum fill line with Throat
Seal Liquid (TSL).
5. Run pump. Each time pump rod reaches bottom of
stroke, check that some TSL is pumped from reser-
voir through wet-cup and back to reservoir.
To change the TSL:
1. Shut off the pump.
Maximum Fill Line
Outlet Check Valve
(53d‡)
53b
‡
Minimum Fill Line
Inlet Check Valve
(53c‡)
Z
TI15857
TI15853b
FIG. 1. Cutaway of TSL Reservoir, and Fill Lines
6
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Repair
Repair
8. Lubricate the throat packings and glands. Install the
spring (28) and one male gland (31†) in the throat
cartridge (27), then seven v-packings with the lips
facing down: one UHMWPE (30†), one leather
(31†), UHMWPE, leather, UHMWPE, leather, UHM-
WPE. Install the female gland (32†). Install three
v-packings with the lips facing up: UHMWPE,
leather, UHMWPE. Install the other male gland
(33†).
Replace the Throat Packings
Without Disconnecting the
Lower
Kit parts are marked with a symbol, for example (30†).
For best results, install the TSL Pump Repair Kit 24F618
each time the throat packings are changed.
9. Lubricate the o-ring (52†) and install it on the
wet-cup (34). Install the wet-cup finger-tight.
NOTE: To replace the throat packings as part of a com-
10. Install the o-ring (52†) on the throat cartridge (27).
Apply lubricant to the throat cartridge threads then
screw the cartridge into the outlet housing (1).
NOTE: Tool Kit 24F494 is available as an accessory.
The kit includes two wrenches for use with the wet-cup
(34) and throat cartridge (27).
11. Torque the cartridge (27) to 95-100 ft-lb (129-135
N•m).
1. Flush the pump, if possible.
2. Stop the pump at the middle of its stroke.
12. Torque the wet-cup (34) to 70-75 ft-lb (95-102 N•m).
13. Reassemble the spring (35), TSL pump piston
seal (36), and o-rings (51).
14. Reassemble the manifold and bottle assembly (53),
cap (40), collar (41) and screws (56). Torque the
cap (40) to 34-40 N•m (25-30 ft-lb).
3. Relieve the pressure. See your separate pump
manual.
4. Following the instructions in your separate pump
manual, remove the 2-piece shield covering the
coupling assembly. Unscrew the coupling nut from
the motor shaft. Lift the motor shaft and remove the
coupling nut and collars.
15. Reinstall the coupling nut and collars on the piston
rod (19).
16. Reconnect the coupling nut to the motor shaft. See
your separate pump assembly manual for correct
torque specifications for your model. Reinstall the
shield.
5. See FIG. 5. Remove the collar (41) and screws (56),
cap (40), and manifold and bottle assembly (53).
6. Remove the wet-cup (34) and o-ring (52). Remove
the TSL pump piston seal (36), spring (35), and
o-rings (51).
7. Remove the throat cartridge (27). Remove the
o-ring (52), glands (32, 33), packings (30, 31), and
spring (28).
NOTE: Inspect the surface of the piston rod (19). If it is
scratched, replace the piston rod.
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Repair
TSL Pump Repair (if present)
Table 1: TSL Pump Troubleshooting
Problem
Cause
Solution
TSL pump not pumping TSL fluid.
Plugged manifold (53a).
Clear the manifold. Verify that the mani-
fold is clear by blowing compressed air
through the opening.
Plugged check valves (53c, 53d).
Plugged inlet strainer (53c).
Clear obstruction in check valves.
Clear strainer mesh.
Damaged TSL pump piston (36).
Replace TSL pump piston.
NOTE: TSL Pump Repair Kit 24F618 is available. See
time the throat packings are changed. Kit parts are
marked with a symbol, for example (36).
2. Clean all parts and inspect for damage.
Shield Disassembly/Reassembly
The lowers include two shield kits. The correct size is
determined by your lower and motor. See manual
406876 to select the correct size kit for your lower and
motor.
See FIG. 2. Remove the 2-piece shield (57) by inserting
a screwdriver straight into the slot, and using it as a
lever to release the tab. Repeat for all tabs. Do not use
the screwdriver to pry the shields apart.
Install the shields (57) by engaging the bottom lips with
the groove in the wet-cup cap (40). Snap the two shields
together.
Shield Disassembly
Shield Reassembly
ti15758a
ti15759a
ti15757a
ti15770a
40
57
FIG. 2. Disassembly and Reassembly of the Shields
8
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Repair
6. Use a 13 mm socket wrench to loosen and remove
the twelve capscrews (9) and lockwashers (8) on
the outlet manifold (1).
Lower Disassembly
NOTE: This pump is easiest to repair when left in the
Part No. 218742 accessory pump stand and disassem-
bled as instructed. For repair at a remote location, have
another pump stand available.
7. Lift the manifold (1) off the outlet valve housing (2)
and remove the ball guides (16), balls (18), seats
(13) and seals (17). Remove the o-ring (15) from the
seats (13).
NOTE: Seal kits are available for each lower size. See
and drawings, for example (3*).
NOTE: See FIG. 3. Seat Puller Kit 220384 is available to
make removal of the seats from the manifolds easier.
Kit parts are marked with a symbol, for example (30†).
For best results, install the TSL Pump Repair Kit 24F618
each time the throat packings are changed.
NOTICE
Be careful not to drop or damage the balls (18) or
seats (13). A damaged ball or seat cannot seal prop-
erly and the pump will leak. The outlet valve seats (13)
can be reversed to provide longer use of the seat.
NOTE: Tool Kit 24F494 is available as an accessory.
The kit includes two wrenches for use with the wet-cup
(34) and throat cartridge (27).
X
NOTE: Complete pump repair kits are also available.
The kits include all seal kit parts, throat packing kit parts,
Seat Puller Kit
220384
Y
1. Flush the pump, if possible.
Screw bolt (X, Part 108481) into Seat
Puller (Y, Part 181630).
Position Seat Puller (Y) under the seat
(S) by slipping it through at an angle.
2. Stop the pump at the middle of its stroke.
S
3. Relieve the pressure. See your separate pump
manual.
4. Remove the lower from the motor as described in
your separate pump manual.
Y
NOTE: See FIG. 5 for an exploded view of the entire
lower. See FIG. 6 for a cutaway view of the lower and an
exploded view of the throat packings.
Place Seat Puller (Z, Part 181629) on top of
seat. Turn bolt (X) to pull the seat out.
5. Remove the collar (41) and screws (56), cap (40),
and manifold and bottle assembly (53).
X
NOTE: To replace the check valves in the TSL bottle,
order Check Valve Repair Kit 24F404. Kit parts are
marked with a symbol, for example (53b‡). To replace
the bottle only, order Bottle Replacement Kit 24F405. Kit
parts are marked with a symbol, for example (48e).
The kit includes 5 bottles and 5 labels. See FIG. 1, FIG.
5, and FIG. 6.
Z
01414
FIG. 3. Removing Seats from Manifold
3A0540L
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Repair
8. Remove the wet-cup (34) and o-ring (52). Remove
the TSL pump piston seal (36), spring (35), and
o-rings (51).
15. Inspect the pressure relief valve in the fluid inlet
seat (14) to make sure it is not clogged. Press down
on the valve's ball to see if the ball and spring are
free to move. See FIG. 4.
9. Remove the throat cartridge (27). Remove the
o-ring (52), glands (32, 33), packings (30, 31), and
spring (28).
ball
10. Remove the nuts (12), lockwashers (11), and six
cylinder capscrews (10). Lift off the outlet valve
housing (2).
11. Lift the riser tubes (6) and cylinder (4) off the inlet
valve housing (7). The piston assembly may stay in
the cylinder. Remove the seals (3 and 5) from the
inlet and outlet housings (2, 7). See FIG. 5.
15
spring
NOTE: Tap on the valve housings with a plastic mallet
and use a slight rocking motion to help loosen and
remove the cylinder and tubes.
14
pressure relief valve
TI15631a
FIG. 4. Inlet Seat with Pressure Relief Valve
12. If Part No. 218742 accessory pump stand is used,
unscrew and remove the three pump stand bolts.
Lift the inlet valve assembly off the stand. Place the
inlet valve housing (7) face down on a protected
surface.
NOTICE
If the pressure relief valve in the inlet seat (14) is
clogged or filled with material, soak the seat in a com-
patible solvent. Make sure all material residue is
cleaned from the ball and seat area.
13. Use a 13 mm socket wrench to loosen and remove
the twelve capscrews (9) and lockwashers (8) from
the inlet manifold (1). See FIG. 5.
14. Lift the manifold (1) off the inlet valve housing (7)
and remove the seats (13 and 14). Remove the
o-ring (15) from the seats. Remove the balls (18),
ball guides (16) and seals (17).
If the relief valve cannot be thoroughly cleaned so that
the ball and spring are free to move, replace the seat
(14).
16. Push the piston assembly through the cylinder just
enough to expose the piston (26) flats. Secure the
piston flats in a vise. Use a plastic mallet to tap the
cylinder (4) up and off the piston assembly.
NOTICE
Be careful not to drop or damage the balls (18) or
seats (13 or 14). A damaged ball or seat cannot seal
properly and the pump will leak. One inlet valve seat
(13) can be reversed to provide longer use of the seat.
However, the fluid inlet seat (14) contains a pressure
relief valve and is not reversible. See FIG. 5 for proper
orientation.
17. Loosen the piston nut (21). Use Tool Kit 220385 (to
remove the piston shaft (19) and piston nut (21).
Remove the piston nut o-ring (22) and o-ring
retainer (20) from the shaft. Remove the plate (24)
and the seal (25) from the piston (26).
18. Inspect the piston shaft (19). If it is damaged or the
surface is scored, replace it.
19. Clean all piston parts and the cylinder thoroughly in
a compatible solvent. Inspect the inner surface of
the cylinder for scoring, and replace it if necessary.
A scored cylinder will quickly damage the packings.
10
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Repair
20
21
3
16
23*
2
5
*22
9
1
10
1
17*
18
4
24
8
1
25* 1
13
56
15*1
26
10
43
40
7
2
36
1
41
11
12
16
18
1
5*
53a
1
*3
4
53f
53d
‡
6
‡
53b
16
6
17*
35
51
1
‡
53c
18
14
1
*17
15*
1
5*
1
34
4
*3
1
1
53e
13
9
1
8
52†
*15
1
19
9
2
1
5
28
27
8
4
7
†52
TI15572c
1
®
1
5
8
Apply lubricant to all packings and
seals.
Torque to 18-20 ft-lb (24-27 N•m).
Tighten uniformly until cylinder is
Apply high strength (red) Loctite 263
or 2760 to entire length of threads.
Sealant must be allowed to cure for a
minimum of 12 hours before use.
6
®
2
Apply removable (blue) Loctite 243 to
entire length of threads.
seated then torque to 60-65 ft-lb (81-88
N•m).
9
Torque to 70-75 ft-lb (95-102 N•m).
Torque to 25-30 ft-lb (34-40 N•m).
3
4
7
Torque to 200-210 ft-lb (270-285 N•m).
Apply thread lubricant.
Torque to 95-100 ft-lb (129-135 N•m).
10
FIG. 5. Exploded View of Lower
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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
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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
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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
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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
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
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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
35 SPRING
36 SEAL, piston, TSL pump
39
40
41
43 PLATE, warning
48 TAG, warning (not shown)
51 O-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
53e BOTTLE; 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
35 SPRING
36 SEAL, 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
43 PLATE, warning
48 TAG, warning (not shown)
51 O-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
53e BOTTLE; 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
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
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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