Graco 24F448 Operation manual

3A0540L
EN
Instructions - Parts List
4-Ball Lowers
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.
See page 2 for model information, including maximum
working pressure.
Important Safety Instructions
Read all warnings and instructions in this
manual and in your separate pump
manual. Save these instructions.
TI15603a
Repair Kits
Accessory Kits
Related Manuals
See page 22
Get other manuals https://www.bkmanuals.com

Models
23A0540L
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4-Ball Lowers Cross Reference Chart . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Changing the TSL . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Replace the Throat Packings Without Disconnecting
the Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TSL Pump Repair (if present) . . . . . . . . . . . . . . . 8
Shield Disassembly/Reassembly . . . . . . . . . . . . 8
Lower Disassembly . . . . . . . . . . . . . . . . . . . . . . . 9
Lower Reassembly . . . . . . . . . . . . . . . . . . . . . . 13
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3000cc Lowers . . . . . . . . . . . . . . . . . . . . . . . . . 18
4000cc Lowers . . . . . . . . . . . . . . . . . . . . . . . . . 20
Repair Kits, Related Manuals, and Accessories . 22
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 24
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 24
Models
3000cc Lowers
4000cc Lowers
Model
No. Series Material
Maximum Pump
Working Pressure
psi (MPa, bar)
Rod/Cylinder
Material Packings
Inlet/Outlet Fitting
Size and Type
Parts
Page
24F448 A SST 440 (3.0, 30) Chromex/Chrome UHMWPE/Leather Inlet: 2 in. npt
Outlet: 2 in. npt
18
24F450 A CST 440 (3.0, 30) Chromex/Chrome UHMWPE/Leather Inlet: 2 in. npt
Outlet: 2 in. npt
18
24F449 A SST 440 (3.0, 30) Chromex/MaxLife UHMWPE/Leather Inlet: 2 in. npt
Outlet: 2 in. npt
18
Model
No. Series Material
Maximum Pump
Working Pressure
psi (MPa, bar)
Rod/Cylinder
Material Packings
Inlet/Outlet Fitting
Size and Type
Parts
Page
24F451 A SST 330 (2.3, 23) Chromex/Chrome UHMWPE/Leather Inlet: 2 in. npt
Outlet: 2 in. npt
20
24F453 A CST 330 (2.3, 23) Chromex/Chrome UHMWPE/Leather Inlet: 2 in. npt
Outlet: 2 in. npt
20
24F452 A SST 330 (2.3, 23) Chromex/MaxLife UHMWPE/Leather Inlet: 2 in. npt
Outlet: 2 in. npt
20
24J888 A SST 330 (2.3, 23) Chromex/Chrome UHMWPE/Leather Inlet: 2 in. BSPP
Outlet: 2 in. BSPP
20
Get other manuals https://www.bkmanuals.com

4-Ball Lowers Cross Reference Chart
3A0540L 3
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.
Earlier Lower
Part No.
Current
Lower Part
No.
218523 24F286
218524 24F448
218530 24F453
218531 24F451
235526 24F448
239813 24F448
240588 24F451
240589 24F451
240590 24F451
240591 24F448
240592 24F448
240593 24F448
243732 24F450
243733 24F453
243735 24F448
243736 24F451
Earlier Lower
Part No.
Current
Lower Part
No.
243772 24F448
243773 24F451
248330 24F448
248331 24F451
248333 24F448
248334 24F451
Earlier Lower
Part No.
Current
Lower Part
No.
Get other manuals https://www.bkmanuals.com

Warnings
43A0540L
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.
WARNINGWARNINGWARNING
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.
Get other manuals https://www.bkmanuals.com

Warnings
3A0540L 5
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.
WARNINGWARNINGWARNING
WARNING
Get other manuals https://www.bkmanuals.com

Changing the TSL
63A0540L
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.
2. Remove and empty the reservoir bottle. Clean any
residue.
3. Clean screen (Z) of inlet check valve (53c
‡ ). If
check valves are not sealing and dirty TSL is getting
into the wet-cup, replace the check valves (53c,
53d). See F
IG . 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.
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.
F IG . 1. Cutaway of TSL Reservoir, and Fill Lines
TI15853b
Z
TI15857
Maximum Fill Line
Minimum Fill Line
53b ‡
Inlet Check Valve
(53c
‡)
Outlet Check Valve
(53d
‡)
Get other manuals https://www.bkmanuals.com

Repair
3A0540L 7
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 (30†).
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.
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.
5. See F
IG . 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.
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†).
9. Lubricate the o-ring (52†) and install it on the
wet-cup (34). Install the wet-cup finger-tight.
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).
11. Torque the cartridge (27) to 95-100 ft-lb (129-135
N•m).
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).
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.
Get other manuals https://www.bkmanuals.com

Repair
83A0540L
TSL Pump Repair (if present)
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 F
IG . 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.
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). Clear obstruction in check valves.
Plugged inlet strainer (53c). Clear strainer mesh.
Damaged TSL pump piston (36). Replace TSL pump piston.
F IG . 2. Disassembly and Reassembly of the Shields
ti15759a
Shield Disassembly
ti15770a
ti15757a
ti15758a
Shield Reassembly
40 57
Get other manuals https://www.bkmanuals.com

Repair
3A0540L 9
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 (30†).
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.
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 F
IG . 5 for an exploded view of the entire
lower. See F
IG . 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 F
IG . 1, F IG .
5, and F
IG . 6.
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 F
IG . 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). 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.
F
IG . 3. Removing Seats from Manifold
X
Y
S
Y
X
Z
01414
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.
Place Seat Puller (Z, Part 181629) on top of
seat. Turn bolt (X) to pull the seat out.
Seat Puller Kit
220384
Get other manuals https://www.bkmanuals.com

Repair
10 3A0540L
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 F
IG . 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 F
IG . 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).
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 F
IG . 4.
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 (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.
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 F
IG . 5 for proper
orientation.
F IG . 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).
TI15631a
15
14
ball
spring
pressure relief valve
Get other manuals https://www.bkmanuals.com

Repair
3A0540L 11
F IG . 5. Exploded View of Lower
See Throat Packing Detail
on pages 18 and 20.
TI15572c
43
18
26
19
25*
24
23*
11
9
6
15*
13
*22
16
8
10
56
41
17*
21
20
27
28
5*
4
2
*3
1
40
34
1
*3
5*
7
12
13
14
15*
16
17*
18
8
9
53a
‡ 53c
53d
‡
‡
53b
 53e
*15
16
*17
18
51
36
Apply lubricant to all packings and
seals.
Apply removable (blue) Loctite
®
243 to
entire length of threads.
Torque to 200-210 ft-lb (270-285 N•m).
Apply thread lubricant.
Torque to 18-20 ft-lb (24-27 N•m).
Tighten uniformly until cylinder is
seated then torque to 60-65 ft-lb (81-88
N•m).
Torque to 95-100 ft-lb (129-135 N•m).
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.
Torque to 70-75 ft-lb (95-102 N•m).
Torque to 25-30 ft-lb (34-40 N•m).
1
2
3
4
5
6
7
8
9
10
1
2
5
3
6
1
1
1
1
1
1
1
1
8
2
1
1
11
5
1
1
52†
†52
4
7
10
4
94
1
53f
35
Get other manuals https://www.bkmanuals.com

Repair
12 3A0540L
F IG . 6. Cutaway View of Lower
53e 
40
TI15858c
TI15604a
26
19
*25
24
6
13
16
41
21
4
2
*3
1
40
1
*3
7
14
17*
18
9
18
5*
5*
18
13
16
18
16
17*
14
16
15*
15
*15
*15
†30 31†
†32
†33
†52
†52
51
36
34
27
28
53c
‡
53d ‡
53b ‡
53a
31†
†30
†33
53f
35
Get other manuals https://www.bkmanuals.com

Repair
3A0540L 13
Lower Reassembly
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 F
IG . 7.
3. 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 N•m. (200-210 ft-lb).
4. Remove the piston assembly from the vise, but do
not lay it down on its side; doing so may dam-
age the seal.
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 F
IG . 9.
6. Clean the remaining pump parts in a compatible sol-
vent.
F
IG . 7. Piston Assembly
F
IG . 8. Tool Kit 220385
TI0219
21
20 19
*22
23*
25*
26
24
Apply lubricant.
Torque to 200-210 ft-lb (270-285 N•m).
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.
1
3
4
8
8
1
3
4
1
01413
19
Tighten the tool on the
widest part of the shaft
(19). Grip the tool with
a wrench and unscrew
the shaft.
F
IG . 9. Install Piston in Cylinder
25
4
19
26
1Do not damage edges of seal.
TI0221
Get other manuals https://www.bkmanuals.com

Repair
14 3A0540L
7. Lubricate and install the new o-rings (15*) around
each of the four ball seats (13 and 14).
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.
9. Place the ball guides (16) and balls (18) in the inlet
valve housing.
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 F
IG . 5 and
F
IG . 6. Press the other seat (13), with the unworn
side facing out, into the other side of the inlet mani-
fold.
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).
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.
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 F
IG . 10.
NOTICE
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 F
IG . 5. If
installed incorrectly, the pump will not operate.
COMPONENT RUPTURE HAZARD
The relief valve seat (14) must be installed at the fluid
inlet, as shown in F
IG . 5 and F IG . 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.
F IG . 10. Manifold Screws Torque Values
10
9
1
2
1
2
Torque oppositely and evenly to 81-88 N•m (60-65 ft-lb).
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).
01410
Get other manuals https://www.bkmanuals.com

Repair
3A0540L 15
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.
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.
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
F
IG . 10.
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).
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.
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 F
IG . 10.
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†).
20. Lubricate the o-ring (52†) and install it on the
wet-cup (34). Install the wet-cup finger-tight.
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).
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).
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).
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.
Get other manuals https://www.bkmanuals.com

Repair
16 3A0540L
Get other manuals https://www.bkmanuals.com

Parts
3A0540L 17
Parts
See Throat Packing Detail
on pages 18 and 20.
TI15572c
43
18
26
19
25*
24
23*
11
9
6
15*
13
*22
16
8
10
56
41
17*
21
20
27
28
5*
4
2
*3
1
40
34
1
*3
5*
7
12
13
14
15*
16
17*
18
8
9
53a
‡ 53c
53d
‡
‡
53b
 53e
*15
16
*17
18
51
36
52†
†52
53f
See Parts Lists:
3000cc, pages 18-19
4000cc, pages 20-21
ti15757a
57
Shields (shipped loose)
35
Get other manuals https://www.bkmanuals.com

Parts
18 3A0540L
3000cc Lowers
Part No. 24F448, Series A, Stainless Steel
Part No. 24F450, Series A, Carbon Steel
Part No. 24F449, Series A, Stainless Steel
Ref.
No. Description
Lower
Qty24F448 24F450 24F449
1 MANIFOLD; sst 16E965 16E965 2
MANIFOLD; cst 180520 2
2 HOUSING, outlet; sst 16E084 16E084 1
HOUSING, outlet; cst 16E085 1
3* GASKET, cylinder; UHMWPE n/a n/a n/a 2
4 CYLINDER, pump; sst/chrome 180498 180498 1
CYLINDER, pump; sst/MaxLife 24A345 1
5* O-RING; PTFE n/a n/a n/a 4
6 TUBE, fluid; sst 180530 180530 180530 2
7 HOUSING, inlet; sst 180523 180523 1
HOUSING, inlet; cst 180521 1
8 WASHER, flat; 8.4 mm; sst 111003 111003 111003 24
9 CAPSCREW, hex hd; M8 x 1.25 x 25; sst 107554 107554 107554 24
10 CAPSCREW, hex hd; 9/16-12 unc x 7.5 in.; sst 107553 107553 107553 6
11 LOCKWASHER, spring; 9/16 in.; sst 108792 108792 108792 6
12 NUT, hex 107538 107538 107538 6
13 SEAT, valve; sst 180529 180529 180529 3
14 SEAT, intake valve, with relief valve; sst 237572 237572 237572 1
15* O-RING; PTFE n/a n/a n/a 4
16 GUIDE, ball; sst 180509 180509 180509 4
17 SEAL; UHMWPE 180761 180761 180761 4
18 BALL; 2 in. (51 mm) dia.; sst 110294 110294 110294 4
19 ROD, piston; sst 16A677 16A677 16A677 1
20 RETAINER, o-ring, piston 196356 196356 196356 1
21 NUT, piston 196243 196243 196243 1
22* O-RING; PTFE encapsulated fluoroelastomer n/a n/a n/a 1
23* O-RING; PTFE n/a n/a n/a 1
24 PLATE, retaining, piston 196264 196264 196264 1
25* PACKING, piston; UHMWPE n/a n/a n/a 1
26 PISTON 196263 196263 196263 1
27 CARTRIDGE, packing, throat 16A679 16A679 16A679 1
28 SPRING 16A545 16A545 16A545 1
30† V-PACKING, throat; UHMWPE n/a n/a n/a 6
31† V-PACKING, throat; leather n/a n/a n/a 4
32† GLAND, female; sst n/a n/a n/a 1
33† GLAND, male; sst n/a n/a n/a 2
TI15573a
Throat Packing Detail
30†
33†
31†
32†
31†
30†
33†
31†
31†
30†
30†
30†
30†
Get other manuals https://www.bkmanuals.com

Parts
3A0540L 19
Click here to return to repair kit page.

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.
34 WET CUP 16A678 16A678 16A678 1
35SPRING n/a n/a n/a 1
36SEAL, piston, TSL pump n/a n/a n/a 1
39 SPACER, open wet-cup (not shown; shipped loose) 16E536 16E536 16E536 1
40 CAP, wet-cup 16F051 16A682 16F051 1
41 COLLAR, rod, piston 16E416 16E416 16E416 2
43PLATE, warning 183460 183460 183460 1
48TAG, warning (not shown) 172479 172479 172479 1
51O-RING; fluoroelastomer 108657 108657 108657 2
52† O-RING; PTFE n/a n/a n/a 2
53 MANIFOLD/BOTTLE; includes 53a-53f 24T075 24T075 24T075 1
53a MANIFOLD; nylon n/a n/a n/a 1
53b‡ NIPPLE; sst n/a n/a n/a 1
53c‡ INLET CHECK; nylon, sst, fluoroelastomer n/a n/a n/a 1
53d‡ OUTLET CHECK; nylon, sst, pvc, fluoroelastomer n/a n/a n/a 1
53eBOTTLE; hdpe n/a n/a n/a 1
53f O-RING 16G290 16G290 16G290 1
56 SCREW; M4 x 12 115263 115263 115263 1
57 SHIELD KITS; lowers include two shield kits; see
manual 406876 to select the correct size kit for your
lower and motor
24F254 24F254 24F254 1
24F255 24F255 24F255
Ref.
No. Description
Lower
Qty24F448 24F450 24F449
Get other manuals https://www.bkmanuals.com

Parts
20 3A0540L
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
Ref.
No. Description
Lower
Qty24F451 24F453 24F452 24J888
1 MANIFOLD; sst; npt 16E965 16E965 2
MANIFOLD; cst; npt 180520 2
MANIFOLD; sst; BSPP 193203 2
2 HOUSING, outlet; sst 16E084 16E084 16E084 1
HOUSING, outlet; cst 16E085 1
3* GASKET, cylinder; UHMWPE n/a n/a n/a n/a 2
4 CYLINDER, pump; sst/chrome 180497 180497 180497 1
CYLINDER, pump; sst/MaxLife 24A346 1
5* PACKING, o-ring; PTFE n/a n/a n/a n/a 4
6 TUBE, fluid; sst 180530 180530 180530 180530 2
7 HOUSING, inlet; sst 180523 180523 180523 1
HOUSING, inlet; cst 180521 1
8 WASHER, flat; 8.4 mm; sst 111003 111003 111003 111003 24
9 CAPSCREW, hex hd; M8 x 1.25 x 25; sst 107554 107554 107554 107554 24
10 CAPSCREW, hex hd; 9/16-12 unc x 7.5 in.;
sst
107553 107553 107553 107553 6
11 LOCKWASHER, spring; 9/16 in.; sst 108792 108792 108792 108792 6
12 NUT, hex 107538 107538 107538 107538 6
13 SEAT, valve; sst 180529 180529 180529 180529 3
14 SEAT, intake valve, with relief valve; sst 237572 237572 237572 237572 1
15* O-RING; PTFE n/a n/a n/a n/a 4
16 GUIDE, ball; sst 180509 180509 180509 180509 4
17 SEAL; UHMWPE 180761 180761 180761 180761 4
18 BALL; 2 in. (51 mm) dia.; sst 110294 110294 110294 110294 4
19 ROD, piston; sst 16A677 16A677 16A677 16A677 1
20 RETAINER, o-ring, piston 196356 196356 196356 196356 1
21 NUT, piston 196243 196243 196243 196243 1
22* O-RING; PTFE encapsulated fluoroelasto-
mer
n/a n/a n/a n/a 1
23* O-RING; PTFE n/a n/a n/a n/a 1
24 PLATE, retaining, piston 196266 196266 196266 196266 1
25* PACKING, piston; UHMWPE n/a n/a n/a n/a 1
26 PISTON 196265 196265 196265 196265 1
27 CARTRIDGE, packing, throat 16A679 16A679 16A679 16A679 1
28 SPRING 16A545 16A545 16A545 16A545 1
30† V-PACKING, throat; UHMWPE n/a n/a n/a n/a 6
31† V-PACKING, throat; leather n/a n/a n/a n/a 4
32† GLAND, female; sst n/a n/a n/a n/a 1
33† GLAND, male; sst n/a n/a n/a n/a 2
TI15573a
Throat Packing Detail
30†
33†
31†
32†
31†
30†
33†
31†
31†
30†
30†
30†
30†
Get other manuals https://www.bkmanuals.com