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
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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
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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.
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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.
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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
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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
‡)
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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.
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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
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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
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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
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