Graco Series A Operation manual

3A2023C
EN
Instructions - Parts List
4-Ball Lowers
1500cc and 2000cc Models
Designed for low pressure oil transfer.
Do not use for flushing or purging lines with caustics, acids, abrasive line strippers, and
other similar fluids. For professional use only.
Models:
24J088 - 1500cc, Series A
24J089 - 2000cc, Series A
Maximum Working Pressure, 460 psi (3.2 MPa, 32 bar)
24J090 - 2000cc, Series A
Maximum Working Pressure, 400 psi (2.8 MPa, 28 bar)
US Patent Pending
Important Safety Instructions
Read all warnings and instructions in this
manual and in your separate pump manual
before using the equipment. Save these
instructions.
Models 24J088 and
24J089
Model 24J090

Warnings
23A2023C
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
When flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be
aware that flammable fumes can ignite or explode. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources, such as cigarettes and portable electric lamps.
• Keep work area free of debris, including rags and spilled or open containers of solvent and gasoline.
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Ground all equipment in the work area.
• Use only grounded hoses.
• 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.

Warnings
3A2023C 3
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.
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.
WARNINGWARNINGWARNING
WARNING

Repair - Models 24J088 and 24J089 Only
43A2023C
Repair - Models 24J088 and 24J089 Only
The following instructions are for models 24J088 and
24J089 only. Instructions for model 24J090 begin on
page 9.
Reference numbers used in the following instructions
refer to parts page 20.
Pressure Relief Procedure
Follow the Pressure Relief Procedure when-
ever you see this symbol.
1. Close the bleed-type master air valve.
2. Open the dispensing valve, if used.
3. Open all fluid drain valves (N) in the system, having
a waste container ready to catch drainage. Leave
drain valve(s) open until you are ready to spray
again.
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 (19†).
1. Flush the pump, if possible.
2. Stop the pump at the middle of its stroke.
3. Relieve the pressure.
4. Unscrews the coupling nut (a) from the motor shaft.
Lift the motor shaft and remove the coupling nut (a)
and collars (b) (FIG. 1).
5. Remove the o-ring (35), glands (19, 26), packings
(20, 25) (FIG. 2).
NOTE: Inspect the surface of the piston rod (17). If it is
scratched, replace the piston rod.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing fluid
and moving parts, follow the Pressure Relief Procedure
when you stop pumping and before cleaning, checking,
or servicing the equipment. FIG. 1
FIG. 2
b
35
19
20
25
26
20 25
19
a

Repair - Models 24J088 and 24J089 Only
3A2023C 5
6. Lubricate the throat packings and glands. Install one
male gland (19†) then seven v-packings with the lips
facing down: one UHMWPE (20†), one leather
(25†), UHMWPE, leather, UHMWPE, leather, UHM-
WPE. Install the female gland (26†). Install three
v-packings with the lips facing up: UHMWPE,
leather, UHMWPE. Install the other male gland
(19†) and o-ring (35†) (FIG. 2, page 4).
7. Reinstall the coupling nut and collars on the piston
rod (17) (FIG. 1, page 4).
8. See your separate pump assembly manual for cor-
rect torque specifications for your model. Reinstall
the shield (52).
Lower Disassembly
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 (2*).
NOTE: Throat packing kits are available. See page 22.
Kit parts are marked with a symbol, for example (19†).
1. Flush the pump, if possible.
2. Stop the pump at the middle of its stroke.
3. Relieve the pressure, page 4.
4. Remove the lower from the motor as described in
your separate pump manual.
NOTE: See FIG. 4, page 7 for an exploded view of the
entire lower. See FIG. 5, page 8 for a cutaway view of the
lower and an exploded view of the throat packings.
5. Secure the inlet manifold (18) in a vise.
6. Remove the four caps crews (9) and washers (8)
from around the outlet manifold (22).
7. Remove the outlet manifold (22), balls (23), seats
(24), and gaskets (7).
8. Remove the o-ring (35), glands (19, 26), packings
(20, 25), and spring (43).
9. Remove the three cylinder screws (13) and lock-
washers (14). Lift off the outlet housing (16).
NOTE: The fluid tubes (3), cylinder (1), and piston
assembly (17, 10, 11, 44, 12) may come loose with the
outlet housing, or may remain in place on the inlet hous-
ing (15).
10. Remove the tubes (3) and cylinder (1). Pull the pis-
ton assembly out of the cylinder. Inspect the surface
of the piston rod (17) and the inside surfaces of the
cylinder and tubes. If any of these parts are
scratched or damaged, replace them.
11. Remove the inlet manifold (18) from the vise.
12. Remove the four caps crews (9) and washers (8)
from the inlet manifold (18).
NOTE: One inlet seat (6) includes a pressure relief
valve. See FIG. 3. This seat must be located exactly
where shown (the left side as viewed in FIG. 4). Use the
text cast into the inlet housing as a guide.
13. Remove the balls (5), inlet seats (6 and 33), and
gaskets (7).
14. Inspect the pressure relief valve (c) in the seat (6) to
make sure it is not clogged. Press down on the
valve's ball to see if the ball and the spring are free
to move. See FIG. 3.
NOTICE
Be careful not to drop or damage the balls (5) or seats
(6 and 33). A damaged ball or seat cannot seal prop-
erly and the pump will leak. One inlet valve seat (33)
can be reversed to provide longer use of the seat.
However, the fluid inlet seat (6) contains a pressure
relief valve and is not reversible. See FIG. 3 for proper
orientation.
FIG. 3. Inlet Seat with Pressure Relief Valve
7
6
a
b
c
P

Repair - Models 24J088 and 24J089 Only
63A2023C
NOTE: If the pressure relief valve in the seat (6) 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
(6).
15. Place the flats of the piston nut (12) in a vise.
Unscrew the rod (17) from the nut. Remove the
spacer (44). Disassemble the piston (10) and
remove the seal (11).
16. Clean all parts in a compatible solvent. Inspect all
parts for wear or damage. If you are using a repair
kit, use all the new parts in the kit, discarding the old
ones they replace. Replace any other parts as
needed. Worn or damaged parts may cause the
pump to perform poorly or cause premature wear of
the new seals and packings.

Repair - Models 24J088 and 24J089 Only
3A2023C 7
FIG. 4. Exploded View of Lower
9
8
22
23
24
*7
*2
3
*2
*4
16
4*
1
17
10
11*
10
14
33
13
9
8
18
6
5
*7
15
12
44
19†
20†
25†
26†
19†
20†
20†
20†
20†
25†
25†
Apply lubricant to all packings and
seals.
Apply removable (blue) Loctite®243 to
entire length of threads.
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.
Tighten uniformly until cylinder (4) is
seated. Torque to 25-30 ft-lb (34-40
N•m).
Torque 25-30 ft-lb (34-40 N•m).
Torque 95-100 ft-lb (129-135 N•m).
Apply thread lubricant.
Torque 70-75 ft-lb (95-102 N•m).
1
2
3
4
5
6
7
1
5 2
5
2
4
1
1
1
1
1
1
3
6
7
34
29
35 †

Repair - Models 24J088 and 24J089 Only
83A2023C
FIG. 5: Cutaway View
OUTLET
INLET
17
16
4*
13
1
15
10
11*
12
7*
33
5
*7
5
6
*2
*2
3
7*, 24
23
22
18
34
29
44
†19
†20
†25
†26
†19
†20
†20
†20
†20
†25
†25
†35

Repair - Models 24J088 and 24J089 Only
3A2023C 9
Lower Reassembly
1. See FIG. 4. Place the halves of the piston (10)
around the packing (11) and snap them together.
2. Apply high strength (red) Loctite®263 or 2760 to
entire length of the piston rod (17) threads. Sealant
must be allowed to cure for a minimum of 12 hours
before use. Screw the rod through the piston and
spacer (44) and into the piston nut (12). Torque the
nut to 95-100 ft-lb (129-135 N•m).
3. With the inlet housing (15) turned upside down,
install the balls (5) and the gaskets (7*).
4. Install the relief valve inlet seat (6) in the left side of
the inlet housing (15), as viewed in FIG. 6. (Text cast
into the inlet housing identifies the correct location
for the relief valve seat.) The pin (P) on the seat
must point into the housing. The pin limits the posi-
tioning of the seat, ensuring that the vent is not
blocked by part of the housing. See FIG. 6.
5. Install the inlet seat without a relief valve (33) in the
right side of the inlet housing (15).
NOTE: The inlet seats (6 and 33) are not reversible; the
chamfered side must face the ball.
6. Place the inlet manifold (18) on the inlet housing
(15). Apply removable (blue) Loctite®243 to entire
length of the screw (9) threads. Install the lockwash-
ers (8) and screws (9), and torque to 25-30 ft-lb
(34-40 N•m).
7. Place the inlet manifold (18) in a vise. Place one
o-ring (2*) in each side of the inlet housing (15),
where the tubes (3) sit. Place o-rings (2*) in the
grooves at each end of the tubes. Place a gasket (4)
in both the inlet and outlet housing (15 and 16).
Position the tubes and cylinder (1) in the inlet hous-
ing.
COMPONENT RUPTURE HAZARD
The relief valve seat (6) must be installed at the fluid
inlet, as shown in FIG. 6. The relief valve reduces the
risk of pump over pressurization. The seat cannot
relieve pressure if installed on the other side of the
inlet housing.
FIG. 6. Inlet Seat with Pressure Relief Valve (Left side
is shown as the back of this illustration)
P
ab
c
7
6

Repair - Model 24J090
10 3A2023C
NOTE: It may be necessary to use a rubber mallet to set
the fluid tubes (3) and cylinder (4) in place.
8. Lubricate the inside of the cylinder (4). Slide the pis-
ton assembly into the cylinder. Rotate the piston as
shown in FIG. 7.
9. Lubricate the throat packings and glands. Install one
male gland (19†) in the throat cartridge (40), then
five v-packings with the lips facing down: one UHM-
WPE (20†), one leather (25†), UHMWPE, leather,
UHMWPE. Install the female gland (26†). Install
three v-packings with the lips facing up: UHMWPE,
leather, UHMWPE. Install the other male gland
(19†).
10. Install the outlet housing (16). It may not seat well
on the tubes and cylinder. Install the screws (13)
and lockwashers (14) from the inlet housing (15). As
you tighten the screws into the outlet housing (16),
they will draw the housings firmly onto the tubes and
cylinders. Tighten the screws uniformly and torque
to 25-30 ft-lb (34-40 N•m).
11. Place a ball (23), seat (24) and gasket (7*) in each
side of the outlet manifold (22). Install the outlet
manifold on the outlet housing (16).
12. Apply removable (blue) Loctite®243 to entire length
of the screw (9) threads. Install the lockwashers (8)
and screws (9), and torque to 25-30 ft-lb (34-40
N•m).
NOTE: The outlet seats (24) are reversible.
13. 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.
Repair - Model 24J090
The following instructions are for models 24J090 only.
Instructions for model 24J088 and 24J089 begin on
page 4.
Reference numbers used in the following instructions
refer to parts page 23.
Replace the Throat Packings Without
Disconnecting the Lower
NOTE: Throat packing kits are available. See page 24.
Kit parts are marked with a symbol, for example (30†).
NOTE: To replace the throat packings as part of a com-
plete service of the lower, see page 11.
1. Flush the pump, if possible.
2. Stop the pump at the middle of its stroke.
3. Relieve the pressure, page 4.
FIG. 7. Install Piston in Cylinder

Repair - Model 24J090
3A2023C 11
4. Unscrews the coupling nut (a) from the motor shaft.
Lift the motor shaft and remove the coupling nut (a)
and collars (b) (FIG. 8).
5. Remove the throat cartridge (45). Remove the
o-ring (40), glands (29, 30), and packings (27, 28).
NOTE: Inspect the surface of the piston rod (19). If it is
scratched, replace the piston rod.
6. Lubricate the throat packings and glands. Install one
male gland (30†) in the throat cartridge (45), then
seven v-packings with the lips facing down: one
UHMWPE (27†), one leather (28†), UHMWPE,
leather, UHMWPE, leather, UHMWPE. Install the
female gland (29†). Install three v-packings with the
lips facing up: UHMWPE, leather, UHMWPE. Install
the other male gland (30†). Also see page 23 for
additional information regarding torque and lubri-
cants for these parts.
7. Install the o-ring (40†) on the throat cartridge (45).
Apply lubricant to the throat cartridge threads then
screw the cartridge into the outlet housing (1).
8. Torque the cartridge (45) to 95-100 ft-lb (129-135
N•m).
9. Reinstall the coupling nut and collars on the piston
rod (19).
10. Reconnect the coupling nut to the motor shaft. See
your separate pump assembly manual for correct
torque specifications for your model.
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 24. Kit parts are marked with an asterisk in the text
and drawings, for example (3*).
NOTE: Throat packing kits are available. See page 24.
Kit parts are marked with a symbol, for example (30†).
NOTE: Complete pump repair kits are also available.
The kits include all seal kit parts. See page 25.
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 FIG. 12, page 14 for an exploded view of the
entire lower. See FIG. 13, page 15 for a cutaway view of
the lower and an exploded view of the throat packings.
FIG. 8
FIG. 9
b
30
27 28
29
27
28
30
45
40
a

Repair - Model 24J090
12 3A2023C
5. Use a 13 mm socket wrench to loosen and remove
the twelve caps crews (9) and lockwashers (8) on
the outlet manifold (1).
6. Lift the manifold (1) off the outlet valve housing (2)
and remove the ball guides (16), balls (18), seats
(13) and seals (17). Remove the o-ring (15) from the
seats (13).
NOTE: See FIG. 10. Seat Puller Kit 220384 is available
to make removal of the seats from the manifolds easier.
7. Remove the throat cartridge (45). Remove the
o-ring (40), glands (29, 30), and packings (27, 28).
8. Remove the nuts (12), lockwashers (11), and six
cylinder caps crews (10). Lift off the outlet valve
housing (2).
9. 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. 12.
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.
10. 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 sur-
face.
11. Use a 13 mm socket wrench to loosen and remove
the twelve caps crews (9) and lockwashers (8) from
the inlet manifold (1). See FIG. 12.
12. 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).
13. Inspect the pressure relief valve in the fluid inlet seat
(14) to make sure it is not clogged. Press down on
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.
FIG. 10. Removing Seats from Manifold
X
Y
S
Y
X
Z
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
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. 11 for
proper orientation.

Repair - Model 24J090
3A2023C 13
the valve's ball to see if the ball and spring are free
to move. See FIG. 11.
NOTE: 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).
14. 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.
15. 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).
16. Inspect the piston shaft (19). If it is damaged or the
surface is scored, replace it.
17. 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.
FIG. 11. Inlet Seat with Pressure Relief Valve
15
14
ball
spring
pressure relief valve

Repair - Model 24J090
14 3A2023C
FIG. 12: Exploded View of Lower
43
18
26
19
25*
24
23*
11
9
6
15*
13
*22
16
8
10 17*
21
20
5*
4
2
*3
1
1
*3
5*
7
12
13
14
15*
16
17*
18
8
9
*15
16
*17
18
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
125
3
6
1
1
1
1
1
1
1
8
2
1
11
5
1
1
44†
40
4
74
1
27†
30 †
1
1
28†
29†
1
1
1
28 †
†
30†
1
46
45
27

Repair - Model 24J090
3A2023C 15
FIG. 13: Cutaway View of Lower
26
19
*25
24
6
13
16
21
4
2
*3
1
46
1
*3
7
14
17*
18
9
18
5*
5*
18
13
16
18
16
17*
14
16
15*
15
*15
*15
†27 28†
†29
†30
†40
†44
46
45
28†
†27
†30

Repair - Model 24J090
16 3A2023C
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 FIG. 14.
3. Install o-ring retainer (20). Lubricate o-ring (22*) and
slide it on over the threads of piston rod (19). 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.
4. 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).
5. Remove the piston assembly from the vise, but do
not lay it down on its side; doing so may dam-
age the seal.
6. 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. 16.
FIG. 14. Piston Assembly
FIG. 15. 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.

Repair - Model 24J090
3A2023C 17
7. Clean the remaining pump parts in a compatible sol-
vent.
8. Lubricate and install the new o-rings (15*) around
each of the four ball seats (13 and 14).
9. 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. Place the ball guides (16) and balls (18) in the inlet
valve housing.
FIG. 16. Install Piston in Cylinder
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 FIG. 18. If
installed incorrectly, the pump will not operate.
25
4
19
26
1Do not damage edges of seal.
TI0221
FIG. 17
COMPONENT RUPTURE HAZARD
The relief valve seat (14) must be installed at the fluid
inlet, as shown in FIG. 18. The relief valve reduces the
risk of pump over pressurization. The seat cannot
relieve pressure if installed on the other side of the
inlet housing.
7
16
18
17
13
15
15
14
17
18
16
1
1
1
1
1
Apply lubricant to all packings and seals.

Repair - Model 24J090
18 3A2023C
11. Press the relief valve seat (14) with the pressure
relief valve into the fluid inlet side of the inlet mani-
fold (1). This seat is not reversible. Orient as shown
in FIG. 18. Press the other seat (13), with the
unworn side facing out, into the other side of the
inlet manifold.
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).
12. 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
caps crews (9) and lockwashers (8) loosely.
13. 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. 19.
14. 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.
15. 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.
16. Install the six cylinder caps crews (10), lockwashers
(11) and nuts (12). Tighten the caps crews oppo-
sitely and evenly to 81-88 N•m (60-65 ft-lb). See
FIG. 19.
17. 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).
18. Apply removable (blue) Loctite®243 to entire length
of the screw (9) threads. Place the outlet manifold
FIG. 18. Inlet Seat with Pressure Relief Valve
14
a
b
P
7
13
FIG. 19. 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

Repair - Model 24J090
3A2023C 19
(1) on the outlet valve housing (2) and install the
twelve screws (9) and lockwashers (8) loosely.
19. 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. 19.
20. Lubricate the throat packings and glands. Install one
male gland (30†) in the throat cartridge (45), then
seven v-packings with the lips facing down: one
UHMWPE (27†), one leather (28†), UHMWPE,
leather, UHMWPE, leather, UHMWPE. Install the
female gland (29†). Install three v-packings with the
lips facing up: UHMWPE, leather, UHMWPE. Install
the other male gland (30†).
21. Torque the cartridge (45) to 129-135 N•m (95-100
ft-lb).
22. Reinstall the coupling nut and collars on the piston
rod (19). Fill the cavity in the bottom of the motor
shaft with grease. Reconnect the lower to the motor
as described in your separate pump manual.
23. 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.

Parts - 24J088 and 24J089
20 3A2023C
Parts - 24J088 and 24J089
9
8
22
23**
24**
*7[**]
*2
3
*2
*4
16
4*
1
17
10
11*
10
14
33
13
9
8
18
6
5
*7
15
12
44
19†
20†
25†
26†
19†
20†
20†
20†
20†
25†
25†
Apply lubricant to all packings and
seals.
Apply removable (blue) Loctite®243 to
entire length of threads.
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.
Tighten uniformly until cylinder (4) is
seated. Torque to 25-30 ft-lb (34-40
N•m).
Torque 25-30 ft-lb (34-40 N•m).
Torque 95-100 ft-lb (129-135 N•m).
Apply thread lubricant.
Torque 70-75 ft-lb (95-102 N•m).
1
2
3
4
5
6
7
1
5 2
5
2
4
1
1
1
1
1
1
3
6
7
34
29
35†