Repair - Parts ® E-Flo 4-Ball Piston Pumps 311594Z EN Durable, energy efficient piston pumps for high volume paint circulation applications. For professional use only. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 3 for model information, including maximum working pressure. See page 5 for approvals.
Related Manuals Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 E-Flo 4-Ball Piston Pumps . . . . . . . . . . . . . . . . . 3 Maximum Working Pressure and Pump Operational Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models Models E-Flo 4-Ball Piston Pumps Check your pump’s identification plate (ID) for the 6-digit part number of your pump. Use the following matrix to define the construction of your pump, based on the six digits. For example, Pump Part No. E P 2 1 6 0 represents electric power (E), pump (P), 230/460V motor (2), sensor circuit installed (1), 2000 cc MaxLife lower (6), and no stand installed (0). To order replacement parts, see Parts, beginning on page 42.
Models 4 311594Z
Approvals Approvals The E-Flo Pump meets requirements of the following approval agencies. Refer to the individual components for other specific hazardous location listings. Component Part No. Approvals Mechanical Pump c T3 ATEX EP1XXX EP3XXX Ex de IIC T4 - CESI 05 ATEX 110X Motor UL/CSA EP2XXX Class I, Group D, Class II, Group F and G, Division 1, T3B Hazardous Locations EP4XXX Class 1, Div.
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation 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.
Warnings WARNING ELECTRIC SHOCK HAZARD Improper grounding, setup, or usage of the system can cause electric shock. • Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment. • Connect only to grounded power source. • All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
Warnings 8 311594Z
Pressure Relief Procedure Pressure Relief Procedure System pressure can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts. 1. Set START/STOP switch (ST) to STOP. 2. Push in SECURE DISABLE (SD) switch. Flushing • Flush before changing colors, before storing, and before repairing equipment. • Flush at the lowest pressure possible. Check connectors for leaks and tighten as necessary.
Troubleshooting Troubleshooting 1. Relieve the pressure. 2. Check all possible problems and solutions before disassembling pump. PROBLEM Pump does not operate. Pressure too low. Pump output low on both strokes. Pump output low on only one stroke. Erratic flow or pressure. 10 CAUSE SOLUTION Insufficient power supply. Verify that power supply meets requirements. See Technical Data, page 50. No flow rate input to VFD. Select speed/flow setting. START/STOP switch set to STOP.
Troubleshooting PROBLEM Pump will not prime Excessive throat leakage. High current trip (t043). High pressure trip (t040). CAUSE SOLUTION Suction line clogged. Clear. Flush more frequently. Held open or worn ball check valves. Check and repair. Lower piston assembled with wrong nut. Use only the large, round, special nut. Worn piston rod or throat packings. Replace. See lower manual. Pressure setting is too high. Reduce pressure. Pump packings are too tight. Loosen and retighten.
Electrical Diagrams Electrical Diagrams FIG. 1 shows components which must be installed in a non-hazardous location. 1 12 Gauge Alpha Wire P/N V16012/equiv. 2 16 Gauge MTW Wire. 3 Blue/White 16 Gauge MTW Wire. 4 Blue 16 Gauge MTW Wire. FIG. 2 shows components approved for installation in a hazardous location, and FIG. 3 shows detail views of hazardous location components. 121 +$=$5'286 $5($ 7(50,1$/ %/2&.6 $ $ %5($.
Electrical Diagrams 6 SEE DETAIL A, 6(( 6+((7 '(7$,/ page 14 +$=$5'286 $5($ Alpha Wire P/N M16107LW/equiv. 326,7,21 6(1625 - *5((1 %/$&. :+,7( %/$&. - 5(' %/$&. - 7'& 1$085 6(1625 ,6 6(1625 &,5&8,7 %2$5' - 35(6685( 75$16'8&(5 /2&$/ &21752/ &20 75,3 5(6(7 581 6723 /2&$/ 5(027( -2* 6(&85( ',6$%/( 9 %/8 *$ 07: :,5( %/8 *$ 07: :,5( *51
Electrical Diagrams DETAIL A HAZARDOUS (CLASSIFIED) LOCATION CLASS I, DIV. 1, GROUP C & D, T3 (FM ONLY) GROUP II, CATEGORY 2 - ZONE 1, GAS (ATEX ONLY) CLASS I, DIV.
Repair Repair Fluid Section NOTE: Complete kits are available to convert from one size lower to another. See the table below for available kits. Use all the new parts in the kit. The kits include two lowers, inlet/outlet manifolds, connecting hardware, and instruction manual 311611. Kit Part No. Lower Part No.
Repair 9. Disconnect the fluid inlet and outlet lines from the pump. Plug the ends to prevent fluid contamination. 11. Loosen the clamps (18) at the inlet and outlet manifolds (17). Remove the manifolds and gaskets (16). 10. See FIG. 5. On pumps with a sensor circuit: At the pump outlet manifold (17), loosen the nut (M) on the sensor conduit (44) and unscrew the adapter (42) from the manifold. Remove the transducer (25a) from the manifold port. Remove the existing o-ring (41) and discard. 12.
Repair Reassembly 1. See FIG. 5. Install the coupling nut (14) on the lower’s piston rod (PR). 2. Orient the lower (22) to the gear reducer (GR) as shown. Position the lower on the tie rods (3). Screw the tie rod locknuts (15) onto the tie rods handtight. 3. Assemble the inlet and outlet manifolds (17) to the lower, using new gaskets (16). Torque the clamps (18) to 15-20 ft-lb (21-27 N•m). 4. Torque the locknuts (15) to 50-60 ft-lb (68-80 N•m). 5. At the outlet manifold (17): a.
Repair Slider Cylinder Rebuild Kit 15H874 NOTE: Slider Cylinder Rebuild Kit 15H874 includes parts to rebuild one slider cylinder assembly. Order two kits to rebuild both slider cylinder assemblies. Use all the new parts in the kit. The kit includes manual 311599. 21 12 32 8 7 2 72 1. Perform the Disassembly procedure on page 15. 2. Remove two screws (12) and the cover. FIG. 6 shows the cover (32) on the side opposite from the motor; the motor side cover is (21). 31 1 3. Remove the setscrew (31).
Repair Slider Cylinder Collector Kit 247341 NOTE: Slider Cylinder Collector Kit 247341 includes parts to install two slider cylinder collectors. Use all the new parts in the kit. The kit includes manual 311607. 2 67 68 1. Perform the Disassembly procedure on page 15. 2. Jog motor to move slider piston (9) up, giving adequate clearance to fit collector (67) between slider cylinder and piston rod. 3. See FIG. 7.
Repair Electrical Section NOTE: Sensor Circuit Kit 24J305 is available to add the optional sensor circuit to a pump. Use all the new parts in the kit. See manual 311603. Pressure Transducer Kit 15H876 4. Remove two screws (12) and the cover (32). 5. See FIG. 9. Remove six screws (12), the circuit board cover (34), and the gasket (33). 6. Disconnect the transducer cable (25a) from J1 on the circuit board (25c). See FIG. 9 and the Electrical Diagrams, page 12.
Repair 11. See FIG. 10. Loosen the nut (M) on the sensor conduit (44) and unscrew the adapter (42) from the transducer port (P). Remove the transducer (25a) from the port. 12. See FIG. 9. Loosen the nut (N) on the strain relief (35). Remove the ferrite (76). Pull the transducer cable (25a) out of the conduit (44). 23. Calibrate the transducer, entering the calibration information found on the new label (L): • • For systems using the Graco ACS Module, see the ACS manual 3A0006.
Repair Pressure Sensor Calibration Information (non-ACS systems) c. Navigate to Pr 20.34 and enter the recorded average value of Pr 20.33. 4. Calibrate the High Pressure Point as follows: NOTE: To calibrate the transducer in systems using the Graco ACS Module, see the ACS manual 3A0006. Pressure sensor information (Pr 20.34, 20.35, and 20.36) for your system must be keyed into the Variable Frequency Drive before system start-up.
Repair TDC Sensor Kit 15H877 NOTE: TDC Sensor Kit 15H877 replaces the TDC sensor. Use all the new parts in the kit. The kit includes manual 311601. 13. Reconnect the TDC cable (25b) to J2 on the circuit board (25c). 14. Reconnect the transducer cable (25a) to J1 on the circuit board (25c). 15. Reconnect the IS circuit field wire to J2 and J3. See the Electrical Diagrams, page 12. 16. Install the new gasket (33), the cover (34), and six screws (12). 1.
Repair Position Sensor NOTE: The Position Sensor (80) measures motor position by detecting holes in the motor coupler (28). The sensor is available separately (see Parts on page 45), or as part of the Sensor Circuit Kit 24J305 (see manual 311603). 1. Jog the motor to bring the lower on the side opposite from the motor to the bottom of its stroke. 2. Relieve pressure, page 9. 3. Shut off electrical power to the unit. 4. Remove two screws (12) and the cover (32). 5. See FIG. 12.
Repair 46 28 (Ref) 1 (Ref) 76 78 80 79 Connect Field Wires here ti17643a 44 (Ref) B Position Sensor Parts and Location %51 %/8 - - - %51 %/8 ,6 6(1625 &,5&8,7 %2$5' G 326,7,21 6(1625 N 7'& 1$085 6(1625 44 - )(55,7( * 5 3 35 - Position Sensor Wires ti16890b 5(' *51 :+7 %/.
Repair Drive Section Slider Bearing Kit 15H882 NOTE: Slider Bearing Kit 15H882 includes parts to rebuild both slider bearing assemblies. Use all the new parts in the kit. The kit includes manual 311616. 1. Jog the motor to bring the pump on the side being repaired to the bottom of its stroke. This provides access to the coupling nut (14). 2. Relieve pressure, page 9. 3. Shut off electrical power to the unit. 4. Remove two screws (12) and the cover. FIG.
Repair 10. See FIG. 16. Rotate the crank arm (4) to allow it to be removed from the output shaft (OS). 14. Slide the piston (9) and connecting rod (7) into the cylinder (2). 11. Pull the crank arm/connecting rod/slider piston assembly (CR) up and out of the cylinder. 15. Position the crank arm (4) to engage the output shaft (OS), and rotate it to the bottom of the output shaft. 12. Remove the old bearings (8). 16.
Repair Drive Linkage Rebuild Kit 15H873 NOTE: Drive Linkage Rebuild Kit 15H873 includes parts to rebuild one drive linkage assembly. Order two kits to rebuild both drive linkage assemblies. Use all the new parts in the kit. The kit includes manual 311598. NOTE: Replace the wrist pin bearings (7a) in the connecting rod annually. Wrist Pin Replacement Kit 255216 includes parts to replace the wrist pin bearings on both drive linkage assemblies. Use all the new parts in the kit. The kit includes manual 311609.
Repair Crank Arm Kit 15H883 NOTE: Crank Arm Kit 15H883 is available. Order two kits to rebuild both crank arm assemblies. Use all the new parts in the kit. The kit includes manual 311604. NOTE: Crank Arm Cover Kit 15H378 is available to replace both crank arm covers (21, 32). Use all the new parts in the kit. 1. Jog the motor to bring the pump on the side being repaired to the bottom of its stroke. This provides access to the coupling nut (14). 2. Relieve pressure, page 9. 3.
Repair Motor/Gear Reducer Motor Removal NOTE: A faint clicking may be heard while the motor is running. This is normal and is due to necessary clearances between the coupler (28), motor shaft, and motor key. If the intensity increases significantly over time, it could indicate the coupler is wearing and should be replaced. Do not open the gear reducer. Opening the gear reducer voids the warranty. The gear reducer is not field serviceable beyond the maintenance recommended in this manual. 1.
Repair Motor/Coupler is Difficult to Remove NOTE: During the following procedure, if the coupler becomes separated from the motor shaft but remains stuck on the input shaft, use the 15J827 coupler removal tool (T) as shown in FIG. 22. T 20 NOTE: Use this procedure only if, after performing steps 1-3 on page 30, the motor does not come off the gear reducer easily. 105 1. Use a mechanical lift and straps capable of supporting a minimum of 100 lb (45 kg) to support the motor.
Repair 32 311594Z
Repair Motor Installation NOTE: A NEMA 182/184 TC Frame is required to mate with gear reducer. If the pump is purchased without a motor you must order a kit to mate with the gear reducer. See TABLE 1. 4. Tighten setscrews to 66-78 in-lb (7.4-8.8 N•m). Apply antiseize lubricant (LPS®-04110 or equivalent) to bore of coupling. 15 Apply antiseize lubricant (LPS®-04110 or equivalent) to bore of coupling (28). Table 1: Motor Adapter Kits Kit No.
Repair Gear Reducer Seal Kit 15H871 NOTE: Gear Reducer Seal Kit 15H871 and Output Shaft Seal Tool Kit 15J926 are available. Use all the new parts in the kit. The kits include manual 311597. NOTE: Do not open the gear reducer. Opening the gear reducer voids the warranty. The gear reducer is not field serviceable beyond the maintenance recommended in this manual. 7. Place tape over the input shaft keyway, to prevent damage to the new seal. Pack the input shaft seal cavity with Part No. 107411 Grease.
Repair f. 11. Install the two output seals (116) as follows: a. Place tape over the output shaft keyway, to prevent damage to the new seals. Pack the output shaft seal cavity with Part No. 107411 Grease. b. See FIG. 26. Push one output seal (116) onto the output shaft (OS), with the lips facing in. c. Remove the tools. Take three measurements 120° apart, from the surface of the seal to the face of the housing (H). The three measurements must be within .020 in. (0.5 mm). If not, repeat steps c through e.
Repair Gear Reducer Replacement Kit b. Disconnect the TDC sensor wires (25b) from J2 on the circuit board (25c). Disassembly c. NOTE: The Gear Reducer Kit is available to replace the entire gear reducer. Use all the new parts in the kit. Order Kit 15H886 for E-Flo 2000/3000/4000 Pumps or Kit 289550 for E-Flo 1500 Pumps. The kit includes manual 311615. NOTE: Do not open the gear reducer. Opening the gear reducer voids the warranty.
Repair 3 Units with a sensor circuit must use the conductive strain relief (74a) to ensure proper grounding of the IS field wire. See page 21. 4 Torque to 50-60 ft-lb (68-80 N•m). 5 Torque to 75-80 ft-lb (102-108 N•m). 7 11 Torque to 15-20 ft-lb (21-27 N•m). 12 Apply antiseize lubricant to screw (5) threads. Torque key-side screw to 210-230 ft-lb (283-310 N•m) first, then torque gap side screw to 210-230 ft-lb (283-310 N•m).
Repair Reassembly 10. On pumps with the sensor circuit: NOTE: Kit 15H886 includes a motor coupler (28), already installed in the gear reducer. The coupler fits all NEMA 182/184 TC Frame electric motors. a. Remove the plug from the TDC sensor port at the back of the circuit board cavity. Clean any excess sealant from the area. NOTE: To install an IEC 112M/B5 or 100L/B5 Frame electric motor, order Motor Adapter Kit 15J893. See TABLE 1 on page 33, and manual 311605. b. See FIG. 29.
Repair 74a* 25b 12 25b 25c 25a 76 35 ti8725b 35 25c 33 34 L ti17640a Circuit Board Location Circuit Board Wire Connections 46 28 (Ref) 1 (Ref) 78 80 79 Connect Field Wires here ti17643a 44 (Ref) B Position Sensor Parts and Location %51 %/8 - - - ,6 6(1625 &,5&8,7 %2$5' Position Sensor Wires 44 ti16890b - G N 326,7,21 6(1625 7'& 1$085 6(1625 %51 %/8 5(' *51 :+7 %/.
Repair j. Thread the IS field wire through the conductive strain relief (74a). Connect the TDC wires to J2, the transducer wires to J3, and the position sensor wires to the two terminal blocks (46). See FIG. 29 and the Electrical Diagrams, page 12. k. See FIG. 30. Tighten the nut (N) on the conductive strain relief (74a) securely. Install the ferrite (77) on the field wire (F), not more than 2 in. (51 mm) from the bottom of the conductive strain relief (74a).
Repair 311594Z 41
Parts Parts Drive Section 19b and 19d 19a and 19c 74a or 74b 5 77 38 32b 39 4 6 37 12 25b 36 28 31 25c 20 21 12 1 9 33 31 34 7 35 44 32a 12 8 25a (Ref) 10 2 76 11 ti8318l 67 68 28 (Ref) 46 35 (Ref) 1 (Ref) 78 80 44 (Ref) ti16890b Detail of Sensor Conduit 42 79 44 (Ref) ti17643a Position Sensor Parts and Location 311594Z
Parts Fluid Section 44 17 3 42 13 14 58 25a 41 18 16 15 72 22 22 16 18 41 45 311594Z 17 ti8230d 43
Parts Common Parts Ref. No. 1 2† 3 4‡ 5*‡ 6*‡ 7* 8*† 9* 10* 11* 12*‡ 13 14 15† 16† 17 18 19a 19b 19c 19d 20 21 44 Part No. Description Qty 1 15H886 KIT, 75:1 gear reducer; E-Flo 2000/3000/4000 only; see 311615 289550 KIT, 75:1 gear reducer; E-Flo 1500 1 only; see 311615 n/a CYLINDER, slider 2 n/a ROD, tie 6 n/a ARM, crank 2 n/a SCREW, cap, socket-head; 5/8-11 x 3 4 in.
Parts Ref. No. 36 37 38‡ 39‡ 41† 42 44 45 46 58 67★ 68★ 69 69a 69b 72 73 74a 74b 76 77 78 79 80 Parts designated n/a are not available separately. Part No. Description Qty 120710 KEY, square; 0.25 x 1.75 in.; for ATEX 5 1 HP motor (19b) only 111195 SCREW, cap, flange-head; 1/2-13 x 4 1.25 in.
Parts Model-Specific Parts NOTE: A checkmark (✓ ) indicates an item is used on your pump. Shaded boxes indicate that an item is not used. Motor Kit (19) Pump Part No.
Parts Motor Kit (19) Pump Part No.
Parts Motor Kit (19) Pump Part No.
Parts Gear Reducer Ref. No. 109* 114 115 116* 118* * Part No. Description n/a SEAL, input shaft 15H525 CAP, fill n/a SIGHTGLASS, n/a SEAL, output 15H432 PLUG, oil drain, with gasket Qty 1 1 1 4 1 NOTE: To replace the entire gear reducer, order one of the following kits: • 15H886 Gear Reducer Replacement Kit, for E-Flo 2000/3000/4000. See manual 311615. • 289550 Gear Reducer Replacement Kit, for E-Flo 1500. See manual 311615. These parts are included in Gear Reducer Seal Kit 15H871.
Technical Data Technical Data Maximum Working Pressure . . . . . . . . . . . . . . Maximum Fluid Temperature . . . . . . . . . . . . . . Electrical Requirements . . . . . . . . . . . . . . . . . . Ambient Temperature Range. . . . . . . . . . . . . . Maximum Fluid Output . . . . . . . . . . . . . . . . . . . Fluid Inlet and Outlet Size . . . . . . . . . . . . . . . . Gear Reducer Oil Capacity . . . . . . . . . . . . . . . Required Gear Reducer Lubricant . . . . . . . . . . Weight . . . . . . . . . . . . .
Technical Data psi (MPa, bar) Pressure and Flow Capability of E-Flo Family with 50 Hz Motor (continuous production use) 500 (3.50, 35.0) Key: 450 (3.15, 31.5) A B C D B A 400 (2.80, 28.0) C E-Flo 1500 E-Flo 2000 E-Flo 3000 E-Flo 4000 350 (2.41, 24.1) Fluid Pressure D 300 (2.10, 21.0) 250 (1.72, 17.2) 200 (1.4, 14.0) 150 (1.03, 10.3) 100 (0.70, 7.0) 50 (0.35, 3.
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.
