Graco E-Flo DC 333389E Parts list manual

Instructions-Parts
E E
E- - -Flo® Flo® Flo®DC DC DC2 2 2- - -Ball Ball BallPiston Piston PistonPumps Pumps Pumps333389E
EN
Electric Electric
Electricdrive drive drivepiston piston pistonpumps pumps pumpsfor for forlow low lowto to tomedium medium mediumvolume volume volumepaint paint paintcirculation circulation circulationapplications. applications. applications.
For For
Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
ReadallwarningsandinstructionsinthismanualandintheE-Flo
DCMotorandE-FloDCThreePhasemanualsbeforeusingthe
equipment.Savetheseinstructions.
SeeTechnicalSpeci󰘰ctationsfor
MaximumWorkingPressure.
Seepage3formodelpartnumbersand
approvalsinformation.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
Models...............................................................3
RelatedManuals................................................4
Warnings...........................................................5
Installation..........................................................8
Location......................................................8
MountthePump..........................................8
PowerRequirements....................................8
ConnecttheSupplyWiring...........................11
Grounding...................................................12
FluidLineAccessories.................................13
ChecktheOilLevelBeforeUsingthe
Equipment......................................13
FlushBeforeUsingtheEquipment................13
ControlModuleAccessory............................13
Operation...........................................................14
Startup........................................................14
Shutdown....................................................14
PressureReliefProcedure............................14
Maintenance......................................................15
PreventiveMaintenanceSchedule................15
ChangetheOil.............................................15
ChecktheOilLevel......................................15
WetCups....................................................15
Flushing......................................................15
Troubleshooting..................................................16
Repair................................................................17
Dura-FloLowers..........................................17
XtremeLowers............................................19
Parts..................................................................21
XtremePumpAssembly...............................21
Dura-FloPumpAssembly.............................23
PumpMatrix................................................25
Dimensions........................................................29
MountingHolePatterns.......................................30
StandMount................................................30
WallMount..................................................31
PerformanceCharts............................................32
TechnicalSpeci󰘰cations......................................35
2333389E

Models
Models Models
Models
Thepartnumberforyourequipmentisprintedontheequipmentidenti󰘰cationlabel.Thepartnumber
includesdigitsfromeachofthefollowingcategories,dependingonthecon󰘰gurationofyourequipment.See
PumpMatrix,page25foracompletelistofpumppartnumbers.
E E
E- - -Flo Flo FloDC DC DCPump Pump Pump
(ES) (ES)
(ES)
Lower Lower
LowerPump Pump Pump
Size Size
Size
(7, (7,
(7,8, 8, 8,9, 9, 9,or or or0) 0) 0)
Motor, Motor,
Motor,Controls, Controls, Controls,Approvals Approvals Approvals
(3–8 (3–8
(3–8or or orC, C, C,D, D, D,G, G, G,H) H) H)
Pump Pump
PumpType Type Typeand and andFittings Fittings Fittings
(4, (4,
(4,5, 5, 5,or or or6) 6) 6)
Mounting Mounting
MountingType Type Type
(0, (0,
(0,1, 1, 1,or or or2) 2) 2)
7:145cc3:2hp,Basic,SinglePhase
ATEX•FM•IECEx
4:CarbonSteelwiththree
Xtremepackingsandtwo
leatherpackings
0:None
8:180cc4:2hp,Advanced,SinglePhase
ATEX•FM•IECEx
5:StainlessSteelwithfour
leatherpackingsandone
PTFEpacking
1:Stand
9:220cc7:2hp,Basic,SinglePhase
ATEX•IECEx•TIIS•KCS
6:StainlessSteelwith
leatherpackingsandPTFE
packings
2:Wall
Bracket
0:290cc8:2hp,Advanced,SinglePhase
ATEX•IECEx•TIIS•KCS
C:2hp,Basic,ThreePhase
ATEX•FM•IECEx
D:2hp,Advanced,ThreePhase
ATEX•FM•IECEx
G:2hp,Basic,ThreePhase
ATEX•IECEx•TIIS•KCS
ES
H:2hp,Advanced,ThreePhase
ATEX•IECEx•TIIS•KCS
Approvals Approvals
Approvals
Singlephaseandthreephasepumpswith
basicmotors:
ESx3xxmodels
ESx7xxmodels
ESxCxxmodels
ESxGxxmodels
II II
II2 2 2G G G
Ex Ex
Exdb db dbh h hIIA IIA IIAT3 T3 T3Gb Gb GbX X X
Singlephasepumpswithadvancedmotors:
ESx4xxmodels
ESx8xxmodels
II II
II2 2 2(1) (1) (1)G G G
Ex Ex
Exdb db dbh h h[ia [ia [iaGa] Ga] Ga]IIA IIA IIAT3 T3 T3Gb Gb GbX X X
Threephasepumpswithadvancedmotors:
ESxDxxmodels
ESxHxxmodels
II II
II2 2 2(1) (1) (1)G G G
Ex Ex
Exdb db dbh h h[ia [ia [iaop op opis is isGa] Ga] Ga]IIA IIA IIAT3 T3 T3Gb Gb GbX X X
NOTE: NOTE:
NOTE:SeetheE-FloDCMotormanualsformotorapprovalsinformation.
333389E3

RelatedManuals
Related Related
RelatedManuals Manuals Manuals
Manual Manual
ManualNo. No. No.Description Description Description
3A2526E-FloDCMotor,Instructions-Parts
3A2527E-FloDCControlModuleKit,Instructions-Parts
3A4409E-FloDCMotor,ThreePhaseInstructions-Parts
311762Xtreme®Lowers,Instructions-Parts
311827Dura-Flo®Lowers,Instructions-Parts
332103DisplayControlModule(DCM)andAdvancedDisplayControlModule(ADCM)
4333389E

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.Theexclamation
pointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰crisks.Whenthese
symbolsappearinthebodyofthismanual,referbacktotheseWarnings.Product-speci󰘰chazardsymbolsand
warningsnotcoveredinthissectionmayappearthroughoutthebodyofthismanualwhereapplicable.
DANGER DANGER
DANGERSEVERE SEVERE
SEVEREELECTRIC ELECTRIC ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentcanbepoweredbymorethan240V.Contactwiththisvoltagewillcausedeath
orseriousinjury.
•Turnoffanddisconnectthepoweratthemainswitchbeforedisconnectinganycablesandbefore
servicingequipment.
•Thisequipmentmustbegrounded.Connectonlytoagroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocalcodesand
regulations.
WARNING WARNING
WARNINGFIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,intheworkareacanigniteorexplode.Paintor
solvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰reandexplosion:
•Useequipmentonlyinawell-ventilatedarea.
•Eliminateallignitionsourcessuchaspilotlights,cigarettes,portableelectriclamps,andplastic
dropcloths(potentialstaticsparking).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Neversprayor󰘱ushsolventathighpressure.
•Keeptheworkareafreeofdebris,includingsolvent,rags,andgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygroundedhoses.
•Holdthegun󰘰rmlytothesideofagroundedpailwhentriggeringintoapail.Donotusepail
linersunlesstheyareantistaticorconductive.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock.Donotuseequipmentuntil
youidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite󰘱ammable
vapors.Tohelpprevent󰘰reandexplosion:
•Cleanplasticpartsonlyinwellventilatedarea.
•Donotcleanwithadrycloth.
•Donotoperateelectrostaticgunsinequipmentworkarea.
333389E5

Warnings
WARNING WARNING
WARNINGSKIN SKIN
SKININJECTION INJECTION INJECTIONHAZARD HAZARD HAZARD
High-pressure󰘱uidfromdispensingdevice,hoseleaks,orrupturedcomponentswillpierceskin.
Thismaylooklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get
Getimmediate immediate immediate
surgical surgical
surgicaltreatment. treatment. treatment.
•Engagethetriggerlockwhennotdispensing.
•Donotpointthedispensingdeviceatanyoneoratanypartofthebody.
•Donotputyourhandoverthe󰘱uidoutlet.
•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopdispensingandbeforecleaning,checking,or
servicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.
6333389E

Warnings
WARNING WARNING
WARNINGEQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestratedsystem
component.SeeTechnical Technical
TechnicalSpeci󰘰cations Speci󰘰cations Speci󰘰cationsinallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
Technical
Speci󰘰cations Speci󰘰cations
Speci󰘰cationsinallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.For
completeinformationaboutyourmaterial,requestSafetyDataSheets(SDSs)fromyourdistributor
orretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovalsand
createsafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
MOVING MOVING
MOVINGPARTS PARTS PARTSHAZARD HAZARD HAZARD
Movingpartscanpinch,cut,oramputate󰘰ngersandotherbodyparts.
•Keepclearofmovingparts.
•Donotoperateequipmentwithprotectiveguardsorcoversremoved.
•Pressurizedequipmentcanstartwithoutwarning.Beforechecking,moving,orservicingequipment,
followthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedureanddisconnectallpowersources.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMES
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,inhaled,or
swallowed.
•ReadSafetyDataSheets(SDSs)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicableguidelines.
BURN BURN
BURNHAZARD HAZARD HAZARD
Equipmentsurfacesand󰘱uidthat’sheatedcanbecomeveryhotduringoperation.Toavoidsevere
burns:
•Donottouchhot󰘱uidorequipment.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,including
eyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Protectiveequipmentincludesbut
isnotlimitedto:
•Protectiveeyewearandhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolventmanufacturer.
333389E7

Installation
Installation Installation
Installation
Installationofthisequipmentinvolvespotentially
hazardousprocedures.Onlytrainedandquali󰘰ed
personnelwhohavereadandwhounderstand
theinformationinthismanualshouldinstallthis
equipment.
Location Location
Location
Whenselectingthelocationfortheequipment,keep
thefollowinginmind:
•Theremustbesuf󰘰cientspaceonallsidesof
theequipmentforinstallation,operatoraccess,
maintenance,andaircirculation.
•Ensurethatthemountingsurfaceandmounting
hardwarearestrongenoughtosupporttheweight
oftheequipment,󰘱uid,hoses,andstresscaused
duringoperation.
•Theremustbeastart/stopcontrol(C)
withineasyreachoftheequipment.See
TypicalInstallation,page10.
Mount Mount
Mountthe the thePump Pump Pump
Stand Stand
StandMount Mount Mount
SeeStandMountingHolePattern,page30
1.Selectalevelsurfaceforthestandtobemounted
to.
2.Securethestandtothe󰘱oorwithM19(5/8in.)
bolts.Useboltsthatengageatleast152mm
(6in.)intothe󰘱oortopreventthepumpfrom
tipping.
3.Placethepumpandaccessoriesoverthe
bracket’smountingholesandsecurewithbolts
(5)andwashers(4)supplied.
4.Useshimstolevelthepumpasrequired.
Wall Wall
WallMount Mount Mount
SeeWallMountingHolePattern,page31.
1.Selectasolidpositiononawallforthemounting
bracket.Thewallshouldbecapableofsupporting
thepumpandaccessoriesthatwillbeattached
tothebracket,anyadditionalweightofthe󰘱uid
usedinthepump,andanystressorstrainthat
maybeappliedduringpumpoperation.
2.Drillfour7/16in.(11mm)diameterholesforthe
mountingbolts,approximately5ft(1.5m)above
the󰘱oor,usingthewallbracketasatemplate.
Useanyofthethreemountingholegroupings
3.Boltthebracketsecurelytothewall.Usebolts
designedtoholdinthewall’sconstruction.
4.Placethepumpandaccessoriesoverthe
bracket’smountingholesandsecurewithscrews
(5)andwashers(4)supplied.
Power Power
PowerRequirements Requirements Requirements
Improperwiringmaycauseelectricshockorother
seriousinjuryifworkisnotperformedproperly.
•Thisequipmentmustbegrounded.Connect
onlytoagroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰ed
electricianandcomplywithalllocalcodesand
regulations.
Thesystemrequiresadedicatedcircuitprotected
withacircuitbreaker.Seethefollowingtablefor
powerrequirements.
Table Table
Table1 1 1. . .Power Power PowerSpeci󰘰cations Speci󰘰cations Speci󰘰cations
Model Model
ModelVoltage Voltage VoltagePhase Phase PhaseHz Hz HzPower Power Power
ESx3xx
ESx4xx
ESx7xx
ESx8xx
200–250
Vac
150/602.9kVA
ESxCxx
ESxDxx
ESxGxx
ESxHxx
380–480
Vac
350/603.0kVA
8333389E

Installation
Hazardous Hazardous
HazardousArea Area AreaCabling Cabling Cablingand and andConduit Conduit Conduit
Requirements Requirements
Requirements
Explosion Explosion
ExplosionProof Proof Proof
Allelectricalwiringinthehazardousareamustbe
encasedinClassI,DivisionI,GroupDapproved
explosion-proofconduit.Followallnational,state,
andlocalelectriccodes.
Aconduitseal(D)isrequiredwithin18in.(457mm)
ofthemotorfortheUSandCanada.SeeFigs.3
and4.
Allcablesmustberatedat70°C(158°F).
Flame Flame
FlameProof Proof Proof(ATEX) (ATEX) (ATEX)
Useappropriateconduit,connectors,andcable
glandsratedforATEXII2G.FollowallNational,
State,andLocalelectriccodes.
Allcableglandsandcablesmustberatedat70°C
(158°F).
333389E9

Installation
Typical Typical
TypicalInstallation Installation Installation
NON NON
NON- - -HAZARDOUS HAZARDOUS HAZARDOUSLOCATION LOCATION LOCATIONHAZARDOUS HAZARDOUS HAZARDOUSLOCATION LOCATION LOCATION
Figure1TypicalInstallation
Key Key
Keyfor for forFig. Fig. Fig.1 1 1
AElectricalSupply(mustbesealedconduit
approvedforuseinhazardouslocations)
BDisconnect,withlock
CStart/StopControl(mustbeapprovedfor
useinhazardouslocations)
DExplosionProofConduitSeal.Required
within18in.(457mm)ofthemotorforthe
USandCanada.
Key Key
Keyfor for forFig. Fig. Fig.1 1 1
EFluidPressureGauge
FFluidShutoffValve
GPumpGroundWire.Twogroundterminals
areprovidediflocalcoderequiresredundant
groundingconnections.
HFluidDrainValve
10333389E

Installation
Connect Connect
Connectthe the theSupply Supply SupplyWiring Wiring Wiring
Improperwiringmaycauseelectricshockorother
seriousinjuryifworkisnotperformedproperly.
•Thisequipmentmustbegrounded.Connect
onlytoagroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰ed
electricianandcomplywithalllocalcodesand
regulations.
1.Ensurethatthedisconnect(B,Fig2)isshutoff
andlockedout.
Figure2LockedOutDisconnect
2.SeeFigs.3and4.Installastart/stopcontrol(C)
intheelectricalsupplyline(A),withineasyreach
oftheequipment.Thestart/stopcontrolmustbe
approvedforuseinhazardouslocations.
3.Opentheelectricalcompartment(S)onthe
motor.
4.Bringthesupplywiresintotheelectrical
compartmentthroughthe3/4–14npt(f)inletport.
Connectthewirestotheterminals,asshownin
Figs.3and4.Torquetheterminalnutsto15
in-lb(1.7N•m)maximum.Do Do
Donot not notover-torque. over-torque. over-torque.
Figure3ConnectthePowerWires,SinglePhase
Figure4ConnectthePowerWires,ThreePhase
Notes Notes
Notesfor for forFigs. Figs. Figs.3 3 3and and and4 4 4
Tightenallterminalnutsto15in-lb(1.7
N•m)maximum.Do Do
Donot not notover over over- - -torque. torque. torque.
Tightencoverscrewsto15ft-lb(20.3
N•m).
Aconduitseal(D)isrequiredwithin18
in.(457mm)ofthemotorfortheUSand
Canada.
5.Closetheelectricalcompartment.Torquethe
coverscrewsto15ft-lb(20.3N•m).
333389E11

Installation
Grounding Grounding
Grounding
Thisequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundingprovidesanescapewireforthe
electriccurrent.
1.Connectthesupplygroundwireinthe
electricalcompartmentasshownin
ConnecttheSupplyWiring,page11.
2.ConnectagroundwireasshowninFig.5.
Loosenthegroundscrewandattachaground
wire(Y,Gracopart222011,notsupplied).
Tightenthegroundscrewsecurely.Connect
theotherendofthegroundwiretoatrueearth
ground.
Figure5GroundWire
NOTE: NOTE:
NOTE:Advancedmodelsrequireinstallation
ofacontrolmodule.Allpumpsconnectedtoa
commoncontrolmodulemustbegroundedto
thesamegroundpoint.Differentgroundpoints
(unequalpotential)maycausecurrentto󰘱ow
throughcomponentcables,causingincorrect
signals.
Pump Pump
PumpControl Control
ControlModule Module Module
ESx4xx24P822
ESx8xx24X599
ESxDxx17V232
ESxHxx17V233
3.Fluid Fluid
Fluidhoses: hoses: hoses:Useonlyelectricallyconductive
hoseswithamaximumof500ft.(150m)
combinedhoselengthtoensuregrounding
continuity.Checktheelectricalresistanceof
hoses.Iftotalresistancetogroundexceeds25
megohms,replacehoseimmediately
4.Fluid Fluid
Fluidsupply supply supplycontainer: container: container:Followyourlocalcode.
5.Solvent Solvent
Solventpails pails pailsused used usedwhen when when󰘱ushing: 󰘱ushing: 󰘱ushing:Followyour
localcode.Useonlyconductivemetalpails,
placedonagroundedsurface.Donotplace
thepailonanon-conductivesurface,suchas
paperorcardboard,whichinterruptsgrounding
continuity.
6.To To
Tomaintain maintain maintaingrounding grounding groundingcontinuity continuity continuitywhen when when󰘱ushing 󰘱ushing 󰘱ushing
or or
orrelieving relieving relievingpressure: pressure: pressure:Holdmetalpartofthespray
gunorvalve󰘰rmlytothesideofagrounded
metalpail,thentriggerthegunoropenthevalve.
12333389E

Installation
Fluid Fluid
FluidLine Line LineAccessories Accessories Accessories
Installthefollowingaccessoriesasshownin
Fig.1,usingadaptersasnecessary.All󰘱uid
linesandaccessoriesmustberatedtothe
maximumworkingpressureofthepump.See
TechnicalSpeci󰘰cations,page35.
•Fluid Fluid
Fluiddrain drain drainvalve valve valve(H): (H): (H):requiredinyoursystem,to
relieve󰘱uidpressureinthehoseandcirculation
system.
•Fluid Fluid
Fluidpressure pressure pressuregauge gauge gauge(E): (E): (E):formoreprecise
adjustmentofthe󰘱uidpressure.
•Fluid Fluid
Fluidshutoff shutoff shutoffvalve valve valve(F): (F): (F):shutsoff󰘱uid󰘱ow.
Check Check
Checkthe the theOil Oil OilLevel Level LevelBefore Before BeforeUsing Using Usingthe the the
Equipment Equipment
Equipment
Themotorispre-󰘰lledwithoil.Beforeusingthe
equipment,replacetheshippingplugwiththevented
󰘰llcap(P)thatisincludedwiththemotor.
Figure6SightglassandOilFillCap
Flush Flush
FlushBefore Before BeforeUsing Using Usingthe the theEquipment Equipment Equipment
Thepump󰘱uidsectionwastestedwithlightweight
oil,whichisleftinthe󰘱uidpassagestoprotectparts.
Toavoidcontaminatingyour󰘱uidwithoil,󰘱ushthe
equipmentwithacompatiblesolventbeforeusing
theequipment.
Control Control
ControlModule Module ModuleAccessory Accessory Accessory
TheControlModuleAccessoryisrequiredwith
AdvancedE-FloDCmotorstoprovidetheinterface
foruserstoenterselectionsandviewinformation
relatedtosetupandoperation.SeetheControl
ModuleAccessoryKitmanualforinstallationand
operationinformation.
333389E13

Operation
Operation Operation
Operation
Startup Startup
Startup
Tooperatethepump,followtheStartupinstructions
fortheBasicorAdvancedmotorintheMotormanual.
TheAdvancedE-FloDCmotorsrequireinstallation
ofaControlModuleAccessoryKit(seetable)to
providetheinterfaceforuserstoenterselectionsand
viewinformationrelatedtosetupandoperation.See
theControlModuleAccessoryKitmanual3A2527for
installationandoperationinformation.
Pump Pump
PumpControl Control
ControlModule Module Module
ESx4xx24P822
ESx8xx24X599
ESxDxx17V232
ESxHxx17V233
Runthepumpataslowspeeduntilthe󰘱uidlinesare
primedandallairisforcedoutofthesystem.
NOTICE NOTICE
NOTICE
DonotuseXtremepumplowersforwaterborne
paints,becausethepumpsarecarbonsteeland
waterbornepaintswillcausethemtorust.
Shutdown Shutdown
Shutdown
FollowthePressureReliefProcedure,page14.Stop
thepumpatthebottomofitsstroketoprevent󰘱uid
fromdryingontheexposeddisplacementrodand
damagingthethroatpackings.
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressure
ismanuallyrelieved.Tohelppreventserious
injuryfrompressurized󰘱uid,suchasskininjection,
splashing󰘱uid,andmovingparts,followthe
PressureReliefProcedurewhenyoustopspraying
andbeforecleaning,checking,orservicingthe
equipment.
1.Disengagethestart/stopcontrol(C).SeeFig.1.
2.Shutoffandlockoutthedisconnect(B).
3.Openthe󰘱uiddrainvalve(H),havingawaste
containerreadytocatchdrainage.Leaveopen
untilyouarereadytopressurizesystemagain.
14333389E

Maintenance
Maintenance Maintenance
Maintenance
Seethemotormanualforrequiredmotor
maintenanceprocedures.
Preventive Preventive
PreventiveMaintenance Maintenance MaintenanceSchedule Schedule Schedule
Theoperatingconditionsofyourparticularsystem
determinehowoftenmaintenanceisrequired.
Establishapreventivemaintenancescheduleby
recordingwhenandwhatkindofmaintenanceis
needed,andthendeterminearegularschedulefor
checkingyoursystem.
Change Change
Changethe the theOil Oil Oil
NOTE: NOTE:
NOTE:Changetheoilafterabreak-inperiodof
200,000–300,000cycles.Afterthebreak-inperiod,
changetheoilonceayear.
1.SeeFig.7.Placeaminimum2quart(1.9liter)
containerundertheoildrainport.Removethe
oildrainplug(25).Allowalloiltodrainfromthe
motor.
2.Reinstalltheoildrainplug(25).Torqueto25–30
ft-lb(34–40N•m).
3.SeeFig.8.Openthe󰘰llcap(P)andaddGraco
PartNo.16W645ISO220silicone-freesynthetic
gearoil.Checktheoillevelinthesightglass(K).
Filluntiltheoillevelisnearthehalfwaypointof
thesightglass.Theoilcapacityisapproximately
1.5quarts(1.4liters).Do Do
Donot not notover󰘰ll. over󰘰ll. over󰘰ll.
4.Reinstallthe󰘰llcap.
Figure7OilDrainPlug
Check Check
Checkthe the theOil Oil OilLevel Level Level
SeeFig.8.Checktheoillevelinthesightglass(K).
Theoillevelshouldbenearthehalfwaypointofthe
sightglasswhentheunitisnotrunning.Iflow,open
the󰘰llcap(P)andaddGracoPartNo.16W645ISO
220silicone-freesyntheticgearoilasrequired.The
oilcapacityisapproximately1.5quarts(1.4liters).
Do Do
Donot not notover󰘰ll. over󰘰ll. over󰘰ll.
Figure8SightglassandOilFillCap
Wet Wet
WetCups Cups Cups
Checkthewetcupdaily.Keepthewetcup1/3󰘰lled
withGracoThroatSealLiquid(TSL™)orcompatible
solvent.
Flushing Flushing
Flushing
Toavoid󰘰reandexplosion,alwaysground
equipmentandwastecontainers.Toavoidstatic
sparkingandinjuryfromsplashing,always󰘱ushat
thelowestpossiblepressure.
•Flushbeforechanging󰘱uids,before󰘱uidcandry
intheequipment,attheendoftheday,before
storing,andbeforerepairingequipment.
•Flushatthelowestpressurepossible.Check
connectorsforleaksandtightenasnecessary.
•Flushwitha󰘱uidthatiscompatiblewiththe󰘱uid
beingdispensedandtheequipmentwettedparts.
333389E15

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
•FollowthePressureReliefProcedure,page
14beforecheckingorservicingtheequipment.
•Checkallpossibleproblemsandcausesbefore
disassembly.
•TheLEDonthemotorblinksifanerrorisdetected.
SeeError Error
ErrorCode Code CodeTroubleshooting Troubleshooting Troubleshootinginthemotor
manualformoreinformation.
Problem Problem
ProblemCause Cause
CauseSolution Solution Solution
Inadequatepower.SeePowerRequirements,page8.
Exhausted󰘱uidsupply.Re󰘰llandreprimepump.
Clogged󰘱uidoutletline,valves,etc.Clear.
Pumpoutputlowonbothstrokes.
Wornpistonpacking.Replace.Seelowermanual.
Heldopenorwornballcheckvalves.Checkandrepair.Seelowermanual. Pumpoutputlowononlyonestroke.
Wornpistonpacking.Replace.Seelowermanual.
Nooutput.Improperlyinstalledballcheck
valves.
Checkandrepair.Seelowermanual.
Exhausted󰘱uidsupply.Re󰘰llandreprimepump.
Heldopenorwornballcheckvalves.Checkandrepair.Seelowermanual.
Pumpoperateserratically.
Wornpistonpacking.Replace.Seelowermanual.
Inadequatepower.SeePowerRequirements,page8.
Exhausted󰘱uidsupply.Re󰘰llandreprimepump.
Clogged󰘱uidoutletline,valves,etc.Clear.
Pumpwillnotoperate.
Fluiddriedonpistonrod.Disassembleandcleanpump.See
lowermanual.Infuture,stoppump
atbottomofstroke.
16333389E

Repair
Repair Repair
Repair
Dura Dura
Dura- - -Flo Flo FloLowers Lowers Lowers
Disassembly Disassembly
Disassembly
Toavoidcrushinginjuriesormusclestrains,use
cautionwhendisconnectingthelower.Itcanweigh
upto25kg(55lbs).
1.Stopthepumpatthebottomofitsstroke.
2.Relievethepressure.Follow
thePressureReliefProcedure,page14.
3.Disconnectthehosesfromthelowerandplug
theendstoprevent󰘱uidcontamination.
4.Loosenthecouplingnut(11)andremovethe
collars(10).SeeFig.9.
5.Removethecouplingnutfromthepistonrod(R).
6.Unscrewthelocknuts(8)fromthetierods(6).
7.Separatethemotor(3)andlower(7).
Torepairthelower,seetheDura-FloLower
instructionmanual311827.Thereareno
user-serviceablepartsinthemotor.Contactyour
Gracorepresentativeforassistance.
333389E17

Repair
Reassembly Reassembly
Reassembly
1.Ifthecouplingadapter(9)andtierods(6)have
notbeendisassembledfromthemotor(3),skip
tostep2.
Ifthecouplingadapter(9)andtierods(6)have
beendisassembledfromthemotor(3),follow
thesesteps:
a.Screwthetierods(6)intothemotor(3)and
torqueto50-60ft-lb(68-81N•m).
b.Screwthecouplingadapter(9)intothemotor
shaftandtorqueto90–100ft-lb(122–135
N•m).
c.Reassemblethepumptothemotor.Use
theapplicableinstructionsforyourpump
(Dura-Flo,page18orXtreme,page20).
d.Continuetostep2.
2.Assemblethecouplingnut(11)tothepistonrod
(R).
3.Orientthelower(7)tothemotor(3).Position
thelower(7)onthetierods(6).Lubricatethe
threadsofthetierods(6).
4.Screwthetierodlocknuts(8)ontothetierods
(6).Tightenthelocknuts(8)andtorqueto50-60
ft-lb(68-81N•m).
5.Insertthecollars(10)intothecouplingnut(11).
Tightenthecouplingnut(11)ontothecoupling
adapter(9)andtorqueto90–100ft-lb(122–135
N•m).
6.Flushandtestthepumpbeforereinstalling
itinthesystem.Connecthosesand󰘱ush
thepump.Whileitispressurized,checkfor
smoothoperationandleaks.Adjustorrepair
asnecessarybeforereinstallinginthesystem.
Reconnectthepumpgroundwirebefore
operating.
NOTE: NOTE:
NOTE:WhenusedwithE-FloDCmotors,Dura-Flo
lowersrequireacheckvalve(35)tobeinstalled.
Figure9Dura-FloPumpAssembly
18333389E

Repair
Xtreme Xtreme
XtremeLowers Lowers Lowers
Disassembly Disassembly
Disassembly
Toavoidcrushinginjuriesormusclestrains,use
cautionwhendisconnectingthelower.Itcanweigh
upto25kg(55lbs).
1.Stopthepumpatthebottomofitsstroke.
2.Relievethepressure.Follow
thePressureReliefProcedure,page14.
3.Disconnectthehosesfromthelowerandplug
theendstoprevent󰘱uidcontamination.
4.Removeclip(2)andslidecouplingcover(10)up
toremovethecoupling(11).
5.Unscrewthenuts(8)andremovethelower(7).
Useawrenchtoholdthetierod󰘱atstokeepthe
rodsfromturning.
Torepairthelower,seetheXtremeLowerinstruction
manual311762.Therearenouser-serviceableparts
inthemotor.ContactyourGracorepresentativefor
assistance.
333389E19

Repair
Reassembly Reassembly
Reassembly
1.Ifthecouplingadapter(9)andtierods(6)have
notbeendisassembledfromthemotor(3),skip
tostep2.
Ifthecouplingadapter(9)andtierods(6)have
beendisassembledfromthemotor(3),follow
thesesteps:
a.Screwthetierods(6)intothemotor(3)and
torqueto50-60ft-lb(68-81N•m).
b.Screwthecouplingadapter(9)intothemotor
shaftandtorqueto90–100ft-lb(122–135
N•m).
c.Reassemblethepumptothemotor.Use
theapplicableinstructionsforyourpump
(Dura-Flo,page18orXtreme,page20).
d.Continuetostep2.
2.Orientthelower(7)tothemotor(3).Position
thelower(7)onthetierods(6).Lubricatethe
threadsofthetierods(6).
3.Screwthetierodlocknuts(8)ontothetierods
(6).Tightenthelocknuts(8)andtorqueto50-60
ft-lb(68-81N•m).
4.Raisethemotorshaft.Placethecouplingcover
(10)ontothecouplingadapter(9)andlowerthe
motorshaft.Placethecoupling(11)ontothe
lower(7)andslidethecouplingcover(10)over
thecoupling(11).Insertclip(2).
5.Flushandtestthepumpbeforereinstalling
itinthesystem.Connecthosesand󰘱ush
thepump.Whileitispressurized,checkfor
smoothoperationandleaks.Adjustorrepair
asnecessarybeforereinstallinginthesystem.
Reconnectthepumpgroundwirebefore
operating.
NOTE: NOTE:
NOTE:WhenusedwithE-FloDCmotors,Xtreme
lowersrequireacheckvalve(33)tobeinstalled.
Figure10XtremePumpAssembly
20333389E