Graco E-Flo DC User manual

Instructions-PartsList
E E
E- - -Flo® Flo® Flo®DC DC DC4 4 4- - -Ball Ball BallPumps, Pumps, Pumps,
Sealed Sealed
Sealedor or orwith with withOpen Open OpenWet Wet WetCup Cup Cup3A3384B
EN
Electric Electric
Electricdrive drive drivepiston piston pistonpumps pumps pumpsfor for forlow low low- - -to to tomedium medium medium- - -volume volume volumepaint paint paintcirculation circulation circulationapplications. applications. applications.
For For
Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
Readallwarningsandinstructionsinthismanual.Save Save
Savethese these these
instructions. instructions.
instructions.
SeeTechnicalData,page31,for
MaximumWorkingPressures.
Seepage3formodelpartnumbersand
approvalsinformation.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
RelatedManuals................................................2
Models...............................................................3
Warnings...........................................................4
Installation..........................................................7
Location......................................................7
MountthePump..........................................7
PowerSupplyRequirements.........................8
ConnectthePowerSupply...........................10
Grounding...................................................11
FluidLineAccessories.................................12
FillWithOilBeforeUsingEquipment.............12
FlushBeforeUsingEquipment......................12
ControlModuleAccessory............................12
Operation...........................................................13
Startup........................................................13
Shutdown....................................................13
PressureReliefProcedure............................13
Maintenance......................................................14
PreventiveMaintenanceSchedule................14
Flushing......................................................14
Troubleshooting..................................................15
Repair................................................................16
Disassembly................................................16
Reassembly................................................16
Parts..................................................................18
PumpAssembly...........................................18
PumpMatrix................................................20
Notes................................................................23
Dimensions........................................................24
MountingHolePatterns.......................................26
PerformanceCharts............................................28
TechnicalData...................................................31
Related Related
RelatedManuals Manuals Manuals
Manual Manual
Manual
No. No.
No.
Description Description
Description
3A2526Instructions-PartsManual,E-FloDCMotor
3A2527Instructions-PartsManual,E-FloDCControlModuleKit
332013Instructions-PartsManual,AdvancedDisplayControlModule(ADCM)
333022Repair/PartsManual,Sealed4–BallLowers
3A3452Repair/PartsManual,4–BallLowerswithOpenWetCup
23A3384B

Models
Models Models
Models
The The
Thepart part partnumber number numberfor for foryour your yourequipment equipment equipmentis is isprinted printed printedon on onthe the theequipment equipment equipmentidenti󰘰cation identi󰘰cation identi󰘰cationlabel label label(L). (L). (L).The The Thepart part partnumber number number
includes includes
includesdigits digits digitsfrom from fromeach each eachof of ofthe the thefollowing following followingcategories, categories, categories,depending depending dependingon on onthe the thecon󰘰guration con󰘰guration con󰘰gurationof of ofyour your yourequipment. equipment. equipment.See See See
Pump Pump
PumpMatrix Matrix Matrix, , ,page page page20 20 20, , ,for for fora a acomplete complete completelist list listof of ofpump pump pumppart part partnumbers. numbers. numbers.
E E
E- - -Flo Flo FloDC DC DC
Pump Pump
Pump
(EC) (EC)
(EC)
Lower Lower
Lower
Pump Pump
PumpSize Size Size
(1, (1,
(1,2, 2, 2,3, 3, 3,or or or
4) 4)
4)
Motor, Motor,
Motor,Controls, Controls, Controls,
Approvals Approvals
Approvals
(1–8) (1–8)
(1–8)
Pump Pump
PumpType Type Typeand and and
Fittings Fittings
Fittings
(4, (4,
(4,5, 5, 5,or or or6) 6) 6)
Mounting Mounting
Mounting
Type Type
Type
(0, (0,
(0,1, 1, 1,or or or2) 2) 2)
EC1:750cc1:1hp,Basic† †
†
ATEX•FM•IECEx
4:Sealed,tri-clamp0:None
2:1000cc2:1hp,Advanced‡ ‡
‡
ATEX•FM•IECEx
5:OpenWetCup,
npt
1:Stand
3:1500cc3:2hp,Basic† †
†
ATEX•FM•IECEx
6:OpenWetCup,
tri-clamp
2:Wall
Bracket
4:2000cc4:2hp,Advanced‡ ‡
‡
ATEX•FM•IECEx
5:1hp,Basic† †
†
ATEX•IECEx•TIIS•
KCS
6:1hp,Advanced‡ ‡
‡
ATEX•IECEx•TIIS•
KCS
7:2hp,Basic† †
†
ATEX•IECEx•TIIS•
KCS
8:2hp,Advanced‡ ‡
‡
ATEX•IECEx•TIIS•
KCS
† †
†PumpswithBasicMotorshavethefollowing
approvals:
‡ ‡
‡PumpswithAdvancedMotorshavethefollowing
approvals:
II II
II2 2 2G G G
Ex Ex
Exdb db dbh h hIIA IIA IIAT3 T3 T3Gb Gb GbX X X
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
NOTE: NOTE:
NOTE:SeetheE-FloDCMotormanualformotorapprovalsinformation.
3A3384B3

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING WARNING
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Paint
orsolvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰reand
explosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticsparking).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Neversprayor󰘱ushsolventathighpressure.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygroundedhoses.
•Holdgun󰘰rmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunless
theyareanti-staticorconductive.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock. . .Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
Staticchargemaybuilduponplasticpartsduringcleaningandcoulddischargeandignite
󰘱ammablevapors.Tohelpprevent󰘰reandexplosion:
•Cleanplasticpartsonlyinwellventilatedarea.
•Donotcleanwithadrycloth.
•Donotoperateelectrostaticgunsinequipmentworkarea.
ELECTRIC ELECTRIC
ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcan
causeelectricshock.
•Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesandbefore
servicingorinstallingequipment.
•Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
43A3384B

Warnings
WARNING WARNING
WARNING
PRESSURIZED PRESSURIZED
PRESSURIZEDEQUIPMENT EQUIPMENT EQUIPMENTHAZARD HAZARD HAZARD
Fluidfromtheequipment,leaks,orrupturedcomponentscansplashintheeyesoronskin
andcauseseriousinjury.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhoses,tubes,andcouplingsdaily.Replacewornordamagedpartsimmediately.
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestSafetyDataSheet(SDS)fromdistributororretailer.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
MOVING MOVING
MOVINGPARTS PARTS PARTSHAZARD HAZARD HAZARD
Movingpartscanpinch,cutoramputate󰘰ngersandotherbodyparts.
•Keepclearofmovingparts.
•Donotoperateequipmentwithprotectiveguardsorcoversremoved.
•Pressurizedequipmentcanstartwithoutwarning.Beforechecking,moving,orservicing
equipment,followthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedureanddisconnectallpowersources.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMES
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadSafetyDataSheet(SDS)toknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
3A3384B5

Warnings
WARNING WARNING
WARNING
BURN BURN
BURNHAZARD HAZARD HAZARD
Equipmentsurfacesand󰘱uidthat’sheatedcanbecomeveryhotduringoperation.Toavoid
severeburns:
•Donottouchhot󰘱uidorequipment.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Protectiveequipment
includesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
63A3384B

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)withineasy
reachoftheequipment.SeeTypicalInstallation,
Fig.1.
Mount Mount
Mountthe the thePump Pump Pump
SeeMountingHolePatterns,page26.
Stand Stand
StandMount Mount Mount
1.Securethestandtothe󰘱oorwithM19(5/8in.)
bolts.Useboltsthatengageatleast152mm(6
in.)intotheconcrete󰘱oortopreventthepump
fromtipping.
2.Levelthepumpasrequired,usingshims.
Wall Wall
WallMount Mount Mount
1.Drillfour7/16in.(11mm)holesusingthe
bracketasatemplate.Useanyofthethree
mountingholegroupingsinthebracket.See
MountingHolePatterns,page26.
2.Boltthebracketsecurelytothewallusingbolts
andwashersdesignedtoholdinthewall’s
construction.
3.Attachthepumpassemblytothemounting
bracket.
3A3384B7

Installation
Power Power
PowerSupply Supply SupplyRequirements Requirements Requirements
Toavoidinjuryfrom󰘰re,explosion,orelectric
shock,allelectricalwiringmustbedonebya
quali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
SeeTable1forpowersupplyrequirements.The
systemrequiresadedicatedcircuitprotectedwitha
circuitbreaker.
Table Table
Table1 1 1. . .Power Power PowerSupply Supply SupplySpeci󰘰cations Speci󰘰cations Speci󰘰cations
Model Model
ModelVoltage Voltage VoltagePhase Phase PhaseHz Hz HzCurrent Current Current
EM0011
EM0012
EM0013
EM0014
100–250
Vac
150/6020A
EM0021
EM0022
EM0023
EM0024
200–250
Vac
150/6020A
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.SeeFig.3.
Allcablesmustberatedat70°C(158°F).
Flame Flame
FlameProof Proof Proof(ATEX) (ATEX) (ATEX)
Useappropriateconduit,connectors,andcable
glandsratedforATEXII2G.FollowallNational,
State,andLocalelectriccodes.
Allcableglandsandcablesmustberatedat70°C
(158°F).
83A3384B

Installation
NON NON
NON- - -HAZARDOUS HAZARDOUS HAZARDOUSAREA AREA AREAHAZARDOUS HAZARDOUS HAZARDOUSAREA AREA AREA
Figure1TypicalInstallation
Key Key
Keyfor for forFig. Fig. Fig.1 1 1
AElectricalSupply(mustbesealedconduit
approvedforuseinhazardouslocations)
BFusedSafetySwitch,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
3A3384B9

Installation
Connect Connect
Connectthe the thePower Power PowerSupply Supply Supply
Toavoidinjuryfrom󰘰re,explosion,orelectric
shock,allelectricalwiringmustbedonebya
quali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
1.Ensurethatthefusedsafetyswitch(B,Fig2)is
shutoffandlockedout.
Figure2LockedOutFusedSafetySwitch
2.SeeFig.3.Installastart/stopcontrol(C)inthe
electricalsupplyline(A),withineasyreachof
theequipment.Thestart/stopcontrolmustbe
approvedforuseinhazardouslocations.
3.Opentheelectricalcompartment(S)onthe
motor.
4.Bringthepowerwiresintotheelectrical
compartmentthroughthe3/4–14npt(f)inletport.
Connectthewirestotheterminals,asshown.
Torquetheterminalnutsto25in-lb(2.8N•m)
maximum.Do Do
Donot not notover-torque. over-torque. over-torque.
5.Closetheelectricalcompartment.Torquethe
coverscrewsto15ft-lb(20.3N•m).
Figure3ConnectthePowerWires
Notes Notes
Notesfor for forFig. Fig. Fig.3 3 3
Tightenallterminalnutsto25in-lb(2.8N•m)
maximum.Do Do
Donot not notover over over- - -torque. torque. torque.
Tightencoverscrewsto15ft-lb(20.3N•m).
Aconduitseal(D)isrequiredwithin18
in.(457mm)ofthemotorfortheUSand
Canada.
103A3384B

Installation
Grounding Grounding
Grounding
Thisequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundingprovidesanescapewireforthe
electriccurrent.
1.Pump: Pump:
Pump:SeeFig.4.Loosenthegroundscrewand
attachagroundwire.Tightenthegroundscrew
securely.Connecttheotherendoftheground
wiretoatrueearthground.
NOTE: NOTE:
NOTE:Advancedmodelsrequireinstallation
ofthe24P822ControlModule.Allpumps
connectedtoacommoncontrolmodulemustbe
groundedtothesamegroundpoint.Different
groundpoints(unequalpotential)maycause
currentto󰘱owthroughcomponentcables,
causingincorrectsignals.
Figure4GroundWire
2.Fluid Fluid
Fluidhoses: hoses: hoses:Useonlyelectricallyconductive
hoseswithamaximumof500ft.(150m)
combinedhoselengthtoensuregrounding
continuity.Checktheelectricalresistanceof
hoses.Iftotalresistancetogroundexceeds25
megohms,replacehoseimmediately
3.Fluid Fluid
Fluidsupply supply supplycontainer: container: container:Followyourlocalcode.
4.Solvent Solvent
Solventpails pails pailsused used usedwhen when when󰘱ushing: 󰘱ushing: 󰘱ushing:Followlocal
code.Useonlyconductivemetalpails,placed
onagroundedsurface.Donotplacethepail
onanon-conductivesurface,suchaspaperor
cardboard,whichinterruptsgroundingcontinuity.
5.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.
3A3384B11

Installation
Fluid Fluid
FluidLine Line LineAccessories Accessories Accessories
Installthefollowingaccessoriesintheordershown
inFig.1,usingadaptersasnecessary.All󰘱uid
linesandaccessoriesmustberatedtothemaximum
workingpressureof400psi(2.8MPa,28.0bar).
•Fluid Fluid
Fluiddrain drain drainvalve valve valve(D): (D): (D):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.
Fill Fill
FillWith With WithOil Oil OilBefore Before BeforeUsing Using UsingEquipment Equipment Equipment
SeeFig.5.Beforeusingtheequipment,openthe󰘰ll
cap(P)andaddGracoPartNo.16W645ISO220
silicone-freesyntheticgearoil.Checktheoillevelin
thesightglass(K).Filluntiltheoillevelisnearthe
halfwaypointofthesightglass.Theoilcapacityis
approximately1.5quarts(1.4liters).Do Do
Donot not notover󰘰ll. over󰘰ll. over󰘰ll.
NOTE: NOTE:
NOTE:Two1quart(0.95liter)bottlesofoilare
suppliedwiththeequipment.
Figure5SightglassandOilFillCap
Flush Flush
FlushBefore Before BeforeUsing Using UsingEquipment 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.
123A3384B

Operation
Operation Operation
Operation
Startup Startup
Startup
Tooperatethepump,followtheStartupinstructions
fortheBasicorAdvancedmotorintheMotormanual.
TheAdvancedE-FloDCmotorsrequireinstallationof
the24P822ControlModuleAccessoryKittoprovide
theinterfaceforuserstoenterselectionsandview
informationrelatedtosetupandoperation.Seethe
ControlModuleAccessoryKitmanualforinstallation
andoperationinformation.
Runthepumpataslowspeeduntilthe󰘱uidlinesare
primedandallairisforcedoutofthesystem.
Shutdown Shutdown
Shutdown
FollowthePressureReliefProcedure,page13.
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressureReliefProcedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressureis
manuallyrelieved.Tohelppreventseriousinjury
fromsplashing󰘱uidandmovingparts,followthe
PressureReliefProcedurewhenyoustopspraying
andbeforecleaning,checking,orservicingthe
equipment.
1.Disengagethestart/stopcontrol(C).SeeFig.1.
2.Shutoffandlockoutthefusedsafetyswitch(B).
3.Openthe󰘱uiddrainvalve(D),havingawaste
containerreadytocatchdrainage.Leaveopen
untilyouarereadytopressurizethesystem
again.
3A3384B13

Maintenance
Maintenance Maintenance
Maintenance
Seethemotormanualforrequiredmotor
maintenanceprocedures.
Preventive Preventive
PreventiveMaintenance Maintenance MaintenanceSchedule Schedule Schedule
Theoperatingconditionsofyourparticularsystem
determinehowoftenmaintenanceisrequired.
Establishapreventivemaintenancescheduleby
recordingwhenandwhatkindofmaintenanceis
needed,andthendeterminearegularschedulefor
checkingyoursystem.
Flushing Flushing
Flushing
Toavoid󰘰reandexplosion,alwaysground
equipmentandwastecontainer.Toavoidstatic
sparkingandinjuryfromsplashing,always󰘱ushat
thelowestpossiblepressure.
•Flushbeforechanging󰘱uids,before󰘱uidcandry
intheequipment,attheendoftheday,before
storing,andbeforerepairingequipment.
•Flushatthelowestpressurepossible.Check
connectorsforleaksandtightenasnecessary.
•Flushwitha󰘱uidthatiscompatiblewiththe󰘱uid
beingdispensedandtheequipmentwettedparts.
143A3384B

Troubleshooting
Troubleshooting Troubleshooting
Troubleshooting
NOTE: NOTE:
NOTE:Checkallpossibleremediesbeforedisassemblingthepump.
NOTE: NOTE:
NOTE:TheLEDonthemotorwillblinkifanerrorisdetected.SeeError Error ErrorCode Code CodeTroubleshooting Troubleshooting Troubleshootinginthemotor
manualforfurtherinformation.
Problem Problem
ProblemCause Cause
CauseSolution Solution Solution
Inadequatepowersupply.SeePowerSupplyRequirements,
page8.
Exhausted󰘱uidsupply.Re󰘰llandreprimepump.
Clogged󰘱uidoutletline,valves,
etc.
Clear.
Pumpoutputlowonbothstrokes.
Wornpistonpacking.Replace.Seelowermanual.
Heldopenorwornballcheck
valves.
Checkandrepair.Seelower
manual.
Pumpoutputlowononlyone
stroke.
Wornpistonpacking.Replace.Seelowermanual.
Nooutput.Improperlyinstalledballcheck
valves.
Checkandrepair.Seelower
manual.
Exhausted󰘱uidsupply.Re󰘰llandreprimepump.
Heldopenorwornballcheck
valves.
Checkandrepair.Seelower
manual.
Pumpoperateserratically.
Wornpistonpacking.Replace.Seelowermanual.
Inadequatepowersupply.SeePowerSupplyRequirements,
page8.
Exhausted󰘱uidsupply.Re󰘰llandreprimepump.
Clogged󰘱uidoutletline,valves,
etc.
Clear.
Pumpwillnotoperate.
Fluiddriedonpistonrod.Disassembleandcleanpump.
Seelowermanual.Infuture,stop
pumpatbottomofstroke.
3A3384B15

Repair
Repair Repair
Repair
Disassembly Disassembly
Disassembly
1.Stopthepumpatthebottomofitsstroke.
2.Relievethepressure. Followthe
PressureReliefProcedure,page13.
3.Disconnectthehosesfromthelowerandplug
theendstoprevent󰘱uidcontamination.
4.Models Models
Modelswith with withSealed Sealed SealedLowers Lowers Lowers:Removethe2-piece
shield(12)byinsertingascrewdriverstraightinto
theslot,andusingitasalevertoreleasethetab.
Repeatforalltabs.Do Do
Donot not notusethescrewdriver
toprytheshieldsapart.
5.Loosenthecouplingnut(11)andremovethe
collars(10).Removethecouplingnutfromthe
pistonrod(R).Unscrewthelocknuts(8)fromthe
tierods(6).Separatethemotor(3)andlower
(7).SeeFig.7.
6.Torepairthelower,seethelowermanual.
7.Therearenouser-serviceablepartsinthe
motor.ContactyourGracorepresentativefor
assistance.
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).SeeFig.7.
b.Applybluethreadlockertothecoupling
adapter(9).
c.Screwthecouplingadapter(9)intothemotor
shaftandtorqueto90–100ft-lb(122–135
N•m).
d.Continuetostep2.
2.Assemblethecouplingnut(11)overthepiston
rod(R).SeeFig.8.
3.Orientthelower(7)tothemotor(3).Positionthe
loweronthetierods(6).
4.Ifyouarereusinglocknuts(8)andthenylonof
thelocknutiswornorcut,addbluethreadlocker
tothetierodthreads.
5.Screwthelocknuts(8)ontothetierods(6).
Leavethelocknuts(8)looseenoughtoallowthe
lowertomovesothatitcanbealignedcorrectly.
6.Insertthecollars(10)intothecouplingnut(11).
Tightenthecouplingnut(11)ontothecoupling
adapter(9)andtorqueto90–100ft-lb(122–135
N•m)toalignthemotorshaftwiththepistonrod.
7.Tightenthelocknuts(8)andtorqueto50-60ft-lb
(68-81N•m).
163A3384B

Repair
8.Models Models
Modelswith with withSealed Sealed SealedLowers: Lowers: Lowers:Installtheshields
(12)byengagingthebottomlipswiththegroove
inthetopplate.Snapthetwoshieldstogether.
9.Flushandtestthepumpbeforereinstalling
itinthesystem.Connecthosesand󰘱ush
thepump.Whileitispressurized,checkfor
smoothoperationandleaks.Adjustorrepair
asnecessarybeforereinstallinginthesystem.
Reconnectthepumpgroundwirebefore
operating.
Figure6PumpAssembly;LowerwithOpenWet
CupShown
Notes Notes
Notes
Torqueto50–60ft-lb(68–81N•m).
Torqueto90–100ft-lb(122–135N•m).
3A3384B17

Parts
Parts Parts
Parts
Pump Pump
PumpAssembly Assembly Assembly
183A3384B

Parts
Ref Ref
RefPart Part
PartDescription Description DescriptionQty. Qty.
Qty.
KIT,mountingbracket,pump;includesitems4and5;seemanual
311619
255143forModelsECxxx1orECxxx21
1
NotusedforModelsECxxx00
STAND,󰘱oor
256193forModelsECxxx01
2
NotusedforModelsECxxx1orECxxx20
3SeePump
Matrix,page20.
MOTOR;BasicorAdvanced;seemotormanual;includesitems3a
and3b
1
3a�16M130LABEL,warning1
3b16W645OIL,gear,synthetic;ISO220silicone-free;
1quart(0.95liter);notshown
2
WASHER
100133forModelsECxxx1orECxxx24
4
NotusedforModelsECxxx00
SeeBOLT
100101forModelsECxxx1orECxxx24
5
NotusedforModelsECxxx00
ROD,tie
15G924forModelsECxx5xorECxx6x
6
16X771forModelsECxx4x
3
7SeePump
Matrix,page20.
PUMP,displacement;seelowermanual1
8108683NUT,lock,hex3
915H369ADAPTER1
10184128COLLAR,coupling2
1117F000NUT,coupling1
1224F251KIT,shield,coupler(includes2pieces);usedonpumpswithsealed
lowers
1
�ReplacementDangerandWarninglabels,tags,andcardsareavailableatnocost.
3A3384B19

Parts
Pump Pump
PumpMatrix Matrix Matrix
Pump Pump
Pump
Model Model
Model
Pump Pump
Pump
Series Series
Series
Motor Motor
Motor
(Ref. (Ref.
(Ref.3) 3) 3)
Lower Lower
LowerPump Pump Pump
(Ref. (Ref.
(Ref.7) 7) 7)
EC1140AEM001117K656
EC1141AEM001117K656
EC1142AEM001117K656
EC1150AEM001117K668
EC1151AEM001117K668
EC1152AEM001117K668
EC1160AEM001117K664
EC1161AEM001117K664
EC1162AEM001117K664
EC1240AEM001217K656
EC1241AEM001217K656
EC1242AEM001217K656
EC1250AEM001217K668
EC1251AEM001217K668
EC1252AEM001217K668
EC1260AEM001217K664
EC1261AEM001217K664
EC1262AEM001217K664
EC1540AEM001317K656
EC1541AEM001317K656
EC1542AEM001317K656
EC1550AEM001317K668
EC1551AEM001317K668
EC1552AEM001317K668
EC1560AEM001317K664
EC1561AEM001317K664
EC1562AEM001317K664
EC1640AEM001417K656
EC1641AEM001417K656
EC1642AEM001417K656
EC1650AEM001417K668
EC1651AEM001417K668
EC1652AEM001417K668
EC1660AEM001417K664
Pump Pump
Pump
Model Model
Model
Pump Pump
Pump
Series Series
Series
Motor Motor
Motor
(Ref. (Ref.
(Ref.3) 3) 3)
Lower Lower
LowerPump Pump Pump
(Ref. (Ref.
(Ref.7) 7) 7)
EC1661AEM001417K664
EC1662AEM001417K664
EC2140AEM001117K657
EC2141AEM001117K657
EC2142AEM001117K657
EC2150AEM001117K669
EC2151AEM001117K669
EC2152AEM001117K669
EC2160AEM001117K665
EC2161AEM001117K665
EC2162AEM001117K665
EC2240AEM001217K657
EC2241AEM001217K657
EC2242AEM001217K657
EC2250AEM001217K669
EC2251AEM001217K669
EC2252AEM001217K669
EC2260AEM001217K665
EC2261AEM001217K665
EC2262AEM001217K665
EC2340AEM002117K657
EC2341AEM002117K657
EC2342AEM002117K657
EC2350AEM002117K669
EC2351AEM002117K669
EC2352AEM002117K669
EC2360AEM002117K665
EC2361AEM002117K665
EC2362AEM002117K665
EC2440AEM002217K657
EC2441AEM002217K657
EC2442AEM002217K657
EC2450AEM002217K669
EC2451AEM002217K669
203A3384B