Graco E-Flo EP G Series Use and care manual

Repair - Parts
E-Flo®4-Ball
Pumps
with Sealed or Open Wet Cup Lowers
Piston pumps for high-volume paint circulation applications.
For professional use only.
See page 3 for model information, including maximum working pressure. See page 4 for approvals.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
ti27591a
E-Flo 4000 Pump Shown
ti27597a
3A3386E
EN

Related Manuals
23A3386E
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E-Flo 4-Ball Piston Pumps . . . . . . . . . . . . . . . . . 3
Maximum Working Pressure and Pump
Operational Limits . . . . . . . . . . . . . . . . . . . . . 3
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 7
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . 10
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fluid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Section . . . . . . . . . . . . . . . . . . . . . . . 18
Drive Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Motor/Gear Reducer . . . . . . . . . . . . . . . . . . . . . 28
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Drive Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fluid Section - Sealed 4-Ball . . . . . . . . . . . . . . . 39
Fluid Section - Open Wet Cup . . . . . . . . . . . . . . 40
Common Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Model-Specific Parts . . . . . . . . . . . . . . . . . . . . . 43
Gear Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 47
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 50
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 50
Related Manuals
Manual Description
311592 E-Flo Installation Manual
3A3385 E-Flo Operation Manual
311595 Pneumatic Back Pressure Regulator
311596 Variable Frequency Drive Instructions
311603 Sensor Circuit Option
333022 Sealed 4-Ball Lowers
3A3452 4-Ball Lowers with Open Wet Cup

Models
3A3386E 3
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. EP21D0represents electric
power (E), pump (P), 230/460V motor (2), sensor circuit installed (1), 1000 cc
lower with an open wet cup (D), and no stand installed (0). To order replace-
ment parts, see Parts, beginning on page 38.
Maximum Working Pressure and Pump Operational Limits
EPxxGx and EPxxHx (E-Flo 1500): 425 psi (2.93 MPa, 29.3 bar) Maximum Working Pressure
EPxxAx and EPxxDx (E-Flo 2000): 460 psi (3.22 MPa, 32.2 bar) Maximum Working Pressure
EPxxBx and EPxxEx (E-Flo 3000): 330 psi (2.31 MPa, 23.1 bar) Maximum Working Pressure
EPxxCx and EPxxFx (E-Flo 4000): 250 psi (1.75 MPa, 17.5 bar) Maximum Working Pressure
See Performance Charts, page 47, for pressure and flow limits.
EP 2 1 D 0
First Digit Second Digit Third Digit Fourth Digit Fifth Digit Sixth Digit
Power
Source
Equipment
Style Motor Sensor Circuit Lower Size
Stand
Option
E(electric) P(pump) 0No motor 0No circuit
installed
A1000cc Sealed 0No stand
installed
1230/400V, 5 HP,
ATEX
1Circuit installed B1500cc Sealed 1Stand
installed
2230/460V, 5 HP,
UL/CSA
C2000cc Sealed
3230/400V, 3 HP,
ATEX
D1000cc Open Wet Cup
4230/460V, 3 HP,
UL/CSA
E1500cc Open Wet Cup
F2000cc Open Wet Cup
G750cc Sealed
H750cc Open Wet Cup
ID
ti8912a

Approvals
43A3386E
Approvals
The E-Flo Pump meets requirements of the following approval agencies.
Refer to the individual components for other specific hazardous location listings.
Component Description Approvals
Mechanical
Pump
Motor
ATEX
(for pump Models
EP1XXX and
EP3XXX)
UL/CSA
(for pump Models
EP2XXX and
EP4XXX)
IS Sensor
Circuit
(for pump Models
EPX1XX)
Ex h IIB T3 Gb
Ex de IIC T4 Gb - CESI 05 ATEX 110X
Class I, Div. 1, Group D, Class II, Div. 1, Group F and G, T3B
Hazardous Locations
EEx ib IIB Ta = 0°C - 50°C - FM 06 ATEX 0025U
Class 1, Div. 1, Group C & D T3 Hazardous Locations
Ex ib IIB Ta = 0°C - 50°C - KTL 13-KB4BO-0088

Warnings
3A3386E 5
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 or on warning labels, 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.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or sol-
vent flowing through the equipment can cause static sparking. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are anti-static or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause elec-
tric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
or installing 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.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, 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/dispensing 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.

Warnings
63A3386E
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 com-
ponent. 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 Safety Data Sheet (SDS) from distributor or retailer.
• 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 manu-
facturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• 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.
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 Safety Data Sheet (SDS) 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.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective 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.

Pressure Relief Procedure
3A3386E 7
Pressure Relief
Procedure
Follow the Pressure Relief Procedure when-
ever you see this symbol.
1. Set START/STOP switch (ST) to STOP.
2. Push in SECURE DISABLE (SD) switch.
3. Open the back pressure regulator and all fluid drain
valves in the system, having a waste container
ready to catch drainage. Leave open until you are
ready to pressurize system again.
4. Check that pressure gauges on fluid supply and
return lines read zero. If gauges do not read zero,
determine cause and carefully relieve pressure by
VERY SLOWLY loosening a fitting. Clear obstruc-
tion before pressurizing system again.
Flushing
• Flush before changing colors, before storing, and
before repairing equipment.
• Flush at the lowest pressure possible. Check con-
nectors for leaks and tighten as necessary.
• Flush with a fluid that is compatible with the fluid
being dispensed and the equipment wetted parts.
1. Follow Pressure Relief Procedure.
2. Supply the appropriate flushing material to the sys-
tem.
3. Set pump to lowest possible fluid pressure, and start
the pump.
4. Flush long enough to thoroughly clean the system.
5. Follow Pressure Relief Procedure.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
splashing fluid and moving parts, follow the Pressure
Relief Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.
To avoid fire and explosion, always ground equipment
and waste container. To avoid static sparking and
injury from splashing, always flush at the lowest possi-
ble pressure.

Troubleshooting
83A3386E
Troubleshooting
1. Follow the Pressure Relief Procedure, page 7. 2. Check all possible problems and solutions before
disassembling pump.
PROBLEM CAUSE SOLUTION
Pump does not operate. Insufficient power supply. Verify that power supply meets require-
ments. See Performance Charts, page
47.
No flow rate input to VFD. Select speed/flow setting.
START/STOP switch set to STOP. Set START/STOP switch to START.
SECURE DISABLE switch not activated. Pull out to activate.
Outlet valve not open. Open valve.
Damaged electric motor. Repair, page 18.
Damaged gear reducer. Disconnect pumps and operate. If speed
is consistent, gear reducer is good. If
speed is erratic, gear reducer is bad.
Fluid dried on piston rod. Disassemble and clean lower. See lower
manual. In future, stop lower at bottom of
stroke.
Throat packing nut is too tight. Loosen packing nut and retighten.
3-phase wiring to motor is not correct. Inspect and confirm wiring continuity.
Pressure too low. Incorrect transducer calibration. Check calibration. Replace transducer if
necessary.
Lowers need repair. Check and repair. See lower manual.
Restricted pump fluid inlet. Clear.
Air in the fluid. Check fluid level. Check inlet fittings for
leaks.
Pump output low on both strokes. Insufficient power supply. Verify that power supply meets require-
ments. See Performance Charts, page
47.
Exhausted fluid supply. Refill and reprime pump.
Held open or worn ball check valves. Check and repair.
Wrong fluid lowers installed. Verify size of lowers installed and config-
ured.
Pump output low on only one stroke. Held open or worn ball check valves. Check and repair.
Worn piston packings. Replace. See lower manual.
Air in the fluid. Check fluid level. Check inlet fittings for
leaks.

Troubleshooting
3A3386E 9
Erratic flow or pressure. Pump cavitation; suction/supply line leak. Check and repair.
Exhausted fluid supply. Refill and reprime pump.
Restricted fluid supply to pump. Ensure all valves are fully open.
Held open or worn ball check valves. Check and repair.
Pump packings are too tight. Loosen and retighten.
Worn piston packing. Replace. See lower manual.
Air in the fluid. Check fluid level. Check inlet fittings for
leaks.
Motor rotation direction is backwards. Check direction of rotation.
3-phase wiring to motor is not correct. Inspect and confirm wiring continuity.
Pump will not prime 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.
Excessive throat leakage. Worn piston rod or throat packings. Replace. See lower manual.
High current trip (t043). Pressure setting is too high. Reduce pressure.
Pump packings are too tight. Loosen and retighten.
Gear reducer oil level is low. Fill to correct oil level.
Incorrect transducer calibration. Perform calibration procedure.
Wrong fluid lowers installed. Verify size of lowers installed and config-
ured.
High pressure trip (t040). Downstream restriction is too high. Open line and remove restriction.
Circulation valve is closed. Open back pressure regulator.
Check solenoid.
Clogged fluid filters. Clean.
Incorrect transducer calibration. Perform calibration procedure.
Excessive noise. Gear reducer oil level is low. Fill to correct oil level.
Loose or worn drive linkage. Inspect; repair or replace.
Worn motor coupling. Inspect; repair or replace.
Worn gear reducer. Replace.
Pump changes direction or shakes. One leg of 3-phase is lost. Inspect and correct wiring connections on
VFD, motor, and wiring.
PROBLEM CAUSE SOLUTION

Electrical Diagrams
10 3A3386E
Electrical Diagrams
FIG. 1 shows components which must be installed in a
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1
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