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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Electrical Diagrams
3A3386E 11
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SEE DETAIL
B, page 12
Alpha Wire P/N M16107LW/equiv.
6
IS Control Drawing 288110
SEE DETAIL
A, page 12

Electrical Diagrams
12 3A3386E
FIG. 3: System Wiring Schematic, Hazardous Location Detail Views
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IS SENSOR
CIRCUIT
BOARD
(249639)
1
2
J2
1
2
3
4
5
TDC
NAMUR
SENSOR
(15H984)
J1
+ (BRN)
- (BLU)
(RED)
(GRN)
(WHT)
(BLK)
PRESSURE
TRANSDUCER
(120371)
3
4
J2
1
2
3
J3
BARRIER
(16A630)
ALL SWITCHES
"ON" POSITION 1
BARRIER
(16A633)
1
3
1
2
3
4
GREEN
RED
BLACK
FERRITE
(16G496)
BELDEN 8777 OR EQUIV.
WITH FERRITE (123375)
POSITION SENSOR
(16K088)
(16J588)
INSTALLED ON PUMP ASSEMBLY
INSTALLED IN E-FLO JUNCTION BOX ONLY
+(BRN) -(BLU)
BLACK
5
2
DETAIL A
DETAIL B
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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. 1, GROUP C & D T3 (CANADA)
IS Control Drawing 288110
NON-HAZARDOUS
AREA
1 The installation must meet the requirements of the National Electric Code,
Canadian Electrical Code Part I, Article 504, NFPA 70, and ANSI/ISA 12.06.01.
Individually shielded cables needed to ensure separation of sensor and
transducer circuits.
The voltage (Vmax or Ui), current (Imax or Ii), and power (Pi) must be equal to or
greater than the voltage (Voc, Uo, or Vt), current (Isc, Io, or It), and power (Po or
Pt) levels, which can be delivered by the associated apparatus. In addition, the
maximum unprotected capacitance (Ci) and inductance (Li) of the intrinsically
safe apparatus, including interconnecting wiring, must be less than the
capacitance (Ca) and inductance (La) which can be safely connected to the
associated apparatus.
Land shield drain and foil to conductive strain relief.
2
3
5
SEE PAGE 11
3
HAZARDOUS AREA

Repair
3A3386E 13
Repair
Fluid Section
NOTE: Manifold Gasket Kit 15H878 is available to
replace the sanitary gaskets at the inlet and outlet mani-
folds. The kit includes items 16, 41, 58, two 120631
PTFE Gaskets, and instruction sheet 406637.
Disassembly
1. Flush the pump, see page 7.
2. Jog the motor to bring the lower on the side being
repaired to the bottom of its stroke. This provides
access to the coupling nut (14).
3. Follow the Pressure Relief Procedure, page 7.
4. Pumps with Sealed Lowers: Remove the 2-piece
shield (72, see FIG. 5) by inserting a screwdriver
straight into the slot, and using it as a lever to
release the tab. Repeat for all tabs. Do not use the
screwdriver to pry the shields apart.
5. See FIG. 5. Place a 3/4 in. wrench on the slider pis-
ton (9) flats (just above the coupling nut), to keep
the slider piston/connecting rod from turning when
you are loosening the coupling nut (14). Orient the
wrench so it is braced against one of the tie rods (3).
Applying excessive force to the slider piston/con-
necting rod can shorten the life of the lower pin
bearing.
6. Using a 1-5/8 in. open-end wrench, unscrew the
coupling nut (14) from the slider piston (9) and let it
slide down onto the pump piston rod. Be careful not
to lose the collars (13).
7. Repeat steps 2-6 for the other lower.
8. Shut off electrical power and allow the unit to cool.
FIG. 4. Shield Disassembly
Step 1
Step 2 ti15759a
ti15770a
FIG. 5. Remove Coupling Nut
ti27600a
3
14
10
9
Hold slider piston (9) flats with 3/4 in. wrench, and brace
against tie rod (3).
10
72

Repair
14 3A3386E
9. Disconnect the fluid inlet and outlet lines from the
pump. Plug the ends to prevent fluid contamination.
10. See FIG. 6. 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.
11. Loosen the clamps (18) at the inlet and outlet mani-
folds (17). Remove the manifolds and gaskets (16).
12. Remove the coupling nut (14) and collars (13) from
the piston rods (PR).
13. Unscrew the lock nuts (15). Remove each lower
(22). See your separate lower manual for repair
instructions.
FIG. 6: Fluid Section
M
41
ti27598a
13
14
22
16
18
17
22
15
18
17
4
514
7
7
Torque to 50-60 ft-lb (68-80
N•m).
Torque to 75-80 ft-lb
(102-108 N•m).
Torque to 15-20 ft-lb (21-27
N•m).
4
5
7
14
1
16
3
9PR
7
41
45 7
42
25a
3
M
41
13
14
67
68
15
4
18
7
16
18
7
44

Repair
3A3386E 15
Reassembly
1. See FIG. 6. 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. On pumps with a sensor circuit: Install a new
black o-ring (41) on the transducer (25a). Insert
the transducer into the outlet manifold (17).
Torque the adapter (42) first, then the nut (M) to
15-20 ft-lb (21-27 N•m).
b. On pumps without a sensor circuit: Install a
black o-ring (41) on the plug (45). Screw the
plug into the outlet manifold (17) and torque to
15-20 ft-lb (21-27 N•m).
6. Install a black o-ring (41) on the plug (45). Screw the
plug into the inlet manifold (17) and torque to 15-20
ft-lb (21-27 N•m).
7. Ensure that the collars (13) are in place in the cou-
pling nut (14).
8. Place a 3/4 in. wrench on the flats of the slider pis-
ton (9), to keep it from turning when you are tighten-
ing the coupling nut (14). Orient the wrench so it is
braced against one of the tie rods (3) or the pump
stand. Tighten the coupling nut (14) onto the slider
piston (9) and torque to 75-80 ft-lb (102-108 N•m).
9. Pumps with Sealed Lowers: Install the shields
(72) by engaging the bottom lips with the groove in
the wet-cup cap. Snap the two shields together.
10. Turn on power and jog the motor to bring the other
drive to the bottom of its stroke. Repeat procedure
to connect the other lower.
NOTE: Update the drive software to reflect the change
in size of the lowers. See manual 311596.
11. Flush and test the pump before reinstalling it in the
system. Connect hoses and flush the pump. While it
is pressurized, check for smooth operation and
leaks. Adjust or repair as necessary before reinstall-
ing in the system.
FIG. 7. Shield Reassembly

Repair
16 3A3386E
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.
1. Perform the Disassembly procedure on page 13.
2. Remove two screws (12) and the cover. FIG. 8
shows the cover (32) on the side opposite from the
motor; the motor side cover is (21).
3. Remove the setscrew (31). Unscrew the slider cylin-
der (2) from the gear reducer (1).
4. Remove the bearings (8) from the slider piston (9).
5. Install the two new bearings (8) on the slider piston
(9). The joints between the bearings must align with
the pin hole (PH) in the slider piston.
6. Screw the slider cylinder (2) into the gear reducer
(1). Torque to 15-20 ft-lb (21-27 N•m). Install the
setscrew (31). Torque to 30-35 in-lb (3.4-3.9 N•m).
7. Install two screws (12) and the cover (32 is shown;
use 21 on the motor side).
8. Perform the Reassembly procedure on page 15.
Use the tie rod locknuts (15) included in the kit.
9. Return the pump to service.
FIG. 8. Slider Cylinder Kit, Sealed 4 Ball
ti27624a
12 32
12
31
1
2
8
21
Torque to 15-20 ft-lb (21-27 N•m).
7
7
9
PH
72

Repair
3A3386E 17
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.
1. Perform the Disassembly procedure on page 13.
2. Jog motor to move slider piston (9) up, giving ade-
quate clearance to fit collector (67) between slider
cylinder and piston rod.
3. See FIG. 9. Position the collector (67) over the cou-
pling nut (14) and drop it down onto the pump piston
rod.
4. Jog motor to move slider piston (9) to bottom of
stroke, allowing reconnection of coupling nut (14).
5. Ensure that the collars (13) are in place in the cou-
pling nut (14).
6. Place a 3/4 in. wrench on the flats of the slider pis-
ton (9), to keep it from turning when you are tighten-
ing the coupling nut (14). Orient the wrench so it is
braced against one of the tie rods (3) or the stand.
Tighten the coupling nut (14) onto the slider piston
(9) and torque to 75-80 ft-lb (102-108 N•m).
7. See FIG. 10. Push the collector (67) up onto the bot-
tom of the slider cylinder (2) so it seats securely.
Install the three setscrews (68) finger-tight.
8. Models with Sealed Lower: Install the shields (72)
by engaging the bottom lips with the groove in the
wet-cup cap. Snap the two shields together.
9. Repeat for the other side.
FIG. 9. Position Collector
ti27643a
14
67
9
FIG. 10. Install Collector
ti9539a
2
67
68

Repair
18 3A3386E
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.
1. Jog the motor to bring the lower on the side oppo-
site from the motor to the bottom of its stroke.
2. Follow the Pressure Relief Procedure, page 7.
3. Shut off electrical power to the unit.
4. Remove two screws (12) and the cover (32).
5. See FIG. 11. 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. 11 and the Electri-
cal Diagrams, page 10.
7. Disconnect the TDC cable (25b) from J2 on the cir-
cuit board (25c).
8. Disconnect the IS circuit field wire from J2 and J3.
9. Remove four screws (12) and the circuit board
(25c).
10. Install the new circuit board (25c) using four screws
(12).
FIG. 11. Circuit Board
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343325c
25b
ti8725b
25c
25b
25a
L
ti16890b
Pressure Transducer Grounding Schematic
76
25a
B
G
N
44
Tighten nut (N) securely to ensure that the shield
and drain wire (G) has firm metal-to-metal
contact between the nut and bushing (B).
3
3
35
ti17644a
ti17640a
76
35
35
74a*
Land shield drain and foil to conductive strain relief.
5

Repair
3A3386E 19
11. See FIG. 12. Loosen the nut (M) on the sensor con-
duit (44) and unscrew the adapter (42) from the
transducer port (P). Remove the transducer (25a)
from the port.
12. See FIG. 11. Loosen the nut (N) on the strain relief
(35). Remove the ferrite (76). Pull the transducer
cable (25a) out of the conduit (44).
13. See FIG. 12. Install one new black o-ring (41) and
the new brass spacer (58) on the transducer (25a).
14. See FIG. 11. Ensure that the conductive strain relief
(35) is screwed tightly into the housing, to ensure
electrical continuity to the pump housing. Thread
the transducer’s cable (25a) through the adapter
(42), short length of the conduit (44), and conductive
strain relief (35). Reconnect the cable to J1 on the
circuit board (25c). Install the ferrite (76) around the
transducer leadwires.
15. See FIG. 11. Tighten the nut (N) on the conductive
strain relief (35) securely to ensure that the shield
and drain wire (G) has firm metal-to-metal contact
between the nut and bushing (B).
16. See FIG. 12. Insert the transducer into the trans-
ducer port (P). Torque the adapter (42) first, then
the nut (M) to 15-20 ft-lb (21-27 N•m).
17. See FIG. 11. Connect the TDC cable (25b) to J2 on
the circuit board (25c).
18. Ensure that the conductive strain relief (74a) is
screwed tightly into the housing. Units with a sensor
circuit must use the conductive strain relief to
ensure proper grounding of the IS field wire and
shield.
19. Thread the IS field wire and shield through the con-
ductive strain relief (74a) and connect it to J2 and
J3. See FIG. 13 and the Electrical Diagrams, page
10.
20. See FIG. 13. 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).
Install ground wire to grounding screw in junction
box.
21. Install the new gasket (33), the cover (34), and six
screws (12).
22. Remove the old label (L) from the circuit board
cover (34). Attach the new label (L) to the cover.
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.
• For non-ACS systems, see page 20.
24. Reinstall the cover (32) with two screws (12).
FIG. 12. Pressure Transducer
FIG. 13. IS Circuit Field Wire
44
42
41
25a
58
M
ti8721c
Torque to 15-20 ft-lb (21-27 N•m).
7
7
7
P
ti16891b
F
N
77
B
74a
Not more than
2 in. (51 mm)
G

Repair
20 3A3386E
Pressure Sensor Calibration Information
(non-ACS systems)
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 Vari-
able Frequency Drive before system start-up.
To prevent accidental change of pressure sensor cali-
bration parameters, they are locked by Pr 20.16. To
enter calibration parameters, perform the following
steps:
a. Set Pr 20.16 to 777, to unlock pressure sensor
parameters.
b. Enter calibration parameters Pr 20.34, 20.35,
and 20.36.
c. Set Pr 20.16 to 0 to lock pressure sensor
parameters.
Calibration Parameters from the label:
Pr 20.34 – Zero Calibration
Pr 20.35 – Calibration Pressure
Pr 20.36 – High Calibration
Pressure Transducer Calibration
Procedure (non-ACS systems)
E-Flo pressure sensor must be calibrated against an
instrument grade High Precision Pressure Transducer,
which should be installed near the E-Flo pressure sen-
sor.
1. Ensure that the High Precision Pressure Transducer
calibration is up to date.
2. Set Pr 20.16 to 777, to unlock pressure sensor
parameters.
3. Calibrate Low Pressure Point as follows:
a. Ensure that system is not pressurized. Calibra-
tion instrument pressure reading should be 0
psi.
b. Use Keypad to navigate to Pr 20.33; monitor its
reading for 5 – 10 seconds to determine its
average value. Make a record of it.
c. Navigate to Pr 20.34 and enter the recorded
average value of Pr 20.33.
4. Calibrate the High Pressure Point as follows:
a. Pressurize the system to 250 – 275 psi.
b. Keep the system pressurized and ensure that
pressure does not fluctuate.
c. Take a pressure reading from the calibration
instrument and make a record of it.
d. Navigate to Pr 20.35 and enter the recorded
system pressure.
e. Navigate to Pr 20.33; monitor its reading for
5-10 seconds to determine its average value.
Make a record of it.
f. Navigate to Pr 20.36 and enter the recorded
value of Pr 20.33.
5. Set Pr 20.16 to 0 to lock pressure sensor parame-
ters.
6. Verify pressure calibration.
a. Relieve system pressure.
b. Navigate to Pr 20.31 and verify that its reading
is within the range of 0-3 psi.
c. Pressurize the system to about 100 psi. Verify
that reading of Pr 20.31 is within +/- 2.5 psi of
the system pressure.
d. Pressurize system to about 250 psi. Verify that
reading of Pr 20.31 is within +/- 2.5 psi of the
system pressure.