Graco E-Flo Plus Operating instructions

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2007, Graco Inc. is registered to I.S. EN ISO 9001
311594 rev.B
Repair - Parts
E-Flo™Plus Electric
Circulation Pump
Durable, energy efficient piston pumps for high volume paint circulation
applications.
See page 3 for model information, including maximum working pressure and approvals.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
ti8317a

2311594B
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E-Flo Plus Electric Circulation Pumps . . . . . . . . 3
Maximum Working Pressure and
Pump Operational Limits . . . . . . . . . . . . . . . 3
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 7
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . 10
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fluid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 12
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 13
Slider Cylinder Rebuild Kit 15H874 . . . . . . 14
Electrical Section . . . . . . . . . . . . . . . . . . . . . . . 15
Pressure Transducer Kit 15H876 . . . . . . . . 15
Pressure Sensor Calibration Information . . 16
Pressure Transducer Calibration Procedure 17
TDC Sensor Kit 15H877 . . . . . . . . . . . . . . . 19
Drive Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Slider Bearing Kit 15H882 . . . . . . . . . . . . . . 20
Drive Linkage Rebuild Kit 15H873 . . . . . . . 22
Crank Arm Kit 15H883 . . . . . . . . . . . . . . . . 23
Motor/Gear Reducer . . . . . . . . . . . . . . . . . . . . . 24
Motor Removal . . . . . . . . . . . . . . . . . . . . . . 24
Motor Installation . . . . . . . . . . . . . . . . . . . . . 24
Gear Reducer Seal Kit 15H871 . . . . . . . . . 26
Gear Reducer Replacement Kit 15H886 . . 28
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Drive Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fluid Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Common Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Model-Specific Parts . . . . . . . . . . . . . . . . . . . . . 35
15H886 Gear Reducer . . . . . . . . . . . . . . . . . . . 36
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 38
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 38

Models
311594B 3
Models
E-Flo Plus Electric Circulation 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. EP2160represents electric
power (E), pump (P), 230/460V motor (2), sensor circuit installed (1), and 2000
cc Maxlife lower (6). The last digit (0) is unassigned. To order replacement
parts, see Parts, beginning on page 32.
Maximum Working Pressure and Pump Operational Limits
1000 cc Pumps: 460 psi (3.22 MPa, 32.2 bar) Maximum Working Pressure
1500 cc Pumps: 330 psi (2.31 MPa, 23.1 bar) Maximum Working Pressure
2000 cc Pumps: 250 psi (1.75 MPa, 17.5 bar) Maximum Working Pressure
See Technical Data, page 37, for pressure and flow limits.
Approvals
This equipment meets requirements of the following
approval agencies:
Refer to the individual components for other specific
hazardous location listings.
Related Manuals
ID
ti8912a
EP 2 1 6 0
First Digit Second Digit Third Digit Fourth Digit Fifth Digit Sixth Digit
Power
Source Equipment
Style Motor Sensor Circuit Lower Size Unassigned
E (electric) P (pump) 0 No motor 0 No circuit 1 1000 cc
Chromex
0 None
assigned
1 230/400V ATEX 1 Circuit installed 2 1500 cc
Chromex
2 230/460V
UL/CSA
3 2000 cc
Chromex
4 1000 cc Maxlife
5 1500 cc Maxlife
6 2000 cc Maxlife
II2G EExdIIA T3
Manual Description
311592 E-Flo Plus Installation Manual
311593 E-Flo Plus Operation Manual
311595 Pneumatic Back Pressure Regulator
311596 Variable Frequency Drive Instructions
311603 Sensor Circuit Option

Warnings
4311594B
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 symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. 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 arc).
• 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.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
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
component. 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 MSDS forms from distributor or retailer.
• 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.
• 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.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.

Warnings
311594B 5
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
• Follow Pressure Relief Procedure in this manual, when you stop spraying 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.
MOVING PARTS HAZARD
Moving parts can pinch 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 in this manual. Disconnect power or air supply.
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 MSDS’s 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.
• Always wear impervious gloves when spraying or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
WARNING

Warnings
6311594B

Pressure Relief Procedure
311594B 7
Pressure Relief
Procedure
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
1. Follow Pressure Relief Procedure, page 7.
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, page 7.
System pressure can cause the pump to cycle unex-
pectedly, which could result in serious injury from
splashing or moving parts.
• Flush before changing colors, before storing,
and before repairing equipment.
• Flush at the lowest pressure possible. Check
connectors for leaks and tighten as necessary.
• Flush with a fluid that is compatible with the
fluid being dispensed and the equipment wetted
parts.

Troubleshooting
8311594B
Troubleshooting
1. Relieve the pressure.
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 Technical Data, page 37.
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 15.
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 311690. In future, stop lower at
bottom of stroke.
Throat packing nut is too tight. Loosen packing nut and re-torque.
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
311690.
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 Technical Data, page 37.
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 311690.
Air in the fluid. Check fluid level. Check inlet fittings for
leaks.
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 re-torque.
Worn piston packing. Replace. See lower manual 311690.
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.

Troubleshooting
311594B 9
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 311690.
High current trip (t043). Pressure setting is too high. Reduce pressure.
Pump packings are too tight. Loosen and re-torque.
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. Pump packings are too tight. Loosen and re-torque.
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

ElectricalDiagrams
10 311594B
Electrical Diagrams
FIG. 1 shows components which must be installed in a
non-hazardous location.
FIG. 2 shows components approved for installation in a
hazardous location.
FIG. 1: System Wiring Schematic, Non-Hazardous Location Only

Electrical Diagrams
311594B 11
FIG. 2: System Wiring Schematic, Hazardous Location
SEE DETAIL
BELOW
SEE ABOVE

Repair
12 311594B
Repair
Fluid Section
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. Relieve pressure, page 7.
4. See FIG. 3. 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.
5. 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).
6. Repeat steps 2-5 for the other lower.
7. Shut off electrical power and allow the unit to cool.
8. Disconnect the fluid inlet and outlet lines from the
pump. Plug the ends to prevent fluid contamination.
9. See FIG. 4. At the pump outlet manifold (17), loosen
the transducer nut (43) and unscrew the adapter
(42) from the manifold. Remove the transducer
(25a) from the manifold port. Remove the existing
o-ring (41) and discard.
10. Loosen the clamps (18) at the inlet and outlet mani-
folds (17). Remove the manifolds and gaskets (16).
11. Remove the coupling nut (14) and collars (13) from
the piston rods (PR).
12. Unscrew the locknuts (15). Remove the lower (22).
To repair the lower, see manual 311690.
Complete kits are available to convert from one size
lower to another. See the table below for available
kits. Use all the new parts in the kit. The kits include
two lowers, inlet/outlet manifolds, connecting hard-
ware, and instruction manual 311611.
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.
Kit Part
No.
Lower
Part No. Description
15J747 253520 1000 cc, Chromex
15J748 253521 1500 cc, Chromex
15J749 253522 2000 cc, Chromex
15J750 253523 1000 cc, Maxlife
15J751 253524 1500 cc, Maxlife
15J752 253525 2000 cc, Maxlife
FIG. 3. Remove Coupling Nut
ti9223a
3
12
14
9
Hold slider piston (9) flats with 3/4 in. wrench, and brace
against tie rod (3).
10
10
32
9

Repair
311594B 13
Reassembly
1. See FIG. 4. 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. Install a new black o-ring (41) on the transducer
(25a).
6. Insert the transducer into the outlet manifold (17).
Torque the adapter (42) first, then the nut (43) to
15-20 ft-lb (21-27 N•m).
7. 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).
8. Ensure that the collars (13) are in place in the cou-
pling nut (14).
9. 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).
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.
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.
Update the drive software to reflect the change in
size of the lowers. See manual 311596.
FIG. 4: Fluid Section
43 41
ti8720a
13
14
22
16
18
17
22
15
16
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).
Apply lithium grease.
4
5
7
14
1
16
3
9
PR
7
41
45 7
42
725a

Repair
14 311594B
Slider Cylinder Rebuild Kit 15H874
1. Perform the Disassembly procedure on page 12.
2. Remove two screws (12) and the cover. FIG. 5
shows the cover (32) on the stand side; 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 set-
screw (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 13.
Use the tie rod locknuts (15) included in the kit.
9. Return the pump to service.
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.
FIG. 5. Slider Cylinder Kit
ti8723a
12 32
12
31
1
2
8
21
Torque to 15-20 ft-lb (21-27 N•m).
7
7
9
PH

Repair
311594B 15
Electrical Section
Pressure Transducer Kit 15H876
1. Jog the motor to bring the stand side lower to the
bottom of its stroke.
2. Relieve pressure, page 7.
3. Shut off electrical power to the unit.
4. Remove two screws (12) and the cover (32).
5. See FIG. 6. 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. 6 and the Electrical
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).
Sensor Circuit Kit 15J755 is available to add the
optional sensor circuit to a pump. Use all the new
parts in the kit. See manual 311603.
Pressure Transducer Kit 15H876 replaces the pres-
sure transducer and the circuit board. Use all the
new parts in the kit. The kit includes manual
311600.
FIG. 6. Circuit Board
12
343325c
25b
ti8725a
25c
25b
25a
L

Repair
16 311594B
11. See FIG. 7. At the pump outlet manifold (17), loosen
the transducer nut (43) and unscrew the adapter
(42) from the manifold. Remove the transducer
(25a) from the manifold port and pull its cable out of
the conduit (44).
12. Install one new black o-ring (41) and the new brass
spacer (58) on the transducer (25a).
13. Thread the transducer’s cable (25a) through the
adapter (42) and conduit (44). Reconnect the cable
to J1 on the circuit board (25c). See FIG. 6.
14. See FIG. 7. Insert the transducer into the outlet
manifold (17). Torque the adapter (42) first, then the
nut (43) to 15-20 ft-lb (21-27 N•m).
15. See FIG. 6. Connect the TDC cable (25b) to J2 on
the circuit board (25c).
16. Connect the IS circuit field wire to J2 and J3. See
the Electrical Diagrams, page 10.
17. Install the new gasket (33), the cover (34), and six
screws (12).
18. Remove the old label (L) from the circuit board cover
(34). Attach the new label (L) to the cover.
19. Enter calibration information found on the new label
(L) into the VFD. See Pressure Transducer Cali-
bration Procedure.
20. Reinstall the cover (32) with two screws (12).
Pressure Sensor Calibration Information
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
FIG. 7. Pressure Transducer
44
42
41
25a
58
43
ti8721a
Torque to 15-20 ft-lb (21-27 N•m).
7
7
7

Repair
311594B 17
Pressure Transducer Calibration Procedure
E-Flo Plus pressure sensor must be calibrated against
an instrument grade High Precision Pressure Trans-
ducer, which should be installed near the E-Flo Plus
pressure sensor.
1. Ensure that the High Precision Pressure Transducer
calibration is up to date.
2. Set Pr 20.11 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 20.11 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.
Do not exceed pressure rating of the system! If system
is rated to a pressure lower then 250 psi, use maxi-
mum allowable rated pressure. Refer to Operation
Manual 311593.

Repair
18 311594B

Repair
311594B 19
TDC Sensor Kit 15H877
1. Jog the motor to bring the stand side lower to the
bottom of its stroke.
2. Relieve pressure, page 7.
3. Shut off electrical power to the unit.
4. Remove two screws (12) and the cover (32).
5. See FIG. 8. 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. 6, page 15.
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.
See the Electrical Diagrams, page 10.
9. See FIG. 8. Remove four screws (12) and the circuit
board (25c).
10. Unscrew the TDC sensor (25b) from the gear hous-
ing.
11. Apply pipe sealant and screw the TDC sensor (25b)
into the gear housing. Torque to 66-78 in-lb (7.4-8.8
N•m).
12. Install the circuit board (25c) using four screws (12).
13. Reconnect the TDC cable (25b) to J2 on the circuit
board (25c).
14. Reconnect the transducer cable (25a) to J1 on the
circuit board (25c).
15. Reconnect the IS circuit field wire to J2 and J3. See
the Electrical Diagrams, page 10.
16. Install the new gasket (33), the cover (34), and six
screws (12).
17. Reinstall the cover (32) with two screws (12).
TDC Sensor Kit 15H877 replaces the TDC sensor.
Use all the new parts in the kit. The kit includes
manual 311601.
TDC sensor nuts are locked in place to ensure cor-
rect positioning. Do not adjust.
FIG. 8. TDC Sensor
12
343325c
25b
ti8725a
Torque to 66-78 in-lb (7.4-8.8 N•m).
11
11

Repair
20 311594B
Drive Section
Slider Bearing Kit 15H882
1. Jog the motor to bring the pump on the side being
repaired to the bottom of its stroke. This provides
access to the coupling nut (14).
2. Relieve pressure, page 7.
3. Shut off electrical power to the unit.
4. Remove two screws (12) and the cover. FIG. 9
shows the cover (32) on the stand side; the motor
side cover is (21).
5. Place a clean rag over the top of the slider cylinder
(2) to prevent debris from falling into the slider
assembly during disassembly.
6. Place a 3/4 in. wrench on the slider piston (9) flats
(just above the coupling nut), to keep the slider pis-
ton/connecting rod from turning when you are loos-
ening 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/connecting rod
can shorten the life of the lower pin bearing.
7. 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).
8. See FIG. 10. Using a 1/2 in. hex driver, unscrew the
two cap screws (5). Remove the crank arm cap (38)
and key (39). If necessary, use a plastic hammer to
break these parts loose.
Slider Bearing Kit 15H882 includes parts to rebuild
both slider bearing assemblies. Use all the new
parts in the kit. The kit includes manual 311616.
FIG. 9. Remove Coupling Nut
ti9223a
3
12
14
9
Place clean rag over slider cylinder (2).
Hold slider piston (9) flats with 3/4 in. wrench, and brace
against tie rod (3).
9
10
10
32
9
FIG. 10. Remove Crank Arm Cap
ti9224a
5
38
39
12
Place clean rag over slider cylinder (2).
Apply antiseize lubricant to screw (5) threads. Torque
key-side screw to 210-230 ft-lb (283-310 N•m) first, then
torque gap side screw to 210-230 ft-lb (283-310 N•m).
9
12
9