Graco E-FLO 4000 manual

Repa ir - Par ts E-Flo ® 4-Ball Piston Pumps Durable, energy efficient piston pumps for high volume paint circulation a pplications. For professional use only. See page 3 for mod el infor mation, in cluding maximum workin g pressure. S ee page 5 f or appro vals. Important Safety Instructio ns Read all wa rnings and instruc tions in thi s manual. S[...]

Relate d Manual s 2 311594Z Contents Related Manua ls . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 E-Flo 4-B all Piston Pumps . . . . . . . . . . . . . . . . . 3 Maximum Working P ressure a nd Pump O peration al Limits . . . . . . . . . . . . . . . . . . . . .[...]

Models 311594Z 3 Model s E-Flo 4-Ball Piston Pumps Check your pump’s id entificat ion plate (ID) for the 6-digit par t number of your pump. Use the fo llowing matr ix to defi ne the co nstruction of your p ump, base d on the si x digits. For example, P ump Part No. EP2 160 represen ts electric power ( E ), pump ( P ), 230/460V moto r ( 2 ), sens [...]

Models 4 311594Z[...]

Approval s 311594Z 5 Approvals The E-F lo Pump m eets requir ements o f the follo wing appr oval agenc ies. Refer to th e individua l compon ents for other spec ific haz ardous loc ation listi ngs. Com pone nt Part No. App rov als Mechanic al Pump Mot or ATEX EP1XXX EP3XXX UL/CSA EP2XXX EP4XXX IS Sensor Circuit EPX1 XX c T3 Ex de I IC T4 - CESI 05 [...]

Warnings 6 311594Z Warnings The foll owing warni ngs are for the setup , use, ground ing, main tenance, a nd repair o f this equ ipment. T he exclama - tion po int symbol alerts yo u to a gener al warning and the haz ard symb ols refe r to proce dure-specif ic risks. W hen these sy mbols a ppear in the body of this ma nual, refer back to these Warn[...]

Warn ings 311594Z 7 ELECTRIC SHOCK HAZARD Imprope r groundin g, setup, o r usage of th e system c an cause el ectric sh ock. • Turn off and disconnec t power at main sw itch before dis connect ing any cables and be fore servic ing equipme nt. • Conne ct only t o grounded po wer source. • All electrical wiring mu st be done by a quali fied ele[...]

Warnings 8 311594Z[...]

Pressure Relief Procedure 311594Z 9 Pressure Rel ief Procedure 1. Set STA RT/STOP s witch (ST) to STOP. 2. Push in SECURE DISAB LE (SD) switch. 3. Open the bac k pressure r egulator and all fluid dr ain valves in the s ystem, ha ving a wast e contai ner ready to catch draina ge. Leave open until you are ready to pressurize s ystem agai n. 4. Check [...]

Troub leshooti ng 10 311594Z Troubleshoot ing 1. Reli eve the pres sure. 2. Ch eck all po ssible problem s and solu tions befor e disas sembling pu mp. PROBLEM CAUSE SOLUTION Pump doe s not operate . Insuffic ient p ower sup ply. Verify that powe r supp ly meets requir e- ments. Se e Techn ical Data , page 5 0. No flow r ate inp ut to VFD. Select s[...]

Troubles hootin g 311594Z 11 Pump w ill not pri me Suction l ine c logged. Clear. Fl ush more frequently . Held o pen or wo rn ball ch eck val ves. Check and repair . Lower piston ass embled w ith wrong nut. Use only the larg e, round, speci al nut. Excess ive throa t leak age. Worn p iston rod or throat pack ings. Replace. See l ower ma nual. High[...]

Electric al Diagrams 12 311594Z Electri cal Diagrams F IG . 1 sh ows compone nts which mu st be ins talled in a non-haz ardous loc ation. F IG . 2 show s compo nents appr oved for i nstallation in a hazar dous locati on, and F IG . 3 sh ows detail v iews of hazar dous loc ation co mponents. F IG . 1: System Wiring Schematic, Non-Ha zardous Location[...]

Electr ical Di agrams 311594Z 13 F IG . 2: System Wiring Schematic, Hazardous Loc ation ,66(1625 &,5&8,7 %2$5'   -      7'& 1$085 6(1625 - 35(6685( 75$16'8&(5   -     - /2&$/&21752/ [...]

Electric al Diagrams 14 311594Z F IG . 3: System Wiring Schematic, Hazardous Location Detail Views 8/(;3/26,213522)02725 -9 $&8/  M 29(57(03 6:,7&+ 02725-81&7,21%2; /2:92/ 7 $*(9?[...]

Repair 311594Z 15 Repair Fluid Section NOTE: Complete kits are a vailable to convert fr om one size lower to another. See the table below fo r available kits. U se all the new parts in the kit. The kits include two lowers, inlet/outlet man ifolds, connec ting hardware , and instruc tion manu al 311611 . NOTE: Manifold Gasket Kit 1 5H878 is ava ilab[...]

Repair 16 311594Z 9. Disconn ect the flu id inlet and outlet li nes from the pump. Plu g the ends to prevent f luid con taminatio n. 10. See F IG . 5. On pum ps with a sen sor circui t: At the pump outlet man ifold (17), loo sen the nut (M) on the sensor conduit (4 4) and unsc rew the ad apter (42) from the m anifold. Remo ve the tr ansducer (25 a)[...]

Repair 311594Z 17 Reasse mbly 1. See F IG . 5. Inst all the coup ling n ut (14) on th e lower’s pis ton rod (PR). 2. Orient the lower (22) to the gea r reducer ( GR) as shown. Position the lower on the tie r ods (3). Screw the tie r od locknuts (15) onto t he tie rods han dtight. 3. Assemb le the inle t and outlet m anifolds ( 17) to the lower, u[...]

Repair 18 311594Z Slider Cylinder Rebuild Kit 15H874 NOTE: Slider Cyli nder Rebuil d Kit 15H8 74 includes parts to rebuild one slider cylin der assemb ly. Order tw o kits to re build both slider cylinder as sembli es. Use all the new parts in the kit. The kit incl udes manual 3115 99. 1. Perform th e Disassemb ly procedure on page 15. 2. Remove two[...]

Repair 311594Z 19 Slider C ylinder Collect or Kit 2473 41 NOTE: Slider Cyli nder Collec tor Kit 247 341 incl udes parts to install two slider cylind er collec tors. Use al l the new parts in the k it. The kit inc ludes manu al 311607. 1. Perform th e Disassemb ly procedure on page 15. 2. Jog m otor to mo ve slid er piston ( 9) up, givi ng ade- quat[...]

Repair 20 311594Z Electrical Section NOTE: Sensor Cir cuit Kit 24 J305 is ava ilable to add the option al sensor circuit to a p ump. Use a ll the new parts in the ki t. See man ual 311603 . Pres sure Transducer Ki t 15H876 NOTE: Pressure T ransduc er Kit 15H87 6 replaces the pressu re transdu cer and the circuit bo ard. Use all the new parts in the[...]

Repair 311594Z 21 11. See F IG . 10. Loo sen the nut (M) on the sensor co n- duit (44 ) and unscrew the ada pter (42) fro m the transdu cer port (P) . Remove the transduc er (25a) from the port. 12. See F IG . 9. Loosen the nut (N) on the s train reli ef (35). Remov e the fer rite (76). Pu ll the trans ducer cable ( 25a) out of th e conduit (44). 1[...]

Repair 22 311594Z Pressure Sensor Calibration Informa tion (non-ACS systems) NOTE: To calibrate the transd ucer in sy stems using the Graco ACS Module, see the AC S manu al 3A0006 . Pressure sensor inf ormation ( Pr 20.34, 20.35, and 20.36) fo r your syst em must be keye d into the Va ri- able Frequ ency Drive b efore syst em start-up. To preven t [...]

Repair 311594Z 23 TDC Sensor Kit 15H877 NOTE: TDC Sensor K it 15H877 replaces t he TDC se n- sor. Us e all the n ew parts in the kit. T he kit inc ludes manual 31 1601. 1. Jog the m otor to br ing the lower on the s ide oppo- site fro m the motor to the bot tom of its stroke. 2. Relieve pr essure, pa ge 9. 3. Shut o ff electrical power to t he unit[...]

Repair 24 311594Z Position Sensor NOTE: The Posi tion Sens or (80) m easures m otor posi- tion by d etecting h oles in the motor co upler (28). T he sensor is availa ble sepa rately (see Parts on pag e 45), or as pa rt of the Sensor Circuit Kit 24J305 (s ee manual 311603). 1. Jog the mo tor to br ing the lower on the s ide oppo- site fro m the moto[...]

Repair 311594Z 25 F IG . 13. Position Sensor ,66(1625 &,5&8,7 %2$5'    -      7'& 1$085 6(1625 - %51 %/8 5(' *51 :+7 %/.  35(6685( 75$16'8&(5   -    -?[...]

Repair 26 311594Z Drive Section Slider B earing Kit 15H882 NOTE: Slider Bear ing Kit 15H882 inclu des parts t o rebuild both slider b earing as semblies . Use all the new parts in the kit. The k it include s manual 311616. 1. Jog the mo tor to br ing the pu mp on the s ide being repaired t o the bottom of its st roke. Thi s provide s access to the [...]

Repair 311594Z 27 10. See F IG . 16. Rotate th e crank ar m (4) to al low it to be removed from the o utput shaft (OS). 11. Pull the crank arm/conn ecting rod/ slider piston assembl y (CR) up a nd out of the cylinder. 12. Remove the old bearin gs (8). 13. See F IG . 17. Instal l the two ne w bearing s (8) on the slider piston (9) . The join ts betw[...]

Repair 28 311594Z Drive Li nkage Rebuil d Kit 15H873 NOTE: Drive Link age Rebui ld Kit 15H873 in cludes parts to rebui ld one driv e linkage a ssembly. O rder two k its to rebuild both drive linkage as semblie s. Use all th e new parts in the kit. The k it include s manual 311598. NOTE: Replace the wrist pin b earings ( 7a) in the c on- necting rod[...]

Repair 311594Z 29 Crank Arm Kit 15H88 3 NOTE: Crank Ar m Kit 15H883 i s availab le. Order two kits to re build both crank arm assem blies. Us e all the new parts in the k it. The kit inc ludes manu al 311604. NOTE: Crank Ar m Cover Ki t 15H378 is available to replace b oth crank arm cov ers (21, 32 ). Use al l the ne w parts in th e kit. 1. Jog th [...]

Repair 30 311594Z Motor/Gear Reducer Motor Removal 1. Relieve pr essure, pa ge 9. 2. Shut o ff electrical power to th e unit. NOTE: See F IG . 20 for al l NEMA 1 82/184 TC F rame electric motors. See F IG . 21 for IEC 112M/B 5 and 100L/B5 F rame elec tric motors. 3. While on e perso n supports the motor (19), remove the scr ews (37). Pul l the moto[...]

Repair 311594Z 31 Motor/Coupler is Difficult to Remove NOTE: Use this proced ure only if, after performing steps 1-3 on pa ge 30, the m otor does no t come off the gear reducer e asily. NOTE: During the f ollowing procedure, if the co upler becomes separated f rom the mo tor shaft but remains stuck o n the input shaft, use the 15J8 27 coup ler remo[...]

Repair 32 311594Z[...]

Repair 311594Z 33 Motor Installation NOTE: A NEMA 182/184 TC F rame is r equired to m ate with gear reducer. If the pump i s purchased without a motor yo u must orde r a kit to ma te with the g ear reducer. S ee T ABLE 1. 1. After re moving the old coupler , thorough ly clean the input sha ft and m otor shaft, r emoving any debris . This e nsures p[...]

Repair 34 311594Z Gear Reduce r Seal Kit 15H8 71 NOTE: Gear Reducer Seal Kit 1 5H871 and Out put Shaft Sea l Tool Kit 15J926 are available. Use all th e new parts in the k it. The kits inc lude manu al 311597. NOTE: Do not open the gear re ducer. Opening the gear re ducer void s the war ranty. The g ear redu cer is not fie ld servic eable be yond t[...]

Repair 311594Z 35 11. Install t he two outpu t seals ( 116) as fo llows: a. Place ta pe over the ou tput shaft key way, to pre- vent dama ge to th e new seals. Pack the out put shaft sea l cavi ty with Pa rt No. 1074 11 Grease . b. See F IG . 26 . Push one output sea l (116) on to the output s haft (OS) , with the lip s facing in . c. Remove the s [...]

Repair 36 311594Z Gear Redu cer Repl acement Ki t Disassemb ly NOTE: The Ge ar Reduc er Kit i s availa ble to r eplace the entire g ear reduce r. Use al l the new p arts in the kit. Order Ki t 15H886 for E -Flo 2000 /3000/4000 Pumps or Kit 2895 50 for E -Flo 150 0 Pumps. The kit include s man- ual 31161 5. NOTE: Do not open the gear re ducer. Openi[...]

Repair 311594Z 37 F IG . 28: Gear Reducer Replacement Units with a sensor circuit must use the conductive strain reli ef (74a) to ensure proper grounding of the IS field wire. See page 21. 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-l b (21-27 N•m). Torque to 66-78 in-lb (7.4-8. 8 N•m). Apply a[...]

Repair 38 311594Z Reassembl y NOTE: Kit 15H886 i ncludes a m otor couple r (28), already i nstalle d in the gear redu cer. The coupler fits all NEMA 182/ 184 TC F rame elect ric motors. NOTE: To install a n IEC 112M /B5 or 10 0L/B5 Fram e electric motor, orde r Motor Ada pter Kit 15J89 3. See T ABLE 1 on p age 33, and manual 31 1605. 1. Apply a nti[...]

Repair 311594Z 39 F IG . 29. Sensor Circ uit Installation ,66(1625 &,5&8,7 %2$5'    -      7'& 1$085 6(1625 - %51 %/8 5(' *51 :+7 %/.  35(6685( 75$16'8&(5   -   [...]

Repair 40 311594Z j. T hread the IS field w ire through the condu ctive strain r elief (74a ). Connect the TDC wires to J2, the trans ducer wires to J3, an d the position sen- sor wir es to the two t erminal blocks ( 46). See F IG . 29 and th e Electrical Diagrams , page 12. k. See F IG . 30. Tigh ten the nut (N ) on the co nduc- tive strain r elie[...]

Repair 311594Z 41[...]

Parts 42 311594Z Parts Drive Section ti83 18l 6 12 11 10 2 8 44 9 35 21 28 19a and 19c 5 38 39 4 7 12 32a 12 34 33 31 25c 25b 1 37 20 31 36 32b 19b and 19d 67 68 77 74a or 74 b ti168 90b Detail of Sensor Conduit 76 25a (Re f) 35 (Ref) 44 (Ref) Position Se nsor Parts and Location 46 78 80 79 44 (R ef) ti17 643 a 1 (Ref) 28 (R ef)[...]

Parts 311594Z 43 Fluid Section ti8230 d 44 42 41 25a 13 14 22 16 18 17 45 22 15 3 16 18 17 41 58 72[...]

Parts 44 311594Z Common Parts Ref. No. Part No. Description Qty 1 15H88 6 KIT, 75:1 gear reduce r; E-Flo 2000/ 3000/4000 only ; se e 3116 15 1 289550 KIT, 75: 1 gear redu cer; E-Flo 1500 only ; see 3116 15 1 2† n/a C YLINDER, slider 2 3 n/a ROD, tie 6 4‡ n/ a ARM, cran k 2 5*‡ n/a SCREW, cap, soc ket-head; 5/8-11 x 3 in. (76 m m) 4 6*‡ 1060[...]

Parts 311594Z 45 Parts desi gnated n/a are no t avai lable sep arately . * Parts include d in Dri ve Lin kage Re build Kit 15H8 73 (pur- chase s eparate ly). O rder two k its to reb uild b oth drive link- age asse mblie s. Inc ludes m anual 311598 . † Parts incl uded i n Slider Cyl inder Re build Kit 1 5H874 (p ur- chase s eparate ly). O rder two[...]

Parts 46 311594Z Model-Specific Parts NOTE: A chec kmark ( ✓ ) indicate s an item is used on your pum p. Shaded boxes indi cate that an item is not used. Pump Part No. Series Motor Kit (19) Lower (22) Sensor Circuit (25) Coupler/Motor Mounting Kit (28) Floor Stand Kit (69) 255226 2 55225 2 89552 2 89551 EP0010 B 24F42 8 EP0011 B 24F42 8 ✔ EP002[...]

Parts 311594Z 47 EP1010 C ✔ 24F42 8 ✔ EP1011 B ✔ 24F42 8 ✔✔ EP1020 C ✔ 24F43 6 ✔ EP1021 B ✔ 24F43 6 ✔✔ EP1030 C ✔ 24F44 4 ✔ EP1031 B ✔ 24F44 4 ✔✔ EP1040 C ✔ 24F42 9 ✔ EP1041 B ✔ 24F42 9 ✔✔ EP1050 C ✔ 24F43 7 ✔ EP1051 B ✔ 24F43 7 ✔✔ EP1060 C ✔ 24F44 5 ✔ EP1061 B ✔ 24F44 5 ✔✔ EP3070 B ✔ 24[...]

Parts 48 311594Z EP2010 B ✔ 24F42 8 ✔ EP2011 B ✔ 24F42 8 ✔✔ EP2020 B ✔ 24F43 6 ✔ EP2021 B ✔ 24F43 6 ✔✔ EP2030 B ✔ 24F44 4 ✔ EP2031 B ✔ 24F44 4 ✔✔ EP2040 B ✔ 24F42 9 ✔ EP2041 B ✔ 24F42 9 ✔✔ EP2050 B ✔ 24F43 7 ✔ EP2051 B ✔ 24F43 7 ✔✔ EP2060 B ✔ 24F44 5 ✔ EP2061 B ✔ 24F44 5 ✔✔ EP4070 B ✔ 24[...]

Parts 311594Z 49 Gear Reducer * These parts are includ ed in Ge ar Reducer Seal Ki t 15H871. See manua l 311597. NOTE: To replac e the entir e gear re ducer, order one of the fo llowing kits: • 15H88 6 Gear Redu cer Replac ement Kit, for E-Flo 2000/300 0/4000. See manua l 311615. • 2895 50 Gear Redu cer Replac ement Kit, for E-Flo 1500. Se e ma[...]

Technic al Data 50 311594Z Technical Data NOTE: All brand nam es or mar ks are used fo r identific ation pur poses and are th e trademark s of their respec tive owne rs. Maximu m Working Pressure . . . . . . . . . . . . . . E-Flo 1 500: 425 psi (2.93 MPa , 29.3 bar) E-Flo 2 000: 460 psi (3.22 MPa , 32.2 bar) E-Flo 3 000: 330 psi (2.31 MPa , 23.1 ba[...]

Technica l Data 311594Z 51 Pressure a nd Flow C apability of E -Flo Family w ith 50 Hz Moto r (continuous pro duction use) Fluid Pressure psi (MPa, bar) 350 (2.41, 24.1) 300 (2.10, 21.0) 250 (1.72, 17.2) 200 (1.4, 14.0) 150 (1.03, 10.3) 100 (0.70, 7.0) 50 (0.35, 3.5) 0 Fluid Flow in gpm (lpm) 5 (19) 10 (38) 15 (57) 20 (76) 25 (95) A B C 400 (2.80, [...]

All written and visual data contained in this document reflects t he latest product i nformation available at the time of publica tion. Graco rese rves the right to make changes at any time without notice. This m anual contains English. MM 311594 Graco H eadquarte rs: Min neapol is International O ffices: Bel gium, China, Jap an, Korea GRACO INC. A[...]