Graco 3A3165B, e-Xtreme™ Driver Owner's Manual

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Graco 3A3165B, e-Xtreme™ Driver Owner's Manual | Manualzz

Instructions-Parts

Read all warnings and instructions in this manual and the system manual. Save these instructions.

See pages 3 for model and approvals information.

3A3165B

EN

PROVEN QUALITY. LEADING TECHNOLOGY.

Model Information ............................................... 3

Driver Model ................................................ 3

Repair Kits and Accessories ................................ 4

Related Manuals ................................................ 4

Warnings ........................................................... 5

Component Identification..................................... 8

Installation.......................................................... 9

Fill With Oil Before Using Equipment ............. 9

Power Supply Requirements......................... 9

Hazardous Area Cabling and Conduit

Requirements................................. 10

Grounding ................................................... 10

Connect the Power Supply ........................... 11

Operation ........................................................... 12

Startup ........................................................ 12

Shutdown .................................................... 12

Pressure Relief Procedure............................ 12

Driver Operation .......................................... 12

Maintenance ...................................................... 13

Preventive Maintenance Schedule ................ 13

Change the Oil............................................. 13

Check Oil Level ........................................... 13

Bearing Pre-Load......................................... 13

Error Code Troubleshooting ................................ 14

Standby Mode ............................................. 14

Error Codes Table........................................ 14

Repair................................................................ 16

Replace Output Seal Cartridge ..................... 16

Control Board Replacement ......................... 17

Encoder Replacement ................................. 19

Position Sensor Replacement ....................... 22

Parts.................................................................. 24

Driver Assembly: 24X901 ............................. 24

Mounting Hole Pattern ........................................ 25

Wiring Schematic................................................ 26

Technical Specifications...................................... 27

Graco Standard Warranty.................................... 28

2 3A3165B

Model Information

24X901 A e-Xtreme Driver

II 2 G

Ex db IIA T4 -5°C≤Ta≤50°C

FM15ATEX0060X

IECEx FMG 15.0035X

For Class I, Div. 1, Group D T4.

Class 1, Zone 1, AEx db IIA T4 -5°C≤Ta≤50°C

Ex d IIA T4 Gb -5°C≤Ta≤50°C

Figure 1 Driver Identification Label

• IEC 60079–0: 2011 (Ed 6)

• IEC 60079–1: 2014 (Ed 7)

• EN 60079–0: 2012 +A11:2013 (Ed 6)

• EN 60079–1: 2014 (Ed 7)

• ANSI/ISA 60079–0: 2013 (Ed 6)

• ANSI/UL 60079–1: 2015 (Ed 7)

• FM 3600: 2011

• FM 3615: 2006

• FM 3810: 2005 ti28402a

• CSA C22.2 No. 0.4:2004 (R2013)

• CSA C22.2 No. 0.5:82 (R2012)

• CSA C22.2 No. 30:M86 (R2012)

• CAN/CSA C22.2 60079–0:2011

• CAN/CSA C22.2 60079–1:2011

• CAN/CSA C22.2 No. 61010.1:2012

Graco distributor if dimensional information on the flameproof joint is necessary.

3A3165B 3

4

Repair Kits and Accessories

24X901 e-Xtreme Driver

Connection kits, to mount an e-Xtreme

Driver to an existing pump lower. Kits include tie rods, tie rod nuts, adapter, and coupler.

— — — Output Seal Cartridge (19); see

Parts, page 24

.

255143 Wall Bracket; see manual 311619.

16W645 ISO 220 Silicone-Free Synthetic Gear Oil;

1 quart (0.95 liter); order 2

— — — Position Sensor; see

Position Sensor Replacement, page 22

.

24U938 Encoder; see

Encoder Replacement, page 19

.

108675 Wiring Post

16U113 Knob Kit (36); see

Parts, page 24 . Includes replacement

parts for one knob.

— — — Software Update Kit

288207 For Xtreme 145 and 180cc Lower

3A3164

311619 e-Xtreme Ex35/Ex45 Sprayer

Pump Mounting Kit Manual

3A3165B

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation 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.

3A3165B or solvent 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).

• 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.

equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable vapors. To help prevent fire and explosion:

• Clean plastic parts only in well ventilated area.

• Do not clean with a dry cloth.

• Do not operate electrostatic guns in equipment work area.

• To prevent the risk of electrostatic sparking, the equipment’s non-metallic parts should be cleaned only with a damp cloth.

• The aluminum housing may spark upon impact or contact with moving parts, which may cause fire or explosion. Take precautions to avoid such impact or contact.

• All flameproof joints are critical to the integrity of the driver as approved for hazardous locations and are not repairable if damaged. Damaged parts must be replaced only with genuine Graco parts with no substitutions.

5

6

Warnings

This equipment must be grounded. 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 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.

• Do not expose to rain. Store indoors.

• Wait five minutes before servicing after power is removed.

Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

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

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

3A3165B

3A3165B

Warnings

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read Safety Data Sheets (SDSs) 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.

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.

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 in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request Safety Data Sheets (SDSs) from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’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.

7

Component Identification

8

S

Y

X

Z

ZZ

H

K

L

N

P

C

G

Ref.

Description

A Driver

Lift Ring

Oil Drain Plug

Driver Output Shaft

Oil Sight Glass

Status Indicator Light (LED)

Pressure Control Knob

Oil Fill Cap (vented)

Power Switch (Lock-out tag-out equipped)

Electrical Junction Box

Conduit Entry

Electrical Junction Box Cover

Ground Screws

3A3165B

Installation

Installation of this equipment involves potentially hazardous procedures. Only trained and qualified personnel who have read and who understand the information in this manual should install this equipment.

Before using the equipment, open the fill cap (P) and add Graco Part No. 16W645 ISO 220 silicone-free synthetic gear oil. Check the oil level in the sight glass

(K). Fill until the oil level is near the halfway point of the sight glass. The oil capacity is approximately

Improper wiring may cause electric shock or other serious injury if work is not performed properly.

Have a qualified electrician perform any electrical work. Be sure your installation complies with all

National, State and Local safety and fire codes.

See the table below for power supply requirements.

The driver requires a dedicated circuit protected with a circuit breaker. .

Phase Hz supplied with the equipment.

24X901 200–240

Vac

1 50/60 2.5

Select the minimum cord wire gauge based on length according to the table below.

50 ft (15.2 m)

100 ft (30.4 m)

200 ft (61 m)

12 AWG

10 AWG

8 AWG mm 2

3.3

5.3

13.3

Figure 2 Sight Glass and Oil Fill Cap

Only use Graco GBL oil (Graco part number

16W645). Any other oil will not lubricate properly and can cause damage to the drive train.

3A3165B 9

Installation

All electrical wiring in the hazardous area must be encased in Class I, Division I, Group D approved explosion-proof conduit. Follow all National, State, and Local electric codes.

A conduit seal is required within 18 in. (457 mm) of the driver for the US and Canada (see

Connect the Power Supply, page 11

).

All cables must be rated at 70°C.

This equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.

The driver is grounded through the power cord.

Use appropriate conduit, connectors, and cable glands rated for ATEX II 2 G. Follow all National,

State, and Local electric codes.

All cable glands and cables must be rated at 70°C.

provided if local code requires redundant grounding connections.

Loosen the ground screw (ZZ) and attach a ground wire (Graco part 244524 - not supplied). Tighten the ground screw securely. Connect the other end of the ground wire to a true earth ground.

10 3A3165B

Installation

Improper wiring may cause electric shock, fire and explosion, or other serious injury if work is not performed properly. Have a qualified electrician perform any electrical work. Be sure your installation complies with all National, State and Local safety and fire codes.

1.

Shut off the fused safety switch (B) and follow the appropriate lock-out/tag-out procedures.

Typical fixed installation for wall mounted systems shown below:

3.

Install the ground wire to the labeled ground lug in the back of the junction box. See

Grounding, page 10 .

4.

Install incoming power wires into the opposite side of the disconnect labeled 2T1 and 4T2, and torque to 7 in-lb (0.8 N•m).

5.

Reinstall junction box cover (Z) and screws (J).

Torque screws to 15–20 ft-lb (21–27 N•m).

1L1 and 3L2.

Be sure that no wires are pinched between the electronics cover and the driver housing. Wires will be damaged and create an electrical hazard and/or fire and explosion hazard if pinched.

1

2

Tighten disconnect block terminals to 7 in-lb

(0.8 N•m). Do not over-tighten.

Tighten cover screws to 15 ft-lb (20.3 N•m).

3

A conduit seal (D) is required within 18 in.

(457 mm) of the driver for the US and Canada.

25 in-lb maximum (terminal bushings)

4

2.

To install wiring, locate the electrical junction box

(Y). Remove four screws (J) and junction box cover (Z). Wires will already be installed in the front side of the disconnect in terminals labeled

1L1 and 3L2.

† Conduit not supplied.

‡ Power cord not supplied.

3A3165B 11

Operation

1.

Unlock the fused safety switch (B) and turn it on.

See

Connect the Power Supply, page 11

2.

Turn the power switch (S) ON.

3.

Check that the status indicator (L) is lit (steady on).

4.

See

Driver Operation, page 12

for further instructions.

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1.

Turn the power switch (S) OFF.

2.

Shut off and lock out the fused safety switch (B).

See

Connect the Power Supply, page 11

.

3.

Relieve all fluid pressure as explained in your separate system manual.

Follow the

Pressure Relief Procedure, page 12 .

The driver will adjust the speed to maintain a constant fluid pressure.

1.

Pull the Pressure Control Knob (N) out to set.

2.

Turn the Pressure Control Knob (N) fully counterclockwise to 0.

3.

Turn the knob clockwise to increase the pressure, or counterclockwise to decrease the pressure.

Push the knob in to lock.

12 3A3165B

Maintenance

The operating conditions of your particular system determine how often maintenance is required.

Establish a preventive maintenance schedule by recording when and what kind of maintenance is needed, and then determine a regular schedule for checking your system.

Check the oil level in the sight glass (K). The oil level should be near the halfway point of the sight glass when the unit is not running. If low, open the fill cap (P) and add Graco Part No. 16W645 ISO

220 silicone-free synthetic gear oil as required. The oil capacity is approximately 1.0–1.2 quarts (0.9–1.1

200,000–300,000 cycles. After the break-in period, change the oil once a year. Order two ISO 220 silicone-free synthetic gear oil (Graco Part No.

16W645).

1.

Place a minimum 2 quart (1.9 liter) container under the oil drain port. Remove the oil drain plug (G). Allow all oil to drain from the driver.

2.

Reinstall the oil drain plug (G). Torque to 25–30 ft-lb (34–40 N•m).

Do not over-torque. The drain plug can become stripped and damaged.

3.

Open the fill cap (P) and add Graco Part No.

16W645 ISO 220 silicone-free synthetic gear oil.

Check the oil level in the sight glass (K). Fill until the oil level is near the halfway point of the sight glass. The oil capacity is approximately 1.–1.2

The bearing pre-loads (R) are factory set and are not user adjustable. Do not adjust the bearing pre-loads.

4.

Reinstall the fill cap.

3A3165B 13

Error Code Troubleshooting

Error codes can take two forms: shuts down the driver.

may continue to run past the set limits until the system absolute limits are reached.

indicator (L) on the driver. The blink code given below indicates the sequence. For example, blink code 2 indicates two blinks, a pause, then two more blinks, and then repeats.

the power switch (S) to the OFF position for at least

30 seconds before turning back ON.

When slow blinking is displayed, the driver has entered Standby Mode. When the driver is on and pressurized but the pump has not moved any material, the driver will enter Standby Mode.

Standby Mode will be exited when:

• Material starts to dispense and causes the pump to move, OR

• The pressure control knob (N) is adjusted, OR

• The power switch (S) is cycled OFF and ON

3

4

1

2

14

Alarm

Alarm

Alarm

Deviation

The pump is diving rapidly.

• Verify that material is being properly fed to the pump.

• Verify that the check valve is installed and is properly working.

• Verify that line voltage is within the range specified in

Technical Specifications, page 27

.

• Use the recommended cord in

Power Supply Requirements, page 9

.

• Cycle power and check status indicator (L) to see if the error is still active.

• Verify that line voltage is within the range specified in

Technical Specifications, page 27

.

• Cycle power and check status indicator (L) to see if the error is still active.

The temperature of the system is near the maximum operation temperature. The performance has been reduced to prevent the driver from completely shutting down.

• Check fan operation. Clean the fan and driver housing.

• Reduce pressure, duty cycle, or gun tip size.

• Move the unit to a cooler location.

3A3165B

Error Code Troubleshooting

5

6

7

8

9

Deviation

Alarm

Alarm

Alarm

Alarm

• Warm equipment.

Motor is running too hot. Allow unit to cool.

• Check fan operation. Clean the fan and driver housing.

• Reduce pressure, duty cycle, or gun tip size.

• Move the unit to a cooler location.

The control board is running too hot. Allow the unit to cool.

• Check fan operation. Clean the fan and driver housing.

• Reduce pressure, duty cycle, or gun tip size.

• Move the unit to a cooler location.

• Cycle power and check status indicator (L) to see if the error is still active.

• Calibrate the encoder (this code will blink if calibration is in progress).

Contact Information

Graco Standard Warranty, page 28

).

• Cycle power and check the status indicator (L) to see if the error is still active.

• Verify that the internal connections are intact.

Contact Information

Graco Standard Warranty, page 28

).

10 Alarm

11

12

13, 14

Alarm

Alarm

Alarm

Slow Blink Deviation your Graco distributor or Tech Service for more information).

• Cycle power and check status indicator (L) to see if the error is still active.

Contact Information

Graco Standard Warranty, page 28

).

• Cycle power and check status indicator (L) to see if the error is still active.

Contact Information

Graco Standard Warranty, page 28

).

• Cycle power and check status indicator (L) to see if the error is still active.

Contact Information

Graco Standard Warranty, page 28

).

See

Standby Mode, page 14

.

3A3165B 15

Repair

To avoid electric shock, fire and explosion hazard, and/or moving parts hazard, turn off equipment power and shut off power at the main circuit breaker before repairing. Wear appropriate protective equipment when in work area. Wait five minutes before servicing.

Graco distributor for genuine replacement fasteners.

M8 x 30 socket-head cap screws of Class 12.9 steel or better with a minimum yield strength of 1100 MPa

(160,000 psi) are acceptable alternatives.

1.

Stop the pump at the bottom of its stroke. Shut off and lock out power to the driver.

2.

Follow the

Pressure Relief Procedure, page 12

.

3.

Disconnect the lower from the driver, as explained in your separate system manual.

4.

Drain the oil from the driver. See

Change the Oil, page 13

.

5.

Reinstall the oil drain plug. Torque to 25–30 ft-lb

(34–40 N•m).

6.

Unscrew the output cartridge (19) from the driver.

See

Parts, page 24

.

7.

Install the new output cartridge. Torque to 70–80 ft-lb (95–108 N•m).

8.

Fill with oil. See

Change the Oil, page 13

.

9.

Reconnect the lower to the driver.

10. Turn on power and resume operation.

16 3A3165B

Repair

To avoid damage to the control board, wear grounding strap (Graco Part No. 112190) and ground appropriately.

1.

Remove power from the driver. Follow appropriate lock-out/tag-out procedures. Wait five minutes before servicing. Wait five minutes before servicing.

2.

Follow the Pressure Relief Procedure, page 12

.

3.

Decouple the pump lower from the driver per the system manual.

The main control board assembly manages the operation of the driver. It is permanently attached to the electronics cover.

• 6 mm Hex Wrench

• Phillips Screwdriver (#1)

• Torque Wrench (15 ft-lb, 20 Nm)

1.

Remove the screws (J) and junction box cover

(Z) from the electrical junction box (Y). Remove screw (Ys) and sleeve housing.

2.

Disconnect wires from terminal bushings L1 and

L2.

3.

Remove the ground lug and disconnect the green ground wire.

4.

Disconnect wires from the opposite side of the disconnect in terminals labeled 2T1 and 4T2.

3A3165B 17

Repair

To avoid equipment damage, carefully support the cover when removing the last bolt. Hold the cover horizontally and take care that the wires are not pulled tight.

1.

Remove the 12 bolts (CB) that hold on the electronics cover using a 6 mm hex wrench.

Place bolts in a safe location.

2.

Pull the cover straight off of the alignment pins that hold the cover in place.

3.

Support the cover after it has been removed to prevent putting excess strain on the wires inside.

1.

Plug in all connectors. Ensure all connectors

(encoder, temperature sensor, and motor) are securely attached to the control board. See

Wiring Schematic, page 26

.

2.

Secure loose motor wires into the clip inside the housing (see

Wiring Schematic, page 26

).

3.

Reinstall electronics cover onto center housing.

4.

Install the 12 bolts using a 6 mm hex wrench.

5.

Torque the bolts to 15 ft-lb (20 Nm).

See

Connect the Power Supply, page 11 .

cover. To replace the control board the entire electronics cover must be replaced.

1.

To disconnect the control board unplug the position sensor, encoder, temperature sensor, and motor from the control board (see

Wiring Schematic, page 26

).

2.

Remove motor wires from clip inside housing

(see

Wiring Schematic, page 26

).

3.

Set the electronics cover/control board aside.

and must be able to cycle freely with no obstructions.

1.

Cycle power to the driver by first turning the power switch (S) OFF, and then ON again.

2.

Wait for the status indicator LED (L) to turn on solid or start blinking.

3.

Within 30 seconds, rapidly turn the pressure control knob (N) back and forth from 0 to 10 at least five times. If the status indicator LED (L) was solid before, it will begin blinking an encoder calibration error (code 8) during the calibration process.

4.

The driver output shaft (H) will run up and down slowly over the course of several minutes.

5.

Midway through the auto-calibration process the driver output shaft (H) will pause as it moves to the next step.

6.

The driver output shaft (H) will move up and down faster 5–6 times.

7.

Ensure the auto-calibration process is complete before continuing (wait for the LED to stop blinking).

Be sure that no wires are pinched between the electronics cover and the driver housing. Wires will be damaged and create an electrical hazard and/or fire and explosion hazard if pinched.

See the system manual.

18 3A3165B

Repair

To avoid damage to the encoder and control board, wear grounding strap (Graco Part No. 112190) and ground appropriately.

1.

Remove power from the driver. Follow appropriate lock-out/tag-out procedures. Wait five minutes before servicing. Wait five minutes before servicing.

2.

Follow the Pressure Relief Procedure, page 12

.

3.

Decouple the pump lower from the driver per the system manual.

The encoder is used by the driver for two purposes.

First, the encoder tells the control board where the motor is in its mechanical rotation and uses that information to properly control the motor torque.

Second, it controls stroke length by allowing the control board to count the number of complete motor rotations.

• 6 mm Hex Wrench

• .050 in Hex Wrench

• Phillips Screwdriver (#1)

• Torque Wrench (15 ft-lb, 20 Nm)

• Blue (medium) thread locking compound

To avoid equipment damage, carefully support the cover when removing the last bolt. Hold the cover horizontally and take care that the wires are not pulled tight.

1.

Remove the 12 bolts (CB) that hold on the electronics cover using a 6 mm hex wrench.

Place bolts in a safe location.

2.

Pull the cover straight off of the alignment pins that hold the cover in place.

3.

Support the cover after it has been removed to prevent putting excess strain on the wires inside.

3A3165B 19

Repair

1.

Remove the 4 bolts that hold on the motor cover using a 6 mm hex wrench. Place bolts in a safe location.

2.

Set motor cover aside.

1.

If replacing the encoder cable (AE/AF) also, place the encoder connector cable through the motor housing.

smaller of the two connectors.

1.

If replacing the encoder cable also, unplug the encoder cable (AE/AF)from the control board and the encoder and remove.

2.

Loosen the 2 hub set screws (AA) using the included .050” hex wrench.

3.

Remove the 2 mounting screws (AC) with a

Phillips head screwdriver.

4.

Pull encoder (AB) off of rotor shaft.

the 2 Phillips head mounting screws. All other bolts should remain in place.

5

AE Encoder connector (smaller)

AF Control board connector (larger)

2.

Slide the new encoder onto the rotor shaft.

3.

Apply a small amount of blue (medium) thread locker to the 2 Phillips head mounting screws

(AC) and secure encoder mounting flange (AB) to motor housing (AD).

4.

Remove the 2 set screws (AA) from the encoder hub using the included .050 in. hex wrench.

5.

Apply a small amount of blue (medium) thread locker to the set screws (AA) and screw back into the encoder. Tighten to 50 +/- 5 in-oz (0.35 N•m).

6.

Plug encoder cable into the encoder (AE). If the encoder cable was also replaced, plug the other end into the control board (AF). See

Wiring Schematic, page 26

.

AA

Set screws 5 50 +/- 5 in-oz (0.35

N•m).

AB Encoder mounting flange

AC Phillips head mounting screws

AD Rotor Bearing Housing

20 3A3165B

Repair

1.

Reinstall motor cover onto driver housing.

Be sure that no wires are pinched between the electronics cover and the driver housing. Wires will be damaged and create an electrical hazard and/or fire and explosion hazard if pinched.

1.

Plug the position sensor, encoder, temperature sensor, and motor into the control board (see

Wiring Schematic, page 26

).

2.

Secure loose motor wires into the clip inside the housing (see

Wiring Schematic, page 26

).

3.

Reinstall electronics cover onto center housing.

4.

Install the 12 bolts using a 6 mm hex wrench.

5.

Torque the bolts to 15 ft-lb (20 Nm).

2.

Install the four bolts and washers that hold on the motor cover using a 6 mm hex wrench. Ensure the lock washers are still in place.

3.

Torque the bolts to 15 ft-lb (20 Nm).

4.

Follow the

Power Unit — Run Calibration

Procedure, page 18 .

See the system manual.

3A3165B 21

Repair

To avoid damage to the encoder and control board, wear grounding strap (Graco Part No. 112190) and ground appropriately.

1.

Remove power from the driver. Follow appropriate lock-out/tag-out procedures. Wait five minutes before servicing. Wait five minutes before servicing.

2.

Follow the Pressure Relief Procedure, page 12

.

3.

Decouple the pump lower from the driver per the system manual.

The position sensor is used to determine where the driver output shaft (H) is in the stroke.

• 6 mm Hex Wrenches

• 13 mm Open-Ended Wrench

• 6 mm Open-Ended Wrench

• Phillips Screwdriver (#2)

• Torque Wrench (15 ft-lb, 20 N•m)

To avoid equipment damage, carefully support the cover when removing the last bolt. Hold the cover horizontally and take care that the wires are not pulled tight.

1.

Remove the 12 bolts (CB) that hold on the electronics cover using a 6 mm hex wrench.

Place bolts in a safe location.

2.

Pull the cover straight off of the alignment pins that hold the cover in place.

3.

Support the cover after it has been removed to prevent putting excess strain on the wires inside.

22 3A3165B

Repair

3.

Tighten the jam nut on the position sensor finger tight.

1.

Unplug the position sensor (AR) from the control board (see

Wiring Schematic, page 26

).

2.

Loosen the position sensor jam nut (AS) using a 13 mm wrench.

3.

Unscrew the position sensor (AR) from the center housing using a 6 mm open ended wrench.

Do not use a wrench to tighten the jam nut.

Damage to the position sensor may result.

4.

Plug the position sensor into the control board

(see

Wiring Schematic, page 26

).

to prevent twisting.

1.

Carefully screw the replacement position sensor into the center housing.

Be sure that no wires are pinched between the electronics cover and the driver housing. Wires will be damaged and create an electrical hazard and/or fire and explosion hazard if pinched.

1.

Plug in all connectors. Ensure all connectors

(encoder, temperature sensor, and motor) are securely attached to the control board. See

Wiring Schematic, page 26

.

2.

Secure loose motor wires into the clip inside the housing (see

Wiring Schematic, page 26

).

3.

Reinstall electronics cover onto center housing.

4.

Install the 12 bolts using a 6 mm hex wrench.

wires will have to be rotated while the position sensor is installed to prevent them from being twisted.

2.

Use the 6 mm wrench to complete the installation of the position sensor. Be careful not to use excessive torque. Stop once the position sensor bottoms out in the bore.

5.

Torque the bolts to 15 ft-lb (20 Nm).

See the system manual.

Do not over tighten the position sensor.

Damage to the position sensor may result.

3A3165B 23

Parts

3

9

Ref.

Part

1 — — — HOUSING, driver

116343

15F931

SCREW, ground; M5 x 0.8

RING, lift

13

14

19

24

25

27

15H525 CAP, oil fill

24E315 SIGHT GLASS

— — — CARTRIDGE, output seal

— — — SCREW, cap, socket head; M8 x 1.25; 30 mm

15H432 PLUG, oil drain

— — — COVER, electrical junction box

33▲ 16T764 LABEL, warning

1

4

1

1

1

3

1

1

1

1

Ref.

Part

34▲ 17K476 LABEL, warning

(English/French/Spanish)

17J430 LABEL, warning, bag

(Dutch/German/Swedish,

36

Polish/Russian, Italian/Turkish)

16U113 KIT, knob; kit includes

38

43 replacement parts for one knob

16W645 OIL, gear, synthetic; ISO 220 silicone-free; 1 quart (0.95 liter);

(not shown)

— — — WASHER, lock, spring; no. 8

44 16U979 LABEL, torque spec

45

46

— — — HOUSING, junction box

— — — SCREW, shcs

2

2

1

1

4

1

1

1

▲ Replacement Danger and Warning labels, tags, and cards are available at no cost.

Items marked — — — are not available separately.

24 3A3165B

Mounting Hole Pattern

3A3165B

6.186 in. (157 mm)

6.186 in. (157 mm)

Four 3/8–16 Mounting Holes

Six 5/8–11 Tie Rod Holes:

• 8 in. (203 mm) x 120° bolt circle

OR

• 5.9 in. (150 mm) x 120° bolt circle

15.6 in. (395 mm)

15.75 in. (400 mm)

25

Wiring Schematic

Install Motor Connector Under Clip

Motor Temp

Motor Power

Token Cable

Encoder

Hall Sensor

Reed Switch (not used)

TOL 1

TOL 2

CC

DD

FF

EE

J6

J9 J7

GG

J2

26 3A3165B

Technical Specifications

Input voltage/power

Minimum circuit breaker size

Maximum continuous cycle rate

Maximum force

Power inlet port size

Ambient temperature range

Sound data

Oil capacity

Oil specification

Weight

Minimum recommended generator size

200–240 VAC single phase, 50/60 Hz, 2.5 kVA

15 A

44 cpm

4,200 lbf 18.7 kN

3/4–14 npt(f)

25° – 120° F -5° – 50° C

Less than 70 dB(A)

1.5 quarts 1.4 liters

Graco Part No. 16W645 ISO 220 silicone-free synthetic gear oil

99 lb 45 kg

5 kW

3A3165B 27

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use.

With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized

Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS

INCLUDING

FOR

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available.

Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO

AND

MATERIALS OR manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en

Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

For the latest information about Graco products, visit www.graco.com.

For patent information, see www.graco.com/patents.

order, contact your Graco Distributor or call to identify the nearest distributor. Phone:

Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

www.graco.com

Revision B – February 2016

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