Operation, Repair, and Parts ToughTek™ ToughTek™ F340e F340e

Operation, Repair, and Parts ToughTek™ ToughTek™ F340e F340e

Operation, Repair, and Parts

For models, related manuals, and

Agency approvals, see page 3.

600 psi (4.13 MPa, 41.3 bar) Maximum

Fluid Working Pressure

3A3109C

EN

PROVEN QUALITY. LEADING TECHNOLOGY.

Models............................................................... 3

Related Manuals ................................................ 3

Agency Approvals............................................... 3

Warnings ........................................................... 4

Component Identification..................................... 7

Overview ..................................................... 7

Component Identification Table..................... 7

Fluid Drain/Purge Valve................................ 8

Motor Power Switch ..................................... 8

Applicator Ball Valve (17J703) ...................... 8

Install the Remote Switch ............................. 9

Pump Control Settings ................................. 9

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

Setup................................................................. 11

Flush ................................................................. 12

Mix the Material .................................................. 13

Prime with Material ............................................. 14

Spray................................................................. 15

Prevent Pack-out ......................................... 15

Before Starting or Stopping Material

Flow .............................................. 15

Sprayer Performance ................................... 15

Spraying...................................................... 15

Spray Adjustments (Pole Spray Applicator Kit

24Y619)................................................ 16

Air Flow Valve Adjustment ............................ 16

Material Flow Adjustment ............................. 16

Spray Techniques ........................................ 17

Installing Nozzle Retaining Cap..................... 17

Pressure Relief Procedure .................................. 18

Hopper Removal ................................................ 19

Shutdown........................................................... 19

Lifting Instructions............................................... 19

Maintenance ...................................................... 20

Daily Maintenance ....................................... 20

Water Exposure ........................................... 20

Preventative Maintenance ............................ 20

Corrosion Protection .................................... 20

Troubleshooting.................................................. 21

Mechanical/Fluid Flow .................................. 21

Electrical ..................................................... 22

Notes................................................................. 24

Repair................................................................ 25

Replace Pump Lower ................................... 25

Replace Pump Components ......................... 26

Notes................................................................. 29

Parts.................................................................. 30

Replacement Parts and Accessories.................... 37

Technical Specifications...................................... 39

Graco Standard Warranty.................................... 40

2 3A3109C

Models

Includes 1 :::

100–120 VAC 200–240 VAC

Qty.

25A500 25A501 25A502 25A503 25A504 25A505 25A506 25A507

1 ✔ ✔ ✔ ✔ Remote Switch

1 in. x 25 ft

Material Hose

2 ✔ ✔ ✔ ✔

1 in. Pole

Spray

Applicator

242005 -

Australia

Adapter Cord

Set

242001 -

Europe Adapter

Cord Set

1

1

1

✔ ✔

1 For other parts included in all four base models, see

Parts, page 30 . Some kits listed in Parts are not included

in the four base models listed above, but can be purchased with them (these kits are noted as such).

Manuals are available at www.graco.com.

Component manuals in English:

3A3244

3A3112

Pole Spray Applicator 24Y619

ToughTek F340e Remote Switch

Accessory Kit 17G554

25A504

25A506

3A3109C 3

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.

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power cord before servicing equipment.

• Connect only to grounded electrical outlets.

• Ensure ground prongs are intact on power and extension cords.

• Do not expose to rain. Store indoors.

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).

• 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 applicator firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic or conductive.

equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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

4 3A3109C

3A3109C

Warnings

Powerful suction could cause serious injury.

• Never place hands near the pump fluid inlet when pump is operating or pressurized.

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

• 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.

• 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.

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

• Do not use chlorine bleach.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

5

Warnings

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce

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

• Do not put your hand over the fluid outlet.

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

checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

6

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.

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.

3A3109C

Component Identification

A

B

C

E

F

H

J

Electric Motor

Pump Lower

Fluid Drain/Purge Valve

Remote Control Switch (optional)

Fluid Outlet

Flow Adjustment Knob

Hopper

P

S

L

M

T

U

Control Board Status Light

Plug

Hopper Pin

Motor Power Switch

Outlet Check Valve

Hopper Latch

3A3109C 7

Component Identification

To avoid injury from splashing fluid, never open a cam-lock hose or applicator fitting while there is pressure in the fluid line. See

Pressure Relief Procedure, page 18 .

Open the drain/purge valve (C) to relieve pressure if pump or hose pack-out occurs, or to relieve pressure inside the hose. Close valve when spraying.

The motor power switch (S) must be in the ON for the sprayer to pump material.

OFF

ON

Power is disconnected. The motor will not run.

The motor will run continuously at a speed determined by the flow adjustment knob.

To prevent material hardening in fluid drain/purge valve, flush the valve after every time it is used.

See

Flush, page 12

.

Additional accessory kit that can be installed on the end of the 1 in. ID, 25 ft material hose (88) directly before the pole spray applicator (89). The applicator ball valve (1, 2) can be used to stop material flow, but only after the pump has been stopped first. Do NOT use the valve to stall the pump.

8 3A3109C

Component Identification

The remote switch is an additional accessory kit and does not come with Models 25A500, 25A501,

25A504, and 25A505. The kit part number is 17G554.

See manual 3A3112 for remote switch installation and replacement.

to the hose or pole spray applicator (follow the illustrations below). The remote switch will fit on hoses/applicators sized .75 in. up to 1.25 in.

ON

OFF

Remote

Control

The motor will run continuously at the speed determined by the flow adjustment knob (K).

The motor will not run. There is still power to the unit.

The “Remote Control” setting allows the user to control ON/OFF functionality of the pump through the remote toggle switch. When the remote toggle switch is installed and the pump control settings are set to “Remote

Control”, the toggle switch can be used to turn the pump ON and

OFF (see descriptions above).

3A3109C 9

Grounding

The 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.

Ground the sprayer by plugging it into an outlet that is properly installed and grounded in accordance with all local codes and ordinances. Do not modify the power cord provided; if it does not fit the outlet, have the proper outlet installed by a qualified electrician.

• Use only a 3-wire extension cord that has a grounding plug and a grounding receptacle that accepts the plug on the product.

• Make sure your extension cord is not damaged. If an extension cord is necessary, use 12 AWG (2.5

mm 2 ) minimum to carry the current that the product draws.

• An undersized cord results in a drop in line voltage and loss of power and overheating.

while using this product. Power sources with a GFCI are not recommended.

200–240 VAC, 1 phase, 50/60 Hz

One separate, dedicated circuits rated at minimum of

10 A each

One IEC 3-20 C20 Plugs

100–120 VAC,

50/60 Hz

One separate dedicated circuits rated at minimum of

15 A each

One NEMA 5–15A Plug

For 120V units, use a dedicated 15 amp circuit.

Euro CEE7 (Europe)

AS/NZS (Australia)

10 3A3109C

Setup

To avoid tipping over, ensure cart is on a flat and level surface. Failure to do so could result in injury or equipment damage.

1.

Turn the motor power switch (S) to OFF.

3.

Check Throat Seal Liquid (TSL) level in packing nut (D). Fill 1/2 full with TSL.

2.

Ground sprayer (see

Grounding, page 10

). Plug the power cord into a dedicated 15 amp, 120 V circuit (or a 10 amp, 230 V circuit, depending on model).

4.

Connect air supply to applicator.

5.

Attach hose to applicator fluid inlet and pump fluid outlet (F), then secure Velcro straps (V) around the cam lock fitting.

6.

Flush the system with water before using (see

Flush, page 12 ).

3A3109C 11

Flush

3.

Place applicator outlet in a waste container. The waste container must be large enough to hold all dispensed material.

Failure to flush prior to material curing in the system will result in damage to system and may require replacement of all system parts in contact with the material.

If the fluid/drain purge valve has been used to relieve pressure, the valve must be flushed to prevent material hardening in fluid/drain purge valve. If that is not sufficient, remove, disassemble, and clean the valve then reinstall.

• Flush if the materials in the system are about to reach their cure time.

• Flush any time the flow rate starts to decrease as this is a sign that material is starting to thicken and cure.

• Always flush the system at least twice, draining all water between flushes then replacing with clean water.

• Flush using water only.

1.

Relieve pressure (see

Pressure Relief Procedure, page 18 ).

2.

Remove applicator tip and retainer.

ti21632a

4.

Turn motor power switch (S) on.

5.

Turn adjustment knob (H) clockwise slowly to increase pressure, until a steady stream flows from gun.

6.

When the material level in the hopper is within a few inches of the material inlet at the bottom: a.

Scrape the material down the sides of the hopper.

b.

Fill the hopper with water as the material runs out and continue dispensing.

7.

Keep the hopper filled with water while dispensing.

adjustment knob (H) when the material exiting the hose changes to water.

8.

When water begins to exit the applicator outlet, turn the motor power switch (S) to OFF to stop dispensing.

9.

Place applicator in the system hopper with the outlet pointing down to enable fluid circulation.

12 3A3109C

Mix the Material

10. Circulate clean water: a.

Fill the system hopper with clean water.

b.

Use a scrub brush to scrub the walls of the hopper.

c.

Turn the motor power switch (S) to ON to begin circulating water.

d.

While pumping, open the fluid drain/purge valve. Allow the water to flush out any material to prevent material hardening in the valve. Once the water appears clean, close the fluid drain/purge valve.

e.

Turn the motor power switch (S) to OFF.

f.

Place applicator outlet in a waste container.

g.

Turn the motor power switch (S) to ON to dispense into a waste container.

h.

Dispense into a waste container until hopper is almost empty then turn the motor power switch (S) to OFF.

i.

Repeat this entire “Circulate clean water” step one more time to ensure system is thoroughly flushed.

11. Remove the remaining material with a hose clean-out ball. See

Replacement Parts and Accessories, page 37

for a list of available clean-out balls and appropriate hose sizes to use with them.

a.

Remove the applicator from the end of the hose and place the hose outlet back in the waste container.

b.

Remove the hose inlet from the pump outlet and place a hose clean-out ball within the hose inlet. The ball must be wetted down before inserting.

c.

Reattach the hose to the pump outlet and turn the motor power switch (S) to ON to resume flushing the hose.

d.

The hose clean-out ball will be pushed out of the hose after several minutes. Once the ball is pushed through the hose, turn the motor power switch (S) to OFF and repeat the entire process listed in step 10 one time to ensure the system is thoroughly flushed.

12. Turn compressed air on to blow out any material that may have back-flowed into the air lines while flushing (this will prevent air line pack out).

13. After performing the previous step at least twice, drain remaining water from system: a.

Place a drain pan beneath pump lower inlet d.

connection.

b.

Detach pump from hopper (see

Hopper Removal, page 19 ).

c.

Use a screwdriver to lift the pump lower inlet ball. This will drain the remaining material from the pump lower. When the pump stops draining, release the pump lower inlet ball.

Reattach pump to hopper.

e.

Starting at the pump, raise the hose bundle above your head and slowly move towards the applicator. As you move towards the applicator, the remaining fluid in the hose will drain from the applicator into the bucket.

14. Dispose of all waste material in accordance with local rules and regulations. See manufacturer’s

SDS for additional information.

Always follow the material manufacturer’s instructions for the material being sprayed. Material must be thoroughly mixed to a smooth consistency before loading it in the hopper.

• Pay close attention to the work life of the material being used.

• Only mix the material kits as needed. Do not let mixed material sit longer than necessary.

• Scrape material down the sides of the hopper as the hopper material level lowers. Do not let older material cure on the walls.

• To ensure that all material in the hopper is used while fresh, occasionally wait until the hopper is almost empty before refilling.

Material left on the throat seal can dry out and damage the seal. Always stop the pump at the bottom of the stroke to avoid damage to the throat seal.

3A3109C 13

Prime with Material

To prevent material curing in system, never load material into a dry system. Loading material into a dry system will cause the material to stick to internal components and cure, causing damage and requiring replacement of those parts.

The applicator nozzle or tip must be removed during priming. Always push out any remaining water into a waste container before circulating material. Always circulate clean material back into the hopper for a few minutes before beginning to spray.

1.

Mix the Material. See

Mix the Material, page 13

.

2.

Turn the flow adjustment knob (H) counterclockwise until it stops.

3.

Remove tip from applicator.

4.

Fill the clean hopper with material to be sprayed.

5.

Place hose outlet in a 5 gallon waste container.

6.

Turn the motor power switch (S) to ON.

7.

Turn the flow adjustment knob (H) clockwise slowly to increase pressure, until water is purged out and a steady stream of material flows from applicator.

8.

To stop dispensing, turn adjustment knob counterclockwise until it stops.

9.

Place the hose outlet into the hopper.

10. Recirculate a few gallons of material to be sure the material is flowing properly.

11. Turn the flow adjustment knob (H) counterclockwise to stop the pump.

12. Install the applicator without a tip onto the hose and pump material until material has been pushed out of the applicator, then stop the pump.

13. Install a tip onto applicator (see applicator manual

3A3244). The system is now primed and ready to spray.

To prevent damage to pump seals caused by cavitation, run the pump slowly until the system is primed.

14 3A3109C

Spray

To avoid “packing out” the pump or hose:

• Use the lowest pressure and largest nozzle size that provides an acceptable spray pattern. This will also result in seals and wear parts lasting much longer.

• Do not use any more fluid hose than is necessary.

• Use an applicator with a rubber tip retainer that will blow off if it plugs.

1.

Mix the Material, page 13 .

2.

Prime with Material, page 14 .

Always have the atomizing air turned on at the applicator before and after spraying fluid (see applicator manual 3A3244).

been installed, do NOT use the valve to stall the pump. The pump must be stopped first before the ball valve can be closed.

• Do not allow pump to run without material in the hopper. It can cause damage to the pump seals.

• Failure to flush prior to material curing in the system will result in damage to system and may require replacement of all system parts in contact with the material.

3.

Turn on atomizing air and adjust the air needle valve on the applicator (see applicator manual

3A3244).

4.

Turn the motor power switch (S) to ON.

performance with highly compressible gypsum based materials. For high density, Portland cement based materials, the check valve (45) can be replaced with

1–1/2 NPT Nipple Fitting (121441) to reduce pressure drop and improve performance.

5.

Turn flow adjustment knob (H) until desired flow is reached. Turn clockwise to increase flow, counterclockwise to decrease flow.

6.

If the system is approaching its cure time or the system will be idle for enough time for material to begin curing in the system, flush the system.

See

Flush, page 12 .

Failure to flush prior to material beginning to cure in the system will result in damage to system and may require replacement of all parts in contact with the material.

3A3109C 15

Spray Adjustments (Pole Spray Applicator Kit 24Y619)

CA

CB

CC

CD

CE

CF

CG

Air Assist Air Line

Air Assist Shutoff Ball Valve

Rubber Tip Retainer

Air Needle (adjustable position)

Air Needle Retaining Screw

Fluid Housing

Tip (Nozzle) restrict or completely block material flow. This can result in the retainer (CC) blowing off. Installing the needle too far back can raise the pressure behind the fluid enough to blow the retainer (CC) off and can cause dripping.

The spray pattern can be adjusted by changing:

• Tip (CG) size

• Air flow, use air ball valve (CB)

• Air Needle (CD) position

To decrease air flow, turn valve knob clockwise.

To increase air flow, turn valve knob counterclockwise.

Check material and thin as needed to maintain the proper consistency. The material may thicken as it sits and could slow down application or affect the spray pattern.

Flush and dry applicator thoroughly at the end of each use. Tips and retainers must be cleaned by hand.

(CB) for the minimum air flow necessary for a good pattern. Air bleeds from the applicator nozzle (CG) whenever the applicator air assist shutoff ball valve

(CB) is open. Close the valve to stop the air flow, if desired. Otherwise, the air valve can stay open during priming. Air must be on prior to fluid flow.

air needle (CD) is slightly behind the tip (CG). The general rule for setting the air needle position is that the air needle should be the same distance back from the tip as the size of the orifice. For example, if you have a 1/2 in. tip installed, the air needle should be approximately 1/2 in. behind the tip.

For a lighter spray pattern, adjust the air needle closer to the fluid nozzle and/or reduce the fluid flow.

For a heavier spray pattern, adjust the air needle farther back from the fluid tip and/or increase the fluid flow.

pressure back into the fluid hose, which can slow material flow.

16 3A3109C

Spray Adjustments (Pole Spray Applicator Kit 24Y619)

1.

Test the spray pattern on cardboard. Hold the applicator 6 – 18 in. (150 – 450 cm) away from the surface. Use this spraying distance for most applications.

2.

Adjust fluid flow until material flow is adequate.

3.

Adjust the applicator air ball valve to achieve a uniform round spray pattern.

4.

Consider the size of aggregate in the material and the coarseness of the spray pattern. Larger nozzles allow heavier patterns.

5.

Overlap each stroke 50%. A circular overlapping pattern may give the best results.

When spraying small confined areas use the air ball valve and air needle position to make fine adjustments without adjusting the pump.

Higher pressures may cause excessive wear on the fluid pump. Select a fluid tip large enough to spray at low pressure. Some materials will pack-out at higher pressures.

1.

Place rubber tip retainer (CC) over top lip of applicator housing.

2.

Insert screwdriver through hole in tab of rubber tip retainer.

3.

Push screwdriver head against notch on applicator tip and pry rubber tip retainer over the tip (CG), spray shield (if being used), and lip until it snaps into place.

4.

Turn the rubber retainer back and forth to be sure it is fully seated.

t i14355a inlet fitting and the rubber nozzle retainer should be hand cleaned and dried after each use.

3A3109C 17

Pressure Relief Procedure

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 splashing fluid, and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1.

Turn the flow adjustment knob (H) counterclockwise until it stops.

2.

Turn the motor power switch (S) off.

3.

Remove the applicator tip and tip retainer, and hold the applicator firmly against a pail.

5.

If you suspect the applicator tip or hose is completely clogged, or that pressure has not been fully relieved after following the previous steps, slowly open the fluid drain/purge valve

(C) at the pump outlet and drain material into a waste pail.

6.

If there is still pressure trapped down the line,

VERY SLOWLY loosen the threaded swivel fitting at the pump outlet while keeping it covered until the pressure is relieved.

To prevent material hardening in fluid drain/purge valve, flush the valve after every use.

ti21632a

To avoid injury from splashing fluid, never open a cam-lock hose or applicator fitting while there is pressure in the fluid line.

4.

If the applicator ball valve kit (17J703) has been installed, open the ball valve.

18 3A3109C

Hopper Removal

cleaned, rotate the second knob (K) to loosen the clamp between the elbow and the hopper. Remove and clean the elbow.

To help prevent injury from suction, never place hands near the pump fluid inlet when pump is operating or when hopper is removed.

The hopper assembly allows easy detachment of the hopper from the pump. To remove the hopper from the pump, perform the following steps:

1.

Relieve pressure (see

Pressure Relief Procedure, page 18 ).

2.

Rotate knob (K) counterclockwise to loosen the clamp between the hopper elbow and the lower.

above in reverse order.

To prevent rust, never leave water or water-based fluid in pump overnight.

To shutdown, flush the system (see

Flush, page 12 ).

3.

Remove the locking pin and pull down the hopper latch (HL) on the hopper plate.

elbow to completely disengage from the pump lower.

4.

Remove the two hopper pins (P) from the front legs of the cart.

5.

Lift up on the handle and pull the hopper (J) away from the sprayer.

When lifting the unit, only lift at the points indicated by the arrows below.

3A3109C 19

Maintenance

1.

Flush the system. See

Flush, page 12

.

2.

Clean hopper with a scrub pad. It is recommended that you clean the outside of the sprayer using a cloth and water.

3.

Check hoses, tubes, and couplings for wear or damage. Tighten all fluid connections before each use.

4.

Check and replace cam-lock gaskets as needed.

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

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

inspect fluid lines for leaks.

operation.

displacement pump packing nut/wet cup. Fill nut

1/2 full with TSL. Maintain TSL level to help prevent material buildup on piston rod and premature wear of packings and pump corrosion.

Exposing the motor and/or control to water can cause damage and possible motor failure.

Do not store the pump outside. Do not spray water directly into the motor fan.

To prevent rust, never leave water or water-based fluid in pump overnight.

Material left on the throat seal can dry out and damage the seal. Always stop the pump at the bottom of the stroke to avoid damage to the throat seal.

Always flush the pump before the fluid dries on the displacement rod. First, flush with water, then with oil. Relieve the pressure, but leave the oil in the pump to protect the parts from corrosion.

20 3A3109C

Troubleshooting

1.

Perform

Pressure Relief Procedure, page 18 .

2.

Check all possible problems, causes, and solutions listed below before disassembling pump.

For troubleshooting and repair questions, please contact your distributor.

Displacement pump operates, but output is low on upstroke

Displacement pump operates, but output is low on down stroke and/or on both strokes

Piston ball check not seating properly

Piston packings worn or damaged

Piston packings worn or damaged

Outlet check valve not seating properly

Intake valve ball check not seating properly

Rubber elbow air leak

Fluid hose on the applicator is obstructed

Loose wet cup Material leaks and runs over the side of the wet cup

Fluid delivery is low

Electric motor does not operate

Throat packings worn or damaged

Applicator tip/gun is dirty or clogged

Clamps on hopper elbow are loose

Large pressure drop in fluid hose

Power switch is not ON

Tripped circuit breaker

Sprayer does not operate

Erratic accelerated speed

Cycles or fails to hold pressure at stall

Service piston ball check

Replace packings

Tighten packing nut or replace packing

Clean check valve

Service intake valve ball check

Tighten clamps

Clean the fluid hose on the applicator

Tighten wet cup enough to stop leakage

Replace packings

Clean or replace

Tighten clamps on hopper elbow

Reduce length or increase diameter

Fluid hose or applicator obstructed

Dried fluid on displacement rod or inlet ball

Clean rod. Always stop pump at bottom of stroke; keep wet cup filled with TSL. Be sure the inlet ball moves freely.

Refill hopper and prime pump Material supply exhausted, clogged suction

Open or worn piston valve or packings

Open or worn intake valve

Worn check balls, seats, or piston packing

Turn power switch ON

Check circuit breaker at power source. Reset motor switch.

Clean hose or application

Clear piston valve; replace packings

Clear or service intake valve

Service lower

3A3109C 21

Troubleshooting

Poor finish or irregular spray pattern

Motor powered but nothing comes out of hose

Inadequate atomizing air pressure

Dirty, worn, or damaged spray applicator

Pump is packed out with dry or cured material

Hose is packed out with dry or cured material

Adjust air needle valve on applicator (see applicator manual 3A3244)

Service spray applicator (see applicator manual 3A3244)

Disassemble and Clean the pump

Material is too thick to push through the hose without packing out

Outlet check valve installed backwards

Hose is too restrictive

Reverse hose and try to push out bad material

Some materials may need only 1 in. inner diameter fluid line all the way to the applicator

Install the outlet check valve in the proper orientation

Thin and mix material thoroughly to a lower viscosity

Use a pump system priming fluid (slime). Wet out the system.

Use a larger diameter hose

Control board status light blinks 4 times repeatedly

The control board is detecting multiple voltage surges

Check voltage supply to the sprayer:

1.

Turn the motor power switch (S) to OFF and unplug the sprayer.

2.

Locate a good voltage supply to prevent damage to electronics.

Control board status light blinks 5 times repeatedly

Control board status light blinks 6 times repeatedly

Control board status light blinks 8 times repeatedly

Check for line obstruction or pack out. Motor is powered but not able to turn.

Outlet check valve installed backwards

The motor is overheating

Incoming voltage is too low for sprayer operation

Remove obstruction and cycle power off and on. If the problem continues, contact your local distributor

Install the outlet check valve in the proper orientation

Allow the sprayer to cool. If the sprayer runs when cool, correct the cause of overheating.

Keep the sprayer in a cooler location with good ventilation. Make sure the motor air intake is not blocked. If the sprayer still does not run, contact your local distributor.

Check voltage supply to the sprayer:

1.

Turn the motor power switch (S) to OFF and unplug the sprayer.

2.

Remove other equipment that uses the same circuit.

3.

Locate a good voltage supply to avoid damage to electronics.

22 3A3109C

Troubleshooting

Control board status light blinks 10 times repeatedly

Control board status light blinks 12 times repeatedly

Control board status light blinks 15 times repeatedly

Control board status light blinks 16 times repeatedly

Control board status light blinks 17 times repeatedly

Repeated tripping of incoming power supply circuit

The control board is overheating 1.

Make sure the motor air intake is not blocked.

2.

Make sure the fan has not failed.

3.

Make sure the control board is properly connected to the back plate and that conductive thermal paste is used on power components.

4.

Replace the control board.

5.

Replace the motor.

Cycle the power on and off.

Excessive current protection is enabled

Connections above the motor may are loose or damaged

1.

Turn the motor power switch (S) to OFF and unplug the sprayer.

2.

Remove the motor shroud.

3.

Disconnect the motor control and inspect for damage at the connectors.

4.

Reconnect the motor control.

5.

Turn the motor power switch (S) to ON. If the blinking code continues, replace the motor.

1.

Turn power OFF.

Check the connections. Check for water in sensor. Control is not receiving motor position sensor signal.

2.

Remove the motor shroud.

3.

Disconnect the motor control and inspect for damage at the connectors.

4.

Inspect the sensor for water. If the sensor is wet, let it dry for 24 hours.

5.

Re-install the sensor, motor control connections, and shroud.

The sprayer is plugged into the wrong voltage

6.

Turn power ON. If the problem continues, replace the motor.

1.

Set the motor power switch (S) to OFF and unplug the sprayer.

Circuit uses a ground fault circuit interrupter (GFCI)

2.

Locate a good voltage supply to avoid damage to electronics.

Unit should be powered from a non-GFCI protected circuit.

3A3109C 23

Notes

24 3A3109C

Repair

Perform the procedure below to replace the entire pump lower with a new or different pump lower. Before following the pump lower replacement procedure, perform the

Pressure Relief Procedure, page 18

and disconnect the hopper and material hose.

1.

Remove outlet fittings from the pump lower outlet.

2.

Lift retaining spring (6m) and remove pin (6k).

3.

Loosen jam nut (19) and unthread the pump lower (6a).

4.

Disconnect the piston extension rod (6b) by removing clip (6e) and disassembling the coupler cover (6d) and assembly coupling (6c). The pump lower (6a) should now be separated from all other parts. Replace the pump lower and reinstall on the unit. If pump components need replacing, see

Replace Pump Components, page 26

.

nut (19) should be threaded on the pump lower until it bottoms out. The pump lower should be threaded completely into the motor adapter (6f) and backed off to the correct orientation position shown below. Once in position, unthread the pump two additional turns and secure the jam nut.

Failure to assemble the pump lower to the correct depth and orientation can cause damage to the pump. To avoid damage to the pump, follow the note above.

2

1

4

3

3A3109C 25

Repair

Remove the pump lower (6a – 17H190) before replacing any pump components.

For a list of available pump lower kits, see the list on the following page.

26 3A3109C

14

15

16

19

9

10

11

12

6

7

8

3

4

5

Ref.

Part

1

2

17G220 HOUSING, outlet

† CLAMP, 4 in., 1000 psi

17G226

HOUSING, inlet, ball guide

STOP, ball, inlet

17G330 CYLINDER, short, pump

17G223 VALVE, piston

17G224

16U801

HOLDER, valve, piston

STOP, upper ball

17G221 HOUSING, inlet

106212

SCREW, cap, hex hd

17G331 ROD, short, displacement

17G321 NUT, packing, 340e

16W492 BEARING, throat seal, 3–pack

16W491 PACKING, cup, 3–pack

21

22

16U977

NUT, extension, 3/8–16

NUT, jam

PACKING, o-ring

O-RING, 50 mm x 2.5 mm

1

1

1

4

1

1

1

1

1

1

1

2

4

1

1

1

2

2

Repair

27

28

Ref.

Part

23 108001

24

25

26

112420

BALL, metallic

SEAT, valve, tungsten carbide

BALL, sst, 1590

SEAT, valve, lapped, tungsten car

† PIN, ball stop

16W490

PACKING, o-ring, 10–pack

1

Apply grease lubricant to threads, o-rings and seal.

3

2

1

1

1

1

3

Apply serviceable thread locker to threads.

4

Torque to 30 +/-5 ft-lb (40 +/- 6.7 N●m).

5

Torque to 100 +/-10 ft-lb (135 +/- 13.5 N●m).

6

7

Torque to 200 +/-10 ft-lb (271 +/- 13.5 N●m).

Orient pump housing outlet (1) as shown in relation to the position of the pump clamps (2) and extension nuts

(16).

17H242

17G456

16W510

17H191

17K490

Repair pump rebuild kit

Pump lower clamp kit

Inlet seat and o-ring repair kit

Piston seat and o-ring repair kit

Ball inlet stop kit

14 (1), 15 (1), 21 (2), 22 (2), 23 (1), 25 (1), 28 (2)

2 (1), 16 (2), 10 (2)

22 (1), 26 (1)

22 (1), 24 (1)

4 (1), 27 (3)

3A3109C 27

Repair

Ref.

Part

1 o---ring) 5 (10)

28 3A3109C

Notes

3A3109C 29

Parts

30 3A3109C

Ref.

Part

17J707 HOPPER,

17J709 BRACKET,

17J812 BRACKET,

17J710 LATCH,

23 17G368 PIN,

26 17H193 BOOT,

27 17H196 CLAMP,

29 100731 WASHER

30 101566 NUT,

34 111800 SCREW,

39 125112 SCREW,

41 100527 WASHER,

42 111040 NUT,

Ref.

Part

44 17H025 PIN,

61 195551

RETAINER,

62 242005 CORD

63 242001 CORD

88 17G550 HOSE,

89 24Y619 APPLICATOR,

90 114271 STRAP,

Parts

3A3109C 31

Parts

32 3A3109C

Ref.

Part

17G364 CART,

17H190 PUMP,

17G283 ROD,

17G279 ADAPTER,

16G920 WHEEL,

11* 17H175 PLUG,

17G720 WIRE,

Ref.

Part

17H194 VALVE,

17G711 FITTING,

17G408 MANIFOLD,

17G388 FITTING,

5

6

1

3

***

17H197 SWITCH,

Parts

3A3109C 33

Parts

34 3A3109C

Ref.

Part

Ref.

Part

192840

Replacement

1

3

5

6

Parts

3A3109C 35

Parts

2

Torque to

3

Replacement

36

16T784

3A3109C

Replacement Parts and Accessories

17G550

17G551

17G552

17G767

24Y391

24Y392

24Y393

128459

128460

128461

128462

128463

128464

128465

128466

128467

16A405

24Y619

123888

17G554

17G665

114271

240296

17H197

17J703

121441

248515

25A227

25A228

25A500

25A501

25A502

25A503

25A504

25A505

System, F340e, 100–120 VAC, bare

System, F340e, 100–120 VAC, package*

System, F340e, 100–120 VAC, bare with remote switch

System, F340e, 100–120 VAC, package with remote switch*

System, F340e, 200–240 VAC, bare

System, F340e, 200–240 VAC, package*

25A506

25A507

System, F340e, 200–240 VAC, bare with remote switch

System, F340e, 200–240 VAC, package with remote switch*

*Package includes 17G550 (2), 24Y619 (1), 114271 (3)

Fluid hose, 1 in. ID x 25 ft (7.5 m), 1000 psi maximum working pressure

Fluid hose, 1.25 in. ID, 50 ft (15 m), 750 psi maximum working pressure

Fluid hose, 1.5 in. ID, 50 ft (15 m), 750 psi maximum working pressure

Hose adapter fitting (1.5 in. camlock female x 1 in. camlock male)

Air hose, 1/2 in. ID, 50 ft (15 m), MxF 1/4 quick disconnect fittings

Air hose, 3/8 in. ID, 50 ft (15 m), MxF 1/4 quick disconnect fittings

Air hose, 3/8 in. ID, 25 ft (7.5 m), MxF 1/4 quick disconnect fittings

Tip, 3/8 in. orifice stamped

Tip, 1/2 in. orifice stamped

Tip, 9/16 in. orifice stamped

Tip, 5/8 in. orifice stamped

Tip, 11/16 in. orifice stamped

Tip, 3/4 in. orifice stamped

Shield, mini, small

Shield, mini, medium

Shield, mini, large

Cap, retaining, nozzle, medium

Applicator, spray, pole

45 degree MxF 1 in. npt fitting (attach on applicator before fluid housing for added spray angles)

Kit, remote switch, 340e

Kit, remote switch, extension cord (100 ft)

Strap, retaining

Kit, retaining straps, 4 pack

Kit, remote switch, cable (switch and 100 ft cable)

Kit, applicator, ball, valve (applicator)

Fitting, 1–1/2 NPT, nipple (check valve replacement nipple fitting)

Kit, clean out, sponge ball, 1.18 in. diameter (30 mm) 5–pack (for use on 1 in. hoses)

Kit, clean out, sponge ball, 1.57 in. diameter (40 mm) 5–pack (for use on 1.25 in. hoses)

Kit, clean out, sponge ball, 1.77 in. diameter (45 mm) 5–pack (for use on 1.5 in. hoses)

3A3109C 37

Replacement Parts and Accessories

128474

128475

128476

128477

Fitting, 1.5 in. camlock male x 1.5 npt F

Fitting, 1.5 in. camlock female x 1.5 npt F

Fitting, 1.5 in. camlock male x 1.25 npt F

Fitting, 1.5 in. camlock female x 1.25 npt F

17J707

17J709

17J812

17J710

17J708

17J702

17J755

17J711

17J714

17J704

287282

17J705

16W492

17H192

113082

17H194

102973

17J712

17H193

17H196

17H242

17G456

16W490

17H190

16W510

112420

17H191

108001

16W491

Kit, repair, pump, rebuild

Kit, lower, clamp (cylinder clamp)

Kit, repair, 10 pack, o-ring, cylinder end (cylinder o-ring)

Kit, pump, lower, F340e, (complete assembled F340e pump lower)

Kit, repair, seat, inlet (inlet seat and o-ring)

Ball, sst, 1590 (1.75 diameter inlet check ball)

Kit, piston seat, o-ring (piston seat and o-ring)

Ball, metallic (1.5 in. diameter piston check ball)

Kit, repair, 3 pack, seal, piston (piston packing cup)

Kit, repair, 3 pack, seal, throat (throat seal)

Kit, outlet seat, o-ring (seat and o-ring)

Packing, o-ring (check valve packing o-ring)

Kit, outlet, check, valve (complete 1.5 in. outlet check valve)

Ball, metallic (1.25 in. diameter outlet check valve)

Kit, check, retainer (check valve ball retainer)

Kit, inlet, elbow (rubber elbow)

Kit, elbow, band clamp (rubber elbow clamp)

Kit, 340e, hopper with cover (hopper and cover)

Kit, 340e, hopper, bracket (hopper bracket)

Kit, 340e, stop, bracket (adjustable stop bracket)

Kit, 340e, adjustable latch (adjustable latch)

Kit, 340e, stop, brackets (hopper stop brackets)

Kit, 340e, MCM, 120V (120V motor control module)

Kit, 340e, MCM, 230V (230V motor control module)

Kit, 340e, motor (340e motor)

Kit, 340e, finger, guard (pump line finger guard)

Kit, 340e, front, cover (front cover)

Kit, repair, shield, motor (motor shield)

Kit, 340e, tool box (tool box)

38 3A3109C

Technical Specifications

Maximum Fluid Working Pressure

Stroke Length

Maximum pump speed (Do not exceed maximum recommended speed of fluid pump to prevent premature pump wear)

Weight (dry)

Wetted Parts

600 psi

2.25 in.

4.1 MPa, 41 Bar

150 cycles per minute

57 mm

210 lb 95 kg

Stainless steel, plated steel, carbide, urethane, PTFE,

UHMWPE, LLDPE, aluminum, solvent-resistant o-rings

Inlet/Outlet Sizes

Fluid Inlet Size

Fluid Outlet Size

Hose Requirements

Minimum Pressure

Minimum Hose Diameter

Minimum Hose Length

Power Requirements

100–120 VAC Models

200–240 VAC Models

Noise Level

Sound Power

Sound Pressure

*per ISO 3744; measured at 3.1 ft

Operating Ambient Temperature Range

Temperature

3 in.

1.5 in. npt(f) with 1.5 in. cam and groove fitting

600 psi

1.0 in.

25 ft

32° F to 120° F

90.4 dBa*

80.5 dBa*

4.1 MPa, 41 Bar

1 phase, 50/60 Hz

1 phase, 50/60 Hz

2.5 cm

7.6 m

4° C to 49° C

3A3109C 39

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.

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

Graco reserves the right to make changes at any time without notice.

www.graco.com

Revision C — January 2016

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