Graco 3A3110K, ToughTek F680e Fireproofing Pump Instructions

Instructions
ToughTek® F680e Fireproofing Pump
3A3110K
EN
water--based cementitious fireproofing materials. For professional use only. Not
Electric sprayer for water
approved for use in explosive atmospheres or hazardous locations.
Important Safety Instructions
Read all warnings and instructions in this and all related manuals.
Save all instructions.
600 psi (4.14 MPa, 41.4 bar) Maximum
Working Fluid Pressure
For models, related manuals, and
Agency approvals, see page 3.
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
Models............................................................... 3
Related Manuals ................................................ 3
Agency Approvals............................................... 3
Warnings ........................................................... 4
Component Identification..................................... 7
Overview ..................................................... 7
Sprayer Controls.......................................... 8
Pump Control Switch (AA) ............................ 8
Fluid Drain/Purge Valve (C) .......................... 9
Pump Components ...................................... 9
Hydraulic Solenoid Valve (J) ......................... 10
Hydraulic Pressure Control (S)...................... 10
Install the Remote Switch (17H197) .............. 10
Applicator Ball Valve (17J703) ...................... 11
Hydraulic Ball Valve ..................................... 11
Pump Pivot Assembly .................................. 12
Installation.......................................................... 13
Connect the Power ...................................... 13
Attach Power Cord ....................................... 14
Grounding .......................................................... 15
Setup................................................................. 15
Flush ................................................................. 16
Mix the Material .................................................. 19
Prime with Material ............................................. 19
Spray................................................................. 20
Prevent Pack-out ......................................... 20
Before Starting or Stopping Material
Flow .............................................. 20
Spraying...................................................... 20
Spray Adjustments (Pole Spray
Applicator)...................................... 22
2
Pressure Relief Procedure .................................. 24
Shutdown........................................................... 25
Corrosion Protection ........................................... 25
Lifting Instructions............................................... 25
Maintenance ...................................................... 26
Daily Maintenance ....................................... 26
Preventative Maintenance ............................ 26
Repair................................................................ 27
Replace Pump Lower ................................... 27
Partial Pump Lower Disassembly .................. 28
Replace Pump Components ......................... 30
Hydraulic Pump and Compressor Belt
Repair............................................ 33
Parts.................................................................. 34
F680e Parts................................................. 34
F680e Parts (continued) ............................... 36
Enclosure Parts ........................................... 39
Breaker, Power Supply, Contact
Module........................................... 40
Reservoir Assembly Parts ............................ 41
Pump Line Parts .......................................... 42
Troubleshooting.................................................. 44
Replacement Parts and Accessories.................... 47
Electrical Schematics.......................................... 48
Motors and Motor Control ............................. 49
Pump Control .............................................. 51
Notes................................................................. 52
Technical Specifications...................................... 53
Graco Standard Warranty.................................... 54
3A3110K
Models
Models
Model (Series D)
Includes:1
200 - 240 VAC, 1Φ, 60 Hz
35 A (24Y500)
Integrated Air Compressor
25 A (24Y502)
✔
1 For other parts included in all base models, see Parts, page 34. Some kits listed in Parts are not included in
the base models listed above, but can be purchased with them (these kits are noted as such).
Related Manuals
Component manuals in English:
Manual
Description
3A3181
Forklift Stabilization Kit 24Y479
Agency Approvals
Approvals (All Models)
Manuals are available at www.graco.com.
3A3110K
3
Warnings
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.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can
cause electric shock.
• Turn off power before servicing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with local codes
and regulations
• Do not expose to rain. Store indoors.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and
plastic drop cloths (potential static sparking).
• Ground all equipment in the work area. See Grounding instructions.
• 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.
• Stop operation immediately if static sparking occurs or you feel a shock.. Do not use
equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing
equipment, follow the Pressure Relief Procedure and disconnect all power sources.
SUCTION HAZARD
Powerful suction could cause serious injury.
• Never place hands near the pump fluid inlet when pump is operating or pressurized.
4
3A3110K
Warnings
WARNING
PRESSURIZED EQUIPMENT HAZARD
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on skin
and cause serious injury.
• Follow the Pressure Relief Procedure when you stop spraying/dispensing and before
cleaning, checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated
system component. See Technical Data in all equipment manuals.
• Use water 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 Sheets (SDSs) from distributor or
retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
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.
PRESSURIZED ALUMINUM PARTS HAZARD
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.
3A3110K
5
Warnings
WARNING
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled, or swallowed.
• Read Safety Data 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.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid
severe burns:
• Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment
includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
6
3A3110K
Component Identification
Component Identification
Overview
Component Identification Table
Key
A
B
Key
M
N
Description
Hydraulic Reservoir
Material Hopper
P
Air Compressor
Packing Nut / Wet Cup
Outlet Check Valve
Pump Lower
Hopper Elbow
Q
R
Sprayer Controls
Electrical Control Box
Hydraulic Pressure Control
Electric Motor for Hydraulic Pump
U
Electric Motor for Air Compressor
Hydraulic Ball Valve
Hydraulic Solenoid Valve
Hydraulic Pump
V
Hopper Elbow Clamp
K
W
Oil Filter
L
Oil Dipstick
C
D
E
F
G
H
J
Description
Hydraulic Driver
Fluid Outlet
Fluid Drain / Purge Valve
3A3110K
S
T
7
Component Identification
Sprayer Controls
Pump Control Switch (AA)
The pump control switch must be in the ON position
or REMOTE position (with the remote control switch
in the ON position) for the sprayer to pump material.
Pump Control Switch Settings:
Ref.
Control
Description
AA
Pump
Control
Switch
Controls the pump lower.
BB
Hydraulic
ON/OFF
Controls power to the
electric motor that drives the
hydraulic pump.
CC
Compressor
ON/OFF
Controls power to the
electric motor that drives the
compressor.
Main Power
Disconnect
Controls power to the
sprayer.
DD
8
OFF
The pump line will not cycle. There
is still power to the unit.
ON
The pump line will cycle at a
speed determined by the hydraulic
pressure control.
REMOTE
CONTROL
The “Remote Control” setting
controls ON/OFF functionality of the
pump through the remote toggle
switch (YY). When the remote
toggle switch is installed and the
pump control switch (AA) is set to
“Remote Control”, the toggle can be
used to turn the pump ON and OFF
(see descriptions above).
3A3110K
Component Identification
Fluid Drain/Purge Valve (C)
Pump Components
To avoid injury from splashing fluid, never open a
cam-lock hose or applicator fitting while there is
pressure in the fluid line.
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.
Ref.
X
Air Outlet, 1/4 in quick disconnect
coupling fitting
Y
Remote Switch Receptacle. The remote
switch cable is plugged into this socket.
Make sure the pump control switch (AA)
is in the OFF position when connecting
and disconnecting the remote switch
cable to prevent unintended operation of
the sprayer.
B
Fluid outlet, 1.5 in. cam and groove fitting
XX
Air Hose. It is recommended to use 1/2
in. ID air hose for at least the first 50 feet.
For hose longer than 50 feet, use a 3/8
in. ID air hose.
YY
Remote toggle switch
ZZ
Material hose
NOTICE
To prevent material hardening in fluid drain/purge
valve, flush the valve after every time it is used.
See Flush, page 16.
3A3110K
Description
9
Component Identification
Hydraulic Solenoid Valve (J)
Install the Remote Switch (17H197)
NOTE: Use zip-tie (ZT) to install the remote switch
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.
The hydraulic solenoid valve (J) is normally closed,
so when de-energized (pump control switch (AA)
in OFF position) it will block flow and the hydraulic
pump will stall. When energized (pump control switch
in the ON position, or REMOTE position with the
remote switch in the ON position) it allows flow and
the hydraulic pump to operate.
If the solenoid is not receiving a signal and remains
closed when the pump control switch is in the ON
position, it can be manually overridden. To override,
push the red button in, turn counterclockwise 180°
and release. The solenoid valve will then remain
open at all times.
Hydraulic Pressure Control (S)
Use to adjust hydraulic pressure available to the
hydraulic drive system. Turn the hydraulic pressure
control (S) clockwise to increase pressure and
counterclockwise to decrease pressure.
10
3A3110K
Component Identification
Applicator Ball Valve (17J703)
Additional accessory kit that can be installed on the
end of the 1 in. ID, 25 ft material hose (115) directly
between the pole spray applicator pipe handle and
adapter fitting. The applicator ball valve (BV) 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.
Hydraulic Ball Valve
When closed, the hydraulic ball valve will stop the
pump from cycling. The ball valve must be open to
pump material.
3A3110K
11
Component Identification
Pump Pivot Assembly
The pump pivot assembly allows easy detachment of the hopper from the pump.
To remove the pump from the hopper, loosen the hopper elbow clamps (V), retract
the spring-loaded locking pin (Z), and slowly swing the pump up until the spring
loaded locking pin clicks into place.
To attach the pump to the hopper, retract the spring-loaded locking pin (Z) and
slowly lower the pump until the elbow fitting is flush with the hopper and the locking
pin clicks into place. Tighten the hopper elbow clamps (V) so the elbow fitting
seals tightly around the hopper outlet.
12
3A3110K
Installation
Installation
To avoid tipping over, ensure cart is on a flat and
level surface. Failure to do so could result in injury
or equipment damage.
Connect the Power
See the table below for power supply requirements.
The system requires a dedicated circuit protected
with a circuit breaker.
Voltage
Phase
Hz
Integrated Air
Compressor
Full Load Peak
Current*
200–240VAC
1 Φ (2 wire +
ground)
60
Yes
35 A
Cord
Specifications
AWG (mm2)
8 (10.0)
No
25 A
12 (4.0)
* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various pressures
and flow rates may be less.
NOTE: The disconnect terminals will accept up to #8 AWG (10 mm2) conductors.
3A3110K
13
Installation
Attach Power Cord
3. Install the power cord as shown below.
200–240 VAC, 1 phase: Use a screwdriver to
connect two power leads as shown.
L1 L2
Improper wiring may cause electric shock or other
serious injury. All electrical wiring must be done
by a qualified electrician and comply with all local
codes and regulations.
1. Strip outer jacket of power cord to expose 8 in.
(20.3 cm) of conductors.
NOTE: Strip individual conductors and add
ferrules as necessary.
2. Attach the power cord to the disconnect block
(PD) located in the electrical control box (R).
Bring the power cord into the electrical control
box through the strain relief (SR).
14
W L D
4. Connect the green ground wire to the ground
terminal (GT).
5. Make sure the strain relief is tightened. Close
the electrical control box.
3A3110K
Grounding
Grounding
5. Turn hydraulic pressure control knob (S)
counterclockwise to lowest pressure.
(-)
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.
W L D
6. Set pump control switch (AA) to OFF.
The system is grounded through the power cord.
Setup
1. Ground sprayer. See Grounding, page 15.
2. Check Throat Seal Liquid (TSL) level in packing
nut (D). Fill 1/2 full with TSL.
WL D
7. Turn main power disconnect (DD) OFF.
Connect unit to power source (see
Attach Power Cord, page 14).
W L D
3. Connect air supply to applicator.
8. Flush the system with water before using (see
Flush, page 16). When finished, pump out the
excess water from the hopper (N).
4. Attach fluid hose (ZZ) to applicator fluid inlet and
fluid outlet (B), then secure Velcro straps (V)
around the cam lock fitting.
3A3110K
15
Flush
Flush
3. Place applicator outlet in a waste container. The
waste container must be large enough to hold
all dispensed material.
NOTICE
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.
NOTICE
The fluid/drain purge valve must be flushed to
prevent material hardening in the fluid/drain purge
valve. If that is not sufficient, remove, disassemble,
and clean the valve then reinstall.
ti21632a
4. Turn hydraulic switch (BB) ON, and pump control
switch (AA) to ON.
• Flush if the materials in the system are about to
reach their cure time.
5. Increase pressure by turning the hydraulic
pressure control (S) clockwise until a steady
stream of material flows from the applicator.
• Flush any time the flow rate starts to decrease as
this is a sign that material is starting to thicken and
cure.
6. When the material level in the hopper is within a
few inches of the material inlet at the bottom:
• Always flush the system at least twice, draining all
water between flushes then replacing with clean
water.
1. With the pump stopped, turn hydraulic pressure
control (S) counterclockwise to lowest pressure.
(-)
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.
NOTE: Be prepared to decrease pressure using
the hydraulic pressure control (S) when the
material exiting the hose changes to water. Cycle
rate can increase as material is flushed from the
hose.
8. When water begins to exit the applicator outlet,
switch the pump control switch (AA) to OFF to
stop dispensing.
W L D
2. Remove applicator tip and retainer.
16
9. Place applicator in the system hopper with the
outlet pointing down to enable circulation of
water.
3A3110K
Flush
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.
Switch the pump control switch (AA) to ON to
begin circulating water.
d. While pumping, turn the hydraulic pressure
control (S) knob to a lower setting and open
the fluid drain/purge valve (C). 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 (C).
e. Turn the pump control switch (AA) to OFF.
f.
d. The hose clean-out ball will be pushed out
of the hose after several minutes. Once
the ball is pushed through the hose, switch
the pump control switch (AA) to OFF and
repeat the entire process listed in step 11
one additional time to ensure the system is
thoroughly flushed.
NOTE: Always use the appropriately sized
clean-out ball for the hose size being
flushed/cleaned.
NOTICE
Material left on the throat seal can dry out and
damage the seal. Always stop the pump (park
the pump) at the bottom of the stroke to avoid
damage to the throat seal.
Place applicator outlet in a waste container.
g. Turn the pump control switch (AA) to ON to
dispense into waste container.
h. Dispense into waste container until hopper
is almost empty, then turn the pump control
switch (AA) 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 47 for
a list of available clean-out balls and the
appropriate hose sizes to use them on):
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).
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 fluid outlet
(B) and place a hose clean-out ball within
the hose inlet. The ball must be wetted with
water before inserting.
c.
Reattach the hose to the fluid outlet (B) and
switch the pump control switch (AA) to ON
to resume flushing the hose. Make sure the
hopper is sufficiently full of water to keep
pushing the ball out.
3A3110K
17
Flush
13. After performing step 11 at least twice, drain
remaining water from system:
a. Place drain pan beneath pump lower and
hopper elbow (G).
b. Remove the material hose prior to pivoting
pump.
c.
Detach pump from hopper and remove
hopper elbow (G) between hopper and pump
lower.
d. 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.
e. Install hopper elbow (G) and attach pump to
hopper.
f.
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 water 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
SDSs for additional information.
18
3A3110K
Mix the Material
Mix the Material
3. Remove applicator from hose outlet.
4. Fill the clean hopper with material to be sprayed.
Always flush the pump, hose, and applicator with
water before loading material.
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.
5. Place hose outlet in a 5 gallon waste container
or container of appropriate size.
NOTICE
To prevent damage to pump seals caused by
cavitation, run the pump slowly until the system
is primed.
Managing Material After Mixing:
• Pay close attention to the work life of the material
being used.
6. Turn main power disconnect (DD) ON.
• 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.
• Occasionally, do not refill the hopper until it is
almost empty. This ensures all material in hopper
is used while fresh.
Prime with Material
WL D
7. Set the hydraulic switch (BB) to ON, and the
pump control switch (AA) to ON.
8. Increase pressure by turning the hydraulic
pressure control (S) clockwise until a steady
stream of mixed material flows from the hose
outlet.
9. To stop dispensing, switch the pump control
switch (AA) to OFF.
10. Remove the tip from the applicator and install
onto the hose outlet. Switch the pump control
switch (AA) to ON and pump until material flows
from the applicator.
NOTICE
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.
11. Turn the pump control switch (AA) OFF to stop
dispensing.
12. Install a tip onto applicator (see Applicator
manual 3A3244). The system is now primed and
ready to spray.
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.
ti14355a
1. Mix the Material. See Mix the Material, page 19.
2. Turn hydraulic pressure control (S)
counterclockwise to lowest pressure.
(-)
W L D
3A3110K
19
Spray
Spray
Spraying
Prevent Pack
Pack--out
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.
Before Starting or Stopping Material
Flow
• Always have the atomizing air turned on at the
applicator (see Applicator manual 3A3244) before
and after spraying.
NOTE: If ball valve kit (17J703) has been installed,
do NOT use the valve to stall the pump. The pump
must be stopped first before the ball valve can be
closed.
Before Starting Material Flow
1. Always open and adjust the air ball valve (CB)
first.
2. Next, switch the pump control switch (AA) to ON.
1.
Mix the Material, page 19.
2.
Prime with Material, page 19.
NOTICE
• Do not allow pump to run without material
in the hopper. It can cause damage to the
pump seals.
• To prevent material curing in system, never
load material into a dry system. Always
prime system with water first. 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.
• 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. Open air ball valve (CB) on spray pole applicator.
See Applicator manual 3A3244.
4. Turn hydraulic pressure control (S)
counterclockwise to lowest pressure.
(-)
Before Stopping Material Flow
1. Always switch the pump control switch (AA) to
OFF first.
2. Turn off the air ball valve (CB) last.
Sprayer Performance
NOTE: The check valve (46) helps to improve pump
performance with highly compressible gypsum based
materials. For high density, Portland cement based
materials, the check valve (46) can be replaced with
1–1/2 NPT Nipple Fitting (121441) to reduce pressure
drop and improve performance.
20
W L D
5. Verify that the main power disconnect (DD) is
ON.
WL D
3A3110K
Spray
6. Turn compressor switch (CC) ON to start the
compressor.
8. Turn the pump control switch (AA) to ON to cycle
the pump, or turn the switch to REMOTE and set
the remote switch to ON to cycle.
W L D
W L D
7. Turn hydraulic switch (BB) ON, to start the
hydraulic pump.
9. Turn the hydraulic pressure control (S)
clockwise until desired flow is reached. Turn
counterclockwise to decrease flow.
W L D
10. 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 16.
WL D
3A3110K
21
Spray
Spray Adjustments (Pole Spray Applicator)
Key:
NOTE: Installing the needle too far forward can
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.
CA
Air Assist Air Line
CB
CC
Air Assist Shutoff Ball Valve
Rubber Tip Retainer
CD
Air Needle (adjustable position)
CE
CF
Air Needle Retaining Screw
Fluid Housing
Air Flow Valve Adjustment
CG
Tip (Nozzle)
To decrease air flow, turn valve knob clockwise.
General Adjustments
The spray pattern can be adjusted by changing:
• Tip (CG) size
• Air flow, use air ball valve (CB)
• Air Needle (CD) position
Adjust Air Flow: Adjust the air assist shutoff ball valve
(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.
Adjust Air Needle (CD) position: Make sure the
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.
22
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.
Material Flow Adjustments
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.
NOTE: Withdrawing the needle too far can force air
pressure back into the fluid hose, which can slow
material flow.
3A3110K
Spray
Spray Techniques
Installing Nozzle Retaining Cap
1. Test the spray pattern on cardboard. Hold
the applicator 6-18 in. (150-450 mm) from the
surface. Use this spraying distance for most
applications.
1. Place the rubber tip retainer (CC) over top lip of
applicator housing.
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.
2. Insert a screwdriver through the hole in the tab of
the rubber tip retainer.
3. Push the screwdriver head against the notch on
the applicator tip and pry the rubber tip retainer
over the tip (CG), spray shield (if one is being
used), and over the lip until it snaps into place.
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.
ti14355a
Figure 1
4. Turn the rubber retainer back and forth to be sure
it is fully seated.
NOTE: The rubber gasket in the cam and groove
inlet fitting and the rubber nozzle retainer should be
hand cleaned and dried after each use.
3A3110K
23
Pressure Relief Procedure
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.
3. Remove the applicator tip and tip retainer, and
hold applicator firmly against a pail.
ti21632a
1. Turn hydraulic pressure control (S)
counterclockwise to lowest pressure.
To avoid injury from splashing fluid, never
open an applicator or hose fitting while there is
pressure in the fluid line.
(-)
4. If the applicator ball valve kit (17J703) has been
installed, open the ball valve.
W L D
2. Turn main power disconnect (DD) off.
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 in the line, very
slowly loosen the threaded swivel fitting at the
pump outlet while keeping it covered until the
pressure is relieved.
W L D
24
3A3110K
Shutdown
Lifting Instructions
Shutdown
NOTICE
To prevent rust, never leave water or water-based
fluid in pump overnight.
NOTE: When lifting the unit, use a forklift and always
lift from the rear of the system. The center of mass
in the F680e is in the middle of the sprayer. With
shorter forklifts or when driving the forklift over rough
terrain while carrying the F680e, install the forklift
stabilization kit 24Y479. These support brackets
will hold the F680e onto the forks and prevent the
sprayer from falling, tipping, or bouncing off the forks.
The forklift stabilization kit (24Y479) is not included
in the base models.
To shut down the sprayer, flush the system. See
Flush, page 16.
Turn main power disconnection (DD) OFF.
W L D
Corrosion Protection
NOTICE
To prevent rust, never leave water or
water-based fluid in pump overnight.
NOTICE
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 material dries on
the displacement rod. For longer periods of time
where the pump is not in use, pump oil through the
pump lower, then relieve the pressure. Leave oil in
the pump to protect the parts from corrosion.
3A3110K
25
Maintenance
Maintenance
DAILY: Check hose for wear and damage.
DAILY: Inspect hydraulic and fluid lines for leaks.
Daily Maintenance
DAILY: Check fluid drain/purge valve (C) for proper
operation. Clean/flush the valve if necessary.
DAILY: Check level of Throat Seal Liquid (TSL)
in displacement pump packing nut (D). Fill nut, if
necessary. Keep TSL in nut to help prevent material
buildup on piston rod and premature wear of packings
and pump corrosion.
1. Flush the system. See Flush, page 16.
2. Relieve pressure. See
Pressure Relief Procedure, page 24.
3. Clean hopper with a scrub pad. It is
recommended that you clean the outside of the
sprayer using a cloth and water.
4. Check hoses, tubes, and couplings. Tighten all
fluid connections before each use.
5. Check and replace cam-lock gaskets as needed.
Preventative Maintenance
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.
DAILY: Check hydraulic oil level and fill as necessary.
DAILY: Check compressor oil level and fill as
necessary. Compressor oil should be replaced after
50 hours (break-in) and every 200 hours after initial
oil change. If the compressor oil is dark black and
shows sediment before the 200 hour time period is
complete, replace the oil.
WEEKLY: Remove compressor air filter cover and
clean element. Replace the element if necessary.
WEEKLY: Check the hydraulic fluid level
weekly using a dipstick. The fluid level must
be between the marks on the dipstick. Refill
as required with approved hydraulic fluid (see
Technical Specifications, page 53). If the fluid is dark
in color, change the fluid and filter. Replace break-in
oil in a new unit after the first 250 hours of use or
within 3 months, whichever comes first. See the table
below for recommended frequency of oil change.
Ambient Temperature
Recommended
Frequency
0° to 90° F
(-17° to 32° C)
1000 hours or 12
months, whichever
comes first
90° F and above
(32° C and above)
500 hours or 6 months,
whichever comes first
NOTE: If operating in an unusually dusty environment,
check the filter daily and replace if necessary.
MONTHLY: Clean the pre-filter and muffler on the
air compressor air relief valve. Replace the air relief
valve (part 17H606) and muffler (part 120206) if
necessary.
SEMI-ANNUALLY: Check belt wear. Replace if
necessary.
NOTE: If the red dot on the compressor sight glass is
visible, add oil.
26
3A3110K
Repair
Repair
Replace Pump Lower
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 24 and disconnect
the material hose.
1. Remove outlet fittings (OF) from the pump lower
outlet.
2. Loosen the hopper elbow clamps (V), retract the
spring-loaded locking pin (Z), and slowly swing
the pump up until the spring loaded locking pin
clicks into place.
3. Remove the hopper elbow (26) from the pump
lower (908).
4. Lift up the pump spring guard (906) and
disconnect the hydraulic displacement rod by
removing clip (916) and disassembling the
coupler cover (917) and assembly coupling (918).
5. Unthread all three lock nuts (907) from the tie rods
and remove the pump lower (908). The pump
lower should now be separated from all other
parts. Replace the pump lower and reinstall it into
the unit. If the pump components need replacing,
see Replace Pump Components, page 30 .
NOTICE
The pump lower (908) is heavy. Dropping the
pump can cause damage to the equipment. Make
sure you have a secure hold on the pump lower
when removing the last lock nut (907).
NOTE: When reinstalling the pump lower, tighten the
jam nut (806) when the top surface of the mounting
cylinder plate (809) is flush to within +/- .060 in. of
the top surface of the outlet housing (805). The 1–1/2
NPT hole in the outlet housing (805) should be in line
with the flats on the mounting cylinder plate (809).
3A3110K
27
Repair
Partial Pump Lower Disassembly
Perform the procedure below to clean or replace a
portion of the pump lower without removing the entire
pump lower from the unit. Before following the partial
pump lower disassembly procedure, perform the
Pressure Relief Procedure, page 24 and disconnect
the material hose.
1. Loosen the hopper elbow clamps (V), retract the
spring loaded locking pin (Z), and slowly swing
the pump up until the spring loaded locking pin
clicks into place.
2. Remove the hopper elbow (26) from the pump
lower.
3. Remove the inlet housing by unthreading the
extension nuts (831, 832) on the bottom pump
clamps (803).
4. Remove the pump cylinder by unthreading the
extension nuts (831, 832) on the top pump
clamps (803) and sliding the cylinder (804) off
the piston rod packing cup.
28
3A3110K
Repair
Notes
3A3110K
29
Repair
Replace Pump Components
Remove the pump lower (908 — 24Y513) before
replacing any pump components.
30
3A3110K
Repair
Ref.
Part
Description
Qty.
801
17G221
HOUSING, inlet
1
821
802
17G226
HOUSING, inlet, ball guide
1
822
CLAMP, 4 in., 100 psi
2
823
†
803
804
16U798
CYLINDER, pump
1
805
17G220
HOUSING, outlet, 680
1
806
16U977
NUT, jam
1
807
16U804
ROD, displacement
1
808
16U805
NUT, packing
1
809
16U976
PLATE, mounting, cylinder
1
810
†
BEARING, seal
1
811
†
PACKING, o-ring
2
812
17G224
†
813
HOLDER, valve, piston, 680
1
PACKING, o-ring
2
814
16U801
STOP, upper ball
1
815
108001
BALL, metallic
1
816
†
O-RING, 50 mm x 2.5 mm
2
817
†
1
818
†
SEAT, valve, tungsten
carbide
PACKING, cup
819
17G223
820
†
1
VALVE, piston, 680
1
STOP, ball, inlet, 680
1
Part
Ref.
Description
†
112420
†
Qty.
PIN, ball, stop
3
BALL, sst, 1590
1
1
1
826▲
15H108
SEA, valve, lapped, tungsten
carbide
LABEL, warning, pinch, point
831
106212
SCREW, cap, hex hd
4
NUT, extension
4
†
832
† See List of Kits below.
▲ Replacement Danger and Warning labels are available
at no cost.
2
Apply grease lubricant to threads, o-rings, and seals.
3
Apply serviceable thread locker to threads.
5
Torque to 30 +/- 5 ft-lb (40 +/- 6.7 N•m).
6
Torque to 100 +/- 10 ft-lb (135 +/- 13.5 N•m).
7
Torque to 200 +/- 10 ft-lb (271 +/- 13.5 N•m).
11 Position the pump housing outlet (805) as shown
in relation to the position of the pump clamps (803) and
extension nuts (832).
List of Kits
Kit
Description
Ref. # (Qty.)
17H242
Repair pump rebuild kit
810 (1), 818 (1), 813 (2), 816 (2), 815 (1), 822 (1), 811 (2)
17G456
Pump lower clamp kit
832 (2), 831 (2), 803 (1)
16W490
10 pack o-ring repair kit
811 (10)
24Y513
F680e complete assembled pump lower
All parts listed in Replace Pump Components, page 30
16W510
Inlet seat and o-ring repair kit
823 (1), 816 (1)
17H191
Piston seat and o-ring repair kit
816 (1), 817 (1)
16W491
3 pack piston packing cup repair kit
818 (3)
16W492
3 pack throat seal repair kit
810 (3)
17K490
Ball inlet stop kit
820 (1), 821 (3)
3A3110K
31
Repair
Replace Check Valve (909 – 17H194)
Remove the check valve before replacing any check valve components.
Ref.
Part
Description
1
†
HOUSING, check valve, outlet
1
2
17J712
RETAINER, ball
1
3
102973
BALL, metallic
1
4
†
SEAT
1
5
113082
Packing, o-ring
1
6
†
Retainer, check valve, seat, outlet
1
Qty.
† See List of Kits tables below.
1 Torque to 70–85 ft
ft--lb (95–115 N●m).
List of Kits
Kit
Description
Kit Contents: Ref. # (Qty.)
17H192
Check valve seat and o-ring repair kit
4 (1), 5 (1)
113082
Packing, o-ring, (check valve packaging o-ring)
5 (10)
17H194
Complete 1.5 in. outlet check valve
1 (1), 2 (3), 3 (1), 4 (1), 5 (1), 6 (1)
32
3A3110K
Repair
Hydraulic Pump and Compressor Belt Repair
Perform the procedure below to replace either the hydraulic pump belt or compressor belt. Before following
the belt repair procedure, see Shutdown, page 25.
Remove the Compressor Belt Guards
Remove the Hydraulic Pump Belt Guards
1. Remove the washers (85), screws (86), and top
cover (88).
1. Remove the washers (85), screws (86), and top
cover (88).
2. Remove the two washers (92) and screws (91)
holding the hydraulic pump guard (93) and
compressor top guard (94) together.
2. Remove the two washers (92) and screws (91)
holding the hydraulic pump guard (93) and
compressor top guard (94) together.
3. Remove the washer (92) and screw (90) holding
the compressor top guard (94) and compressor
side guard (79) together, and then slide the
compressor top guard up and out of the sprayer.
3. Remove the two screws (20) holding the
hydraulic pump guard (93) to the frame and slide
the guard up and out of the sprayer.
4. Remove the two screws (20) holding the
compressor side guard (79) to the frame and
slide guard out sideways.
4. Rotate the belt tension adjuster (23) in towards
the sprayer, then remove and replace the
hydraulic pump belt (27).
5. Rotate the belt tension adjuster (23) in towards
the sprayer, then remove and replace the air
compressor belt (58).
3A3110K
33
Parts
Parts
F680e Parts
34
3A3110K
Parts
F680e Parts List
Ref.
Part
Description
2
113362
WHEEL
3
154628
WASHER
Ref.
Part
Description
2
75
17G250
BRACKET, hopper, painted
2
2
85
WASHER, 3/8 in. plain flat
4
Qty.
Qty.
4
113436
RING, retainer
2
86
111803
SCREW, cap, hex hd
4
5
17G235
CASTER, forged
2
87
†
LABEL, F680e
1
6
112958
NUT, hex, flanged
12
88
†
BRACKET, top, painted
1
7
17G245
NUT, 5/8–11 x 3/8 thk
1
95
17G246
BOLT, carriage, 3/8–16 x 2.25 in.
4
8
17G537
PLUNGER, spring
1
96
25A315
TANK, 30 gal, 680e
1
9
24Y236
PUMP, hydraulic, 680
1
97
17G248
4
10
119975
GRIP, vinyl, gray
2
11
17G236
2
99
17H196
12
17G237
SCREW, shoulder, .75 in.
diameter
BEARING, bronze
SCREW, truss, slotted, 3/8–16
x1
CLAMP, hose, t-bolt
20
107257
ENCLOSURE, elec, 230V, with
compressor
SCREW, thd forming
41
17G257
HOSE, return, pivot
1
42
17G260
HOSE, supply, pivot
1
43
121311
FITTING, connector, npt x jic
2
44
162024
COUPLING
1
46
117441
VALVE, ball
1
49
128553
1
50
128554
51
128555
HARNESS, motor, hydraulic,
680e
HARNESS, motor, compressor,
680e
HARNESS, remote, switch, 680e
1
52
128556
HARNESS, solenoid, 680e
1
60
111192
SCREW, cap, flange hd
12
73
114421
BUSHING, strain relief
1
19
2
100
17H193
BOOT, elbow, rubber, 3 in. ID
1
2
101
17H197
SWITCH, remote, on/off
1
1
113
127265
TOOL, wrench, ratchet, 5/8 in.
1
19
1
114
206994
FLUID, TSL, 8 oz. bottle
1
121
114271
STRAP, retaining
4
150
117607
FITTING, elbow, std thd
1
151
17G219
TUBE, hydraulic, driver
1
152
117609
FITTING, tee, branch, str thd
1
153▲
15B063
LABEL, warning, hot surface
1
† See List of Kits below.
▲ Replacement Danger and Warning labels are available
at no cost.
Apply serviceable thread locker to threads.
8
12
26
Torque to 120 +/- 5 in-lb (13.5 +/- 0.5 N•m).
Position wheel (2) with the grease fitting on the
outside.
List of Kits:
Kit
Description
Kit Contents: Ref. (Qty.)
25A316
F680e top cover
87 (1), 88 (1)
3A3110K
35
Parts
F680e Parts (continued)
36
3A3110K
Parts
F680e Parts List (continued)
Ref.
Part
1
Description
CART, 680e, weldment, painted
Qty.
1
Ref.
Part
Description
65
17K007
TUBE, cooling, compressor
1
Qty.
6
112958
NUT, hex, retaining
12
66
114526
FITTING, tee, pipe
1
13
17K004
MOTOR, 230VAC, 4.0 hp
1
67
118758
FITTING, adapter
1
14
113802
SCREW, hex, hd, flanged 8
8
68
122533
FITTING, 45 degree elbow, #8 JIC x 3/8
1
15
25A321
RESERVOIR, assembly, F680e
1
69
121486
FITTING, elbow, male, 1/2 JIC x 1/2 npt
1
16
100527
WASHER, plain
2
70
17G255
HOSE, air
1
17
108481
SCREW, cap, hex hd
2
71
17H021
FITTING, coupling, qd, 1/4 in.
1
18
117791
SCREW, cap, tri lobe
2
73
114421
BUSHING, strain relief
1
20
107257
SCREW, thd forming
19
74▲
15K616
LABEL, caution
1
21
15H207
BRACKET, tensioner
1
76
17K021
BRACKET, support, hopper, painted
1
22
111802
SCREW, cap, hex hd
2
77
116780
SCREW, hex, hd, flanged
2
23
247853
ADJUSTER, belt, tensioner
2
78
†
TRIM, edge, protection
2
24
C19843
SCREW, cap, sockethead
2
79
†
GUARD, belt, air, side
1
25
17H048
GROMMET, 3/4 in. ID
2
80▲
LABEL, warning, ISO, pinch hazard
3
26
247845
PULLEY, drive, vee
1
81
GUARD, cooling, side, painted
1
27
125834
16M768
†
BELT, tri-power, AX48
1
82▲
16D646
LABEL, warning, ISO, hot surface
1
28
†
PULLEY, fan
1
89
15A464
LABEL, control
1
29
†
SCREW, set, 1/4 x 1/2
2
90
100157
SCREW, cap, hex hd
1
30
17G258
TUBE, supply
1
91
15X227
SCREW, cap hex head
3
31
17K006
TUBE, cooling, hydraulic fluid, return
1
92
110755
WASHER, plain
4
32
17G704
FITTING, 90 degree elbow, 3/4–16 unf
1
93
†
GUARD, belt, fluid
1
33
17G694
FITTING, straight, 3/4–16, nptf
2
94
†
GUARD, belt, air, top
1
34
17G706
FITTING, straight, 3/8–18 npt
1
98
17G254
COVER, splash, painted
1
35
17G261
SOLENOID, supply, switch
1
199*
131366
KIT, air filter, F680
1
36
118896
FITTING
1
† See List of Kits on the following page.
37
17G256
HOSE, return
1
*Replacement pleated filter elements are available for steel, twist
38
17G259
HOSE, supply
1
lock-style filters (131367). Purchase an upgraded filter (131366) for plastic
wingnut-style filters.
39
17H028
CLAMP, hose, .75 ID, stacking
1
▲ Replacement Danger and Warning labels are available at no cost.
40
17H616
CLAMP, hose, .690 ID, stacking
1
45
122401
Locate approximately as shown.
2
ADAPTER, bulkhead, #8 JIC — #6 nptf
3
47
†
NUT, bushing
2
48
†
BUSHING, strain relief
2
11
12
51
128555
HARNESS, remote switch, 680e
1
52
128556
HARNESS, solenoid, 680e
1
56
17K005
MOTOR, 230 VAC, 2.0 HP
1
57
24N370
PUMP, compressor, air
1
58
17G244
BELT, AX, air
1
59
17G241
PULLEY, 2.6 in. pitch diameter
1
60
111192
SCREW, cap, flange hd
61
62
128662
Add PTFE thread seal tape to pneumatic fittings.
Torque to 120 +/- 5 in-lb (13.5 +/- 0.5 N•m).
Torque to 177.5 +/- 2.5 in-lb (20 +/- 0.28 N•m).
13
15
Feed motor cable (50) through hole.
17
BRACKET, tensioner, air, painted
1
18
CLAMP, vibration damping
1
63
17H606
VALVE, air, relief
1
120206
MUFFLER, 1/8 npt
1
Align pulleys to belt tension adjuster (23) before installing the
corresponding screws. Apply serviceable thread locker to the set
screws.
Feed motor cable (49) through hole.
16
12
64
3A3110K
Apply serviceable thread locker to threads.
8
Feed remote switch cable (51) through hole.
Feed solenoid cable (52) through hole.
19
Position cable plug toward the inside of the unit.
20
37
Parts
List of Kits
Kit
Description
Ref. (Qty.)
25A312
25A314
25A318
25A319
25A321
25A313
25A317
Hydraulic pump pulley and set screws
Air compressor side belt guard
Hydraulic pump belt guard
Air compressor top belt guard
F680e complete hydraulic pump and reservoir assembly
Bushing with nut
28
78
93
94
15
47
81
38
Cooling Side guard
(1), 29 (2)
(2), 79 (1), 80 (1)
(1), 80 (1)
(1), 80 (1)
(1)
(1), 48 (1)
(1), 82 (1)
3A3110K
Parts
Enclosure Parts
(Electrical enclosure for 24Y500 shown below)
W L E
Part
Description
601
ENCLOSURE, electrical
1
616
120493
LATCH, mounting
4
602
1
617
120494
BLOCK, switch, N.O.
2
17F719
MODULE, brkr, power supply,
contact
SWITCH, rocker, 3–position
618
120495
BLOCK, switch, N.C.
2
LABEL, warning, ENG/FRE/SPA
1
122313
LABEL, control, electrical
enclosure
BAR, ground, kit
Ref.
604
605
606
Qty.
1
1
Ref.
Part
619▲ 16T784
620
1
621
172953
Description
Qty.
LABEL, designation
1
TRIM, edge protection
1
PLUG, hole, 1/5 in. hole diameter
1
607
117682
BUSHING, strain relief,
3
623
608
123970
SWITCH, disconnect, 40A
1
▲ Replacement Danger and Warning labels are available
609
123971
KNOB, disconnect, operator
1
611
114421
BUSHING, strain relief
2
612
113505
NUT, keps, hex hd
4
613
109466
NUT, lock, hex
2
614
121618
615
121619
SWITCH, start, push button,
green
SWITCH, stop, push button, red
3A3110K
123398
at no cost.
Install disconnect switch (609). Make sure up is
1
ON, and left is OFF.
2
Locate approximately as shown.
2
5
For 24Y500 only.
2
6
For 24Y502 only.
39
Parts
Breaker, Power Supply, Contact Module
Ref. Part
Description
302
120838
BLOCK, clamp end
2
303
17B346
CIRCUIT, breaker, 2p, 20A,
UL1077, AB
RELAY, contactor, 65A, 3p
2
304
255022
305
17B347
401
514014
403
40
120570
CIRCUIT, breaker, 2p, 25A,
UL1077, AB
RAIL, mt. (cut to length at
assembly)
BLOCK, terminal
Qty.
2
1
Ref. Part
Description
404
120490
COVER, end
Qty.
1
405
126812
BLOCK, ground, terminal
1
406
126453
POWER SUPPLY, 24V
1
407
24R723
BLOCK, terminal, quad M4, AB
1
408
120573
BRIDGE, plug-in (jumper)
4
0.71
2
Torque the end stops to 4–5 in-lb (0.45–0.56 N•m).
6
3A3110K
Parts
Reservoir Assembly Parts
Ref.
Part
501
502
101754
503
120604
504
505
116618
506
Description
Part
Description
Qty.
Ref.
TANK, reservoir, blue
1
522
KNOB, pressure
1
PLUG, pipe
1
523
SCREW, set, socket head
1
Qty.
GASKET, reservoir
4
525
TUBE, hydraulic, case drain
1
SCREW, mach, hex flat head
1
526
118896
FITTING
1
MAGNET
1
527
†
FILTER, oil, spin on
1
FILTER, screen, suction, hyd
1
533
17G556
MANIFOLD, pump, 680e
1
507
TUBE, section
1
534
17G263
SCREW, cap, socket hd, M5 x 10mm
4
508
PACKING, o-ring
1
537
15C939
PACKING, o-ring
3
509
COVER, reservoir, 200HS, blue
1
538
118579
PLUG, pipe
3
510
PACKING, o-ring
4
▲ Replacement Danger and Warning labels are available at no
511
PACKING, o-ring
1
FITTING, hydraulic
1
513
SCREW, mach, hex washer
8
514
CAP, breather, filler
1
512
120184
515
†
RETAINER, ball, pressure bypass
1
516
†
BALL, metallic
1
517
†
SPRING, compression
1
520
521
cost.
† See List of Kits below.
6
7 Turn 3/4 of a turn after gasket contact, then apply a thin film
of oil to gasket prior to assembly.
9
PUMP, hydraulic
1
FITTING, elbow, male, 90 degree
1
Apply serviceable thread locker sealant.
Torque to 25 ft-lb (34 N•m).
10 Tighten with o-ring, washer and jam nut fully retracted, orient
and torque jam nut appropriately.
13
Torque to 70 +/- 5 in-lb (7.9 +/- 0.5 N•m).
15
Torque to 125 +/- 10 in-lb (14 +/- 1.1 N•m).
List of Kits
Kit
Description
Ref. # (Qty.)
246173
Kit, repair, oil filter
515 (1), 516 (1), 517 (1), 527 (1)
25A321
F680e complete hydraulic pump and reservoir assembly
All reservoir assembly parts listed above are included.
3A3110K
41
Parts
Pump Line Parts
W L F
42
3A3110K
Parts
Pump Line Parts List
Ref.
Part
Description
Qty.
Ref.
Part
Description
901
25A320
902
17G587
DRIVER, 3.75 in. stroke, 2 in.
diameter
PLATE, driver, 680, painted
1
916
244820
CLIP, hairpin, (with lanyard)
1
1
903
103263
SCREW, mach flw, skt
4
904
17G588
905
17G231
BRACKET, pump, plunger,
painted
TIE, rod
906
17G232
907
101712
Qty.
917
197340
COVER, coupler
1
918
244819
1
2
930*
-----
3
931*
17N566
COUPLING, assembly, 145–290
Xtreme
ADAPTER, 1.5 npt m x 1.5 bspp
m
SEAL, 1.5 in. bspp
1
GUARD, spring, pump
1
932*
17N891
COUPLING, 35 mm x 1.5 bspp f
1
NUT, lock
3
*
Additional fittings (mortar coupling) shipped loose
with system.
†
See List of Kits below.
908
24Y513
LOWER, pump, 680
1
909
17H194
VALVE, check, outlet, 1.5 in.
1
910
113864
UNION, swivel, 1 1/2 npt
1
911
17G408
MANIFOLD, outlet, pump
1
912
128473
1
913
17G388
FITTING, 1.50 cmlk m x 1.50 npt
m
FITTING, hose, 1–11 1/2 npt
1
914
127232
VALVE, ball, 1000 psi, 1 in.
1
915
113467
SCREW, cap, socket hd
4
1
2
3
1
Torque to 55 +/- 5 ft-lb (74 +/- 6.7 N•m).
Apply serviceable thread locker to threads.
Apply pipe sealant to threads.
List of Kits
Kit
24Y513
17H194
Description
Complete assembled F680e pump lower
Complete 1.5 in. outlet check valve
Ref. (Qty.)
908 (1)
909 (1)
25A320
17N875
Complete driver (4.75 in. stroke)
35 mm x 1.5 npt m adapter kit
901 (1)
930 (1), 931 (1), 932 (1)
3A3110K
43
Troubleshooting
Troubleshooting
2. Check all possible problems, causes, and
solutions listed below before disassembling
pump.
For troubleshooting and repair questions, please
contact your local Graco distributor.
1. Perform Pressure Relief Procedure, page 24.
Problem
Displacement pump
operates, but output is
low on upstroke
Displacement pump
operates, but output is
low on down stroke and/or
on both strokes
Cause
Piston ball check not seating
properly
Piston packings worn or
damaged
Piston packings worn or
damaged
Intake valve ball check not
seating properly
Hopper elbow air leak
Fluid hose/applicator is
obstructed
Hose ID is too small
Material leaks and runs over Loose wet cup
the side of the wet cup
Throat packings worn or
damaged
Fluid delivery is low
Pressure setting too low
Applicator gun or tip is dirty or
clogged
Clamps on hopper elbow are
loose
Hydraulic motor is worn or
damaged
Large pressure drop in fluid hose
The sprayer overheats
Material buildup on hydraulic
components
Oil level is low
Pump noise
Low hydraulic fluid level
44
Solution
Service the piston ball check.
Replace the packings.
Tighten packing nut or replace packing.
Service the intake valve ball check.
Tighten the clamps on the hopper elbow.
Clear the hose or applicator.
Use a hose with a larger ID.
Tighten wet cup enough to stop leakage.
Replace the packings.
Increase the pressure.
Clean or replace the gun or tip.
Tighten the clamps on the hopper elbow.
Bring the sprayer to a Graco distributor for
repair.
Reduce hose length and/or increase
diameter.
Clean the hydraulic components.
Fill with oil.
Turn the sprayer OFF and add hydraulic
fluid.
3A3110K
Troubleshooting
Problem
Sprayer does not operate
Cause
Hydraulic motor solenoid valve
is closed
Solution
1. Verify the pump control switch (AA)
setting.
2. Verify the remote switch position.
Fluid hose or applicator
obstructed
Dried material on displacement
rod or inlet ball
Hydraulic ball valve is closed
Erratic accelerated speed
3. If the solenoid is not receiving a signal
and remains closed when the pump
control switch is in the ON position,
it can be manually overridden. To
override, push the red button in, turn
counterclockwise 180°, and release.
The solenoid valve will remain open at
all times.
Clean the hose or applicator.
Clean rod. Always stop pump at bottom of
stroke; keep wet cup filled with TSL. Be sure
the inlet ball moves freely.
Verify that the ball valve is in the open
position.
Refill the hopper and prime pump with
material.
Clear the piston valve; replace the packings.
Material supply exhausted,
clogged suction
Open or worn piston valve or
packings
Open or worn intake valve
Clear or service the intake valve.
Worn check balls, seats, or
Cycles or fails to hold
Service the pump lower.
piston packing
pressure at stall
Poor finish or irregular spray Inadequate air assist air pressure Adjust the air assist needle valve on the
applicator.
pattern
Dirty, worn, or damaged spray
Service the spray applicator (see Applicator
applicator
manual 3A3244).
Motor powered but nothing Pump is packed out with dry or Disassemble and clean the pump (daily).
comes out of hose
cured material
Hose is packed out with dry or
Reduce length and/or increase diameter of
cured material
the hose.
Install the outlet check valve in the correct
Outlet check valve is installed
orientation.
backwards
Material is too thick to push Hose is too restrictive
Thin and mix material thoroughly to a lower
through the hose without
viscosity.
packing out
Use a pump system priming fluid (slime).
Wet out the system.
Reduce length and/or increase diameter of
the hose.
3A3110K
45
Troubleshooting
Problem
Hydraulic pump does not
develop pressure. Low
or zero pressure with
screeching noise.
Cause
Pump is not primed or lost its
prime.
Solution
Check dipstick to ensure that hydraulic
reservoir is properly filled.
Make sure the hydraulic pump inlet fitting is
fully tight, to ensure no air is leaking into the
hydraulic pump inlet.
To prime pump, run unit at lowest pressure
setting and slowly increase pressure. In
some cases it may be necessary to remove
cover shroud, belt guard, and drive belt to
allow for manual (counterclockwise) rotation
of hydraulic pump. Turn fan pulley by hand.
Verify oil flow by removing oil filter to see
flow into filter manifold. Reinstall oil filter. Do
NOT operate unit without a properly installed
oil filter.
Screeching noise is
If noise continues longer than 30 seconds,
characteristic of cavitation
turn off main power disconnect to shut off
and is normal at initial startup for the motor. Check that the hydraulic pump
a maximum of 30 seconds.
inlet fittings are tight and that the pump has
not lost its prime.
Ensure that the reservoir is properly
Hydraulic fluid is too hot.
serviced. Improve ventilation to allow more
efficient heat dissipation.
Drive belt loose or broken.
Check drive belt condition. Replace if
broken.
Electric motor will not start or Loose connections
Check connections in electrical enclosure.
stops during operation
Check for 200–240 VAC at input of motor
contactor.
Reset breaker inside the electrical control
Circuit breaker tripped
box (R).
Over temperature switch in the Wait for the motor to cool, then restart the
motor is tripped.
motor.
Air compressor surging or
Restriction in air compressor
Verify that the air hoses, fittings, and cooling
output low
outlet path
tube on the machine are free of debris. Also,
verify that the air relief valve (part 17H606)
and muffler (part 120206) are clean and free
of debris.
Air compressor motor stops Circuit breaker tripped
Verify that the air hoses, fittings, and cooling
during operation
tube on the machine are free of debris. Also,
verify that the air relief valve (part 17H606)
and muffler (part 120206) are clean and free
of debris.
Over temperature switch in the Wait for the motor to cool, then restart the
motor is tripped
motor.
46
3A3110K
Replacement Parts and Accessories
Replacement Parts and Accessories
Accessories
24Y479
F680e forklift stabilization kit
17H197
Kit, remote switch, cable (remote ON/OFF switch with 100 ft (30 m) of cable)
17G665
Kit, remote switch, extension cord (110 ft, 33.5 m)
114271
Strap, retaining
240296
Kit, retaining straps, 4 pack
17J703
Kit, ball, valve (material hose ball valve attachment)
121441
Fitting, 1–1/2 NPT, nipple (check valve replacement nipple fitting)
Belts
17G244
Belt, AX, air compressor (AX44 cogged V-belt)
125834
Belt, tri-power, AX48, hydraulic (AX48 cogged V-belt)
Air Compressor
125809
Lubricant, oil, synthetic
24N370
Pump, compressor, air (air compressor)
131366
Kit, air filter (replacement air filter element and cover)
Hydraulic System
246173
Kit, repair, oil filter
25A320
Kit, driver, 4.75 in. stroke (complete driver)
25A321
Kit, reservoir, assembly, F680e (complete hydraulic pump and reservoir)
Repair Parts
Lower Assembly
16W490
Kit, repair, 10 pack, o-ring, cylinder end (cylinder o-ring)
17G456
Kit, lower, clamp (cylinder clamp)
17H242
Kit, repair, pump rebuild
24Y513
Kit, pump, lower, F680e (complete assembled F680e pump lower)
Inlet
16W510
Kit, repair, seat, inlet (inlet seat and o-ring)
112420
Ball, sst, 1590 (1.75 in. diameter inlet check ball)
Piston
17H191
Kit, piston seat, o-ring (piston seat and o-ring)
108001
Ball, metallic (1.5 in. diameter piston check ball)
16W491
Kit, repair, 3 pack, seal, piston (piston packing cup)
Outlet
16W492
Kit, repair, 3 pack, seal, throat (throat seal)
Rubber Elbow
17H193
Kit, inlet elbow (rubber elbow)
17H196
Kit, elbow, band clamp (rubber elbow clamp)
Check Valve
17H192
Kit, outlet seat, o-ring (seat and o-ring)
17H194
Kit, outlet, check, valve (complete 1.5 in. outlet check valve)
102973
Ball, metallic (1.25 in. diameter outlet check ball)
113082
Packing, o-ring (check valve packing o-ring)
17J712
Kit, check, retainer (check valve ball retainers)
3A3110K
47
Electrical Schematics
Electrical Schematics
Incoming Power
N L
24 VDC
N L
CT2-A1
CT3-L1
CT2-L1
L1 L2
SW2-4
CT1-L2
CT2-L2
ti27455a
L1 L2
ti27457a
SW2-4
CT2-L2
48
200–240 VAC 1Φ no compressor
CT2-A1
CT2-L1
24 VDC
200–240 VAC 1Φ with compressor
3A3110K
Electrical Schematics
Motors and Motor Control
NOTE: Compressor motor and related components are only present in systems with an integrated air
compressor.
INSIDE ELECTRICAL CONTROL BOX
ti27333a
230V
Ref.
A
F
F
E
D
Description
Motor, hydraulic
B
A
E
C
Circuit
Breaker
CB1
Circuit
Breaker
CB2
CT1-L2
Contactor
CT2
CT1-L1
SW2-4
Contactor
CT1
CT2-L2
CT2-A1
CT2-L1
A1 A2
A1 A2
1L1 3L2 5L3 1L1 3L2 5L3
2T1 4T2 6T3 2T1 4T2 6T3
Diagram Key
Motor Junction Box Wiring Connections
Wiring Label
MTR1
Color
Black
Motor Wire
#4 and #5
MTR2
White
#1 and #8
PE
Green
GND Lug
B
Motor, compressor
C
Harness, hydraulic motor
D
Harness, compressor motor
OT1
Orange
J
E
Over-temperature
OR2
Red
J
F
Power
3A3110K
49
Electrical Schematics
F
A
E
C
ti30975a
230V
Diagram Key
Ref.
A
50
Description
Motor, hydraulic
B
Motor, compressor
C
Harness, hydraulic motor
Motor Junction Box Wiring Connections
Wiring Label
MTR1
Color
Black
Motor Wire
#4 and #5
MTR2
White
#1 and #8
PE
Green
GND Lug
D
Harness, compressor motor
OT1
Orange
J
E
Over-temperature
OR2
Red
J
F
Power
3A3110K
Electrical Schematics
Pump Control
24 VDC
TB08
C
B
A
ti27332a
INSIDE ELECTRICAL CONTROL BOX
Diagram Key
Ref.
A
Description
Remote Switch
B
Hydraulic Solenoid Valve
C
Pump Control Switch
3A3110K
51
Notes
Notes
52
3A3110K
Technical Specifications
Technical Specifications
ToughTek F680e Fireproofing Pump
Maximum Fluid Working Pressure
Stroke Length
Maximum pump speed (Do not exceed maximum
recommended speed of fluid pump to prevent
premature pump wear)
Weight (empty)
Wetted Parts
Hydraulic Tank Capacity
Metric
U.S.
600 psi
4.14 MPa, 41.4 Bar
4.75 in.
120 mm
77 cycles per minute
625 lb
283.5 kg
Stainless steel, plated steel, carbide, urethane, PTFE,
UHMWPE, LLDPE, aluminum, solvent-resistant o-rings
1.25 gallons
4.73 liters
Oil Specification
Graco Hydraulic Oil, ISO 46 169236 (5 gallon / 18.9
liter) or 207428 (1 gallon / 3.8 liter)
Maximum Pump Line Speed
60 Hz
77 cycles per minute
Inlet/Outlet Sizes
3 in.
Fluid Inlet Size
Fluid Outlet Size
Hose Requirements
Minimum Pressure
1.5 in. npt(f) with 1.5 in. male camlock
600 psi
4.14 MPa, 41.4 bar
Minimum Hose Diameter
1 in.
2.54 cm
Minimum Hose Length
25 ft
7.6 m
85 psi
5.9 bar (0.59 MPa)
10 cfm at 40 psi
17 m³/h at 2.7 bar (0.27 MPa)
Air Compressor Performance
Maximum Working Air Pressure
Maximum Air Compressor Output
Sound Pressure, measured at 3.1 ft (1 m) per ISO 3744
Model 24Y500
82.8 dB(A)
Model 24Y502
80.2 dB (A)
Sound Power, measured at 3.1 ft (1 m) per ISO 3744
Model 24Y500
93.1 dB(A)
Model 24Y502
90.9 dB (A)
Operating Ambient Temperature
Temperature
32° F to 120° F
4° C to 49° C
46 in.
117 cm
Dimensions
Height
Width
33 in.
84 cm
Length
Weight
62.25 in.
158 cm
Model 24Y500
625 lb
284 kg
Model 24Y502
515 lb
234 kg
3A3110K
53
Graco Standard Warranty
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 WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS
FOR A PARTICULAR PURPOSE.
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 MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT,
MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not
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.
Graco Information
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
To place an order, contact your Graco Distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
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.
Original Instructions. This manual contains English. MM 3A3110
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2020, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision K – April 2020

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