Graco ToughTek F340e Use and care manual

3A6393D
EN
Operation, Repair, and Parts
ToughTek®F340e
Portable Fireproofing Pump
Electric sprayer for water-based cementitious fireproofing material.
For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
600 psi (4.13 MPa, 41.3 bar)
Maximum Fluid Working Pressure
See page 3 for model information and approvals.
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment.
Save these instructions.
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Contents
23A6393D
Contents
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component Identification . . . . . . . . . . . . . . . . . . . . 7
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Extension Cords . . . . . . . . . . . . . . . . . . . . . . . . 10
Power Requirements . . . . . . . . . . . . . . . . . . . . 10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mix the Material . . . . . . . . . . . . . . . . . . . . . . . . . 13
Prime with Material . . . . . . . . . . . . . . . . . . . . . . 14
Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Spray Adjustments (Pole Spray Applicator) . . . 16
Spray Techniques . . . . . . . . . . . . . . . . . . . . . . . 17
Installing Nozzle Retaining Cap . . . . . . . . . . . . 17
Pressure Relief Procedure . . . . . . . . . . . . . . . . 18
Clearing a Clogged Hose . . . . . . . . . . . . . . . . . 18
Hopper Removal . . . . . . . . . . . . . . . . . . . . . . . . 19
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . 19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Water Exposure . . . . . . . . . . . . . . . . . . . . . . . . 20
Preventative Maintenance . . . . . . . . . . . . . . . . 20
Corrosion Protection . . . . . . . . . . . . . . . . . . . . . 20
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Mechanical/Fluid Flow . . . . . . . . . . . . . . . . . . . . 21
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . 25
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Replace Pump Components . . . . . . . . . . . . . . . 27
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
F340e Systems . . . . . . . . . . . . . . . . . . . . . . . . . 29
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
F340e (continued) . . . . . . . . . . . . . . . . . . . . . . . 31
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Driver and Motor . . . . . . . . . . . . . . . . . . . . . . . . 34
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Replacement Parts and Accessories . . . . . . . . . . 39
Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Technical Specifications . . . . . . . . . . . . . . . . . . . . 42
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 44

Models
3A6393D 3
Models
Related Manuals
Manuals are available at www.graco.com
Bare
Model
Electric
Requirements Approvals Country Includes Compressor*
25B502 120 V, 15 A, 50/60 Hz, 1 Phase North America
25B552 
25B558 120 V, 15 A, 50/60 Hz, 1 Phase United Kingdom
25B506
230 V, 10 A, 50/60 Hz, 1 Phase Europe, Asia, Australia
25B556 
* Models with an air compressor require an additional dedicated 15 A circuit (120 V systems) or 8.5 A circuit (230 V systems).
† All 230 V pumps include a Europe adapter and Australia adapter cord set.
Manual in English Description
3A3244 Pole Spray Applicator 24Y619
3A3112 ToughTek F340e Remote Switch Accessory Kit 17G554
3A3998 Compressor Manual
3A5637 ToughTek Camlock Mortar Hose
3A4554 ToughTek Mortar Coupling Hose

Warnings
43A6393D
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 and disconnect power cord before servicing equipment.
• Connect only to grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on power and extension cords.
• Do not expose to rain. Store indoors.
• Wait five minutes after disconnecting power cord before servicing.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or
solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:
• Use equipment only in well-ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Use only grounded hoses.
• Hold applicator firmly to side of grounded pail when triggering into pail. Do not use pail liners unless
they are anti-static 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.
• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
SUCTION HAZARD
Misuse can cause death or serious injury.
• Never place hands near the pump fluid inlet when pump is operating or pressurized.

Warnings
3A6393D 5
SKIN INJECTION HAZARD
High-pressure fluid from applicator, hose leaks, or ruptured components will pierce skin. This may look
like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Do not point applicator at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses 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 Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications 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.
WARNING

Warnings
63A6393D
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.
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.
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.
WARNING

Component Identification
3A6393D 7
Component Identification
Overview
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A Electric Motor
B Pump Lower
C Fluid Drain/Purge Valve
E Remote Control Switch
F Fluid Outlet
H Flow Adjustment Knob
J Hopper
K Over-Center Latch
L Control Board Status Light
M Remote Switch Connector
P Hopper Pin
S Motor Power Switch
U Hopper Latch

Component Identification
83A6393D
Fluid Drain/Purge Valve
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.
Motor Power Switch
The motor power switch (S) must be in the ON position
for the sprayer to pump material.
Motor Power Switch Settings:
Applicator Ball Valve (17J703)
Additional accessory kit that can be installed on the end
of the 1 in. ID, 25 ft material hose (88) directly between
the pole spray applicator pipe handle and adapter fitting.
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.
To avoid injury from splashing fluid, never open a
cam-lock hose or applicator fitting while there is
pressure in the fluid line. Follow the Pressure Relief
Procedure on page 18.
NOTICE
To prevent material hardening in fluid drain/purge
valve, flush the valve after every time it is used. Follow
the Flush procedure on page 12.
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OFF Power is disconnected. The motor will not run.
ON The motor will run continuously at a speed
determined by the flow adjustment knob.
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Component Identification
3A6393D 9
Install the Remote Switch
NOTE: Use zip-tie (Z) 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 0.75 in. up to 1.25 in.
Pump Control Settings
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Pump
Control
Setting
Description
ON
The motor will run continuously at the
speed determined by the flow adjustment
knob (H).
OFF The motor will not run. There is still power
to the unit.
Remote
Control
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).
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Grounding
10 3A6393D
Grounding
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.
Extension Cords
• 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
mm2) 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.
NOTE: Certain GFCI outlets have been known to trip
while using this product. GFCI outlets have a range of
sensitivities. Motor controllers can cause false trips of
GFCI outlets. If you experience issues while using this
product, switch to a different GFCI model.
Power Requirements
NOTE: Models with an air compressor require an
additional dedicated 15 A circuit (120 V systems) or
8.5 A circuit (230 V systems).
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.
Model Required
Power Source
Power
Cord Connectors
Supplied
Local Adapters
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
Euro CEE7 (Europe)
AS/NZS (Australia)
100–120 VAC,
50/60 Hz
One separate dedicated
circuits rated at minimum
of 15 A each
One NEMA 5–15A
Plug

Operation
3A6393D 11
Operation
Setup
1. Turn the motor power switch (S) to OFF.
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).
3. Check Throat Seal Liquid (TSL) level in packing nut
(D). Fill 1/2 full with TSL.
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 on page 12).
To avoid tipping over, make sure the cart is on a flat
and level surface. Failure to do so could result in
injury or equipment damage.
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Operation
12 3A6393D
Flush
• 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
on page 18).
2. Remove applicator tip and retainer.
3. Place applicator outlet in a waste container. The
waste container must be large enough to hold all
dispensed material.
4. Turn motor power switch (S) on.
5. Turn adjustment knob (H) clockwise slowly to
increase pressure, until a steady stream flows from
applicator.
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.
NOTE: Be prepared to decrease the flow
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.
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.
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
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.
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Operation
3A6393D 13
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 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
connection.
b. Detach pump from hopper (see Hopper
Removal on 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.
d. 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.
Mix the 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.
Managing Material After Mixing:
• 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.
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.

Operation
14 3A6393D
Prime with Material
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. Follow the Mix the Material procedure on 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 your applicator
manual). The system is now primed and ready to
spray.
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.
NOTICE
To prevent damage to pump seals caused by
cavitation, run the pump slowly until the system is
primed.

Operation
3A6393D 15
Spray
Prevent 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 before and after spraying fluid (see your
applicator manual).
NOTE: If the applicator 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.
Sprayer Performance
NOTE: The check valve (45) helps to improve pump
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.
Spraying
1. Follow the Mix the Material procedure on page 13.
2. Follow the Prime with Material procedure on page
14.
3. Turn on atomizing air and adjust the air needle
valve on the applicator (see your applicator
manual).
4. Turn the motor power switch (S) to ON.
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. Follow
the Flush procedure on page 12.
NOTICE
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.
NOTICE
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.
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Operation
16 3A6393D
Spray Adjustments (Pole Spray Applicator)
NOTE: See the Pole Spray Applicator manual for model
information.
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.
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.
Air Flow Valve Adjustment
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.
Material Flow Adjustment
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.
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Ref. Description
CA Air Assist Air Line
CB Air Assist Shutoff Ball Valve
CC Rubber Tip Retainer
CD Air Needle (adjustable position)
CE Air Needle Retaining Screw
CF Fluid Housing
CG Tip (Nozzle)

Operation
3A6393D 17
Spray Techniques
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.
Installing Nozzle Retaining Cap
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.
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.
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Operation
18 3A6393D
Pressure Relief Procedure
Follow the Pressure Relief Procedure
whenever you see this symbol.
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.
4. If the applicator ball valve kit (17J703) has been
installed, open the ball valve.
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.
Clearing a Clogged Hose
1. Follow the Pressure Relief Procedure, page 18.
2. If you suspect there is a clog in the hose, disconnect
the hose at the connection farthest from the pump.
Continue to disconnect the hose back toward the
pump (upstream) until the hose with the clog is
reached.
3. To clear a clogged hose:
a. Disconnect the clogged hose from the pump if
not done already.
b. Use a rope or a strap to secure the clogged
hose to a permanent, stationary column.
c. Use a water hose to clear the clogged or dried
material from the material hose. Do not use a
hammer on the hose, or insert any potential
projectiles (such as sticks, rebar, etc) into the
hose end.
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.
To avoid injury from splashing fluid, never open a
cam-lock hose or applicator fitting while there is
pressure in the fluid line.
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NOTICE
To prevent material hardening in fluid drain/purge
valve, flush the valve after every use.

Operation
3A6393D 19
Hopper Removal
The hopper assembly allows easy detachment of the
hopper from the pump. To remove the hopper from the
pump, perform the following steps:
1. Follow the Pressure Relief Procedure on page 18.
2. Open the over-center latch (K) to loosen the clamp
between the hopper elbow and the lower.
3. Remove the locking pin and pull down the hopper
latch (U) on the hopper plate.
NOTE: If needed, push down on the hopper 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.
NOTE: If the hopper elbow needs to be thoroughly
cleaned, rotate the second knob (K) to loosen the clamp
between the elbow and the hopper. Remove and clean
the elbow.
NOTE: To re-install the hopper, follow the steps above
in reverse order.
Shutdown
1. To shutdown, follow the Flush procedure on page
12.
2. Turn the motor power switch (S) to OFF.
Lifting Instructions
When lifting the unit, only lift at the points indicated by
the arrows shown in the illustration.
To help prevent injury from suction, never place
hands near the pump fluid inlet when pump is
operating or when hopper is removed.
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3
To avoid injury from splashing fluid, never open a
cam-lock hose or applicator fitting while there is
pressure in the fluid line.
NOTICE
To prevent rust, never leave water or water-based fluid
in the pump overnight.
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Operation
20 3A6393D
Maintenance
1. Follow the Flush procedure on page 12.
2. Clean the hopper with a scrub pad. Clean the
outside of the sprayer with 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.
Water Exposure
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 hose for wear and damage, and inspect
fluid lines for leaks.
DAILY: Check fluid drain/purge valve for proper
operation.
DAILY: Check level of Throat Seal Liquid (TSL) in
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.
Corrosion Protection
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.
NOTICE
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. NOTICE
To prevent rust, never leave water or water-based fluid
in the 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.