Graco 262927, ToughTek M680a, 24T834, 262926, 24T835 Instructions Manual

Instructions-Parts

ToughTek

ToughTek ToughTek

High

performance,

High High

performance, performance,

and

epoxies.

and and

epoxies. epoxies.

Important

Important Important
Readallwarningsandinstructionsinallmanuals.Save Save
instructions.

instructions. instructions.

See page 6 for models and approvals
information.

1000 psi (7 MPa, 69 bar) Maximum
Fluid Working Pressure

150 psi (1.0 MPa, 10 bar) Maximum Air
Inlet Pressure

100 psi (0.7 MPa, 7 bar) Maximum
Pump Air Regulator Pressure

M680a

M680a M680a

high

output

high high

output output

For

professional

For For

professional professional

Safety

Safety Safety

Instructions

Instructions Instructions

Mortar

Mortar Mortar

Sprayer

Sprayer Sprayer

332612C

EN

spray

spray spray

use

use use

packages

packages packages

only.

only. only.

for

high

for for

viscosity

high high

viscosity viscosity

Save

materials,

materials, materials,

all

all all

such

as

such such

mortars,

as as

mortars, mortars,

mastics,

mastics, mastics,

PROVENQUALITY.LEADINGTECHNOLOGY.

Contents

Contents Contents

RelatedManuals................................................2

Warnings...........................................................3

Models...............................................................6

ComponentIdenti󰘰cation.....................................8

Overview.....................................................8

Details.........................................................9

MortarSprayApplicator................................10

HTX680(InternalAir)Applicator...................11

SystemComponents....................................12

Grounding..........................................................13

Setup.................................................................14

PressureReliefProcedure..................................15

WetOuttheSystem............................................16

MixtheMaterial..................................................19

PrimewithMortarorEpoxy.................................20

Spray.................................................................22

PreventPackout..........................................22

BeforeStartingorStoppingMaterial

Flow..............................................22

Spraying......................................................22

SprayAdjustments(MortarSpray

Applicator)............................................24

AirFlowValveAdjustment............................24

MaterialFlowAdjustments............................24

SprayTechniques........................................25

InstallingNozzleRetainingCap.....................25

MaterialCompatibility...................................25

SprayAdjustments(HTX680Applicator).............26

Flush.................................................................27

DisassembleandCleanthePump(Daily).............30

Shutdown...........................................................33

Maintenance......................................................33

PreventativeMaintenance............................33

DailyMaintenance.......................................33

CorrosionProtection....................................34

CartMaintenance.........................................34

Troubleshooting..................................................35

Repair................................................................37

ReplacePumpComponents.........................37

ReplaceAirMotor........................................37

ReplacePumpLower...................................37

Parts..................................................................38

Accessories........................................................44

TechnicalSpeci󰘰cations......................................45

GracoStandardWarranty....................................48

Related

Related Related

Manualsareavailableatwww.graco.com.

ComponentmanualsinEnglish:

Manual

Manual Manual
332651
332767

332768
312796NXTAirMotorsInstructions-Parts
332649PumpLowerInstructions-Parts
332650PumpInstructions-Parts

Manuals

Manuals Manuals

Description

Description Description
MortarSprayingTips
MortarSprayApplicatorsOperation-

Parts
HTX680ApplicatorOperation-Parts

2

332612C

Warnings

Warnings Warnings

Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.

WARNING

WARNING WARNING

FIRE

AND

FIRE FIRE

Flammablefumes,suchassolventandpaintfumes,inwork work
prevent󰘰reandexplosion:

•Useequipmentonlyinwellventilatedarea.

•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).

•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.

•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.

•Groundallequipmentintheworkarea.SeeGrounding Grounding

•Useonlygroundedhoses.

•Holdapplicator󰘰rmlytosideofgroundedpailwhentriggeringintopail.Donotusepail
linersunlesstheyareantistaticorconductive.

Stop

•Stop Stop
equipmentuntilyouidentifyandcorrecttheproblem.

•Keepaworking󰘰reextinguisherintheworkarea.

EXPLOSION

AND AND

EXPLOSION EXPLOSION

operation

operation operation

immediately

immediately immediately

HAZARD

HAZARD HAZARD

work

area

area area

canigniteorexplode.Tohelp

Grounding

ifstaticsparkingoccursoryoufeelashock. ..Donotuse

instructions.

Warnings

SKIN

INJECTION

SKIN SKIN

INJECTION INJECTION

High-pressure󰘱uidfromdispensingdevice,hoseleaks,orrupturedcomponentswillpierce
skin.Thismaylooklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get
immediate

immediate immediate

•Donotpointdispensingdeviceatanyoneoratanypartofthebody.

•Donotputyourhandoverthe󰘱uidoutlet.

•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.

•FollowthePressure Pressure
checking,orservicingequipment.

•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.

•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.

surgical

surgical surgical

HAZARD

HAZARD HAZARD

treatment.

treatment. treatment.

Pressure

Relief

Procedure

Relief Relief

Procedure Procedure

whenyoustopdispensingandbeforecleaning,

Get

332612C 3

Warnings

WARNING

WARNING WARNING

EQUIPMENT

EQUIPMENT EQUIPMENT

Misusecancausedeathorseriousinjury.

•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.

•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical

•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnicalData
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestMSDSfromdistributororretailer.

•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.

•TurnoffallequipmentandfollowthePressure Pressure

•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.

•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.

•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.

•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.

•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.

•Donotkinkoroverbendhosesorusehosestopullequipment.

•Keepchildrenandanimalsawayfromworkarea.

•Complywithallapplicablesafetyregulations.

MOVING

MOVING MOVING

MISUSE

MISUSE MISUSE

PARTS

PARTS PARTS

HAZARD

HAZARD HAZARD

Technical

HAZARD

HAZARD HAZARD

Data

Data Data

Pressure

inallequipmentmanuals.

Relief

Relief Relief

Procedure

Procedure Procedure

whenequipmentisnotinuse.

Movingpartscanpinch,cutoramputate󰘰ngersandotherbodyparts.

•Keepclearofmovingparts.

•Donotoperateequipmentwithprotectiveguardsorcoversremoved.

•Pressurizedequipmentcanstartwithoutwarning.Beforechecking,moving,orservicing
equipment,followthePressure Pressure

TOXIC

TOXIC TOXIC

Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.

•ReadMSDSstoknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.

•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable

PERSONAL

PERSONAL PERSONAL

Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:

•Protectiveeyewear,andhearingprotection.

•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent

SUCTION

SUCTION SUCTION

Powerfulsuctioncouldcauseseriousinjury.

FLUID

FLUID FLUID

guidelines.

manufacturer.

OR

OR OR

PROTECTIVE

PROTECTIVE PROTECTIVE

HAZARD

HAZARD HAZARD

Pressure

FUMES

FUMES FUMES

Relief

Procedure

Relief Relief

Procedure Procedure

HAZARD

HAZARD HAZARD

EQUIPMENT

EQUIPMENT EQUIPMENT

anddisconnectallpowersources.

•Neverplacehandsnearthepump󰘱uidinletwhenpumpisoperatingorpressurized.

4

332612C

Warnings

Material

Material Material

Somematerialsmaybecomeself-ignitingifapplied
toothick.Readmaterialmanufacturer’swarningsand
materialMSDS.

Changing

Changing Changing

Changingthematerialtypesusedinyourequipment
requiresspecialattentiontoavoidequipmentdamage
anddowntime.

•Whenchangingmaterials,󰘱ushtheequipment
multipletimestoensureitisthoroughlyclean.

•Alwayscleanthe󰘱uidinletstrainersafter󰘱ushing.

•Checkwithyourmaterialmanufacturerforchemical
compatibility.

•Whenchangingbetweenepoxiesandurethanes
orpolyureas,disassembleandcleanall󰘱uid
componentsandchangehoses.

Self

ignition

Self Self

- --ignition ignition

Materials

Materials Materials

NOTICE

NOTICE NOTICE

332612C 5

Models

Models

Models Models

Model

9

9 9

Includes

Includes Includes

:

: :

262927

262927 262927

262909

262909 262909

262926

262926 262926

Model Model

24T834

24T834 24T834

24T835

24T835 24T835

24T836

24T836 24T836

24T837

24T837 24T837

PumpinstalledonCart

24T837

BasicSparePartsKit

1

2

(includedintoolbox)

FeedHopper24T853

3

Standard35ft(1.7m)
HoseBundle24T852

FlexApplicator24T947

4

5

HTX680Manifold

Applicator24U209

AdditionalSpareParts

6

7

Additional25ft(7.6m)

HoseKit24R254

1

Includesairmotor,stainlesssteelpumplower,zerocavityreliefvalve,1in.malecamlockoutlet,aircontrols,

8

✔✔✔✔✔✔✔

✔✔✔✔✔✔✔

✔✔✔✔

✔✔✔✔✔

✔✔✔

✔✔✔

✔

✔

andthetwowheelcart.

2

Includesgasketsforcamandgroove󰘰ttings,completepumprepairsoftsealkit,andpilottuberepair󰘰ttings.

3

Includes10gallon(38liter)stainlesssteelhopper,hoppermounting,straightand90degree2inchfemale

camlockoutlet.

4

Fluidhoseportionofkitincludes1in.x25ft󰘱uidhose,3/4x10ft󰘱uidwhiphose,stainlesssteelshutoffball
valve,and󰘱uidcamlockends.Airlineportionofkitincludes38ftairlinewithpumppilotline,airlinequick
disconnects,andmeshwrap.Includes6milpolyurethanebagtubesfor󰘱uidlinesandairlines.

5

Flexapplicatorincludes23in.(58cm)󰘱exiblehosewithcamlock󰘱uidinlet,angledsprayhead,sprayair
volumecontrol,sprayairshutoffvalve,andmotorpilotsignalcontrolvalve,adjustablepositioncenterair
injectiontube,rubbertipretainer,andinclude3tipsizes.Flexapplicatorisforuseinlowpressuresprayingof
materialsthatpackouteasilyandthatwillbe󰘰nish-troweled.

6

HTX680includescamlock󰘱uidinlet,angledaluminumsprayhead,sprayairvolumecontrol,sprayairshut
offvalve,andmotorpilotsignalcontrolvalve.HTX680usesventuri-typeairinjection󰘱uidnozzlesand
aluminumscrewontipretainer.Includesfournozzlesizes,aFineFinishadapter,andfourFineFinishtips.
HTX680isforuseinmediumpressuresprayofmaterialsthatdonotpackouteasily.

7

Additionalsparepartsoptionincludes󰘱exapplicatorandpoleapplicatorparts(rubberretainer,3/16,4/16,
8/16,9/16in.tips,andairtubeo-ring),HTXapplicatorparts(nozzleretainerand4mm,6mm,8mm,10mm
nozzlesand1/8,1/4,3/8,5/16in.FineFinishdiscs,aircheckvalve,andspoolo-rings),andpumprebuildkit.

8

Extendstotallengthto60ft(18.3m).Includes25ftx1in.󰘱uidhosewithcamlock󰘱uid󰘰ttings,and25ftair
hoseassemblywithhosequickdisconnectsandpilottube.

9

SeeParts,page38,fordetailsregardingwhatisincludedwitheachmodel.

6 332612C

Models

II 2 G Ex h IIA T5 Gb

Agency

Agency Agency

Model

Model Model

262927

262909

262926

24T834

24T835

24T836

24T837

Approvals

Approvals Approvals

Certi󰘰cation

Certi󰘰cation Certi󰘰cation

332612C

7

ComponentIdentication

AA

AB

AC

AD

AE

AF

AGAHAI

AJ

AK

AK

ti21568a

Component

Component Component

Overview

Overview Overview

Identi󰘰cation

Identi󰘰cation Identi󰘰cation

Figure1

Key:

Key: Key:

AAMaterialHopper

ABAirMotor

AC

AD

AEApplicator

AF

Lower

Cart

MaterialHose(connectspumptowhip
hose)

AG

AH

AI

AJ

AK

MaterialWhipHose

AirSupplytoApplicator(forAirAssistand
AirMotorON/OFFPilotValve),shown
disconnected

ReturnAirtoAirMotorON/OFFPilotValve

SystemAirInlet

Optionalhoseextension

8 332612C

ComponentIdentication

Details

Details Details

DetailedView
Figure2

Key:

Key: Key:

A

B

CAirPressureReliefValve

D

E

FMotorAirPressureRegulatorAdjustment

GPilotBallValve(starts/stopsAirMotor)

HMotorAirPilotValve

J

KAirAssistTube

L

AirInlet,3/4npt(f)Claw(Chicago)Fittings

BleedTypeMasterAirValve(required)

AirFilter(40micron)

MotorAirPressureGauge

Knob

ZeroCavityReliefValve

GroundingWire,required(see

Grounding,page13)

M

N

P

R

S

TApplicatorTipAssembly

U

V

W

X

Y

NeedleValveforAirAssistFlowControl

AirSupplyQuickDisconnecttoApplicator
AirInletQuickDisconnect(W)

FluidOutlet,1in.MaleCamlockFitting

PackingNut/WetCupunderSpringGuard

AirAssistNozzlePositionAdjustment
Screw

AirAssistShutoffBallValve

ApplicatorMaterialSupplyBallValve

ApplicatorAirInletQuickDisconnect

PilotValveSignalfromApplicatorPilot
Valve(G)

WhipCheckHoseSafetyCable

332612C 9

ComponentIdentication

CC

CD

CE

CF

CB

CA

U

M

Mortar

Mortar Mortar

Figure3

Key:

Key: Key:
M
U
CA
CBAirNeedle(adjustableposition)
CCAirNeedleRetainingScrew
CD
CETip(Nozzle)
CF

Spray

Spray Spray

NeedleValveforAirAssistFlowControl
AirAssistShutoffBallValve
AirAssistAirLine

FluidHousing

RubberTipRetainer

Applicator

Applicator Applicator

10 332612C

ComponentIdentication

DD

DB

DG

DA

DE

DF

U

M

DC

HTX

HTX HTX

680

(Internal

680 680

(Internal (Internal

Air)

Applicator

Air) Air)

Applicator Applicator

Figure4

Key:

Key: Key:

M
U
DAAirAssistAirLine
DB
DCTip(Nozzle)
DDTipRetainer
DE
DF
DG

NeedleValveforAirAssistFlowControl
AirAssistShutoffBallValve

FluidandAirManifold

AirCheckValve
FluidInletSwivel
Handle

332612C

11

ComponentIdentication

System

System System

* Required system components.

Toavoidtippingover,ensurecartisona󰘱atand
levelsurface.Failuretodosocouldresultininjury
orequipmentdamage.

Bleed

* **Bleed Bleed

•Besurethevalveiseasilyaccessiblefromthe

applicator.

•Requiredinyoursystemtorelieveairtrapped

betweenitandtheairmotorwhenthevalveis
closed.

–Opentosupplyairtothemotor.

–Closetoshutoffairtothemotorandbleedany

trappedairfromthemotor.

Air

* **Air Air

Components

Components Components

Type

Type Type

Pressure

Pressure Pressure

Master

Master Master

Relief

Relief Relief

Air

Valve

Air Air

Valve Valve

Valve

Valve Valve

(C)

(C) (C)

Air

Regulator

Air Air

Regulator Regulator

Adjustsairpressuretothemotorand󰘱uidoutlet
pressureofpump.Readairpressureongauge(E).

Zero

* **Zero Zero

Openvalvetorelievepressureifpumporhose
packoutoccurs.Closevalvewhenspraying.

(B)

(B) (B)

Topreventmaterialhardeninginzerocavityrelief
valve,󰘱ushthevalveaftereverytimeitisused.
SeeFlush,page27.

Toavoidskininjectionandsplashing,never
openacamlockhoseorapplicator󰘰tting
whilethereispressureinthe󰘱uidline.See

PressureReliefProcedure,page15.

Cavity

Cavity Cavity

Adjustment

Adjustment Adjustment

Relief

Relief Relief

Valve

Valve Valve

NOTICE

NOTICE NOTICE

(F)

(F) (F)

(J)

(J) (J)

Automaticallyopenstorelieveairpressureifset
pressureexceedspresetlimit.

Air

Filter

Air Air

Filter Filter

Removesharmfuldirtandwaterfromcompressed
airsupply.

(D)

(D) (D)

12

332612C

Grounding

L

ti21630a

ti1102

Grounding

Grounding Grounding

Theequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundingprovidesanescapewireforthe
electriccurrent.

Tools

Required

Tools Tools

Required Required

•Groundingwiresandclampsforpails

•Two5gallon(19liter)metalpails

1.Connectthegroundwire(L),PartNo.262908,to
thegroundstudontheairmotor.

2.Connecttheotherendofthegroundwiretoa
trueearthground.

3.Groundtheobjectbeingsprayed,󰘱uidsupply
container,andallotherequipmentinthe
workarea.Followyourlocalcode.Useonly
electricallyconductiveairand󰘱uidhoses.

4.Groundallsolventpails.Useonlymetalpails,
whichareconductive,placedonagrounded
surface.Donotplacepailonanon-conductive
surface,suchaspaperorcardboard,which
interruptsgroundingcontinuity.

Figure6

GroundingWire
Figure5

332612C 13

Setup

R

ti21631a

B

A

ti21575a

Setup

Setup Setup

Tools

Required

Tools Tools

Required Required

•Twoadjustablewrenches

•Non-sparkinghammerorplasticmallet

1.Groundsprayer.SeeGrounding,page13.

2.CheckThroatSealLiquid(TSL)levelinpacking
nut(R).Fill1/2fullwithTSL.

9.Wrapblue,velcro,camlockretainingstraps
aroundeachcamlockconnectiontosecure.

Note

NOTE:

NOTE: NOTE:
betweenthehopperandpumplower,the
camlockatthepumpoutlet,thecamlocks
onthe󰘱uidhoses,andthecamlockon
theapplicatorinlet.Theretainingstraps
shouldbetightandmustnotbeableto
slideoffcamlock.

10.Goingfromapplicatorbacktothesystem,wrapa
ziptiearoundallhoseseveryfewfeettosecure
themtogether.

11.Connectairsupplyhose:

a.Closebleedtypemasterairvalve(B).

b.Expandendofwhipcheckcable(Y)and

slideitovertheendofyourairhose.

c.Connectairsupplyhoseto3/4npt(f)claw

󰘰ttingsairinlet(A).

d.Installsafetyclipsinclaw󰘰ttings.

Thisincludesthetwocamlocks

Figure7

3.Attach1in.x25ftelectricallyconductive󰘱uid
hosetopumpoutlet.

Note

NOTE:

NOTE: NOTE:
connectedtotheendofthe1in.hoseat
thefactory.

4.Attachlargeairlinefromhosebundletomainair
quickdisconnect(N).SeeDetails,page9.

5.Attachsmallairtubefromhosebundletomotor
pilotsignal(X).Usewrenchtosecureairtubein
place.SeeDetails,page9.

6.Attach3/4in.hosetoapplicator󰘱uidinlet.

7.Attachlargeairlinefromhosebundletoapplicator
quickdisconnect(W).SeeDetails,page9.

8.Attachsmallairtubefromhosebundleto
airmotorpilotballvalve(G)onapplicator.
Usewrenchtosecureairtubeinplace.See

Details,page9.

The3/4in.hosewillbe

Figure8

12.Wetoutthesystemwithmaterial󰘱ushingagent
beforeusing.SeeWetOuttheSystem,page16.

14

332612C

PressureReliefProcedure

B

A

ti21575a

t

i21632a

Pressure

Pressure Pressure

FollowthePressureReliefProcedure
wheneveryouseethissymbol.

Thisequipmentstayspressurizeduntilpressure
ismanuallyrelieved.Tohelppreventserious
injuryfrompressurized󰘱uid,suchasskininjection,
splashing󰘱uidandmovingparts,followthe
PressureReliefProcedurewhenyoustopspraying
andbeforecleaning,checking,orservicingthe
equipment.

1.Flushthesystem.SeeFlush,page27.

2.Closeincomingairballvalve(B).

Relief

Relief Relief

Procedure

Procedure Procedure

4.Holdapplicator󰘰rmlyagainstagroundedmetal

pail.Openthematerialballvalve(V)onthebase
oftheapplicator.

Figure10

Figure9

3.Setairregulator(F)tozeropressure.

5.Ifyoususpecttheapplicatortiporhoseis

completelyclogged,orthatpressurehasnot
beenfullyrelievedafterfollowingtheprevious
steps,slowlyopenthezerocavityreliefvalve(J)
atthepumpoutlet.SeeDetails,page9.

6.Ifthereisstillpressuretrappeddowntheline,

veryslowlyloosenthethreadedswivel󰘰ttingat
thepumpoutletwhilekeepingitcovereduntilthe
pressureisrelieved.

7.Flushthezerocavityreliefvalve(J).See

Flush,page27.

NOTICE

NOTICE NOTICE

Topreventmaterialhardeninginzerocavityrelief
valve,󰘱ushthevalveaftereveryuse.

332612C 15