Graco 332612A User Manual

Instructions - Parts

M680 Mortar Sprayer

High performance, high output spray packages for high viscosity materials, such as mortars, mastics,
and epoxies. For professional use only.

Important Safety Instructions

Read all warnings and instructions in all manuals.

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

Save all instructions.

332612A

EN

Ex II 2 G c IIA T5

ti21568a

Contents

Related Manuals ................................................ 2

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

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

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

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

Details......................................................... 8

Mortar Spray Applicator................................ 9

HTX 680 (Internal Air) Applicator...................10

System Components.................................... 11

Grounding .......................................................... 12

Setup................................................................. 13

Pressure Relief Procedure .................................. 14

Wet Out the System............................................ 15

Mix the Material.................................................. 18

Prime with Mortar or Epoxy ................................. 19

Spray................................................................. 21

Prevent Packout .......................................... 21

Before S tarti ng or Stopping Material

Flow .............................................. 21

Spraying...................................................... 21

Spray Adjustments (Mortar Spray

Applicator) ............................................ 23

Air Flow Valve Adjustment............................ 23

Material Flow Adjustments............................ 23

Spray Techniques........................................ 24

Installing Nozzle Retaining Cap..................... 24

Material Compatibility................................... 24

Spray Adjustments (HTX 680 Applicator) ............. 25

Flush ................................................................. 26

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

Disassemble and Clean the Pump (Daily).............30

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

Maintenance ...................................................... 34

Daily Maintenance ....................................... 34

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

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

Replace Pump Components......................... 37

Replace Air Motor........................................37

Replace Pump Lower ................................... 37

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

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

Technical Specifications...................................... 45

Graco Standard Warranty....................................48

Related Manuals

Manuals are available at www.graco.com.

Component manuals in Engli sh:

Manual Description

332651
332767

332768
312796 NXT Air Motors Instructions - Parts
332649 Pump Lower Instructions - Parts
332650 Pump Instructions - Parts

Mortar Spraying Tips
Mortar Spray Applicators Op erati on -

Parts
HTX 680 Applicator Operation - Parts

2

332612A

Warnings

Warnings

The following warnings are f or 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 label s, 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

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in
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 arc).

• 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.

• Ground all equipment in the work area. Se e

• 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

equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, 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 amputatio n.

immediate surgical treatment.

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

• Do not put your hand over the fluid outlet.

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

•Followthe
checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

Pressure Relief Procedure

if static sparking occurs or you feel a shock.Do not u se

Grounding

when you stop dispensing and before cleaning,

work area

instructions.

canigniteorexplode.Tohelp

Get

332612A 3

Warnings

WARNING

EQUIPMEN T MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs o r alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated
system component. See

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For comple te
information about your material, request MSDS from distributor or retailer.

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

• Turn off all equipment and follow the

• 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.

Technical Data

Pressure Relief Procedure

in all equipment manuals.

when equipment is not in use.

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

TOXIC FLUID OR FUMES HAZARD

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

• Read MSDSs 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.

Pressure Relief Procedure

and disconnect all power sources.

4

332612A

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. This 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.

SUCTION HAZARD

Powerful suction could cause serious injury.

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

Material Self-ignition

Warnings

WARNING

Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings and
material MSDS.

Changing Materials

NOTICE

Changing the material types used in your equipment
requires special attention to avoid equipment damage
and downtime.

• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical
compatibility.

• When changing between epoxies and urethanes
or polyureas, disassemble and clean all fluid
components and change hoses.

332612A 5

Models

Models

Includes9:

Model

262927 262909 262926 24T834 24T835 24T836 24T837

Pump installed on Cart

24T837

Basic Spare Parts Kit

1

2

(included in tool box)

Feed Hopper 24T853

3

Standard 35 ft (1.7 m)
Hose Bundle 24T852

Flex Applicator 24T947

4

5

HTX 680 Manifold

Applicator 24U209

Additional Spare Parts

6

7

Additional 25 ft (7.6 m)

Hose Kit 24R254

1

Includes air motor, stainless steel pump lower, zero cavity relief valve, 1 in. male camlock outlet, air controls,

8

✔✔✔✔✔✔✔

✔✔✔✔✔✔✔

✔✔ ✔ ✔

✔✔✔✔✔

✔✔✔

✔✔✔

✔

✔

andthetwowheelcart.

2

Includes gaskets for cam and groove fittings, complete pump repair soft seal kit, and pilot tube repair fittings.

3

Includes 10 gallon (38 liter) stainless steel hopper, hopper mounting, straight and 90 degree 2 inch female

cam lock outlet.

4

Fluid hose portion of kit includes 1 in. x 25 ft fluid hose, 3/4 x 10 ft fluid whip hose, stainless steel shut off ball
valve, and fluid cam lock ends. Air line portion of kit includes 38 ft air line with pump pilot line, air line quick
disconnects, and mesh wrap. Includes 6 mil polyurethane bag tubes for fluid lines and air l ines.

5

Flex applicator includes 23 in. (58 cm) flexible hose with cam lo ck fluid inlet, angled spray head, spray air
volume control, spray air shut off valve, and motor pilot signal control valve, adjustable position center air
injection tube, rubber tip retainer, and include 3 tip sizes. Fl ex applicator is for use in low pressure spraying of
materials that pack out easily and that will be finish-trowe led.

6

HTX 680 includes cam lock fluid inlet, angled aluminum spray head, spray air volume control, spray air shut
off valve, and motor pilot signal control valve. HTX 680 uses venturi-type air injection fluid nozzles and
aluminum screw on tip retainer. Includes four nozzle sizes, a Fine Finish adapter, and f our Fine Finish tips.
HTX 680 is for use in medium pressure spray of materials that do not pack out easily.

7

Additional spare parts option includes flex applicator and pole applicator parts (rubber retainer, 3/16, 4/16,
8/16, 9/16 in. tips, and air tube o-ring), HTX applicator parts (nozzle retainer and 4 mm, 6 mm, 8 mm, 10 mm
nozzles and 1/8, 1/4, 3/8, 5/16 in. Fine Finish discs, air check valve, and spool o-rings), and pump rebuild kit.

8

Extends total length to 60 ft (18.3 m). Includes 25 ft x 1 in. fluid hose with cam lock fluid fittings, and 25 ft air
hose assembly with hose quick disconne cts and pilot tube.

9

See Parts, page 38, for details reg arding what is included with each model.

6 332612A

Component Identification

Overview

Component Identification

AA

AC

AB

AD

AJ

AF

AK

AE

Figure 1

Key:

AA Material Hopper
AB Air Motor
AC
AD
AE Applicator
AF Material Hose (connects pump to whip

332612A

Lower
Cart

hose)

AK

AGAHAI

AG Material Whip Hose
AH

AI
AJ
AK

Air Supply to Applicator (for Air Assist and
Air Motor ON/OFF Pilot Valve), shown
disconnected

Return Air to Air Motor ON/OFF Pilot Valve
System Air Inlet
Optional hose extension

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7

Component Identification

Details

D

B

Y

A

F

N

C

J

E

HX

L

K

U

M

P

R

G

W

U

M

G

K

G

W

S

T

S

T

U

T

M

Detailed View
Figure 2

Key:

A

B

Air Inlet, 3/4 npt(f) Claw (Chicago) Fittings

Bleed Type Master Air Valve (required)
C Air Pressure Relief Valve
D
E
FMot

Air Filter (40 micron)

Motor Air Pressure Gauge

or Air Pressure Regulator Adjustment

b

Kno
G Pilot Ball Valve (starts/stops Air Motor)
H Motor Air Pilot Valve
J
KA
L

Zero Cavity Relief Valve

ir Assist Tube

Grounding Wire, required (see

Grounding, page 12)

M
N

V

Needle Valve for Air Assist Flow Control
Air Supply Quick Disconnect to Appl icato r

W

ti21569a

Air Inlet Quick Disconnect (W)
P
R

Fluid Outlet, 1 in. Male Camlock Fitting

Packing Nut/Wet Cup under Spring Guard
S Air Assist Nozzle Position Adjustment

Screw
T Applicator Tip Assembly
U
V

Air Assist Shutoff Ball V al ve

Applicator Material Supply Ball Valve
W Applicator Air Inlet Quick Disconnect
X

Pilot Valve Signal from App li cator Pil ot

Valve (G)
Y

Whip Check Hose Safety Cable

8 332612A

Mortar Spray Applicator

Component Identification

M

Figure 3

Key:

M
U
CA
CB Air Needle (adjustable position)
CC Air Needle Retaining Screw
CD
CE Tip (Nozzle)
CF

Needle Valve for Air Assist Flow Control
Air Assist Shutoff Ball Valve
Air Assist Air Line

Fluid Housing

Rubber Tip Retainer

U

CF

CA

CB

CC

CD

CE

332612A 9

Component Identification

HTX 680 (Internal Air) Applicator

DG

Figure 4

Key:

M Needle Valve for Air Assist Flow Control
U Air Assist Shutoff Ball Valve
DA Air Assist Air Line
DB Fluid and Air Manifold
DC Tip (Nozzle)
DD Tip Retainer
DE Air Check Valve
DF Fluid Inlet Swivel
DG Handle

M

DF

DA

DE

U

DB

DD

DC

10 332612A

System Components

Component Identification

* Required system components.

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

* Bleed Type Master Air Valve (B)

• Be sure the valve is easily accessible from the
applicator.

• Required in your system to relieve air trapped
between it and the air motor when the valve is
closed.

– Open to supply air to the motor.
– Close to shut off air to the motor and bleed any

trapped air from the motor.

* Air Pressure Relief Valve (C)

Air Regulator Adjustment (F)

Adjusts air pressure to the motor and fluid outlet
pressure of pump. Read air pressure on gauge (E).

* Zero Cavity Relief Valve (J)

Open valve to relieve pressure if pump or hose
packout occurs. Close valve when spraying.

NOTICE

To prevent material hardening in zero cavity relief
valve, flush the valve after every time it is used.
See Flush, page 26.

To avoid skin injection and splashing, never
open a camlock hose or applicator fitting
whilethereispressureinthefluidline. See

Pressure Relief Procedure, page 14.

Automatically opens to relieve air pressure if set
pressure exceeds preset limit.

Air Filter (D)

Removes harmful dirt and water from compressed
air supply.

332612A

11

Grounding

Grounding

The equipmen
risk of stati
or static sp
explode. Im
shock. Grou
electric cu

Tools Requ

• Grounding wires and clamps for pails

• Two 5 gallon (19 liter) metal pai ls

1. Connect the ground wire (L), Part No. 262908, to
the ground stud on the air motor.

t must be grounded to reduce the

c sparking and electric shock. Electric

arking can cause fumes to ignite or

proper grounding can cause electric

nding provides an escape wire for the

rrent.

ired

L

2. Connect the other end of the ground wire to a
true earth ground.

3. Ground the object being sprayed, fluid supply
container, and all other equipment in the
work area. Follow your local code. Use only
electrically conductive air and fluid hoses.

4. Ground all solvent pails. Use only metal pails,
which are conductive, placed on a grounded
surface. Do not place pail on a non-conductive
surface, such as paper or cardboard, which
interrupts grounding continuity.

ti1102

Figure 6

Grounding Wire
Figure 5

ti21630a

12

332612A

Setup

Setup

Tools Required

• Two adjustable wrenches

• Non-sparking hammer or plastic mallet

1. Ground sprayer. See Grounding, page 12.

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

R

9. Wrap blue, velcro, camlock retaining straps
around each camlock connection to secure.

NOTE:

between the hopper and pump lower, the
camlockat the pump outlet, the camlocks
on the fluid hoses, and the camlock on
the applicator inlet. The retaining straps
should be tight and must not be able to
slide off camlock.

10. Going from applicator back to the system, wrap a
zip tie around all hoses every few feet to secure
them together.

11. Connect air supply hose:

a. Close bleed type master air valve (B).
b. Expand end of whip check cable (Y) and

slide it over the end of your air hose.

c. Connect air supply hose to 3/4 npt(f) claw

fittings air inlet (A).

d. Install safety clips in claw fittings.

This includes the two camlocks

ti21631a

Figure 7

3. Attach1in.x25ftelectricallyconductivefluid
hose to pump outlet.

NOTE:

connected to the end of the 1 in. hose at
the factory.

4. Attach large air line from hose bundle to main air
quick disconnect (N). See Details, page 8 .

5. Attach small air tube from hose bundle to motor
pilot signal (X). Use wrench to secure air tube in
place. See Details, page 8 .

6. Attach 3/4 in. hose to applicator fluid inlet.

7. Attach large air line from hose bundle to applicator
quick disconnect (W ). See Details, page 8 .

8. Attach small air tube from hose bundle to
air motor pilot ball valve (G) on applicator.
Use wrench to secure air tube in place. See

Details, page 8 .

The 3/4 in. hose will be

B

A

ti21575a

Figure 8

12. Wet out the system with material flushing agent
before using. See Wet Out the System, page 15.

332612A 13

Pressure Relief Procedure

Pressure Relief Procedure

Follow the Pressure Relief Procedure

whenever you see this symbol.

This equipm
is manually
injury from
splashing fl
Pressure R
and before
equipment

1. Flush the

2. Close inc

ent stays pressurized until pressure

relieved. To help prevent serious

pressurized fluid, such as skin injection,

uid and moving parts, fol low the

elief Procedure when you stop spraying

cleaning, checking, or servicing the

.

system. See Flush, page 26.

oming air ball valve (B).

B

A

ti21632a

Figure 10

To avoid injection and splashing, never open a
camlock hose or applicator fitting whi le there is
pressureinthefluidline.

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 zero cavity relief valve (J)
at the pump outlet. See Details, page 8 .

6. If there is still pressure trapped down the line,
very slowly loosen the threaded swivel fitting at
the pump outlet while keeping it covered until the
pressure is relieved.

ti21575a

Figure 9

3. Set air regulator (F) to zero pressure.

4. Hold applicator firmly against a grounded metal
pail. Open the material ball valve (V) on the base
of the applicator.

14

7. Flu s h the zero cavi t y relief va l v e (J). See

Flush, page 26.

NOTICE

To prevent material hardening in zero cavity relief
valve, flush the valve after every use.

332612A

Wet Out the System

NOTICE

To prevent
mortar or e
or epoxy in
to stick t
damage an

material curing in system, never load
poxy into a dry system. Loading mortar
to a dry system will cause the material

o internal components and cure causing

d requiring replacement of those parts.

Wet Out the System

3. Partially fill the clean hopper with material
flushing agent, depending on the material you
will be spraying.

4. Turn air regulator adjustment knob (F)
counterclockwise until it stops and gauge (E)
reads zero.

E

Always w
fluid thr
before l
done wit
or comm
fluids a
spraye

et out the system by circulating clean
ough the applicator back into the hopper
oading any mixed mortar. This is normally

h the flushing fluid, but som etimes resin

ercially available concrete pump priming

re used depending on what material is being

d.

• Use the material flushing agent recommended on
the material application data sheet.

• When finished, pump out the excess fluid. Then
drain out remaining fluid by loosening the bottom
cam fitting.

1. Close the bleed type master air valve (B).

F

ti21571a

Figure 12

5. Verify zero cavity relief valve (J) is closed.

6. Place applicator outlet in grounded pail.

7. Open the fluid ball valve (V) on the applicator.

B

A

ti21575a

ti21663a

Figure 11

Figure 13

2. Remove tip from applicator.

332612A 15