Graco 332612A User manual

Graco 332612A User manual
Instructions - Parts
M680 Mortar Sprayer
332612A
EN
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.
Save all instructions.
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
ti21568a
Ex II 2 G c IIA T5
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 Starting 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 English:
Manual
332651
332767
332768
312796
332649
332650
2
Description
Mortar Spraying Tips
Mortar Spray Applicators Operation Parts
HTX 680 Applicator Operation - Parts
NXT Air Motors Instructions - Parts
Pump Lower Instructions - Parts
Pump Instructions - Parts
332612A
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
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in
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 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. See
instructions.
• 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.
•
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.
work area
Grounding
Stop operation immediately
.
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 amputation.
Get
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.
Follow the
when you stop dispensing 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.
332612A
Pressure Relief Procedure
3
Warnings
WARNING
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
in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request 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
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.
Technical Data
Pressure Relief Procedure
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
and disconnect all power sources.
Pressure Relief Procedure
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 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.
4
332612A
Warnings
WARNING
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
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
Includes
Model
9:
Pump installed on Cart
24T837 1
Basic Spare Parts Kit 2
(included in tool box)
Feed Hopper 24T853 3
Standard 35 ft (1.7 m)
Hose Bundle 24T852 4
Flex Applicator 24T947 5
HTX 680 Manifold
Applicator 24U209 6
Additional Spare Parts 7
Additional 25 ft (7.6 m)
Hose Kit 24R254 8
262927
262909
262926
24T834
24T835
24T836
24T837
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
Includes air motor, stainless steel pump lower, zero cavity relief valve, 1 in. male camlock outlet, air controls,
and the two wheel cart.
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 lines.
5 Flex applicator includes 23 in. (58 cm) flexible hose with cam lock 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. Flex applicator is for use in low pressure spraying of
materials that pack out easily and that will be finish-troweled.
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 four 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 disconnects and pilot tube.
9 See Parts, page 38, for details regarding what is included with each model.
1
6
332612A
Component Identification
Component Identification
Overview
AD
AJ
AB
AF
AA
AK
AC
Figure 1
AE
AK
Key:
AA
AB
AC
AD
AE
AF
332612A
Material Hopper
Air Motor
Lower
Cart
Applicator
Material Hose (connects pump to whip
hose)
AI
AH
AG
AH
AI
AJ
AK
AG
ti21568a
Material Whip Hose
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
7
Component Identification
Details
X
H
E
D
B
L
Y
A
K
F
S
N
C
U
J
T
S
M
P
K
G
R
W
U
T
M
G
U
T
M
W
V
Detailed View
Figure 2
M
N
Key:
A
Air Inlet, 3/4 npt(f) Claw (Chicago) Fittings
B
C
D
E
F
Bleed Type Master Air Valve (required)
Air Pressure Relief Valve
Air Filter (40 micron)
Motor Air Pressure Gauge
Motor Air Pressure Regulator Adjustment
Knob
Pilot Ball Valve (starts/stops Air Motor)
Motor Air Pilot Valve
Zero Cavity Relief Valve
Air Assist Tube
Grounding Wire, required (see
Grounding, page 12)
G
H
J
K
L
8
P
R
S
T
U
V
W
X
Y
G
W
ti21569a
Needle Valve for Air Assist Flow Control
Air Supply Quick Disconnect to Applicator
Air Inlet Quick Disconnect (W)
Fluid Outlet, 1 in. Male Camlock Fitting
Packing Nut/Wet Cup under Spring Guard
Air Assist Nozzle Position Adjustment
Screw
Applicator Tip Assembly
Air Assist Shutoff Ball Valve
Applicator Material Supply Ball Valve
Applicator Air Inlet Quick Disconnect
Pilot Valve Signal from Applicator Pilot
Valve (G)
Whip Check Hose Safety Cable
332612A
Component Identification
Mortar Spray Applicator
M
U
CA
CB
CC
CD
CF
CE
Figure 3
Key:
M
U
CA
CB
CC
CD
CE
CF
332612A
Needle Valve for Air Assist Flow Control
Air Assist Shutoff Ball Valve
Air Assist Air Line
Air Needle (adjustable position)
Air Needle Retaining Screw
Fluid Housing
Tip (Nozzle)
Rubber Tip Retainer
9
Component Identification
HTX 680 (Internal Air) Applicator
DG
M
DA
DE
U
DB
DD
DC
DF
Figure 4
Key:
M
U
DA
DB
DC
DD
DE
DF
DG
10
Needle Valve for Air Assist Flow Control
Air Assist Shutoff Ball Valve
Air Assist Air Line
Fluid and Air Manifold
Tip (Nozzle)
Tip Retainer
Air Check Valve
Fluid Inlet Swivel
Handle
332612A
Component Identification
System Components
* Required system components.
Air Regulator Adjustment (F)
Adjusts air pressure to the motor and fluid outlet
pressure of pump. Read air pressure on gauge (E).
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)
* 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
while there is pressure in the fluid line. 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 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.
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.
Tools Required
• Grounding wires and clamps for pails
• Two 5 gallon (19 liter) metal pails
1. Connect the ground wire (L), Part No. 262908, to
the ground stud on the air motor.
Figure 6
L
ti1102
ti21630a
Grounding Wire
Figure 5
12
332612A
Setup
Setup
9. Wrap blue, velcro, camlock retaining straps
around each camlock connection to secure.
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
This includes the two camlocks
between the hopper and pump lower, the
camlock at 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.
NOTE:
ti21631a
Figure 7
3. Attach 1 in. x 25 ft electrically conductive fluid
hose to pump outlet.
The 3/4 in. hose will be
connected to the end of the 1 in. hose at
the factory.
Attach large air line from hose bundle to main air
quick disconnect (N). See Details, page 8 .
Attach small air tube from hose bundle to motor
pilot signal (X). Use wrench to secure air tube in
place. See Details, page 8 .
Attach 3/4 in. hose to applicator fluid inlet.
Attach large air line from hose bundle to applicator
quick disconnect (W). See Details, page 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 .
NOTE:
4.
5.
6.
7.
8.
332612A
B
A
ti21575a
Figure 8
12. Wet out the system with material flushing agent
before using. See Wet Out the System, page 15.
13
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 skin injection,
splashing fluid and moving parts, follow the
Pressure Relief Procedure when you stop spraying
and before cleaning, checking, or servicing the
equipment.
1. Flush the system. See Flush, page 26.
2. Close incoming air ball valve (B).
B
A
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
Figure 10
ti21632a
To avoid injection and splashing, never open a
camlock hose or applicator fitting while there is
pressure in the fluid line.
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.
7. Flush the zero cavity relief valve (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
Wet Out the System
NOTICE
To prevent material curing in system, never load
mortar or epoxy into a dry system. Loading mortar
or epoxy into a dry system will cause the material
to stick to internal components and cure causing
damage and requiring replacement of those parts.
Always wet out the system by circulating clean
fluid through the applicator back into the hopper
before loading any mixed mortar. This is normally
done with the flushing fluid, but sometimes resin
or commercially available concrete pump priming
fluids are used depending on what material is being
sprayed.
• 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).
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
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
Figure 11
2. Remove tip from applicator.
332612A
ti21663a
Figure 13
15
Wet Out the System
8. Open the motor on/off pilot ball valve (G) located
on base of applicator.
10. Rotate the air regulator adjustment knob (F)
clockwise until pump begins to move slowly.
F
Figure 14
9. Open bleed type master air valve (B).
ti21578a
ti21570a
Figure 16
NOTICE
To prevent damage to pump seals caused by
cavitation, run the pump slowly until the system
is primed.
11. Continue running the pump until all of the flushing
fluid is dispensed into the pail. The system is
now wetted out.
B
ti21574a
Figure 15
Figure 17
16
ti21632a
332612A
Wet Out the System
12. To stop dispensing, close the air motor on/off
pilot ball valve (G) and the main bleed type
master air valve (B).
B
A
ti21575a
Figure 18
332612A
13. If needed, drain remaining fluid from system.
Materials that separate more easily may
require draining the remaining fluid from the
system. Check material data sheet to determine
whether it is necessary to drain the remaining
fluid from the system.
a. Place grounded metal drain pan beneath
pump lower inlet fittings.
b. Remove hopper and fittings between hopper
and pump lower.
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. Install fittings and hopper.
e. Install camlock retaining straps.
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 fluid in the hose will
drain from the applicator into the bucket.
NOTE:
17
Mix the Material
Mix the Material
Always wet out the pump, hose, and applicator
before loading the mortar or epoxy material. See
Wet Out the System, page 15.
Always follow the material manufacturer’s instructions
for the material being sprayed. Mortar must be
thoroughly mixed to a smooth consistency before
loading it in the hopper.
• Always add the powder slowly to the fluid while
mixing. Do not add fluid to the powder.
• In non-explosive environments only: Use a
powerful mixer drive such as a minimum 800
watt, 1/2 in. drive, electric drill. Gear reduced
drills work best. Drill should have high torque at
300-1200 rpm.
• A heavy-duty drywall mud “H” blade or large “Jiffy”
blade generally works well for mixing.
Managing Mortar After Mixing:
• Pay close attention to the work life of the material
being used.
• Only mix the mortar kits as needed. Do not let
mixed mortar sit longer than necessary.
• Scrape mortar down the sides of the hopper as
the hopper material level lowers. Do not let older
mortar 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.
It will take most of the first batch of
material to fill the pump and hoses.
NOTE:
18
332612A
Prime with Mortar or Epoxy
Prime with Mortar or Epoxy
NOTICE
To prevent material curing in system, never load
mortar into a dry system. Loading mortar into
a dry system will cause the mortar to stick to
internal components and cure causing damage
and requiring replacement of those parts.
The applicator nozzle or tip must be removed during
priming. Always push out any remaining “wet out”
fluid into a waste container before circulating mortar.
Always circulate clean mortar back into the hopper
for a few minutes before beginning to spray.
1. Wet out the system. See
Wet Out the System, page 15.
2. Mix the Material. See Mix the Material, page 18.
3. Close the bleed type master air valve (B).
4. Remove tip from applicator.
5. Fill the clean hopper with at least 4 gallons of the
material to be sprayed. If using 60 ft of material
hose, then fill with 6 gallons.
6. Turn air regulator adjustment knob (F)
counterclockwise until it stops and gauge (E)
reads zero.
E
F
ti21571a
B
Figure 20
7. Open the fluid ball valve (V) on the end of the
fluid hose.
8. Place applicator outlet in a grounded metal 5
gallon waste container.
9. Open the motor ON/OFF pilot ball valve (G)
located on base of applicator.
A
ti21575a
Figure 19
332612A
19
Prime with Mortar or Epoxy
12. Continue running the pump until a steady stream
of material comes from the applicator.
10. Open bleed type master air valve (B).
B
ti21632a
Figure 23
13. To stop dispensing, close the motor ON/OFF
pilot ball valve (G). Do not close the fluid ball
valve (V) when the air motor is running.
ti21574a
Figure 21
NOTICE
To prevent damage to pump seals caused by
cavitation, run the pump slowly until the system
is primed.
11. Rotate the air regulator adjustment knob (F)
clockwise until pump begins to move slowly.
ti21579a
F
Figure 22
20
ti21570a
Figure 24
14. Place the applicator outlet into the hopper.
15. With the fluid ball valve (V) open, open the motor
ON/OFF pilot ball valve (G). Material will begin
dispensing.
16. Recirculate a few gallons of material to be sure
the material is flowing properly.
17. Install a tip onto applicator. The system is now
primed and ready to spray.
332612A
Spray
Spray
NOTICE
Do not operate the pump motor with the applicator
material ball valve (V) closed. This may cause the
pump or hose to pack out.
Prevent Packout
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
• Never dead end the pump against the fluid shut-off
ball valve.
• Start and stop the fluid flow with the red-handled
brass air motor pilot valve at the applicator.
• Always have the atomizing air turned on before
and after spraying fluid.
Before Starting Material Flow
1. Always open the air assist valve (U) and adjust
air assist needle valve (M) first.
2. Open applicator material ball valve (V) second.
3. Open (turn on) the motor pilot ball valve (G) last.
Before Stopping Material Flow
Spraying
NOTICE
Do not allow pump to run without material in the
hopper. It will quickly accelerate to a high speed
causing pump seal damage.
NOTICE
To prevent material curing in system, never load
mortar into a dry system. Loading mortar into
a dry system will cause the mortar to stick to
internal components and cure causing damage
and requiring replacement of those parts.
1. Wet Out the System, page 15.
2. Mix the Material, page 18.
3. Prime with Mortar or Epoxy, page 19.
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.
4. Turn air regulator adjustment knob (F)
counterclockwise until it stops and gauge (E)
reads zero.
E
F
1. Always close (turn off) the motor pilot ball valve
(G) first.
2. Close applicator material ball valve (V) second.
3. Turn off the air assist valve (U) last.
Figure 25
332612A
ti21571a
21
Spray
5. Install tip on applicator by stretching rubber
retainer with a screwdriver or screwing on
retainer, depending on your application kit.
9. Adjust air motor regulator adjustment knob (F)
until desired material flow rate is achieved. Turn
clockwise to increase pressure, counterclockwise
to decrease pressure.
E
F
Figure 26
6. Open air assist valve (U) and adjust the air assist
needle valve (M). See Details, page 8 .
7. Open the material ball valve (V) on the base of
the applicator.
NOTICE
Do not operate the pump motor with the
applicator material ball valve (V) closed. This
may cause the pump or hose to pack out.
8. Open the pilot ball valve for air motor (G) located
on base of applicator. See Details, page 8 .
Material will begin dispensing.
ti14355a
ti21571a1
Figure 27
See Spray Adjustments (Mortar Spray
Applicator), page 23 or Spray Adjustments (HTX
680 Applicator), page 25for details about all of
the adjustments that can be made to the way the
system sprays.
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 26.
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.
NOTE:
11. If the flushed system will be idle for more than
90 minutes, Disassemble and Clean the Pump
(Daily). See Disassemble and Clean the Pump
(Daily), page 30.
22
332612A
Spray Adjustments (Mortar Spray Applicator)
Spray Adjustments (Mortar Spray Applicator)
M
CA
U
CB
CC
CD
CF
CE
Figure 28
Key:
M
U
CA
CB
CC
CD
CE
CF
Needle Valve for Air Assist Flow Control
Air Assist Shutoff Ball Valve
Air Assist Air Line
Air Needle (adjustable position)
Air Needle Retaining Screw
Fluid Housing
Tip (Nozzle)
Rubber Tip Retainer
General Adjustments
The spray pattern can be adjusted by changing:
• Tip (CE) size
• Fluid flow, use air motor regulator adjustment knob
(G)
• Air flow, use needle valve (M)
• Air needle (CB) position
Fully open the air assist valve (U),
while adjusting the needle valve (M) for the minimum
air flow necessary for a good pattern. Air bleeds from
the applicator nozzle whenever the applicator air
assist valve (U) 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.
Ensure the air
needle (CB) is slightly behind the tip (CE).
Installing needle too far forward can
restrict or completely block material flow.
This can result in the retainer (CF) blowing
off. Installing the needle too far back can
raise the pressure behind the fluid enough
to blow the retainer (CF) off and can cause
dripping.
NOTE:
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.
Adjust Air Flow:
Adjust Air Needle (CB) position:
332612A
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.
23
Spray Adjustments (Mortar Spray Applicator)
Withdrawing needle too far can force
air pressure back into fluid hose, slowing
material flow.
NOTE:
2. Insert screwdriver through hole in tab of nozzle
retaining cap.
3. Push screwdriver head against notch on
applicator tip and pry nozzle retaining cap over
lip until it snaps into place.
Spray Techniques
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.
2. Adjust fluid flow until material flow is adequate.
3. Adjust the applicator air assist needle 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, and is obtained
by grasping the flex-head and swinging the head
around as the hose flexes.
When spraying small confined areas use the valve
and knob to make fine adjustments without adjusting
the pump.
Typically desired spray pressure is 20-25 psi
(140-170 kPa, 1.4-1.7 bar) on the motor air
regulator (F). Higher pressures may cause excessive
wear on the fluid pump. Select a fluid tip large
enough to spray at low pressure. Some materials will
packout at higher pressures.
Figure 29
4. Turn the rubber retainer back and forth to be sure
it is fully seated.
Material Compatibility
NOTICE
To prevent the seals and rubber tip from swelling,
do not leave solvent in the applicator when not in
use.
The nylon hose in the Flex Applicator is compatible
with solvents. The rubber gasket in the cam and
groove inlet fitting and the rubber nozzle retainer
should be hand cleaned and dried after each use.
Installing Nozzle Retaining Cap
1. Place nozzle retaining cap over top lip of
applicator housing.
24
332612A
ti14355a
Spray Adjustments (HTX 680 Applicator)
Spray Adjustments (HTX 680 Applicator)
DG
M
DA
DE
U
DB
DD
DC
DF
Figure 30
Key:
M
U
DA
DB
DC
DD
DE
DF
DG
Needle Valve for Air Assist Flow Control
Air Assist Shutoff Ball Valve
Air Assist Air Line
Fluid and Air Manifold
Tip (Nozzle)
Tip Retainer
Air Check Valve
Fluid Inlet Swivel
Handle
The spray pattern can be adjusted by changing:
• Tip (DC) size
• Fluid flow, use air motor regulator adjustment knob
(G)
• Air flow, use needle valve (M)
The standard applicator adjustment is to fully open
the air assist valve (U), while adjusting the needle
332612A
valve (M) for the minimum air flow necessary for a
good pattern.
Air bleeds from the applicator nozzle whenever
the applicator air assist needle valve (M) is open.
Close the valve (U) to stop the majority of air flow, if
desired. Some air will still bleed through valve (U) to
help keep the air passages clean. Otherwise, the air
valve (U) can stay open during priming. Air must be
on prior to any fluid flow.
Adjusting the spray pattern requires testing to
balance the fluid flow and the air to the applicator,
and requires the correct tip size.
Always run full air volume through the applicator
when you are done spraying to remove any fluid
residue. Remove and clean the tip (DC) by hand.
Remove air check valve (DE) to be sure no fluid has
backed up to the check valve. If it has, remove and
clean air spool valve (U).
Fine Finish pattern discs and adapter kit 287227 is
included and can be added for more pattern control.
See manual 310617.
25
Flush
Flush
2. Remove applicator tip and retainer.
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 zero cavity pressure relief valve has been
used to relieve pressure, the valve must be flushed
to prevent material hardening in zero cavity relief
valve. If that is not sufficient, remove, disassemble,
and clean the valve then reinstall.
• Flush if the materials in the system are about to
reach their cure time.
• Flush any time the flow rate starts to decrease as
this is a sign that material is starting to thicken and
cure.
• Always flush the system at least twice, draining
all material flushing agent between flushes then
replacing with clean material flushing agent.
• For some mortars, it is recommended to flush
every 3 - 5 kits. Others can run continuously
without flushing. See material manufacturer
recommendation.
1. Close the bleed type master air valve (B).
ti21643a
Figure 32
3. Place applicator outlet in a waste container. The
waste container must be large enough to hold
all dispensed material.
ti21632a
Figure 33
4. With air assist air flowing, open the material ball
valve (V) on the base of the applicator.
5. Open the pilot ball valve (G) located on base of
applicator.
B
A
ti21575a
Figure 31
26
332612A
Flush
6. Open bleed type master air valve (B) to begin
dispensing.
10. Place applicator in the system hopper with the
outlet pointing down to enable fluid circulation.
If flushing with solvent, do not
submerge the applicator in the solvent.
11. Circulate clean water or solvent:
a. Fill the system hopper with clean water or
solvent.
NOTE:
B
ti21574a
Figure 34
7. 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 or solvent as the
material runs out and continue dispensing.
8. Keep the hopper filled with material flushing
agent while dispensing.
ti21644a
Figure 36
b. Use a scrub brush to scrub the walls of the
hopper.
c. Open the pilot ball valve (G) on applicator to
begin circulating water or solvent.
d. Run the pump at 60-90 cycles per minute
for 3-5 minutes. Adjust air pressure as
necessary to maintain 60-90 cycles per
minute.
High flushing fluid velocity is
the most important item for effective
cleaning. The fluid hose should
shake while the pump is running.
This is necessary to maximize the
cleaning effects of flushing.
e. While pumping at 60–90 cycles per minute,
close then open the pilot ball valve (G) many
times to clean it. Each time the pilot ball valve
(G) is closed, close then open the fluid ball
valve (V) to flush the fluid ball valve. Ensure
NOTE:
Figure 35
ti21657a
Be prepared to decrease the air
pressure when the material exiting the
hose changes to water or solvent. Water
and solvent pump more easily so pump
speed will increase.
9. When water or solvent begins to exit the
applicator outlet, close the pilot ball valve (G)
located on base of applicator to stop dispensing.
NOTE:
332612A
27
Flush
fluid ball valve is open before opening pilot
ball valve (G).
When the fluid ball valve
gets hard to operate, it should
be disassembled, cleaned, and
re-packed with grease.
Decrease air pressure to air motor back to
operating pressure.
Close the air motor pilot ball valve (G).
Place applicator outlet in a grounded metal
waste container.
Open air motor pilot ball valve (G) to dispense
into grounded metal waste container.
Dispense into grounded metal waste
container until hopper is almost empty then
close air motor pilot ball valve (G).
Repeat this entire “Circulate clean water
or solvent” step one more time to ensure
system is thoroughly flushed.
NOTE:
f.
g.
h.
i.
j.
k.
28
12. After performing the previous step at least twice,
drain remaining flushing fluid from system:
a. Place grounded metal drain pan beneath
pump lower inlet fittings.
b. Remove hopper and fittings between hopper
and pump lower.
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. Install fittings and hopper.
e. Install camlock retaining straps.
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 fluid in the hose will
drain from the applicator into the bucket.
13. Disassemble and clean the pump at the end
of every day. The procedure takes about 10
minutes. See Disassemble and Clean the Pump
(Daily), page 30.
332612A
Notes
Notes
332612A
29
Disassemble and Clean the Pump (Daily)
Disassemble and Clean the Pump (Daily)
Suggested Tools
• 5/8 in. box end wrench or 5/8 in. socket and ratchet
• Rubber mallet (to break items loose, if necessary)
BM
BL
BJ
BU
BK
BT
BI
BF
BG
BS
BP
BH
BV
BB
BE
BD
BT
BC
BN
BA
BR
ti21645a
Figure 37
30
332612A
Disassemble and Clean the Pump (Daily)
Key
BA
BB
BC
BD
BE
BF
BG
BH
BI
BJ
BK
BL
BM
BN
BP
BR
BS
BT
BU
BV
Inlet Elbow with Camlock
Inlet Housing Clamp
Inlet Housing Assembly
Inlet Ball
Inlet Ball Stop
Pump Rod Assembly
Outlet Ball Stop
Piston Seal
Cylinder
Cylinder Clamp
Outlet Housing
Throat Packing
Packing Nut (non-adjustable)
Hopper
Pump Outlet
Hopper Release Camlock
Outlet Ball
Cylinder O-rings
Outlet Housing Lock Nut
Ball Cage Spring
As items are disassembled, use a
soft brush and water or a compatible solvent
to clean components.
Flush the system. See Flush, page 26. Stop
pump near bottom of its stroke.
Perform Pressure Relief Procedure. See
Pressure Relief Procedure, page 14.
With fluid pressure relieved, remove material
hose from pump outlet (BP).
Disconnect hopper at outlet camlock (BR) then
remove hopper (BN).
Remove inlet elbow (BA).
Tip cart back so it rests on the back of the cart.
NOTE:
1.
2.
3.
4.
5.
6.
Always Keep Spare Parts Stocked
Always keep spare parts stocked to ensure getting
back up and running as quickly as possible. Parts
to keep stocked include:
• Cam and groove fitting gaskets
• Spray tips
• Tip retainer
• Rod and cylinder seals
• Cylinder o-rings
• Other parts as needed
To prevent skin injection and splashing, never
open a camlock hose or applicator fitting
while there is pressure in the fluid line. See
Pressure Relief Procedure, page 14.
See the figure at the beginning of this section for part
references.
Disassemble and clean the pump at the end of every
day. The procedure takes about 10 minutes.
332612A
ti21655a
Figure 38
7. While holding onto the inlet housing (BC), use
a 5/8 in. wrench to loosen the two nuts on
the inlet housing clamp (BB) then remove inlet
housing (BC).
8. Remove inlet ball stop (BE) and ball cage spring
(BV).
9. Use 5/8 in. wrench (64) to loosen the two nuts on
the cylinder clamp (BJ) then remove cylinder (BI).
10. Disconnect pump rod (see the following figure):
a. Push piston rod protective spring up and
away from coupling assembly (BF1-BF3).
b. Remove clip (BF1), and slide coupling cover
(BF2) up to remove coupling (BF3).
31
Disassemble and Clean the Pump (Daily)
9. Slide cylinder (BI) over rod (BF) with o-ring (BT)
installed between outlet housing (BK) and
cylinder (BI).
BF3
If the o-ring (BT) does not stay in
place while assembling the cylinder (BI)
to the housing (BK), the cart may need
to be tipped upright to install properly.
ti21656a
After clamp is installed, tip cart back to
Figure 39
horizontal position to finish assembly.
11. Pull rod (BF) down and out of outlet housing (BK). 10. Use cylinder clamp (BJ) to secure cylinder (BI)
to outlet housing (BK).
12. Remove outlet ball stop (BG) from rod (BF) by
pushing o-rings off of ball stop (BG).
13. Loosen and remove packing nut (BM) then
Each clamp has one flat so that
remove throat packing (BL).
only one wrench is required to tighten
clamp. Align bolt head with flat then
14. Use a brush and solvent to clean all loose pieces.
use a wrench on the nut to tighten.
The pump rod (BF) is not disassembled
Tighten both sides of the clamp evenly to
unless the piston packing or seat needs to be
approximately 10 ft-lb (14 N•m).
replaced.
11. Install inlet ball (BD), ball cage spring (BV), and
The inlet housing (BC) is not
inlet ball stop (BE) in inlet housing (BC).
disassembled unless the inlet seat needs to be
12. With inlet ball (BD), ball cage spring (BV), and
replaced.
inlet ball stop (BE) in place, place o-ring (BT)
between cylinder (BI) and inlet housing (BC)
then use inlet housing clamp (BB) to install inlet
1. Loosely install throat packing (BL) with the open
housing (BC) onto cylinder (BI).
end facing into the pump.
2. Install packing nut (BM) hand-tight.
Each clamp has one flat so that
3. Lubricate the balls (BS, BD) to ensure they do
only
one
wrench is required to tighten
not stick.
clamp. Align bolt head with flat then
4. Install outlet ball (BS), outlet ball stop (BG) with
use a wrench on the nut to tighten.
o-rings into rod (BF). Ensure outlet ball stop
Tighten both sides of the clamp evenly to
o-rings are in the grooves on the outlet ball stop
approximately 10 ft-lb (14 N•m).
rod.
13. Install inlet elbow (BA) onto inlet housing (BC).
5. Grease the packing on the rod (BF).
14. Tip cart up.
6. Gently slide rod (BF) through throat packing (BL). 15. Install hopper (BN) onto the hopper bracket and
7. Install coupling (BF3), slide coupling cover (BF2)
connect to inlet elbow (BA).
over coupling, then install clip (BF1) to secure
16. Install material hose onto pump outlet (BP).
pump rod (BF) to air motor.
BF1
BF2
NOTE:
NOTE:
NOTE:
NOTE:
Assemble the Pump
NOTE:
8. Use a flat-tip screwdriver and a plastic mallet to
tighten packing nut (BM) until it stops.
This is not an adjustable packing
but the packing nut (BM) does need to
be tight against the throat packing (BL).
NOTE:
32
332612A
Shutdown
17. Wrap blue, velcro, camlock retaining straps
around each camlock connection to secure.
This includes the two camlocks
between the hopper and pump lower, the
camlock at 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.
18. Add TSL to the packing nut (BM) until 1/2 full.
NOTE:
Shutdown
NOTICE
To prevent rust, never leave water or water-based
fluid in pump overnight.
1. Flush the system. See Flush, page 26.
If you are pumping water-based fluid,
flush with water first, then with a rust inhibitor,
such as mineral spirits solvent (also called white
spirit), to prevent rust.
2. Perform Disassemble and Clean the Pump
(Daily) procedure. See Disassemble and Clean
the Pump (Daily), page 30.
NOTE:
332612A
33
Maintenance
Maintenance
Preventative Maintenance
The operating conditions of your particular system determine how often maintenance is required. Establish
a preventive maintenance schedule by recording when and what kind of maintenance is needed, and then
determine a regular schedule for checking your system.
Daily Maintenance
4.
5.
1. Flush the system. See Flush, page 26.
2. Relieve pressure. See
Pressure Relief Procedure, page 14.
3. Perform the Disassemble and Clean the Pump
(Daily) procedure at the end of every day. See
6.
7.
Disassemble and Clean the Pump (Daily), page
30.
Drain water from air filter.
Clean hopper with a scrub pad. It is
recommended that you clean the outside of the
sprayer using a cloth and compatible solvent.
Check hoses, tubes, and couplings. Tighten all
fluid connections before each use.
Check and replace camlock gaskets as needed.
Corrosion Protection
NOTICE
To prevent rust, never leave water or water-based fluid
in pump overnight.
Always flush the pump before the fluid dries on the displacement rod. First, flush with water or a compatible
solvent, then with oil. Relieve the pressure, but leave the oil in the pump to protect the parts from corrosion.
Cart Maintenance
Periodically lubricate the axle between points A and
B with lightweight oil. See the following figure.
Keep the cart clean by wiping up spills daily, using a
compatible solvent.
A
B
ti21634a
Cart Assembly
Figure 40
34
332612A
Troubleshooting
Troubleshooting
•
Output low on both strokes.
–
To prevent skin injection and splashing, never
open a camlock hose or applicator fitting
while there is pressure in the fluid line. See
Pressure Relief Procedure, page 14.
1. Perform Pressure Relief Procedure. See
Pressure Relief Procedure, page 14.
2. Check all possible problems, causes, and
solutions listed below before disassembling
pump.
PROBLEM — CAUSE — SOLUTION
Example:
•
– Cause.
♦ Solution.
Problem.
•
Does not operate.
–
–
–
–
–
–
•
–
•
Output low on up-stroke.
–
Open or worn piston valve or packings.
♦ Clear piston valve; replace packings.
•
Erratic accelerated speed.
–
Valve closed or clogged.
–
♦ Clear air line; increase air supply. Check that
valves are open.
♦ Clean rod; always stop pump at bottom of
stroke; keep wet-cup filled with compatible
solvent. Be sure inlet ball moves freely.
Open or worn intake valve.
♦ Clear or service intake valve.
–
Dried fluid on displacement rod or inlet ball.
Fluid hose/applicator obstructed; hose ID too
small.
Output low on down-stroke.
♦ Remove valve by disconnecting swivel unions.
Connect hose directly to air motor. Operate
motor directly with air regulator (210).
♦ Clean hose or applicator.*
♦ Clear air line; increase air supply. Check that
valves are open.
♦ Clear hose or applicator*; use hose with larger
ID.
Air motor pilot valve (211) is faulty.
Fluid hose or applicator obstructed.
Air line restricted or air supply inadequate.
Valves closed or clogged.
Fluid supply exhausted, clogged suction.
♦ Refill hopper and prime pump.
Open or worn piston valve or packings.
♦ Clear piston valve; replace packings.
Open or worn intake valve.
♦ Clear or service intake valve.
•
Cycles or fails to hold pressure at stall.
–
Worn check balls, seats, or piston packing.
♦ Service lower. See Disassemble and Clean
the Pump (Daily), page 30.
Air motor parts dirty, worn or damaged.
♦ Clean or repair air motor. See motor manual.
332612A
35
Troubleshooting
•
Poor finish or irregular spray pattern.
–
–
–
•
♦ See applicator manual; read fluid
manufacturer’s recommendations.
–
Inadequate air assist air pressure.
♦ Adjust air assist needle valve.
Cannot open or close air motor pilot ball valve on
Dirty air clogged the air motor pilot valve.
♦ If no ball valve is immediately available:
Bypass the air motor pilot valve so air is
always supplied to air motor, regardless of
applicator pilot valve position. Then control
fluid flow by adjusting air regulator pressure
up and down as needed. Install new pilot ball
valve when one becomes available.
•
Pump is packed out with dry or cured material.
♦ Disassemble and Clean the Pump (Daily),
page 30
Hose is packed out with dry or cured material.
♦ Reverse hose and try to push out bad material.
♦ Some materials may need only 1 in. inner
diameter fluid line all the way to the applicator.
Dirty, worn, or damaged spray applicator.
applicator.
•
Motor powered but nothing comes out of hose.
–
Incorrect fluid pressure at applicator.
♦ Service spray applicator. See spray applicator
manual.
–
•
Material is too thick to push through hose without
packing out.
–
3/4 in. x 10 ft whip hose is too restrictive.
♦ Remove 3/4 in. x 10 ft whip hose from bundle
at applicator end. Move fluid ball valve to end
of 1 in. x 25 ft hose. Coil up extra air hose at
machine end.
♦ Thin and mix material thoroughly to a lower
viscosity.
♦ Use a pump system priming fluid (slime). See
Wet Out the System, page 15.
Cannot open or close fluid ball valve on hose at
applicator.
–
Mortar cured in valve due to insufficient flushing.
♦ If no ball valve is immediately available:
Relieve pressure in system, remove ball valve,
then control fluid flow by adjusting air regulator
up and down as needed.
♦ Disassembly, clean, and repack ball valve with
lithium grease.
♦ Replace ball valve.
36
* To determine if fluid hose or applicator is obstructed,
follow Pressure Relief Procedure, page 14.
Disconnect fluid hose and place a container at pump
fluid outlet to catch any fluid. Turn on air power just
enough to start pump. If pump starts, the obstruction
is in fluid hose or applicator.
332612A
Repair
Repair
To prevent skin injection and splashing, never
open a camlock hose or applicator fitting while
there is pressure in the fluid line. Perform
Pressure Relief Procedure, page 14, before
performing any repair procedure.
Replace Pump Components
To replace any pump components
(excluding the air motor), perform the
Disassemble and Clean the Pump (Daily), page 30,
procedure.
Replace Air Motor
1. Perform Pressure Relief Procedure, page 14.
2. Note location of small air tube connections on air
motor then remove air tubes.
3. Disconnect pump rod (see the following figure):
a. Push piston rod protective spring up and
away from coupling assembly (BF1-BF3).
b. Remove clip (BF1), and slide coupling cover
(BF2) up to remove coupling (BF3).
7. Tighten tie rod nuts (44).
8. Connect pump rod. See figure shown previously
in this section.
9. Connect small air tubes to air motor.
Replace Pump Lower
Perform this procedure to replace the entire
pump lower with a new or different pump lower.
To repair or replace any internal components
in the pump (excluding the air motor), perform
Disassemble and Clean the Pump (Daily), page 30.
1. Perform Pressure Relief Procedure, page 14.
2. Disconnect pump lower from hopper.
3. Disconnect material hose from pump lower outlet.
4. Disconnect pump rod (see the following figure):
a. Push piston rod protective spring up and
away from coupling assembly (BF1-BF3).
b. Remove clip (BF1), and slide coupling cover
(BF2) up to remove coupling (BF3).
BF1
BF1
BF2
Figure 41
4. Loosen three tie rod nuts (44), then loosen
and remove tie rods (42) from air motor. See
Parts, page 38.
5. Remove air motor.
6. Align air motor with tie rods (42) then tighten tie
rods to air motor.
332612A
BF3
BF2
Figure 42
5. Loosen three tie rod nuts (44), then loosen
and remove tie rods (42) from air motor. See
Parts, page 38.
ti21656a
6. Remove pump lower.
7. Align new pump lower with tie rods (42) then
tighten tie rods to air motor.
8. Tighten tie rod nuts (44).
9. Connect pump rod. See figure shown previously
in this section.
10. Connect pump lower to hopper.
BF3
37
ti21656a
Parts
Parts
M680 Systems
7
4
67
3 1
49
66
68
4
8
65
47
41
45
48
6
7
50
7
18
3 2
46
42 5
4
26
20
6
7
51
53
17 1
44 5
1 15
1 14
7
20
10
13
43
3
11,55,58
12,55,58
Assemble fitting (15) and zero cavity relief
1
ti22048a
Pack grease around the end of the
4
valve (17) then assemble to swivel (14)
zero-cavity relief valve in front of the
with relief hole pointing downward or at the
threads.
pump.
2
3
Apply pipe sealant to all non-swiveling pipe
threads.
Apply clear, liquid petrolatum to axles (1)
before assembling wheels (2).
5
Torque to 50–60 ft-lb (68–81 N∙m).
6
Torque to 145–155 ft-lb (197–210 N∙m).
Apply medium strength thread-locking fluid
7
to threads.
Quantity
Ref
Part
Description
24T834
24T835
24T836
24T837
262909
262926
262927
1
262914
CART
1
1
1
1
1
1
1
2
116406
WHEEL
2
2
2
2
2
2
2
3
113436
RING, retaining
2
2
2
2
2
2
2
4
- - -
MODULE, air controls; see
1
1
1
1
1
1
1
Air Controls
38
332612A
Parts
Quantity
Ref
Part
Description
6
104572
WASHER, lock spring
7■
114193
SCREW, machine, hex washer
24T834
24T835
24T836
24T837
262909
262926
262927
4
4
4
4
4
4
4
12
10
12
10
12
10
12
1
1
1
1
1
1
head
8
155470
SWIVEL, union, 90 degree
1
10■
- - -
BRACKET, hopper
1
1
1
1
11■
16V510
CAM AND GROOVE, elbow,
1
1
1
1
1
1
1
1
1
1
1
2 inch
12■
16V509
CAM AND GROOVE, 2 inch x
1-1/2 npt
13■
16U536
HOPPER
1
14
160022
UNION, adapter
1
1
1
1
1
1
1
15
127082
TEE, branch, female
1
1
1
1
1
1
1
17
16W513
VALVE, relief, zero cavity
1
1
1
1
1
1
1
18
- - -
PLUG, tubing, cart
2
2
2
2
2
2
2
20■
- - -
NUT, hex, flange, serrated
8
6
29
114958
STRAP, tie
30
110198
31
159841
8
6
8
6
8
10
10
10
10
10
COUPLER, line, air
1
1
1
1
2
BUSHING, 3/8 x 1/4 in.
1
1
1
1
2
1
1
32
169970
FITTING, line air
33
24U209
APPLICATOR, texture, pole
34
24T947
APPLICATOR, texture, flexible
1
1
41◆
M34LN0
MOTOR, air
1
1
1
1
2
1
1
2
1
1
1
1
1
1
42◆
16U817
ROD, tie, 10-5/8
3
3
3
3
3
3
3
43◆
24R253
LOWER, pump (see manual
1
1
1
1
1
1
1
44◆
101712
NUT, lock
3
3
3
3
3
3
3
45◆
15H392
ROD, adapter
1
1
1
1
1
1
1
332649)
46◆
244819
COUPLING, assembly
1
1
1
1
1
1
1
47◆
197340
COVER, coupler
1
1
1
1
1
1
1
48◆
244820
CLIP, hairpin with lanyard
1
1
1
1
1
1
1
49◆
262908
WIRE, ground, with clamp
1
1
1
1
1
1
1
50◆
111799
SCREW, cap, hex head
1
1
1
1
1
1
1
51◆
16V671
GUARD, spring
1
1
1
1
1
1
1
186620
LABEL, symbol, ground
1
1
1
1
1
1
1
GASKET, 2 in, coupler, cam
2
53
▲
55**
16W506
2
2
2
and groove (6–pack)
57**
16W490
O-RING, pump cylinder
2
2
2
2
2
2
2
(10–pack)
59**
16A443
NOZZLE, 3/16 inch
1
60**
16A444
NOZZLE, 1/4 inch
1
61**
16A448
NOZZLE, 1/2 inch
1
62**
16A449
NOZZLE, 9/16 inch
1
63**
16W508
KIT, seals, pump
1
64**
127265
TOOL, wrench, ratchet
332612A
1
1
1
1
1
1
1
39
Parts
Quantity
Ref
Part
Description
24T834
24T835
24T836
24T837
262909
262926
262927
65
- - -
BRACKET, tool box
1
1
1
1
1
1
1
66
- - -
KIT, tool box
1
1
1
1
1
1
1
67
113505
NUT, keps, hex head
4
4
4
4
4
4
4
4
4
4
4
4
1
1
1
68
107251
SCREW, machine, panhead
4
4
98
24T854
BUNDLE, hose, 35 ft
1
1
99
24R254
BUNDLE, hose, extension, 25
1
ft
▲ Replacement Danger and Warning labels, tags, and cards are available at no cost.
*
■
◆
Parts included in Pack Out Hose Clean Kit 16W601 (purchase separately).
Parts included in Hopper Replacement Kit 24T853 (purchase separately).
Parts included in Pump 16W514 (purchase separately). See manual 332650.
Spare parts shipped with machine.
Not for sale.
**
- - -
40
332612A
Parts
Air Controls
213
214
222
221
223
220
211
219
206
205
212
216
202
201 202
203
206
204
215
207
2
222
210
224
218
225
208
209
ti22050a
1
Apply pipe sealant to all non-swiveling pipe threads.
2
Assemble one end of lanyard between ball valve (207) and fitting (208). One end hangs loose.
Ref
Part
Description
Qty
Ref
Part
Description
Qty
201
262658
FILTER, air, 40 micron
1
213
160430
GAUGE, pressure, air
1
202
158491
FITTING, nipple
2
214
155470
FITTING, swivel, union, 90
1
203
C20432
FITTING, cross, pipe
1
215
101950
204
C20461
FITTING, nipple, reducing,
1
205
- - -
FITTING, elbow, street
1
206
159239
FITTING, nipple, pipe,
2
hex
reducing
degree
SCREW, socket head cap,
2
1/4 x 2.5 inch
216
115942
NUT, hex, flange head
2
218
110198
COUPLER, line, air
1
219
127313
FITTING, elbow
1
207
113332
VALVE, ball, vented, 0.750
1
220
111881
MUFFLER
1
208
113429
COUPLING, universal,
1
221
100737
PLUG, pipe
1
222
218093
HOSE, coupled
1
223
162505
FITTING, union, swivel
1
3/4–14 npt male
209
113430
COUPLING, universal,
1
3/4–14 npt female
210
104267
REGULATOR, air
1
224
113498
VALVE, safety, 110 psi
1
211
16W146
VALVE, 3-way, pilot
1
225
16W586
CABLE, lanyard, whip
1
212
- - -
check
operated
- - -
BRACKET, air controls
1
Not for sale.
332612A
41
Parts
Zero Cavity Relief Valve, 16W513
3
2
4
301
303
305 4
304 1
302
306 3
3
307
ti22051a
Use assembly tool 15T630 to install seal
1
3
(304).
Apply medium strength thread-locking fluid
2
to threads prior to installing seat (305).
Ref
Part
Description
301
- - -
302
308
4
Apply lithium grease to seal, thread, and
o-ring.
Torque to 95–105 in-lb (10.7–11.9 N∙m).
Qty
Ref
Part
Description
HOUSING, end
1
305
16V956
SEAT
1
16U807
STEM
1
306
15Y627
O-RING, PTFE
1
303
15M189
SPACER, backup, seal
1
307
16V957
HOUSING
1
304
15M529
SEAL, check valve
1
308
102915
PIN, drive
1
- - -
42
Qty
Not for sale.
332612A
Parts
Hose Bundles
416,456,458 432431
424
425
416,456,458
423
432
431
452
428 454
430
416
424
430
454 425
427
ti22047a
425
426
Quantity
24T854 (35 24R254 (25
ft bundle)
ft bundle)
Ref
Part
Description
416
289874
COUPLER KIT, 1 in. female cam/groove
2
1
421
24U184
COVER, hose, plastic, 2 in. x 50 ft
1
1
422
24U185
COVER, hose, plastic, 3 in. x 50 ft
1
1
423
16W512
HOSE, fluid, 3/4 in., coupled, 10 ft
1
424
16W511
HOSE, fluid, 1 in., coupled, 25 ft
1
1
425*
15T116
COUPLER, male, cam and groove, 1 in.
2
1
426*
158585
FITTING, nipple
1
1
427
127232
VALVE, ball, 1 inch, stainless steel,
1
1
10
10
24U331 (38 24T852 (25
ft air hose ft air hose
bundle)
bundle)
1
1
1000 psi
428
24T762
HOSE, air and pilot in scuff jacket, 38 ft
429
114958
STRAP, tie
430
110198
COUPLER, line, air
1
1
1
1
431
159841
BUSHING, 3/8 x 1/4 in.
1
1
1
1
432
169970
FITTING, line air
1
1
1
1
452
24T829
HOSE, bundle, air, 26 ft
1
1
454
127312
FITTING, 1/4 to 1/4 tube
1
1
1
1
456
16W507
GASKET, coupler, 1 in. (6–pack)
2
2
458
240296
STRAP (4–pack)
2
2
*
1
Parts included in Pack Out Hose Clean Kit 16W601 (purchase separately).
Not for sale.
- - -
332612A
43
Accessories
Accessories
Pole Applicator, 24T946
Ideal for spraying in long-reach, open areas and
low-pressure spraying of materials that packout
easily and that will be finish-troweled. The pole
applicator is similar to the Flexible Applicator, but
with a pipe in place of the hose. See manual 332767.
Includes:
• 30 in. (76 cm) aluminum pipe with cam lock fluid
inlet
• Angled spray head
• Spray air volume control
• Spray shut-off valve
• Motor pilot signal control valve
• Adjustable position center air injection tube
• Rubber tip retainer
• 4 different-sized tips
44
332612A
Technical Specifications
Technical Specifications
Mortar and Epoxy Sprayer Package
Maximum Working Pressure
Maximum Air Inlet Pressure
Minimum Inlet Air Flow (Typical)
Minimum Inlet Air Flow (Pump
Only)
Pressure Ratio (Fluid to Air)
Air Motor Piston Diameter
Stroke Length
Lower Output
Flow Rate at 30 cycles per minute
Flow Rate at 60 cycles per minute
Air Inlet Size
Fluid Inlet Size
Fluid Outlet Size
Weight (without fluid)
Sound Pressure
Sound Power
Dimensions
Height
Width
Depth (pump on cart only)
Deep (pump on cart with hopper)
U.S.
1000 psi
100 psi
30 standard cubic feet per minute
8 scfm per gallon at 100 psi
10:1
Metric
7 MPa, 70 bar
0.7 MPa, 7 bar
0.85 cubic meters per minute
0.06 cubic meters per minute
per liter at 7 bar
7.5 in.
191 mm
4.75 in.
120 mm
41.9 cu. in. per cycle
686 cc per cycle
5.44 gpm
20.6 lpm
10.88 gpm
41.2 lpm
3/4 npt(f) (Chicago Fitting)
2 in. Cam Groove (Male)
1 npt(f) with a 1 in. Cam and Groove Fitting
113 kg
250 lb
(with 7.6 m of 25 mm hose and
(with 25 ft of 1 in. hose and
3.0 m of 19 mm hose)
10 ft of 3/4 in. hose)
118 dB(A)*
118 dB(A)*
44.5 in.
27.5 in.
32 in.
37 in.
113 cm
70 cm
81 cm
94 cm
Maximum Pump Speed
(Do not exceed maximum recommended pump speed of fluid pump to prevent premature pump wear)
Spraying
40 cycles per minute (typically less than 10 cycles per minute)
Flushing
60–90 cycles per minute (only when pumping flushing fluid)
Wetted Parts
Entire System
Pump
Hose Kits
Stainless steel, UHMWPE, nylon, plated steel, anodized
aluminum, FX-75
Stainless steel, carbide, PTFE, UHMWPE, solvent-resistant o-rings
Nylon core, plated carbon steel fittings, anodized aluminum, nitrile gaskets
Notes
* Spraying simulated acoustical texture under typical conditions as specified by the material maufacturer.
332612A
45
Technical Specifications
M680
Performance
Chart
(with 30–weight oil)
Pump Cycles Per Minute
0
1000
10
20
30
40
50
D
H 60
800
Pump
Outlet Fluid
Pressure in
psi
G
C
Cubic Feet
B
30 Per Minute
F
400
20
A
E
200
1
2
3
4
10
5
6
7
Flow Rate in Gallons Per Minute
Ref
Description
A
B
C
D
E
F
G
H
Fluid Pressure at 20 psi Air
Fluid Pressure at 40 psi Air
Fluid Pressure at 70 psi Air
Fluid Pressure at 100 psi Air
Air Consumption at 20 psi Air
Air Consumption at 40 psi Air
Air Consumption at 70 psi Air
Air Consumption at 100 psi Air
46
Air Flow in
40 Standard
600
00
50
8
9
0
10
332612A
Technical Specifications
M680 Applicator Air Consumption
(100 psi feed to the machine)
30
20
Standard
Cubic Feet
Per Minute
of Air (Cubic
Meters Per
Hour) 10
0
1.0
2.0
3.0
4.0
5.0
Needle Valve Turns Open from Closed
332612A
47
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.
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.
For patent information, see www.graco.com/patents.
Original Instructions. This manual contains English. MM 332612
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2013, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
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