Graco M680 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 nlet 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 pray Applicator................................ 9
HTX 680 (Internal Air) Applicator................... 10
ystem Components.................................... 11
Grounding.......................................................... 12
etup................................................................. 13
Pressure Relief Procedure .................................. 14
Wet Out the ystem............................................ 15
Mix the Material.................................................. 18
Prime with Mortar or Epoxy ................................. 19
pray................................................................. 21
Prevent Packout .......................................... 21
Before tarting or topping Material
Flow .............................................. 21
praying...................................................... 21
pray Adjustments (Mortar pray
Applicator) ............................................ 23
Air Flow Valve Adjustment............................ 23
Material Flow Adjustments............................ 23
pray Techniques........................................ 24
Installing Nozzle Retaining Cap.....................24
Material Compatibility................................... 24
pray Adjustments (HTX 680 Applicator) ............. 25
Flush ................................................................. 26
Notes................................................................. 29
Disassemble and Clean the Pump (Daily)............. 30
hutdown........................................................... 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 pecifications...................................... 45
Graco tandard Warranty.................................... 48
Related Manuals
Manuals are available at www.graco.com.
Component manuals in English:
Manual Description
332651 Mortar praying Tips
332767 Mortar pray Applicators Operation -
Parts
332768 HTX 680 Applicator Operation - Parts
312796 NXT Air Motors Instructions - Parts
332649 Pump Lower Instructions - Parts
332650 Pump Instructions - Parts
2332612A

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 HA ARD
Flammable fumes, such as solvent and paint fumes, in work area canigniteorexplode.Tohelp
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. ee Grounding 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.
• Stop operation immediately if static sparking occurs or you feel a shock . Do not use
equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
SKIN INJECTION HA ARD
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.
•Followthe Pressure Relief Procedure 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 3

Warnings
WARNING
EQUIPMENT MISUSE HA ARD
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. ee Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. ee Technical Data
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request M D from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals
and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
MOVING PARTS HA ARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing
equipment, follow the Pressure Relief Procedure and disconnect all power sources.
TOXIC FLUID OR FUMES HA ARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled, or swallowed.
• Read M D s to know the specific hazards of the fluids you are using.
• tore hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
4332612A

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 HA ARD
Powerful suction could cause serious injury.
• Never place hands near the pump fluid inlet when pump is operating or pressurized.
Material Self-ignition
ome materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings and
material M D .
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
Model
Includes
9
:262927 262909 262926 24T834 24T835 24T836 24T837
Pump installed on Cart
24T837
1
✔✔✔✔✔✔✔
Basic pare Parts Kit
2
(included in tool box) ✔✔✔✔✔✔✔
Feed Hopper 24T853
3
✔✔ ✔ ✔
tandard 35 ft (1.7 m)
Hose Bundle 24T852
4
✔✔✔✔✔
Flex Applicator 24T947
5
✔✔✔
HTX 680 Manifold
Applicator 24U209
6
✔✔✔
Additional pare Parts
7
✔
Additional 25 ft (7.6 m)
Hose Kit 24R254
8
✔
1
Includes air motor, stainless steel pump lower, zero cavity relief valve, 1 in. male camlock outlet, air controls,
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 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
ee Parts, page 38, for details regarding what is included with each model.
6332612A

Component Identification
Component Identification
Overview
AA
AB
AC
AD
AE
AF
AGAHAI
AJ
AK
AK ti21568a
Figure 1
Key:
AA Material Hopper
AB Air Motor
AC Lower
AD Cart
AE Applicator
AF Material Hose (connects pump to whip
hose)
AG Material Whip Hose
AH Air upply to Applicator (for Air Assist and
Air Motor ON/OFF Pilot Valve), shown
disconnected
AI Return Air to Air Motor ON/OFF Pilot Valve
AJ ystem Air Inlet
AK Optional hose extension
332612A 7

Component Identification
Details
A
D
E
C
G
P
M
B
W
W
W
F
J
K
R
S
T
N
HX
U
Vti21569a
Y
S
K
U
U
M
M
G
G
L
T
T
Detailed View
Figure 2
Key:
AAir Inlet, 3/4 npt(f) Claw (Chicago) Fittings
BBleed Type Master Air Valve (required)
C Air Pressure Relief Valve
DAir Filter (40 micron)
EMotor Air Pressure Gauge
FMot
or Air Pressure Regulator Adjustment
Knob
G Pilot Ball Valve (starts/stops Air Motor)
H Motor Air Pilot Valve
JZero Cavity Relief Valve
KA
ir Assist Tube
LGrounding Wire, required (see
Grounding, page 12)
MNeedle Valve for Air Assist Flow Control
NAir upply Quick Disconnect to Applicator
Air Inlet Quick Disconnect (W)
PFluid Outlet, 1 in. Male Camlock Fitting
RPacking Nut/Wet Cup under pring Guard
Air Assist Nozzle Position Adjustment
crew
T Applicator Tip Assembly
UAir Assist hutoff Ball Valve
VApplicator Material upply Ball Valve
W Applicator Air Inlet Quick Disconnect
XPilot Valve ignal from Applicator Pilot
Valve (G)
YWhip Check Hose afety Cable
8332612A

Component Identification
Mortar Spray Applicator
CC
CD
CE
CF
CB
CA
U
M
Figure 3
Key:
MNeedle Valve for Air Assist Flow Control
UAir Assist hutoff Ball Valve
CA Air Assist Air Line
CB Air Needle (adjustable position)
CC Air Needle Retaining crew
CD Fluid Housing
CE Tip (Nozzle)
CF Rubber Tip Retainer
332612A 9

Component Identification
HTX 680 Internal Air) Applicator
DD
DB
DG
DA
DE
DF
U
M
DC
Figure 4
Key:
M Needle Valve for Air Assist Flow Control
U Air Assist hutoff 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 wivel
DG Handle
10 332612A

Component Identification
System Components
* 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)
Automatically opens to relieve air pressure if set
pressure exceeds preset limit.
Air Filter D)
Removes harmful dirt and water from compressed
air supply.
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.
ee Flush, page 26.
To avoid skin injection and splashing, never
open a camlock hose or applicator fitting
whilethereispressureinthefluidline. ee
Pressure Relief Procedure, page 14.
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.
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.
L
ti21630a
Grounding Wire
Figure 5
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
12 332612A

Setup
Setup
Tools Required
• Two adjustable wrenches
• Non-sparking hammer or plastic mallet
1. Ground sprayer. ee Grounding, page 12.
2. Check Throat eal Liquid (T L) level in packing
nut (R). Fill 1/2 full with T L.
R
ti21631a
Figure 7
3. Attach1in.x25ftelectricallyconductivefluid
hose to pump outlet.
NOTE: The 3/4 in. hose will be
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). ee Details, page 8 .
5. Attach small air tube from hose bundle to motor
pilot signal (X). Use wrench to secure air tube in
place. ee 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). ee 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. ee
Details, page 8 .
9. Wrap blue, velcro, camlock retaining straps
around each camlock connection to secure.
NOTE: 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.
B
A
ti21575a
Figure 8
12. Wet out the system with material flushing agent
before using. ee Wet Out the ystem, page 15.
332612A 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. ee Flush, page 26.
2. Close incoming air ball valve (B).
B
A
ti21575a
Figure 9
3. et 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.
ti21632a
Figure 10
To avoid injection and splashing, never open a
camlock hose or applicator fitting while 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. ee 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). ee
Flush, page 26.
NOTICE
To prevent material hardening in zero cavity relief
valve, flush the valve after every use.
14 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).
B
A
ti21575a
Figure 11
2. Remove tip from applicator.
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.
ti21663a
Figure 13
332612A 15

Wet Out the System
8. Open the motor on/off pilot ball valve (G) located
on base of applicator.
ti21578a
Figure 14
9. Open bleed type master air valve (B).
B
ti21574a
Figure 15
10. Rotate the air regulator adjustment knob (F)
clockwise until pump begins to move slowly.
F
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.
ti21632a
Figure 17
16 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
13. If needed, drain remaining fluid from system.
NOTE: 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. Useascrewdrivertoliftthepumplowerinlet
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. tartingatthepump,raisethehosebundle
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.
332612A 17

Mix the Material
Mix the Material
Always wet out the pump, hose, and applicator
before loading the mortar or epoxy material. ee
Wet Out the ystem, 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.
NOTE: It will take most of the first batch of
material to fill the pump and hoses.
Managing Mortar After Mixing:
• Paycloseattentiontotheworklifeofthematerial
being used.
• Only mix the mortar kits as needed. Do not let
mixed mortar sit longer than necessary.
• crape 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.
18 332612A

Prime with Mortar or Epoxy
Prime with Mortar or poxy
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. ee
Wet Out the ystem, page 15.
2. Mix the Material. ee Mix the Material, page 18.
3. Close the bleed type master air valve (B).
B
A
ti21575a
Figure 19
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
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.
332612A 19

PrimewithMortarorEpoxy
10. Open bleed type master air valve (B).
B
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.
F
ti21570a
Figure 22
12. Continue running the pump until a steady stream
of material comes from the applicator.
ti21632a
Figure 23
13. To stop dispensing, close the motor ON/OFF
pilot ball valve (G). Do not close the fluid ball
valve(V)whentheairmotorisrunning.
ti21579a
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.
20 332612A