Graco 332612A User's Manual
Contents
1. ae N ti21574a Figure 15 ti21632a Figure 17 16 332612A 12 To stop dispensing close the air motor on off pilot ball valve G and the main bleed type master air valve B ti21575a Figure 18 332612A Wet Out the System 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 Remove hopper and fittings between hopper and pump lower 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 Install fittings and hopper Install camlock retaining straps 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 17 Mix the Material Mix the Material Managing Mortar After Mixing e Pay close attention to the work life of the material Always wet out the pump hose and applicator being used before loading the mortar or epoxy material See e Only mix the mortar kits as needed Do not let Wet Out the System2. 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 Disassemble and Clean the Pump Daily page 30 4 Drain water from air filter mPatarPsi 5 Clean hopper with a scrub pad It is recommended that you clean the outside of the sprayer using a cloth and compatible solvent 1 Flush the system See Flush page 26 6 Check hoses tubes and couplings Tighten all 2 Relieve pressure See P fluid connections before each use Pressure Relief Procedure page 14 3 Perform the Disassemble and Clean the Pump 7 Check and replace camlock gaskets as needed Daily procedure at the end of every day See 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 ti21634a
3. xs lt cd lt 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 Figure 3 Key M Needle Valve for Air Assist Flow Control U Air Assist Shutoff Ball Valve CA Air Assist Air Line CB Air Needle adjustable position CC Air Needle Retaining Screw CD Fluid Housing CE Tip Nozzle CF Rubber Tip Retainer 332612A Component Identification HTX 680 Internal Air Applicator 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 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 e Required in you
4. Cart Assembly Figure 40 34 332612A Troubleshooting ACE 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 Problem Cause 4 Solution Does not operate Air motor pilot valve 211 is faulty 4 Remove valve by disconnecting swivel unions Connect hose directly to air motor Operate motor directly with air regulator 210 Valve closed or clogged 4 Clear air line increase air supply Check that valves are open Fluid hose or applicator obstructed 4 Clean hose or applicator Dried fluid on displacement rod or inlet ball 4 Clean rod always stop pump at bottom of stroke keep wet cup filled with compatible solvent Be sure inlet ball moves freely Air motor parts dirty worn or damaged 4 Clean or repair air motor See motor manual 332612A Troubleshooting Output low on both strokes Air line restricted or air supply inadequate Valves closed or clogged Clear air line increase air supply Check that valves are open Fluid hose applicator obstructed hose ID too small 4 Clear hose or applicator use hose with
5. A Replacement Danger and Warning labels tags and cards are available at no cost Parts included n Pack Out Hose Clean Kit 16W601 purchase separately Parts included in Hopper Replacement Kit 247853 purchase separately Parts included in Pump 16W514 purchase separately See manual 332650 Spare parts shipped with machine Not for sale 40 332612A Air Controls 213 222 222 214 ti22050a MA Apply pipe sealant to all non swiveling pipe threads DA Assemble one end of lanyard between ball valve 207 and fitting 208 One end hangs loose Ref Part Description Qty Ref Part Description 201 262658 FILTER air 40 micron 213 160430 GAUGE pressure air 202 158491 FITTING nipple 214 155470 FITTING swivel union 90 a Nal 203 C20432 FITTING cross pipe E ida pe eee 204 20461 FITTING nipple reducing ace a er neag cap hex y 205 FITTING elbow street 1 a se e el hean 206 159239 FITTING nipple pipe 2 line air reducing 219 127313 FITTING elbow 207 113332 VALVE ball vented 0 750 1 220 111881 MUFFLER 208 113429 COUPLING universal 1 221 100737 PLUG pipe O ICI OR 222 218093 HOSE coupled Universal E 3 4 14 npt female 223 162505 FITTING union swivel 210 104267 REGULATOR air 1 224 113498 VALVE safety 110 psi 211 16W146 VALVE 3 way pilot 1 225 16W586 CABLE lanyard whip operated check 212 BRACKET air controls 1 Not for sale 332612A Parts Qty 2
6. page 15 mixed mortar sit longer than necessary Always follow the material manufacturer s instructions Scrape mortar down the sides of the hopper as for the material being sprayed Mortar must be the hopper material level lowers Do not let older thoroughly mixed to a smooth consistency before mortar cure on the walls loading it in the hopper Occasionally do not refill the hopper until it is Always add the powder slowly to the fluid while almost empty This ensures all material in hopper mixing Do not add fluid to the powder is used while fresh 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 18 332612A 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 fe
7. BE in place place o ring BT between cylinder BI and inlet housing BC then use inlet housing clamp BB to install inlet housing BC onto cylinder BI NOTE Each clamp has one flat so that only one wrench is required to tighten clamp Align bolt head with flat then use a wrench on the nut to tighten Tighten both sides of the clamp evenly to approximately 10 ft lb 14 Nem Install inlet elbow BA onto inlet housing BC Tip cart up Install hopper BN onto the hopper bracket and connect to inlet elbow BA Install material hose onto pump outlet BP 332612A 17 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 18 Add TSL to the packing nut BM until 1 2 full Shutdown NOTICE To prevent rust never leave water or water based fluid in pump overnight 1 Flush the system See Flush page 26 NOTE 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 332612A Shutdown 33
8. G on applicator Use wrench to secure air tube in place See Details page 8 332612A 10 11 12 Setup 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 Going from applicator back to the system wrap a zip tie around all hoses every few feet to secure them together 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 aa ti21575a Figure 8 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 th
9. SS nananana pNymwyN 47 Parts Zero Cavity Relief Valve 16W513 A A Ref 301 302 303 304 Not for sale 42 307 Use assembly tool 15T630 to install seal 304 Apply medium strength thread locking fluid to threads prior to installing seat 305 Part 16U807 15M189 15M529 Description HOUSING end STEM SPACER backup seal SEAL check valve Qty ZA ASA gt a A A Ref 305 306 307 308 ti22051a Apply lithium grease to seal thread and o ring Torque to 95 105 in Ib 10 7 11 9 Nem Part 16V956 15Y627 16V957 102915 Description SEAT O RING PTFE HOUSING PIN drive Qty 1 1 1 1 332612A Parts Hose as 416 456 Le 428 454 Sl ft ti22047a 426 rey 38 241852 25 Ref Part Description ft bundle ft ae AN En 289874 COUPLER KIT 1 in female camigroove 2 Ce o o e 222 240185 COVER Fose plaste Ti x50 2270067 ROSE ea cap 08 JO aa pows HOSE id Tm coupled 25 7 7 25 peme COUPLER male comando a Tf O O zor pess FITTINGS ripple A AO A IS Dr AO IO O NL SEUL FE se sra pS 50700 COUPLER ear 550 BUSING we a 0 armor AAA 52201025 HOSE Bnd ar2o A Ce E anos A AA 5590607 GASKET cooler a 2 2 O 520 SRP OR OS 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 re
10. aed 6 104572 WASHER lock spring head 155470 SWIVEL union 90 degree ref O OE BRACKET hoppar En EE oo 16V509 ri sable CAND GROOVE 2 inch x 1 1 2 npt 13m 16U536 HOPPER ME 14 ena UNION 127082 TEE branch female 17 FWETE VALVE rei zero ca La PLUG bg cart 1 Hei 1777 p 2 a E E poe OT ange sored II E 29 114958 STRAP tie 110198 COUPLER line air 31 159841 BUSHING 3 8 x 1 4 in 32 169970 FITTING line air 24U209 APPLICATOR texture pole PO Oe A O ERE EE ae ENDE BEERE M34LNO MOTOR air 16U817 ROD tie 10 5 8 tie 10 5 8 caia LOWER pump e sl manual 332649 101712 NUT lock lock Ea ash Te BAS adapter 244819 COUPLING assembly COVER coupler Ea e EI E O E 262908 WIRE ground with clamp pia ess 50 pen pa Bie pever feom sping FM E 16W506 GASKET 2 in coupler cam and groove 6 pack 57 16W490 O RING pump cylinder 10 pack 16A443 NOZZLE 3 16 inch eae NOZZLE 1 4 inch 16A448 NOZZLE 1 2 inch 62 16A449 NOZZLE 9 16 inch 16W508 KIT seals pump ear K TOOL wen AAA ATA al gt 44444 E g 444444 Bee i J 4 d EEE Ni J 4 332612A 39 Parts ge Description BRACKET tool box ec a tool box 113505 NUT keps hex head 107251 98 247854 BUNDLE hose 35ft hose 35 ft Da OE a A E T
11. 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 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 nudes 2 0 Pe Model tes 262927 262909 262926 247834 24T835 24T836 241837 Pump installed on Cart Basic Spare Parts Kit 2 included in tool box Feed Hopper 241853 3 Y v Standard 35 ft 1 7 m Hose Bundle 24T852 4 Flex Applicator 2479475 Y HTX 680 Manifold Applicator 24U209 6 Additional Additional Spare Parts 7 Parts Additional Spare 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 and the two wheel cart 2 Includes gaskets for cam and groove fittin
12. larger ID Output low on down stroke Open or worn intake valve 4 Clear or service intake valve Output low on up stroke Open or worn piston valve or packings 4 Clear piston valve replace packings Erratic accelerated speed Fluid supply exhausted clogged suction 4 Refill hopper and prime pump Open or worn piston valve or packings 4 Clear piston valve replace packings Open or worn intake valve 4 Clear or service intake valve e Cycles or fails to hold pressure at stall Worn check balls seats or piston packing 4 Service lower See Disassemble and Clean the Pump Daily page 30 35 Troubleshooting Poor finish or irregular spray pattern Motor powered but nothing comes out of hose Incorrect fluid pressure at applicator Pump Is packed out with dry or cured material See applicator manual read fluid Disassemble and Clean the Pump Daily manufacturer s recommendations page 30 Inadequate air assist air pressure Hose is packed out with dry or cured material 4 Adjust air assist needle valve 4 Reverse hose and try to push out bad material Dirty worn or damaged spray applicator 4 Some materials may need only 1 in inner diameter fluid line all the way to the applicator 4 Service spray applicator See spray applicator manual e Material is too thick to push through hose without acking out Cannot open or close air motor
13. size Fluid flow use air motor regulator adjustment knob G Air flow use needle valve M e Air needle CB position Adjust Air Flow 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 Adjust Air Needle CB position Ensure the air needle CB is slightly behind the tip CE 332612A CA CE NOTE 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 Air Flow Valve Adjustment To decrease air flow turn valve knob clockwise To increase air flow turn valve knob counterclockwise Check material and thin as needed to maintain the proper consistency The material may thicken as it sits and could slow down application or affect the spray pattern Flush and dry applicator thoroughly at the end of each use Tips and retainers must be cleaned by hand Material Flow Adjustments For a lighter spray pattern adjust the air needle closer to the fluid nozzle and or reduce the fluid flow For a h
14. typically less than 10 cycles per minute Flushing 60 90 cycles per minute only when pumping flushing fluid Wetted Parts Entire System Stainless steel UHMWPE nylon plated steel anodized aluminum FX 75 Pump Stainless steel carbide PTFE UHMWPE solvent resistant o rings gt lt lt w 4 5 I 216 a gt Ey Hose Kits Nylon core plated carbon steel fittings anodized alu minum nitrile gaskets 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 10 20 30 40 50 o 1000 60 800 50 Pump 40 Air Flow in Outlet Fluid 600 Standard Pressure in do Cubic Feet psi a 30 Per Minute 400 IZ 20 1 2 3 4 5 6 7 8 9 10 Flow Rate in Gallons Per Minute ps O Description 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 TO TMOOU gt Air Consumption at 100 psi Air 46 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 49 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
15. 6 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 6 332612A Component Identification Component Identification Overview Figure 1 Key AA Material Hopper AB Air Motor AC Lower AD Cart AE Applicator AF 332612A AD AJ AA AC AE AK Al AH AG teers AG Material Whip Hose AH Air Supply to Applicator for Air Assist and Air Motor ON OFF Pilot Valve shown disconnected Al Return Air to Air Motor ON OFF Pilot Valve Ad System Air Inlet AK Optional hose extension Material Hose connects pump to whip hose Component Identification Details Detailed View Figure 2 Key gt Air Inlet 3 4 npt f Claw Chicago Fittings Bleed Type Master Air Valve required Air Pressure Relief Valve Air Filter 40 micron Motor Air Pressure Gauge mmo o DW 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 r A amp IQ nO D
16. 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 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 EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data 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 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 a
17. Housing Clamp BC Inlet Housing Assembly BD Inlet Ball BE Inlet Ball Stop BF Pump Rod Assembly BG Outlet Ball Stop BH Piston Seal Bl Cylinder BJ Cylinder Clamp BK Outlet Housing BL Throat Packing BM Packing Nut non adjustable BN Hopper BP Pump Outlet BR Hopper Release Camlock BS Outlet Ball BT Cylinder O rings BU Outlet Housing Lock Nut BV Ball Cage Spring 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 e Cam and groove fitting gaskets Spray tips e Tip retainer Rod and cylinder seals e Cylinder o rings e 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 Disassemble and Clean the Pump Daily NOTE As items are disassembled use a soft brush and water or a compatible solvent to clean components 1 Flush the system See Flush page 26 Stop pump near bottom of its stroke 2 Perform Pressure Relief Procedure See Pressure Relief Procedure page 14 3 With fluid pressure relieved remove material hose from pump outlet BP 4 Disconnect hopper at outlet ca
18. Instructions Parts GRACO 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 Ede A Contents Related Manuals 0 c cccceeceeeeeeeeeeeaeeeeaeeeeaes 2 Wa ui aba 3 ModelS 0 ee dee 6 Component Identification oocoocccoccconnconnos 7 A A age eee eee 7 Detalla rd rt oa 8 Mortar Spray Applicator ooocoocccocncocncccc 9 HTX 680 Internal Air Applicator 10 System COMPONENTS occcocccccccncnnoconncnnnnnnnnnnns 11 GOL raccns A 12 SA a 13 Pressure Relief Procedure oooocccccccccociccnnccccncnnnns 14 Wet Out the SySteM oocoocccccncccncccnoccconcconnnnnnnnons 15 Mix the Material ooooooconocccccnccnoccccnncccnnincnncncnnnnnnns 18 Prime with Mortar or EPOXY oocccoccccccccncccncncnnccnos 19 MY ii ltda idad 21 Prevent Packout ooocoooccccnccccnncccnccnnnnccccnnninnons 21 Before Starting or Stopping Material FOW eich A i te ed a 21 SPRAVING iis dectacs seeds iaducs sagen dead daisies secede 21 Spray Adjustments Mortar Spray Applicator anane cla 23 Related Manuals Manuals are availa
19. OX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2013 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com
20. ach 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 e 30 in 76 cm aluminum pipe with cam lock fluid inlet e Angled spray head Spray air volume control e Spray shut off valve e Motor pilot signal control valve Adjustable position center air injection tube e Rubber tip retainer e 4 different sized tips 44 332612A Technical Specifications Technical Specifications Mortar and Epoxy Sprayer Package Maximum Working Pressure 1000 psi 7 MPa 70 bar Maximum Air Inlet Pressure 100 psi 0 7 MPa 7 bar Minimum Inlet Air Flow Typical 30 standard cubic feet per minute 0 85 cubic meters per minute per liter at 7 bar Pressure Ratio Fluid lo Al Air Motor Piston Diameter Stroke Length Lower Output Flow Rate at 30 cycles per minute Flow Rate at 60 cycles per minute 10 88 gpm Fluid Inlet Size Fluid Outlet Size 1 npt f with a 1 in Cam and Groove Fitting Weight without fluid 250 Ib 113 kg with 25 ft of 1 in hose and with 7 6 m of 25 mm hose and 10 ft of 3 4 in hose 3 0 m of 19 mm hose i 173 om 70 om Depth pump on cart only 32 in 81 cm Deep pump on cart with hopper in 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
21. alve 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 NOTE High flushing fluid velocity is the most important item for effective vie cleaning The fluid hose should Figure 35 shake while the pump is running This is necessary to maximize the cleaning effects of flushing NOTE 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 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 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 332612A 27 Flush 28 fluid ball valve is open before opening pilot ball valve G NOTE 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 int
22. alve 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 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 e 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 fl
23. ator material ball valve V second Turn off the air assist valve U last 332612A Spraying Spray 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 Wet Out the System page 15 Mix the Material page 18 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 Turn air regulator adjustment knob F counterclockwise until it stops and gauge E reads zero Figure 25 21 Spray 5 Install tip on applicator by stretching rubber 9 retainer with a screwdriver or screwing on retainer depending on your application kit ti14355a 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 Se
24. ble at www graco com Component manuals in English Manual Description 332651 Mortar Spraying Tips 332767 Mortar Spray Applicators Operation Parts 312798 Air Flow Valve Adjustment ccccccceeeees 23 Material Flow Adjustments cccceceees 23 Spray Techniques ccocccocccccccccncncncncnnonnnnnnnns 24 Installing Nozzle Retaining Cap o 24 Material Compatibility ooocoocnoonncccc 24 Spray Adjustments HTX 680 Applicator 25 El sch catia cas ea ee docenas al as 26 NOIES nene E a E A ae eee 29 Disassemble and Clean the Pump Daily 30 A pend nartien Bes area ae ee 33 Maintenance 2 0ccecceeeeeeeecceeeeceeeeeeeeeeneeeeaes 34 Daily Maintenance cccccce cece esse eeeaeeees 34 TrOUDIESHOOTING 0 cc cceccc cece cece cece seca seen esse eeneees 35 Repal ti ida 37 Replace Pump Components ooooccccccccncccnnccno 37 Replace Air Motor cceeeeeeeeeeeeeeee ees 37 Replace PUMP LOWE cccecseeeeeeeeeeeees 37 O at cara a 38 ACCESO Nini 44 Technical SpecificationS ooccoccconncooncnnnnnon 45 Graco Standard Warranty oooccocccocncociconinonnns 48 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 t
25. ction 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 Figure 41 4 Loosen three tie rod nuts 44 then loosen and remove tie rods 42 from air motor See Parts page 38 Remove air motor Align air motor with tie rods 42 then tighten tie rods to air motor 332612A Repair 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 h
26. e Details page 8 Material will begin dispensing 10 1 22 Adjust air motor regulator adjustment knob F until desired material flow rate is achieved Turn clockwise to increase pressure counterclockwise to decrease pressure ti21571a1 Figure 27 NOTE 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 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 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 332612A Spray Adjustments Mortar Spray Applicator Spray Adjustments Mortar Spray Applicator M U Ad Wy KP En omen Y Figure 28 Key M Needle Valve for Air Assist Flow Control U Air Assist Shutoff Ball Valve CA Air Assist Air Line CB Air Needle adjustable position CC Air Needle Retaining Screw CD Fluid Housing CE Tip Nozzle CF Rubber Tip Retainer General Adjustments The spray pattern can be adjusted by changing Tip CE
27. e system See Flush page 26 2 Close incoming air ball valve B ti21575a Figure 9 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 ti21632a To avoid injection and splashing never open a camlock hose or applicator fitting while there is pressure in the fluid line 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 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 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 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 flushin
28. eavier spray pattern adjust the air needle farther back from the fluid tip and or increase the fluid flow 23 Spray Adjustments Mortar Spray Applicator NOTE Withdrawing needle too far can force air pressure back into fluid hose slowing material flow 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 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 Installing Nozzle Retaining Cap 1 Place nozzle retaining cap over top lip of applicator housing 24 2 Insert screwdriver through hole in tab of nozzle retaining cap 3 Pus
29. 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 equip
30. g 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 ne ti21575a Figure 11 2 Remove tip from applicator 332612A D Wet Out the System Partially fill the clean hopper with material flushing agent depending on the material you will be spraying Turn air regulator adjustment knob F counterclockwise until it stops and gauge E reads zero ti21571a Figure 12 Verify zero cavity relief valve J is closed Place applicator outlet in grounded pail Open the fluid ball valve V on the applicator Figure 13 ti21663a 15 Wet Out the System 8 Open the motor on off pilot ball valve G located 10 Rotate the air regulator adjustment knob F on base of applicator clockwise until pump begins to move slowly ti21578a Fi re 14 ti21570a a Figure 16 9 Open bleed e master air valve B p yp 8 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
31. gs 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 1
32. h screwdriver head against notch on applicator tip and pry nozzle retaining cap over lip until it snaps into place ti14355a 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 332612A Spray Adjustments HTX 680 Applicator Spray Adjustments HTX 680 Applicator gt DG Figure 30 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 The spray pattern can be adjusted by changing e 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 v
33. h the fluid ball valve V open open the motor ON OFF pilot ball valve G Material will begin F dispensing 16 Recirculate a few gallons of material to be sure the material is flowing properly ti21570a ax 17 Install a tip onto applicator The system is now Figure 22 primed and ready to spray 20 332612A 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 e 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 1 Always close turn off the motor pilot ball valve G first 2 Close applic
34. ment will be returned to the original purchaser transportation prepaid If inspection of the supe 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 ee dera Graco will provide purchaser with reasonable assistance in making any claim for breach of ese warranties In no event will Graco be liable for indirect incidental special or consequential damages resulti
35. mlock BR then remove hopper BN 5 Remove inlet elbow BA 6 Tip cart back so it rests on the back of the cart 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 BF 2 up to remove coupling BF3 31 Disassemble and Clean the Pump Daily Figure 39 Pull rod BF down and out of outlet housing BK Remove outlet ball stop BG from rod BF by pushing o rings off of ball stop BG Loosen and remove packing nut BM then remove throat packing BL Use a brush and solvent to clean all loose pieces NOTE The pump rod BF is not disassembled unless the piston packing or seat needs to be replaced NOTE The inlet housing BC is not disassembled unless the inlet seat needs to be replaced Assemble the Pump 1 32 Loosely install throat packing BL with the open end facing into the pump Install packing nut BM hand tight Lubricate the balls BS BD to ensure they do not stick Install o
36. ng 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es 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 B
37. o 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 12 After performing the previous step at least twice drain remaining flushing fluid from system 13 a Place grounded metal drain pan beneath pump lower inlet fittings Remove hopper and fittings between hopper and pump lower 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 Install fittings and hopper Install camlock retaining straps 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 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 332612A Notes 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 e Rubber mallet to break items loose if necessary N INN NSH Y AS le SPIN SY ti21645a Figure 37 30 332612A Key BA Inlet Elbow with Camlock BB Inlet
38. o 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 FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area 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 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 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 e
39. opper 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 ti21656a Figure 42 Loosen three tie rod nuts 44 then loosen and remove tie rods 42 from air motor See Parts page 38 18 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 37 Parts Parts M680 Systems 11 55 58 a Torque to 145 155 ft lb 197 210 Nem Apply medium strength thread locking fluid to threads Apply clear liquid petrolatum to axles 1 before assembling wheels 2 1 2 55 58 ti22048a Assemble fitting 15 and zero cavity relief Pack grease around the end of the A valve 17 then assemble to swivel 14 A N zero cavity relief valve in front of the with relief hole pointing downward or at the threads pump a N Torque to 50 60 ft lb 68 81 Nem A Apply pipe sealant to all non swiveling pipe threads A p Quantity S Description a AAA eae 1 262914 CART 116406 WHEEL 2 2 2 2 2 811935 RING retina e er Air Controls 38 332612A Parts a Description al rat re EEN a rac
40. pilot ball valve on pacing ou applicator 3 4 in x 10 ft whip hose is too restrictive Dirty air clogged the air motor pilot valve 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 4 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 4 Thin and mix material thoroughly to a lower fluid flow by adjusting air regulator pressure viscosity up and down as needed Install new pilot ball 4 imi i i Cain ore becomes ava lable 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 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 4 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 332612A Repair To prevent skin inje
41. pproved 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 HAZARD Moving parts can pinch cut or amputate fingers and other body parts e Keep clear of moving parts Do not operate equipment with protective guards or covers removed e 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 HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDSs to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines 332612A Warnings 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 e Respirators protective clothing and gloves as recommended
42. r 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 332612A Component Identification 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 while there is pressure in the fluid line See Pressure Relief Procedure page 14 17 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 e Grounding wires and clamps for pails e Two 5 gallon 19 liter metal pails 1 Connect the ground wire L Part No 262908 to the gro
43. und stud on the air motor ti21630a Grounding Wire Figure 5 12 Connect the other end of the ground wire to a true earth ground 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 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 332612A 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 ti21631a Figure 7 3 Attach 1 in x 25 ft electrically conductive fluid 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 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
44. ushing 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 ON ti21575a Figure 31 26 2 Remove applicator tip and retainer J e 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 332612A Flush 6 Open bleed type master air valve B to begin 10 Place applicator in the system hopper with the dispensing outlet pointing down to enable fluid circulation NOTE 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 EN 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 Fi 36 mews agent while dispensing igure b Use a scrub brush to scrub the walls of the hopper c Open the pilot ball v
45. utlet ball BS outlet ball stop BG with o rings into rod BF Ensure outlet ball stop o rings are in the grooves on the outlet ball stop rod Grease the packing on the rod BF Gently slide rod BF through throat packing BL Install coupling BF3 slide coupling cover BF2 over coupling then install clip BF1 to secure pump rod BF to air motor Use a flat tip screwdriver and a plastic mallet to tighten packing nut BM until it stops NOTE This is not an adjustable packing but the packing nut BM does need to be tight against the throat packing BL 9 ti21656a 10 11 12 13 14 16 Slide cylinder BI over rod BF with o ring BT installed between outlet housing BK and cylinder BI NOTE If the o ring BT does not stay in place while assembling the cylinder Bl to the housing BK the cart may need to be tipped upright to install properly After clamp is installed tip cart back to horizontal position to finish assembly Use cylinder clamp BJ to secure cylinder BI to outlet housing BK NOTE Each clamp has one flat so that only one wrench is required to tighten clamp Align bolt head with flat then use a wrench on the nut to tighten Tighten both sides of the clamp evenly to approximately 10 ft lb 14 Nem Install inlet ball BD ball cage spring BV and inlet ball stop BE in inlet housing BC With inlet ball BD ball cage spring BV and inlet ball stop
46. w 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 N ti21575a Figure 19 332612A Prime with Mortar or Epoxy Remove tip from applicator 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 Turn air regulator adjustment knob F counterclockwise until it stops and gauge E reads zero Figure 20 Open the fluid ball valve V on the end of the fluid hose Place applicator outlet in a grounded metal 5 gallon waste container Open the motor ON OFF pilot ball valve G located on base of applicator 19 Prime with Mortar or Epoxy 10 Open bleed type master air valve B 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 when the air motor is running SN 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 Figure 24 14 Place the applicator outlet into the hopper 15 Wit
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