Download Graco Inc. 308-522 Pressure Washer User Manual
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INSTRUCTIONS-PARTS LIST This manual conteins IMPORTANT WARNINGS and INSTRUCTIONS READ AND RETAIN FOR REFERENCE HYDRA-CLEAN 4040 Pressure Washer @ Model 800-345, Series A 230/460 Volt, 3 Phase 4ooo psi (276 bar) OPERATING PRESSURE 4300psi (296 bar) MAXIMUM WORKING PRESSURE GRACO INC. RO. Box 1441 MINNEAPOLIS, MN 55440-1441 @COPYRIGHT1990,GRACO INC. ~ BNG HIGH PRESSURE SPRAY CAM CAUSE SERIOUS INJURY. FOR PROFESSIONAL USE ONLY. OBSERWE ALL WARNINGS. Read and understand all instruction manuals before operating equipment. FLUID INJECTIONHAZARD General Safety This pressure washer generates very high fluid pressure.Sprayfromthegun,leaksorruptured components can injectfluid through your skinand into your body and cause extremely serious bodily injury includingtheneedforamputation. Als0,fluid injectedor splashed into the eyes or on theskin can cause serious damage. Pressure Relief Procedure To reduce the risk of serious bodily Injury, includingfluid injectionandsplashing in theeyesorontheskin, always follow thisprocedure whenever you stop spraying for more than 10 minutes, when shutting down, and before checking or repairingany part of the system. NNER point the spray gun or wand at anyone of at any part of the body. NNER put hand or fingers over the spray tip. 2. Turn the sprayer off. ALWAYS follow the Pressure Rellef Procedure, before cleaning or servicing any part of the sprayer. 1. Engage the trigger safety latch. 3. Disconnect the electrical supply. 4. Shut off the water supply. NNER try to stop or deflect leaks with your hand or body. 5. Disengage the trigger safety latch and trigger the gun to relieve pressure, and then engage the trigger safety latch again. Be sureequipmentsafetydevicesareoperating properly before each use. 6. Beforelong-term(overnight)storage,disconnect the water supply and disconnect the electricity. Medical Treatment If any fluid appears to penetrateyourskin,get EMERGENCY MEDICALTREATMENTATONCE. DO NOTTREATAS A SIMPLE CUT. Tell the doctor exactly what fluid was injected. Spray Gun Safety Devices Be sure all gun safety devices are operating properly before eachuse. Do not remove ormodify any part of thegun; this can cause a malfunction and result in serious bodily injury. NOTE TOPHYSICIAN: lnjection in the skin is a traumatic injufg It Is Important to treat the Injury surglcally as soon as posslble. Do not delay treatment to research toxicip Toxicily is a concern with some exoticcoatings injected directw into the bloodstream. Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable. S A F m LATCH: Whenever you stop sprayingfora moment, always set the gun safety inlatch the engaged 0r"safe" position, makingthe guninoperative. Failure to properly set the safety latch can result in accidental triggering of the gun. 2 308-522 SPRAY TIP S A F m Use extreme caution when cleaning or changing spray tips. If a spray tip clogs while spraying, engage the gun safety latch immediately. ALWAYS follow the Pressure Relief Procedure and then remove the spray tip to clean it. .. .. ... DANGER This product must be grounded. If it should malfunction or breakdown,groundingprovidesa path of least resistance for electriccunent to reducetherisk of electric shock. This equipmentis equipped with a cord having an equipment-groundingconductoranda groundingplug. The plug must be plugged Into an appropriate outlet that is properly installed and grounded in accordancewith all local codes and ordinances. Improper connection of the equipmentgrounding conductor can result in the risk of electrocution. Check with aqualified electrician orserviceperson if youare in doubtas to whether the outletis properly grounded. Do not modify the plug provided with the product- if it will not fit theoutlet,haveaproperoutlet installed by a qualified electrician. GROUND FAULT CIRCUIT INTERRUPTER PROTECTION receptacle that is protected by ground-fault a circuit-intempter (GFCI). To comply with the National Electrical Code (NFPA 70) and to provide additional protection from the risk of electric pressure washer connect shock, this to a .. , EXTENSION CORDS Use only 4-wire extension cords that have 4-prong grounding-type plugs and 4-pole cord connectors that accept the plug from the product. Use only extension cords that are intendedforoutdoor use. These extension cords are identified by marking, a "Acceptable for use with outdoor appliances; store indook while not in use." Use only.extension cords having an electrical rating notless than the rating of the product. Do not use damaged extension cords. Examine extension cord before using and replace if cord and do not yank damaged. Do not abuse extension ' or pull on any cord to disconnect. Keep cord awayfrom heat and sharp edges. Always disconnect the extension cord fromthereceptaclebeforedisconnectingthe Droduct from the extension cord. WARNING 1- 1 To reducetheriskofelectrocution, keep all connectionsdry and off the ground.Donot touch plug with wethands. EQUIPMENT MISUSEHAZARD General Safety System Pressure Any misuse of the pressure washer or accessories, such as overpressurizing, modifying parts, using incompatible chemicals and fluids, or using worn or damaged parts, can cause them to rupture andresult in fluid injection, splashing in the eyesor on the skin, or other serious bodily injury, fire, -explosion or property damage. This sprayer can develophigh operating pressure. Be sure thatall spray equipment and accessories rated are to withstand the maximum workingpressure of this sprayer. DO NOT exceedthemaximumworking pressure of any component or accessory used in the system. N N E R alter or modify any part ofthis equipment; doing so could cause it to malfunction. BE SURE that all chemicalsused in thechemical injector are compatible with the wetted parts of the hose, gun, wand andtip, as given in the Technical Data (inside back cover). Always read the chemical manufacturer's literature before using any chemicalin this pressure washer. CHECK all spray equipment regularly and repair or replace worn or damaged park immediately. Chemical Compatibility " ALWAYS wear protective eyewear and appropriate clothing. If using a chemical injector, read and follow chemical the manufacturer's literature for recommendations on additional protective equipment, such as a respirator. 308-522 3 HOSE SAFETY Highpressurefluid in the hoses canbe very dangerous. Ifthe hose develops aleak, split or rupture dueto any kind of wear, damage or misuse, the high pressure spray emittedfrom it can causefluid a injection injury or other seriousbodily injury or property damage. ALL FLUID HOSES MUST HAVE STRAIN RELIEFSON BOTH ENDS. The strain reliefs help protect the hose from kinks or bends at or close to the coupling, which can result in hose rupture. TlGHTEN all fluid connections securely before each 'use. High pressure fluid can dislodge a loose coupling or allow high pressure spray to be emitted from the coupling. NNER use a damaged hose. Beforeeach use, check entire hose forcuts, leaks, abrasion,bulging cover, or damage or movement of the hose couplings. If any of these condRions exist, replace the hose immediately. DO NOT try to recouple high pressure hose or mend it with tape or any other device.A repaired hose cannot contain thehigh pressure fluid. HANDLEAND ROUTEHOSES CAREFULLY Do not pull on hoses to move the pressure washer. Do not use chemicals which are not compatible wlth inner the tube and cover of the hose. DO NOT expose Gracohose to temperatwes above 2M)" F (93' G)M below 4 0 'F (-400 C). MOVING PARTS HAZARD Moving partscan pinch oramputatefingersorother body parts. KEEP CLEAR ofmoving parts when starting or operating the pressure washer. Pressure Rellet Procedure before checking or servicing the pressure washer to prevent discharging high pressure fluid from the gun. NNER operate the pressure washer withoutall guards and interlocks installed andfunctioning.Followthe TERMS WARNING or DANGER Alertsuser to avoid or correct conditions that could cause bodily injury. NOTE Identifies helpful procedures and information. CAUTION Alerts user to avoid or correct conditions that could cause damageto the equipment. IMPORTANT United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards-particularly the General Standards, Part 1910, and the Construction Standards, Part 1926-should be consulted. 4 308-522 INSTALLATION PUMP DIPSTICK MOTOR PUMP OIL LEVEL INDICATOR CONNECTION 314" GARDEN HOSE (9 Figure 1 Check for Shipping Damage Check the unit for any damage that mayhave occurred in shipping. Not@ the carrier Immediately if there is any damage. Set Up Beforeplugging in the unit, be sure theelectrical service matchesthespecification in TechnicalData (inside back cover) and the voltagelabel on the unit. With the. , unit off, plug the power supply cord into a grounded, GFCi-protected outlet. Donotremovethe electrical plug which comes with the unit or bend connecting prongs tofit an improper outlet! Use an extension cord that meets the requirementsof the EXTENS/ON CORD section andis no more than100 fl(30 m) long. Added length of cord will affect current draw of unit. If you are using a downstream chemical injector, install it betweenthepumpunloader and the high pressure hose, using the quick couplers provided. Connect the high pressure hose between the pump outlet and the gun inlet. Both of these connections are made with quick couplers. 1- CAUTION Up lo 100 ft (30m) of high pressure hose may beused. Longerhosesmayaffectsprayer and chemical injector performance, if used. Installtheappropriatespray tip on thewand.See lnstaliing and ChangingSpray Tips. If you are using a sandblaster kit, seeits separate manual forinstallation instructions. Connect to Water Supply CAUTION Before attaching to the water supply, check your local plumbing code regarding crossconnection to the water supply. A backilow preventer, P/N 8 0 1 -1 33, is available to prevent backflow of contaminated water Into the fresh water supply. Install it upstream from the pump. Install a regulating water valve, P/N 800-258, if inlet water pressureis over €0psi (4.1 bar). Do notexceed 160° F (70" C) inlet water temperature. Connect ahose with at least a3/4 inch (19 mm) IDand not longer than 50 fl(15 m) to the unit's 314 Inch garden hose inlet. NOTE m e watersourceatthe unit must havea minimum flowrate equalto that of the unit (see Technical Data, inside back cover). 308-522 5 STARTUP Always use this start up procedureto ensure that the unit Trigger Safety Latch is started safely and properly. WARNING 1. Check the oil level. Pump: Add SAE X I or 30 weight non-detergent oil as necessary. To reduce the risk of serious bodily injury, including fluid injection, splashingin the eyesor on the skin,ALWAYS engage the trigger safety latch whenever spraying stops, evenfora moment. 2. Tum on the water supply. CAUTION In the engaged position, the trigger safety latch prevents the gun from being triggered accidentally by hand or ifit is dropped or bumped. Be sure thelatch is pushed fully down when engaging it or it cannot prevent the gun from being triggered. See Figure 2. I Never run the unit dry. Costly damage to the pump will result.Always be sure the water supply is completely tumed on before operating. 3. Triggerthegun until waterspraysfromthe tip indicating that the air is purged from the system. 4. Plugtheelectrical cord into proper,grounded, GFCI-protected outlet. 5. ALWAYS engagethegun’striggersafety latch whenever you stop spraying, even for a momentto reduce the riskof fluid injection or splashing in the eyes or on the skin if the gunis bumped or triggered accidentally. 6. ALWAYS observe the following CAUTIONS to avoid costly damage to the pressure washer. TRIGGER SAFETY LATCH SHOWN ENGAGED CAUTION DO NOT allow the pressure washerto idle for more than10 minutes. Doingso may causethe recircuiating water lo overheat and seriously damage the pump. Tum off the pressure washer if it will not De sprayingor cleaningat leastevery 10 minutes. If heated inlet water is used, reduce this timefurther. DO NOT run the pump dry, which will quickly damage the pump. Be sure the watersupply is fully tumed on before starting the pump. DO NOT operate the pressure washer with the inlet water screen removed. This screen helps keep abrasive sediment out of the pump, which could clog or scratchthepump,Keepthis screen clean. DO NOT pump caustic materiais; such materials may corrodethe pump components. 7. See the chemical injectoror sandblasterkit manual for detailed cleaning information these if accessories are used. 6 308-522 TRIGGER SAFETY LATCH SHOWN DISENGAGED Figure 2 Installing and Changing Spray lips WARNING To reduce therisk of serious bodily injury, including fluid injection or splashing inthe eyes orontotheskin,useextremecautionwhen changing spray tips. ALWAYS follow the procedure below. CAUTION To avoid blowing the O-ring out of the qulck coupler, dueto the high pressure in the system, never operatethe pressure washer without a tip securely mounted in the quick coupler. 1. Follow the Pressure Rellet Procedure. 2. Pointthegunandwandaway anyone else. from yourselfand 3. Without holding your hand over the spray tip (A), pull back the quick coupler ring(B), remove the tip and then release the ring.See Figure 3. 4. Be surethe tip is secure before starting to spray again. 5. Tip holding holes are provided on the chassis. Figure 3 308-522 7 SHUTDOWN, FLUSHING AND STORAGE MAINTENANCE Observing regular maintenance intervals helps ensure that you get maximum performance and life from the pressure washer. WARNING Pressure Rellef Procedure To reducetherisk of serious bodily injury, including fluid injection and splashing in the eyes, or ontheskin,always follow this procedurewhenever you stop spraying for more than 10 minutes,whenshuttingdown,and before checking or repairing any part ofthe system. 1. Engage the trigger safety latch. 2. Tum the sprayer off. There is a break-inperiod for the pump. Afler changing the oil initially, the interval between required changes Is longer. WARNINGI To reducetherisk of serious bodily injury, includingfluid injection, splashinginthe eyes or on the skin or injury frommoving parts, always follow the Pressure Relief Procedure Warning 3. Disconnect the electrical supply. 4. Shut off the water supply. 5. Disengage thetriggersafetylatch and trigger the gun to relieve pressure, and then engage the trigger safety latch again. 6. Before long-term (overnight) storage, disconnect the water supply and disconnect the electricity. 1. If the pressure washer will be exposed to freezing temperatures, drain all water out of the pump. If it must be stored in freezing temperatures, flush the unitwitha 50% anti-freezesolution.Relieve pressure. Flush the pressure washer before using it again to remove the anti-freeze. NOTE: An anti-freeze flush kit P/N 802-327 is available to make flushingeasier. CAUTION Ifwater does freeze in thepressurewasher, thaw it in a warm room before trying tostart it. DO NOT pour hot water on or into the pump; it 2. After each use, wipe all surfaces of the pressure washer with a clean, damp cloth. 3. Perform the appropriatemaintenance. maintenance chart. E 308-522 See the interval What to do Daily Clean water inlet screen and filter. Check pump oil level. Fill as necessary. After first 50 hours of operation Changepumpbreak-in oil. Use SAE 20 or 30 non-detergent oil. Each 500 hours Change pump oil. Use SAE 20 or of operationor 30 non-detergent oil. 6 months I TROUBLESHOOTING CHART WARNING To reduce the risk of seriousbodily injury, including fluid injection, splashing in the eyes or on the skin, or injury from moving parts, always fallow the Pressure Relief Procedure Warning before proceeding. CAUSE I SOWTION PROBLEM tip. Replace withtip of proper size. DW pressure and/or Wom or wrong size ump runs rough Inlet filter clogged. Clean. Check more frequently. Checlc filter. Replace packings.See PUMP SERVICE. Wom packings, abrasivesin water or natural wear. Check water flowrate to pump. Inadequate water supply. Tighten or replace. Coupling slippage. Fouledor dirty inlet or discharge valves. Clean Inlet and discharge valve assemblies. Check filter. Even a small particle can cause the valve lo stick. Reslricted inlet. Check garden hose. maybe collapsed orkinked. Replaceworn valves. Worn inlet or discharge valves. Reolace hlahm w r e hose. Leakina hiahm s u r e hose. rater leakage from Wom packings. Install new packings.See PUMP SERVICE. nder pump manifolc rater in pump Humid air condensing inside crankcase. Change oil as specifiedin MAINTENANCE. Install new packings.See PUMP SERVICE. Wom packings. Install newoil seals. See PUMP SERVICE. Oil seals leaking. e 'q e q u e n t or See PUMP SERVICE. Scored, damaged or worn plungers. Install new plungers. emature failure of Abrasive material in the fluid being pumped. Install proper filtration on pump inlet plumbing. 1 8 packings Inlet water temperaturetoo high. Check water temperature; maynot exceed 160°F. Overpressurizing pump. Do not modify any factory-set adjustments. See EQUIPMENT MISUSEHAZARD. Excessivepressuredue to partiallypluggedorreplace tip. See InstallingandChangingSpra) or damaged tip. 10 minutes without spraying Pump runningtoo long without spraying. Never run pump more than Do notrun pump without water. Running pump dry. lrong surging at theForeign particlesin the inlet or discharge Clean or replace valves.See PUMP SERVICE. let and low pressurt valve or wom inlet and/or discharge valves. 1 the discharoe side nit will n d start Unit not pluggedin. Check power cord. Electrical service off/GFCI activated. Check fuse/circuit breaker. Check for proper grounding. mermai overload has tripped. Press stop button on the motor starter. 308-522 9 PARTS DRAWING 800-345 Hvdra-Clean@4040 Pressure Washer For wiring diagram, see page14 ~~~~~ 10 308-522 PARTS LIST 800-345 Hydra-Clean@4040 Pressure Washer REF PART NO. DESCRIPTION NO. DESCRIPTION QN NIPPLE, Hex 800-579 PUMP & MOTORASSEMBLY 35 3/8 156-849 803-591WASHER, Flat 1/2 1 36 (see page 15) 802-784 WASHER, Lock 112 803-554BRACKET,PumpSupport 1 37 2 803-592SCREW,Cap,hexhd. 801-382CORD,Power10/4 38 48 in 3 1/2-13 4 X 1-1/2 1 4 803-263BRACKET.Starter. left 801-012GROMMET.,Rubber 39 159-239 NIPPLE, Hex 1/2 x 3/8 2 5 800-124TIPASSEMBLY, OOO4 802-732WASHER.Flat #6 4 40 6 (includes 4 5 , 60) 802-731 WASHER: Lock #6 4 7 800-125TIPASSEMBLY,1504 41 803-484 SCREW, Cap, pan4hd. 8 (includes 45, 61) 1 803-517 LABEL, Keep From Freezing 1 9 800-126TIPASSEMBLY,2504 42 1 800-427UNLOADER, 4ooo psi 10 (includes 1 45, 62) 11 800-450HOSEASSEMBLY, w/Quick 800-127TIPASSEMBLY. 4004 Couplers (includes 14, 18, 20) 1 43 (includes 45,’63)~ 12 801-009QUICKCOUPLER, Femaie 1/4 801-WBDECAL.GracoG 1 44 Soi-Os0 QUICKCOUPLER, Male 1/4 154-594 O-RING, (includes Quic 1/4 13L1 Coupler 45 13 176-250LABEL,Warning, chassis 14 801-568 QUICK COUPLER, Male 3/8 46 2 47 176-981LABEL,Warning. chassis 802-534 NIPPLE, Hex 1/2 NPSM X 15 803-396 LABEL, WamingICavtion 1 1 48 112 NPT 49 803-141HOSE,Bvoass 1 100-527 WASHER, Flat 5/16 16 100-21 4 WASHER, Lock 5/16 803-395 LABEL, Model1 4040 50 17 803-519 HOSE, High Pressure 3/8 x 50 ft 1 100-188 NUT, Hex 5/16-18 51 18 803-007 LABEL, Caution, 230 volt, 800-429GUN &WAND ASSEMBLY 19 52 3 phase fincl.12.20.28.29.34.35)1 803-006 LABEL, Caution, 460 volt, 803-157 QUiCK COUPLER, Femaie 318 20 152 phase 3 2 (includes 21) CONNECTOR, 801-226 4 Wire 156-082 O k N G , Quicik Coupler 3/8 2 53 21 801-382CORD.Power12/4 402-278PLUG. Plastic 1 54 22 802-81 1 CORD’GRiP STRAiNEWFiLTER 55 231 804-051 804-043SWITCH.Starter.15 hD 230 Volt 801-110ADAPTER, Garden Hose 1 56 24 803-749SWITCH:Starter:15 hp 460 Volt 801-111NUT,Garden Hose 1 25 57 27 112801-106 TEE. 801-937 NUT. Lock. electrical 1 801-523 NIPPLE, 1i2 X 2 801-957 SLERIE, 18” 1 58 28 WAND, 34 29 -1 801 32 1 801-221 TERMINAL. Rina 59 803-262 BRACKET, Starter, 1right 30 801 -599 TIP, Spray 6 60 0 0 4 ’ CHASSiS31 800-441 80-600 TIP SDrav 1504 61 802-993PLUG,-Locking15hp,460volt1 801-661 TIP; sprai, 2504 32 62 801-602 TIP SDrav 4004 803-186LABEL,Cordset 33 63 1 803-351GUN,Spray,SST 34 (See 801-304 TERMINAL, Ring 64 InstructionManual308-51 1)1 REF NO. 1 PART NO. ON 1 4 4 5 1 ~~~ 1 2 ~ 4 1 1 2 2 2 1 8n 3 1 1 1 308-522 11 I 12 308-522 53 Model 4040 Wirlng Diagram 230 Volt. 3 Phase Model 4040 Wring Diagram 460 Volt, 3 Phase PARTS DRAWING 800-579 Pump and Motor Assembly PARTS LIST 800-579 Pump and Motor Assembly REF NO. 1 2 3 4 5 6 7 8 9 10 11 PART NO. 803-584 hp 802-698 802-540 802-784 803-750 DESCRIPTION QTY MOTOR, 15.0 hp TEFC, 3 phase 1 COUPLER, 15 1 HOUSING 1 WASHER, Lock 1/2 4 SCREW, Cap, socket hd. 1/2-13 X 3 4 802-508 PUMP (see page 16) 1 100-527 WASHER, 4 Lock 5/16 801 -559 SCREW, Cap, hex hd. M8 x 30 4 802-783 K M , Motor 1 802-794 KM,Pump 1 803-552 RING, Adapter 1 308-522 13 PARTS DRAWING 803-508 Pump Assembly,4000 psi 1 45 -// /- 14 308-522 PARTS LIST 803-508 Pump Assembly, 4000 psi REF .PART ..... REF PART NO. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 DESCRIPTION 801-647MANIFOLD ~801-468SCRNV,Cap,hexhd. 801-469WASHER. Lock KIT 1 O-RING SEAT, Valve KIT 1 KIT 1 PLATE, Valve KIT 1 SPRING KIT 1 GUIDE, Valve KIT 106 O-RING KIT 106 CAP KIT 1 VALVE ASSEMBLY 803-283 SCREW, Cap, sockethd. 803-506 COVER, Crankcase 802-500 O-RING, Crankcase Cover 803-324 BEARING, Tapered Roller KIT 2 SEAL, Oil 803-286 BUSHING, Piston 803-501 CRANKCASE 801 -475 DIPSTICK 803-1 44 GASKET, Cover 803-287 CRANKSHAFT 803-288 RING, Retaining 802-794 KEY 803-289 PIN, Wrist 803-503 GUIDE, Piston 803-291 ROD, Connecting 803-292 SCREW, Cap, socket hd. ~~ ~ ~~ Repalr Kit Part No. Ret. 1 801-472 Valve 4 No. 5 6 7 8 11 2 3 106 801-473 16 Oil Seal Kit 802-511 41 Crankshaft Seal 802-509 Valve Cap 4000 psi 1 8 8 ~~~ Klt No. 9 10 NO. NO. QTY 8 1 2 2 1 1 1 1 1 6 1 3 3 3 DESCRIPTION 803-507COVER, Crankcase 802-345GAUGE, SigM 802-793PLUG, Oil Drain KIT 107 O-RING 803-294 SCREW, Cap, socket hd. 801-652WASHER, Lock KIT107WASHER, Flinger 801-490PLUNGER, Ceramic 803-502PLUNGER,Ceramic KIT107RING, Backup KIT 107 WASHER KIT 107 SCREW, Piston 803-505COVER,Crankcase 803-296 SHIM KIT 3 SEAL, Oil KIT 109 O-RING KIT 109 RETAINER. Packing KIT 109 PACKING KIT 112 PACKING KIT 109 RING, Head KIT 109 RETAINER, Packing KIT 109 RING, Long Life 801-482 PLUG, Hex 801-483 WASHER, Flat 801 -484 PLUG, Hex 801 -485 WASHER, Flat 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 51 52 53 54 6 6 6 6 6 6 SEAL. Oil 3 Kk No. QW Repalr Kit Part No. 3 3 1 2 1 1 1 1 Ref. No. Descrlptlon WASHER, Plunger RING,Repair 2 I 6 6 t I46 I I 112 QiY. Flinger Backup Retainer O-RING CAP 6 6 5 Descrlption O-RING SEAT, Valve PLATE, Valve SPRING GUIDE, Valve . VALVEASSEMBLE SEAL, Oil QTY 1 1 1 Packing PACKING RING. Head I RETAINER, I1 . 803-512 Packing 4ooo psi 44 PACKING 6 308-522 15 PUMP SERVICE Servicing the Plungers I 1 I To reducetherisk Of serious bodily injury, includingfluid injection, splashingin the eyes or on the skin, or injury from moving parts, always follow the Pressure Relief ProcedureWarning WARN'NG before proceeding. I NOTE: The following metricwrenchesareneeded: M10,M13 a n i M30. ReDair kits are available. Refer to the individual repair sections and the pump parts page for moredetails. For the best results, useall parts in the kits. NOTE Thereare two different tool kits to aidin servicing the pump. P/N 800-298 is used to ease installation of packings. P/N 800-271 includes the items in800-298 andtools to aid in the removalof packing retainers. NOTE 1. Loosentheplungerretainingscrew five to sixtums, using an M10 wrench. Push the plunger towards the and retaining crankcase to separate the plunger . . screw. 2. Remove the screw from the plunger and examine the O-ring,backup ring and copper bearindgasket washer. Replacethese parts,ifnecessary,using kit 803-510. 3.Removethe plunger and flinger from the plunger shaft. Clean, examine and replace parts as necessary. 4. Valves NOTE For a set of six valves, order P/N 801 -472. 1. Remove the hex plug . - from the manifold using an M30 wrench. plug and replace 2. Examine the O-ring under the hex it if itis cut or distorted. 3. Remove the valve assembly from the cavity; the assembly maycome apart. the O-ring and hex plug; 4. lnslall the newvalve. Install torque to 75 ft-lb (103 Nm). NOTE Plunger repair kit, P/N 803-510 is available to replace retainers, O-rings, washers and backup rings for three cylinders. Inspect the plunger shaft for oil leakage from the crankcase. If leaking is obvious, replace the oil seals. Otherwise, DO NOT remove these seals as they cannotbe reused. An oil seal kit is availableto replace the seals. 5. Lightly grease the oil seal, if it is being replaced, and the flinger and replace them on the plunger shaft. Theninstall the plunger. 6. Lightly grease the retaining screw and the outer end of the plunger. Place the washer, O-ring and backup ring around the screwand install the screw through the plunger. Torqueto 14.4 ft-lb (19.5 Nm). NOTE: Retorque the plug after 5 hours of operation. If vou plan to replace the Packinas. - refer to Sitvicing the V-backings. ' 7. Lubricatetheoutside of each plunger. Slide the manifold onto the crankcase, being careful not to 1. Remove the eight capscrews and lockwashers from damage the seals. the manifold using an M13 wrench. 8. Installthecapscrews and washersfinger-tight. 2. Carefully separatethemanifoldfrom the crankcase. Torque the screws to 21.7 ft-lb ( 2 9 Nm) following the tighteningpattem (Figure4).Uneven tightening NOTE: It may be necessaryto tap themanifold lightly may cause the manifold to bind or jam. with a soft mallei to loosen. Pumping Section I Keep the manifold properly aligned with the ceramicplungers whenremoving to avoid damage to the plungeror seals. 3. Carefully examine each plunger for any scoring or cracking and replace as necessary. Figure 4 16 308-522 I Servicing V-Packings the NOTE There are two lypes of packing kits: one is 5. Thoroughly clean the packingcavities and examine for debris and damage. pacltlngs only, the other includes the packings, ringsand retainers. 6. Lightlygreasethe packing cavitiesandthen replace the packings in the following order: head ring, v-packing. intermediate ring, head ring, v-packing and packing retainer with. theO-ring installed In the retainer groove. 1. Remove the manifold as outlined In the Pumping Section. 2. Carelully pull the packing retainer from the manifold. Examine the O-ring andreplace It if it is cut or damaged. the 3. Remove the v-packing and head ring. Pull out intermediateretainerring.Removethe v-packing and second head ring. second CAUTION Install the parts in the proper order andfacing the correct direction. Improperly installed parts will cause a malfunction. 7. Reassemble ¶hemanifold as instructed in Servicing the Plungers. 4. inspect all parts and replace as necessary. 308-522 17 ~ ACCESSORIES (Must be purchased separately) DOWNSTREAM CHEMICAL INJECTOR KIT WATER SANDBLASTING KIT 800-120 For cleaning abrasive 800-649 For injecting harshcleaningchemicalsdownstream from the pump. Stainless steel construction. UPSTREAM CHEMICAL INJECTORKIT 800-257 For injecting mild cleaning chemicals upstream into the Pump. dirt of stubborn and paint. Requires a spray tip (801-600) which is not included in kit. ANTI-FREEZE FLUSH KIT 802-327 For flushing system with 50% anti-freeze solution prior to transporting or storing pressure washer in below freezing temperatures. BACKFLOW PREVENTOR 801-133 INLET PRESSURE REGULATOR 800-258 Prevent back-up of contaminated water into fresh Regulates inlet water pressure supply. Install upstreammaximum. of pump. to 60 psi (4 bar) TECHNiCAL DATA High Pressure Hase Acrylonitrile and Buna-Ncoverandtube Synthetic yam andEPDM PressureWasherAnodizedaluminum,AluminumorBronzealloys, Brass, Copper,Nylon-TefionQcomposite. (including fittings) Ceramic, Buna-N, Conon Phenolic. 303,304, and 316 Stainless Steel. Polymide-12 Thermoplastic. Teflono, CarbonSteel, Zinc with or without Yellow Chromare Plate THE GRACO WARRANTY WARRANTY AND DISCLAIMERS Gram warrants ail equipment manufachrred by fi and bearing its name to be frea from defectsin material andwo~manshiponthedateofsaiebyanauthorizedGramdistnbutortotheonginalpurchaserforuse. As purchaser's sole remedy for breach ofthis warranty, Graco will, for a period of twenty four months from dateofsale,repairorreplaceanypartoftheequipmentpmvendefscthe.Thiswarran~appliesonlywhen the equipment is installed. operated and maintained in accordancB with Gram's written recommendations. or caused This warranty does not cover. Gram and shall not be liable for, any malfunction. damagewear by tauily installation.misapplication.abrasion,corrosion,inadequateorImpropermaintenance, negligence. accident, tampering, or substihltion of non-Graco component parts Nor shall Graco be liableform~nction,damageorwearcausedbytheinmmpatibilitywithGramequipmentofsfruchrres, accessories. equipment or materials not supplied by Graco. or the improper design, manufacture, installation. operation or maintenance of sfruotures. accessories.equipmentor materials not supplied by Grm. Thii warranty is conditioned upon the prepaid return of the equipment claimed to be defective for examination by Gram to verify the claimed defect.If me claimed defect is verified. Graco will repair or replace free of charge any defecthe parts. The equipment will be returnedto the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or be madeata reasonable charge. which charges may include thecosts of parts. workmanship. repairs will labor and transportation. DISCLAIMERS AND LIMITATIONS METERMSOFTHlSWARRANPlCONSTiTUTETHEPURCHASER'SSOLEANDEXCLUSlVEREMEDY ANDAREINLlEUOFANYOTHERWARRANTIES(EXPRESSORIMPLIED),lNCLUDlNGWARRANTYOF MERCHANTABILITY OR WARRANTY OF FITNESSFOR A PARTICULARPURPOSE,AND OF ANY NON-CONTRACTUALLIABILITIES. INCLUDING PRODUCTLIABILITIES. BASEDON NEGLIGENCEOR STRICTLIABILITY: EVERY FORMOF UABiLlTY FOR DIRECTSPECIAL OR CONSEQUENTIAL IN NOCASESHALLGRACOS DAMAGES OR LOSS IS EXPRESSLYEXCLUDEDANDDENIED. LIABILITYEXCEEDTHEAMOUNTOFTHEPURCHASEPRICE. ANY ACTIONFORBREACH OF WARRANTY MUST BE BROUGHT WITHIN THREE (3) YEARS OF THE DATE OF SALE. EQUIPMENT NOT COVEREDBY GRACO WARRANTY GRACOMAKESN0WARRANPl.ANDDiSCLAlMSALLIMPLIEDWARRANTIESDFMERCHANTABlLlTY ANDFITNESSFOR A PARTICULARPURPOSE,WITHRESPECTTOACCESSORIES,EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. Theseitems sold, but notmanufacturedbyGraw(suchaselectricmotor,switches,hose,etc.)aresubjecttothewarranty,ifany. of their manufacturer. Graco willprovide purchaser with reasonable assistance in making any for claim breach of these warranties. IMPORTANT PHONE NUMBERS TO PLACE AN ORDER, wntacd your Graw distributor, or call this number to identify the distributor closest to you: 1-800-328-021 1 Toll Free FOR TECHNICAL ASSISTANCE, service repair information or assistance regarding the application of Graw equipment: 1-800-543-0339 Toll Free Factory Branches:Atlanta, Chicago. Dallas, Delmi. Los Angeles. West Caldwel (N.J.) Subsldlary and AffiliateCompanies: Canada; England; Swiizeriand; France; Germany; Hong Kong:Japan: Korea GRACO INC. PO.BOX 1441 MINNEAPOLIS, MN 55440-1441 PRINTED IN U.S.A. 308-522 1/91