Download Graco Inc. 2104ES Pressure Washer User Manual
Transcript
This manual contains IMPORTANT WWARNINOS and INSTRUCTIONS READ AND RETAINFORREFERENCE MODEL 800-048 SERIES "A" 2 150 psi (150 bar) OPERATING PRESSURE 2250psi (155 bar) MAXIMUM WORKING PRESSURE ~NJECTOQIMHAZARD Fluids under high pressure from spray or leaks can penetratetheskinandcauseextremelyserious injury, including the need for amputation. NEVER point the spray gun at anyone or any part of Do notusechemicalsoragentswhicharenot compatible with Buna-N andPVC or neoprene cover of hose. Do not leave a pressurized unit unattended. Shut off the unit and release pressure before leaving. the body. FORE NEVER put hand or fingers over the spray tip. Do not spray flammable liquids. Do not operate the engine where combustible fumes or dust may be present. NEVER try to stop or deflect leaks with your hand or body. GENERAL ALWAYS have the tip guard in place when spraying. NEVER run the unit with the belt guard removed. MEDlCAU TREATMENT Keep clear of moving parts when the unit is running. If anyfluidappearstopenetrateyourskin. get EMERGENCY M E D K A L C A R E AB ONCE. DO MOK TREAT AS A SIMPLE GUT. Tell the doctor exactly what fluid was injected. treatmentinstructions haveyourdoctorcallthe For RIAJIORIAU POISON CENTER NETWORK ($a2w~-666~ AVOID COMPONENT RUPTURE Even after you shut off the gasoline engine, there is high pressure in the pump, hose and gun until you release it by triggering the gun. So before removing the spray tip or servicing the unit, always shut off the unit and trigger the gun to release pressure. Be sure that all accessory items and system components will withstand the pressure developed. NEVER exceed the pressure rating of any component in system. NEVER alter or modify equipment -your personalsafety,aswell as thefunctionofthe equipment, is at stake. Beforeeach use,checkhoseforweak, worn or damaged conditions caused by traffic, sharp corners, pinchingorkinking.Tightenallfluidconnections securelybeforeeachuse. Replace anydamaged hose. O b s e r vdee t e r g e m n ta n u f a c t u r e rs' sa f e t y precautions. Avoid getting detergent or other liquids in your eyes. Follow the directions on the container regarding contact with eyes, nose, and skin, breathing fumes, etc. Always wear full goggles to protect your eyes from the spray as well as any debris dislodged by the spray. If necessary, wear gloves or other protective clothing. If antidotes or treatment are 'recommended, be prepared to use them. DON'T spray toxic chemicals such as insecticide or weed killer. This unit is supplied with an 8-foot power cord made up of three AWG No. 10 wires. The green wireof the electric cord is connected to the unit chassis and motor frame. The other three wires are connected to the starter switch. to the appropriate Be sure to connect the power cord approved plug to f i t your requirements. The starter switch has a built-in circuit breaker that will shut off the power to the unit whenever the circuit is overloaded. Always check to be sure the switchis off andthat the of movingparts hosesandelectriccordareclear before plugging in the power cord. : 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 1 9 2 6 Should be consulted in connection with your use of airlessspray equipment. 2 801-457 ... ... . . .. ._i.. . . . ~. . .... . .. . . - . ~ . . .. ~ . INSTALLATION Check Electrical Service and Plug In Before plugging in the sprayer, be sure the electrical service is 1 phase 220 V, 60 H A C , 30 Amp. WitKthe ON-OFF switch in the OFF position, plug the power supply cord into a groundedoutlet.Ifyouusean extension cord, it must have 3 wires of at least 1 0 gauge (2.5 mm2) and should not be over100 ft (30.3 m) long. Install Wheels and Handle Slide the axle through the frame. Slide the wheels and washers onto the axle and secure in place with cotter pins provided. Install the hubcaps. Attach the handle with thefour screws, flatwashers, lock washers and nuts provided. l,nstall Hose and Spray Gun Connect the spray hose to the spray gun by inserting thepinattheend of the hose intothequick disconnect coupler on the gun. Connect the hose to the fluid outlet in the same way. For removing rust andold paint we recommend using a water sandblaster.See Accessoriesand instruction manual 801.190 for installation and operation. Connect To Water Supply CAUTION Before attaching to water supply. check local plumbing code regarding cross-connection to water supply. Backflow check valve 801-133. Do not exceed 16OoF(7OOC) water temperature to pump in a direct supply system. Connect a hose w i t h at least a 3 / 4 in. (19 mm) ID 3/4 in. from your city water supply to the unit's garden hose threaded inlet. The supply hose should not be more than 50 ft. (15 m) long. NOTE: For adirectsupply system,your water source at theunit must have aflow rate of AT LEAST 5 GPM (19 LITER/MINI. Remove the tape from the cap on top of the pump. - .. . $. ..' i ' Cleaning Accessories For sprayingdetergent or othercleaningsolution,we recommend using a chemical injector kit. See Accessories andinstructionmanual801-192for installation and operation. If your operating conditions are different from above. contact our Customer Service Department for assistance. CAUTION OPERATION will spraying. for longer pump life. The pump overheatifleftrunningforover 10 minutes Startup Before starting, be sure to read the safety warnings and setup instructions. 1 . . Check the filter screen in the water inlet connection as often as necessary, at least daily. Do not operate the unit with the inlet and filter screen removed. Turn on the water supply. Trigger the gun to release any back pressure. DONOTtrytoadjusttheunloadervalveorchangethe engine speed. Changing these settings may cause excessive pressure, intermittent unloader operation, wastedfuelandincreasedwearonpartsandwillvoid the warranty. CAUTION PUMP MUST NOT BE RUN DRY and must bedrained of water prior to exposure to freezing temperatures. Never run the cleaning unit dry. Costlydamage to the pump will result. Always be sure water supplyiscompletelyturnedonbeforeoperating. Inspect allconnectionsforany necessary. Cleaning For cleaning technique, manual, 801 - 1 92. For abrasivecleaning, manual, 801- 1 90. Use and store the unit where will it not be subjected to freezing temperatures. If water does freeze in the unit, thaw before trying to start. A 50% anti-freeze solutionmaybepumpedpriortocoldweather storage. leaks. Tightenif see the Chemical lniector Use only spray tips that are matched to the unit to avoidexcessivecyclingandwearoftheunloader valve. See Accessories. see the Water Sandblaster pour hot water on a frozen pump. A sudden temperaturechangemaycracktheceramic plungers. Follow these precautions when removing and installing nozzles: 1 . Shut off the cleaning unit and trigger thegun to relieve pressure. Engage the trigger safety. Do not pump caustic materials. Before extended storage, flush the pump with light oil. 2. Keep the nozzle a.nd the tube pointed away from you and everyone else. Avoiddragginghoseoveranabrasivesurfacesuchas cement.Thiscausesexcessivewearandshorter hose life. 3. Do not put your handover the tipto push the nozzle into place. Grasp it from the side and keep your fingers away from the tip. Clean the intake line strainer daily 4. Do not let anyone else touch the spray'valve while you are cleaning nozzles. Lubrication and Care Fill pump crankcase to dot on oil gauge window with 25 02. (0.75 liters) of crankcase oil (part no. 801-1 44)' or equivalentSAE 40 weighthydraulicoil with antiwear and rust inhibitor additives. Change initial fill after 50 hour running period.Change oil every 3 months or at 500 hour intervals. 5. Be sure the slip ring is pushedforward tolock the nozzle in place beforetriggering thespray gun. . S h u t d o w n a n d Care Of Unit When unit is not in use, turn off water supply. When shutting down for the day or weekend,shut off unit, shut off water supply valve, and trigger gun to release pressure. Wipe off the unit with a damp rag. 4 WARMING I NEVER alter adiustment or modifv the unloader I Altering or adjusting unloader willnot increase performance of unit. I 1 valve. 801-457 . . . ... , . .. . . . . ._ .. .. . . . ... . . .. ~ . . . . . . . . . . . . I. .. PROBLEM CAUSE SOLUTION Low pressure. Worn nozzle. Replace with nozzle of proper size. Belt slippage. Tighten or replace; use correct belts and replac both at same time. Air leak in inlet plumbing. Disassemble, reseal, and reassemble. Relief valve stuck, partially plugged or improperly adjusted valve seat worn. Clean. and adjust relief valve; check for worn and dirty valve seats. Kit available. Inlet suction strainer clogged o improper size. Clean. Use adequate size. Check more frequently. Worn packing. Abrasives in pumped fluid or severe cavitation. Inadequate water supply. Install proper filter. Check flow available to pump. Fouled or dim/ inlet or discharge valves. Clean inlet and discharge valve assemblies. Worn inlet or discharge valves. Leaky discharge hose. Replace worn valves, valve seats and/or discharge hose. Pump runs extremely rough, Restricted inlet or air entering the inlet plumbing. uressure low. Proper size inlet plumbing; check for airtight seal. Inlet restrictions and/or air leaks. Stuck inlet or discharge valve. Clean out foreign material, replace worn valve: Leaking H.P. seals. Replace seals. Water leakage from under the manifold. Worn packing. Install new packing. Water in pump crankcase. M a y be caused by humid air condensing into water inside the crankcase. Change oil at 3 month or 500 hour interval using Graco Crankcase Oil (other approved o every month or 200 hours) P.N. 801-144. Frequent or premature failure of the packing. Scored plungers. ?eplace plungers. Over pressure to inlet manifold ?educe inlet pressure. Damaged or worn plungers. 3eplace plungers. Abrasive material in the fluid being pumped. nstall proper filtration on pump inlet plumbing Excessive pressure and/or tern perature of fluid being pumped. :heck pressures and fluid inlettemperature; bc jure they are within specified range. Over pressure of pumps. ?educe pressure. Running pump dry. 10 not run pump without water. Foreign particles in the inlet or discharge valve, or worn inlet and/or discharge valves. :heck for smooth lap surfaces on inlet and iischarge valve seats. Discharge valve seats m d inlet valve seats may be lapped on a very ine oil stone. Strong surging at the inlet 3nd low pressure on the jischarge side. SOLUTION Check, replace. building circuit fuse blown. Overload switch has opened. Unplug power cord'. decrease pressure ~ Electric motor stops while spraying. Electric motor runs, but no output. ~~~ Power cord unplugged, or building circuit fuse blown. Check, replace. Overload breaker.has opened. Unplug powei cord'. relieve pressure-allow to cool. Extension cord DonZ usemore than loOftoi 8 ga extension cord. Tip plugged. Remove and clean Displacement pump frozen or gear train damage. Thaw, 'This unit has an overload breaker built into the switch assembly. itIf opens, unplug power cord and let sprayer cool for 30 to 60 minutes. Also, try to correct the cause of overheating. Always use the lowest pressure setting needed. NOTE: A M11 and M30 metricwrenchesare required for servicing pump. PUMP Valves Photo 1 and 2. 1 ) Remove the hex plug using an M30 wrench. 2 ) Examine O-ring under plug and replace if evidence of cuts or distortion. 3)Removevalveassemblyincluding,retainer. spring, valve and valve seat from valve cavity. MOTE: Valve assembly may come apart during removal. 41 Replacevalve parts with service kit (801-041) including retainer, spring, valve,valveseat, oring and back-up-ring. 5)Replace valve cover and torque to 75 ft-lb (100 Nm). Pumping Section Photo 3. 1) Remove the four {4) hex nuts from the manifold. 2) Separate the manifold from the crankcase. NOTE: It maybenecessarytotap manifold lightly with mallet to loosen. I 1 Keep manifold properlyaligned with ceramic plungers when removing toavoid damage to either Dlunclers or seals. ~ ~~ ~~ ~ 3) Carefully examine each plunger for any scoring and replace if necessary. 6 801-457 . .... .. . ~ ...... ... ~ .. Plungers Photo 4. 1 ) U s i n g. a n M1 1 w r e n c h , remove the plunger retainer. 2) Slide out the seal retainerw i t h oilwickandrubberbarrier slinger. 3).With a slight twisting motion, loosen theplungerfromthe plunger rod and remove. MOTE: The stud may remain with the retainer w h erne m o v e d . D i s a s s e m b laen d screw s t u idn t o plunger rod finger tight. 4) ReplaceO-ring and back up ring on plunger retainer. 5) Saturate new oil wick by soaking in oil. 6) Install new plunger. 7) Replace plunger retainer and torque to 80 in-lb (9 N m ) . 8) Installnewoilwickinseal retainer. 9) Replace barrierslingerover new plunger. 10) Lubricate each plunger sleeve andcarefullyslidemanifold onto crankcase. Seals or V-Packings Photo 5, 6,7 a n d 8. 1) Remove C-ring fromseal case. 2) Then remove the low pressure seal from the seal case. 3) Unscrew the seal case from themanifoldusingaspecial key wrench (801-044). 4)Remove thehighpressure seal and examine. Before' replacing, lubricate ID and OD of new high-pressure seal and press into manifold. NOTE: A socket andextension may be used to pressure seal from manifold. 5)Install new O-ring on seal case 9) Lubricate each plunger sleeve andcarefullyslidemanifold onto crankcase. 10) Torqueallfour(4)bltsto240ir-lb (27 Nm). and lubricate OD of O-ring. 6) Screw seal case into manifold. 7) Lubricate ID and OD of low NOTE: Carefullystudythe NOTE: W h e nr e p l a c i n g order of respective para t snndo t e positionof seals to assure proper reassembly and operation. manifold onto plungers, enreme caution should be exercised to avoid damage to the seals. pressuresealandpressinto seal case. 8) Replace C-ringholding low pressure seal in place. 801-457 .. ~. .. - ..~ . , .. . , ,... . ~.. . . .. .. _. . . . . . . " 7 ... ... ,. 8 - .., 801-457 ".. . ... ~, ~. ~ . . . . .. .. . . . . -~. . . . .. Ref. No. 50 Includes items 51-66, 79 & 81 62 63 fj/7g 52 64 65 REF PART N O . NO. 66 56 59 24 801 -082 QTY DESCRIPTION SCREW, machine. hexhd, 30 mm SCREW. machine, hex hd. MB x 20 mm WASHER. flat. 1/4 WASHER. flat, 5/16 WASHER, lock, 1/4 WASHER. lock, 5/16 NUT, hex. 5/16-18 NC GROMMET BUMPER WHEEL PULLEY, pump PULLEY, motor HUE. pulley KEY, pulley (2” lg) AXLE WASHER, flat BRACKET, tensioner BELTGUARD. cover BELTGUARD. baseplate HUBCAP PIN, cotter RIVET, drive LABEL, warning LABEL. warning LABEL. warning LABEL, starting UNLOADER, includes items 51-66. 79. 81 CAGE, valve O-RING SPRING BALL SEAT . O-RING UNLOADER SUE-ASSY. 4 A!r ..6 x 25 801-081 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 42 43 44 45 46 47 48 49 50 801 -023 801-015 801 -1 39 801 -025 801 -024 801 -01 2 801 -367 801.241 801 -004 801-381 801-135 801 -1 37 801 -393 801 -235 801 -018 801 -364 801.365 801 -242 801 -243 801-132 801-130 801 -388 801-141 801-41 7 800-045 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 801 -045 801-046 801 -047 801 -048 801 -049 801 -050 801 -046 801 -059 801 -41 2 801-432 801 -062 801-063 801 -068 801-069 801 -070 801-071 801 -090 801-105 69 70 71 72 73 74 75 76 801-106 801-41 6 801-108 801-109 801-110 801 - 1 11 801-112 801-113 77 78 79 80 81 801-445 801 -450 800-044 801 -008 801 -465 41 8 PARTS LIST REF PART NO. N O . 1 parts 2 .DESCRIPTION for 801-001 3 4 5 6 800-015 800-038 800-047 801-390 8 801-285 9 801-231 warning 801-140 10 11 801-129 12 801-022 13 801-131 14 801-221 801.394 15 16 801-379 17 801-448 18 801-446 19 801-292 20 21 .. . ’ 800-039 801-088 22 801-298 23 801-302 CITY HOSE & GUN ASSY. see gun detail PUMP, REPLACEMENT PARTS, include items 77-90 ANTI VIBRATION FOOT CHASSIS ELECTRIC MOTOR ASSY BRACKET. spacer BELT. drive LABEL. LABEL, identification LABEL. warning .SCREW, machine, hex hd.. 5/16-18 NC x 1-3/4” PLATE, serial no. CONNECTOR, crimp HANDLE SWITCH, starter CORD. power (8 f t Ig) STRAIN RELIEF SCREW, self tapping. no. 6-32 NC x 1/2 RAIL STIFFNER ASSY SCREW, machine, hex hd, 5/16-18 N C x 1-1/2” SCREW, machine. hex hd. 5/16-18 NC x 2-1/2” SCREW, machine hex tid, 5/16-18 N C x 1” 1 1 2 1 1 1 2 2 1 1 4 1 2 1 1 1 2 2 1 4 1 4 2 8 18 4 12 9 4 1 2 1 1 1 1 1 2 1 1 ~~ 1 n.m~G HOUSSG CYLINDER O-RING PLUG HOUSING VALVE SPRING VALVE SEAT. COUPLER, male quick disconnect. NIPPLE, straight. brass, 1/2 NPT x/2” 3-1 TEE, brass, 1/2 NPT NIPPLE,hex, steel, 1/2 x 3/8 NPT NIPPLE, hex, brass, 1/4 x 1/2 NPT PLUG. hex. brass. .~3/8 NPT ADAPTER, 1 /2 hose NUT. brass, adapter SCREEN,inlet HOSE, coupled, 1/2 NPT (MBE) 17-1 /2”lg LABEL. caution O-RING SLEEVE ASSY LABEL SCREW, button hd, #6-32 NC x 5/16 ~ 801-457 .. . .. . . .. ... .. . 1 1 1 1 1 1 9 .. . PARTS LIST (continued) REF PART ELECTRICAL SCHEMATIC D.ESCRlPTlON QTY NO. NO. Items 77-90 are pump internal replacement parts. See exploded view of pump for details. ?E 77 ~ -nn ". n l". 79 801.028 801-267 80 81 801-030 801-031 801-032 801-033 801-034 801-035 801-036 801-037 801-038 801-039 801-040 82 83 84 85 86 87 88 89 90 A..P . C_. . O-RING, cap . DISCHARGE 1 1 MANIFOLD WASHER . SEAL . RETAINER . WASHER 1 3 3 3 3 3 3 3 3 3 3 3 . . WICK. ~ . RING, retaining . PLUNGER . . STUD RING, backup . O-RING . RETAINER, plunger Order parrs by name and number. Always give the model number andseries letter of the assembly for which you are ordering. 801-042 SEAL KIT INCLUDES 3 SETS OF PARTS -r 77. -86 90 SERVICE TOOLS Rnl-nAA .KEY .- . WRFNCH ....-. - -.. - . - .. EXTRACTOR TOOL 801-205 10 801-457 .. .. . ..... . ~ , . .. .. . .. . .-. , . .. . . . . . . ~. ~ .. . . . . .. . ... .. . ~ . . ~ ij /A))) L @ Repair Kit 801 -083 Includes items A, B. C, D, E and F PARTS LIST RE:F PART DESCRIPTION N<). NO. k 2 1 SERVICE 1. Pressaccesspin(17)fromgunhandleandremove access plate ( 4 ) by sliding plate towards back of handle. Unscrew both short and long tubes with fittings (12 and 15) from valve body (10); Valve body should now slide out of the handle through the access plate opening. 2. Remove the cap (14). spring (5) and ball (A) from the valve body (10). 3. Remove the snap ring (e).Then remove the valve seat (C)and O-ring (13). 4. Remove t h e sleeve nut ( 1 1 )and O-ring (E) with the actuator rod (F). 5. Afterinstallingthenewseat(C)andball(A),tapthe ." .... balllightly with a hammertoassureaproper seating between the ball and seat. 6. Reassemble in reverse order. Use pipe sealant on 5 6 7 8 9 10 11 12 13 14 15 16 17 .. 18 19 20 21 22 23 24 25 26 27 28 an 801-007 SPRAY HOSE, 3/8" ID, 50 ft. (1 5 m) IQ 800-043 SPRAY GUN, (replaceable parts include items 3-18) HANDLE ACCESS PLATE SPRING TRIGGER . NEEDLE . HEX PLUG . DISCHARGE FllTlNG . VALVE BODY . GUIDE SLEEVE . TUBE . INLET FllTlNG 801-250 . CAP 1 1 1 1 1 1 1 1 1 1 1 1 1 . . SAFETY LATCH . ACCESS PIN . LATCH PIN TUBE, 32" GRIP COUPLER, female quick disconnect '801 -090 COUPLER, male quick disconnect 801 -073 HOUSING, nozzle '801 -010 TIP, blasting; 0" "801 -01 1 TIP, cleaning; 150 801-074 GUARD, tip 801-103 NIPPLE, hex; 1/4 x 3/8" npt; brass *a01 -091 COUPLER, male quick disconnect pipe threads on both short and long tubes(l2 and Order parts byname and series letter of the assembly for which you are ordering. 151. *Recommended "tool box" spare parts. 801.457 11 .. . _. ACCESSORIES (Must be purchased separately) CHECK VALVE 801- 1 33 CHEMICAL INJECTOR Prevent back up of contaminated water into fresh supply. Install upstream from pump. For injecting harsh cleaning chemicals downstream from pump. WATER SANDBLASTER 8 0 0 - 1 03 ADJUSTABLE SAND SAVER 801-031 For abrasive cleaning For adjustingsandflow. of stubborndirtandpaint. KIT 8 0 0 - 1 0 2 TECHNICAL DATA MOTOR: 5 hp, 1phase 2 2 0 V. 60 Hz, 27.5 Amp WATER PUMP: 2150 PSI (150 bar) max pressure; 4 G,PM (15 liter/min). WETTED PARTS: WEIGHT: StainlessSteel,Aluminum, Phenolic Plastic, Ceramic Liners, Nitrile Rubber. 195 Ibs (88 kg) 38 in (965 mm) OVERALLDIMENSION:Length: Width:27 in (686mm) Height: 26 in (660 mm) MAX. WATER TEMPERATURE: INLET HOSE CONNECTION: 16OoF (70°C) 3/4-in. garden hose (f) THE GRACO WARRANTY GracoInc.warrantsallequipmentmanufacturedbyitandbear~ngitsnametobefreeframdefectsin material and workmanship under normal use and service. This warranty extends to the original purchaserforaperiodof12monthsfromthedateofpurchaseandappliesanlywhentheequipment is installed and operated in accordance with writtenfactaryrecommendations.This warrantydoes not cover damage or wear which. in the reasonable judgment of Graco. arises from misuse. abrasion. corrosion. negligence, accident. substitution of non-Graco parts. faulty installation or tampering. This warranty is conditioned upon the prepaid return of the equipment clatmed to be defective for examination by Graco toverify the claimeddefect. If the claimed defect is verified. Graco will repair or replace free of charge. any defective parts. The equipment will be returned IO the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in workmanship or material, repairs will be madeata reasonablechargeandreturntranspartationwill be charged. .............. PURPOSE AND OF ANY NON-CONTR EOUIPMENT NOT COVERED BY GRACO WARRANTY. Accessories or components of equipment sold bv Graco that are not manufactured byGraco(such aselectric motors. switches. hose.etc.)are subject to the warranty.if any. of their manufacturer.Graco will provide purchaser wcth reasonable assistance in making such claims. Factory Branches: Atlanta. Pallas, Detroit, Lo6 Angeles. West Caldweli 1N.J.l Subsidiary and AffiliateCompanies: Canada: England; Switzerland; France; Germany; Hong Kong: Japan GRACO INC. P.Q. BOX 1441 MORIRIEAPQLIS, MRI 55440-1444 PRINTED IN U.S.A. 801.457 Rev A 7/83 45-10051A . .~ . - .. ........ . . . . . . . . . . ..... ." .....