Graco Hydra-Clean 208008 User manual

Instructions – Parts List
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Copyright 1971, Graco Inc. is registered to I.S. EN ISO 9001
STAINLESS STEEL
Hydra–CleanrSpray Gun
1000 psi (6.9 MPa, 69 bar) Maximum Working Pressure
Model 208008, Series D
Spray tip not included, purchase separately. See page 12 for Tip Selection Chart.
307010L
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for Table of Contents.
8106

2 307010
Table of Contents
Setup 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip Selection Chart 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 14. . . . . . . . . . . . . . . . . . . . . .
Graco Information 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result
in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck the equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure of the lowest rated system component. This equip-
ment has a 1000 psi (6.9 MPa, 69 bar) maximum fluid working pressure.
DRoute the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180_F (82_C) or below –40_F (–40_C).
DDo not use the hoses to pull the equipment.
DUse only Graco approved hoses. Do not remove hose spring guards, which help protect the hose
from rupture caused by kinks or bends near the couplings.
DUse fluids or solvents that are compatible with the equipment wetted parts. See the Technical
Data section of all the equipment manuals. Read the fluid and solvent manufacturer’s warnings.
DComply with all applicable local, state and national fire, electrical and other safety regulations.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

307010 3
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in fire or explosion and serious injury.
DGround the equipment and the object being sprayed. See Grounding on page 4.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvent or the fluid being
sprayed.
DExtinguish all the open flames or pilot lights in the spray area.
DElectrically disconnect all the equipment in the spray area.
DKeep the spray area free of debris, including solvent, rags, and gasoline.
DDo not turn on or off any light switch in the spray area while operating or if fumes are present.
DDo not smoke in the spray area.
DDo not operate a gasoline engine in the spray area.
DIf there is any static sparking while using the equipment, stop spraying immediately. Identify and
correct the problem.
SKIN INJECTION HAZARD
Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause an
extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin
can also cause a serious injury.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate surgi-
cal treatment.
DDo not point the spray gun at anyone or at any part of the body.
DDo not put hand or fingers over the spray tip.
DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.
DDo not “blow back” fluid; this is not an air spray system.
DAlways have the tip guard and the trigger guard on the spray gun when spraying.
DBe sure the gun trigger safety operates before spraying.
DLock the gun trigger safety when you stop spraying.
DFollow the Pressure Relief Procedure on page 4 whenever you: are instructed to relieve pres-
sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.
DTighten all the fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.

4 307010
Setup
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. To
reduce the risk of an injury from accidental spray
from the gun, splashing fluid, or moving parts,
follow the Pressure Relief Procedure whenever
you:
Dare instructed to relieve the pressure,
Dstop spraying,
Dcheck or service any of the system equipment,
Dor install or clean the spray nozzle.
1. Lock the gun trigger safety.
2. Shut off the power supply to the pump and close
any bleed-type master air valves in the air supply.
3. Unlock the gun trigger safety.
4. Hold a metal part of the gun firmly to the side of a
grounded metal pail, and trigger the gun into the
pail to relieve pressure.
5. Lock the gun trigger safety.
6. Open the pump fluid drain valve (required in the
system), having a container ready to catch the
drainage.
7. Leave the drain valve open until you are ready to
spray again.
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, very slowly loosen the
tip guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Now clear
the tip or hose.
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Proper electrical grounding is essential
to reduce the risk of fire or explosion
which can result in serious injury and
property damage. Also read FIRE OR
EXPLOSION HAZARD on page 3.
1. Pump or Sprayer: as instructed in your separate
pump or sprayer manual.
2. Air compressor or hydraulic power supply: accord-
ing to local code.
3. Fluid hoses: use only grounded hoses with a
maximum of 500 feet (150 m) combined hose
length to ensure grounding continuity.
4. Spray gun: obtain grounding through connection to
a properly grounded fluid hose and sprayer or
pump.
5. Fluid supply container: according to local code.
6. Object being sprayed: according to local code.
7. All solvent pails used when flushing, according to
local code. Use only metal pails, which are con-
ductive. Do not place the pail on a non-conductive
surface, such as paper or cardboard, which inter-
rupts the grounding continuity.
8. To maintain grounding continuity when flushing or
relieving pressure, always hold a metal part of the
gun firmly to the side of a metal pail, then trigger
the gun.

307010 5
Installation
WARNING
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 4.
SKIN INJECTION HAZARD
NOTE: Numbers and letters in parentheses in the text
correspond to the reference numbers and letters in the
text and drawings.
WARNING
Be sure your system has a bleed-type
master air valve (pneumatic pumps
only) and a fluid drain valve. These two
accessories help reduce the risk of serious injury,
including fluid injection, splashing in the eyes, or
on the skin, or injury from moving parts, if you are
adjusting or repairing the pump or gun.
1. The bleed-type master air valve relieves air
trapped between this valve and the pump after
the air regulator is shut off. Trapped air can
cause the pump to cycle unexpectedly.
2. The fluid drain valve assists in relieving fluid
pressure in the displacement pump, hose,
and gun; triggering the gun to relieve pressure
may not be sufficient.
SKIN INJECTION HAZARD
1. Connect a grounded fluid hose to the gun inlet.
2. With no tip installed, start the pump/sprayer. Flush
it according to the instructions supplied with it.
Prime the system with the fluid you are using.
3. Relieve the pressure.
Fig. 1 8105
9
AB
4. WIth the gun safety latch engaged, unscrew the tip
guard (9) and install the tip (A) and gasket (B) in
the nut of the tip guard. Screw the assembly firmly
onto the gun. TIghten with a wrench. See Fig. 1.
NOTE: Failure to install the tip gasket (B) will result in
leaking.
5. Strain the fluid you are spraying if it contains
particles which could clog the spray tip.

6 307010
Operation
WARNING
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 4.
Whenever you stop spraying for a moment, en-
gage the gun safety latch. See Fig. 2.
SKIN INJECTION HAZARD
WARNING
The wallet-sized warning card provided with this
gun should be kept with the operator at all times.
The card contains important treatment informa-
tion should an injection injury occur. Additional
cards are available at no charge from Graco Inc.
1. Start the pump. Adjust the fluid pressure so the
spray is completely atomized. Always use the
lowest pressure necessary to get the desired
results. Higher pressure may not improve the
spray pattern and will cause premature tip and
pump wear.
2. If adjusting the pressure does not give a good
spray pattern, try another tip size. Be sure to relive
pressure completely before changing tips.
3. Use a full-open, full-close trigger action. Hold the
gun about 14 in. (350 mm) from and at right angles
to the work surface. Do not swing the gun in an
arc. Practice to find the best length and speed of
stroke.
Fig. 2
8122
Safety Off
Safety On

307010 7
Operation
WARNING
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 4.
SKIN INJECTION HAZARD
Adjust the Spray Pattern
1. To adjust the spray pattern, relieve the pressure.
Engage the safety latch and loosen the tip guard
retaining nut. Turn the spray tip so the groove is
horizontal for a horizontal spray pattern, and
vertical for a vertical pattern. Tighten the nut.
2. The spray tip orifice size and spray angle deter-
mines the coverage and size of pattern. When
more coverage is needed, use a larger spray tip
rather than increasing fluid pressure.
WARNING
To reduce the risk of a fluid injection
injury, never use the gun with the tip
guard or trigger guard removed.
SKIN INJECTION HAZARD
CAUTION
Openings in the tip guard are designed to reduce
paint buildup on the guard while spraying. Any
damage to the sharp edges of the openings causes
paint to collect at that area. To reduce the risk of
damage, never hang the gun by the tip guard.
Cleaning and Clearing the Spray Tip
Clean off the front of the tip frequently during the day’s
operation and at the end of the work day. Always
relieve the pressure and use a solvent soaked brush
to clean the spray tip and to keep fluid buildup from
drying and clogging the spray tip.
If the spray tip clogs while spraying, release the spray
gun trigger, engage the trigger safety, shut off the
pump, and relieve the pressure. Then, remove the air
spray tip and blow out the obstruction with air from the
front of the spray tip, or let the spray tip and gun
nozzle soak long enough to dissolve the obstruction. If
the obstruction will not dissolve, jar it out by tapping
the back of the spray gun against a flat surface.
CAUTION
Never soak the entire gun in solvent. Prolonged
exposure to solvent can ruin the packings.
Flushing the Gun
WARNING
Before flushing, be sure the entire sys-
tem and flushing pails are properly
grounded. Refer to Grounding on page
4. Relieve the pressure and remove the spray
tip from the gun. Always use the lowest possible
fluid pressure, and maintain firm metal-to-metal
contact between the gun and the pail during flush-
ing to reduce the risk of a fluid injection injury,
static sparking, and splashing.
SKIN INJECTION HAZARD
Relieve the pressure, remove the spray tip, and then
flush the gun and spray system with a compatible
solvent. Always flush the gun before the fluid being
sprayed can dry in it.

8 307010
Troubleshooting
If the gun leaks at the swivel (21), see Swivel
Repair, below.
If the gun leaks at the nozzle, try adjusting the
trigger free play. See Needle Adjustment on page 9.
If the leakage is not stopped, the needle (10) or valve
seat (8) may need to be replaced. See Gun Repair on
page 10.
If the gun leaks at the packing nut (14), check the
tightness of the packing nut. Remove the tip guard or
nozzle extension. Insert a 0.125 in. (3.18 mm) diame-
ter rod into the needle tip and tighten just enough to
stop leakage. See Fig. 3. If leakage is not stopped, the
packings or needle may need to be replaced. See Gun
Repair, page 10.
Fig. 3
8125
14
Safety Off

307010 9
Service
WARNING
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 4.
SKIN INJECTION HAZARD
Swivel Repair
1. Relieve the pressure.
2. Unscrew the swivel stud (21) from the gun. Re-
move the spring (22), glands (24†, 25†), and
packings (23†) from the swivel housing (26). See
Fig. 4.
3. Clean all parts and inspect. The ball bearing in the
swivel stud should rotate freely. Replace any worn
or damaged parts.
NOTE: Repair kit 207308 is available for the swivel.
Use all the parts in the kit for the best results.
4. Install the spring (22), male gland (24†) and five
v-packings (23†) one at a time, make sure the lips
of the v-packings face into the housing. Install the
female gland (25†) and the swivel stud.
Needle Adjustment
WARNING
Proper adjustment of the needle is essential to
be sure the trigger safety latch makes the gun
inoperative when engaged. Improper adjustment
may allow the gun to be triggered, even with the
trigger safety latch engaged, resulting in serious
injury, including fluid injection and splashing in
the eyes or on the skin.
1. Relieve the pressure. Disconnect the hose.
2. With the trigger safety latch (29) engaged,
squeeze the trigger. There should be about 0.125
in. (3.18 mm) free play at the end of the trigger.
See Fig. 6 on page 10.
3. To adjust, remove the tip guard or nozzle exten-
sion. Release the safety latch. Squeeze the
trigger and loosen the locknut (4). Insert the
wrench (3) into the tip of the needle (10) and turn it
in or out until the proper free play is obtained.
Tighten the locknut (4).
4. Install the tip guard. Start the system. Trigger the
gun and release; fluid flow should stop immediate-
ly. Now engage the trigger safety latch. Try to
trigger the gun; no fluid should flow. If the gun
fails either test, relieve the pressure and re-
adjust the needle.
Fig. 4
8124
22
24†
23†
25†
21
Fig. 5 8102
3
4
10

10 307010
Service
WARNING
To reduce the risk of serious injury,
whenever you are instructed to relieve
pressure, follow the Pressure Relief
Procedure on page 4.
SKIN INJECTION HAZARD
Gun Repair (See Fig. 6)
NOTE: Repair kit 208328 is available for the needle
packings. Use all the parts in the kit for the best re-
sults.
1. Relieve the pressure. Disconnect the hose.
Remove the tip guard (9) or nozzle extension.
2. Unscrew the seat housing (18) and valve seat (8*)
from the gun body.
3. Using the wrench (3), loosen the packing nut (14).
Then use the wrench (3) to unscrew the needle
(10) from the adjusting nut.
4. Pull back the trigger (27) and remove the packing
nut (14) and two glands (11*, 13*), four packings
(12*) and locknut (4).
5. Clean and inspect all parts. Replace worn or
damaged parts as needed. If using a repair kit, use
all the parts in the kit during reassembly.
6. Lubricate the needle and slide it into the front of
the gun body (2).
7. Lubricate the new packings and glands. One at a
time, place these parts on the needle; the male
gland (11*), four v-packings (12*) with the lips of
the v-packings facing the front of the gun, and the
female gland (13*).
8. Screw the packing nut (14) into the center of the
gun body. Screw the locknut (4) onto the needle.
9. Be sure the spring (16) is in the gun body at the
rear of the center opening. Then, install the adjust-
ing nut (7). Using the wrench (3), insert through
the front of the gun, screw the needle (10) into the
adjusting nut until its end is flush with the valve
body.
10. Press the new valve seat (8*) into the body. Screw
on the seat housing.
11. Adjust the needle before operating the gun. See
Needle Adjustment on page 9.
12. Be sure the tip guard and trigger guard are
installed before using the gun.
Fig. 6
8104
8123
3
9
18
*8
10
2
*11
*12
13*
14
4
7
16
Safety On
1.25in. (3.18 mm)
Free Travel