Graco AquaMax 804594 A Series Operation manual

309016
Rev. B
First choice when
quality counts.t
INSTRUCTIONS–PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
Direct-Drive
AquaMaxt Pressure Washers
Model 804594, Series A
AquaMax DD6814 pressure washer with 5.5-hp engine
and 680 liters/hr (3 gpm) pump on Hi-Boy cart with hose, gun, and tips
140 bar, 14 MPa (2000 psi) Maximum Working Pressure
Model 804597, Series A
AquaMax DD9021 pressure washer with 11-hp engine
and 900 liters/hr (4 gpm) pump on Hi-Boy cart with hose, gun, and tips
210 bar, 21 MPa (3000 psi) Maximum Working Pressure
Model 804596, Series A
AquaMax DD9023 pressure washer with 13-hp engine
and 900 liters/hr (4 gpm) pump on Hi-Boy cart with hose, gun, and tips
230 bar, 23 MPa (3300 psi) Maximum Working Pressure
U.S. Patent
Patented 1983, Canada
and other patents pending
Related Manual
Spray Gun 308511. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Model 804597 9259A

2309016
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Service
Model 804594 (DD6814) 12. . . . . . . . . . . . . . . . . . . . . .
Models 804596 (DD9023) & 804597 (DD9021) 14. . .
Parts Drawings and Lists
Model 804594 (DD6814) 16. . . . . . . . . . . . . . . . . . . . . .
Models 804596 (DD9023) & 804597 (DD9021) 18. . .
Pump Repair Kits 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 22. . . . . . . . . . . . . . . . . . . . . . . . . .
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
INJECTION HAZARD
Spray from the gun, leaks, or ruptured components can inject fluid into your body and cause serious
injury. Fluid splashed in the eyes or on the skin can also cause serious injury.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get emergency
medical attention.
DDo not point gun at anyone or at any part of body.
DDo not stop or deflect leaks with hand, body, glove, or rag.
DDo not put hand or fingers over spray tip.
DTighten fluid connections before starting equipment.
DEngage the gun trigger safety whenever you stop spraying.
DFollow Pressure Relief Procedure on page 5 if spray tip clogs and before cleaning, checking, or
servicing equipment.
DRepair or replace worn or damaged parts immediately.
DCheck hoses, tubes, and coupling daily. Do not repair high-pressure couplings: replace entire
hose. Fluid hoses must have spring guards on both ends to prevent kinks and rupture.

3309016
WARNING
MOVING PARTS HAZARD
Moving parts, such as the drive belt, can pinch or amputate fingers.
DKeep clear of moving parts when starting or operating this equipment.
DDo not operate the pressure washer without all guards and interlocks installed and functioning.
HAZARDOUS FLUIDS
Improper handling of hazardous fluids can cause serious injury or death due to splashing in eyes,
ingestion, or bodily contamination.
DKnow specific hazards of fluid being used.
DStore hazardous fluids in approved containers. Dispose of hazardous fluids per local, state, and
national guidelines.
DWear protective eyewear, gloves, clothing, and respirator as recommended by the fluid manufac-
turer.
FUEL HAZARD
The fuel used in this unit is combustible and when spilled on a hot surface can ignite and cause a fire.
Do not fill the fuel tank while the engine is running or hot.
EXHAUST HAZARD
The exhaust contains poisonous carbon monoxide which is colorless and odorless. Do not operate
this equipment in a closed building.
EQUIPMENT MISUSE HAZARD
Misuse of the pressure washer or accessories could cause them to rupture and result in fluid injection,
splashing in the eyes or on the skin, or other serious injury.
DDo not alter or modify any part or factory-set adjustment of this equipment.
DDo not exceed the maximum working pressure of any component or accessory in the system.
DDo not use any chemicals that are incompatible with the wetted parts as stated in Technical Data
on page 21.
DDo not alter throttle setting.

4309016
Setup
Fig. 1
high-pressure hose
connection
hose
rack
3/4 in. garden
hose connection
for water inlet
spray
gun
hose
9259A
pump
pressure gauge
Check for Shipping Damage
Check the unit for any damage that could have
occurred during shipping. Notify the carrier
immediately if there is any damage.
Setup
Connect the high-pressure hose between the pump
outlet and the gun inlet. Both of these connections are
made with quick couplers.
CAUTION
Up to 100 ft (30 m) of high-pressure hose may
be used. Longer hoses might affect pressure
washer performance and chemical injector
performance.
Install the appropriate spray tip on the wand. See
Installing and Changing Spray T ips on page 7. If
you are using a sandblaster kit, see its separate
manual for installation instructions.
Connect to Water Supply
CAUTION
Before you connect to the water supply, check your
local plumbing code regarding cross-connection to
the water supply. A backflow preventer, Part No.
801133, is available to prevent backflow of
contaminated water into the fresh water supply.
Install it upstream from the pump.
If inlet water pressure is over 414 kPa, 4.1 bar
(60 psi), a regulating water valve, Part No. 800258,
must be installed at the garden hose connection.
Do not exceed 70_ C (160_F) inlet water
temperature.
Connect a hose with at least a 3/4 in. (19 mm) ID from
the water supply to the unit’s 3/4 in. garden hose inlet.
The supply hose should not be more than 50 ft (15 m)
long.
NOTE: The water source at the unit must have a
minimum flow rate equal to that of the unit. See
Technical Data on page 21.

5309016
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you
DAre instructed to relieve the pressure
DStop spraying for more than 10 minutes
DCheck or service any of the system equipment
DInstall or clean the spray nozzle
1. Engage the trigger safety latch.
2. Turn the engine off.
3. Pull the plug wire off the spark plug.
4. Shut off the water supply.
5. Disengage the trigger safety latch, and trigger the
gun to relieve pressure. Then engage the trigger
safety latch 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, disengage the trigger
safety latch, and trigger the gun to relieve pressure.
Wrap a rag around the hose end coupling, and very
slowly loosen the coupling to relieve pressure
gradually, then loosen it completely, and clear the tip or
hose.
WARNING
PRESSURE INDICATED ON GAUGE
The pressure gauge (shown in Fig. 1) indicates the
spraying pressure when the gun is triggered and
the bypass pressure when the gun is not triggered.
Pressure at the gun may be significantly higher
than the bypass pressure indicated on the pressure
gauge. Therefore, always follow the Pressure
Relief Procedure above regardless of the
pressure indicated on the gauge.
Operating Cautions
Always observe the following CAUTIONS when
operating the pressure washer to avoid costly damage
to the pressure washer.
CAUTION
Do not allow the pressure washer to idle for more
than 10 minutes. Doing so could cause the
recirculating water to overheat and seriously
damage the pump. Turn off the pressure washer if
it will not be spraying for 10 minutes. If heated
inlet water is used, reduce this time further . Do
not operate the pressure washer with the inlet
water screen removed; the screen helps keep
abrasive sediment out of the pump, which could
clog the pump or damage the cylinders. Keep the
screen clean. Do not pump caustic materials
through the pump; such materials could corrode the
pump components. However, it is safe to pump
antifreeze through the pump for cold-weather
transport and storage.
Trigger Safety Latch
WARNING
To reduce the risk of serious bodily injury, including
fluid injection and splashing in the eyes or on the
skin, always engage the trigger safety latch when
you stop spraying, even for a moment. In the
engaged position, the trigger safety latch prevents
the gun from being triggered accidentally by hand
or if it is dropped or bumped. Be sure the latch is
pushed fully down to prevent the gun from being
triggered. See Fig. 2.
Fig. 2 04612
trigger safety
engaged trigger safety
disengaged

6309016
Operation
Startup
Always use this startup procedure to ensure that the
unit is started safely and properly.
1. Check the oil levels.
NOTE: All units are equipped with a low-oil sensor
that shuts the engine off if the oil level falls below a
certain level. If the unit stops unexpectedly, check the
oil and the fuel levels. Check the oil level each time
the unit is refueled.
WARNING
FIRE HAZARD
Do not refuel a hot engine. Refueling a
hot engine could cause a fire. Use only
fresh and clean regular or unleaded gasoline.
Close the fuel shutoff valve when refueling.
2. Check the fuel level.
CAUTION
Never run the unit dry. Costly damage to the pump
will result. Always be sure the water supply is
completely turned on before operating.
3. Turn on the water supply.
4. Trigger the gun until water sprays from the tip
indicating that the air is purged from the system.
5. Open the fuel shutoff valve. Be sure the spark
plug ignition cable is pushed firmly onto the spark
plug. Put the switch in the ON position, and put
the throttle in the RUN position.
6. Pull the starter rope to start the engine. Brace one
foot on the pressure washer cart, and pull the
starter rope out quickly. Pull and return the rope
until the engine starts.
CAUTION
Do not allow the starter rope to snap back against
the engine. Return it gently to prevent damage to
the recoil mechanism.
NOTE: For easier starting, have one person start
the engine while another person triggers the spray
gun.
If the engine is cold, start the engine with the
choke completely closed. In cool weather, you
might have to let the engine run with the choke
closed for the first 20 to 30 seconds, then open it
completely. In warm weather, open the choke
completely as soon as the engine starts.
If the engine is warm, start the engine with the
choke completely open or partially closed. When
the engine starts, open the choke completely.
Chemical Injector Operation
NOTE: See manual 308513 for detailed chemical
injector operation and service instructions.
1. Relieve the pressure.
See page 5.
2. Insert the chemical filter (attached with clear tubing
to the chemical injector) into the container of
chemical.
3. Install the black, large-orifice chemical tip (see
Installing and Changing Spray T ips on
page 7).
The large orifice of the chemical injector tip causes
a drop in pressure that actuates the chemical
injector. Changing back to a small diameter spray
tip deactivates the chemical injector and produces
high pressure for rinsing. The chemical filter can
be left in the chemical container during
high-pressure use. To regulate the flow rate of the
chemical, turn the chemical adjustment knob on
the injector. Maximum chemical flow is two full
turns counterclockwise from the closed (clockwise)
position.

7309016
Operation
Installing and Changing Spray Tips
Tips are stored in storage holes on the cart of the
pressure washer.
WARNING
To reduce the risk of serious bodily injury, including
fluid injection and splashing in the eyes or on the
skin, use extreme caution when changing spray
tips. Always follow the procedure below.
1. Relieve the pressure.
See page 5.
2. Select a spray tip appropriate for your application.
Spray tips are stamped with 4- or 5-digit numbers.
The first two digits denote the spray angle. The
following table lists the spray tips.
NOTE: The chemical injector tip is brass and has
a large opening and a black plastic cap.
Spray Tip Number Spray Pattern Fan Angle
00XXX 0_ blaster (red)
15XXX 15_ (yellow)
25XXX 25_ (green)
40XXX 40_ (white)
3. Point the gun and wand away from yourself and
anyone else.
4. Without holding your hand over the spray tip (A),
pull back the quick coupler ring (B). Remove the
current tip, install a different one, and push back
the ring. See Fig. 3.
04929
Fig. 3
A
B
5. Pull on the tip to be sure the tip is secure before
you spray again.
CAUTION
To avoid blowing the O-ring out of the quick coupler
due to the high pressure in the system, never
operate the pressure washer without a tip securely
mounted in the quick coupler.
NOTE: See the sandblaster kit manual for detailed
cleaning information if this accessory is used.
Shutdown, Flushing, and Storage
Antifreeze Flush Kit 802327 is available to make
flushing easier. This kit is for flushing the system with
50% antifreeze solution prior to transporting or storing
the pressure washer in below-freezing temperatures.
CAUTION
If water does freeze in the pressure washer, thaw it
in a warm room before trying to start it. Do not
pour hot water on or into the pump; it could crack
the ceramic plungers.
For Pressure Relief,
see page 5.
DIf the pressure washer will be exposed to freezing
temperatures, flush the unit with a 50% antifreeze
solution. Relieve the pressure and flush the
pressure washer before you use it again to remove
the antifreeze.
DBefore long-term (overnight) storage or transporting
of unit, disconnect the water supply and turn off the
fuel supply valve.
DAfter each use, wipe all surfaces of the pressure
washer with a clean, damp cloth.
DPerform the appropriate maintenance. See
Maintenance chart on page 9.

8309016
Notes

9309016
Maintenance
Observe regular maintenance intervals to ensure that
you get maximum performance and life from the
pressure washer.
There is a break-in period for the engine and pump.
After you change the oil in these components following
their break-in periods, the interval between required
maintenance procedures is longer.
If operating the unit in dusty conditions, you should
perform these maintenance procedures more often.
Always relieve the pressure before you begin.
For Pressure Relief,
see page 5.
Interval Maintenance
Daily Clean water inlet screen and filter.
Check engine and pump oil levels.
Fill as necessary. Check gasoline
level. Fill as necessary.
After first
5 hours of
operation
Change engine break-in oil. Drain
oil when warm. Use SAE 30 or
10W–30 detergent oil.
After first
25 hours of
operation
Retorque exhaust manifold nuts to
27 N-m (20 ft-lb). Do not over
tighten.
Every 25 hours
of operation
Clean and remove air cleaner
foam. Wash with water and
detergent. Dry thoroughly. Rub
with oil, and squeeze to distribute
oil.
After first
50 hours of
operation
Change pump break-in oil. Use
SAE 20 or 30 non-detergent oil.
Every 100
hours of
operation or
every 3 months
Clean or replace paper air cleaner
cartridge. Tap gently to remove
dirt. Change engine oil. Use SAE
30 or 10W–30 detergent oil.
Retorque exhaust manifold nuts to
27 N-m (20 ft-lb). Do not over
tighten.
Every 500
hours of
operation or
every 6 months
Change pump oil. Use SAE 20 or
30 non-detergent oil.

10 309016
Troubleshooting
WARNING
To reduce the risk of serious injury, including fluid injection and splashing in the eyes or on the skin, always
follow Pressure Relief Procedure on page 5 before you proceed.
Problem Cause Solution
Engine does not
start or is hard to
start
No gasoline in fuel tank or carburetor Fill the tank with gasoline, and open fuel shutoff valve.
Check fuel line and carburetor.
Low oil Add to proper level.
Start/Stop switch in Stop position Move switch to Start position.
Water in gasoline or fuel is old Drain fuel tank and carburetor. Use new fuel and dry
spark plug.
Choked improperly, engine flooded Open choke, and cycle engine several times to clear
out gas. Use a dry spark plug.
Dirty air cleaner filter Remove and clean.
Spark plug dirty, wrong gap, or wrong
plug type
Clean, adjust spark plug gap, or replace.
Spray gun closed Trigger spray gun while starting.
Engine misses or
lacks power
Partially plugged air cleaner filter Remove and clean.
Spark plug dirty, wrong gap, or wrong
plug type
Clean, adjust spark plug gap, or replace.
Low pressure and/or
pump runs rough
Worn or wrong size tip Replace with tip of proper size.
Inlet filter clogged Clean. Check more frequently.
Worn packings, abrasives in water, or
natural wear
Check filter. Replace packings. See Pump Service
on page 12 or 14.
Inadequate water supply Check water flow rate to pump.
Fouled or dirty inlet or discharge valves Clean inlet and discharge valve assemblies. Check
filter.
Restricted inlet Check garden hose; it might be collapsed or kinked.
Worn inlet or discharge valves Replace worn valves. See Pump Service on page
12 or 14.
Leaking high-pressure hose Replace high-pressure hose.
Water leaking from
under pump
manifold
Worn packings Install new packings. See Pump Service on page
12 or 14.

11309016
Troubleshooting
Problem Cause Solution
Water on oil side of
pump
Humid air condensing inside crankcase Change oil as specified in Maintenance on page 9.
Worn packings Install new packings. See Pump Service on page
12 or 14.
Oil seals leaking Install new oil seals. See Pump Service on page
12 or 14.
Frequent or
premature failure of
packings
Scored, damaged, or worn plungers Install new plungers. See Pump Service on page
12 or 14.
Abrasive material in the fluid being
pumped
Install proper filtration on pump inlet plumbing.
Inlet water temperature too high Check water temperature; may not exceed 70_ C
(160_ F).
Over pressurizing pump Do not modify any factory-set adjustments. See
Equipment Misuse Hazard on page 3.
Excessive pressure due to partially
plugged or damaged tip
Clean or replace tip. See Installing and Changing
Spray Tips on page 7.
Pump running too long without spraying Never run pump more than 10 minutes without
spraying.
Running pump dry Do not run pump without water.
Strong surging at
inlet, and low
pressure on
discharge side
Foreign particles in the inlet or discharge
valve or worn inlet and/or discharge
valves
Clean or replace valves. See Pump Service on page
12 or 14.

12 309016
Pump Service — Model 804594
AquaMax DD6814
Always relieve the pressure before you begin.
For Pressure Relief,
see page 5.
NOTES:
DThe following metric wrenches are needed: 5 mm,
13 mm, and 22 mm.
DThere is a tool kit to aid in servicing the pump:
Tool Kit 800271 includes tools to aid in removing
packing retainers.
DRepair kits are available. See the individual repair
sections in this manual, and see the instructions
that come with the kits for location of parts. For the
best results, use all parts in the kits.
Valves
NOTE: For a set of six valves, order 801472. See
Pump Repair Kits on page 20.
1. Remove the hex plug from the manifold using a 22
mm socket.
2. Examine the O-ring under the hex plug, and
replace if cut or distorted.
3. Remove the valve assembly from the cavity; the
assembly can come apart.
4. Install the new valve. Install the O-ring and hex
plug, and torque to 45 N-m (33 ft-lb).
NOTE: Retorque the plug after 5 hours of
operation.
Pumping Section
1. Remove the eight capscrews and lockwashers
from the manifold using a 5 mm wrench.
2. Carefully separate the manifold from the
crankcase.
NOTE: You might have to tap the manifold lightly
with a soft mallet to loosen it.
CAUTION
Keep the manifold properly aligned with the ce-
ramic plungers when removing to avoid damage to
the plunger or seals.
3. Carefully examine each plunger for any scoring or
cracking, and replace as necessary.
Servicing the Plungers
NOTE: Plunger Repair Kits are available for replacing
retainers, O-rings, washers, and backup rings for three
cylinders. See Pump Repair Kits on page 20.
1. Loosen the plunger retaining nut five to six turns,
using a 13 mm wrench. Push the plunger toward
the crankcase to separate the plunger and
retaining screw.
2. Remove the nut from the plunger, and examine the
O-ring, backup ring, and copper bearing/gasket
washer. Replace these parts, if necessary, using
parts from Plunger Repair Kit 801474.
3. Remove the plunger and flinger from the plunger
shaft. Clean, examine, and replace parts as
necessary.
4. Inspect the plunger shaft for oil leakage from the
crankcase. If leaking is obvious, replace the oil
seals. If leaking is very minor, do not remove the
seals, because they cannot be reused. Oil Seal
Kits are available to replace the seals. See Pump
Repair Kits on page 20.
5. Lightly grease the flinger and oil seal if they are
being replaced, and put them on the plunger shaft.
Then install the plunger.

13309016
Pump Service — Model 804594
AquaMax DD6814
6. Lightly grease the retaining screw and the outer
end of the plunger. Place the washer, O-ring, and
backup ring around the screw, and install the nut
through the plunger. Torque to 15 N-m (11 ft-lb).
7. If you plan to replace the packings, see Servicing
the V-Packings at right.
8. Lubricate the outside of each plunger. Slide the
manifold onto the crankcase, being careful not to
damage the seals.
9. Install the capscrews and washers fingertight.
Torque the screws to 12 N-m (8.8 ft-lb) following
the tightening pattern shown in Fig. 4. Uneven
tightening could cause the manifold to bind or jam.
Fig. 4
14
2
3
5
8
7
6
9292A
Servicing the V-Packings
There are two types of packing kits: one is packings
only, the other includes the packings, rings and
retainers. See Pump Repair Kits on page 20.
1. Remove the manifold as outlined in Pumping
Section on page 12.
2. Carefully pull the packing retainer from the
manifold. Examine the O-ring, and replace if cut
or damaged.
3. Remove the v-packing and head ring. Pull out the
intermediate retainer ring. Remove the second
v-packing and second head ring.
4. Inspect all parts, and replace as necessary.
5. Thoroughly clean the packing cavities, and
examine for debris or damage.
6. Lightly grease the packing cavities, and replace
the packings in the following order: head ring,
v-packing, intermediate ring, head ring, v-packing,
and packing retainer with the O-ring installed in the
retainer groove.
CAUTION
Install the parts in the proper order and facing the
correct direction. Improperly installed parts will
cause a malfunction.
7. Reassemble the manifold as instructed in
Servicing the Plungers on page 12.

14 309016
Pump Service — Models 804596 & 804597
AquaMax DD9023 & DD9021
Always relieve the pressure before you begin.
For Pressure Relief,
see page 5.
NOTES:
DThe following metric wrenches are needed: 6 mm,
13 mm, and 27 mm.
DThere is a tool kit to aid in servicing the pump:
Tool Kit 800271 includes tools to aid in removing
packing retainers.
DRepair kits are available. See the individual repair
sections in this manual, and see the instructions
that come with the kits for location of parts. For the
best results, use all parts in the kits.
Valves
NOTE: For a set of six valves, order 801472. See
Pump Repair Kits on page 20.
1. Remove the hex plug from the manifold using a 27
mm socket.
2. Examine the O-ring under the hex plug, and
replace if cut or distorted.
3. Remove the valve assembly from the cavity; the
assembly can come apart.
4. Install the new valve. Install the O-ring and hex
plug, and torque to 99 N-m (73 ft-lb).
NOTE: Retorque the plug after 5 hours of
operation.
Pumping Section
1. Remove the eight capscrews and lockwashers
from the manifold using a 6 mm wrench.
2. Carefully separate the manifold from the
crankcase.
NOTE: You might have to tap the manifold lightly
with a soft mallet to loosen.
CAUTION
Keep the manifold properly aligned with the ce-
ramic plungers when removing to avoid damage to
the plunger or seals.
3. Carefully examine each plunger for any scoring or
cracking, and replace as necessary.
Servicing the Plungers
NOTE: Plunger Repair Kits are available for replacing
retainers, O-rings, washers, and backup rings for three
cylinders. See Pump Repair Kits on page 20.
1. Loosen the plunger retaining nut five to six turns,
using a 13 mm wrench. Push the plunger toward
the crankcase to separate the plunger and
retaining screw.
2. Remove the nut from the plunger, and examine the
O-ring, backup ring, and copper bearing/gasket
washer. Replace these parts, if necessary, using
parts from appropriate Plunger Repair Kit listed on
page 20.
3. Remove the plunger and flinger from the plunger
shaft. Clean, examine, and replace parts as
necessary.
4. Inspect the plunger shaft for oil leakage from the
crankcase. If leaking is obvious, replace the oil
seals. If leaking is very minor, do not remove the
seals, because they cannot be reused. Oil Seal
Kits are available to replace the seals. See Pump
Repair Kits on page 20.
5. Lightly grease the flinger and oil seal, if it is being
replaced and, replace them on the plunger shaft.
Then install the plunger.

15309016
Pump Service — Models 804596 & 804597
AquaMax DD9023 & DD9021
6. Lightly grease the retaining screw and the outer
end of the plunger. Place the washer, O-ring, and
backup ring around the screw, and install the nut
through the plunger. Torque to 19.5 N-m
(14.4 ft-lb).
7. If you plan to replace the packings, see Servicing
the V-Packings at right.
8. Lubricate the outside of each plunger. Slide the
manifold onto the crankcase, being careful not to
damage the seals.
9. Install the capscrews and washers fingertight.
Torque the screws to 30 N-m (22 ft-lb) following
the tightening pattern shown in Fig. 4. Uneven
tightening could cause the manifold to bind or jam.
Fig. 4
14
2
3
5
8
7
6
9292A
Servicing the V-Packings
There are two types of packing kits: one is packings
only, the other includes the packings, rings, and
retainers. See Pump Repair Kits on page 20.
1. Remove the manifold as outlined in Pumping
Section on page 14.
2. Carefully pull the packing retainer from the
manifold. Examine the O-ring, and replace if cut
or damaged.
3. Remove the v-packing and head ring. Pull out the
intermediate retainer ring. Remove the second
v-packing and second head ring.
4. Inspect all parts, and replace as necessary.
5. Thoroughly clean the packing cavities, and
examine for debris or damage.
6. Lightly grease the packing cavities, and replace
the packings in the following order: head ring,
v-packing, intermediate ring, head ring, v-packing,
and packing retainer with the O-ring installed in the
retainer groove.
CAUTION
Install the parts in the proper order and facing the
correct direction. Improperly installed parts will
cause a malfunction.
7. Reassemble the manifold as instructed in
Servicing the Plungers on page 14.

9260A
Detail 1
3
14
16
7
6
9
5
4
13
12
11
27
26
8
52
15
31
30
2
25
24
23
3 Ref18 19
17
1Apply sealant to threads
3All parts supplied with unloader
10
28
29
43
39
47
See Detail 1
48 1
1
2Supplied with pump
2
39
3
49 1
51
50
4Shaft key supplied with engine
4
40
41
53
16 309016
Parts — Model 804594
AquaMax DD6814

17309016
Parts — Model 804594
AquaMax DD6814
USE ONLY GENUINE GRACO PARTS AND ACCESSORIES
Ref.
No. Part No. Description Qty.
Ref.
No. Part No. Description Qty.
1 802264 ENGINE, Hondat OHV; 5.5 hp 1
2 804531 PUMP ASSEMBLY 1
3 240998 FRAME, cart 1
4 239998 HANDLE, cart 1
5 191084 SLEEVE, cart 2
6 183350 WASHER 2
7 110243 RING, retaining 2
8 115481 FOOT, cart 2
9 112827 BUTTON, snap 2
10 179811 WHEEL, semi-pneumatic 2
11 154636 WASHER 2
12 101242 RING, retaining, ext 2
13 104811 CAP, hub 2
14 110837 SCREW, flange, hex hd; 5/16 in. 4
15 111040 NUT, lock, nylock; 5/16–18 in. 4
16 108795 SCREW, mach, pan hd 4
17 801012 GROMMET, rubber 6
18 805543 TIP, spray, Q-type;
0004 (0_ – red) 1
805544 TIP, spray, Q-type;
1504 (15_ – yellow) 1
805545 TIP, spray, Q-type;
2504 (25_ – green) 1
805546 TIP, spray, Q-type;
4004 (40_ – white) 1
19 805634 TIP, spray, chemical injector, (black) 1
23 114801 HOOK, pail 1
24 112380 SCREW, mach, fil hd; 1/2 in. 2
25 109466 LOCKNUT 2
26 804381 GUN & WAND ASSEMBLY
See instruction manual 308511 1
27 804479 HOSE, high pressure;
3/8 x 50 ft (15 m) 1
28 801569 QUICK COUPLER, female; 3/8 1
29 801568 QUICK COUPLER, 3/8; male 1
30 801683 STRAINER, chemical 1
31 194188 TUBING, chemical 1
39Y290013 LABEL, danger 1
40Y290131 LABEL, warning 1
41Y290133 LABEL, “Prevent Freezing” 1
43 195405 LABEL, identification 2
47 804543 KIT, unloader/injector 1
48 800742 VALVE, thermal relief 1
49 804546 VALVE, relief 1
50 804593 ADAPTER, pressure gauge 1
51 804582 GAUGE, pressure 1
52 115496 SCREW, thread forming, panhead 2
53 244350 KIT, repair, chemical injector 1
YExtra danger and warning labels are available free
of charge.

Detail 1
3
14
16
7
6
9
5
4
13
12
11
26
8
53
15
31
30
2
1
25
24
23
3 Ref
18 19
17
1Apply sealant to threads
2
50
48
1
2
All parts supplied with unloader
3Supplied with pump
3
27
10
28
29
40
39
9261A
49 1
47
See Detail 1
52
51
43
41
54
18 309016
Parts — Models 804596 & 804597
AquaMax DD9023 & DD9021

19309016
Parts — Models 804596 & 804597
AquaMax DD9023 & DD9021
USE ONLY GENUINE GRACO PARTS AND ACCESSORIES
Ref.
No. Part No. Description Qty.
Ref.
No. Part No. Description Qty.
1 ENGINE 1
114703 Model 804596: Hondat OHV; 13 hp 1
803158 Model 804597: Hondat OHV; 11 hp 1
2 PUMP ASSEMBLY 1
114707 Model 804596 1
804503 Model 804597 1
3 240998 FRAME, cart 1
4 239998 HANDLE, cart 1
5 191084 SLEEVE, cart 2
6 183350 WASHER 2
7 110243 RING, retaining 2
8 115481 FOOT, cart 2
9 112827 BUTTON, snap 2
10 179811 WHEEL, semi-pneumatic 2
11 154636 WASHER 2
12 101242 RING, retaining, ext 2
13 104811 CAP, hub 2
14 110837 SCREW, flange, hex hd; 5/16 in. 4
15 111040 NUT, lock, nylock; 5/16–18 in. 4
16 108795 SCREW, mach, pan hd 6
17 801012 GROMMET, rubber 6
18 TIP, spray, Q-type; 0_ – red
805543 Model 804596: 0004 1
805547 Model 804597: 00045 1
TIP, spray, Q-type; 15_ – yellow
805544 Model 804596: 1504 1
805548 Model 804597: 15045 1
TIP, spray, Q-type; 25_ – green
805545 Model 804596: 2504 1
805549 Model 804597: 25045 1
TIP, spray, Q-type; 40_ – white
805546 Model 804596: 4004 1
805550 Model 804597: 40045 1
19 805634 TIP, spray, chemical injector, (black) 1
23 114801 HOOK, pail 1
24 112380 SCREW, mach, fil hd; 1/2 in. 2
25 109466 LOCKNUT 2
26 804381 GUN & WAND ASSEMBLY
See instruction manual 308511 1
27 804474 HOSE, high pressure;
3/8 x 50 ft (15 m) 1
28 801569 QUICK COUPLER, female; 3/8 1
29 801568 QUICK COUPLER, 3/8; male 1
30 801683 STRAINER, chemical 1
31 194188 TUBING, chemical 1
39Y290013 LABEL, danger 1
40Y290131 LABEL, warning 1
41Y290132 LABEL, “Prevent Freezing” 1
43 LABEL, identification
195406 Model 804596 2
195407 Model 804597 2
47 KIT, unloader/injector 1
114706 Model 804596 1
804528 Model 804597 1
48 804397 VALVE, thermal relief 1
49 VALVE, relief 1
114705 Model 804596 1
804547 Model 804597 1
50 801137 KEY, shaft 1
51 804595 ADAPTER, pressure gauge 1
52 804582 GAUGE, pressure 1
53 115496 SCREW, thread forming, panhead 2
54 244350 KIT, repair, chemical injector 1
YExtra danger and warning labels are available free
of charge.

20 309016
Pump Repair Kits
Repair Kit
Pressure
Washer
Model 804594
Pressure Washer
Model 804596
Pressure Washer
Models 804596
and 804597 Description Qty.
Parts for
Entire
Pump
Parts for
One
Cylinder
804033
Oil seal
801658
Oil seal
801658
Oil seal
Oil seal 3
*
801472
Valve assembly
804402
Valve assembly
804402
Valve assembly
O-ring
Valve seat
Valve
Spring
Valve cage
6
6
6
6
6
*
804034
Valve cap
804403
Valve cap
804403
Valve cap
O-ring
Cap
6
6*
804036
Packing
assembly
114793
Packing assembly
804404
Packing assembly
O-ring
Packing retainer
Intermediate ring
Packing
Packing
Head ring
1
1
1
1
2
2
*
801474
Plunger
assembly
241325
Plunger
assembly
801474
Plunger
assembly
Washer
O-ring
Back up
Retaining screw
Flinger
3
3
3
3
3
*