Graco Hydra-Clean 2104E Operation manual

This manual contains IMPORTANT
WARNINGS and INSTRUCTIONS-
READ AND RETAIN FOR REFERENCe
2104E.MODEL 800-053 SERIES "A"
2 150 psi (1 50 bar) OPERATlNG PRESSURE
2250 psi (155 bar).MAXIMUM WORKINGPRESSURE

~~JJj~~~~Q,&! [=;'b~~.j~~~
Fluids under high pressure from spray or leaks can
penetrate the skinandcauseextremelyserious
injury, including.the need for amputation.
NEVER point the spray gun at anyone or any part of
the body.
NEVER put hand orfingersover thespray tip.
NEVER try tostop or deflect leakswith your handor
body.
ALWAYS havethe tipguard in placewhenspraying.
MEDlCAL TRE&TMEF%B
If any fluid appears to penetrateyour skin, get
treatmentinstructions have' your doctor callthe
F.Sb,iTlONAE PQ@OM CENTER NETWORK
(41 2)6$1-6669
Avena ~QM?~HENT
Even after you shut off the gasoline engine, there is
high pressure in the pump, hose and gun untilyou
release
it bytriggering thegun. So before removing
the spraytipor servicing the unit, alwaysshut offthe
unit andtrigger the gun torelease pressure.
Be surethat
.all accessory itemsand system
NEVER exceedthe pressure ratingof anycomponent
components will withstand thepressuredeveloped.
personal safety, as well as thefunction of the
insystem.
NEVER alter or modify equipment-your
equipment,
is atstake.
damagedconditions causedbytraffic, sharpcorners,
Before each use, check hosefor weak, worn or
pinching or kinking.Tighten
all fluid connections
securelybefore.each
.use. Replace anydamaged
hose.
DO not use chemicalsoragents which are not
compatiblewith Buna-Nand PVC or neoprenecover
. '
of hose.
Do not leavea pressurizedunit unattended. Shut off
the unit and release pressure before leaving.
FORE
Do not spray flammable liquids. Do not operatethe
present.
engine where combustible fumes or 'dust maybe
GENERAL
NEVER run the unitwith thebeltguard removed.
Keepclear of moving partswhen the unitis running.
observedetergentmanufacturer'ssafety
precautions. Avoid getting detergent or other liquids
regardingcontact with eyes,nose,andskin,
in your eyes. Follow
the directions on thecontainer'
breathing fumes, etc. Alwayswear full goggles to
dislodged by the spray. If necessary, wear gloves or
protectyour eyes fromthe sprayaswellasanydebris
otherprotectiveclothing. If.antidotesortreatment
are recommendbd, be prepared to use them.
DON'T spray toxic chemicals such as insecticide or
weed killer.
This unit issuppliedwith an8-foot powercordmade
up of four AWG
No. 12 wires. The green wireof the
electric cord is connectedto theunit chassis and
motorframe. The other three wiresare connectedto
the starter switch.
approved plug to fityour requirements.
Be sure to connectthepower cord tothe appropriate
The starter switch has
a built-in.circuit breakerthat
will shut
off the power totheunit whenever the
circuit
is overloaded.
Always checktobe surethe switchis
off and thatthe
before plugging
in the power cord.
hoses and electric cord areclear of movingparts
IMPORTANT
United States Government safety standards have beenadoptedunder the Occupational Safety and HealthAct.
Thesestandards
- particulsrlythe.GeneralStandards,Part 1910, and the ConstructionStandards, Part 1926 -
should be consulted in connection with your use of airless spray equipment.
2 . 801-392 .. ..
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, ..-..
: :
REMOVE TAPE
FROM PUMP CAP
!’
I
SPRAY
GUN
\SPRAY HOSE
r ..
.
.. :,
..
L:’: ..,<
, ...
.~
Check Electrical Service and Plug In
Beforeplugging in thesprayer. besurethe electrical
service is
3 phase 220 V, 60 HAC. 20 Amp.Withthe
ON-OFF switch in theOFF position, plug the power
supplY cord into
a groundedoutlet.If you use an
gauge(2.5
mm2) and should notbe over.100ft (30.3
extension cord, it must have 4 wires of at least 12
m) long.
Install Hose and Spray Gun
Connect the spray hose tothe spraygunby inserting
thepin
at theend of the hose intothe quick
the fluid outlet in thesame way.
disconnect coupler
on the gun. Connectthe hoseto
Removethe tape from thecap
on top of the pump.
Cleaning Accessories
Forspraying detergent or other cleaningsolution, we
recommendusing
a chemicalinjecior kit. See
Accessories and instructionmanual801-192 for
installation and operation.
a water sandblaster.SeeAccessoriesand instruction
For removing rustandoldpaint we recommend using
manual 801-190for installation and operation.
Connect
To Wate~ Supply
Do not exceed 16OoF (7OOC) ,water temperature to
pump in
a direct supply system.
from your citywatersupply to theunit’s
3/4 in.
Connect a hose with at least a 3/4 in. (19mm) ID
garden hose threaded inlet. The supply hoseshould
not be more than 50 ft. (1 5 m)long.
NOTE: For a directsupply system. your water
AT LEAST 5 GPM (19 LITER/MIN).
source at the unitmusthave a flow rateof
If your operating conditions are different fromabove,
assistance.
contact our Customer ServiceDepartmentfor
801-392 3

OPERATlQM
: Startup
' . Beforestarting, be sure'toreadthe safety warnings
and setup instructions.
Turn on the watersupply.
Trigger the gun to release any back pressure.
CAUTION I
',
to the pump will result. Always be sure water
Never runthe cleaning unitdry. Costlydamage
necessary.
supplyiscompletelyturned
on beforeoperating.
Cleaning
Inspect
all connectionsforany leaks. Tighten if
Injector manual, 801
-1 92.
For Hydra-Clean technique, see the Chemical
'I For abrasive cleaning, see the Water Sandblaster
manual, 801 -1
90.
WAffiNBNG
Follow these precautions when removing and
installing nozzles:
1. Shutoffthe cleaning unit andtriggerthegun
torelievepressure. Engagethe triggersafety.
2. Keep the nozzle and the tube pointed away
from you and everyone else.
3. Do not put your handover the tip to push the
nozzle into place. Grasp
it from the side and
keep your fingers away from thetip.
4. Do not let anyoneelse touch thespray valve
while you are cleaning nozztes.
5. Be sure the slipring is pushedforwardto lock
the nozzle inplacebefore triggering thespray
gun.
Shutdownand.Care
Of Unit
When unit is not in use, turn off water supply.
When shutting down for theday orweekend,shut off
release pressure. Wipe offthe unit with
a damp rag.
unit, shut off water supplyvalve, and trigger gun to
Check the filter screen
in the water inlet connection
as often as necessary,
at least daily. Do not operate
the unit with the inletand filter screen removed.
DO NOTtrytoadjusttheunloadervalveorchangethe
engine speed. Changingthesesettings rnay cause
wasted fuel and increased wear
on parts and will void
excessivepressure, intermittent unloader operation,
the warranty.
of water prior to exposuretofreezing temperatures.
PUMP MUST
NOT BE RUN DRY andmustbedrained
Useand storethe unit where it
will not be subjected
to freezing temperatures.
If water doesfreeze in the
unit, thaw before trying to start.
.A 50% anti-freeze
solution rnaybe pumpedprior to coldweather
storage.
Use only spray tips that are matched to the unit to
valve. See Accessories.
avoid excessive cyclingandwear of the unloader
CAUTION
temperature change may crack the ceramic
pourhot water
on a frozen pump. A sudden
Do not pump caustic materials.
oil.
Before extended storage, flush the pump with light
Avoid dragging hoseoveranabrasivesurfacesuchas
cement. This causes excessive wearandshorter
hose life.
Clean the intake line strainer daily.
Lubrication
and Care
Fill pump crankcasetodot on oil,gaugewindow with
25 oz. (0.75 liters)of crankcaseoil(part no. 801 -1 44)
or equivalent SA€ 40 weighthydraulic oil with
antiwear and rust inhibitor additives. Change initial
fill after
50 hour runningperiod. Change oil every 3
months or at 500 hour intervals.
WARNONG
NEVER alter adlustmentor modifythe unloader
1 valve.
. ~i ..
...
..
.. . .
. ,.
~...
.: i
..

. .. .I
.. . .
: ..
” .. : .
-.
PROBLEM
-0w~pressure.
’ump runs extremely rough,
Iressure low.
Nater leakagefrom under
:he manifold.
Nater in pump crankcase.
:requent or premature
ailureof the packing.
;trow surging
at the inlet
lnd low pressure
on the
lischarge side.
CAUSE
Worn nozzle.
Belt slippage.
Air leak ininlet plumbing.
Relief valve stuck, partially
plugged or improperlyadjusted,
valve seat worn.
Inlet suctionstrainer clogged
01
improper size.
Worn packing. Abrasivesin
pumpedfluid or severe cavita-
tion. Inadequate water supply.
Fouled or dirty inletor discharge
valves.
Worn inlet or dischargevalves.
Leaky discharge hose.
Restrictedinlet or air entering
the inlet plumbing.
Inlet restrictionsand/or air
‘eaks. Stuck inlet or discharge
talve.
-caking H.P. seals.
vVorn packing.
May be caused by humid air
:ondensing intowater inside the
:rankcase.
Scored plungers.
3ver pressureto inlet manifold.
lamagedor worn plungers.
4brasive material in the fluid
)eing pumped.
ixcessive pressure-and/ortem.
)eratureof fluid being pumped.
herpressureof pumps.
lunning pump dry.
:oreign particles inthe inlet or
lischarge valve, or worn inlet
Ind/or discharge valves.
SOLUTION
Replacewith nozzle of proper Size.
Tighten or replace; usecorrectbeltsand replacl
both
at same time.
Disassemble, reseal, and reassemble
Clean, andadjust relief valve; check for worn
and dirtyvalve seats.
Kit available.
Clean. Use adequate size. Check more
frequently.
Install proper filter. Check flow available
to
..
pump.
Clean inlet anddischarge valve assemblies.
Replaceworn valves, valve seats and/or
discharge hose.
seal.
Proper size inlet plumbing; check for airtight
Cleanout foreign material,replaceworn valves
Replaceseals.
Install newpacking
Change oil
at 3 monthor 500 hour intervals usins
GracoCrankcase Oil (other approvedoil evenl
month or
200 hours) P.N. 801-144.
Replaceplungers,
Reduce inlet pressure.
Replaceplungers.
Installproperfiltration
on pumpinlet plumbing,
Check pressures andfluid inlettemperature; be
sure they are within specified range.
Reduce pressure.
Do not run DumD without water.
801-392 5
Check for smooth lap surfaces on inlet and.
discharge valve seats. Dischargevalve seats
and inlet valve seats may be lapped
on a very
fine oil stone.

ectrtc motor wont run.
Electric motor runs, but
no output.
CAUSE
Power cord unplugged, or
building circuit fuse blown
Overload switch has opened.
Power.cordunplugged, or
building circuitfuse blown,
Overload breaker has opened.
Extensioncord.
Tip plugged.
Displacementpump frozen or
gear train damage.
Check, replace
Unplug power cord+, decrease pressure.
Check, replace.
tO.CO01.
Unplug power cord*, relieve pressure-allow
Don't
use morethan 100 ftof 12 ga extension cord.
Remove and clean.
Thaw.
*This unithas an overload breakerbuilt into the switchassembly. If
it opens, unplug power cord and letsprayer
cool for 30to
60 minutes. Also,try tocorrect thecauseof overheating. Alwaysusethe lowest pressure setting
needed.
NOTE: A M11 and M30 metricwrenches are
required for servicingpump.
PUMP
Photo 1 and 2.
Valves
2) Examine O-ring underplugandreplaceif
1) Remove the hex plug using an M30 wrench.
3) Remove valve assembly includingretainer,
evidence of cuts or distortion.
spring, valve and valve seat from valve cavity.
NOTE: Valve assembly may come apart during
removal.
4) Replace valve parts with service kit (801-041)
ring and back-up-ring.
includingretainer,spring, valve, valve seat,
o-
5) Replace valve cover and torque to 75 ft-lb (100
Nm).
Pumping
Section
Photo 3.
2) Separate the manifold from thecrankcase.
1) Removethe four (4) hex nuts from the manifold.
NOTE: It may be necessary totapmanifold
lightly with mallet to loosen.
CAUTION
plungers when removing toavoiddamage to
Keep manifold properly alignedwithceramic
either plungers or seals.
3) Carefully examine each plunger for any scoring
and replace if necessary.
6 801-392

,.
. ,.
, :.
..,,.
Plungers
Photo 4.
1)UsinganM1 1 wrench,
2) Slideout thesealretainerwith
remove the plunger retainer.
oilwick and rubberbarrier
slinger.
3) With a slight twistingmotion,
loosen the plungerfromthe
plunger rod and remove.
NOTE: The studmay remain
whenremoved.
withthe retainer
Disassembleand
screwstudinto
plungerrodfinger
tight.
4) Replace O-ring 'and backup
5) Saturate newoil wick by
6) Install new plunger.
7) Replace plunger retainer and
torque to
80 in-lb (9 Nm).
8) Installnew oil wick in seal
retainer.
9) Replace barrierslinger over
new plunger.
10)Lubricate each plungersleeve
andcarefullyslidemanifold
onto crankcase.
ring on plunger retainer.
soaking in oil.
Photo 5, 6, 7 and 8.
Seals or V-Packings
2) Then removethe lowpressure
1
) RemoveC-ring fromsealcase:
3) Unscrewthe seal case from
seal from the seal case.
themanifoldusing
a special'
key wrench (801-044).
4) Remove thehighpressure
seal and examine. Before
replacing, lubricate
ID and OD
of newhigh-pressuresealand
press into manifold.
MOTE: A socket andexten-
sion maybeused to
pressure seal from
manifold.
5) Install newO-ringon sealcase
and lubricate
OD of O-ring.
6) Screw seal caseintomanifold.
7) Lubricate ID and OD of low
pressure seal and pressinto
8) Replace C-ringholding low
seal case.
pressure seal in place.
k
9) Lubricateeach plunger sleeve
andcarefullyslidemanifold
onto crankcase.
.NOTE: Whenreplacing
manifold
onto plungers,
ememe caution should
be exercised to avoid
damage
to the seals.
10) Torqueallfour(4)boltsto240in-lb
(27 Nm).
NOTE: Carefullystudythe
order of respective
partsandnote
position of sealsto
assure proper re-
assembly and opera-
tion.
801-392 7

8 801-392

i
!
,
Ref. No. 50 Includes items 51-66
62
-52 63
PARTS LIST
REFPARTDESCRIPTION
NO. NO.
1 HOSE & GUNASSY. see aun
2
4
3
5
8
6
9
10
13
11
14
17
16
19
18
20
21
22
23
24
25
801-001
800-036
800-01 5
800-037
801-390
801 -285
801-231
801-140
801-129
801-131
801-221
801-382
801-379
801-292
801-380
801 -021
801 -088
801-298
801 -302
801-082
801-081
~
PUMP,REPLACEMENTPARTS,
detail'for parts
includes items 77-90
ANTIVIBRATIONFOOT
CHASSIS
ELECTRICMOTORASSY
BRACKET.
spacer
BELT, drive
LABEL. warning
LABEL. identification
LABEL, warning
PLATE, serial no.
CONNECTOR, crimp
SWITCH^ starter
STRAINRELIEF
CORD,
power (8 fi lg)
SCREW, self tapping,
no. 6-32 NC x 1 /2
~~~~~
BOLT. carriage,
5/16-18 NCx 5" ~
SCREW, machine, hex hd.
SCREW, machine, hexhd.
hd.
5/16-18 NC x
1-1/2"
hd. 5/16-18 NC x 2-1/2"
SCREW,
machinehexhd.
5/16-18 NCr 1"
SCREW, machine,hexhd.
M6 x 30 mm
M8 x 20 mm
SCREW. machine,hexhd.
. . . . . - . . - .. .
QTY
1
4
1
.1
1
2
1
2
1
1
1
2
1
1
2
2
2
4
1
4
4
2
REFPARTDESCRIPTION
NO, NO.
QN
26
27
28
29
30
32
31
34
35
37
36
40
41
44
42
46
48
47
50
51
52
53
54
55
56
57
58
59
60
61
62
64
63
65
66
68
67
.69
70
72
71
74
73
75
76
801 -023
801
-01 5
801
-1 39
801.025
80.1-024
801-367
801 -01
2
801 -004
801-381
801-135
801-137
801
-01 8
801-364
801-365
801 -132
801 -008
801-388
801-389
801 -084
801-045
801 -046
801-047
801-048
801-049
801-050
800-012
,801-059
801-060
801 -OB1
801-105
801-106
801-236
801-108
801-109
801-110
801-11~2
801
-1 1 1
801-113
WASHER,
flat, 1/4
WASHER,
flat, 5/16
WASHER,
IocIc 1 /4
WASHER, lock, 5/16
NUT,
hex, 5/16-18 NC
GROMMET
BUMPER
PULLEY.
rnntnr
PULLEY,
pump
HUB. pulley
KEY, pulley (2" lg)
BRACKET, tensioner
BELTGUARD, cover
BELTGUARD. baseplate
RIVET, drive
LABEL, warning
LABEL. identification
UNLOADER. includesitkms 51-66
LABEL.
identification
. O-RING
. CAGE, valve
. SPRING
. SEAT
, BALL
. UNLOADERSUB-
, O-RING.
. O-RING
. CYLINDER
HOUSING
. PLUG
O-RING
. SPRING
. VALVE'
COUPLER,
male quickdisconnect
. SEAT
NIPPLE,
straight,brass,
TEE, brass, 1 /2 NPT
1 /2 NPT x 3- 1 /2"
NIPPLE,
hex, steel, 1 /2 z 3/8 NPT
NIPPLE,
hex, brass,.l/4x 1/2 NPT
ADAPTER, 1/2
hose
PLUG, hex,brass, 3/8 NPT
HOUSING VALVE
NUT,
brass,adapter
SCREEN, inlet
HOSE, coupled, 1 /2 NPT (MBE)
17-1
/2" Ig
801 -392
16
8
10
4
4
7
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
9

REF PART DESCRIPTION
NO. NO.
Qn
Items 77-90 arepump internal replacement parts.
See exploded view of pump for details.
77801-027 ,
CAP
79801-267 . DISCHARGE
78801-028 . O-RING, cap
MANIFOI n
80
81
82
83
84
85
86
87
88 801-038 .
RING, backup
89801-039 . O-RING
90801-040 . RETAINER,
plunge1
. . . . - . . - . - -
1
1
1
3
3
3
3
3
3
3
3
3
3
3
number and seriesletter of theassembly forwhich you are
Order parts by name and number. Always give the model
ordering.
ELECTRICAL SCHEMATIC
801-042 SEAL KIT
INCLUDES
3 SETS
SERVICE TOOLS
KEY WRENCH
801-044
EXTRACTOR TOOL 801-205
'80 801-392

PARTS DWAVVlMG
Gun and Hose Assern
I-3
'7
8
14
5
A
Repair Kit 801 -083
Includes items A, B, C. D, E and F
SERVICE
1. Re'movethe 8 screws from thebody halves (3) and
(4). See the Parts Drawing. Separate the body
halves.
2. Removethe Plug (14). spring (5) and ball (A) from
the valve body
(G).
3. Remove the snap ring (6). Then remove the valve
seat
(C) and'o-ring (0).
4. Removethesleeve nut (1 1) andO-ring (E) with'the
actuator rod
(F).
5.Afterinstallingthenewseat(C)andball(A),tapthe
balllightly with a hammer to assure a proper
seating between the ball andseat.
6. Reassemble in reverseorder, using the remaining
newparts from the repair kit.
REF PART
NO.
NO.
1 801")7
2 800-017
3 801-244
4
' 801-245
5 801-249
6 801-254
7 801-256
8 801-262
10801-247
9 801-261
11 801-253
12 801-246
13 801-263
14801-250
15801.264
16801-265
17 801-134
18 801-029
20'801 -090
19801-009
21801-073
22"801-010
23'801 -011
24801-074
25 801-076
27801-103
26 801-077
28'801-091
DESCRIPTION
QTY
(15 ml Ig
SPRAYHOSE, 3/8" ID. 50 ft.
SPRAYGUN, (replaceable parts
include items3-16)
. HANDLE, left
. HANDLE, right
;PRING
IEEDLE
EVER
IEX PLUG
. VALVEBODY
IISCHARGE FIlTING
. GUIDESLEEVE
. TUBE
. INLET FllTlNG
CAP
. -. ..
. SCREW
. SCREW
TUBE.
32"
COUPLER,femalequickdisconnea
GRIP
COUPLER, male quick disconnect
HOUSING,nozzle
TIP,
blasting; Oo
TIP, cleaning; 15O
GUARD,
tip
PLATE, warning
RIVET
NIPPLE,hex: 1/4
x 3/8" npc brass
COUPLER, male quick disconnect
1
1
1
1
1
1
1
1
1
1
1
1
1
7
1
1
1
3
1
1
2
1
2
1
1
2
2
1
Order
parts by name and series letter of the assembly for
which you are ordering.
*Recommended .'tool box" spare parts.
801 -392 1 d

ACCESSORIES (Must be purchased separately)
CHECK VALVE 801 -1 33 CHEMICALINJECTOR KIT 800-182
supply. lnstatl upstream from pump.
Prevent backup
of contaminatedwaterintofresh For injectingharshcleaningchemicalsdownstream
from pump.
WATERSANDBLASTER 800-103 ADJUSTABLE SAND SAVER 800-031
For abrasive cleaning of stubborndirtand paint. For adjusting sand flow.
TECHNICAL DATA
MOTOR:
WATERPUMP:
WETTEDPARTS:
WEIGHT:
OVERALL DIMENSION:
MAX. WATERTEMPERATURE:
INLETHOSECONNECTION:
5 hp, 3 phase,
220
V, 60 Hz, 17Amp
21
50 PSI(1 50 bar) rnax.
pressure;
4 GPM
(15 liter/min).
Stainless Steel, Aluminum,
Phenolic Plastic, Ceramic
Liners, NitrileRubber.
140
Ibs
Width: 18 in (457 mm)
Length: 36
in (914 mrn)
Height:
17 in (432.rnm)
1
6OoF (70°C)
3/4-in. garden hose (f)
THE GRACO WARRANTY
GracoInc.warrantsa1Iequipmentmanufacturedbyitandbearingitsnametobefreefromdefectsin
material and workmanship under normal use and service. This warranty extends to the original
purchaserforaperiodof 12monthsfromthedateofpurchaseandappliesonlywhentheequipment
is installedand operated in accordancewith written factoryrecommendations.Thiswarrantydoes
not cover damageor wear which. in the reasonable judgment ofGraco. arises from misuse,
abrasion. corrosion, negligence. accident, substitution of non-Graco parts, faulty installation or
tampering.
This warranty isconditioned upon the prepaid returnof the equipment claimed to bedefective for
examinationby Gram to verify the claimeddefect.Ifthe claimeddefect is verified, Gram willrepair
or replace free of charge. any defective parts. The equipment will be returned to theoriginal
purchaser transportation prepaid. If inspection of the equipmentdoes not disclose any defect in
workmanshipormaterial,repairswill bemadeatareasonablechargeandreturntransportationwill
be charged.
soldby Gracothat are not manufactured by Graco(suchas electric motors. switches, hose.etc.)are
EOUIPMENTNOTCOVEREDBYGRACOWARRANTY. Accessories or componentsof equipment
subiect to thewarranty, if any. of their manufacturer. Gracowillprovide purchaserwithreasonable
assistance in making suchclaims.
FaEtory Branches: Atlanta. Dallas, Detroit, Los Angeles. West Caldwell [N.J.)
Subsidiary and AMIIata Companies: Canada: England: Switzerland; France; Germany; Hong Kong:'Japan
GRACO BNC. P.O. ~QX IWT MBNMEAIPOLQS. MN %wo-na . .
PRINTED IN U.S.A. 801-392 9-82
45-10043A