Graco HYDRA-CLEAN 2104ET Operation manual

Thls manual contains IMPORTANT
WARNINOS and INSTRUCTIONS
READ AND RETAIN FORREFERENCE
i
i MODEL 800-054 SERIES "A"
2150 psi(150 bar} OPERATING PRESSURE
2250 psi (155 bar} MAXIMUM WORKING PRESSURE
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INJECTION HAZARD
penetratetheskinandcauseextremelyserious
Fluids under high pressure from sprayor leaks can
injury, including the need for amputation.
NEVER point.the spray gun at anyone or any partof
the body.
NEVER put hand or fingers over thespray tip.
NEVER try to stopor deflect leakswith your hand or
body.
ALWAYS have the tip guard in place when spraying.
WJE~ICAL TREATMENT
If any fluid appears topenetrateyourskin,get
EMERGENCQ MEDICAL CARE AT ONCE.
DO NOT TREAT AS A SIMPLE CUT.
ell the doctor exactly what fluid was injected. For
treatmentinstructionshaveyourdoctorcallthe
NATIONAL POBSQN CENTER NETWORK
(41 2)681-6669
AVOID COMPONENT WUPTBIRE
high pressure in the pump, hose and gun until you
Even after you shut off the gasolineengine, there is
the spray tipor servicing the unit, always shut offthe
release
it by triggering the gun. So before removing
unit and trigger the gun to release pressure.
components'will withstand the pressuredeveloped.
Besurethatall accessory itemsandsystem
NEVER exceedthe pressure ratingof any component
in system.
NEVER alter or modify equipment -your
personal safety, aswell as the function of the
equipment, is at stake.
damaged conditions causedby traffic, sharp corners,
Before each use, checkhosefor weak, worn or
pinching or kinking.Tightenallfluidconnections
securelybeforeeach use. Replace anydamaged
hose.
Do not use chemicalsoragentswhicharenot
compatible
with Buna-N andPVC or neoprenecover
of hose.
Do not leave a pressurized unit unattended. Shut off
the unit and release pressure before leaving.
FIRE
enginewherecombustiblefumes or dust may be
Do not spray flammable liquids. Do not operate the
present.
GENERAL
.NEVER runtheunitwiththebeltguard removed.
Keep clearof moving parts when the
unit is running.
Observedetergentmanufacturer'ssafety
precautions. Avoid getting detergent or other liquids
in your eyes. Follow the directions on the container
breathingfumes,etc.Alwayswearfull goggles
to
regardingcontact.with eyes, nose. and skin,
dislodged by the spray. If necessary, wear gloves or
protect your eyesfrom thespray aswellasany debris
otherprotectiveclothing. If antidotes or treatment
are recommended, be prepared
to use them.
DONT spray toxic chemicals such as insecticide or
weed killer.
This unit
is supplied with an 8-foot power cordmade
up of four AWG No.
12 wires. The green wireof the
electriccord is connectedtothe unit chassisand
the starter switch.
motor frame.The other three wires are connected to
Be sure
to connect the power cord to the appropriate
approved plug to fit your requirements.
The starter switch has a built-in circuit breaker that
willshut off thepowertothe
unit wheneverthe
circuit is overloaded.
Always check to be sure the switch isoff and thatthe
hosesandelectriccord are clear of movingparts
before plugging
in the power cord.
IMPORTANT
These standards - particularly the General Standards,Part 1910, and the Construction Standards,Part 1926-
United States Government safety standards have been adopted under the Occupational Safety and Health Act.
Should be consulted
in connection with your use of airless spray equipment.

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Check Electrical Service and Plug In
service is 3 phase 220 V. 60HzAC, 20 Amp. With the
Before plugging in thesprayer, be sure the electrical
ON-OFF switch in theOFF position, plug the power
supplycord intoagroundedoutlet. If youusean
gauge (2.5 mm2) and should notbe over l00ft(30.3
extensioncord,
it must have 4 wires of at least 12
m) long.
Install Wheels and Handle
and washers onto the axleand secure in place with
Slide the axle through the frame. Slide the wheels
cotter pins provided. Install the hub caps. Attach the
handlewiththefourscrews,flatwashers,lock
washers and nuts provided.
Install Hose and
Spray Gun
thepin at theend of the hose intothequick
Connect thespray hose to thespray gunby inserting
disconnect coupler on the gun. Connect the hose to
the fluid outlet in thesame way.
Remove the tape from thecap on top of the pump
Cleaning Accessories
recommendusing
a chemicalinjectorkit. See
For spraying detergentor other cleaning solution, we
Accessoriesandinstructionmanual801-192for
installation and operation.
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a water sandblaster.SeeAccessoriesand instruction
For removing rust and old paint we recommend using
manual 801-190 for installation and operation.
Connect
To Water Supply
CAUTION
Beforeattachingtowatersupply, check local
plumbing code regardingcross-connectionto
water supply. Backflow check valve 801 -1
33.
pump in a direct supply system.
Do not exceed 160°F(70°C)watertemperatureto
Connect
a hose with at least a 3/4 in. (19 mm) ID
fromyourcitywatersupplytotheunit's 3/4 in.
garden hose threaded inlet. The supply hose should
not be more than 50 ft.
(15 m) long.
NOTE: For a directsupplysystem.yourwater
source atthe unit
must have a flow rateof
AT LEAST 5 GPM (19 LITER/MIN).
.
If youroperating conditions are different fromabove,
contactourCustomerServiceDepartmentfor
assistance.
801-456 3
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OPERATION
Startup
Before starting,be sure to read thesafety warnings
and setup instructions.
Turn on the water supply.
Trigger the gun to release any back pressure
to the pump
will result. Always be sure water
supplyiscompletelyturnedon beforeoperating.
Inspect
all connectionsforany leaks. Tighten if
necessary.
Cleaning~
For cleaningtechnique, see the Chemical Injector
manual,
801-192.
manual, 801-190.
For abrasive cleaning, see theWaterSandblaster
1. Shut off the cleaning unit and triggerthegun
to relieve pressure.Engagethe trigger safety.
2. Keep the nozzle and the tube pointed away
from you and everyone else.
3. Do not putyour handover the tip to push the
nozzle into place. Grasp it from theside and
keep your fingers away from the tip.
4. Do not let anyoneelse touch thespray valve
while youare cleaning nozzles.
5. Besure the slip ring is pushed forward tolock
the nozzle in place before triggering thespray
When unit is not
in use, turn off water supply.
Shutdown and Care Of Unit
When shutting down for theday orweekend. shutoff
unit, shut off water supplyvalve, and trigger gun to
release pressure. Wipe off the unit with a damp rag.
spraying, forlongerpumplife. The pump will
without spraying.
overheatifleftrunningfor over
10 minutes
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.
engine speed. Changingthesesettings may cause
DONOTtrytoadjusttheunloadervalveorchangethe
excessive pressure, intermittent unloader operation,
wasted fuel and increased wear on parts and will void
the warranty.
PUMP MUSTNOT
BE RUN DRY and mustbe drained
of water prior to exposure to freezing temperatures.
to freezing temperatures.If water does freeze
in the
Use and store the unit where
it will not be subjected
solutionmay be pumpedpriortocoldweather
unit, thaw before trying to start. A
50% anti-freeze
storage.
avoid excessive cyclingandwear of theunloader
Use only spray tips that are matched to the
unit to
valve. See Accessories.
pourhotwateron
a frozenpump.A sudden
temperaturechangemaycracktheceramic
Do not pump caustic materials.
Beforeextended storage, flush the pump with light
oil.
Avoiddragginghoseoveranabrasivesurfacesuchas
cement. Thiscauses excessivewearandshorter
hose life.
Clean the intake line strainer daily.
Lubrication and Care
25 oz. (0.75 liters)of crankcase oil (part no. 801 -1 44)
Fill pumpcrankcase to dot on oil gauge window with
or equivalent SAE 40 weighthydraulic oil with
antiwear and rust inhibitor additives. Change initial
,fill after 50 hour running period.Change oil every 3
months or at 500 hour intervals.
WARN1NG
NEVER alter adjustmentor modifv the unloader 1
I
valve
I
Altering or adjusting unloader willnot increase
Derformance of unit.
4 801-456
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1
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SERVICE
TROUBLESHOOTING
'ROBLEM
1 CAUSE I SOLUTION
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.ow pressure. Worn nozzle
Belt slippage.
Replacewith nozzle of proper size,
Tighten or replace; use correct'belts and replacl
both
at same time.
Air leak in inlet plumbing. Disassemble, reseal. and reassemble
Relief valve stuck, partially Clean, and adjust relief valve; check for worn
plugged or improperly adjusted;
valve seat worn. and dirty valve seats. Kit available.
Inlet suctionstrainer clogged or Clean.
Use adequate size. Check more
improper size. frequently.
Worn packing. Abrasives in Install proper filter. Check flow available to
pumped fluidor severe cavita- pump.
tion. Inadequate water supply.
Fouled ordirty inlet or discharge Clean inlet and discharge valve assemblies
valves.
Worn inlet or discharge valves. Replaceworn valves, valve seats and/or
Leaky discharge hose. discharge hose.
'ump runs extremely.rough, seal.
the inlet plumbing.
vessure low. Proper size inlet plumbing; check for airtight
Restricted inlet or air entering
Inlet restrictions and/or air
valve.
Clean out foreign material,replaceworn valves
leaks. Stuck inlet or discharge
Replaceseals.Leaking
H.P. seals.
Yater leakage from under Worn packing.
he manifold. Install new packing.
%ter in pumpcrankcase.
every month or
200 hours) P.N. 801-144.
crankcase. using GracoCrankcase Oil~(otherapproved oilcondensing into water insidethe Change
oil at 3 month or 500 hour intervals
May becaused by humid air
:requent or premature
ailure of the packing. Scored plungers Replace plungers.
Over pressure to inlet manifold.
Abrasive material
in the fluid
Replace plungers
Damaged or worn plungers.
Reduce inlet pressure.
Install proper filtration on pumpinlet plumbing.
being pumped.
Excessivepressure and/or tem- Check pressures andfluid inlettemperature; be
peratureof fluid being pumped. sure they are within specified range.
Over pressure of pumps. Reduce pressure.
Running pumpdry.
Do not run pump without water.
trow surging at the inlet.
and/or discharge valves.
ischarge side. discharge valve seats. Discharge valve seats
discharge valve, or worn inlet
nd low pressure on the Check for smooth lap surfaces on inlet and
Foreign particles
in the inlet or
fine oil stone.
and inlet valve seats may be lapped on a very

ectric motor won't'run
spraying.
Electric motor runs, but
no output.
CAUSE
building circuit fuse blown.
Power cord unplugged, or
Overload switch has opened.
Power cord unplugged, or
building circuit fuse blown.
Overload breaker has opened.
Extension cord.
Tip plugged.
:
Displacement pumpfrozen or
gear train damage.
SOLUTION
Check, replace.
Unplug power cord*, decrease pressure
Check, replace.
Unplug power cord'. relieve pressure-allow
to cool.
Don't use morethan 70ftof
1 Zgaextensioncord.
Remove and clean
Thaw.
'This unit has an overload breaker built into the switch assembly.
If it opens. unplug power cord and letsprayer
cool for 30 to 60 minutes. Also, try to correct thecause of overheating. Always use the lowest pressure setting
needed
NOTE: A M11 and M30 metricwrenches are
required for servicing pump.
PUMP
Photo 7 and 2.
Valves
1) Remove the hex plug using an M30 wrench.
2) Examine O-ring underplugandreplace if
evidence of cuts or distortion.
3) Remove valve assemblyincludingretainer,
spring, valve and valve seat from valve cavity.
NOTE: Valve assembly may come apart during
removal.
4) Replace'valvepartswith service kit (801-041)
includingretainer,spring, valve, valve seat, o-
5) Replace valve cover and torque to 75 ft-lb (100
ring and back-up-ring.
Nm).
Pumping Section
P.bot0 3.
1) Remove the four (4) hex nuts from the manifold.
2) Separate the manifold from thecrankcase.
NOTE: It may be necessary to tap manifold
lightly with mallet to loosen.
plungers when removing toavoid damageto
either plungers or seals.
3) Carefully examine each plunger for any scoring
and replace
if necessary.
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Photo 4.
Plungers
1)Using 'an
M1 1 wrench,
remove the plunger retainer.
2) Slide out theseal retainer with
oilwickandrubberbarrier
3) With a slight twisting motion,
slinger.
plunger rod and remove.
loosen theplungerfromthe
NOTE: The stud may remain
with theretainer
whenremoved.
screwstudinto
Disassembleand
tight.
plungerrodfinger
4) Replace O-ring and back up
5) Saturatenewoilwick by
6) Install new plunger.
7) Replace plungerretainerand
8) Installnewoilwickin seal
torque to 80 in-lb (9 N.m).
9) Replace barrierslinger over
retainer.
new plunger.
10) Lubricateeach plunger sleeve
onto crankcase.
andcarefullyslidemanifold
ring on plunger retainer.
soaking
in oil.
Photo 5. 6. 7 and 8.
Seals or V-Packings
2) Then remove the low pressure
1) Remove C-ring fromseal case.
3) Unscrewthe sealcase from
seal from the seal case.
themanifoldusing a special
key wrench (801 -044).
4) Remove thehighpressure
seal andexamine. Before
replacing, lubricate ID and
OD
of new high-pressureseal and
press into manifold.
NOTE: A socket andexten-
sion may be used to
pressuresealfrom
manifold.
5) Install newO-ringon sealcase
and lubricate OD of O-ring.
6) Screw seal case into manifold.
7) Lubricate ID and OD of low
pressure seal andpressinto
8) Replace C-ringholding low
seal case.
pressure seal in place.
9) Lubricateeach plunger sleeve
andcarefullyslidemanifold
onto crankcase.
NOTE: Whenreplacing
extreme caution should
manifold onto plungers,
be exercised to avoid
damage to the seals.
10) Torqueallfour(4)boltsto240in-lb
(27 Nm).
NOTE: Carefully study the
order of respective
partsandnote
assure proper re-
positionof seals to
tion.
assembly and opera-
801-456 7
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Ref. No. 50 Includes items 51-66. 77 & 79
61
7
- 65
66
56
59
& 56
.. PARTS LIST
REF PART
NO. NO.
1
2 801-001
3 800-015
4
800-038
5 800-037
6801-390
8801-285
9801-231
10801-140
11 801-129
12 801-022
13 801-131
14801-221
15 801-394
17801-382
16801.379
18 801.380
19 801-292
20 800-039
21 801-088
22
801-298
,, 23 801.302
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8
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HOSE & GUN ASSY.seegun
detail for parts
PUMP, REPLACEMENTPARTS,
ANTIVIBRATIONFOOT
include items
77-90
CHASSIS
ELECTRIC MOTOR ASSY
BRACKET. spacer
BELT, drive
LABEL, warning
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 ft lg)
STRAIN RELIEF
SCREW, self tapping.
nu.
6-32 NC x 1/2
RAIL STIFFNER ASSY
DESCRIPTION
QTY
SCREW,machine,hex hd,
5/16-18 NCx 1-112”
SCREW,machine, hex hd.
5/16-18 NC x 2-1/2”
SCREW,machinehexhd,
5/16-18 NC x 1“
1
1
2
1
1
2
1
2,
1
1
4
2
1
1
1
1
2
2
1
4
1
4
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
48
47
50
49
51
52
54
53
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
72
71
73
74
76
75
77
78
79
801-082
801-081
801.023
801-015
801-139
801-025
801-024
801-01
2
801-367
801.241
801-004
801-1
35
801-381
801-1 37
801-393
801-235
801.01 8
801.364
801-365
801
-242
801-243
801-132
801-130
801-388
801-141
801-41 7
800-045
801-045
801-046
801-047
801-048
801-049
801 -050
801.059
801-046
801-412
801-432
801.062
801 -06.3
801-068
801-069
801-070
801-071
801-090
801-105
801-106
801-41 6
801-108
801-109
801-110
801-11 1
801-113
801-112
800-044
801 -008
801-465
DESCRIPTION
SCREW,machine, hex hd.
SCREW, machine, hex hd,
M6 x 30 mm
WASHER,fiat,
114
M8 x 20 mm
WASHER.flat.
5/16
WASHER, lock, 1/4
WASHER, lock, 5/16
NUT, hex, 5/16-18 NC
GROMMET
BUMPER
WHEEL
PULLEY, pump
HUB. pulley
PULLEY, motor
KEY, pulley
(2” lg)
AX1 F
.
WASHER, flat
BRACKET, tensioner
BELTGUARD. cover
BELTGUARD. baSeDiate
HUBCAP
PIN, cutter
RIVET, drive
LABEL, warning
LABEL, warning
LABEL, warning
UNLOAOER.includes
LABEL. starting
items
51-66, 77, 79
CAGE, valve
O-RING
BALL
SPRING
. SEAT
O-RING
. O-RING
. UNLOADERSUB-ASSY
. HOUSING
. CYLINDER
O-RING
. PLUG
HOUSING VALVE
. VALVE
. SPRING
. SEAT
COUPLER, male quick disconnect
NIPPLE,straight. brass.
1/2 NPT x 3-1/2”~
TEE, brass, 1/2 NPT
NIPPLE, hex. steel.
1 /2 x 3/8 NPT
NIPPLE,
hex. brass, 1/4 x 1/2 NPT
ADAPTER,
1 /2 hose
PLUG,hex.brass, 3/B NPT
SCREEN, inlet
NUT,
brass, adapter
HOSE, coupled,
1 /2 NPT (MBE)
SLEEVE ASSY
17-1 /2” lg
LABEL
#6-32 NC x 5/16
SCREW,buttonhd,
QTY
4
2
8
18
4
12
4
9
1
2
1
1
1
1
2
1
1
1
2
1
2’
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
1
1
2
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801-456 9
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REFPARTDESCRIPTION
NO. NO.
ON
Items 77-90 are pump internal replacement parts.
See exploded view of pump for details.
77801-027 . CAP
78 801.028 .
O-RING, cap
79 801-267 . DISCHARGE
80
81
82
84
83
85
86
87
88
89
90
WASHFR
MANIFOLD
STUD
O-RING
RETAINER,
plunger
. RING, backup
1
1
3
1
3
3
3
3
3
3
3
3
3
3
Order parts by name and number. Always give the model
number andseries letter
of the assembly forwhich you are
ordering.
I T2-
' T3-
q
T6
I T7-
ELECTRICAL SCHEMATIC
I
801-042 SEAL KIT
SERVICE TOOLS
KEY WRENCH
801-044
EXTRACTOR TOOL 801 -205

i
F
PARTS DRAWING
Gun and Hose Assembly
\
Repair Kit 801 -083
'd Includesitems A, 6, C. D. E and F
- & PARTSLIST
REF PART
NO.NO.DESCRIPTION
QN
1 801 -007 SPRAYHOSE, 318" ID, 50 ft.
I1 5 rnl Io 1
<. - ...I .-
2 800-043 SPRAYGUN, (replaceable parts
1
SERVICE
include items 3-1 8)
7 Rtll-AlQ UANnlF
handle. Unscrew both short and long tubes with
fittings(12and15)from valve body (10). Valve
8 OUI-LOL . I
body should now slide out of the handle through
9 801-422 . I
10 801-247
. \
the access plate opening. 11
801-253 ..I
49 on, Am :
- ". _.I . ..,,..I" i
1. Pressaccesspin(17)fromgunhandleandremove
4 801-427 . ACCESSPLATE
5 801-249 . SPRING
1
1
1
801-256 . NEEDLE 1
qEX PLUG
ISCHARGE FITTING
1
4ALVE BODY
1
1
5UlDE SLEEVE 1
1
1
1
1
1
1
1
20801-029 GRIP
1
4. Remove thesleeve nut (11) ado-ring (E) with the
1
21 801 -009 COUPLER, femalequickdisconnect 3
1
23801-073 HOUSING, nozzle 2
24 *801-010
TIP, blasting; Oo
.)E *anr.nrr TIP, 150
1
JARD, tip
1
PPLE, hex; 1 /4 x 3/8" npt: brass 1
2
yv I dUPLER, male quick disconnect 2
access plate (4)by slidingplatetowards back of 6 801-424 . TRIGGER
,%A. mn"
IL ""I"L" . rUBE
13 801.423 ,
INLET FITTING
2. Remove the cap (14). spring (5) andball (A) from 14 801.250 . CAP
the valvebody (10). 15801-421 . TUBE
16 801 -425 . SAFETYLATCH
lCCESS PIN
ATCH PIN
BE.
32
actuatorrod (F). 22 '801 -090 COUPLER, male quickdisconnect
tapthe
3. Remove the snap ring (E). Thenremovethe valve 17 801-428 .
seat (C) and O-ring (D).
18801-426 . I
19801-134 TL
5. Afterinstallingthenewseat(C)andball(A).'
balllightlywith a hammertoassure a proper
26801-074 GL
seatingbetweentheballand seat. 27801-103 NII
90 *an, nor P<
" ". -. . ...
6' Reassemble in Order' Use pipe Sealant On Orderparrs by name andseries letter of the assembly for
pipethreadsonbothshortandlongtubes(12and which you are ordering,
15) 'Recommended "tool box" spare parts.
801-456 14
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ACCESSORIES (Must be purchased separately)
""1
.s,m#&" ~~~~~
CHECKVALVE 801-1 33 CHEMICALINJECTORKIT800-102
Prevent back upofcontaminatedwaterintofresh For injecting harsh cleaning chemicals downstream
supply. Install upstream from pump. from pump.
WATERSANDBLASTER 800-103 . ADJUSTABLESAND SAVER 801-031
For abrasivecleaning of stubborndirtandpaint. For adjustingsandflow.
TECHNICAL DATA
MOTOR: 5 hp, 3phase,
220 V, 60 Hz, 17 Amp
WATER PUMP: 21
50 PSI (1 50 bar) max
(1
5 liter/min).
pressure; 4 GPM
WElTED PARTS: Stainless Steel, Aluminum,
Liners,NitrileRubber.
Phenolic Plastic, Ceramic
WEIGHT: 160Ibs
OVERALLDIMENSION: Length: 36
in (914mm)
Width: 26
in (660 mm)
Height:
26 in (660 mm)
MAX. WATER TEMPERATURE: 1 6OoF (7OoC)
INLET HOSE CONNECTION: 3/4-in. gardenhose (f)
THE GRACO WARRANTY
GracoInc.warrantsallequipmentmanufacturedbyi1andbearingitsnametobefreefromdefectsin
material and workmanship under normal use and Service. This warranty extends to the original
purchaserforaperiodof
12monthsfromthedateofpurchaseandappliesonlywhentheequipment
is installed and operated in accordance with written factoryrecommendatians. Thiswarrantydoes
abrasion.corrosion.negligence.accident.substitution of non-Gram parts.faultyinstallation or
notcoverdamage or wearwhich, in the reasonablejudgment of Graco. arisesfrom mlsuse.
tampering.
This warranty
is conditioned upon the prepaid returnof the equipment claimed tobe defective for
examination by Graco toverify theclaimed defect.
If the claimed defect is verified. Gram willreDair
or replacefree of charge,anydefectiveparts. The equipmentwill be returned to the oriinal
purchaser transportation prepaid. If inspection of the equipment does not disclose
any defect in
workmanshipor material. repairs
will be madeatareasonablechargeandreturntransportationwill
be charged.
\BILITIES INCLUDING PRODUC
. .. . . .... . . . . .. -. . ... . -- - . - ..
sold by Gram that are not manufactured by Graco(Such as electrlc motors. switches, hose. etc.Jare
EQUIPMENT
NOT COVEREDBY GRACO WARRANTY. Accessories or components of equipment
assistance in making such claims.
Subject to the warranty. ifany, of their manufacturer. Graco will provide purchaserwith reasonable
FactoryBranches: Atlanta, Dallas. Detroit. Los Angeles. West Caldwell IN.J.1
Subsidiary and Affiliate Companies: Canada; England; Switzerland: France; Germany: Hong Kong; Japan
GRACO OMC. P.Q. BOX 044q RWIWMEAPOLPS. MRl 55440-0444
PRINTED IN U.S.A. 801-456 Rev A 7/83
45-1005OA