Graco Hydra-Clean 4040 Instructions- Operation manual

INSTRUCTIONS-PARTS LIST
This manual conteins IMPORTANT
WARNINGS
and INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
HYDRA-CLEAN @ 4040
Pressure Washer
Model 800-345, Series A 230/460 Volt, 3 Phase
4ooo psi (276 bar) OPERATING PRESSURE
4300psi (296 bar) MAXIMUM WORKING PRESSURE
GRACO INC. RO. Box 1441 MINNEAPOLIS,MN 55440-1441
@COPYRIGHT 1990, GRACO INC.

~
BNG
HIGH PRESSURE SPRAY CAM CAUSESERIOUS INJURY.
FOR PROFESSIONAL USE ONLY. OBSERWE ALL WARNINGS.
Read and understand all instruction manuals before operating equipment.
FLUID INJECTIONHAZARD
General Safety
This pressure washergeneratesvery high fluid
pressure.Sprayfromthegun,leaksorruptured
components can injectfluidthrough your skinandinto
your body and cause extremelyserious bodily injury
includingtheneedforamputation.Als0,fluidinjectedor
splashedinto the eyesor on theskincan cause serious
damage.
NNER pointthe spray gun or wandat anyone of at any
part of the body.
NNER put handor fingers over the
spray tip.
ALWAYS followthe PressureRellef Procedure,before
cleaningor servicingany part of the sprayer.
NNER try to stop or deflect leaks with your hand or
body.
properlybeforeeachuse.
Be sureequipmentsafetydevicesareoperating
Medical
Treatment
If any fluid appears to penetrateyourskin,get
NOTTREATAS A SIMPLECUT. Tell thedoctor exactly
EMERGENCY MEDICALTREATMENTATONCE.
DO
what fluid was injected.
NOTE TOPHYSICIAN: lnjection
in the skin is a
traumatic
injufg It Is Important to treat the Injury
surglcally assoon as posslble. Do not delay
treatment
to research toxicip Toxicily is a
concern with some exoticcoatings injected
directwintothe bloodstream. Consultationwitha
plastic surgeon or reconstructive handsurgeon
maybeadvisable.
Pressure Relief Procedure
To reduce the risk of seriousbodilyInjury, includingfluid
injectionandsplashing in theeyesorontheskin,
always follow thisprocedure whenever you stop
spraying for more than
10 minutes, when shutting down,
and before checkingorrepairinganypartof the system.
1. Engage the trigger safety latch.
2. Turn thesprayer off.
3. Disconnecttheelectricalsupply.
4. Shut off thewatersupply.
5. Disengagethetriggersafetylatch and triggerthe
safety latchagain.
gun
to relieve pressure, and then engage the trigger
6. Beforelong-term(overnight)storage,disconnect
the water supply and disconnect the electricity.
Spray Gun Safety Devices
Be sure all gun safety devicesare operating properly
thegun; thiscancauseamalfunction and result in
before each
use. Do not remove ormodifyany partof
serious bodily
injury.
SAFmLATCH: Whenever you stop sprayingfora
moment, always set the gun safety latchinthe engaged
0r"safe"position,makingtheguninoperative. Failure
to
properly set thesafetylatchcanresult in accidental
triggeringof the gun.
cleaning or changing spray tips.
If a spray tip clogs
SPRAY TIP SAFm Use extreme caution when
whilespraying,engagethegunsafetylatch
immediately.
ALWAYS follow the Pressure Relief
Procedure and then remove the spraytip
to clean it.
..
..
. ..
2 308-522

This productmustbegrounded. Ifitshould malfunction
or breakdown,groundingprovidesa path
of least
resistance for electriccunent
to reducetherisk of
electricshock.This equipmentisequippedwith acord
having an equipment-groundingconductoranda
groundingplug. The plug must be plugged Into an
appropriateoutlet that is properly installed and
grounded
in accordancewith all local codes and
ordinances.
DANGER
Improperconnection of theequipment-
groundingconductorcanresult in theriskof
electrocution.Checkwith aqualifiedelectrician
orserviceperson
if youare in doubtas to
whether the outletisproperly grounded. Do not
will not
fit theoutlet,haveaproperoutlet
modifythe plugprovidedwiththe product
- if it
installedby a qualifiedelectrician.
GROUND FAULT CIRCUIT INTERRUPTER PROTECTION
To complywith the National Electrical Code(NFPA 70)
and to provide additionalprotectionfromtherisk of receptacle that is protected by aground-fault
circuit-intempter (GFCI).
electric shock,connectthispressurewasher
to a .. ,
EXTENSION CORDS
Use only4-wireextensioncordsthathave4-prong
grounding-type plugs and 4-polecordconnectorsthat
' heat and sharp edges. Always disconnect the extension
orpullonany cord
to disconnect.Keepcordawayfrom
accept the plug from the product. Use only extension
cords that are intendedforoutdoor
use. These cord fromthereceptaclebeforedisconnectingthe
Droduct from the extension cord.
extensioncords are identified by amarking,
"Acceptable foruse withoutdoorappliances;store
1- WARNING -1
havinganelectricalrating not less than the ratingofthe
indook while not in
use." Use only.extension cords
product.Donotusedamagedextensioncords.
To reducetheriskofelectrocution, keep all
Examineextensioncordbeforeusing and replace
if
connectionsdry and off the ground.Donot
damaged.
Do notabuse extensioncordanddonotyank
touch plugwith wethands.
EQUIPMENT MISUSE HAZARD
General Safety
Any misuse of thepressurewasheroraccessories,
suchasoverpressurizing, modifying parts,using
damagedparts, can causethem
to rupture and
resultin
incompatible chemicals and fluids, or using wornor
fluid injection, splashing in the eyesor on the skin, or
other serious bodily injury, fire, -explosionor property
damage.
NNER alter or modifyany partofthisequipment;doing
so could cause it to malfunction.
CHECK all sprayequipmentregularly and repair or
replaceworn or damagedpark immediately.
This sprayer can develophigh operating pressure.
Be
System Pressure
sure thatallspray equipment and accessories arerated
to withstandthe maximum workingpressure of this
sprayer.
DO NOT exceedthemaximumworking
pressure of any component or accessory used inthe
system.
Chemical Compatibility
BE SURE that all chemicalsused in thechemical
hose, gun, wand andtip, as giveninthe Technical Data
injector are compatiblewiththewettedparts ofthe
manufacturer's literature before using any chemicalin
(inside back
cover). Always read the chemical
ALWAYS wear protective eyewear and appropriate
thechemical manufacturer'sliteraturefor
clothing.
If using a chemical injector, read andfollow
suchas a respirator.
recommendationson additional protective equipment,
this pressurewasher.
"
308-522 3

HOSE SAFETY
High pressurefluid in thehoses canbevery dangerous.
If the hosedevelops aleak, splitor rupture due to any
spray emittedfrom it can cause afluidinjectioninjuryor
kind
of wear, damage or misuse,the high pressure
other seriousbodily injury or property damage.
ALL FLUIDHOSES MUST HAVE STRAIN RELIEFSON
BOTH ENDS.
The strain reliefs help protect the hose
from kinks or bendsat or close
to the coupling, which
can resultinhoserupture.
TlGHTEN all fluid connectionssecurelybefore each
'use. Highpressurefluidcandislodgea loosecoupling
or allow high pressurespray
to be emitted fromthe
coupling.
NNER use a damaged hose. Beforeeach use, check
entire hose for
cuts, leaks, abrasion, bulging cover, or
damage or movement of thehosecouplings. If anyof
these condRions exist, replace the hose immediately.
DO NOT try to recouplehighpressurehose or mendit
withtape or any other device.
A repairedhose cannot
contain thehighpressure fluid.
HANDLEAND ROUTEHOSESCAREFULLY Do notpull
onhosestomovethepressure washer.
Do not use
chemicalswhichare not compatible wlth theinner
tube
andcover of the hose. DO NOT expose Gracohoseto
temperatwes above
2M)" F (93' G) M below -40' F
(-400 C).
MOVING PARTS HAZARD
Moving partscan pinch oramputatefingersorother PressureRelletProcedure before checking or
bodyparts.
KEEP CLEAR ofmoving parts when starting
or operating the pressurewasher. servicing the pressurewasher
to prevent discharging
highpressurefluidfrom the gun.
NNER operate the pressurewasher withoutall guards
and interlocks installed andfunctioning.Followthe
TERMS
conditionsthat couldcause bodily injury.
WARNING or DANGER Alertsuser to avoidor correct NOTE Identifieshelpfulproceduresandinformation.
that could cause damage to the equipment.
CAUTION Alertsuser to avoid orcorrectconditions
IMPORTANT
standards-particularly theGeneralStandards,Part1910, and the Construction Standards,Part 1926-should be
United States Government safety standards have beenadoptedunder the Occupational SafetyandHealthAct. These
consulted.
4 308-522

INSTALLATION
PUMP
MOTORDIPSTICKQUICK
PUMPOILLEVEL
INDICATOR
CONNECTION
314"
GARDEN HOSE (9
Figure 1
Check for Shipping Damage
Check the unit foranydamage that mayhaveoccurred
in shipping. Not@ thecarrier Immediately
if there is
any damage.
Set Up
Beforepluggingin the unit,besure theelectrical service
matchesthespecification
in TechnicalData (inside
back cover) andthe voltagelabel on the unit. With the
. ,
unit off, plug the power supply cord into a grounded,
GFCi-protected
outlet. Donotremovethe electrical
plug whichcomeswiththeunit or bend connecting
prongs tofit an improper outlet! Use an extensioncord
that meets the requirements
of the EXTENS/ON CORD
section andisno more than
100 fl(30 m) long. Added
lengthof cordwill affect current draw of unit.
betweenthepumpunloader and the high pressure
Ifyouareusinga downstream chemical injector,installit
hose, usingthe quick couplers provided.
Connectthehighpressurehosebetweenthepump
made with quick couplers.
outlet and the gun inlet. Both of these connections
are
CAUTION
and -1
beused. Longerhosesmayaffectsprayer
Up lo 100 ft (30 m) of high pressurehosemay
chemicalinjector
performance,if used.
Installtheappropriatespray tip on thewand.See
sandblaster kit, seeitsseparate manual forinstallation
lnstaliing and ChangingSpray
Tips. If you are using a
instructions.
Connect to Water Supply
CAUTION
Before attachingtothe water supply, check your
local plumbing code regarding
cross-
connection to the water supply.
A backilowpreventer, P/N 801 -1 33, isavailable
to prevent backflowof contaminated water Into
the fresh water supply. Install it upstream from
the pump.
Install a regulatingwater valve,
P/N 800-258, if
inlet water pressureisover €0 psi (4.1 bar).
temperature.
Do notexceed 160° F (70" C) inlet water
Connect ahosewithat least a
3/4 inch (19 mm) ID and
not longer than 50 fl(15 m) to theunit's 314 Inch garden
hose inlet.
NOTE mewatersourceatthe unit must havea
minimumflowrate equal
to that of the unit (see
Technical Data, insideback cover).
308-522 5

STARTUP
Always use thisstartupprocedure to ensure that the unit
isstarted safely and properly.
1. Checkthe oil level.
Pump: Add SAE
XI or 30 weight non-detergentoil
asnecessary.
I
2. Tum on the watersupply.
CAUTION
Never run the unit dry. Costly damage to the
pump will result.Always be sure the water
supply
is completelytumed on before
operating.
3. Triggerthegun until waterspraysfromthe tip
indicatingthat
the air ispurgedfrom the system.
4. Plugtheelectrical cord into proper,grounded,
GFCI-protected
outlet.
5. ALWAYS engagethegun’striggersafety latch
whenever youstop spraying,
even for a moment to
reduce the riskof fluidinjectionor splashinginthe
eyesor on the skin
if the gunisbumpedortriggered
accidentally.
6. ALWAYS observe thefollowing CAUTIONS toavoid
costly damage
to the pressure washer.
CAUTION
DO NOT allow the pressure washer to idle for
more than
10 minutes. Doing so may cause the
recircuiating water lo overheat and seriously
damage the pump.Tum
off the pressure washer
ifitwillnot
De sprayingorcleaningat leastevery
this timefurther.
10 minutes. If heated inlet waterisused, reduce
DO NOT run the pump dry, which will quickly
fully tumed on before starting the pump.
damage the pump.
Be sure the watersupply is
DO NOT operate the pressure washer with the
inletwater screen removed. This screen helps
keepabrasivesediment
out of the pump, which
could clog or scratchthepump,Keepthis
screen clean.
DO NOT pump caustic materiais;such
materials may corrodethe pump components.
7. See thechemical injectoror sandblasterkitmanual
for detailed cleaninginformationifthese
accessories are used.
Trigger Safety Latch
WARNING
To reduce the risk of serious bodily injury,
includingfluidinjection, splashinginthe eyesor
on the skin,
ALWAYS engage the trigger safety
latch whenever spraying
stops, evenfora
moment.
In
the engaged position, the trigger safetylatch
preventsthegunfrom being triggered
accidentally by hand or ifit is dropped or
bumped.
Be sure thelatchispushedfullydown
when engagingit or it cannot prevent the gun
from beingtriggered.
See Figure 2.
TRIGGER SAFETY LATCH SHOWN ENGAGED
TRIGGER SAFETY LATCH
SHOWN DISENGAGED
Figure 2
6 308-522

Installing and Changing Spraylips
WARNING
To reduce therisk of serious bodily injury,
includingfluid injection
or splashing inthe eyes
orontotheskin,useextremecautionwhen
changingspraytips.
ALWAYS follow the
procedure below.
1. Follow the Pressure Rellet Procedure.
2. Pointthegunandwandaway from yourselfand
anyone
else.
3. Without holding your handoverthespray tip (A),
pullbackthe quick coupler ring (B), remove thetip
and then release the ring.
See Figure 3.
4. Be surethe tip is securebeforestartingtospray
again.
5. Tip holdingholesare providedon the chassis.
CAUTION
To avoid blowing theO-ring out of the qulck
coupler, dueto the high pressure
in the system,
never operate
the pressure washer withouta tip
securely mounted in the quick coupler.
Figure
3
308-522 7

SHUTDOWN, FLUSHING
AND STORAGE
WARNING
Pressure Rellef Procedure
To reducetherisk of serious bodily injury,
eyes,or ontheskin,always follow this
including fluid injectionandsplashing in the
procedurewheneveryoustop sprayingfor more
than
10 minutes,whenshuttingdown,and
before checking or repairing any part ofthe
system.
1. Engagethetriggersafetylatch.
2. Tum the sprayer off.
3. Disconnectthe electrical supply.
4. Shut off thewatersupply.
5. Disengage thetriggersafetylatch and
trigger the gun to relieve pressure, and then
engage the trigger safety latchagain.
6. Beforelong-term (overnight)storage,
disconnect
the water supplyand
disconnect the electricity.
1. If the pressure washer will be exposed to freezing
temperatures, drainall water out of the pump. If it
must be stored in freezing temperatures, flush the
pressure. Flush the pressure washer beforeusing
it
unitwitha 50% anti-freezesolution.Relieve
again
to remove the anti-freeze.
NOTE: An anti-freezeflush kit P/N 802-327 is
available
to make flushingeasier.
CAUTION
Ifwater does freeze in thepressurewasher,
thaw it
in a warm room before trying tostart it.
DO NOT pour hot water on or into the pump; it
2. After each use, wipe all surfacesofthepressure
washer with a clean, damp cloth.
3. Perform the appropriatemaintenance. See the
maintenance chart.
MAINTENANCE
Observing regular maintenance intervalshelps ensure
that you get maximum performance and life from the
pressure washer.
There isa break-inperiodfor the pump. Afler changing
the oilinitially, the interval between required changes
Is
longer.
WARNING -I
To reducetherisk of serious bodily injury,
includingfluidinjection, splashinginthe eyes or
on
the skinor injury frommovingparts, always
followthe
Pressure Relief Procedure Warning
interval What to do
Daily Cleanwater inletscreenand
filter. Check pumpoil level. Fill
as necessary.
Afterfirst
50 Changepumpbreak-in oil. Use
hours of SAE 20 or 30 non-detergent oil.
operation
Each
500 hours Change pumpoil. Use SAE 20 or
of operationor
30 non-detergent oil.
6 months
I
E 308-522

TROUBLESHOOTING CHART
WARNING
To reduce the risk of seriousbodilyinjury, including fluid injection, splashing in the eyes or on the skin, or
injury from moving parts, alwaysfallow the Pressure Relief Procedure Warningbefore proceeding.
PROBLEM
DW pressure and/or
ump runs rough
rater leakage from
nder pump manifolc
rater
in pump
'eqequent or
emature failure of
18 packings
lrong surging at the
let and low pressurt
1 the discharoe side
nit
will nd start
CAUSE I SOWTION
Wom or wrong size tip.
Inlet filter clogged.
Wom packings, abrasives
in water or
natural wear.
Inadequate water supply.
Coupling slippage.
Fouled
or dirty inlet or discharge valves.
Even a small particle can cause the valve
lo stick.
Reslricted inlet.
Worn inlet or discharge valves.
Leakina hiahmsurehose.
Replace withtip
of proper size.
Clean. Check more frequently.
Checlc filter. Replace packings.
See PUMP SERVICE.
Check water flow
rate to pump.
Tighten or replace.
filter.
Clean Inlet and discharge valve assemblies. Check
Check
garden hose. may be collapsed or kinked.
Replace worn valves.
Reolace hlahmwrehose.
Wom packings. Install new packings.
See PUMP SERVICE.
Humid air condensing inside crankcase. Change oilas specifiedinMAINTENANCE.
Wom packings. Install newoilseals.
See PUMP SERVICE. Oil seals leaking.
Install new packings.
See PUMP SERVICE.
Scored, damaged or worn plungers. Install new plungers.
See PUMP SERVICE.
Abrasive materialinthe
fluid being pumped. Install proper filtration on pump inlet plumbing.
Inlet water temperature
too high. Check water temperature; may
not exceed 160°F.
Overpressurizing pump.
Do not modify any factory-set adjustments. See
EQUIPMENT MISUSE HAZARD.
Excessivepressuredue to partiallypluggedorreplace tip. See InstallingandChangingSpra)
or damaged tip.
Pump running
too long without spraying.
valve or wom inlet and/or discharge valves.
Running pump dry.
Never run pump more than
10 minutes without spraying
Foreign particles
in the inlet or discharge Clean or replace valves.
See PUMP SERVICE.
Unit not plugged
in.
Check power cord.
Electrical service off/GFCI activated. Check fuse/circuit breaker. Check for proper
mermai overload has tripped.
Do not
run pump without water.
grounding.
Press stop button on the motor starter.
308-522 9

PARTS DRAWING
800-345 Hvdra-Clean@ 4040 Pressure Washer
For wiring diagram, see page
14
~~~~~
10 308-522

PARTS LIST
800-345 Hydra-Clean@ 4040 Pressure Washer
REF
NO.
1
2
3
4
5
6
7
8
10
9
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
27
28
30
29
31
32
33
34
PART
800-579PUMP & MOTORASSEMBLY
NO. DESCRIPTION QN
(see page 15)
803-554BRACKET,PumpSupport 1 1
801-382CORD,Power10/4
803-263BRACKET.Starter.
left
48 in
1
802-732WASHER.Flat #6
159-239NIPPLE,Hex 1/2 x 3/8 2
4
802-731WASHER: Lock
#6 4
803-484SCREW,Cap, panhd.4
803-517LABEL,KeepFromFreezing
1
800-427UNLOADER, 4ooo psi
800-450HOSEASSEMBLY, w/Quick 1
801-009QUICKCOUPLER, Femaie 1/4
Couplers (includes14,18,
20) 1
154-594 O-RING, (includes Quic 13L Coupler1/4 1
1
801-568QUICKCOUPLER, Male3/8
2
802-534NIPPLE,Hex1/2NPSM X
112NPT
803-141HOSE,Bvoass 1 1
803-395LABEL, Model40401
803-519HOSE, HighPressure3/8x
50 ft1
fincl.12.20.28.29.34.35)1
800-429GUN &WAND ASSEMBLY
803-157QUiCKCOUPLER,Femaie 318
(includes 21)2
402-278PLUG. Plastic
156-082 OkNG,QuicikCoupler3/82 1
804-051STRAiNEWFiLTER1 801-110ADAPTER, GardenHose
801-111NUT,Garden Hose 1 1
801-106 TEE.112 1
801-957
SLERIE, 18” 1
803-262BRACKET,Starter, right1
801-134WAND, 32 1
800-441CHASSiS1 802-993PLUG,-Locking15hp,460volt1
803-186LABEL,Cordset
803-351GUN,Spray,SST
(See
1
InstructionManual308-51 1)1
REF
35
NO.
36
37
38
39
40
41
42
43
44
45
46
47
49
48
50
51
52
53
55
54
56
57
58
59
61
60
62
63
64
PART
NO.DESCRIPTION
ON
803-591WASHER, Flat 1/2
156-849NIPPLE,Hex3/8
1
4
802-784WASHER, Lock 112 4
1/2-13
X 1-1/24
5
(includes 45, 60) 1
(includes
45, 61) 1
(includes
45, 62)1
803-592SCREW,Cap,hexhd.
801-012GROMMET.,Rubber
800-124TIPASSEMBLY,
OOO4
800-125TIPASSEMBLY,1504
800-126TIPASSEMBLY,2504
800-127TIPASSEMBLY.
4004
~~~
(includes 45,’63)~
801-WBDECAL.GracoG
2
1
Soi-Os0 QUICKCOUPLER, Male 1/4 4
176-250LABEL,Warning, chassis
176-981LABEL,Warning. chassis 1
1
803-396LABEL,WamingICavtion1
2
2
2
~
100-527 WASHER, Flat 5/16
100-21 4WASHER, Lock 5/16
100-188 NUT, Hex 5/16-18
803-007LABEL,Caution,230 volt,
3 phase
3phase152
8n
803-006LABEL,Caution,460 volt,
801-382CORD.Power12/4
801-226CONNECTOR,Wire4
1
802-81
1 CORD’GRiP
804-043SWITCH.Starter.15
hD 230 Volt 1
3
803-749SWITCH:Starter:15
hp 460 Volt 1
801-937 NUT. Lock. electrical 1
801-523
NIPPLE, 1i2 X 2
801-221 TERMINAL. Rina
801 -599 TIP, Spray
6004’
80-600 TIPSDrav1504
801-661
TIP; sprai, 2504
801-602 TIP SDrav 4004
801-304 TERMINAL, Ring
308-522
11

I
53
Model4040
Wirlng Diagram
230 Volt. 3 Phase
Model4040
Wring Diagram
460
Volt, 3 Phase
12 308-522

PARTS DRAWING
800-579 Pump and Motor Assembly
PARTS LIST
800-579 Pump and Motor Assembly
REF
NO.
2
1
3
4
5
6
7
8
9
10
11
PART
NO.
803-584
802-698
802-540
802-784
803-750
802-508
801 -559
802-783
802-794
100-527
803-552
DESCRIPTION
MOTOR, 15.0hpTEFC, 3 phase 1
COUPLER,15hp 1
WASHER,Lock 1/2
HOUSING
4
1
SCREW, Cap, socket hd.
1/2-13
X 3 4
PUMP (see page 16)
WASHER,Lock 5/16
4
1
SCREW, Cap, hex hd. M8 x 30 4
KM, Motor
KM, Pump
1
RING, Adapter
1
1
QTY
308-522 13

PARTS DRAWING
803-508 Pump Assembly, 4000 psi
45
1
-/-
/
/-
14 308-522

PARTS LIST
803-508 Pump Assembly, 4000 psi
REF
NO.
1
2
3
4
5
7
6
8
10
9
11
13
12
14
15
17
16
18
19
21
20
22
23
24
25
26
27
PART
NO. DESCRIPTION
. .....
801-647MANIFOLD
~~ ~
801-468SCRNV,Cap,hexhd.
~~ ~~~ ~-
801-469WASHER. Lock
KIT 1
KIT 1
KIT
1
KIT 1
KIT 1
KIT 106
KIT
1
KIT 106
803-283
803-506
802-500
803-324
KIT 2
803-286
803-501
801 -475
803-1
44
803-287
803-288
802-794
803-289
803-503
803-291
803-292
O-RING
SEAT, Valve
SPRING
PLATE, Valve
GUIDE, Valve
CAP
VALVE ASSEMBLY
SCREW, Cap, sockethd.
COVER,Crankcase
O-RING, Crankcase Cover
BEARING, Tapered Roller
SEAL, Oil
BUSHING, Piston
CRANKCASE
DIPSTICK
CRANKSHAFT
GASKET, Cover
KEY
RING, Retaining
PIN, Wrist
GUIDE, Piston
ROD, Connecting
SCREW, Cap, socket hd.
O-RING
QTY
1
8
8
8
2
1
2
1
1
1
1
6
1
1
3
3
3
5
REFPART
NO.
28
29
30
31
33
32
35
34
36
37
39
38
40
41
43
42
44
45
46
51
47
52
54
53
803-507COVER, Crankcase
NO. DESCRIPTION
802-345GAUGE, SigM
802-793PLUG, OilDrain
803-294 SCREW, Cap,
socket hd.
801-490PLUNGER, Ceramic
KIT107WASHER, Flinger
803-502PLUNGER,Ceramic
KIT107RING, Backup
KIT107SCREW, Piston
803-505COVER,Crankcase
KIT 3 SEAL, Oil
KIT107O-RING
801-652WASHER, Lock
KIT107WASHER
803-296SHIM
KIT 109
KIT 109
KIT 109
KIT 112
KIT 109
KIT 109
801-482
KIT 109
801
-483
801 -484
801 -485
O-RING
RETAINER. Packing
PACKING
PACKING
RING, Head
RETAINER, Packing
RING, LongLife
PLUG, Hex
WASHER,Flat
WASHER, Flat
PLUG,Hex
QTY
1
1
1
6
6
3
3
2
1
1
1
1
1
Klt
1
QW
Descrlption
No.
Part No. No.
Ret.
Repalr Kit
O-RING
4
801-472
Valve
5
SEAT, Valve 6
6
6 PLATE, Valve 6
7
8 6
SPRING 6
GUIDE,Valve
.
2
801-473
16 SEAL. Oil 3
11 6
VALVEASSEMBLE
Oil Seal Kit
Crankshaft
Seal
ValveCap
4000 psi CAP
10
3 2
SEAL,
Oil
41
802-511
106 O-RING
9
802-509
6
6
Kk
QiY. Descrlptlon
No.
Part No. No. Ref.
Repalr Kit
PlungerWASHER, Flinger
RepairRING, Backup
PlungerWASHER, Flinger
RepairRING, Backup
Retainer Packing
RING. Head
PACKING
It I46 I RETAINER, I1
II
.
112 6
PACKING
44 803-512
4ooo psi
Packing
308-522
15

PUMP SERVICE
I WARN'NG 1
Servicing the Plungers
To reducetherisk Of serious bodily injury,
including
fluid injection, splashinginthe eyes or
NOTE Plungerrepairkit,P/N 803-510isavailable to
replace retainers,O-rings,washersand
onthe skin, orinjury from moving parts, always
followthe
Pressure Relief Procedure Warning
backupringsfor threecylinders.
I beforeproceeding.
NOTE: The following metricwrenchesareneeded: usinganM10 wrench. Push theplunger towards the
crankcase
to separatetheplunger and retaining
I 1. Loosentheplungerretainingscrew five to sixtums,
-
M10, M13 aniM30.ReDair kitsare available. screw.
..
1.
2.
3.
4.
pump partspagefor moredetails.Forthebest
Refer
to the individual repair sectionsand the
results, useall partsinthe kits.
NOTE Thereare two different tool kits to aidin
servicing thepump. P/N 800-298 is used
to
easeinstallation of packings.P/N 800-271
includes
the items in 800-298 and tools to aid
inthe removalof packingretainers.
Valves
NOTE For a set of six valves, order P/N801 -472.
Remove the hex plugfrom the manifoldusing an
2.Removethescrewfromtheplunger and examine
washer. Replacethese parts,
if necessary,usingkit
the O-ring,backupringandcopperbearindgasket
803-510.
3.Removethe plunger and flinger from theplunger
shaft.Clean,examineand replace partsas
necessary.
4. Inspecttheplunger shaftfor oil leakagefromthe
crankcase.Ifleaking is obvious,replacethe oil
seals. Otherwise,
DO NOT remove these seals as
they cannotbereused.
An oilsealkit is available to
replacethe seals.
M30 wrench.
Examine the O-ring under the hexplugandreplace
it if itiscut ordistorted.
.-
5. Lightlygreasethe oil seal, if it is being replaced,
and theflingerandreplace them on the plunger
shaft. Theninstallthe plunger.
Remove the valve assembly from the cavity; the
assembly maycomeapart.
lnslallthe newvalve. Installthe O-ring and hexplug;
torque
to 75 ft-lb (103 Nm).
6. Lightly grease the retaining screwandthe outer end
of the plunger. Place the washer, O-ringandbackup
ringaround the screwandinstallthe screw through
the plunger. Torque
to 14.4 ft-lb (19.5 Nm).
NOTE: If vou plan to replacethePackinas. refer to
NOTE Retorque theplugafter 5 hours of operation.
Pumping Section
1. Remove the eight capscrews and lockwashers from
the manifoldusingan M13 wrench.
2. Carefully separatethemanifold
from the crankcase.
NOTE: It maybenecessary to tap themanifoldlightly
with
a soft mallei to loosen.
Keep
the manifold properly aligned withthe
ceramicplungers whenremoving
to avoid
damage to the plungeror seals.
Sitvicingthe V-backings.
'
-
7. Lubricatetheoutside of each plunger. Slide the
manifold
onto the crankcase, being careful not to
damage the seals.
8. Installthecapscrews and washersfinger-tight.
Torque the screws
to 21.7 ft-lb (29 Nm)followingthe
tighteningpattem (Figure4).Uneven tightening
may cause the manifold
to bindor jam.
I I
3. Carefully examine each plunger for any scoringor
crackingand replaceas necessary.
Figure 4
16 308-522

ServicingtheV-Packings 5. Thoroughly cleanthe packingcavitiesandexamine
NOTE There are two lypes of packing kits:one is for debris and damage.
1.
2.
3.
4.
pacltlngsonly,theother includes the
packings, rings
and retainers.
Remove the manifold as outlined In the Pumping
Section.
Carelully pull the packing retainerfrom the
manifold. Examine the O-ring andreplace
It if it is
cut or damaged.
Remove thev-packing and head ring. Pull outthe
v-packing andsecond head ring.
intermediateretainerring.Removethe second
inspect all parts and replace as necessary.
6. Lightlygreasethe packing cavitiesandthen
replace the packings in the following order: head
ring,v-packing.intermediatering, head ring,
v-packingand packing retainer with.theO-ring
installedInthe retainer groove.
CAUTION
the correct direction. Improperly installed parts
Install the partsin
the proper order andfacing
will cause a malfunction.
7. Reassemble ¶hemanifold as instructedinServicing
the Plungers.
308-522 17

~
ACCESSORIES
(Must be purchased separately)
DOWNSTREAMCHEMICALINJECTORKITWATERSANDBLASTINGKIT800-120
800-649
For abrasivecleaning of stubborndirt and paint.
from the pump. Stainless steel construction.
For injecting harshcleaningchemicalsdownstream kit.
Requires a spraytip
(801-600) which isnot included in
UPSTREAM CHEMICAL INJECTOR KIT
ANTI-FREEZE FLUSH KIT 802-327
800-257
Forflushing system with 50% anti-freeze solutionprior
For injectingmildcleaning chemicals upstreamintothe
to transporting or storingpressurewasher in below
Pump. freezing temperatures.
BACKFLOWPREVENTOR801-133INLETPRESSUREREGULATOR800-258
Prevent back-up of contaminatedwaterintofreshRegulatesinletwaterpressure to 60 psi (4 bar)
supply. Installupstream
of pump.maximum.
TECHNiCAL DATA
High Pressure Hase Acrylonitrile and Buna-Ncoverandtube
Synthetic yam and
EPDM
PressureWasherAnodizedaluminum,AluminumorBronzealloys, Brass, Copper,Nylon-TefionQcomposite.
(including fittings) Thermoplastic. Teflono, Carbon
Steel, Zinc with or without Yellow Chromare Plate
Ceramic, Buna-N, Conon Phenolic. 303,304, and 316 Stainless Steel. Polymide-12

THE GRACOWARRANTY
WARRANTY ANDDISCLAIMERS
Gramwarrants ail equipment manufachrredby fi and bearing its nameto be frea from defects in material
andwo~manshiponthedateofsaiebyanauthorizedGramdistnbutortotheonginalpurchaserforuse.
As purchaser's sole remedy for breachofthiswarranty, Graco will, for a period of twenty four months from
the equipment is installed.operated and maintained in accordancBwith Gram's written
dateofsale,repairorreplaceanypartoftheequipmentpmvendefscthe.Thiswarran~appliesonlywhen
recommendations.
This warranty does not cover. andGram
shall not be liable for, any malfunction. damage or wear caused
by
tauily installation.misapplication.abrasion,corrosion,inadequateorImpropermaintenance,
negligence. accident, tampering, or substihltion
of non-Graco component parts Nor shall Graco be
accessories.equipmentormaterialsnot supplied by Graco.ortheimproperdesign,manufacture,
liableform~nction,damageorwearcausedbytheinmmpatibilitywithGramequipmentofsfruchrres,
installation. operation or maintenance of sfruotures. accessories.equipmentormaterials not supplied by
Grm.
Thii warrantyis conditioned upon the prepaid return of the equipment claimed to be defective for
examinationby Gram
to verify the claimed defect. If me claimed defect isverified. Graco will repair or
replace
free of charge any defecthe parts. The equipment will be returned to the original purchaser
transportationprepaid.
If inspection of theequipmentdoesnotdisclose anydefect in materialor
workmanship. repairs will
be madeatareasonable charge. which charges mayinclude thecosts of parts.
labor and transportation.
METERMSOFTHlSWARRANPlCONSTiTUTETHEPURCHASER'SSOLEANDEXCLUSlVEREMEDY
DISCLAIMERSAND LIMITATIONS
ANDAREINLlEUOFANYOTHERWARRANTIES(EXPRESSORIMPLIED),lNCLUDlNGWARRANTYOF
NON-CONTRACTUALLIABILITIES. INCLUDING PRODUCTLIABILITIES. BASEDON NEGLIGENCEOR
MERCHANTABILITY
OR WARRANTY OF FITNESSFOR A PARTICULARPURPOSE,AND OF ANY
STRICTLIABILITY:
EVERY FORMOF UABiLlTY FOR DIRECTSPECIAL OR CONSEQUENTIAL
DAMAGES
OR LOSS IS EXPRESSLYEXCLUDEDANDDENIED. IN NOCASESHALLGRACOS
LIABILITYEXCEEDTHEAMOUNTOFTHEPURCHASEPRICE.
ANY ACTIONFORBREACH OF
WARRANTY MUST BE BROUGHT WITHIN THREE (3) YEARS OF THE DATE OF SALE.
EQUIPMENTNOT COVERED BY GRACOWARRANTY
GRACOMAKESN0WARRANPl.ANDDiSCLAlMSALLIMPLIEDWARRANTIESDFMERCHANTABlLlTY
ANDFITNESSFOR A PARTICULARPURPOSE,WITHRESPECTTOACCESSORIES,EQUIPMENT
notmanufacturedbyGraw(suchaselectricmotor,switches,hose,etc.)aresubjecttothewarranty,ifany.
MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold,but
of their manufacturer. Graco willprovide purchaser with reasonable assistance in making any claim for
breach of these warranties.
IMPORTANT PHONE NUMBERS
TO PLACE AN ORDER, wntacd your Graw distributor, or call this number to identify the
distributor closest to you: 1-800-328-021 1 Toll Free
FOR TECHNICAL ASSISTANCE, service repair information or assistance regarding the
application of Graw equipment: 1-800-543-0339 Toll Free
Subsldlary and AffiliateCompanies: Canada; England; Swiizeriand; France; Germany; Hong Kong: Japan: Korea
Factory Branches: Atlanta, Chicago. Dallas, Delmi. Los Angeles. West Caldwell (N.J.)
GRACO INC. PO. BOX 1441 MINNEAPOLIS,MN55440-1441
PRINTEDINU.S.A. 308-522 1/91