Graco Hydra-Clean 6880242 Series Operation manual

6000134
Rev. H
First choice when
quality counts. 
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.

PORTABLE, STAINLESS STEEL
Hydra-Clean
Pressure W ashers
193 bar ( 2800 psi ) Maximum Working Pressure
Model 6880242*, Series D (shown)
The Graco warranty will not apply if cleaning
solutions other than those recommended by
Graco are used in these units. Only use
solutions that are not harmful to the wetted
parts. See the T echnical Data on page 9.
GRACO N.V. ; Industrieterrein ’’ Oude Bunders ’’
Slakweideweg 31 , 3630 Maasmechelen , Belgium
COPYRIGHT
1999, GRACO INC.
Tel. : [phone] ; Fax : [phone]
238 bar(3400 psi ) Maximum Working Pressure
Model 965389, Series A
II 2 G
28:1 Ratio King
34:1 Ratio Premier
* Package only available in Europe.

2 6000134
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Performance Chart 9. . . . . . . . . . . . . . . . . . . . . . .
Technical Data 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco W arranty . . . . . . . . . . . . . . . . . . . . 16
Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . 16
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury .

This equipment is for professional use only .

Read all instruction manuals, tags, and labels before operating the equipment.
 Use the equipment only for its intended purpose. If you are unsure about usage, call your Graco
distributor.

Do not alter or modify this equipment. Use only Graco parts and accessories.
 Check equipment daily . Repair or replace worn or damaged parts immediately .

Do not exceed the maximum working pressure stated for your equipment. Do not exceed the
maximum working pressure of the lowest rated component in your system.
 Do not lift pressurized equipment.
 Handle hoses carefully . Do not pull on hoses to move equipment.
 Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82  C (180  F) or below –40  C (–40 F).
W
ear hearing protection when operating this equipment.
 Comply with all applicable local, state, and national fire, electrical, and safety regulations.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
 Know the specific hazards of the fluid you are using.
 Store hazardous fluid in an approved container . Dispose of hazardous fluid according to all local,
state and national guidelines.
 Always wear protective eyewear , gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer .

3 3
WARNING
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely
serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also
cause serious injury .

Fluid injected into the skin is a serious injury . The injury may look like just a cut, but it is a serious
injury . Get immediate medical attention.
 Do not point the gun at anyone or at any part of the body .
 Do not put your hand or fingers over the spray tip.
 Do not stop or deflect leaks with your hand, body , glove or rag.
 Always have the tip guard and the trigger guard on the gun when spraying.
 Be sure the gun trigger safety operates before spraying.
 Lock the gun trigger safety when you stop spraying.
 Follow the Pressure Relief Procedure on page 6 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
T ighten all fluid connections before operating the equipment.
 Check the hoses, tubes, and couplings daily . Replace worn, damaged, or loose parts immediately .
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and re -
sult in a fire or explosion and serious injury .
 Ground the equipment and the object being sprayed. Refer to Grounding on page 4.
 If there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing immediately . Do not use the equipment until you identify and correct the problem.
 Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
 Keep the spray area free of debris, including solvent, rags, and gasoline.
 Before operating this equipment, electrically disconnect all equipment in the spray area.
 Before operating this equipment, extinguish all open flames or pilot lights in the spray area.
 Do not smoke in the spray area.
 Do not turn on or of f any light switch in the spray area while spraying or while operating if fumes
are present.
 Do not operate a gasoline engine in the spray area.

4 6000134
Installation
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below . Also read
the section FIRE AND EXPLOSION
HAZARD on page 3.
Grounding is essential to maintain a safe operating
system.
T o reduce risk of static sparking, ground pump. Check
local electrical code for detailed grounding instructions
for area and type of equipment. Be sure to ground all
equipment.
1.
Pump: use the ground wire and clamp (supplied).
See Fig. 1. Loosen the grounding lug locknut (W)
and washer (X). Insert one end of the ground wire
(Y) into the slot in lug (Z) and tighten the locknut
securely . Connect the other end of the wire to a
true earth ground.
2. Air and fluid hoses: use only electrically conductive
hoses. Use a maximum of 500 feet (150 m) com -
bined hose length to ensure grounding continuity .
3. Spray gun: ground through connection to a prop -
erly grounded fluid hose and pump.
4. Fluid supply container: follow your local code.
5. Object being sprayed: follow your local code.
6. Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place the
pail on a nonconductive surface, such as paper or
cardboard, which interrupts the grounding continu -
ity.
7.
T o maintain grounding continuity when flushing or
relieving pressure , hold a metal part of the spray
gun firmly to the side of a grounded metal pail,
then trigger the gun.
Fig. 1
XW
Y
Z
04111

5
Installation
06649A
Fig. 2
41
39
36
B
A
47
46
E
D
F
G
20
H
43
C
Pump Setup
See Fig. 2. Connect the suction hose (36) between the
pump inlet (A) and the suction tube (39), using thread
sealant on the male threads. Screw on the suction
tube filter (B). Place the suction tube in the supply
drum, and adjust it so it is 1 in. (25 mm) of f the bottom
of the drum. T ighten the thumbscrew (41) of the pipe
hanger onto the drum.
Connect the spray hose (46) to the pump outlet mani -
fold (43). Connect the spray gun (47) to the hose (46).
Use thread sealant on the male threads.
Fill the displacement pump wet-cup (C) 1/2 full with
Throat Seal Liquid, or a compatible solvent.
Refer to the separate instructions, supplied, for instruc -
tions on filling and adjusting the air line oiler (F),
Close the air shutof f valve (G). Then, connect a 3/4” ID
(minimum) air supply hose (D) to the 3/4 npt (m) air
manifold (H) swivel.
Ground the system as described on page 4.
An important step in installing this sprayer is to read
and understand each of the instruction manuals sup -
plied with sprayer . These manuals contain additional
warnings, cautions, and detailed instructions about
installing, operating, and servicing the various system
components.
for Model 6880242 only.
NOTE: The previous paragraph applies to Model 6880242
only. Model 965389 comes without suction hose and
tube, to allow different feed options.

6 6000134
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
Fluid under high pressure can be in -
jected through the skin and cause seri -
ous injury . T o reduce the risk of an injury
from injection, splashing fluid, or moving parts, fol -
low the Pressure Relief Procedure whenever you:
 are instructed to relieve the pressure,
 stop spraying/dispensing,
 check or service any of the system equipment,
 or install or clean the spray tips.
1. Engage the gun safety latch.
2. Close the air regulator .
3.
Open the bleed-type air shutof f valve.
4. Disengage the gun safety latch.
5. Hold a metal part of the gun firmly to the side of a
grounded metal pail, and trigger then gun to relieve
pressure.
6.
Engage the gun safety latch.
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, very slowly loosen the
tip guard retaining nut or hose end coupling and relieve
pressure gradually . Then, loosen completely . Clear the
tip or hose obstruction.
Pump Operation
Prepare the cleaning solution according to the
manufacturer’ s instructions. For your own safety , be
sure to observe all warnings. If you are using pow -
dered cleaners, mix them thoroughly in a separate pail
before adding them to a supply drum. Undissolved
powders are extremely abrasive and may damage
pump parts.
WARNING
W ear appropriate protective clothing, such as
waterproof outerwear and eye goggles, according
to the cleaner manufacturer ’ s recommendations.
Cleaning chemicals may be toxic, and cause
serious irritation to your eyes or skin.
See Fig. 2. T o start the pump, close the air shutof f
valve (G), close the air regulator (20) by turning the
t-handle all the counterclockwise until the spring ten -
sion is relieved. Open the shutof f valve, hold a metal
part of the gun firmly to the side of a grounded metal
pail, trigger the gun, and slowly open the regulator until
fluid comes from the gun. Release the trigger; the
pump will stall against pressure.
When supplied with an adequate air pressure and
volume, the pump will start and stop as the spray valve
is opened and closed.
Use the air regulator (20) to control pump speed and
fluid pressure. Always use the lowest pressure neces -
sary to get the desired result. Higher pressures will
waste the material and cause early spray tip and pump
wear.


Operation
WARNING
T o reduce the risk of overpressurizing the sprayer ,
NEVER exceed the Maximum Working Pressure
(see the Technical Data). Be sure all accessories
are rated to withstand the Maximum Working
Pressure of the sprayer.
Model 6880242 only:
through the sight glass when the pump is running.
Refer to the separate instruction manual, supplied, for
adjustment instructions.
Useful Hints
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
Protect surfaces that may be damaged by the cleaning
solution. Rinse the solution of f before it dries.
Hold the spray nozzle about 2 feet (2/3 meter) from the
surface and completely mist-wet the object you are
cleaning. Let the object soak briefly , then use the
spray to “chisel” the dirt of f. Keep the nozzle about
6 in. (153 mm) from and at an angle to the surface. If
some dirt remains, wet the surface again, let it soak a
little longer, then hold the nozzle close to the surface to
blast the dirt of f. A heated cleaning solution may work
better; check with your cleaner manufacturer .
After all dirt is cleaned of f, rinse all the solution of f with
clean, cold water. Relieve the Pressure whenever you
stop spraying.
Always stop the pump at the bottom of its stroke to
prevent material from drying on the rod and damaging
the packings.
CAUTION
Never let the pump run dry . A pump that is running
too fast can damage itself. Shut the pump of
f imme -
diately
, then check and refill the supply container to
prevent air from being sucked into the system, keep
liquid in the supply container at all times.
WARNING
Check the air shutof f valve (24) weekly to be sure it
relieves all air in the motor when in the closed
position. If it is not completely relieved, the pump
could cycle unexpectedly and cause serious bodily
injury . Replace the valve immediately it it is, or
appears to be faulty .
Shutdown and Care of the Sprayer
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
Check the air line lubricator to ensure that it contains
enough oil.
Relieve the pressure , and check the displacement
pump packing nut adjustment often. The packing nut
should be tight enough to stop leakage, but no tighter .
Keep the displacement pump wet-cup (C) 1/2 full at all
times. The TSL helps protect the pump packings. See
Fig. 2.
Adjust the air line oiler to about 2 drops per minute

8 6000134
Troubleshooting
NOTE: Refer to the separate instruction manuals
which were supplied with this sprayer , and the manuals
which were supplied with any accessories you added,
for complete operation, troubleshooting and repair
instructions.
NOTE: Check all possible problems and solutions
before disassembling the unit.
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
NOTE: Relieve the pressure before checking or
servicing the equipment.
Problem Cause Solution
Will not spray
Insuf ficient air supply See performance chart on page 9.
Will not spray
Closed or clogged air regulator , valve,
supply line, etc.
Open, clear .
Obstructed spray tip, valve, or hose Clear , use larger tip.
W orn or damaged pump parts See manual 308–148.
V alve will not stop pump operation
Clogged fluid intake filter Clean.
V alve will not stop pump operation
Exhausted cleaning solution supply Refill.
W orn or damaged pump parts See manual 308–148
V alve will not stop fluid spray
Incorrect valve adjustment Adjust
V alve will not stop fluid spray
Obstructed or worn valve stem or
seat Clear
, replace
Fluid leaking from valve at needle
Closed or clogged air regulator , valve,
supply line, etc.
Open, clear .
W orn needle packings or loose pack -
ing nut
T ighten
Fluid will not come from pump
(h d)
Insuf ficient air supply See performance chart on page 9.
Fluid will not come from pump
(hose removed)
Closed or clogged air regulator , valve,
supply line, etc.
Open, clear .
Obstructed spray tip, valve, or hose Clear , use larger tip.
Clogged fluid intake filter Clean.
Exhausted cleaning solution supply Refill.
W orn or damaged pump parts See manual 308–148
Pump operating, but output low
Obstructed spray tip, valve, or hose Clear , use larger tip.
Pump operating, but output low
Exhausted cleaning solution supply Refill.
W orn or damaged pump parts See manual 308–148
Fluid leaking from valve handle Spray valve swivel packings worn Replace

9 6000134
Technical Data
Model 6880242
Model 965389
Delrin®is a registered trademark of the DuPont Company.
Ratio 28:1
Maximum fluid working pressure 193 bar (19,3 MPa, 2800 psi)
Maximum air input pressure 7 bar (0,7 MPa, 100 psi)
Pump cycles per 3.8 liters (1 gallon) 9
Recommended pump speed for continuous operation 50 cycles/min
Maximum flow 21,8 liters/min at 50 cycles/min
Air motor piston effective area 506 cm2(78,5 in.2)
Stroke length 120 mm (4,75 in.)
Displacement pump effective area 18 cm2(2,79 in.2)
Maximum pump operating temperature 65°C (150°F)
Air inlet size 3/4 npsm(f)
Fluid inlet size 2 in. npt(f)
Fluid outlet size 1-1/2 in. npt(m)
Weight approx. 138 kg
Wetted parts 304 and 329 grades of stainless steel, tungsten carbide, Delrin, PTFE,
ultra-high molecular weight polyethylene
Sound pressure level (dBa) measured at 1 meter from unit,
at 15 cycles/min
at air pressure 2,8 bar (0,28 MPa, 40 psi): 78,8
at air pressure 4,8 bar (0,48 MPa, 70 psi): 82,7
at air pressure 6,3 bar (0,63 MPa, 90 psi): 90,5
Sound power level (dBa) tested in accordance with
ISO 9614-2, at 15 cycles/min
at air pressure 2,8 bar (0,28 MPa, 40 psi): 86,5
at air pressure 4,8 bar (0,48 MPa, 70 psi): 88,7
at air pressure 6,3 bar (0,63 MPa, 90 psi): 97,7
Ratio 34:1
Maximum fluid working pressure 238 bar (23,8 MPa, 3400 psi)
Maximum air input pressure 7 bar (0,7 MPa, 100 psi)
Pump cycles per 3.8 liters (1 gallon) 6,5
Recommended pump speed for continuous operation 60 cycles/min
Maximum flow 34,6 liters/min (9,2 gpm)
Air motor piston effective area 800 cm2(124 in.2)
Stroke length 120 mm (4,75 in.)
Displacement pump effective area 24 cm2(3,72 in.2)
Maximum pump operating temperature 82°C (180°F)
Air inlet size 3/4 npsm(f)
Fluid inlet size 1 in. npt(f)
Fluid outlet size 1-1/2 in. npt(m) or M42 x 2.0
Weight 182 kg
Wetted parts 304, 329, and 17-4 PH grades of stainless steel, tungsten carbide, Del-
rin, PTFE, ultra-high molecular weight polyethylene
Sound pressure level (dBa) measured at 1 meter from unit,
at 15 cycles/min
at air pressure 2,8 bar (0,28 MPa, 40 psi): 82,5
at air pressure 4,8 bar (0,48 MPa, 70 psi): 82,4
at air pressure 7,0 bar (0,70 MPa, 100 psi): 83,0
Sound power level (dBa) tested in accordance with
ISO 9614-2, at 15 cycles/min
at air pressure 2,8 bar (0,28 MPa, 40 psi): 90,6
at air pressure 4,8 bar (0,48 MPa, 70 psi): 90,6
at air pressure 7,0 bar (0,70 MPa, 100 psi): 95,9

Parts
10 6000134
TI0320
10 23
19 & 20
43
48
47
46
A
11
6,7,8,9
36
37
38
40
41
39
42
35
45
Model 6880242