Graco Hydra-Clean 206-515 Operation manual

306–817
Rev. J
Supersedes Rev. G,
unreleased Rev. H
First choice when
quality counts. 
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
10:1 President Pump
Hydra-Clean Units
For Mounting on Open 55 Gallon Supply Drum
(Can be wall mounted with accessory bracket)
Model 206–515, Series D
7 MPa (69 bar, 1000 psi) Maximum Working Pressure
0.7 MPa (7 bar, 100 psi) Maximum Incoming Air Pressure

Stainless steel pump and spray valve handle powerful clean
solutions at high pressure.
 Divorced design pump – keeps cleaning solution from fouling
air motor.

Accumulator reduces line pulses – air charged at the factory .
 Air line lubricator for automatic lubrication of air motor .

Suction tube has intake filter .
Solution volume and working pressure can be adjusted
using a dif ferent tip orifice size and an air regulator .
Fan pattern can be changed to concentrating jet
stream using blasting tip.
CAUTION
The Graco warranty will not apply if abrasive or
corrosive materials, other than those Graco recom -
mends are used with this unit.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
http://www.graco.com
COPYRIGHT
1996, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

 
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 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 .
Use this pump only for pumping water and water–diluted cleaning solutions in a pressure washing sys -
tem. Never use the pump for paint or any other coatings. Any misapplication of the pump may cause
dangerous operating conditions which can result in serious injury and substantial property damage.
 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 not sure, 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 on the equipment or in the T echnical Data
for your equipment. Do not exceed the maximum working pressure of the lowest rated component
in your system.
 Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer ’ s warnings.
 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 66  C (150  F) or below –40  C (–40 F).
W ear hearing protection when operating this equipment.
 Do not move or lift pressurized equipment.
 Comply with all applicable local, state, and national fire, electrical, and safety regulations.


WARNING
INJECTION HAZARD
Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause an
extremely serious injury
, including the need for amputation. Splashing fluid in the eyes or on the skin
can also cause a serious injury .

Fluid injected into the skin might look like just a cut, but it is a serious injury . Get immediate medi -
cal attention.

Do not point the spray gun at anyone or at any part of the body .

Do not put hand or fingers over the spray tip.
 Do not stop or deflect fluid leaks with your hand, body , glove, or rag.
 Do not “blow back” fluid; this is not an air spray system.
 Always have the tip guard and the trigger guard on the spray gun when spraying.
 Check the gun dif fuser operation weekly . Refer to the gun manual.
 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 whenever you: are instructed to relieve pres -
sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.
T ighten all the fluid connections before operating the equipment.
 Check the hoses, tubes, and couplings daily . Replace worn, damaged, or loose parts immediately .
Do not repair high pressure couplings; replace the entire hose.
 Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
MOVING P ARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
 Keep clear of all moving parts when starting or operating the pump.
 Never operate the pump with the air motor plates removed.
 Before checking or servicing the equipment, follow the Pressure Relief Procedure on page 6 to
prevent the equipment from starting unexpectedly .

4 306-817
WARNING
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 5.
 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.
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 .

5306-817
Setup
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below . Also read
the section FIRE OR EXPLOSION
HAZARD on page 4.
Although water generally provides a natural electrical
ground, the following equipment must be grounded if
the cleaning chemical are volatile.
1. When cleaning in enclosed areas, such as storage
tanks, locate the pump and air compressor outside
the area and well away from it. Provide adequate
ventilation. If the area you are cleaning has stored
flammable materials. take appropriate precautions
to avoid static sparking. Consul your local codes.
2. Pump: use a ground wire and clamp. See Fig. 1.
Loosen the grounding lug locknut (W) and washer
(X). Insert one end of a 1.5 mm  (12 ga) minimum
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. Order Part No.
237–569 Ground Wire and Clamp.
Fig. 1
W
X
Y
Z

3. Air and fluid hoses: use only electrically conductive
hoses.
4.
Air compressor: follow manufacturer ’ s recommen -
dations.
5.
Spray gun: ground through connection to a prop -
erly grounded fluid hose and pump.
6. Fluid supply container: follow your local code.
7. Object being sprayed: follow your local code.
8. 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.
9.
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.
General Information
The typical setup shown in Figure 2 is only a guide to
selecting and installing required and optional compo -
nents. For assistance in designing a system to suit
your needs, contact your Graco distributor. Refer to
Figure 2 for callouts in parentheses.
Connect Hoses and Mount Pump
1. Using Loctite Pipe Sealant, screw the hose
stud (10) of the suction hose into the pump’ s
intake housing. See Fig. 2. Remove one of the
screws from the pump base opposite the outlet,
and assemble the hanging bracket (19) to the
pump with the provided screw (9) – use the lock -
washer that was on the replaced screw .
2.
Using Loctite  Pipe Sealant, screw the accumula -
tor (7) inlet adapter into the pump outlet. Connect
the fluid hose to the accumulator , the nozzle to the
spray valve, and the air line lubricator (3) to the
pump air inlet. Hang the pump on your cleaning
solution drum.
NOTE: The filter on the suction hose should be about
1/2 in. (12.7 mm) of f the bottom of the drum. If the
hose is too long, cut it of f as necessary .
3.
Close the air ball valve (24), then connect your 1/2
ID (min) air supply hose to the 1/2 nptm(f) inlet
union (15) – do not use thread sealer . Install an
accessory air filter and water separator to remove
excessive moisture that could cause air motor
icing. Pour high quality SAE 10 into the lubricator
until oil reaches the level mark on the sight glass.
CAUTION
Oils containing phosphate ester or chlorinated hydro -
carbons are not compatible with the plastic bowl of
the lubricator – be sure that oil used to lubricate the
compressor is free of these additives.

 
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
Fluid under high pressure can be in -
jected through the skin and cause
serious injury . T o reduce the risk of an
injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
 are instructed to relieve the pressure,
 stop spraying,
 check or service any of the system equipment,
 or install or clean the spray nozzles.
1. Lock the Hydra-Clean

gun trigger safety .
2.
Close the pump air regulator .
3. Close the red handled bleed-type master air valve
(required in your system)
4. Unlock the gun trigger safety and trigger the gun to
relieve pressure.
5. Lock the gun trigger safety .
6.
Open the pump drain valve, having a container
ready to catch the drainage.
7. Leave the drain valve open until you are ready to
spray again.
If you suspect that the dispensing valve, extension, or
grease fitting coupler is clogged, or that pressure has
not been fully relieved after following the steps above,
VER Y SLOWL Y loosen the coupler or hose end cou -
pling and relieve pressure gradually , then loosen
completely , now clear the clog.


Operation
WARNING
T o avoid serious injury , including fluid injection and
splashing in the eyes or on the skin, never point the
gun at yourself or anyone else.
Before Using
Prepare cleaning solution as instructed, observing all
safety precautions. Pre-mix powered cleaners in a
separate bucket of hot water before adding to water in
the supply drum.
WARNING
T ake care not to get spray containing cleaning
chemicals into your eyes, ears, or nose. If any
spray does get on your skin or in your eyes, flush
immediately and thoroughly with water . Seek
immediate medical attention.
See Fig. 2. Open the main air supply valve, hold the
spray valve open and slowly open the air petcock until
the pump is running slowly . After solution is coming
from the spray nozzle, open the ball valve (24) all the
way and adjust the air line lubricator (3) to deliver
about 1 drop per minute. Refer to the separate lubrica -
tor instruction manual.
Release the spray valve trigger and let the pump run.
The pump will charge the accumulator with liquid
pressure, then stall.
NOTE: Protect surfaces that might be damaged by the
cleaning solution and rinse before the solution dries on
both surfaces. Y ou can clean stubborn dirt of f better
with a stronger , heated solution.
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.
Hold the spray nozzle about 2 feet (0.6 m) from the
surface and completely mist-wet the object you are
cleaning. Let it soak briefly , then use the spray to
“chisel” the dirt of f – keep the nozzle about 6 in.
(152.4 mm) from, and at an angle to the surface. If
some dirt remains, wet the surface again. Let the
object soak a little longer, then hold the nozzle as
close as possible and spray to blast the dirt of f.
06018B
10
Fig. 2
24
3
19
16
7
*1
915
34
After all the dirt is cleaned off, rinse all the solution of f
with clear , cold water . When you are through cleaning,
close the air petcock and relieve the pressure.
Shutdown and Care of Unit
CAUTION
Do not allow the pump to run dry . It will quickly
accelerate to a high speed, causing damage. If your
pump is running too fast, stop it immediately and
check the fluid supply . If the container is empty and
air has been pumped into the lines, refill the contain -
er and prime the pump and the lines, or flush and
leave it filled with a compatible solvent. Eliminate all
air from the fluid system.
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.
When shutting down for the day or weekend, shut of f
the main air supply and relieve the pressure. Rinse
all solution of f the equipment with clear , cold water ,
Shut of f the water supply valve and relieve the water
pressure.
Check the air line lubricator (3) often and keep it filled
with oil. Also check the pump packing nut regularly and
keep it just tight enough to stop leakage, but no tighter .
Use a 1/4 in. diameter rod to tighten.

 
Troubleshooting
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.
Before servicing this equipment always make sure to
Relieve the pressure .
Note: Check all possible problems and solutions
before disassembling.
Problem Cause Solution
Excessive surge at spray nozzle
Obstructed spray tip, valve, or hose Clean, clear
Excessive surge at spray nozzle
Cleaning solution supply empty Refill
Accumulator not working Recharge – see page 9 and manual
306–933
Clogged intake filter, kinked or col -
lapsed suction hose
Clean, unkink
Fluid leaking from valve Loose packing nut or worn packings See manual 307–010
V alve will not stop dispensing
V alve not adjusted properly See manual 307–010
V alve will not stop dispensing
Dirty or worn valve stem or seat Clean, clear , or replace – See manual
307–010
V alve will not stop the pump
Cleaning solution supply empty Refill
V alve will not stop the pump
Clogged intake filter, kinked or col -
lapsed suction hose
Clean, unkink
Dirty or worn valve stem or seat Clean clear , or replace – See manual
307–010
Dirty or worn fluid piston or packings Service – See manual 308–1 17
Pump operating, but spray pres -
sure low on up stroke.
Dirty or worn fluid piston or packings Service – See manual 308–1 17
Pump operating, but spray pres -
sure low on down stroke
Dirty or worn fluid intake valve Clean, clear , or replace – See manual
308–117
Pump operating, but spray pres -
sure low on both strokes
Clogged intake filter, kinked or col -
lapsed suction hose
Clean, unkink
sure low on both strokes
Dirty or worn fluid piston or packings Service – See manual 308–1 17
Dirty or worn fluid intake valve Clean, clear , or replace – See manual
308–117
Loose packing nut or worn packings T ighten, replace – See manual
308–117
Fluid will not come from pump
(hose removed)
Restricted air line Check for closed valve; use larger
supply hose
(hose removed)
Pump throat packing nut too tight Loosen
Pump air motor not working Service – See manual 306–982
System will not spray
Restricted air line Check for closed valve; use larger
supply hose
Pump air motor not working Service – See manual 306–982

9306-817
Service
General
See Fig. 2. Check the air line lubricator often and keep
it filled with oil. Also check the pump packing nut
regularly to keep it just tight enough to stop leakage,
but no tighter . Use a 1/4 in. (6.3 mm) diameter rod to
tighten.
Proper packing nut take-up will stop leakage. However ,
all the packings should be replaced after 1000 hours
of operation or delivery of 120,000 gallons of solution
at 2 gpm. Use Repair Kit 206–923.
Accumulator Repair
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 6.
NOTE: Before disassembling the accumulator (7),
check the air valve for leakage. Remove the air valve
cap and recharge the air chamber to 0.58–1.36 MPa
(5.78–13.6 bar , 85–200 psi). W et the valve stem with
saliva and watch for bubbling, indicating leakage. If
leakage it detected, replace the valve core – release
the air pressure first by depressing the valve core
plunger pin.
1. Shut of f the air supply to the pump and relieve the
pressure . Release air pressure in the accumulator
by depressing the valve core plunger pin. Discon -
nect the spray hose and remove the accumulator
from the pump.
2. Screw the inlet adapter out of the housing and
remove the o-ring, poppet, and spring. Screw the
housing of f of the cylinder . T ake the piston out and
remove the bearings and seal. Clean all parts and
inspect for wear and damage, replacing as neces
-
sary
. Check the piston and cylinder wall for pitting
or scoring. Check the valve seat in the inlet adapt -
er for wear or damage.
3. Lubricate the piston seal, and reassemble the
accumulator . Remount the accumulator on the
pump and reconnect the spray hose. Charge the
accumulator to 0.58–1.36 MPa (5.78–13.6 bar ,
85–200 psi). Start the pump and check for air or
liquid leaks.

 
Accessories
Stainless Steel Spray Tips
AIR SUPPL Y T O PUMP
TIP
NO. ORIFICE
SIZE
SPRAY
ANGLE
476 kPa
(4.76 bar , 70 PSI)
680 kPa
(6.8 bar , 100 psi)
NO
.
SIZE
ANGLE
GPM CFM WP GPM CFM WP
164–435 .043 40
160–951 .043 65 1.2 13 630 1.4 19 885
160–964 .043 25
164–434 .052 25
164–436 .052 40 1.6 17 610 1.8 24 840
164–438 .052 65
160–950 .062 65
160–957 .062 40
2.3 23 560 2.6 32 750
160–963 .062 25
2
.
3
23
560
2
.
6
32
750
160–969 .062 15
KEY:
GPM : Gallons Per Minute
CFM : Cubic Feet Per Minute
PSI : Pounds Per Square Inch
WP : W orking Pressure in PSI
Stainless Steel Blasting Tips
TIP NO. ORIFICE SIZE
102–442 .067
102–444 .078
102–446 .086
102–448 .107
102–450 .125