Graco Inc Hydra-Clean 308-534 User Manual

Size:
443.44 Kb
Download

INSTRUCTIONS-PARTSLIST

308–534

Rev A

This manual contains IMPORTANT

WARNINGS and INSTRUCTIONSREAD

AND RETAIN FOR REFERENCE

HYDRA-CLEAN735, 740, 1035, 1040

Pressure Washers

Model 800–906,Series A 230/460 Volt, 3 Phase, 35 GPM Model800–908,Series A 230/460 Volt, 3 Phase, 40 GPM

700 psi (48 bar) OPERATING PRESSURE

1100 psi (75 bar) MAXIMUM WORKING PRESSURE

Model 800–907,Series A 230/460 Volt, 3 Phase, 35 GPM Model800–909,Series A 230/460 Volt, 3 Phase, 40 GPM

1000 psi (69 bar) OPERATING PRESSURE

1300 psi (91 bar) MAXIMUM WORKING PRESSURE

Water supply tank, gun & wand assembly, hose assembly and motor starter are not included.

GRACO INC. P.O. Box 1441 MINNEAPOLIS, MN 55440–1441

COPYRIGHT 1991, GRACO INC.

WARNING

HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY. FOR PROFESSIONAL USE ONLY. OBSERVE ALL WARNINGS.

Read and understand all instruction manuals before operating equipment.

FLUID INJECTION HAZARD

General Safety

This pressure washer generates very high fluid pressure. Spray from the gun, leaks or ruptured components can inject fluid through your skin and into your body and cause extremely serious bodily injury including the need for amputation. Also, fluid injected or splashed into the eyes or on the skin can cause serious damage.

Pressure Relief Procedure

To reduce the risk of serious bodily injury, including fluid injection and splashing in the eyes or on the skin, always follow this procedure whenever you stop spraying for more than 10 minutes, when shutting down, and before checking or repairing any part of the system.

1. Engage the trigger safety latch.

NEVER point the spray gun or wand at anyone or at any part of the body .NEVER put hand or fingers over the spray tip.

ALWAYS follow the Pressure Relief Procedure, before cleaning or servicing any part of the sprayer.

NEVER try to stop or deflect leaks with your hand or body.

Be sure equipment safety devices are operating properly before each use.

Medical Treatment

If any fluid appears to penetrate your skin, get

EMERGENCY MEDICAL TREATMENT AT ONCE. DO NOT TREAT AS A SIMPLE CUT. Tell the doctor exactly what fluid was injected.

NOTE TO PHYSICIAN: Injection in the skin is a traumatic injury.It is important to treat the injury surgically as soon as possible. Do not delay treatment to research toxicity. Toxicity is a concern with some exotic coatings injected directly into the bloodstream. Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable.

2.Turn the sprayer off.

3.Disconnect the electrical supply.

4.Shut off the water supply.

5.Disengage the trigger safety latch and trigger the gun to relieve pressure, and then engage the trigger safety latch again.

6.Before long–term(overnight) storage, disconnect the water supply and disconnect the electricity.

Spray Gun Safety Devices

Be sure all gun safety devices are operating properly before each use. Do not remove or modify any part of the gun; this can cause a malfunction and result in serious bodily injury.

SAFETY LA TCH: Whenever you stop spraying for a moment, always set the gun safety latch in the engaged or “safe” position, making the gun inoperative. Failure to properly set the safety latch can result in accidental triggering of the gun.

SPRAY

TIP SAFETY: Use extreme

caution when

cleaning or changing spray tips. If a spray tip clogs while

spraying,

engage the gun safety latch

immediately.

ALWAYS follow the Pressure Relief Procedureand then remove the spray tip to clean it.

GROUNDING INSTRUCTIONS

This product must be grounded. If it should malfunction or break down, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This equipment is equipped with a cord having an equipment–groundingconductor and a grounding plug. The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances.

 

DANGER

 

 

 

 

 

 

Improper connection of the

equipment–

 

grounding conductor can result in the risk of

 

electrocution. Check with a qualified electrician or

 

service person if you are in doubt as to

whether

 

the outlet is properly grounded.

 

 

 

 

 

 

GROUND FAULT CIRCUIT INTERRUPTER PROTECTION

To comply with the National Electrical Code (NFP A 70) and to provide additional protection from the risk of electric shock, connect this pressure washer to a circuit that is protected by a ground–faultcircuit–interrupter(GFCI).

EQUIPMENT MISUSE HAZARD

General Safety

Any misuse of the pressure washer or accessories, such as overpressurizing, modifying parts, using incompatible chemicals and fluids, or using worn or damaged parts, can cause them to rupture and result in fluid injection, splashing in the eyes or on the skin, or other serious bodily injury, fire, explosion or property damage.

NEVER alter or modify any part of this equipment; doing so could cause it to malfunction.

CHECK all spray equipment regularly and repair or replace worn or damaged parts immediately.

ALWAYS wear protective eyewear and appropriate clothing. If using a chemical injector, read and follow the chemical manufacturer’s literature for recommendations on additional protective equipment, such as a respirator.

System Pressure

This sprayer can develop high operating pressure. Be sure that all spray equipment and accessories are rated

to withstand the maximum working pressure of this sprayer. DO NOT exceed the maximum working pressure of any component or accessory used in the system.

Chemical Compatibility

BE SURE that all chemicals used in the chemical injector are compatible with the wetted parts of the hose, gun, wand and tip, as given in the Technical Data (inside back

cover). Always read the chemical manufacturer ’s literature before using any chemical in this pressure washer.

3 8 534 3

HOSE SAFETY

High pressure fluid in the hoses can be very dangerous. If the hose develops a leak, split or rupture due to any kind of wear, damage or misuse, the high pressure spray emitted from it can cause a fluid injection injury or other serious bodily injury or property damage.

ALL FLUID HOSES MUST HA VE STRAIN RELIEFS ON BOTH ENDS. The strain reliefs help protect the hose from kinks or bends at or close to the coupling, which can result in hose rupture.

TIGHTEN all fluid connections securely before each use. High pressure fluid can dislodge a loose coupling or allow high pressure spray to be emitted from the coupling.

NEVER use a damaged hose. Before each use, check entire hose for cuts, leaks, abrasion, bulging cover , or damage or movement of the hose couplings. If any of these conditions exist, replace the hose immediately.DO NOT try to recouple high pressure hose or mend it with tape or any other device. A repaired hose cannot contain the high pressure fluid.

HANDLE AND ROUTE HOSES CAREFULL Y.Do not pull on hoses to move the pressure washer. Do not use chemicals which are not compatible with the inner tube and cover of the hose. DO NOT expose Graco hose to temperatures above 200_ F (93_ C) or below –40_ F (–40_ C).

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers or other body parts. KEEP CLEAR of moving parts when starting or operating the pressure washer.

NEVER operate the pressure washer without all guards and interlocks installed and functioning. Follow the

Pressure Relief Procedure before checking or servicing the pressure washer to prevent discharging high pressure fluid from the gun.

TERMS

WARNING or DANGER: Alerts user to avoid or correct

NOTE: Identifies helpful procedures and information.

conditions that could cause bodily injury.

 

CAUTION: Alerts user to avoid or correct conditions that

 

could cause damage to the equipment.

 

IMPORTANT

United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards—particularlythe General Standards, Part 1910, and the Construction Standards, Part1926—shouldbe consulted.

4 3 8 534

INSTALLATION

PUMP OIL

LEVEL

INDICATOR

WINDOW

HIGH

 

PRESSURE

 

HOSE

PUMP DIP-

CONNECTION

2 x 1/2” NPT(f)

STICK

WATER

 

CONNECTION

 

2 x 1” NPT(f)

 

Water supply tank, gun & wand assembly, hose assembly and motor starter are

not included.

Figure 1

Check for Shipping Damage

Check the unit for any damage that may have occurred in shipping. Notify the carrier immediately if there is any damage.

Set Up

Before connecting the unit, be sure the electrical service matches the specification in Technical Data (inside back cover) and the voltage label on the unit. With the unit off, connect the power supply cord to a grounded, GFCI–protectedcircuit.

If you are using a downstream chemical injector, install it between the pump unloader and the high pressure hose.

Connect the high pressure hose between the pump outlet and the gun inlet.

CAUTION

Up to 100 ft (30 m) of high pressure hose may

be used. Longer hoses may af fect sprayer performance, and chemical injector performance,

if used.

Install the appropriate spray tip on the wand. See Installing and Changing Spray T ips. If you are using a sandblaster kit, see its separate manual for installation instructions.

Connect to Water Supply CAUTION

Before attaching to the water supply, check your local plumbing code regarding cross–connectionto the water supply.

A backflow preventer P/N 801–133is available to prevent backflow of contaminated water into the fresh water supply . Install it upstream from the pump.

Install a regulating water valve, P/N 800–258,if inlet water pressure is over 60 psi (4.1 bar).

Do not exceed 160_ F (70_ C) inlet water temperature.

NOTE: The water source for the unitmust have a minimum 100 gallon float valve controlled water holding tank.

3 8 534 5

STARTUP

Use this procedure whenever starting the pressure washer to help insure that the unit is ready to operate and starting is done safely.

1.Check the oil level.

Pump: Add SAE 20 or 30 weight non–detergentoil as necessary.

2.Turn on the water supply.

CAUTION

Never run the unit dry . Costly damage to the pump will result. Always be sure the water supply is completely turned on before operating.

3.Trigger the gun until water sprays from the tip indicating that the air is purged from the system.

4.Start the unit.

5.ALWAYS engage the gun’ s trigger safety whenever you stop spraying, even for a moment to reduce the risk of fluid injection or splashing in the eyes or on the skin if the gun is bumped or triggered accidentally.

6.ALWAYS observe the followingCAUTIONS to avoid 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 recirculating water to overheat and seriously damage the pump. T urn of f the pressure washer if it will not be spraying or cleaning at least every 10 minutes. If heated inlet water is used, reduce this time further.

DO NOT run the pump dry , which will quickly damage the pump. Be sure the water supply is fully turned on before starting the pump.

DO NOT pump caustic materials; such materials may corrode the pump components.

latch

7.See the chemical injector or sandblaster kit manual for detailed cleaning information if these accessories are used.

6 3 534

Trigger Safety Latch

 

Installing and Changing Spray Tips

 

WARNING

 

 

WARNING

 

To reduce the risk of serious bodily injury

,

 

To reduce the risk of serious bodily injury

,

including fluid injection, splashing in the eyes or

 

 

including fluid injection or splashing in the eyes

 

on the skin, ALWAYS engage the trigger safety

 

 

or onto the skin, use extreme caution when

 

latch whenever spraying stops, even for a

 

 

changing spray tips. ALWAYS follow the

 

moment.

 

 

procedure below.

 

In the engaged position, the trigger safety latch

 

1.

Follow the Pressure Relief Procedure.

 

prevents the gun from being triggered

 

 

 

 

 

 

accidentally by hand or if it is dropped or

 

2.

Point the gun and wand away from yourself and

bumped. Be sure the latch is pushed fully down

 

 

 

anyone else.

 

when engaging it or it cannot prevent the gun

 

 

 

 

 

 

 

from being triggered. See Figure 2.

 

3.

Without holding your hand over the spray tip (A), pull

 

 

 

back the quick coupler ring (B), remove the tip

and

 

 

 

then release the ring. See Figure 3.

 

 

 

4.

Be sure the tip is secure before starting to spray

 

 

 

again.

 

 

 

5.

Tip holding holes are provided on the chassis.

 

TRIGGER SAFETY LATCH SHOWN ENGAGED

TRIGGER SAFETY LATCH SHOWN DISEN-

Figure 2

GAGED

 

CAUTION

To avoid blowing the o–ringout of the quick coupler, due to the high pressure in the system, never operate the pressure washer without a tip securely mounted in the quick coupler.

A

B

Figure 3

3 534 7

SHUTDOWN, FLUSHING AND STORAGE

 

WARNING

 

PRESSURE RELIEF PROCEDURE

 

To reduce

the risk of serious bodily injury

,

including fluid injection and splashing in the

 

eyes, or

on the skin, always follow this

 

procedure whenever you stop spraying for

 

more than 10 minutes, when shutting down,

 

and before checking or repairing any part of the

 

system.

 

 

1.Engage the trigger safety latch.

2.Turn the sprayer off.

3.Disconnect the electrical supply.

4.Shut off the water supply.

5.Disengage the trigger safety latch and trigger the gun to relieve pressure, and then engage the trigger safety latch again.

6.Before long–term(overnight) storage, disconnect the water supply and disconnect the electricity.

MAINTENANCE

Observing regular maintenance intervals helps ensure that you get maximum performance and life from the pressure washer.

There is a break–inperiod for the pump. After changing the oil initially, the interval between required changes is longer.

 

WARNING

 

 

 

 

To reduce the risk of serious bodily injury

,

 

including fluid injection, splashing in the eyes or

 

 

on the skin or injury from moving parts, always

 

 

follow the Pressure Relief Procedure

 

 

Warning before proceeding.

 

1.If the pressure washer will be exposed to freezing temperatures, drain all water out of the pump. If it must be stored in freezing temperatures, flush the unit with a 50% anti–freezesolution. Relieve pressure. Flush the pressure washer before using it again to remove theanti–freeze.

CAUTION

If water does freeze in the pressure washer , thaw it in a warm room before trying to start it. DO NOT pour hot water on or into the pump; it may crack the ceramic plungers!

2.After each use, wipe all surfaces of the pressure washer with a clean, damp cloth.

3.Perform the appropriate maintenance. See the maintenance chart.

Interval

What to do

Daily

Clean water inlet screen and

 

filter. Check pump oil level. Fill

 

as necessary.

After first 50

Change pump break–inoil. Use

hours of

SAE 20 or 30 non–detergentoil.

operation

 

Each 500 hours

Change pump oil. Use SAE 20

of operation or 6

or 30 non–detergentoil.

months

 

8 3 8 534

TROUBLESHOOTING CHART

WARNING

To reduce the risk of serious bodily injury, including fluid injection, splashing in the eyes or on the skin, or injury from moving parts, always follow the Pressure Relief Procedure Warning before proceeding.

PROBLEM

CAUSE

SOLUTION

Low pressure and/or

Worn or wrong size tip.

Replace with tip of proper size.

pump runs rough

Inlet filter clogged.

Clean. Check more frequently.

 

 

Worn packings, abrasives in water or

Check filter. Replace packings. See PUMP SERVICE.

 

natural wear.

 

 

Inadequate water supply.

Check water flow rate to pump. Unit must have a

 

 

minimum 55 gallon float valve controlled water holding

 

 

tank.

 

Belt slippage.

Tighten or replace.

 

Fouled or dirty inlet or discharge valves.

Clean inlet and discharge valve assemblies. Check

 

Even a small particle can cause the valve

filter.

 

to stick.

 

 

Restricted inlet.

Check garden hose, may be collapsed or kinked.

 

Worn inlet or discharge valves.

Replace worn valves.

 

Leaking high pressure hose.

Replace high pressure hose.

Water leakage from

Worn packings.

Install new packings. See PUMP SERVICE.

under pump manifold

 

 

Water in pump

Humid air condensing inside crankcase.

Change oil as specified in MAINTENANCE.

 

Worn packings.

Install new packings. See PUMP SERVICE.

 

Oil seals leaking.

Install new oil seals. See PUMP SERVICE.

 

 

 

Frequent or

Scored, damaged or worn plungers.

Install new plungers. See PUMP SERVICE.

premature failure of

Abrasive material in the fluid being pumped.

Install proper filtration on pump inlet plumbing.

the packings

Inlet water temperature too high.

Check water temperature; may not exceed 160_F.

 

 

Overpressurizing pump.

Do not modify any factory–setadjustments. See

 

 

EQUIPMENT MISUSE HAZARD.

 

Excessive pressure due to partially plugged

Clean or replace tip. See Installing and Changing Spray

 

or damaged tip.

Tips.

 

Pump running too long without spraying.

Never run pump more than 10 minutes without

 

 

spraying.

 

Running pump dry.

Do not run pump without water.

Strong surging at the

Foreign particles in the inlet or discharge

Clean or replace valves. See PUMP SERVICE.

inlet and low pressure

valve or worn inlet and/or discharge

 

on the discharge side

valves.

 

Unit will not start

Unit not plugged in.

Check power cord.

 

Electrical service off/GFCI activated.

Check fuse/circuit breaker. Check for proper grounding.

 

Thermal overload has tripped.

Press reset button on motor for 1 phase units. Press

 

 

stop button on the motor starter for 3 phase units.

 

 

 

3 8 534 9

PUMP SERVICE

 

WARNING

 

 

 

 

To reduce the risk of serious bodily injury

,

 

including fluid injection, splashing in the eyes or

 

 

on the skin, or injury from moving parts, always

 

 

follow the Pressure Relief Procedure

 

 

Warning before proceeding.

 

NOTE: The following metric wrenches are needed: M10, M13 and M30. Repair kits are available. Refer to the individual repair sections and the pump parts page for more details. For the best results, use all parts in the kits.

NOTE: There are two dif ferent tool kits to aid in servicing the pump. P/N800–298is used to ease installation of packings. P/N800–271includes the items in800–298and tools to aid in the removal of packing retainers.

Valves

NOTE: For a set of six valves, order P/N803–664or803–666.

1.Remove the hex plug from the manifold using an M30 wrench.

2.Examine the o–ringunder the hex plug and replace it if it is cut or distorted.

3.Remove the valve assembly from the cavity; the assembly may come apart.

4.Install the new valve. Install the o–ringand hex plug; torque to 75ft–lb(103 Nm).

NOTE: Retorque the plug after 5 hours of operation.

Pumping Section

1.Remove the eight capscrews and lockwashers from the manifold using an M13 wrench.

2.Carefully separate the manifold from the crankcase.

Servicing the Plungers

NOTE: Plunger repair kit, P/N803–677is available to replace retainers,o–rings,washers and backup rings for three cylinders.

1.Loosen the plunger retaining screw five to six turns, using an M10 wrench. Push the plunger towards the crankcase to separate the plunger and retaining screw.

2.Remove the screw from the plunger and examine the o–ring,backup ring and copper bearing/gasket washer. Replace these parts, if necessary, using kit801–474.

3.Remove the plunger and flinger from the plunger shaft. Clean, examine and replace parts as necessary.

4.Inspect the plunger shaft for oil leakage from the crankcase. If leaking is obvious, replace the oil seals. Otherwise, DO NOT remove these seals as they cannot be reused. An oil seal kit is available to replace the seals.

5.Lightly grease the oil seal, if it is being replaced, and the flinger and replace them on the plunger shaft. Then install the plunger.

6.Lightly grease the retaining screw and the outer end of the plunger. Place the washer, o–ringand backup ring around the screw and install the screw through the plunger. Torque to 14.4ft–lb(19.5 Nm).

NOTE: If you plan to replace the packings, refer to Servicing theV–Packings.

7.

Lubricate the outside of each plunger

. Slide the

 

manifold onto the crankcase, being careful not to

 

damage the seals.

 

8.

Install the capscrews and washers

finger–tight.

Torque the screws to 21.7 ft–lb(29 Nm) following the tightening pattern (Figure 4). Uneven tightening may cause the manifold to bind or jam.

NOTE: It may be necessary to tap the manifold lightly with a soft mallet to loosen.

CAUTION

Keep the manifold properly aligned with the ceramic plungers when removing to avoid damage to the plunger or seals.

3. Carefully examine each plunger for any scoring or

Figure 4

cracking and replace as necessary.

5

1

4

7

8

3

2

6

1