Graco Inc Hydra-Clean 801-392 User Manual

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This manual contains IMPORTANT

WARNINGS and INSTRUCTIONS-

READ AND RETAIN FOR REFERENCe

2104E.MODEL 800-053 SERIES "A"

2150p s i ( 1 50 bar) OPERA TlNG PRESSURE

2250 p s i (155bar).MAXIMUM WORKINGPRESSURE

~ ~ J J j ~ ~ [~= ~; ' Qb ~,~&. j!~ ~ ~

Fluids under high pressure from spray or leaks can penetrate the skinandcauseextremelyserious

injury, including .the need for amputation.

NEVER point the spray gun at anyone or any part of the body.

NEVER put hand or fingersover the spray tip.

NEVER try tostop or deflect leakswith your hand or body.

ALWAYS have the tipguardin place when spraying.

MEDlCAL TRE&TMEF%B

If any fluid appears to penetrateyour skin, get

treatmentinstructions have' your doctor callthe

F.Sb,iTlONAE PQ@OM CENTER NETWORK

(412)6$1-6669

Avena ~ Q M ? ~ H E N T

Even after you shut off the gasoline engine, there is high pressure in the pump, hose and gun until you releaseit by triggering thegun.So before removing the spray tip or servicing the unit, alwaysshut offthe unit andtrigger the gun to release pressure.

Be surethat .all accessory itemsand system components will withstand thepressure developed. NEVER exceed the pressure ratingof anycomponent in system.NEVER alter or modifyequipment-yourpersonal safety, as well as thefunction of the equipment,is at stake.

Before each use, check hosefor weak, worn or damaged conditions causedby traffic, sharp corners, pinching or kinking.Tighten all fluid connections securelybefore.each .use. Replace anydamaged hose.

DO not use chemicalsoragents which are not compatible withBuna-NandPVC or neoprene cover. ' of hose.

Do not leave a pressurizedunit unattended. Shut off the unit and release pressure before leaving.

FORE

Do not spray flammable liquids.Do not operatethe engine where combustible fumes or 'dust maybe present.

GENERAL

NEVER run the unitwith thebeltguard removed. Keep clear of moving partswhen the unitis running.

observedetergentmanufacturer'ssafety

precautions. Avoid getting detergent or other liquids in your eyes. Follow the directions on thecontainer' regardingcontact with eyes,nose,andskin,

breathing fumes, etc. Alwayswear full goggles to protect your eyes from the spray as well as any debris dislodged by the spray. If necessary, wear gloves or otherprotectiveclothing. If.antidotesortreatment are recommendbd, be prepared to use them.

DON'T spray toxic chemicals such as insecticide or weed killer.

This unit issupplied with an8-footpowercord made up of four AWGNo. 12 wires. The green wire of the electric cord is connectedto theunit chassis and motor frame. The other three wiresare connected to the starter switch.

Be sure to connectthepower cord tothe appropriate approved plug to fit your requirements.

The starter switch has a built-in.circuitbreaker that will shut off the power totheunit whenever the circuit is overloaded.

Always check to be surethe switchis off and thatthe hoses and electric cord areclear of movingparts before pluggingin the power cord.

IMPORTANT

United States Government- safety standards have beenadopted under the Occupational Safety and HealthAct.

These standards particulsrlythe.General Standards, Part 1910, and the ConstructionStandards, Part1926 - should be consultedin connectionwith your use of airless spray equipment.

2 . 801-392

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::

REMOVE TAPE

FROM PUMP CAP

I

SPRAY

GUN

!’

\SPRAY HOSE

. .. .

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, ...

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Check Electrical Service and Plug In

Before plugging in thesprayer. besure the electrical service is3 phase220V, 60 HAC.20Amp. With theON-OFFswitch in the OFF position, plug the power supplY cord intoa groundedoutlet.If you use an extension cord,it must have4 wires of at least12

gauge (2.5 mm2)and should notbe over.100ft(30.3 m) long.

Install Hose and SprayGun

Connect the spray hose tothe spray gun by inserting thepin at theend of the hose intothe quick disconnect coupler on the gun. Connect the hose to the fluid outlet in thesame way.

Remove the tape from the cap on top of the pump.

Cleaning Accessories

For spraying detergent or other cleaningsolution, we recommendusing a chemicalinjecior kit. See Accessories and instructionmanual801-192for installation and operation.

For removing rust and old paint we recommend using a water sandblaster.See Accessories and instruction manual 801-190for installation and operation.

Connect To W a t e ~Supply

Do not exceed 16OoF (7OOC) ,water temperature to pump in a direct supply system.

Connect a hose with at least a 3/4 in. (19 mm)ID from your citywatersupply to theunit’s3/4 in. garden hose threaded inlet. The supply hose shouldnot be more than50 ft. (15 m) long.

NOTE: For a directsupply system. your water source at the unitmusthave a flow rateof

AT LEAST 5 GPM (19 LITER/MIN).

If your operating conditions are different fromabove, contact our Customer ServiceDepartmentfor assistance.

801-3923

OPERATlQM

:Startup

'. Beforestarting, be sure'to readthe safety warnings

and setup instructions.

Turn on the water supply.

Trigger the gun to release any back pressure.

CAUTION I

Never run the cleaning unitdry. Costlydamage ' , to the pump will result. Always be sure water supply iscompletelyturnedon before operating.

Inspect all connectionsforany leaks. Tighten if necessary.

Cleaning

For Hydra-Cleantechnique, see the Chemical Injector manual,801-192.

'I For abrasive cleaning, see the Water Sandblaster manual, 801-901.

WAffiNBNG

Follow these precautions when removing and installing nozzles:

1.Shutoff the cleaning unit andtriggerthegun to relieve pressure. Engagethe triggersafety.

2.Keep the nozzle and the tube pointed away from you and everyone else.

3.Do not put your handover the tip to push the nozzle into place. Grasp it from the side and keep your fingers away from thetip.

4.Do not let anyoneelse touch the spray valve while you are cleaning nozztes.

5.Be sure the slipring is pushedforward to lock the nozzle in place before triggering thespray gun.

Shutdown and.Care Of Unit

When unit is not in use, turn off water supply.

When shutting down for theday or weekend, shut off unit, shut off water supplyvalve, and trigger gun to release pressure. Wipe off the unit witha damp rag.

Check the filter screen in the water inlet connection as often as necessary, at least daily. Do not operate the unit with the inletand filter screen removed.

DO NOTtrytoadjusttheunloadervalveorchangetheengine speed. Changingthesesettings rnay cause excessive pressure, intermittent unloader operation, wasted fuel and increased wearon parts andwillvoid the warranty.

PUMP MUST NOT BE RUNDRY and must be drained of water prior to exposure to freezing temperatures. Use and storethe unit where itwill not be subjected to freezing temperatures.If water does freezein the unit, thaw before trying to start..A 50% anti-freezesolution rnaybe pumpedprior to coldweather storage.

Use only spray tips that are matched to the unit to avoid excessive cyclingandwear of the unloader valve. See Accessories.

CAUTION

pourhot water on a frozen pump. A sudden temperature change may crack the ceramic

Do not pump caustic materials.

Before extended storage, flush the pump with light oil.

Avoid dragging hoseoveranabrasivesurfacesuchas cement. This causes excessive wearandshorter hose life.

Clean the intake line strainer daily.

Lubrication and Care

Fill pump crankcase to dot on oil,gauge window with25 oz.(0.75 liters) of crankcase oil (part no.801-1 44)

or equivalent SA€ 40 weighthydraulic oil with antiwear and rust inhibitor additives. Change initial fill after50 hour running period. Change oil every3 months or at500 hour intervals.

WARNONG

1 NEVER alter adlustmentor modify the unloader valve.

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PROBLEM

-0w~pressure.

’ump runs extremely rough, Iressure low.

Nater leakage from under :he manifold.

Nater in pump crankcase.

:requent or premature ailure of the packing.

;trow surging at the inlet lnd low pressure on the lischarge side.

CAUSE SOLUTION

Worn nozzle.

Belt slippage.

Air leak in inlet plumbing.

Relief valve stuck, partially plugged or improperly adjusted, valve seat worn.

Inlet suctionstrainer clogged 01 improper size.

Replace with nozzle of proper Size.

Tighten or replace; usecorrect belts and replacl both at same time.

Disassemble, reseal, and reassemble

Clean, and adjust relief valve; check for worn and dirty valve seats. Kit available.

Clean. Use adequate size. Check more frequently.

. .

Worn packing. Abrasives in pumped fluid or severe cavitation. Inadequate water supply.

Fouled or dirty inlet or discharge valves.

Worn inlet or discharge valves. Leaky discharge hose.

Restricted inlet or air entering the inlet plumbing.

Inlet restrictions and/or air ‘eaks. Stuck inlet or discharge talve.

Install proper filter. Check flow available to pump.

Clean inlet anddischarge valve assemblies.

Replace worn valves, valve seats and/or discharge hose.

Proper size inlet plumbing; check for airtight seal.

Clean out foreign material, replace worn valves

-cakingH.P. seals.

vVorn packing.

May be caused by humid air :ondensing into water inside the :rankcase.

Scored plungers.

3ver pressure to inlet manifold.

lamaged or worn plungers.

4brasive material in the fluid )eing pumped.

ixcessive pressure-and/ortem. )erature of fluid being pumped.

h e r pressure of pumps.

lunning pump dry.

:oreign particles in the inlet or lischarge valve, or worn inlet Ind/or discharge valves.

Replace seals.

Install new packing

Change oil at 3 month or500hour intervals usins Graco Crankcase Oil (other approved oil evenl month or200 hours)P.N. 801-144.

Replace plungers,

Reduce inlet pressure.

Replace plungers.

Install proper filtration on pump inlet plumbing,

Check pressures andfluid inlettemperature; be sure they are within specified range.

Reduce pressure.

Do not run DumD without water.

Check for smooth lap surfaces on inlet and. discharge valve seats. Discharge valve seats and inlet valve seats may be lapped on a very fine oil stone.

801-3925

CAUSE

ectrtc motor wont run.

Power cord unplugged, or

Check, replace

 

building circuit fuse blown

 

 

Overload switch has opened.

Unplug power cord+, decrease pressure.

 

Power.cord unplugged, or

Check, replace.

 

building circuitfuse blown,

 

 

Overload breaker has opened.

Unplug power cord*, relieve pressure-allow

 

 

tO.CO01.

 

Extension cord.

Don't use morethan 100ftof 12ga extension cord.

 

Tip plugged.

Remove and clean.

Electric motor runs, but

Displacement pump frozen or

Thaw.

no output.

gear train damage.

 

*This unit has an overload breakerbuilt into the switchassembly. If it opens, unplug power cord and letsprayer cool for 30 to 60 minutes. Also, try tocorrect the cause of overheating. Alwaysuse the lowest pressure setting needed.

NOTE: A M11 and M30 metricwrenches are required for servicing pump.

PUMP

Valves

Photo 1 and 2.

1 ) Remove the hex plug using an M30 wrench.

2)Examine O-ringunderplugandreplaceif evidence of cuts or distortion.

3)Remove valve assembly includingretainer, spring, valve and valve seat from valve cavity.

NOTE: Valve assembly may come apart during removal.

4)Replace valve parts with service kit (801-041)includingretainer,spring, valve, valve seat,o- ring andback-up-ring.

5)Replace valve cover and torque to75 ft-lb(100 Nm) .

Pumping Section

Photo 3.

1) Remove the four (4)hex nuts from the manifold.

2)Separate the manifold from thecrankcase.

NOTE: It may be necessary totapmanifold lightly with mallet to loosen.

CAUTION

Keep manifold properly alignedwith ceramic plungers when removing to avoid damage to either plungers or seals.

3)Carefully examine each plunger for any scoring and replace if necessary.

6 801-392

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Plungers

Photo 4.

1 ) U s i n ga nM 1 1 wrench,

remove the plunger retainer.

2)Slide out theseal retainer with oilwick and rubberbarrier slinger.

3)With a slight twistingmotion, loosen the plungerfromthe plunger rod and remove.

NOTE: The stud may remain withthe retainer w h erne m o v e d .

Disassembleand s c r e ws t u idn t o plungerrodfinger tight.

4)Replace O-ring'and backup ring on plunger retainer.

5)Saturate newoil wick by soaking in oil.

6)Install new plunger.

7)Replace plunger retainer and

torque to 80 in-lb(9 Nm).8)Installnewoil wick in seal

retainer.

9) Replace barrierslinger over new plunger.

10)Lubricate each plunger sleeve andcarefullyslidemanifold

onto crankcase.

Seals or V-Packings

Photo 5, 6, 7 and 8.

1) RemoveC-ringfromseal case:

2)Then removethe lowpressure seal from the seal case.

3)Unscrewthe seal case from themanifoldusing a special' key wrench (801-044).

4)Remove thehighpressure

seal and examine. Before replacing, lubricateID and OD of new high-pressureseal and press into manifold.

MOTE: A socket andextension maybeused to pressure seal from manifold.

5)Install newO-ringon sealcase and lubricateOD ofO-ring.

6)Screw seal case into manifold.

7)Lubricate ID and OD of low pressure seal and pressinto seal case.

8)Replace C-ringholdinglow pressure seal in place.

k

9)Lubricate each plunger sleeve andcarefullyslidemanifold

onto crankcase.

.NOTE: W h e nr e p l a c i n g manifoldonto plungers, ememe caution should be exercised to avoid damageto the seals.

10)Torqueallfour(4)boltsto240in-lb(27 Nm).

NOTE: Carefullystudythe order of respective p a r tasnndo t e

position of sealsto assure proper reassembly and operation.

801-3927

8 801-392

i

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Ref. No.5 0 Includes items51-66

,

62

63

-52

 

 

 

 

 

 

PARTDESCRIPTIONREF

 

 

QN

 

 

 

 

 

 

NO,

NO.

 

 

 

 

 

 

 

 

 

 

26

801 -023WASHER,flat,

1/4

8

 

 

 

 

 

 

27

801-015

WASHER, flat,

5/16

16

 

 

 

 

 

 

28

801-139

WASHER, IocIc 1/4

4

 

 

 

 

 

 

29

801.025

WASHER, lock, 5/16

10

 

 

 

 

 

 

30

80.1-024

NUT, hex, 5/16-18NC

7

 

 

 

 

 

 

31

801 -012

GROMMET

 

4

 

 

 

 

 

 

32

801-367

BUMPER

 

1

 

 

 

 

 

 

34

801-004

PULLEY, pump

 

1

 

 

 

 

 

 

35

801-381

PULLEY. rnntnr

 

1

 

 

 

 

 

 

36

801-135

HUB. pulley

 

1

 

 

 

 

 

 

37

801-137

KEY, pulley(2" lg)

1

PARTS LIST

 

 

 

 

40

801-018

BRACKET, tensioner

1

 

 

 

 

41

801-364BELTGUARD,cover

1

 

 

 

 

 

 

PARTDESCRIPTIONREF

 

 

QTY

42

801-365

BELTGUARD. baseplate

1

 

 

44

801 -132

RIVET, drive

 

2

NO. NO.

 

 

 

 

46

801 -008LABEL.identification

1

1

 

HOSE & GUNASSY.

 

 

 

see ~aun

1

47

801-388

LABEL, warning

1

2

801-001

detail'for parts

 

48

801-389

LABEL. identification

1

PUMP,REPLACEMENTPARTS,

 

50

801 -084UNLOADER.includesitkms 51-66

1

3

 

includes items 77-90

1

51

801-045

.

CAGE, valve

 

1

800-015 ANTIVIBRATIONFOOT

4

52

801 -046

.

O-RING

 

2

4 800-036CHASSIS

 

1

53

801-047

.

SPRING

 

1

5

800-037

ELECTRICMOTORASSY

.1

54

801-048

,

BALL

 

1

6

801-390

BRACKET. spacer

 

1

55

801-049

.

SEAT

 

1

8

801 -285

BELT, drive

 

2

56

801-050

,

O-RING.

 

2

9

801-231

LABEL. warning

 

2

57

800-012

.

UNLOADERSUB-

1

10

801-140

LABEL. identification

1

58

,801-059

.

O-RING

 

1

11

801-129

LABEL, warning

 

1

59

801-060

.

HOUSING

 

1

13

801-131

PLATE, serial no.

 

1

60

801-OB1

CYLINDER

 

1

14

801-221

CONNECTOR, crimp

2

61

 

.

O-RING

 

1

16

801-379

SWITCH^ starter

 

1

62

 

PLUG

 

2

17

 

~~~~~

 

 

 

 

 

 

 

 

 

801-382

CORD, power (8fi lg)

1

63

 

.

HOUSING VALVE

1

18

801-380

STRAINRELIEF

 

2

64

 

SPRING

 

1

19

801-292

SCREW, self tapping,

 

65

 

.

VALVE'

 

1

 

 

no. 6-32NCx 1/2

 

2

66

 

.

SEAT

 

1

20

801 -021BOLT.carriage,

 

2

67

801-105

COUPLER, male quick disconnect

1

21

801-088

5/16-18NCx 5"

~

68

NIPPLE, straight,brass,

1

SCREW, machine, hex hd.

 

.69

801-106

1/2 NPTx 3-1/2"

22

801-298

hd. 5/16-18NC x 1-1/2"

4

TEE, brass, 1/2 NPT

1

SCREW, machine, hexhd.

1

70

801-236

NIPPLE, hex, steel, 1/2 z 3/8 NPT

1

23

 

hd. 5/16-18NCx 2-1/2"

71

801-108

NIPPLE, hex, brass,.l/4x1/2 NPT

1

801 -302SCREW,machinehexhd.

 

72

801-109

PLUG, hex,brass, 3/8 NPT

1

 

 

5/16-18

N C r 1"

 

4

73

801-110

ADAPTER, 1/2 hose

1

24

801-082

. . .. -

..- .. .

 

SCREW, machine,hexhd.

 

74

801-111

NUT, brass,adapter

1

25

801-081

M6 x 30mm

 

4

75

801-11~2SCREEN,inlet

 

1

SCREW. machine,hexhd.

2

76

801-113

HOSE, coupled, 1/2 NPT (MBE)

1

 

 

M8 x 20 mm

 

 

 

17-1/2" Ig

 

801-3929

ELECTRICAL SCHEMATIC

REF PART DESCRIPTION

NO. NO.

Qn

Items 77-90arepumpinternal replacement parts.

See exploded view of pump for details.

77801-027

, CAP

1

78801-028

. O-RING,cap

1

79801-267

. DISCHARGE

1

80

MANIFOI n

 

3

81

 

3

82

 

3

83

 

3

84

 

3

85

 

3

86

 

3

87 ... .- .

. - . - -

3

88 801-038

. RING,backup

3

89801-039

. O-RING

3

90801-040

. RETAINER,plunge1

3

Order parts by name and number. Always give the model number and series letter of the assembly forwhich you are ordering.

801-042 SEAL KITINCLUDES 3 SETS

SERVICE TOOLS

KEY WRENCH 801-044

EXTRACTOR TOOL 801-205

'80 801-392