Graco AquaMax 804594 A Series, AquaMax 804596 A Series, AquaMax 804597 A Series, AquaMax DD6814, AquaMax DD9023 Instructions-parts List Manual
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INSTRUCTIONS–PARTS LIST
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This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
Direct-Drive
AquaMaxt Pressure Washers
Model 804594, Series A
AquaMax DD6814 pressure washer with 5.5-hp engine
and 680 liters/hr (3 gpm) pump on Hi-Boy cart with hose, gun, and tips
140 bar, 14 MPa (2000 psi) Maximum Working Pressure
Model 804597, Series A
AquaMax DD9021 pressure washer with 11-hp engine
and 900 liters/hr (4 gpm) pump on Hi-Boy cart with hose, gun, and tips
210 bar, 21 MPa (3000 psi) Maximum Working Pressure
Rev. B
First choice when
quality counts.t
Model 804596, Series A
AquaMax DD9023 pressure washer with 13-hp engine
and 900 liters/hr (4 gpm) pump on Hi-Boy cart with hose, gun, and tips
230 bar, 23 MPa (3300 psi) Maximum Working Pressure
U.S. Patent
Patented 1983, Canada
and other patents pending
Related Manual
Spray Gun 308511. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 804597
9259A
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Service
Model 804594 (DD6814) 12. . . . . . . . . . . . . . . . . . . . . .
Models 804596 (DD9023) & 804597 (DD9021) 14. . .
Parts Drawings and Lists
Model 804594 (DD6814) 16. . . . . . . . . . . . . . . . . . . . . .
Models 804596 (DD9023) & 804597 (DD9021) 18. . .
Pump Repair Kits 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 22. . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING
INJECTION HAZARD
Spray from the gun, leaks, or ruptured components can inject fluid into your body and cause serious
injury. Fluid splashed in the eyes or on the skin can also cause serious injury.
D Fluid injected into the skin might look like just a cut, but it is a serious injury. Get emergency
medical attention.
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.
D Do not point gun at anyone or at any part of body.
D Do not stop or deflect leaks with hand, body, glove, or rag.
D Do not put hand or fingers over spray tip.
D Tighten fluid connections before starting equipment.
D Engage the gun trigger safety whenever you stop spraying.
D Follow Pressure Relief Procedure on page 5 if spray tip clogs and before cleaning, checking, or
servicing equipment.
D Repair or replace worn or damaged parts immediately.
D Check hoses, tubes, and coupling daily. Do not repair high-pressure couplings: replace entire
hose. Fluid hoses must have spring guards on both ends to prevent kinks and rupture.
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WARNING
MOVING PARTS HAZARD
Moving parts, such as the drive belt, can pinch or amputate fingers.
D Keep clear of moving parts when starting or operating this equipment.
D Do not operate the pressure washer without all guards and interlocks installed and functioning.
HAZARDOUS FLUIDS
Improper handling of hazardous fluids can cause serious injury or death due to splashing in eyes,
ingestion, or bodily contamination.
D Know specific hazards of fluid being used.
D Store hazardous fluids in approved containers. Dispose of hazardous fluids per local, state, and
national guidelines.
D Wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid manufac-
turer.
FUEL HAZARD
The fuel used in this unit is combustible and when spilled on a hot surface can ignite and cause a fire.
Do not fill the fuel tank while the engine is running or hot.
EXHAUST HAZARD
The exhaust contains poisonous carbon monoxide which is colorless and odorless. Do not operate
this equipment in a closed building.
EQUIPMENT MISUSE HAZARD
Misuse of the pressure washer or accessories could cause them to rupture and result in fluid injection,
splashing in the eyes or on the skin, or other serious injury.
D Do not alter or modify any part or factory-set adjustment of this equipment.
D Do not exceed the maximum working pressure of any component or accessory in the system.
D Do not use any chemicals that are incompatible with the wetted parts as stated in Technical Data
on page 21.
D Do not alter throttle setting.
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pressure gauge
pump
Setup
spray
gun
hose
rack
hose
3/4 in. garden
hose connection
for water inlet
Fig. 1
Check for Shipping Damage
Check the unit for any damage that could have
occurred during shipping. Notify the carrier
immediately if there is any damage.
Setup
Connect the high-pressure hose between the pump
outlet and the gun inlet. Both of these connections are
made with quick couplers.
CAUTION
Up to 100 ft (30 m) of high-pressure hose may
be used. Longer hoses might affect pressure
washer performance and chemical injector
performance.
Install the appropriate spray tip on the wand. See
Installing and Changing Spray T ips on page 7. If
you are using a sandblaster kit, see its separate
manual for installation instructions.
high-pressure hose
connection
9259A
Connect to Water Supply
CAUTION
Before you connect to the water supply, check your
local plumbing code regarding cross-connection to
the water supply. A backflow preventer, Part No.
801133, is available to prevent backflow of
contaminated water into the fresh water supply.
Install it upstream from the pump.
If inlet water pressure is over 414 kPa, 4.1 bar
(60 psi), a regulating water valve, Part No. 800258,
must be installed at the garden hose connection.
Do not exceed 70_ C (160_F) inlet water
temperature.
Connect a hose with at least a 3/4 in. (19 mm) ID from
the water supply to the unit’s 3/4 in. garden hose inlet.
The supply hose should not be more than 50 ft (15 m)
long.
NOTE: The water source at the unit must have a
minimum flow rate equal to that of the unit. See
Technical Data on page 21.
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Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you
D Are instructed to relieve the pressure
D Stop spraying for more than 10 minutes
D Check or service any of the system equipment
D Install or clean the spray nozzle
1. Engage the trigger safety latch.
2. Turn the engine off.
3. Pull the plug wire off the spark plug.
4. Shut off the water supply.
5. Disengage the trigger safety latch, and trigger the
gun to relieve pressure. Then engage the trigger
safety latch again.
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, disengage the trigger
safety latch, and trigger the gun to relieve pressure.
Wrap a rag around the hose end coupling, and very
slowly loosen the coupling to relieve pressure
gradually, then loosen it completely, and clear the tip or
hose.
Operating Cautions
Always observe the following CAUTIONS when
operating the pressure washer to avoid costly damage
to the pressure washer.
CAUTION
Do not allow the pressure washer to idle for more
than 10 minutes. Doing so could cause the
recirculating water to overheat and seriously
damage the pump. Turn off the pressure washer if
it will not be spraying for 10 minutes. If heated
inlet water is used, reduce this time further . Do
not operate the pressure washer with the inlet
water screen removed; the screen helps keep
abrasive sediment out of the pump, which could
clog the pump or damage the cylinders. Keep the
screen clean. Do not pump caustic materials
through the pump; such materials could corrode the
pump components. However, it is safe to pump
antifreeze through the pump for cold-weather
transport and storage.
Trigger Safety Latch
WARNING
To reduce the risk of serious bodily injury, including
fluid injection and splashing in the eyes or on the
skin, always engage the trigger safety latch when
you stop spraying, even for a moment. In the
engaged position, the trigger safety latch prevents
the gun from being triggered accidentally by hand
or if it is dropped or bumped. Be sure the latch is
pushed fully down to prevent the gun from being
triggered. See Fig. 2.
WARNING
PRESSURE INDICATED ON GAUGE
The pressure gauge (shown in Fig. 1) indicates the
spraying pressure when the gun is triggered and
the bypass pressure when the gun is not triggered.
Pressure at the gun may be significantly higher
than the bypass pressure indicated on the pressure
gauge. Therefore, always follow the Pressure
Relief Procedure above regardless of the
pressure indicated on the gauge.
trigger safety
engaged
Fig. 2
trigger safety
disengaged
04612
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Operation
Startup
Always use this startup procedure to ensure that the
unit is started safely and properly.
1. Check the oil levels.
NOTE: All units are equipped with a low-oil sensor
that shuts the engine off if the oil level falls below a
certain level. If the unit stops unexpectedly, check the
oil and the fuel levels. Check the oil level each time
the unit is refueled.
WARNING
FIRE HAZARD
Do not refuel a hot engine. Refueling a
hot engine could cause a fire. Use only
fresh and clean regular or unleaded gasoline.
Close the fuel shutoff valve when refueling.
2. Check the fuel level.
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.
6. Pull the starter rope to start the engine. Brace one
foot on the pressure washer cart, and pull the
starter rope out quickly. Pull and return the rope
until the engine starts.
CAUTION
Do not allow the starter rope to snap back against
the engine. Return it gently to prevent damage to
the recoil mechanism.
NOTE: For easier starting, have one person start
the engine while another person triggers the spray
gun.
If the engine is cold, start the engine with the
choke completely closed. In cool weather, you
might have to let the engine run with the choke
closed for the first 20 to 30 seconds, then open it
completely. In warm weather, open the choke
completely as soon as the engine starts.
If the engine is warm, start the engine with the
choke completely open or partially closed. When
the engine starts, open the choke completely.
Chemical Injector Operation
NOTE: See manual 308513 for detailed chemical
injector operation and service instructions.
3. Turn on the water supply.
4. Trigger the gun until water sprays from the tip
indicating that the air is purged from the system.
5. Open the fuel shutoff valve. Be sure the spark
plug ignition cable is pushed firmly onto the spark
plug. Put the switch in the ON position, and put
the throttle in the RUN position.
1.
2. Insert the chemical filter (attached with clear tubing
to the chemical injector) into the container of
chemical.
3. Install the black, large-orifice chemical tip (see
Installing and Changing Spray T ips on
page 7).
The large orifice of the chemical injector tip causes
a drop in pressure that actuates the chemical
injector. Changing back to a small diameter spray
tip deactivates the chemical injector and produces
high pressure for rinsing. The chemical filter can
be left in the chemical container during
high-pressure use. To regulate the flow rate of the
chemical, turn the chemical adjustment knob on
the injector. Maximum chemical flow is two full
turns counterclockwise from the closed (clockwise)
position.
Relieve the pressure.
See page 5.
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Operation
Installing and Changing Spray Tips
Tips are stored in storage holes on the cart of the
pressure washer.
WARNING
To reduce the risk of serious bodily injury, including
fluid injection and splashing in the eyes or on the
skin, use extreme caution when changing spray
tips. Always follow the procedure below.
1.
2. Select a spray tip appropriate for your application.
Spray tips are stamped with 4- or 5-digit numbers.
The first two digits denote the spray angle. The
following table lists the spray tips.
NOTE: The chemical injector tip is brass and has
a large opening and a black plastic cap.
Spray Tip Number Spray Pattern Fan Angle
00XXX 0_ blaster (red)
15XXX 15_ (yellow)
25XXX 25_ (green)
40XXX 40_ (white)
Relieve the pressure.
See page 5.
5. Pull on the tip to be sure the tip is secure before
you spray again.
CAUTION
To avoid blowing the O-ring out 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.
NOTE: See the sandblaster kit manual for detailed
cleaning information if this accessory is used.
Shutdown, Flushing, and Storage
Antifreeze Flush Kit 802327 is available to make
flushing easier. This kit is for flushing the system with
50% antifreeze solution prior to transporting or storing
the pressure washer in below-freezing temperatures.
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 could crack
the ceramic plungers.
For Pressure Relief,
see page 5.
3. Point the gun and wand away from yourself and
anyone else.
4. Without holding your hand over the spray tip (A),
pull back the quick coupler ring (B). Remove the
current tip, install a different one, and push back
the ring. See Fig. 3.
B
A
Fig. 3
04929
D If the pressure washer will be exposed to freezing
temperatures, flush the unit with a 50% antifreeze
solution. Relieve the pressure and flush the
pressure washer before you use it again to remove
the antifreeze.
D Before long-term (overnight) storage or transporting
of unit, disconnect the water supply and turn off the
fuel supply valve.
D After each use, wipe all surfaces of the pressure
washer with a clean, damp cloth.
D Perform the appropriate maintenance. See
Maintenance chart on page 9.
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