Page 1
This manual
WARNINGS
READ
AND
contains
and
INSTRUCTIONS-
RETAIN
FOR
IMPORTANT
REFERENCe
2104E.MODEL
2
150
psi
(1
50
bar) OPERA TlNG PRESSURE
2250
psi
(155
bar).MAXIMUM WORKING PRESSURE
800-053
SERIES
"A"
Page 2
~~JJj~~~~Q,&!
Fluids under high pressure from spray or leaks can
penetrate the skin and cause extremely serious
injury, including .the need for amputation.
NEVER
the body.
NEVER
NEVER
body.
point the spray
put hand or fingersover the spray tip.
try to stop or deflect leaks with your hand or
ALWAYS
MEDlCAL
[=;'b~~.j~~~
gun
at anyone or any part of
have the tip guard
in
TRE&TMEF%B
place when spraying.
DO
not use chemicals or agents which are not
compatible with Buna-N and PVC or neoprene cover
of hose.
Do
not leave a pressurized unit unattended. Shut off
the unit and release pressure before leaving.
FORE
Do
not spray flammable liquids.
engine where combustible fumes or 'dust may be
present.
Do
not operatethe
GENERAL
NEVER
Keep clear of moving parts when the unit is running.
run the unit with the belt guard removed.
.
'
If
any
fluid appears to penetrate your skin, get
treatment instructions have' your doctor call the
F.Sb,iTlONAE
Avena
Even after you shut
high pressure
release
the spray tip or servicing the unit, always shut offthe
unit and trigger the gun to release pressure.
Be sure that
components will withstand the pressure developed.
NEVER
in system.
personal safety, as well as the function of the
equipment,
Before each use, check hose for weak, worn or
damaged conditions caused by traffic, sharp corners,
pinching or kinking. Tighten
securely before.each
hose.
~QM?~HENT
it
exceed the pressure rating of any component
PQ@OM
(41
in
the pump, hose and gun until you
by triggering the gun.
.all
NEVER
alter or modify equipment -your
is
at stake.
CENTER
2)6$1-6669
off
the gasoline engine, there
accessory items and system
.use.
Replace any damaged
NETWORK
So
before removing
all
fluid connections
is
observe detergent manufacturer's safety
precautions. Avoid getting detergent or other liquids
in your eyes. Follow
regarding contact with eyes, nose, and skin,
breathing fumes, etc. Always wear full goggles to
protect your eyes from the spray as well as any debris
dislodged by the spray. If necessary, wear gloves or
other protective clothing. If. antidotes or treatment
are recommendbd, be prepared to use them.
DON'T
weed killer.
This unit is supplied with an 8-foot power cord made
up of four AWG
electric cord is connected to the unit chassis and
motor frame. The other three wires are connected to
the starter switch.
Be sure to connectthe power cord to the appropriate
approved plug to fit your requirements.
The starter switch has
will shut
circuit
Always check to be sure the switch is
hoses and electric cord are clear of moving parts
before plugging
spray toxic chemicals such as insecticide or
off
the power to the unit whenever the
is
overloaded.
the
directions on the container'
No.
12
wires. The green wire of the
a
built-in.circuit breaker that
in
the power cord.
off
and thatthe
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act.
These standards
should
2
be
.
801-392
-
consulted
~~~
particulsrlythe.General Standards, Part
in
connection
with
your
use
.. ..
..
of
~~
airless
..
1910,
and the Construction Standards, Part
spray equipment.
.
..
1926
-
Page 3
,
..-..
:
:
REMOVE
FROM
!’
TAPE
PUMP CAP
\SPRAY
I
SPRAY
GUN
HOSE
..
r
.
,
L:’:
..,<
.~
..
..
:,
...
Check Electrical Service and
Plug
In
Before plugging in the sprayer. be sure the electrical
service is
3
phase
220
V,
60 HAC.
20
Amp. With the
ON-OFF switch in the OFF position, plug the power
supplY cord into
extension cord,
gauge (2.5
m)
long.
Install
mm2)
Hose and Spray
a
grounded outlet. If you use an
it
must have 4 wires of
at
and should not be over.100ft
Gun
least
(30.3
12
Connect the spray hose to the spray gun by inserting
at
the pin
disconnect coupler
the end of the hose into the quick
on
the gun. Connect the hose to
the fluid outlet in the same way.
Remove the tape from the cap
on
top of the pump.
Cleaning Accessories
For spraying detergent or other cleaning solution, we
recommend using
chemical injecior
kit.
See
a
Accessories and instruction manual 801-192 for
installation and operation.
For removing rust and old paint we recommend using
a
water sandblaster. See Accessories and instruction
manual 801 -190 for installation and operation.
To
Connect
Do
not exceed 1 6OoF (7OOC) ,water temperature to
pump in
Wate~
a
direct supply system.
Connect a hose with at least
from your city water supply to the unit’s
Supply
a
3/4
in. (19 mm)
3/4
ID
in.
garden hose threaded inlet. The supply hose should
not
be more than
NOTE:
For a direct supply system. your water
source
AT
50
ft.
(1
5
m) long.
at
the unitmust have a flow rate of
LEAST 5 GPM
(19
LITER/MIN).
If your operating conditions are different from above,
contact our Customer Service Department for
assistance.
801-392
3
Page 4
OPERATlQM
:
Startup
'
.
Before starting, be sure'to read the safety warnings
and setup instructions.
in
Turn on the water supply.
Trigger the gun to release any back pressure.
CAUTION
Never run the cleaning unit dry. Costlydamage
',
to the pump
supply iscompletelyturned
Inspect
necessary.
Cleaning
For Hydra-Clean technique, see the Chemical
Injector manual, 801
'I
For abrasive cleaning, see the Water Sandblaster
manual, 801 -1
all
will
result. Always be sure water
on
before operating.
connections for any leaks. Tighten if
-1
92.
90.
I
Check the filter screen
as often as necessary,
the unit with the inlet and filter screen removed.
DO
NOTtrytoadjusttheunloadervalveorchangethe
engine speed. Changing these settings rnay cause
excessive pressure, intermittent unloader operation,
wasted fuel and increased wear
the warranty.
PUMP MUST
of water prior to exposure to freezing temperatures.
Use and store the unit where it
to freezing temperatures.
unit, thaw before trying to start.
solution rnay be pumped prior to cold weather
storage.
Use only spray tips that are matched to the unit to
avoid excessive cycling and wear of the unloader
valve. See Accessories.
NOT
BE
the water inlet connection
at
least daily.
RUN
DRY
If
water does freeze
Do
on
parts and
and must be drained
will
not be subjected
.A
50%
CAUTION
not operate
will
void
in
the
anti-freeze
WAffiNBNG
Follow
installing nozzles:
1.
2.
3.
4.
5.
Shutdown and. Care
When unit is not in use, turn off water supply.
When shutting down for the day or weekend, shut off
unit, shut off water supply valve, and trigger gun to
release pressure. Wipe off the unit with
these precautions when removing and
Shutoff the cleaning unit andtriggerthegun
to relieve pressure. Engage the triggersafety.
Keep the nozzle and the tube pointed
from you and everyone else.
Do
not put your hand over the tip to push the
nozzle into place. Grasp
keep your fingers away from the tip.
Do
not let anyone else touch the spray valve
while you are cleaning nozztes.
Be sure the slip ring
the nozzle in place before triggering the spray
gun.
Of
it
from the side and
is
pushedforward to lock
Unit
away
a
damp rag.
pour hot water
temperature change may crack the ceramic
Do
not pump caustic materials.
Before extended storage, flush the pump with light
oil.
Avoid dragging hoseoveranabrasivesurfacesuch as
cement. This causes excessive wear and shorter
hose life.
Clean the intake line strainer daily.
Lubrication
Fill
pump crankcase to dot
25
oz.
or equivalent SA€
antiwear and rust inhibitor additives. Change initial
fill after
months or
and
(0.75
liters) of crankcase oil (part
50
hour running period. Change oil every
at
on
Care
40
500
hour intervals.
a
frozen pump. A sudden
on
oil,gauge window
no.
801
weight hydraulic
oil
with
-1
44)
with
WARNONG
NEVER
1
valve.
alter adlustment or modify the unloader
3
.
~i
.. .
.. . .
..
..
.:
.
~. ..
..
i
,.
Page 5
PROBLEM
CAUSE
SOLUTION
-0w~pressure.
’ump runs extremely rough,
Iressure low.
Worn nozzle.
Belt slippage.
Air leak in inlet plumbing.
Relief valve stuck, partially
plugged or improperly adjusted,
valve seat worn.
Inlet suction strainer clogged
01
improper size.
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.
Replace with nozzle of proper Size.
Tighten or replace; use correct belts and replacl
both
at
same time.
Disassemble, reseal, and reassemble
Clean, and adjust relief valve; check for worn
Kit
and dirty valve seats.
available.
Clean. Use adequate size. Check more
frequently.
..
Install proper filter. Check flow available
to
pump.
Clean inlet and discharge valve assemblies.
Replace worn valves, valve seats and/or
discharge hose.
Proper size inlet plumbing; check for airtight
seal.
.. .
.
:
”
-.
Inlet restrictions and/or air
Clean out foreign material, replace worn valves
‘eaks. Stuck inlet or discharge
talve.
Replace seals.
Install new packing
Nater leakage from under
-caking
H.P. seals.
vVorn packing.
:he manifold.
Nater in pump crankcase.
:requent or premature
May be caused by humid air
:ondensing into water inside the
:rankcase.
Scored plungers.
Change oil
Graco Crankcase Oil (other approved oil evenl
month or
Replace plungers,
at
200
3
month or
hours)
500
hour intervals usins
P.N.
801-144.
ailure of the packing.
3ver pressure to inlet manifold.
lamaged or worn plungers.
4brasive material in the fluid
Reduce inlet pressure.
Replace plungers.
Install proper filtration
on
pump inlet plumbing,
)eing pumped.
ixcessive pressure-and/or tem.
)erature of fluid being pumped.
.
..
.I
..
..
:
.
her pressure of pumps.
lunning pump dry.
Check pressures and fluid inlet temperature; be
sure they are within specified range.
Reduce pressure.
Do
not run DumD without water.
;trow surging
at
lnd low pressure
lischarge side.
the inlet
on
the
:oreign particles in the inlet or
lischarge valve, or worn inlet
Ind/or discharge valves.
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.
801-392
5
Page 6
CAUSE
ectrtc motor wont run.
Electric motor runs, but
no output.
*This unit has an overload breaker built into the switch assembly. If
60
cool for 30 to
needed.
NOTE:
minutes. Also, try to correct the cause of overheating. Always use the lowest pressure setting
A
M11 and M30 metric wrenches are
required for servicing pump.
Power cord unplugged, or
building circuit fuse blown
Overload switch has opened.
Power.cord unplugged, or
building circuit fuse blown,
Overload breaker has opened.
Extension cord.
Tip plugged.
Displacement pump frozen or
gear train damage.
Check, replace
Unplug power cord+, decrease pressure.
Check, replace.
Unplug power cord*, relieve pressure-allow
tO.CO01.
Don't
Remove and clean.
Thaw.
use
more than
it
opens, unplug power cord and let sprayer
100
ftof 12
ga
extension cord.
PUMP
Valves
Photo
Pumping
Photo
1
and
2.
1)
Remove the hex plug using an M30 wrench.
2) Examine O-ring under plug and replace if
evidence of cuts or distortion.
3)
Remove valve assembly including retainer,
spring, valve and valve seat from valve cavity.
NOTE:
4)
Replace valve parts
including retainer, spring, valve, valve seat,
ring and back-up-ring.
5)
Replace valve cover and torque to
Nm).
Valve assembly may come apart during
removal.
with
service
kit
75
Section
3.
1)
Remove the four
2)
Separate the manifold from the crankcase.
NOTE:
It
lightly with mallet to loosen.
(4)
hex nuts from the manifold.
may be necessary to tap manifold
(801-041)
o-
ft-lb (100
CAUTION
Keep manifold properly aligned with 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
Page 7
Plungers
Photo
4.
1)Using an M1 1 wrench,
remove the plunger retainer.
2)
Slide out the seal retainer with
oil wick and rubber barrier
slinger.
3)
With a slight twisting motion,
loosen the plunger from the
plunger rod and remove.
NOTE:
4)
Replace O-ring 'and back up
ring on plunger retainer.
5)
Saturate new oil wick by
soaking in oil.
6)
Install new plunger.
7)
Replace plunger retainer and
torque to
8)
Install new
retainer.
9)
Replace barrier slinger over
new plunger.
10) Lubricate each plunger sleeve
and carefully slide manifold
onto crankcase.
Seals
or
Photo
5,
)
Remove C-ring from seal case:
1
2)
Then remove the low pressure
seal from the seal case.
3)
Unscrew the seal case from
the manifold using
key wrench (801-044).
4)
Remove the high pressure
seal and examine. Before
replacing, lubricate
of new high-pressure seal and
press into manifold.
The stud may remain
with the retainer
when removed.
Disassemble and
screw stud into
plunger rod finger
tight.
80
in-lb
(9
oil
wick in seal
V-Packings
6,
7
and
8.
ID
Nm).
a
special'
and
OD
,.
,
:.
.
,.
..,,.
MOTE:
5)
Install new O-ring on sealcase
and lubricate
6)
Screw
7)
Lubricate
pressure seal and press into
seal case.
8)
Replace C-ring holding low
pressure seal in place.
A
socket and extension may be used to
pressure seal from
manifold.
OD
of O-ring.
seal
case into manifold.
ID
and
OD
of low
9)
Lubricate each plunger sleeve
and carefully slide manifold
onto crankcase.
.NOTE:
When replacing
manifold
ememe caution should
be
damage
onto
plungers,
exercised to avoid
to
the seals.
k
10)
Torqueallfour(4)boltsto240in-lb
(27
Nm).
NOTE:
Carefully study the
order of respective
parts and note
position of seals to
assure proper reassembly and operation.
801-392
7
Page 8
8
801-392
Page 9
i
!
Ref.
No.
50
Includes items
,
51-66
62
63
-52
PARTS
LIST
REF PART DESCRIPTION
NO.
NO.
1 HOSE & GUN ASSY.
detail'for parts
2
3
4
5
6
8
9
10
11
13
14
16
17
18
19
20
801-001
800-01 5
800-036
800-037
801-390
801 -285
801 -231
801-140
801-129
801-131
801-221
801 -379
801-382
801 -380
801-292
801 -021
PUMP, REPLACEMENT PARTS,
includes items
ANTI VIBRATION FOOT
CHASSIS
ELECTRIC MOTOR ASSY
BRACKET.
BELT,
drive
LABEL.
LABEL.
LABEL,
PLATE,
CONNECTOR,
SWITCH^
~~~~~
CORD,
STRAIN RELIEF
SCREW,
no.
6-32 NC
BOLT.
carriage,
5/16-18 NCx 5"
21
801
22
23
24
-088
801-298
801 -302
801-082
SCREW,
5/16-18
hd.
SCREW,
hd.
5/16-18 NC x 2-1/2"
SCREW,
5/16-18
.
. . . .
SCREW,
M6 x 30
25
801-081
SCREW.
M8
x
20
77-90
spacer
warning
identification
warning
serial
no.
crimp
starter
power
(8
fi
lg)
self tapping,
x
1
/2
NC
1"
~
x
1-1/2"
machine, hex hd.
machine, hex hd.
machine hex hd.
NCr
-
.
. - . . .
machine, hex hd.
mm
machine, hex hd.
mm
see
aun
~
QTY
2
2
4
4
4
2
REF PART DESCRIPTION
NO,
NO.
26
801 -023
27
801
28
29
30
31
32
34
35
36
37
40
41
42
44
46
47
1
48
50
1
4
1
.1
1
2
2
1
1
1
2
1
1
2
51
52
53
54
55
56
57
58
59
60
61
62
63
64
-01
-1
801
801.025
80.1 -024
801 -01
801-367
801
-004
801 -381
801-135
801-137
-01
801
801-364
801 -365
801 -132
801 -008
801 -388
801-389
801 -084
801 -045
801 -046
801 -047
801 -048
801 -049
801-050
800-012
,801-059
801-060
801
-OB1
65
66
67
68
801-105
801-106
.69
70
1
71
72
73
74
75
76
801-236
801-108
801-109
801-110
801
-1
801-11~2
801-113
WASHER,
5
WASHER,
WASHER,
39
WASHER,
NUT,
2
GROMMET
BUMPER
PULLEY,
PULLEY.
HUB.
KEY,
8
BRACKET,
BELTGUARD,
BELTGUARD.
RIVET,
LABEL.
LABEL,
LABEL.
UNLOADER.
.
CAGE,
.
O-RING
.
SPRING
,
BALL
.
SEAT
,
O-RING.
.
UNLOADER SUB-
.
O-RING
HOUSING
.
CYLINDER
O-RING
.
PLUG
HOUSING
.
SPRING
.
VALVE'
.
SEAT
COUPLER,
NIPPLE,
1
/2
TEE,
NIPPLE,
NIPPLE,
PLUG,
ADAPTER, 1 /2
1
1
NUT,
SCREEN,
HOSE,
17-1
flat,
1/4
flat,
5/16
IocIc
1
lock,
hex,
pulley
pulley
drive
identification
warning
identification
valve
5/16
5/16-18 NC
pump
rnntnr
(2"
lg)
tensioner
cover
baseplate
includes itkms
VALVE
male quick disconnect
straight, brass,
NPT x 3- 1 /2"
brass,
1
/2 NPT
hex, steel,
hex, brass,.l/4x
hex, brass,
brass, adapter
coupled,
/2"
inlet
Ig
hose
1
/2
/4
1
/2
z
3/8 NPT
NPT (MBE)
51-66
3/8 NPT
1/2 NPT
QN
8
16
4
10
7
4
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
801
-392
9
Page 10
REF
NO.
Items
PART
NO.
77-90
See exploded view of pump for details.
DESCRIPTION
are pump internal replacement parts.
ELECTRICAL SCHEMATIC
Qn
77 801-027
78 801-028
79 801-267
CAP
,
. O-RING,
.
DISCHARGE
MANIFOI
cap
n
80
81
82
83
84
85
86
87
.
. . .
-
88
801-038
. . - .
89 801-039
90 801-040
Order parts by name and number. Always give the model
number and series letter
ordering.
-
-
RING,
.
.
O-RING
.
RETAINER,
of
backup
plunge1
the assembly for which
you
are
801-042
INCLUDES
1
1
1
3
3
3
3
3
3
3
3
3
3
3
SEAL KIT
3
SETS
'80
801-392
SERVICE TOOLS
KEY WRENCH
EXTRACTOR TOOL 801-205
801-044
Page 11
PARTS
Gun and Hose
14
DWAVVlMG
5
A
Assern
'7
I-3
8
Repair
Includes items
Kit
801
-083
A,
B,
C.
D,
E
and
F
SERVICE
1.
Re'move the 8 screws from the body halves
(4).
See the Parts Drawing. Separate the body
halves.
2.
Remove the Plug
the valve body
3.
Remove
seat
4.
Remove the sleeve
actuator rod
the
(C)
and'o-ring
(14).
(G).
snap ring
(0).
nut
(F).
spring
(6).
(1 1)
(5)
Then remove
and O-ring
and ball
5.Afterinstallingthenewseat(C)andball(A),tapthe
ball lightly
seating between the ball and seat.
6.
Reassemble
new parts from the repair kit.
with
a hammer to assure a proper
in
reverse order, using the remaining
(A)
the
(E)
with'the
(3)
from
valve
and
REF
PART
NO.
NO.
1
801")7
2 800-017
3 801-244
4
'
801-245
5 801-249
6
801-254
7 801-256
8 801-262
9 801-261
10 801-247
11
801-253
12 801-246
13 801-263
14 801-250
15 801.264
16 801-265
17 801-134
18 801-029
19 801-009
20 '801 -090
21 801-073
22 "801 -010
23 '801 -01 1
24 801-074
25 801-076
26 801-077
27 801-103
28 '801 -091
Order
parts
you
by
are
which
DESCRIPTION
SPRAY HOSE, 3/8" ID. 50
(15
ml
SPRAY GUN,
include items 3-1 6)
.
.
.
.
.
.
. -.
.
.
TUBE.
GRIP
COUPLER,femalequickdisconnea
COUPLER, male quick disconnect
HOUSING, nozzle
TIP,
TIP, cleaning; 15O
GUARD,
PLATE,
RIVET
NIPPLE, hex: 1/4
COUPLER, male quick disconnect
name
ordering.
Ig
(replaceable
HANDLE, left
HANDLE,
;PRING
EVER
IEEDLE
IEX PLUG
IISCHARGE FIlTING
VALVE BODY
GUIDE SLEEVE
TUBE
INLET FllTlNG
CAP
..
SCREW
SCREW
blasting;
and
32"
tip
warning
series
right
Oo
x
letter
3/8" npc
ft.
parts
of
the assembly
brass
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
7
1
1
1
3
1
2
1
1
2
1
2
1
2
for
*Recommended
.'tool
box"
spare parts.
801
-392
1
d
Page 12
ACCESSORIES
(Must
be
purchased
separately)
CHECK VALVE
Prevent back up
supply. lnstatl upstream from pump.
WATER SANDBLASTER
For
abrasive cleaning of stubborn dirt and paint. For adjusting sand
801
-1
33
of
contaminated water into fresh For injecting harsh cleaning chemicals downstream
CHEMICAL INJECTOR
from pump.
800-103
ADJUSTABLE SAND SAVER
TECHNICAL DATA
MOTOR:
WATER PUMP:
WETTED PARTS:
WEIGHT:
OVERALL DIMENSION:
5
hp, 3 phase,
220
V,
60
50
PSI (1
21
pressure;
(15
liter/min).
Stainless Steel, Aluminum,
Phenolic Plastic, Ceramic
Liners, Nitrile Rubber.
Ibs
140
Length: 36
Width:
Height:
18
17
Hz, 17 Amp
50
bar) rnax.
4
GPM
in
(914 mrn)
in
(457
in
(432.rnm)
flow.
mm)
KIT
800-182
800-031
6OoF
MAX. WATER TEMPERATURE:
INLET HOSE CONNECTION:
THE
GRACO
GracoInc.warrantsa1Iequipmentmanufacturedbyitandbearingitsnametobefreefromdefectsin
material and workmanship under normal use and service. This warranty extends
purchaserforaperiodof
is installed and operated
not cover damage or wear which.
abrasion. corrosion, negligence. accident, substitution of non-Graco parts, faulty installation or
tampering.
This warranty is conditioned
examination by Gram
or
replace free
purchaser transportation prepaid. If inspection of the equipment does
workmanshipormaterial,repairswill
be
charged.
EOUIPMENT NOT COVERED BY GRACO WARRANTY. Accessories or components of equipment
sold by Graco that are
subiect to the warranty,
assistance
of
in
making such claims.
12monthsfromthedateofpurchaseandappliesonlywhentheequipment
in
accordance with written
to
verify the claimed defect. If the claimed defect
charge. any defective parts. The equipment will be returned to the original
not
manufactured
if
any. of their manufacturer. Graco will provide purchaserwith reasonable
in
the reasonable judgment of Graco. arises from misuse,
upon
the prepaid return of the equipment claimed
bemadeatareasonablechargeandreturntransportationwill
by
Graco (such as electric motors. switches, hose. etc.)are
1
3/4-in. garden hose
WARRANTY
factoryrecommendations.Thiswarrantydoes
(70°C)
is
not
(f)
to
the original
to
verified, Gram will repair
be defective for
disclose any defect in
Subsidiary
FaEtory
and
GRACO
AMIIata
BNC.
Branches:
Companies:
P.O.
Atlanta. Dallas, Detroit,
Canada: England: Switzerland; France; Germany; Hong Kong:'Japan
~QX
IWT
PRINTED IN U.S.A.
Los
Angeles. West Caldwell
MBNMEAIPOLQS.
801-392
9-82
MN
[N.J.)
%wo-na
. .
45-10043A
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