Read and understand all instruction manuals before operating equipment.
FLUID INJECTION HAZARD
WARNING
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
splashed
damage.
NEVER
part of the body.
spray
ALWAYS
before
NEVER
body.
Be sure equipment safety devices are operating
properly
the need for amputation. Also, fluid injected or
into the eyes or on the skin can cause serious
point the spray gun or wand at anyone
NEVER
tip.
follow the Pressure Relief Procedure ,
cleaning or servicing any part of the sprayer
try to stop or deflect leaks with your hand or
before each use.
put hand or fingers over the
or at any
.
Medical Treatment
If any fluid appears to penetrate your skin, get
EMERGENCY
NOT
TREA
what
fluid was injected.
NOTE TO PHYSICIAN:
traumatic
surgically as soon as possible.
treatment
with
some exotic
MEDICAL TREA
T AS A SIMPLE CUT. T
injury
.
It is important to treat the injury
to research toxicity
coatings injected directly into the
bloodstream. Consultation with a plastic surgeon
reconstructive hand surgeon may be advisable.
or
TMENT A
ell the doctor
T ONCE. DO
exactly
Injection in the skin is a
Do not delay
. T
oxicity is a concern
Pressure Relief Procedure
To
reduce the risk of
injection and splashing in the eyes, or on the skin,
always follow this procedure whenever you stop
spraying
and
1. Engage
2. T
3.
4.
5. Disengage the trigger safety latch and trigger the
6. Before long–term (overnight) storage or
for more than 10 minutes, when shutting
before checking or repairing any part of the
the trigger safety latch.
urn the sprayer of
Remove the ignition cable from the spark plug.
Shut of
gun
safety
transporting of unit, disconnect the water supply ,
and
f the water supply
to relieve pressure,
latch again.
turn of
serious bodily injury
f.
.
and then engage the trigger
f the fuel supply valve.
, including fluid
down,
system.
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
SAFETY LA TCH: Whenever you stop spraying for a
moment,
or
properly set the safety latch can result in accidental
triggering
SPRAY TIP SAFETY : Use extreme caution when
cleaning
spraying, engage the gun safety latch immediately.
ALWAYS
then
bodily injury
always set the gun safety latch in the engaged
“safe” position, making the gun inoperative. Failure to
of the gun.
or
changing spray tips. If a spray tip clogs while
follow the Pressure Relief Procedure and
remove the spray tip to clean it.
.
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
fluid injection, splashing in the eyes or on the skin, or
other serious bodily injury , fire, explosion or property
damage.
NEVER
so
could cause it to malfunction.
CHECK
replace
ALWAYS
clothing.
chemical manufacturer’s literature for
recommendations on additional protective equipment,
such
parts, can cause them to rupture and result in
alter or modify any part of this equipment; doing
all spray equipment regularly and repair or
worn or damaged parts immediately
wear protective eyewear and appropriate
If using a chemical injector
as a respirator
.
, read and follow the
.
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
emitted from it can cause a fluid injection injury or
spray
other
serious bodily injury or property damage.
ALL FLUID HOSES MUST HA VE STRAIN RELIEFS
ON BOTH ENDS.
hose from kinks or bends at or close to the coupling,
can result in hose rupture.
which
TIGHTEN
use.
allow high pressure spray to be emitted from the
coupling.
all fluid connections securely before each
High pressure
The strain reliefs help protect the
fluid can dislodge a loose coupling or
System
This
sure
to withstand the maximum working pressure of this
sprayer.
pressure of any component or accessory used in the
system.
Pressure
sprayer can develop high operating pressures.
that all spray equipment and
DO NOT
exceed the maximum working
accessories are rated
Be
Chemical Compatibility
BE SURE
injector
gun,
back cover). Always read the chemical manufacturer ’s
literature before using any chemical in this pressure
washer.
NEVER
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
with tape or any other device. A repaired hose cannot
contain
HANDLE AND ROUTE HOSES CAREFULLY.
on hoses to move the pressure washer
pull
chemicals
and
temperatures
(–40_ C).
that all chemicals used in the chemical
are compatible
wand
and tip, as given in the T
use a damaged hose. Before each use, check
try to recouple high pressure hose or mend it
the high pressure fluid.
which
cover of the hose.
above 200
with the wetted parts of the hose,
echnical Data (inside
. Do not use
are not compatible with the inner tube
DO NOT
_ F
expose Graco hose to
(93
_ C)
or below –40
Do not
_ F
FUEL AND EMISSION HAZARDS
NEVER
The
on
tank
NEVER
exhaust contains carbon monoxide, a poisonous,
odorless,
death
fill the fuel tank
fuel used in
a hot surface can ignite and cause a fire.
slowly to avoid spilling.
operate the unit in a closed building. The
if inhaled.
this unit is combustible and when spilled
invisible gas which can cause serious injury or
while the unit is running or hot.
ALWAYS
fill
NEVER
Tampering with this adjustment can damage the
pressure
alter the throttle setting, which is factory set.
washer and will void the warranty
.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers or other
parts.
body
or
operating the pressure washer
NEVER
and interlocks installed and functioning. Follow the
KEEP CLEAR
operate the pressure washer without all guards
of moving parts when starting
.
Pressure Relief Procedure before checking or
servicing the pressure washer to prevent discharging
pressure fluid from the gun.
high
TERMS
WARNING: Alerts user to avoid or correct conditions
could cause bodily injury
that
CAUTION: Alerts user to avoid or correct conditions
could cause damage to or destruction of equipment.
that
.
NOTE:Identifies
helpful procedures and
information.
IMPORTANT
United
States Government safety standards have been adopted under the Occupational Safety and Health Act. These
standards—particularly the General Standards, Part 1910, and the Construction Standards, Part 1926—should be
consulted.
4308-505
INSTALLATION
HIGH
PRESSURE
HOSE
CONNECTION
INLET WATER
CONNECT
GARDEN HOSE
2040
ON 3/4”
QUICK
COUPLER
SPRAY
GUN
QUICK
COUPLER
HIGH PRESSURE
HOSE CONNECTION
Figure
INLET WATER CONNECT
3/4” GARDEN HOSE
1
ON
Check for Shipping Damage
The unit should be checked for any damage that may
have
and
occurred
the
in shipping. Any damage should be noted
carrier notified immediately
.
Set Up
If
you are using a downstream chemical
between the pump unloader and the high pressure
using the quick couplers provided.
hose,
Connect the high pressure hose between the pump
outlet and the gun inlet. Both of these connections are
with quick couplers.
made
injector
, install it
SPRAY
HOSE
1535
Connect to Water Supply
CAUTION
Before attaching to the water supply , check
your local plumbing code regarding cross–
connection to the water supply . A backflow
preventer P/N 801–133 is available to prevent
backflow of contaminated water into the fresh
supply
water
If
inlet water pressure is over
regulating water valve P/N 800–258 must be
installed
. Install it upstream from the pump.
60 psi (4.1 bar) a
at the garden hose connection.
CAUTION
Up to 100 ft
be used.
performance, and chemical injector
performance,
Install the appropriate spray tip on the wand. See
Installing and Changing Spray T ips. If you are using a
sandblaster
instructions.
(30 m) of high pressure hose may
Longer hoses may affect sprayer
if used.
kit, see its separate manual for installation
Do not exceed 160_F (70_C) inlet water
temperature.
Connect
the water supply to
The supply hose should not be more than 50 ft (15 m)
long.
NOTE:The water source at the unit
a hose with at least a 3/4 inch (19 mm) ID from
minimum
Technical
the unit’
flow rate equal to that of the unit (see
Data, inside back cover).
s 3/4 inch garden hose inlet.
must
have a
STARTUP
Use this procedure whenever starting the pressure
washer to help insure that the unit is ready to operate
starting is done safely
and
Check oil levels.
1.
Engine: Add SAE 30 or 10W–30 weight detergent
as necessary
oil
Add
Pump:
as
necessary
NOTE:
2. Check
SAE 20 or 30 weight non–detergent oil
.
Some
units are
that shuts the engine of f if the oil level falls
below a certain level. If the unit stops
unexpectedly, check both the oil and the fuel
Check the oil level each time the unit is
levels.
refueled.
fuel level.
.
.
equipped with a low–oil sensor
WARNING
DO NOT
engine
regular or unleaded gasoline. Close the fuel
shutoff
3. T
urn on the water supply
refuel a hot engine. Refueling a hot
could cause a fire. Use only fresh, clean
valve during refueling.
.
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.
4. Trigger the gun until water sprays from the tip
indicating
5. Open the fuel shutof f valve and be sure the spark
plug ignition cable is pushed firmly onto the spark
plug. On those units equipped with an ignition
shutoff switch, the switch should be in the “on”
position.
6.
Start the engine.
NOTE:For
that the air is purged from the system.
Throttle should be in the “run” position.
easier starting, have one person start the
pressure washer while another person
triggers
the spray gun.
If the engine is cold, completely close the engine
choke.
pressure washer chassis and pull rope rapidly
firmly. Continue holding the rope as it returns. Pull
and return the rope until the engine starts. In cool
weather,
10 to 30 seconds before opening it to keep the
engine
as
If
partly close it. Start the engine as described in the
preceding paragraph. When it starts, be sure to
open
Grasp the starter rope, brace one foot on the
the choke
running. Otherwise, open the choke as soon
the engine starts.
the engine is warm, leave
the choke completely
may have to be kept closed for
the choke open, or just
.
CAUTION
On recoil start engines, never let the starter
rope return by itself. It could jam the recoil
system.
ALWAYS
7.
whenever
reduce the risk of fluid injection or splashing in the
eyes
accidentally.
ALWAYS
8.
avoid
engage the gun’ s trigger safety latch
you stop spraying, even for a moment,
or on the skin if the gun is bumped or triggered
observe the following CAUTIONS to
costly damage to the pressure washer
CAUTION
DO NOT
more
recirculating water to overheat and seriously
damage the pump. Turn of f the pressure
washer if it will not be spraying or cleaning at
least every 10 minutes. If heated inlet water is
used,
DO NOT
damage
fully
DO
inlet
keep
could clog or scratch the pump. Keep this
screen
DO NOT
materials
9. See
for detailed cleaning information if these
accessories
allow the pressure washer to idle for
than 10 minutes. Doing so may cause the
reduce this time further
run the pump dry , which will quickly
the pump. Be sure the
turned on before starting the pump.
NOT
operate the pressure washer with the
water
screen removed. This screen helps
abrasive sediment out of the pump, which
clean.
pump caustic materials; such
may corrode the pump components.
the chemical injector or sandblaster kit manual
are used.
.
water supply is
and
to
.
6308-505
Trigger Safety Latch
WARNING
To reduce the risk of serious bodily injury,
including
on
latch whenever spraying stops, even for a
moment.
fluid injection, splashing in the eyes or
the skin,
ALWAYS
engage the trigger safety
Installing and Changing Spray Tips
WARNING
To reduce the risk of serious bodily injury,
including
or onto the skin, use extreme caution when
changing spray tips.
procedure
fluid injection or splashing in the eyes
below
ALWAYS
.
follow the
the engaged position, the
In
prevents the gun from being triggered
accidentally by hand or if it is dropped or
Be
bumped.
when engaging it or it cannot prevent the gun
being triggered. See Figure 2.
from
TRIGGER SAFETY LA
sure the latch is pushed fully down
trigger safety latch
TCH SHOWN ENGAGED
1.
Follow the
2. Point the gun and wand away from yourself and
anyone
3. Without
back
and/or
See
Figure 3.
4. Be sure the tip is secure before starting to spray
again.
5. Tip
holding holes are provided on the chassis.
Pressure Relief Procedure
else.
holding your hand over the spray tip (A), pull
the quick coupler ring
install a new one, and then release the ring.
(B). Remove the old tip
.
CAUTION
To avoid blowing the o–ring out of the quick
coupler,
never
securely
due to the high pressure in the system,
operate the pressure washer without a tip
mounted in the quick coupler
.
Figure 2
TRIGGER SAFETY LA
DISENGAGED
A
B
TCH SHOWN
Figure 3
7308-505
SHUTDOWN, FLUSHING AND STORAGE
WARNING
PRESSURE
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,
before checking or repairing any part of the
and
system.
RELIEF PROCEDURE
MAINTENANCE
Observing regular maintenance intervals helps ensure
that you get maximum performance and life from the
pressure
There is a break–in period for the engine, pump and
gear reducer (if used). After changing the oil in these
components
the
If the unit is operating in dusty conditions, these
maintenance
washer
interval between required changes is longer
.
following their
checks should be made more often.
respective break–in periods,
.
1. Engage
2. T
3. Remove the ignition cable from the spark
plug.
4. Shut
5. Disengage the trigger safety latch and
trigger
engage
6. Before long–term (overnight) storage or
transporting of unit, disconnect the water
supply,
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–freeze solution. Relieve
pressure.
again
NOTE:An anti–freeze flush kit P/N 802–327 is
the trigger safety latch.
urn the sprayer of
of
f the water supply
the gun to relieve pressure, and then
the trigger safety latch again.
and turn of
Flush the pressure washer before using it
to remove the anti–freeze.
available
to make flushing easier
f.
.
f the fuel supply valve.
.
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
may
crack the ceramic plungers!
2. After each use, wipe all surfaces of the pressure
washer
3. Perform the appropriate maintenance. See
maintenance
with a clean, damp cloth.
chart.
or into the pump; it
WARNING
To reduce the risk of serious bodily injury,
including
on
follow the Pressure Relief Procedure
Warning
Interval
Daily
After first 5
hours of
operation
Each 25 hours
of operation
After first 50
hours of
operation
Each 100 hours
of operation
or 3 months
Each 500 hours
of operation
or 6 months
fluid injection, splashing in the eyes or
the skin or injury from moving parts, always
before proceeding.
What to do
Clean water inlet screen and
filter
. Check engine and pump oil
levels. Fill as necessary
gasoline level. Fill as necessary
Change engine break–in oil.
Drain oil when warm. Use SAE
30 or 10W–30 detergent oil.
Clean and remove air cleaner
foam. Wash with water and
detergent. Dry thoroughly
with oil and squeeze to distribute
oil.
Change pump break–in oil. Use
SAE 20 or 30 non–detergent oil.
Change gear reducer oil. Use
SAE 90 gear oil.
Clean or replace paper air
cleaner cartridge. T
remove dirt. Change engine oil.
Use SAE 30 or 10W–30
detergent oil.
Change pump oil. Use SAE 20
or 30 non–detergent oil. Change
gear reducer oil. Use SAE 90
gear oil.
. Check
ap gently to
.
. Rub
TROUBLESHOOTING CHART
To
reduce the risk of serious bodily injury
injury
from moving parts, always follow the
WARNING
, including fluid injection, splashing in the eyes or on
Pressure Relief Procedure W
arning
before proceeding.
the skin or
PROBLEM
Engine will not start or
is hard to start
Engine misses or
lacks power
pressure and/or
Low
pump runs rough
W
ater leakage from
under pump manifold
W
ater in pump
Frequent or premature
failure of the packings
Strong surging at the
inlet and low pressure
on the discharge side
Oil leakage between
the gear reducer cover
and case
Oil leakage between
the gear reducer cover
and the pump
Oil leakage between
the gear reducer case
and the engine
CAUSESOLUTION
No gasoline in fuel tank or carburetor
Low oil (on units with low oil sensor).
Start/Stop switch in Stop position.
W
ater in gasoline or old fuel.
Choked improperly
Dirty air cleaner filter
Spark plug dirty
Spray gun closed.
Partially plugged air cleaner filter
Spark plug dirty
W
orn or wrong size tip.
Inlet filter clogged.
W
orn packings, abrasives in water or
natural wear
Inadequate water supply
Fouled or dirty inlet or discharge valves.
Even a small particle can cause the valve
to stick.
Restricted inlet.
W
orn inlet or discharge valves.
Leaking high pressure hose.
orn packings.
Humid air condensing inside crankcase.
W
orn packings.
Oil seals leaking.
Scored, damaged or worn plungers.
Abrasive material in the fluid being pumped.
Inlet water temperature too high.
Overpressurizing pump.
Excessive pressure due to partially plugged
or damaged tip.
Pump running too long without spraying.
Running pump dry
Foreign particles in the inlet or discharge
valve or worn inlet and/or discharge valves.
W
orn gasket.
W
orn oil seals and/or o-ring.
W
orn oil seal.
. Flooded engine.
.
, wrong gap or wrong type.
, wrong gap or wrong type.
.
.
.
.
.
Fill the tank with gasoline, open fuel shut of
Check fuel line and carburetor
Add to proper level.
Move switch to start position.
Drain fuel tank and carburetor
spark plug.
Open choke and crank engine several times to clear
out gas.
Remove and clean.
Clean, adjust the gap or replace.
T
rigger spray gun.
Remove and clean.
Clean, adjust the gap or replace.
Replace with tip of proper size.
Clean. Check more frequently
Check filter. Replace packings. See PUMP SERVICE.
Check water flow rate to pump.
Clean inlet and discharge valve assemblies. Check
filter.
Check garden hose, may be collapsed or kinked.
Replace worn valves.
Replace high pressure hose.
Install new packings. See PUMP SER
Change oil as specified in MAINTENANCE.
Install new packings. See PUMP SER
Install new oil seals. See PUMP SER
Install new plungers. See PUMP SER
Install proper filtration on pump inlet plumbing.
Check water temperature; may not exceed 160
Do not modify any factory–set adjustments. See
EQUIPMENT MISUSE HAZARD.
Clean or replace tip. See Installing and Changing
Spray Tips.
Never run pump more than 10 minutes without
spraying.
, including fluid injection, splashing in the eyes or on the
arning
on page 2 before proceeding.
skin or injury
Replacing the O–Ring
1. Remove the four bolts and lockwashers, and the
four washers, bumpers, and bolts. Then pull the
and gear reducer assembly of
pump
2. Drain the gear reducer oil by placing a container
it and removing the drain plug with
under
wrench.
3. Remove the four screws and lockwashers with a
6 mm wrench and pull the gear case of f the gear
cover.
4. Remove the old o–ring. Clean the gear cover and
case surface. Lightly coat the new o–ring with
grease
5. Follow steps 4 through 6 under Assembling the
Gear
Replace the o–ring if damaged.
and install it in the gear case.
Reducer if this is all the service required.
f the engine.
a 22 mm
Replacing the Gasket
1. Follow steps 1 through 3 under Replacing the
O–Ring.
2. Using
3. Remove
4. Remove
5. Follow
a 4 mm wrench, loosen the setscrew and pull
the
gear of
gear
Clean
both
the
gear cover
Reducer
f the pump with a gear puller
the four
cover
the
the gear cover and pump surface. Lightly coat
sides of the gasket with grease and install it on
the instructions under Assembling the Gear
if this is all the service required.
screws and lockwashers from the
.
gear cover and gasket from the pump.
.
.
Replacing the Oil Seal
NOTE:The
1. Follow
2. Pry
damage
3. Wipe
lightly
gear
of the seal, to push the seal into the case until its top
surface
4. Follow steps 4 through 6 under Assembling the
Gear
oil seal MUST be replaced if removed.
steps 1 and
the oil seal out of the gear case. Be careful not
the gear case.
the inner surface of the gear case clean, then
coat it with grease. Place the oil seal into the
case. Use a socket, placed against the surface
is past the ridge in the bore.
Reducer if this is all the service required.
2 under Replacing the O–Ring.
Assembling the Gear Reducer
1. Make
2. Align
3. Align
4. Make sure the o–ring is in place. Refer to step 4
sure the
cover.
Refer to step 4 under Replacing the Gasket.
Then,
install the gear cover on the pump shaft.
the holes in the gear cover with the holes in the
pump. Apply low strength Loctite (blue) on the
screw threads and secure the cover with the four
screws and lockwashers. T ighten them oppositely
evenly
and
the gear’s slot
and slide the gear onto the shaft, up to the pump’s
shoulder. Apply low strength Loctite on the
setscrew threads and tighten the setscrew to lock
gear on the shaft.
the
under Replacing the O–Ring. Install the gear case
on the cover, aligning the holes, and secure it with
the four screws and lockwashers. Tighten them
oppositely
gasket is properly placed on the gear
.
with the key on the pump shaft
and evenly
.
to
5. Grease the engine shaft. Align the gear ’s slot with
the key on the engine shaft and slide the gear
reducer
9802–342 SCREW4
10802–355
11802–356
12802–357
13802–358 BEARING1
14802–359
15801–484 CAP
16802–344 O–RING1
17802–345
18802–331 BOLT
19802–360 SCREW4
20801–139 W
COVER, Mounting
, Set
GEAR, Pump
CASE, Mounting
ASHER, Lock
SEAL, Oil
RING, Snap
RING, Snap
GEAR, Engine
, G 3/8 BSP
GAUGE, Sight
, 5/16–24 x 1”
ASHER, Lock
1
1
1
1
8
1
1
1
1
1
1
4
4
15308-505
GEAR REDUCER SERVICE (2040)
To
reduce the risk of serious bodily injury
from
moving parts, always follow the
Pressure Relief Procedure W
WARNING
, including fluid injection, splashing in the eyes or on the
arning
on page 2 before proceeding.
skin or injury
Replacing the Gasket
NOTE:To maintain a good seal, the gasket must be
replaced whenever the gear reducer is
disassembled.
1. Remove the four bolts and lockwashers, washers
and pull the pump and gear reducer assembly of f
engine.
the
2. Drain the gear reducer oil by placing a container
it and removing the drain plug with
under
wrench.
3. Remove the nine screws with a 6 mm wrench and
pull
4. Remove the old gasket. Clean the gear cover and
case surface. Lightly coat the new gasket with
grease
5. Follow steps 5 through 7 under Assembling the
Gear
Replace the o–ring if damaged.
the gear case of
and install it in on the gear case.
Reducer if this is all the service required.
f the gear cover
a 22 mm
.
Replacing the Oil Seals
1. Follow steps 1 through 3 under Replacing the
Gasket.
2. Loosen
the
3. Using
sure to keep them separate from the other nine
screws
4.
Remove the four oil seals and replace them.
5. Follow steps 2 through 7 under Assembling the
Gear
the setscrew
gear of
f the pump with a gear puller
a 6 mm wrench,
removed previously
Reducer if this is all the service required.
, using a 4 mm wrench, and pull
.
remove the four screws. Be
.
Replacing the O–Ring
1. Follow
2. Pull the gear cover of f the pump and replace the
3. Follow instructions under Assembling the Gear
the instructions under
and Replacing the Oil Seals to disassemble the
gear reducer.
o–ring.
Reducer
if this is all the service required.
Replacing the Gasket
Replacing the Oil Seal
NOTE: The oil seal MUST be replaced if removed.
1.
Follow steps 1 and 3 under Replacing the Gasket.
2. Remove the snap ring from the gear case, using a
ring pliers. Pull the gear and bearing.
snap
3. Push the seal from the inside to the outside of the
gear case by placing screwdriver against the seal
lightly tapping it with hammer
and
4. Wipe
5. Place
6. Follow steps 4 through 7 under Assembling the
the inner surface of the case clean, then lightly
coat it with grease. Place the oil seal into the gear
case. Use a socket, placed against the surface of
the seal, to push the seal into the case until its top
surface
and
Gear
is past the ridge in the bore.
the gear and bearing back into the gear case
install the snap ring.
Reducer if this is all the service required.
.
Assembling the Gear Reducer
1. Grease the o–ring and make sure it’s properly
on the gear cover
placed
2. Place
3. Apply low strength Loctite (blue) on the screw
4. Grease
5. Make sure the gasket is in place (refer to step 4
6. Grease the engine shaft. Align the gear ’s slot with
the four oil seals and screws in the gear cover
the o–ring on the screw to hold it in the cover
Place
threads,
and
key on the pump shaft and slide the gear onto the
shaft,
Loctite on the setscrew threads and tighten the
setscrew
under
on the case, aligning the holes, and secure it with
the nine screws and lockwashers. Tighten the
screws
the key on the engine shaft and slide the gear
reducer
NOT USED
49802–305 SCREW
50802–304 W
51801–482
52801–483 W
53801–484
54801–485 W
RING, Head
RET
AINER, Packing
RING, Long Life
, Cap, socket hd.
ASHER, Lock
PLUG, Hex
ASHER, Flat
PLUG, Hex
ASHER, Flat
2
2
1
1
1
1
:
Part of kit 1, 801–472 V
h
Part of kit 2, 801–473 Oil Seal Kit
K
Part of kit 3, 802–51
D
Part of kit 4, 802–306 V
n
Part of kit 6, 801–474 Plunger Repair Kit
[
Part of kit 8, 801–486 Packing Kit
J
Part of kit 28, 801–487 Packing and Retainer Kit
alve Kit
1 Crankshaft Seal Kit
alve Cap Kit
21308-505
PUMP
SER
VICE
WARNING
To reduce the risk of serious bodily injury,
including
on
follow the Pressure Relief Procedure
Warning
NOTE:The following metric wrenches are needed:
NOTE:There are two dif ferent tool kits to aid in
fluid injection, splashing in the eyes or
the skin, or injury from moving parts,
before proceeding.
M13 and M30. Repair kits are available.
M10,
Refer to
pump
results,
servicing the pump. P/N 800–298 is used to
ease installation of packings. P/N 800–271
includes
in
the
individual repair sections and the
parts page for more details.
use all parts in the kits.
the items in 800–298 and tools to aid
the removal of packing retainers.
always
For the best
Valves
NOTE:
1. Remove the hex plug from the manifold using an
2. Examine
3. Remove the valve assembly from the cavity; the
4. Install
NOTE:
For a set of six valves, order P/N 801–472.
wrench.
M30
the o–ring under the hex plug and replace
it
if it is cut or distorted.
assembly
torque
may come apart.
the new valve. Install the o–ring and hex plug;
to 75 ft–lb (103 Nm).
Retorque the plug after 5 hours of operation.
Servicing the Plungers
NOTE:Plunger
replace retainers, o–rings, washers and
backup
1. Loosen
using
an M10 wrench.
crankcase to separate the plunger and retaining
screw.
2. Remove the screw from the plunger and examine
o–ring,
the
washer. Replace these parts if necessary using kit
801–474.
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
cannot be reused. An oil seal kit is available to
they
replace
5. Lightly grease the flinger and oil seal, if it is being
replaced and replace them on the plunger shaft.
install the plunger
Then
6. Lightly
of the plunger
ring
around the screw and install the screw through
the
plunger
NOTE:If you plan to replace the packings, refer to
Servicing
repair kit, P/N 801–474 is available to
rings for three cylinders.
the plunger retaining screw five
Push the plunger towards the
backup ring and copper bearing/gasket
the seals.
.
grease the retaining screw and
. Place the washer
. T
orque to 14.4 ft–lb (19.5 Nm).
the V–Packings.
, o–ring and backup
to six turns,
the outer end
Pumping Section
1. Remove
the
2. Carefully
NOTE:It
the
eight capscrews and lockwashers from
manifold using an M13 wrench.
separate the manifold
may be necessary to tap the manifold lightly
with
a soft mallet to loosen.
from the crankcase.
CAUTION
Keep the manifold properly aligned with the
ceramic plungers when removing to avoid
damage
3. Carefully examine each plunger for any scoring or
cracking
to the plunger or seals.
and replace as necessary
.
7. Lubricate the outside of each plunger . Slide the
manifold onto the crankcase, being careful not to
damage
8. Install the capscrews and washers finger–tight.
Torque the screws to 21.7 ft–lb (29 Nm) following
the
may
Figure 4
the seals.
tightening pattern (Figure
cause the manifold to bind or jam.
5
8
14
3
4). Uneven tightening
2
7
6
Servicing the V–Packings
PTFE
PTFE
PTFE
PTFE
PTFE
PTFE
PTFE
NOTE: There
1. Remove the manifold as outlined in the Pumping
Section.
2. Carefully pull the packing retainer from the
manifold.
or
damaged.
3. Remove the v–packing and head ring. Pull out the
intermediate retainer ring. Remove the second
v–packing
4.
Inspect all parts and replace as necessary
are two types of packing kits:
one is just
packings, the other includes the packings,
and retainers.
rings
Examine the o–ring and replace it if it is cut
and second head ring.
.
ACCESSORIES
(Must be purchased separately)
5. Thoroughly
6. Lightly
clean the packing cavities and examine.
grease the packing cavities and then replace
the packings in the following order: head ring,
v–packing,
and
packing retainer with the o–ring installed in
retainer
intermediate ring,
groove.
head ring, v–packing
CAUTION
Be
very sure the parts are installed in the proper
order and facing the correct direction. See
Pump assembly on pages 18 and 20.
Improperly installed parts will cause a
malfunction.
Anodized aluminum, Aluminum or bronze alloys, Brass Copper
Ceramic, Buna–N, Cotton phenolic, 303, 304, and 316 Stainless steel, Polymide–12
thermoplastic,
is a registered trademark of the DuPont Company
r
, Carbon steel, Zinc with or without yellow chromate plate
.
, Nylon–
r
composite,
THE GRACO WARRANTY
WARRANTY
Graco
workmanship
purchaser’s
of
sale, repair or replace any part of the equipment proven defective. This warranty applies only when the
equipment
This
warranty does not cover
faulty
accident, tampering, or substitution of non–Graco component parts. Nor shall Graco be liable for
malfunction, damage or wear caused by the incompatibility with Graco equipment of structures,
accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation,
Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective for
examination by Graco to verify the claimed defect. If the claimed defect is verified, Graco will repair or
replace free of charge any defective parts. The equipment will be returned to the original purchaser
transportation prepaid. If inspection of the equipment does not disclose any defect in material or
workmanship,
labor
DISCLAIMERS AND LIMIT
THE TERMS OF THIS W ARRANTY CONSTITUTE THE PURCHASER’S SOLE AND EXCLUSIVE
REMEDY
WARRANTY
AND
NEGLIGENCE OR STRICT LIABILITY . EVER Y FORM OF LIABILITY FOR DIRECT , SPECIAL OR
CONSEQUENTIAL DAMAGES OR LOSS IS EXPRESSL Y EXCLUDED AND DENIED. IN NO CASE
SHALL
BREACH
EQUIPMENT
GRACO MAKES NO W ARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WITH RESPECT TO
ACCESSORIES,
BY
GRACO. These items sold, but not manufactured by Graco (such as electric motor
are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable
assistance
AND DISCLAIMERS
warrants all equipment manufactured by it and bearing its
on the date of sale by an authorized Graco distributor
sole remedy for breach of this warranty
is installed, operated and maintained in accordance with Graco’
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance,
operation or maintenance of structures, accessories, equipment or materials not supplied by
and transportation.
OF ANY NON–CONTRACTUAL LIABILITIES, INCLUDING PRODUCT LIABILITIES, BASED ON
repairs will be
AND ARE IN LIEU OF ANY OTHER W
OF MERCHANT
GRACO’S LIABILITY EXCEED THE AMOUNT OF THE PURCHASE PRICE.
OF W
ARRANTY MUST BE BROUGHT WITHIN THREE (3) YEARS OF THE DA
NOT COVERED BY GRACO W
EQUIPMENT
in making any claim for breach of these warranties.
, and Graco shall not be liable for
made at a reasonable charge, which charges may include the costs of parts,
ATIONS
ABILITY OR W
, MA
TERIALS OR COMPONENTS SOLD BUT NOT MANUF
, Graco will, for a period of twenty four months from date
ARRANTIES (EXPRESS OR IMPLIED), INCLUDING
ARRANTY OF FITNESS FOR A P
ARRANTY
name to be free from defects in material and
to the original purchaser for use. As
s written recommendations.
, any malfunction, damage or wear caused by
ARTICULAR
, switches, hose,
negligence,
PURPOSE,
ANY ACTION FOR
TE OF
SALE.
ACTURED
etc.)
Subsidiary and Affiliate Companies:
Factory Branches:
Atlanta, Chicago, Dallas, Detroit, Los Angeles, W
Canada; England; Switzerland; France; Germany; Hong Kong; Japan
est Caldwell (N.J.)
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
PRINTED
IN U.S.A. 308–505 10/89
24308-505
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