Graco Inc Hydra-Clean 800-700, Hydra-Clean 800-699, Hydra-Clean 308-530, Hydra-Clean 800-698 User Manual

INSTRUCTIONS-PAR

This

manual contains

WARNINGS

AND RETAIN FOR REFERENCE

and

IMPORTANT

INSTRUCTIONS

READ

TS LIST

308–530

Rev

HYDRA-CLEAN Pressure W

HYDRA-CLEAN

P/N 800–698, Series A

1500 psi (103 bar) OPERA

1900 psi (131 bar) MAXIMUM WORKING PRESSURE

HYDRA-CLEAN 2040, 8 HP ENGINE

P/N 800–699, Series A

2000 psi (138 bar) OPERA

2400 psi (165 bar) MAXIMUM WORKING PRESSURE

HYDRA-CLEAN 2540, 9 HP ENGINE

P/N 800–700, Series A

2500 psi (172 bar) OPERA

3000 psi (207 bar) MAXIMUM WORKING PRESSURE

1535, 5 HP ENGINE

ashers

TING PRESSURE



1535, 2040, 2540

1535

2040 2540

GRACO INC. P

.O. Box 1441 MINNEAPOLIS, MN 55440–1441

COPYRIGHT

1991, GRACO INC.

INDEX

Warnings 3.

Installation 5

Startup 6

Shutdown, Flushing and Storage 8.

Maintenance 8

Troubleshooting Chart 9.

Hydra–Clean 1535 10.

Hydra–Clean 2040 12.

Hydra–Clean 2540 14.

Gear Reducer (Model 1535) 16.

Gear Reducer (Models 2040 & 2540) 18.

Pump (Model 1535) 20.

Pump (Model 2040) 22.

Pump (Model 2540) 24.

Pump Service (Model 1535) 26.

Pump Service (Models 2040 & 2540) 28.

Accessories 30

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Technical Data 31.

Warranty Back Cover.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TERMS

WARNING: Alerts user to avoid or correct conditions

could cause bodily injury

that

CAUTION:

could

Alerts

user to avoid or correct conditions that

cause damage to the equipment.

NOTE:

Identifies helpful procedures and information.

 308–530

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

WARNING

General Safety

This

pressure washer Spray from the gun, leaks or ruptured components can inject fluid through your skin and into your body and

extremely serious bodily injury including the need

cause for amputation. Also, fluid injected or splashed into the

or on the skin can cause serious damage.

eyes

NEVER

part of the body . spray

ALWAYS

cleaning

NEVER

body.

Be before

point the

tip.

follow the

or servicing any part of the sprayer

try to stop or deflect leaks with your hand or

sure equipment safety devices are operating properly

each use.

generates very high fluid pressure.

spray gun or wand at anyone or at any

NEVER

put hand or fingers over the

Pressure Relief Procedure

before

Medical Treatment

If any fluid appears to penetrate your skin, get

EMERGENCY MEDICAL TREATMENT AT ONCE. DO

TREA

NOT

what

NOTE TO PHYSICIAN:

traumatic

surgically as soon as possible.

treatment with bloodstream. reconstructive

T AS A SIMPLE CUT. T

fluid was injected.

Injection in the skin is a

injury

It is important to treat the injury

to research toxicity

some exotic coatings injected directly into the

Consultation with a plastic surgeon or

hand surgeon may be advisable.

ell the doctor exactly

Do not delay

. T

oxicity

is a concern

Pressure Relief Procedure

reduce the risk of serious bodily injury injection follow this procedure whenever you stop spraying for more than 10 minutes, when shutting down, and before checking

2. T

5. Disengage

6. Before

and splashing in the eyes or on the skin, always

or repairing any part of the system.

Engage the trigger safety latch.

urn the sprayer of

Remove the ignition cable from the spark plug.

Shut of

to relieve pressure, and then engage the trigger safety

of the unit, disconnect the water supply and turn off the

f the water supply

the trigger safety latch and

latch again.

long–term (overnight)

fuel supply valve.

storage or transporting

, including

trigger the gun

fluid

Spray Gun Safety Devices

Be sure all gun safety devices are operating properly

each use. Do not remove or modify any part of the

before gun; this can cause a malfunction and result in serious

injury

bodily

SAFETY LA TCH: Whenever you stop spraying for a moment, or

“safe” 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

remove the spray tip to clean it.

then

always set the gun safety latch in the engaged

position, making the gun inoperative. Failure to

of the gun.

or changing spray tips. If a spray tip clogs

follow the Pressure Relief Procedure and

while

MOVING PARTS HAZARD

Moving parts. operating

NEVER

and interlocks installed and functioning. Follow the Pressure Relief Procedure before checking or

parts can pinch or amputate fingers or other body

KEEP CLEAR

the pressure washer

operate the pressure washer

of moving parts when starting or

without all guards

servicing the pressure washer to prevent discharging

pressure fluid from the gun.

high

arnings continued on page 4.

3308–530

EQUIPMENT MISUSE HAZARD

General Safety

Any

misuse of the as overpressurizing, modifying 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

injury

bodily

NEVER

CHECK

replace

ALWAYS

clothing. chemical manufacturer’s literature for recommendations on

alter or modify any part of this equipment; doing

could cause it to malfunction.

all spray equipment regularly and repair or

worn or damaged parts immediately

wear protective eyewear and appropriate

If using a chemical injector

additional protective equipment, such as a respirator

pressure washer or accessories, such

parts, using incompatible

, fire, explosion or property damage.

, read and follow

the

HOSE SAFETY

High

pressure fluid in the hoses can be very dangerous. If

the

hose develops a leak, split or 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

BOTH ENDS.

from kinks or bends at or close to the coupling, which can result

in hose rupture.

TIGHTEN

High high

all fluid connections securely before each use.

pressure fluid can dislodge a loose coupling or allow

pressure spray to be emitted from the coupling.

The strain

rupture due to any kind

reliefs help protect the hose

System

This sprayer can develop high operating pressures. Be sure to withstand the maximum working pressure of this sprayer. pressure of any component or accessory used in the system.

Pressure

that all spray equipment and accessories are rated

DO NOT

exceed the maximum working

Chemical Compatibility

SURE

that all chemicals used in the chemical

are compatible with the wetted parts of the hose, gun,

and tip, as given in the T

wand 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

NOT

tape the

use a damaged hose. Before each use, check

conditions exist, replace the

try to recouple high pressure hose or mend it with

or any

other device. A repaired hose cannot contain

high pressure fluid.

echnical Data (inside back

hose immediately

HANDLE AND ROUTE HOSES CAREFULL Y.

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. temperatures (–40_ C).

above 200

DO NOT

_ F

expose Graco hose to

(93

_ C)

or below –40

injector

Do not

_ F

FUEL AND EMISSION HAZARDS

NEVER

The on tank

NEVER

contains carbon monoxide, a poisonous, odorless,

fill the fuel tank while the unit is running or hot.

fuel used in this unit is combustible and when spilled

a hot surface can ignite and cause a fire.

slowly to avoid spilling.

operate the unit in a closed building. The exhaust

ALWAYS

fill

invisible gas which can cause serious injury or death if inhaled.

NEVER

Tampering with this adjustment can damage the pressure

alter the throttle setting, which is factory set.

washer and will void the warranty

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.

4 308–530

INSTALLATION

2540

HIGH

PRESSURE

HOSE

CONNECTION

CONNECTION 3/4”

INLET WATER

GARDEN HOSE

1535

HIGH PRESSURE

HOSE

CONNECTION

INLET WATER

CONNECTION 3/4”

GARDEN HOSE

QUICK

COUPLER

2040

HIGH PRESSURE

HOSE CONNECTION

INLET WATER

CONNECTION 3/4”

GARDEN HOSE

Figure

Check for Shipping Damage

Check

the unit for any damage that may have occurred

shipping. Notify

the carrier immediately

if there is any

damage.

Set Up

you are using a downstream chemical injector between using

Connect

the pump unloader and the high pressure hose,

the quick couplers provided.

the high pressure hose between the pump

, install it

outlet

and the gun inlet. Both of these connections are made

quick couplers.

with

CAUTION

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

Longer hoses may af fect sprayer

and chemical injector

performance,

SPRAY

GUN

QUICK

COUPLER

SPRAY

HOSE

Connect to Water Supply

CAUTION

Before attaching to the water supply, check your local plumbing code regarding to the water supply . A backflow preventer , P/N 801–133, is available to prevent backflow of contaminated water into the fresh water supply .

it upstream from the pump.

Install

If inlet water pressure is over 60 psi (4.1 bar) a regulating water valve, P/N 800–258, must be installed

at the garden hose connection.

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

Connect

a hose with at least a 3/4 inch (19 mm) ID from the water supply to the unit’ The supply hose should not be more than 50 ft (15 m) long.

NOTE: The water source at the unit

minimum Technical

flow rate equal to that of the unit (see

Data, inside back cover).

cross–connection

s 3/4 inch garden hose inlet.

must

have a

5308–530

STARTUP

Always is

NOTE:

use this startup procedure to ensure that the

started safely and properly

Check oil levels.

Engine: as

Pump: genuine

Gear as necessary . The 1535 uses the oil in pump crankcase.

Check fuel level.

Add SAE 30 or 10W–30 weight detergent oil

necessary

Reducer (2040 and 2540): Add SAE 90 gear oil

All shuts certain level. If the unit stops unexpectedly , check oil

Add SAE 20 or 30 weight non–detergent oil or

Cat pump oil as necessary

units are equipped with a low–oil sensor that

the engine of

both the oil and the fuel levels. Check the

level each time the unit is refueled.

f if the oil level

falls below a

WARNING

DO NOT

engine could cause a fire. Use only fresh, clean regular or unleaded gasoline. Close the fuel shutoff

3. T

refuel a hot engine. Refueling a hot

valve during refueling.

urn on the water supply

CAUTION

Never

run the unit dry will result. Always be sure the water supply is completely

turned on before operating.

. Costly damage to the pump

unit

If the engine is cold, completely close the engine

Grasp the starter rope, brace one foot on the

choke. pressure washer chassis and pull rope rapidly and firmly. Continue holding the rope as it returns. Pull and return the rope until the engine starts. In cool

the

weather, to 30 seconds before opening it to keep the engine running. Otherwise, open the choke as soon as the engine

If the engine is warm, leave the choke open, or just partly close it. Start the engine as described in the preceding the

choke completely

choke may have to be kept closed for 10

starts.

paragraph. When it starts, be sure to open

CAUTION

recoil start engines, never let the starter rope

return by itself. It could jam the recoil system.

ALWAYS

whenever reduce the risk of fluid injection or splashing in the eyes accidentally.

ALWAYS

8. costly

engage the gun’ s trigger safety latch

you stop spraying, even for a moment, to

or on the skin if the gun is bumped or triggered

observe the following

damage to the pressure washer

CAUTIONS

CAUTION

NOT

allow

the pressure washer to idle for more than 10 minutes. Doing so may cause the recirculating water to overheat and seriously damage will not be spraying or cleaning at least every 10 minutes. If heated inlet water is used, reduce this time further.

the pump. T

urn of

f the pressure washer if it

to avoid

4. Trigger the gun until water sprays from the tip indicating

5. Open the fuel shutoff valve. Be sure the spark plug ignition those put in

the “run” position.

Start the engine.

NOTE: For easier starting, have one person start the

that the air is purged from the system.

cable is pushed firmly onto the

units equipped with an

the

switch in the “on” position and put the throttle

pressure the

washer while

spray gun.

ignition shutof

another person triggers

spark plug. On

f switch,

DO NOT

damage turned

NOT

water screen removed. This screen helps keep abrasive sediment out of the pump, which could clog

DO NOT

may

9. See the chemical injector or sandblaster kit manual for are

run the pump dry , which will quickly

the pump. Be sure

on before starting the pump.

operate the pressure washer

or scratch the pump. Keep this screen clean.

pump caustic materials; such materials

corrode the pump components.

detailed cleaning information if these accessories

used.

the water supply is fully

with the inlet

6 308–530

Trigger Safety Latch

WARNING

To reduce the risk of serious bodily injury , including fluid injection, splashing in the eyes or on the skin, latch whenever spraying stops, even for a moment.

In the engaged position, the trigger safety latch prevents the gun from being triggered accidentally Be sure the latch is pushed fully down when engaging triggered.

ALWAYS

by hand or if it is dropped or bumped.

it or it cannot

See Figure 2.

engage the trigger safety

prevent the gun from being

Installing and Changing Spray Tips

WARNING

reduce the risk of serious bodily injury fluid injection or splashing in the eyes or onto the skin, use extreme caution when changing spray

ALWAYS

tips.

Follow the

2. Point the gun and wand away from yourself and anyone

3. Without back the quick coupler ring (B). Remove the old tip and/or install a new one, and then release the ring. See

4. Be sure the tip is secure before starting to spray again.

follow the procedure below

Pressure Relief Procedure

else.

holding your hand over the spray tip (A), pull

Figure 3.

, including

TRIGGER SAFETY LA

DISENGAGED

Figure 2

TCH SHOWN ENGAGED

TCH SHOWN

5. Tip

holding holes are provided on the chassis.

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

Figure 3

mounted in the quick coupler

7308–530

SHUTDOWN, FLUSHING AND STORAGE

WARNING

Pressure

reduce the risk of serious bodily injury fluid skin, always follow this procedure whenever you stop spraying for more than 10 minutes, when shutting down, and before checking or repairing any

Relief Procedure

, including

injection and splashing in the eyes, or on

part of the system.

the

MAINTENANCE

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

There reducer (if used). After changing the oil in these components the

If the unit is operating in dusty conditions, these maintenance

washer

is a break–in period for

interval between required changes is longer

the engine, pump and gear

following their respective break–in periods,

checks should be made more often.

Engage the trigger safety latch.

2. T

urn the sprayer of

3. Remove

4. Shut

5. Disengage

the the

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 ignition cable from the spark plug.

f the water supply

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

and turn of

Flush the pressure washer before using it

to remove the anti–freeze.

available

to make flushing easier

trigger safety latch and trigger

f the fuel supply valve.

CAUTION

water does freeze in the

in a

warm room before trying to start it.

pour hot water on or into the pump; it may crack

ceramic plungers!

the

2. After each use, wipe all surfaces of the pressure washer

3. Perform the appropriate maintenance. See maintenance

with a clean, damp cloth.

chart.

pressure washer

DO NOT

, thaw

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

proceeding.

before

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

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 or genuine Cat pump oil. Change gear reducer oil. Use SAE 90 gear oil on 2040 and

2540. The 1535 uses the oil in pump crankcase.

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 or genuine Cat

pump oil. Change gear reducer oil on 2040 and 2540. Use SAE 90 gear oil. The 1535 uses the oil in pump crankcase.

. Check

. Rub

ap gently to

8 308–530

TROUBLESHOOTING CHART

reduce the risk of serious bodily injury

moving

parts, always follow the

Pressure Relief Procedure W

WARNING

, including fluid injection,

splashing in the eyes or on the skin or injury from

arning

before proceeding.

PROBLEM

Engine will not start or is hard to start

Engine misses or lacks power

pressure and/or

Low pump runs rough

ater leakage from

under pump manifold

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

CAUSE SOLUTION

No gasoline in fuel tank or carburetor

Low oil

Start/Stop switch in Stop position.

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

orn or wrong size tip.

Inlet filter clogged.

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.

orn inlet or discharge valves.

Leaking high pressure hose.

orn packings.

Humid air condensing inside crankcase.

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.

orn gasket.

orn oil seals and/or o-ring.

orn oil seal.

. Flooded engine.

, 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.

rigger spray gun.

Remove and clean.

Clean, adjust the gap or replace.

Replace with tip of proper size.

Clean. Check more frequently

filter

Check

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.

Do not run pump without water

Clean or replace valves. See PUMP SER

Replace the gasket. See SER

Replace oil seals and/or o-ring. See SER SECTION.

Replace oil seal. See SER

. Replace packings. See PUMP SER

. Use new fuel and dry

VICE SECTION.

f valve.

VICE.

VICE.W

VICE.

F.

VICE.

VICE

9308–530

PARTS DRAWING

800–698 Hydra–Clean 1535 Pressure Washer

27 30

28 59

65 66

48 49

67 36

50 51

36 35

10 308–530

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