Graco Inc. Hydra-Clean 800-232 User's Manual
Contents
1. N DESCRIPTION HOOD PANEL End TIP 1506 NOZZLE Adjustable WAND SLEEVE Safety LABEL Warning LABEL Warning Ground GUN NIPPLE 3 8 x 1 4 QUICK COUPLE Female QUICK COUPLE Male LOCK 10 SCREW 10 24 x 3 4 FLAT 5 16 LOCK 3 8 BOLT 3 8 16 x 1 1 4 BOLT 3 8 16 x 1 3 4 CORD GRIP Cord HOSE H P 30 Continued 5 74 CHEMICAL INJECTOR 73 See Parts Drawing Page 15 Vni RPM QTY 1 1 1 1 1 1 1 1 1 1 1 1 10 10 12 10 2 2 w 2 DuBois 826 800 232 Tem HOW TO ORDER REPLACEMENT PARTS REF PART REF PART NO NO DESCRIPTION QTY NO NO DESCRIPTION QTY 23 801 937 LOCKNUT 1 2 1 66 801 966 CORD W Piug 1 24 801 501 LABEL Serial No 1 67 802 627 ADAPTOR Included with 25 800 246 CHASSIS 1 Hose 801 866 1 26 802 729 HANDLE 1 68 801 620 ELBOW Street 1 4 x 90 1 27 801 941 BOLT 5 16 18 x 1 4 69 801 891 COUPLING 3 8 M x 3 8 M 1 28 801 025 LOCK 5 16 8 70 801 890 COUPLING 3 8 M x 3 8 F 1 29 801 023 FLAT 1 4 8 71 801 709 PLUG 1 4 1 30 801 878 NUT 3 8 16 4 72 801 865 UNLOADER Replacement 1 31 801 818 BOLT 3 8 16 x 1 6 73 801 907 WASHER Aluminum 1 32 801 857 AXLE 1 74 801 905 ADAPTOR 3 8 FXG3 8B M 1 33 801 235 FLAT 5 8 4 75 800 138 INJECTOR Chemical 1 34 801 880 PIN Cotter 2 76 801 900 GROMMET 4 35 801 879 WHEEL 2 77 801 901 SUPPORT Unloader 1 36 802 648 PIVOT 2 78 801 881 COUPLING 3 8F x 1 4 F 1 37 801 024 NUT 5 16 18 4 79 82. 226 WIRE NUT Orange 7 63 801 884 SWITCH GFI 1 101 801 304 CONNECTOR Crimp 2 64 801 894 SCREW Ground 1 102 801 221 CONNECTOR Crimp 1 65 801 893 BOX Switch 1 See below for How To Order Replacement Parts 1 To be sure you receive the correct replacement parts kit or accessories always give all of the information requested in the chart below 2 Check the parts list to identify the correct part number do not use the ref no when ordering 3 Order all parts from your nearest Graco distributor 802 776 1 3 mnm n jai Vi ar i o La al a Rz ot li e Rain has ndn mira e RA RT RI RI a a Ar di Ar Ph aL Na gt ah ri ma SR Vi ra ad a bm nm BA n med ar n MR n Der a lila A c m Ln mg Ap E ph IR I Nr Aer AINE B a PII IPEA lh M DB E PARTS DRAWING Pump 801 864 221 201 Pump 801 864 ROGA MUT ue Ee OR SUSE ALE ar OS Dc Ree EGE EOL Re ai ec EE d AE SS ee REPAIR KITS OIL SEAL KIT PACKING KIT REF PART 801 658 801 662 NO NO DESCRIPTION QTY inciudes Includes 201 801 651 SCREW M8 6 eS 202 801 652 WASHER 6 210 t 1203 VALVE 4 1204 801 470 O RING 4 t 1205 4 VALVE VALVE PLUG KIT 206 802 795 MANIFOLD 1 801 472 802 306 207 801 485 WASHER 1 Includes Includes 208 801 484 3 8 BSP 1 REF 209 HEAD RING 4 NO t 210
3. I a INSTRUCTIONS PARTS LIST 5 902 776 craco ROVA This manua contains IMPORTANT WARNINGS and INSTRUCTIONS READ AND RETAIN FOR REFERENCE HYDRA CLEAN 826 Pressure Washer 800 psi 55 bar OPERATING PRESSURE 1100 psi 76 bar MAXIMUM WORKING PRESS URE GRACO INC P O Box 1441 MINNEAPOLIS MN 55440 1444 COPYRIGHT 1987 GRACO INC git WARNING 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 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 the need for amputation Also fluid injected or splashed into the eyes or on the skin can cause serious damage In addition some cleaning solutions may be toxic and can cause chemical burns skin irritations and allergic reactions if inhaled or if they come in contact with the body or eyes Always follow these precautions when operating your pressure washing system to reduce the risk of serious bodily injury NEVER point the spray gun at anyone or at any part of the body NEVER use the spray gun without the wand NEVER put hand or fingers over the spray tip NEVER try to stop or deflect leaks with your hand or body i ALWAYS be sure equi
4. Re em d d I lh can Ru id 4 CUN rd pi LR n RB i m a Ra a Ns mi mn hak AALS UA a LA ma o n a A ura A din Subsidiary and Affiliate Companies Canada England Switzerland France Germany Hong Kong Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1444 PRINTED IN U S A 802 776 6 87
5. brass 3 8 NPT O RING NOZZLE NO 2 O RING CHEMJET BODY jak SM MR UY EE er SPRING cone BALL SST O RING O RING VALVE SEAT SPRING O RING NEEDLE HOSE BARB ADJUSTMENT KNOB SPRING retaining ha TT 3 a eek wb m ah ab kh a If an extremely harsh chemical is be injected or if corrosion problems exist the standard brass needle hose barb Ref No 13 may be replaced with a stainless steel needie hose barb Part No 801 969 See page 13 for How To Order Replacement Parts 100 Ib 46 kg 160 F 70 C Length 38 in 965 mm Width 19 in 482 mm Height 33 in B38 mm 3 4 garden hose f 10 1 oz 3 liters PTFE S registered trademark of the DuPont Company 800 psi 55 bar measured at pump 2 6 GPM 9 8 liter min 1 5 hp single phase 115 V 60 Hz 15 Amp TEFC cca High Pressure Hose Acrylonitrilie and Buna N cover and tube Bypass Hose Synthetic yarn EPDM Pressure Washer including fitting Anodized Aluminum Aluminum or Bronze alloys Brass Copper Nylon TDTF E omposite Ceramic Buna N Cotton r cuius 316 303 amp 304 Stainless Steel Polymide 12 Thermo piastic TPTFE Carbon Steel zinc or yellow chromate 802 776 15 n Pini m d LECT LU THE GRACO WARRANTY WARRANTY x Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material
6. or 3 months p OIL CAPACITY Change pump oil Use SAE 20W or 30W non detergent oil TYPE 802 776 7 Mormon 10 1 Oz SAE 20W or 30W 3 liters Non Detergent Lid d NS QURE MAT Seo SER ese or TROUBLESHOOTING CHART WARN 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 on page 7 before proceeding Low Pressure Worn nozzle Replace with nozzle of proper size m Coupling slippage Tighten or replace Air leak in inlet plumbing Disassemble reseal replace bad parts i and reassemble Clean Use adequate size Check more frequently Install proper filter Check flow available to pump Replace packings Inlet filter clogged Worn packing Abrasives in pumped fluid or severe cavita tion Inadequate water supply Fouted or dirty inlet or dis charge valves Worn inlet or discharge valves Leaky discharge hose Pressure adjustment set down Clean inlet and discharge valve assemblies Replace worn valves and or discharge hose Turn adjustment knob in to increase pressure Proper size inlet plumbing check for air tight seal Clean out foreign material replace worn valves Restricted inlet or air entering the inlet plumbing Inlet restrict
7. turned on before starting the pump DO NOT operate the pressure washer with the inlet screen removed This screen helps keep abrasive sediment out of the pump which could clog or scratch the pump DO NOT pump caustic materials such materials may corrode the pump components 802 776 5 ov PORE EE i ree Chemical Injector Operation 8 Be sure that the control ring on the injector is open two full turns from the closed position To check this the hood must be opened Once the control ring is open it may be left alone The chemical mixture is controlled by the chemical metering valves on the control panel 9 Place the chemical strainer s and chemical line s into your chemical container s Select which chemical you want to use with the chemical selector valve on the control panel 10 11 To apply the cleaning chemical to the work surface the adjustable nozzle on the end of the spray wand must be open The chemical s can only be drawn into the water stream and applied to the work surface in a low pressure situation By opening the adjustable nozzle you create low pressure Closing it produces high pressure for rinsing and pre chemical flushing or no chemical cleaning One chemical may be turned off and on at the gun by using the adjustable nozzle as described above WARNING DO NOT attempt to adjust the adjustable nozzle when the spray gun is in use Be sure that the saf
8. 00 154 PUMP MOTOR Includes 38 801 940 BOLT 5 16 18 X 3 4 4 Ref No s 80 92 1 39 802 703 CASTER 1 80 802 297 MOTOR 1 5 hp C Face 40 800 247 BRACKET Caster 1 Includes Ref No 81 1 41 802 730 BUMPER 1 81 802 782 KEY 1 42 802 735 HOSE Inlet 1 82 801 871 COUPLER Inciudes Ref No 83 1 43 801 112 FILTER WASHER 1 83 801 887 SPIDER 1 44 801 910 PLUG 1 84 801 872 BOLT Hex Hd M6 x 20 mm 4 45 801 683 STRAINER Chemical 2 85 801 139 WASHER Lock 1 4 4 46 801 813 TUBING 1 4 ID 16 86 801 023 WASHER Flat 1 4 4 47 802 683 VALVE Metering 2 87 801 870 COUPLER HOUSING 1 48 802 669 HOSE BARB 1 8 x 1 4 2 88 801 015 WASHER Flat 5 16 4 49 802 636 PANEL End Control 1 89 801 363 WASHER Lock 5 16 4 50 802 686 LABEL Control Panel 1 90 801 546 BOLT Hex hd 3 8 16 x 1 1 4 2 51 802 843 LABEL Knob 2 91 801 864 PUMP T 9791 See Parts 52 802 733 SCREW 6 32 x 1 2 4 Drawing page 14 1 53 802 731 LOCK 6 4 92 801 818 BOLT Hex Hd 3 8 16 x 1 2 54 802 732 FLAT 6 4 93 801 524 LABEL Pump 1 55 801 547 FLAT 3 4 1 94 801 866 HOSE By Pass Includes 56 802 684 VALVE 3 Way 1 802 627 Adaptor 1 57 801 733 HOSE BARB 1 4 1 4 3 95 801 523 NIPPLE 1 2 x 2 1 58 802 292 FLAT 10 4 96 801 622 CROSS 1 2 1 59 801 417 LABEL Relieve Pressure 1 97 801 178 ELBOW Street 1 2 x 90 1 60 802 685 LABEL instruction 1 98 802 665 ELBOW Street 1 2 x 45 1 61 802 027 KIT Cover 1 99 800 115 VALVE Relief Temp 1 62 801 903 LABEL Start Stop 1 100 801
9. PACKING 4 203 211 INTERMEDIATE RING 2 212 RETAINER Packing 2 213 O RING 2 214 OIL SEAL 2 PACKING amp RETAIN PLUNGER REPAIR 4 215 SCREW Retainer 2 801 664 KIT 801 474 216 WASHER 2 Two kits needed forentire Includes 217 O RING 2 Pamp AR ary 218 BACK UP RING 2 REF 215 219 801 661 PLUNGER 2 NO 216 220 801 660 FLINGER 2 209 217 221 801 659 DIPSTICK 1 210 218 See page 13 for How To Order Replacement Parts 211 212 213 NOTE Most repair kits for this pump will have extra parts because they are also standard kits for other pumps Keep extra parts for future use 14 802 776 23 st 9 me EO acc aaa ee 2 mae bl e Rat Qe Mah ore Na nh deve uie AMAA n Aa daa RC lh Vm each M VAR Rn ad l Ee Nl o road Dae c R d ER Ln URL db Ia QT a Mrd Al Ra nh di r Rd Los t E RET e D P PARTS DRAWING Exi Chemical Injector 800 138 TECHNICAL DATAE MOTOR WATER PUMP WETTED PARTS UNIT WEIGHT OVERALL DIMENSION MAX INLET WATER TEMPERATURE INLET HOSE CONNECTION PUMP OIL CAPACITY PARTS LIST E Chemical Injector 80 REF PART NO NO 1 801 684 2 801 685 3 801 687 4 801 688 5 801 689 6 801 690 7 801 784 8 801 692 9 801 693 10 801 694 11 801 695 12 801 696 13 801 697 14 801 698 15 801 682 DESCRIPTION NIPPLE Hex
10. Turn pressure washer OFF Remove the power cord from outlet Shut off the water supply Disengage the trigger safety latch and triggerthe gun to relieve pressure and engage the latch again msc Spray Gun Safety Do not remove or modify any part of the gun this can cause a malfunction and result in serious bodily injury Safety Latch ALWAYS engage the gun safety latch whenever you stop cleaning even for a moment The latch MUST pushed fully down to make the gun inoperative Failure to properly set the safety latch can result in accidental triggering of the gun See Figure 2 page 6 Spray Tip Safety Use extreme caution when cleaning or changing spray tips If the spray tip clogs while spraying engage the gun safety latch immediately ALWAYS follow the Pressure Relief Procedure and then remove the spray tip to clean it PIT d 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 parts can cause them to rupture and result in fluid injection splashing in the eyes or on the skin or other serious bodily injury or property damage NEVER aiter or modify any part of this equipment doing so could cause it to malfunction CHECK all cleaning equipment regularly and repair or replace worn or damaged parts immediately if using a chemical injector read and follow
11. ade at a reasonable charge which charges may include the costs of parts labor and transportation DISCLAIMERS AND LIMITATIONS THE TERMS OF THIS WARRANTY CONSTITUTE PURCHASER S SOLE AND EXCLUSIVE REMEDY AND ARE IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND OF ANY NON CONTRACTUAL LIABILITIES INCLUDING PRODUCT LIABILITIES BASED ON NEGLIGENCE OR STRICT LIABILITY EVERY FORM OF LIABILITY FOR DIRECT SPECIAL OR CONSEQUENTIAL DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND DENIED IN NO CASE SHALL GRACO S LIABILITY EXCEED THE AMOUNT OF THE PURCHASE PRICE ANY ACTION FOR BREACH OF WARRANTY MUST BE BROUGHT WITHIN TWO 2 YEARS OF THE DATE OF SALE EQUIPMENT NOT COVERED BY GRACO WARRANTY GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABIL AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motor switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties Factory Branches Atlanta Dallas Detroit Los Angeles West Caldwell N J AA Ns n n e p p pn did E n hd ord dir hm gu rtr B d TIN a et i PA th eO II AS n Ae Cc n NR m a rn
12. and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use As purchaser s sole remedy for breach of this warranty Graco will for a period of _ twelve months from the date of sale repair or replace any part of the equipment proven defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be fiable for any malfunction damage or wear caused by fauity installation misapplication abrasion corrosion inadequate or improper maintenance negligence 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 operation or maintenance of structures accessories equipment or materials not supplied by 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 repairs will be m
13. eck pump oil level Look at oil level indicator window through inspection hole in side of the hood Pump also has a dipstick located under hood on top of pump Oil level should be up to dot on oil level indicator window and within the notch on dipstick Add SAE 20 or 30 weight non detergent oil as necessary 2 Connect pressure washer to water supply and to proper electrical service as described in set up 3 Turn water supply on and trigger the gun until water sprays from the tip and all air is purged from the system 4 Press start button on control panel NOTE Avoid pressing start button when unit is not plugged in because the stop button cannot be pushed unless unit is plugged in Always use motor control switch when starting and stopping unit 5 Always engage the gun s trigger safety latch whenever you stop spraying even for a moment to reduce the risk of fluid injection or splashing in the eyes or on the skin if the gun is bumped or triggered accidentally 6 Most pressure washer spraying is done at fuil pressure If a reduced pressure is desired for a special application there are two methods to reduce the maximum output from the pressure washer a Turn the pressure control knob on the unloader counterclockwise as needed This method is best if you are operating consistently at a reduced pressure A Check flow rate of the water supply it must be atleast 3 gpm or the pressure wasner will not develop
14. ensure that you get maximum performance and life from your pressure washer There is a break in period for the pump After changing the oil after the pump s break in period the interval between required changes is longer if you are operating in dusty conditions these maintenance checks should be made more often ma 2 If the pressure washer will be exposed to freezing temperatures drain all water out of the pump If you must store the pressure washer in freezing temperatures flush it with a 50 antifreeze solution This can be done by placing the end of the inlet hose into a bucket of 5096 antifreeze solution Start the pressure washer Trigger the gun for 10 seconds release the trigger for 10 seconds Trigger and release about 10 times until the 50 antifreeze solution comes out of the Spray tip 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 the pump it may crack the ceramic plungers 3 After each use wipe all surfaces of the pressure washer with a clean damp cloth 4 Perform the appropriate maintenance See the chart on page 7 WHAT TO DO Clean water inlet screen Check pump oil level Fill as necessary INTERVAL Daily Change pump break in oil Use SAE 20W or 30W non detergent oil After first 50 hours of operation Each 500 hours of operation
15. estruction of equipment NOTE Identifies helpful procedures and information 802 776 3 p uton IU HANDLE SPRAY GUN QUICK COUPLERS HOSE STORAGE CHEMICAL ore CONTAINER HIGH PRESSURE HOLDER OUTLET TOP OF HOOD PRESSURE ADJUSTMENT KNOB SPRAY WAND PUMP OIL LEVEL SIGHT GAUGE VIEW THRU ADJUSTABLE INSPECTION HOLE NOZZLE CONTROL ON SIDE OF HOOD RING ON OFF HIGH PRESSURE CHEMICAL HOSE 30 FT SELECTOR VALVE CHEMICAL METERING VALVES HOOD BOLTS CHEMICAL HOSES CHEMICAL FILTERS FLUID INLET 13 4 GARDEN HOSE NOTE THE PUMP OIL DIPSTICK AND MOTOR RESET BUTTON ARE NOT VISIBLE IN THIS PHOTO BUT ARE EASILY ACCESSIBLE WITH THE HOOD OPEN POWER CORD 1 Remove the two hood bolts flats and locks from 4 Remove the plastic plug from the top of the pump the center bottom of each side of the hood Pivot and install the dipstick the hood open NOTE The plastic plug may be reused to 2 Position the handle into the end of the chassis prevent splashing oil when closest to the wheels Line up the four mounting transporting the pressure washer in a holes Install the four 3 8 x 1 inch bolts from the vehicle Be sure to reinstall the outside of the chassis Use flat washers only on dipstick before using the unit to allow head of bolt Use a flat washer lock washer and proper venting nut on each bolt on the inside of the chas
16. ety latch on the gun is in the ON position before adjusting to avoid serious bodily injury or fluid injection mA a LN N NA TRIGGER SAFETY LATCH SHOWN DISENGAGED 6 802 776 A AUISPULAAURAARARAETuUY FIGURE 2 12 Adjust the chemical mixture s with the chemical metering valve s on the control panel Once the chemical metering valve s are adjusted to the desired setting they may be left there for future chemical applications 13 To change to the other chemical turn the chemical selector valve to the other chemical To shut off chemical turn the chemical selector valve to the OFF position or close the adjustable nozzle The chemical metering valve s do not have to be closed to change or shut off chemical supply CAUTION The chemicals used must be compatible with the wetted parts shown in the technical data at the end of this manual to avoid serious damage to the pressure washer and components Trigger Safety Latch WARNING To reduce the risk of serious bodily injury including fluid injection splashing in the eyes or on the skin ALWAYS engage the trigger safety latch whenever you stop spraying even for a moment In the engage 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 fully seated in slot in handle or it cannot prevent the gun from being t
17. evice A repaired hose cannot contain the high pressure fluid HANDLE AND ROUTE HOSES CAREFULLY Do not 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 DO NOT expose Graco hose to temperatures above 200 F 94 C or below 40 F 40 C ELECTRICAL HAZ AR M y NEVER operate the pressure washer without the unit being properly grounded This includes internal wiring on unit plug ground plug must be intact and building wiring Because water is natural conductor it is very important to provide a good ground circuit to avoid serious bodily miu if equipment should fail MOVING PARTS HAZ ARD Moving parts can pinch or amputate your fingers or other body parts KEEP CLEAR of moving parts when starting or operating the pressure washer Follow the Pressure Relief Procedure page 2 before checking or servicing the pressure washer to prevent discharging high pressure fluid from the gun IMPORTANT ESSEE 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 WARNING Alerts user to avoid or correct conditions that could cause bodily injury CAUTION Alerts user to avoid or correct conditions that could cause damage to or d
18. from the cavity the assembly may come apart 4 Install a new valve 203 Install the o ring 204 and plug 205 and torque to 75 ft Ib 10 3 Nm NOTE Retorque the plug after 5 hours of operation Pumping Section 1 Remove the six Allen head cap screws 201 and lockwasher 202 from the manifold 206 using a MO Allen wrench 2 Carefully separate the manifold from the crankcase It may be necessry to tapthe manifold lightly with a rubber mallet CAUTION To avoid damaging the plungers or seals keep the manifold properly aligned with the ceramic plungers when removing it 3 Carefully examine each plunger 219 and replace it if there is any scoring Servicing The V Packings NOTE To replace just the v packings use kit part no 801 662 which will service the entire pump To replace the v packings rings and retainers order two of kit part no 801 664 to service the entire pump 1 If the manifold is not already removed follow Steps 1 and 2 of pumping section 2 Carefully pull the packing retainer 212 from the manifold Examine the o ring 213 and replace it if it is cut or damaged 3 Remove the v packing 210 and head ring 209 Pull out the intermediate retainer ring 211 Remove the v packing 210 and head ring 209 4 Inspect ali parts and replace as necessary 5 Thoroughly ciean the packing cavities and examine 6 Lightly grease the packing cavities and then re
19. full pressure zo B To check flow tate time how long it takes to fil a standard five gallon pail it should take no longer than 1 minute and 40 seconds Electrical Supply 7 Connect the power cord to the proper power supply The electrical service required is single phase 115V 60 Hz AC 15 Amp Electrical service must include a ground wire If an extension cord is used it must have a ground wire and be at least No 14 gage wire Extension cord must not be over 100 feet long b Turn chemical selector valve to the OFF position then open the adjustable nozzle on the end of the spray wand as needed This method is best to quickly reduce pressure for a special application WARNING DO NOT attempt to adjust the adjustable nozzle when the spray gun is in use Be sure that the safety latch on the gun is in the ON position before adjusting to avoid serious bodily injury or fluid injection 7 Always observe the following cautions to help avoid costly damage to your pressure washer CAUTION DO NOT allow the pressure washer to idle for more than 10 minutes The unit is equipped with a thermal relief valve to help avoid the recirculating water from becoming too hot and seriously damaging the pump but it is a good idea to turn the pressure washer off if you are not spraying or cleaning at least every 10 minutes DO NOT run the pump dry which will quickly damage the pump Be sure the water supply is fully
20. ions and or air leaks Stuck inlet or discharge valve Leaking high pressure seals Replace seals Inadequate water supply Check flow available to pump Water leakage from under Worn packings Replace packings the manifold Water in pump crankcase Worn packings Replace packings Cil seal leaking Replace oil seals May be caused by humid air Change oil at 3 month or 500 hour intervals condensing into water inside the crankcase Scored damaged or worn plungers Abrasive material in the water being pumped Inlet water temperature too high Over pressurizing pump Pump runs extremely rough pressure low Frequent or premature Replace plungers failure of the packing Install proper intet filter Check inlet water temperature be sure not to exceed 160 F Do not modify any factory set adjustments Clean or replace tip Excessive pressure due to partially plugged or damaged tip Pump running too long without spraying or cleaning Running pump dry Foreign particles in the inlet or discharge valve or worn inlet and or discharge valves Unit not plugged in G F I C activated Never run pump more than 10 minutes without spraying or cleaning Do not run pump without water Replace or clean valves Strong surging at the inlet and low pressure on the discharge side Unit will not sta
21. place the packings in the following order head ring 209 v packing 210 intermediate ring 211 head ring 209 packing 210 and packing retainer 212 with the o ring 213 installed into the retainer groove CAUTION Be very sure the parts are installed in the proper order and facing the correct direction See Figure 4 improperly installed parts will cause a malfunction 7 Reassemble the manifold as instructed in Steps 7 and 8 of Servicing The Plungers Servicing The Plungers NOTE Plunger repair kit part no 801 474 is available to service all the plungers 1 Loosen the plunger retaining screws 215 5to6 turns using an M10 wrench Push the plunger 219 toward the crankcase to separate the plunger and retaining screw 2 Remove the screw 215 from the plunger and examine the o ring 217 backup ring 218 and copper bearing gasket washer 216 Replace these parts if necessary using k t part no 801 474 3 Remove the plunger 219 and flinger 220 from the plunger shaft Clean examine and replace parts as necessary AE 802 778 9 4 h n 4 Inspect the plunger shaft for oil leakage from the crankcase If leaking is obvious replace the oil seals 214 Otherwise DO NOT remove these seals as they cannot be reused NOTE Oil Seal Kit part no 801 658 is available to replace both seals Lightly grease the oil seal if it is being replaced and the flinger and
22. pment safety devices are operating properly before each use Use this pump only for pumping water and water diluted cleaning solutions NEVER use the pump for paint or any other coatings ALWAYS wear protective eyewear and appropriate clothing to protect yourself from the overspray and the debris that is removed as you clean Read and follow the cleaning chemical manufacturer s recommendations on preparation and use of the cleaning solution and the use of breathing apparatus and proper ventilation MEDICAL TREATMENT If any fluid appears to penetrate your skin get EMERGENCY MEDICAL CARE AT ONCE DO NOT TREAT AS A SIMPLE CUT Tell the doctor exactly what fluid was injected Note To Physician njection in the skin is a traumatic injury It is important to treat the injury surgically as soon as possible Do not delay treatment to research toxicity Toxicity isa concern with some exotic coatings injected directly into the blood stream Consultation with a plastic surgeon reconstructive hand surgeon may be advisable 2 802 776 Pressure Relief Procedure To reduce the risk of serious bodily i injury including fluid injection and splashing in the eyes or on the skin always follow this procedure whenever you shut off the pump when checking or servicing any part of the system when installing or changing spray tips and whenever you stop spraying for more than 10 minutes Engage the gun trigger safety latch
23. replace them on the plunger shaft Then install the plunger Lightly grease the retaining screw 215 and the outer end of the plunger Place the washer 216 o ring 217 and backup ring 218 around the screw and install the screw through the plunger Torque to 14 4 ft lb 2 Nm NOTE Ifyou plan to replace the packings go to Servicing the V Packings Lubricate the outside of each plunger Slide the manifold onto the crankcase being careful not to damage the seals FIGURE 3 8 Install the six Allen head cap screws 201 and washers 202 finger tight Torque the screws to 15 9 ft lb 2 2 Nm following the tightening pattern in Figure 3 Uneven tightening may cause the manifold to bind or jam 10 802 776 FIGURE 4 2 A PARTS DRAWING amp DuBois 826 P N 800 232 Md 802 776 11 3 LEADS ON MOTOR LINE TO BE TIED js TOGETHER PER MOTOR WIRING 101 DIAGRAM be I gt 100 66 Ref 101 65 Ref aan O p 2 SWITCH E TOP 100 4 63 Ref 12 802 776 PARTS LIST Ex DuBois 826 800 232 REF PART NO NO 802 664 802 637 801 666 800 118 801 935 801 957 801 129 801 388 802 699 801 103 801 009 801 090 801 875 801 605 801 015 801 363 801 546 801 214 802 704 801 931 801 967 M mh A m A
24. riggered See Figure 2 TRIGGER SAFETY LATCH SHOWN ENGAGED Aee ee a ee e e e I UE ma A us e RR y RT m P Rasa a Ros pe e A n n CMM 008 rag ox D SHUTDOWN FLUSHING AND STORAGE WARNING Pressure Relief Procedure 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 shut off the pump when checking or servicing any part of the system when installing or changing spray tips and whenever you stop spraying for more than 10 minutes 1 Engage the gun trigger safety latch 2 Turn the pressure washer off 3 Remove the power cord from the outlet 4 Shut off water supply 5 Disengage the trigger safety latch andtrigger the gun to relieve pressure and engage latch again 1 After using the chemical injector system it should be flushed out with water or a 5096 antifreeze solution if unit will be exposed to freezing temperatures This is best done by replacing the chemical container s with a bucket of water or a 50 antifreeze solution Operate pressure washer as described in start up Draw water or antifreeze solution into both chemical lines until it passes through the injector By flushing the chemical injector system you will help avoid unnecessary wear and prolong the life of components MAINTENANCE 0072400 Observing regular maintenance intervals helps
25. rt Check power cord Check for proper grounding Push switch ON RESET button Let motor cool and push reset button on motor Check fuse circuit breaker panel Disassemble chemical valve and clean Check and clean chemical hose and filter Turn control ring on nozzle clockwise to cause drop in pressure Check level of chemical Electric motor overheated Electric service off Chemical injector clogged Chemical injection system doesn t work Adjustable nozzle completely closed Low chemical level 8 802 776 i C PUMP SERVICE i Re 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 on page 7 proceeding NOTE The following metric wrenches are needed M6 M10 M30 Allen wrenches A pump repair tool kit P N 800 271 is available It includes packing extraction and insertion tools Repair kits are available Refer to the individual repair sections andthe pa rts page for more details For the best results use all the parts in the kit Valves NOTE To replace valves order kit part no 801 472 1 Remove the hex plug 205 from the manifold 206 using an M30 wrench 2 Examine the o ring 204 under the plug and replace it if it is cut or distorted 3 Remove the valve assembly 203
26. sis 5 Hood may now be closed and secured with hood 3 Connect one end of the 30 foot high pressure bolts flat washers and lock washers removed in hose to the pump outlet This connection is made Step 1 with a threaded swivel fitting Connect the other end to the gun using the quick couplers provided 6 Remove the plastic plug from the inlet hose Check the water supply flow rate see page 5 CAUTION Connect inlet hose to water supply A standard Up to 90 feet of high pressure hose may be used 5 8 1 D garden hose may be used to connect inlet Using longer hoses may affect sprayer hose to the water supply performance and chemical injector performance 4 802 776 M t M ee A sary oe P wrin S9 i 4 o nM age d np T N nO ski C Water Supply CAUTION Before connecting the water supply to the pump check your local plumbing code regarding cross connection to the water Supply A backflow preventor Part No 801 133 is available to prevent the back flow of contaminated water into the fresh water supply Install upstream from the pump NOT exceed 160 F 70 C inlet water temperature Higher temperatures will damage the pump packings START UP Use this procedure each time you start the pressure washer to help ensure the pressure washer is ready to operate and that you start it safely 1 Ch
27. the chemical manufacturer s literature regarding the use of protective eyewear clothing and equipment System Pressure This sprayer can develop 7700 psi 76 bar MAXIMUM WORKING PRESSURE Be sure that all spray equipment and accessories are rated to withstand the maximum working pressure of this sprayer DO NOT exceed the maximum working pressure of any component or accessory used in the system Chemical Compatibility BE SURE that all chemicals used in the chemical injector are compatible with the wetted parts of the hose gun wand and tip as given in the Technical Data on the back cover Always read the chemical manufacturer s literature before using any chemical in this pressure washer 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 spray emitted from it can cause a fluid injection injury or other serious bodily injury or property damage TIGHTEN ail fluid connections securely before each use High pressure fluid can dislodge a loose coupling or allow high pressure spray to be emitted from the coupling NEVER use a damaged hose Before each use check 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 try to recouple high pressure hose or mend it with tape or any other d
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