Graco Inc. 308-522 Pressure Washer User Manual
Contents
1. 308 522 Rev A INSTRUCTIONS PARTS LIST GRACO This manual contains IMPORTANT WARNINGS and INSTRUCTIONS READ AND RETAIN FOR REFERENCE HYDRA CLEAN 4040 Pressure Washer Model 800 345 Series A 230 460 Volt 3 Phase 4000 psi 276 bar OPERATING PRESSURE 4300 psi 296 bar MAXIMUM WORKING PRESSURE GRACO INC P O Box 1441 MINNEAPOLIS MN 55440 1441 6 COPYRIGHT 1990 GRACO INC 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 NEVER point the spray gun or wand at anyone or at any part of the body NEVER put hand or fingers over the spray tip ALWAYS follow the Pressure Relief Procedure before cleaning or servicing any part of the sprayer NEVER try to stop or deflect leaks with your hand or body Be sure equipment safety devices are operating properly before each use Medical Treatment If any fluid appears to penetrate your skin get EMERGENCY MEDICAL TREATMENT AT ONCE DO NOT TREAT AS A SIMPLE CUT Tell the doct2. that could cause damage to the equipment 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 4 308 522 ann i i a Ma a aN AC ME Dp Fa a a a ri ad PP a at E a DO ASAP ll Sata a i a th ait KG SS a RS R a nee e PUMP MOTOR DIPSTICK STARTER PUMP OIL LEVEL INDICATOR WINDOW PUMP OIL DRAIN PLUG 9 WATER CONNECTION 3 4 HIGH PRESSURE GARDEN HOSE f HOSE CONNECTION Figure 1 Check for Shipping Damage Check the unit for any damage that may have occurred in shipping Notify the carrier Immediately if there is any damage Set Up Before plugging in the unit be sure the electrical service matches the specification in Technical Data inside back cover and the voltage label on the unit With the unit off plug the power supply cord into a grounded GFCl protected outiet Do not remove the electrical plug which comes with the unit or bend connecting prongs to fit an improper outlet Use an extension cord that meets the requirements of the EXTENSION CORD section and is no more than 100 ft 30 m long Added length of cord will affect current draw of unit If you are using a downstream chemical injector install it between the pump unioader and the high pressure hose usin
3. 483 mm Maximum Inlet Water 160 F 70 C Temperature inlet Hose Connection Wetted Parts High Pressure Hose Bypass Hose Synthetic yam and EPDM Pressure Washer including fittings 18 308 522 Mode 800 345 15 0 hp 3 phase Electrical Service 230 volt 40 amp 3 phase Optional Service 460 volt 20 amp 3 phase Water Pump Maximum 4000 psi 276 bar Working Pressure Water Pump Maximum Flow 4 0 gpm 15 Ipm Unit Weight 475 ibs 215 kg 3 4 in garden hose f Acrylonitrile and Buna N cover and tube Anodized aluminum Aluminum or Bronze alloys Brass Copper Nylon Tefion composite Ceramic Buna N Cotton Phenolic 303 304 and 316 Stainiess Steel Polymide 12 Thermoplastic Teflon Carbon Steel Zinc with or without Yellow Chromate Plate Teflon is a registered trademark of the DuPont Company THE GRACO WARRANTY WARRANTY AND DISCLAIMERS Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material 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 twenty four months from date of sale repair or replace any part of the equipment proven detective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendation
4. e a a au rn n a n n o n n he KA Always use this start up procedure to ensure that the unit is started safely and properly 1 Check the oil level Pump Add SAE 20 or 30 weight non detergent oil as necessary 2 Tum on the water supply CAUTION Never run the unit dry Costly damage to the pump will result Always be sure the water supply iS completely tumed on before operating 3 Trigger the gun until water sprays from the tip indicating that the air is purged from the system 4 Plug the electrical cord into proper grounded GFCI protected outlet 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 ALWAYS observethe following CAUTIONS to avoid costly damage to the pressure washer CAUTION DO NOT allow the pressure washer to idle for more than 10 minutes Doing so may cause the recirculating water to overheat and seriously damage the pump Turn off the pressure washer if it will not be spraying or cleaning at least every 10 minutes If heated inlet water is used reduce this time further DO NOT run the pump dry which will quickly damage the pump Be sure the water supply is fully tumed on before starting the pump DO NOT operate the pressure washer with the inlet water screen removed This screen helps keep abrasive
5. 0 TIP ASSEMBLY 1504 includes 45 61 TIP ASSEMBLY 2504 includes 45 62 TIP ASSEMBLY 4004 includes 45 63 DECAL Graco G QUICK COUPLER Male 1 4 LABEL Warning chassis LABEL Waring chassis LABEL Warning Caution WASHER Flat 5 16 WASHER Lock 5 16 NUT Hex 5 16 18 LABEL Caution 230 volt 3 phase LABEL Caution 460 volt 3 phase CONNECTOR Wire CORD Power 12 4 CORD GRIP SWITCH Starter 15 hp 230 Volt SWITCH Starter 15 hp 460 Voit NUT Lock electrical NIPPLE 1 2 x 2 TERMINAL Ring TIP Spray 0004 TIP Spray 1504 TIP Spray 2504 TIP Spray 4004 TERMINAL Ring PNN A NG gt gt CHAR Band oo gt gt web ab b ambk ami amb uh md mk 43 308 522 11 Depan ii e ian Ken RED E A 8 Model 4040 Model 4040 Wiring Diagram I Wiring Diagram 230 Volt 3 Phase 460 Volt 3 Phase 12 308 522 PARTS DRAWING SSR SSE eS SO cr acta ie ge son eee a aera A eR RS 800 579 Pump and Motor Assembly PARTS LIST k 800 579 Pump a REF PART TE NO NO DESCRIPTION QTY 803 584 MOTOR 15 0 hp TEFC 3 phase 1 802 698 COUPLER 15 hp 1 802 540 HOUSING 802 784 WASHER Lock 1 2 803 750 SCREW Cap socket hd 1 2 13 x 3 802 508 PUMP see page 16 100 527 WASHER Lock 5 16 801 559 SCREW Cap hex hd M8 x 30 802 783 KEY Motor 802 794 KEY Pump 803 552 RING Adapter O0OND URWH ID hh pma myak 308 522 13 14 308 522 PARTS LIST NRN E 80
6. 3 508 Pump Assembly 4 4000 psi REF NM ND Do N DD nN mh mak i kh cmd h mds ek akh PART NO 801 647 801 468 801 469 KIT 1 KIT 1 KIT 1 KIT 1 KIT 1 KIT 106 KIT 106 KIT 1 803 283 803 506 802 500 803 324 KIT 2 803 286 803 501 801 475 803 144 803 287 803 288 802 794 803 289 803 503 803 291 803 292 DESCRIPTION MANIFOLD SCREW Cap hex hd WASHER Lock O RING SEAT Valve PLATE Valve SPRING GUIDE Valve O RING CAP VALVE ASSEMBLY SCREW Cap socket hd COVER Crankcase O RING Crankcase Cover BEARING Tapered Roller SEAL Oil BUSHING Piston CRANKCASE DIPSTICK GASKET Cover CRANKSHAFT RING Retaining KEY PIN Wrist GUIDE Piston ROD Connecting SCREW Cap socket hd aia NN ON GO Co G OD vi ol Ao REF PART NO NO 28 808 507 29 802 345 30 802 793 31 KIT 107 32 803 294 33 801 652 34 KIT 107 35 801 490 803 502 36 KIT107 37 KIT 107 38 KIT 107 39 803 505 40 803 296 41 KIT3 42 KIT 109 43 KIT 109 44 KIT 109 KIT 112 45 KIT109 46 KIT 109 47 KIT 109 51 801 482 52 801 483 53 801 484 54 801 485 DESCRIPTION COVER Crankcase GAUGE Sight PLUG Oil Drain O RING SCREW Cap socket hd WASHER Lock WASHER Flinger PLUNGER Ceramic PLUNGER Ceramic QTY ab h ah 6 C9 o o RING Backup WASHER SCREW Piston COVER Crankcase 1 SHIM SEAL Oil O RING RETAINER Packing PACKING PACKING RING Head RETAINE
7. 801 957 29 801 134 30 803 262 31 800 441 32 802 993 33 803 186 34 803 351 DESCRIPTION PUMP amp MOTOR ASSEMBLY see page 15 BRACKET Pump Support CORD Power 10 4 BRACKET Starter left NIPPLE Hex 1 2 x 3 8 WASHER Flat 6 WASHER Lock 6 SCREW Cap pan hd LABEL Keep From Freezing UNLOADER 4000 psi HOSE ASSEMBLY w Quick Couplers includes 14 18 20 QUICK COUPLER Female 1 4 includes 13 O RING Quick Coupler 1 4 QUICK COUPLER Male 3 8 NIPPLE Hex 1 2 NPSM x 1 2 NPT HOSE Bypass LABEL Model 4040 HOSE High Pressure 3 8 x 50 ft GUN amp WAND ASSEMBLY inci 12 20 28 29 34 35 QUICK COUPLER Female 3 8 includes 21 O RING Quick Coupler 3 8 PLUG Plastic STRAINER FILTER ADAPTER Garden Hose NUT Garden Hose TEE 1 2 SLEEVE 18 WAND 32 BRACKET Starter right CHASSIS PLUG Locking 15 hp 460 volt LABEL Cordset GUN Spray SST See Instruction Manual 308 51 1 QTY ak wah amb wak N Pore EE oe aka b L PART NO 156 849 803 591 802 784 803 592 801 012 800 124 800 125 800 126 800 127 801 008 801 090 176 250 176 981 803 396 100 527 100 214 100 188 803 007 803 006 801 226 801 382 802 811 804 043 803 749 801 937 801 523 801 221 801 599 801 600 801 601 801 602 801 304 DESCRIPTION NIPPLE Hex 3 8 WASHER Flat 1 2 WASHER Lock 1 2 SCREW Cap hex hd 1 2 13 x 1 1 2 GROMMET Rubber TIP ASSEMBLY 0004 includes 45 6
8. AZARD Moving parts can pinch or amputate fingers or other body parts KEEP CLEAR of moving parts when starting or operating the pressure washer NEVER operate the pressure washer without all guards and interlocks installed and functioning Follow the 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 device 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 93 C or below 40 F 40 C Pressure Rellef Procedure before checking or servicing the pressure washer to prevent discharging high pressure fluid from the gun A eye etre As atari eaa level el tee lt PEN 5 M M eve Ple Nin La e ae Oe Seen uin a aa ek aci veri NER ete eee ae PLN eene ero tola tat Ta tat trt Itera rats tte tetti teurer AKM KIM ed OKK ME AI 4 4 4 tat unu i LI tuat tor ul anu LOGRA AAK DONO A plattere MAS T 7 VN i pa Caen 5 MOEN r WARNING or DANGER Alerts user to avoid or correct conditions that could cause bodily injury CAUTION Alerts user to avoid or correct conditions
9. ES 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 THREE 3 YEARS OF THE DATE OF SALE EQUIPMENT NOT COVERED BY GRACO WARRANTY GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY 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 IMPORTANT PHONE NUMBERS TO PLACE AN ORDER contact your Graco distributor or call this number to identify the distributor closest to you 1 800 328 0211 Toll Free FOR TECHNICAL ASSISTANCE service repair information or assistance regarding the application of Graco equipment 1 800 543 0339 Toll Free Factory Branches Atlanta Chicago Dallas Detroit Los Angeles West Caldwell N J Subsidiary and Affiliate Companies Canada England Switzerland France Germany Hong Kong Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 PRINTED IN U S A 308 522 1 91
10. R Packing RING Long Life PLUG Hex WASHER Flat PLUG Hex WASHER Flat tmbah b 0 O RING SEAT Valve PLATE Valve SPRING OAM 0 0 Repair Kit Part No Description Qty 801 472 Valve i 6 7 8 GUIDE Valve 11 VALVE ASSEMBLE 2 8 473 SEAL Oil ME Seal Kit 802 511 SEAL Oil Crankshaft Seal 802 509 O RING Ha Cap CAP 4000 psi 107 803 510 803 511 Packing amp Retainer 4000 psi 803 512 Packing 4000 psi O RING WASHER Flinger RING Backup WASHER SCREW Piston O RING RETAINER Packing PACKING RING Head RETAINER Packing RING Long Life 308 522 15 PUMP SERVICE 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 before proceeding NOTE The following metric wrenches are needed M10 M13 and M30 Repair kits are available Refer to the individual repair sections and the pump parts page for more details For the best results use ail parts in the kits NOTE There are two different tool kits to aid in servicing the pump P N 800 298 is used to ease installation of packings P N 800 271 includes the items in 800 298 and tools to aid in the removal of packing retainers Valves NOTE For a set of six valves order P N 801 472 1 Remove the hex plug from the manif
11. can result in accidental triggering of the gun SPRAY TIP SAFETY Use extreme caution when cleaning or changing spray tips If a spray tip clogs while spraying engage the gun safety latch immediately ALWAYS follow the Pressure Rellef Procedure and then remove the spray tip to clean it GROUNDING INSTRUCTIONS This product must be grounded If it should malfunction or break down grounding provides a path of least resistance for electric current to reduce the risk of electric shock This equipment is equipped with a cord having an equipment grounding conductor and a grounding plug The plug must be plugged into an appropriate outiet that is properly installed and grounded in accordance with all local codes and ordinances GROUND FAULT CIRCUIT INTERRUPTER PROTECTION To comply with the National Electrical Code NFPA 70 and to provide additional protection from the risk of electric shock connect this pressure washer to a EXTENSION CORDS Use only 4 wire extension cords that have 4 prong grounding type plugs and 4 pole cord connectors that accept the plug from the product Use only extension cords that are intended for outdoor use These extension cords are identified by a marking Acceptable for use with outdoor appiiances store indoors while not in use Use only extension cords having an electrical rating not less than the rating of the product Do not use damaged extension cords Examine extension cord before using and repla
12. ce if damaged Do not abuse extension cord and do not yank 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 fire explosion or property damage NEVER alter or modify any part of this equipment doing SO could cause it to malfunction CHECK all spray equipment regularly and repair or replace worn or damaged parts immediately ALWAYS wear protective eyewear and appropriate clothing if using chemical injector read and follow the chemical manufacturers literature for recommendations on additional protective equipment such as a respirator DANGER Improper connection of the equipment grounding conductor can result in the risk of electrocution Check with a qualified electrician or service person if you are in doubt as to whether the outlet is properly grounded Do not modify the plug provided with the product if it will not fit the outlet have a proper outlet installed by a qualified electrician receptacle that is protected by a ground fault circuit interrupter GFCI or pull on any cord to disconnect Keep cord away from heat and sharp edges Always disconnect the extension cord from the receptacie before dis
13. connecting the product from the extension cord WARNING To reduce the risk of electrocution keep all connections dry and off the ground Do not touch plug with wet hands System Pressure This sprayer can develop high operating 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 ail 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 inside back cover Always read the chemical manufacturer s literature before using any chemical in this pressure washer 308 522 3 HOSE SAFETY Susan ERS ec ere ee Due ee 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 ALL FLUID HOSES MUST HAVE STRAIN RELIEFS ON BOTH ENDS The strain reliefs help protect the hose from kinks or bends at or close to the coupling which can result in hose rupture TIGHTEN all 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 MOVING PARTS H
14. g the quick couplers provided Connect the high pressure hose between the pump outlet and the gun inlet Both of these connections are made with quick couplers CAUTION Up to 100 ft 80 m of high pressure hose may be used Longer hoses may affect sprayer performance and chemical injector performance if used QUICK fh on COUPLER ELECTRIC PLUG Install the appropriate spray tip on the wand See Installing and Changing Spray Tips If you are using a sandbiaster kit see its separate manual for installation instructions Connect to Water Supply CAUTION Before attaching to the water supply check your focal 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 water supply Install it upstream from the pump Install a regulating water valve P N 800 258 if inlet water pressure is over 60 psi 4 1 bar Do not exceed 160 F 70 C inlet water temperature Connect a hose with at least a 3 4 inch 19 mm ID and not longer than 50 ft 15 m to the unit s 3 4 inch garden hose inlet NOTE The water source at the unit must have a minimum flowrate equal to that of the unit see Technical Data inside back cover 308 522 5 MCN ba e hg a UR idit e MEA Ae LO SEPH TOLLAL AT ES OSCH de a n a a ttr nn PP ola uela anuo a S T In Ia n n a a a Ia a e a a a
15. g to spray again 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 mounted in the quick coupler Figure 3 308 522 7 SHUTDOWN FLUSHING EEE 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 stop spraying for more than 10 minutes when shutting down and before checking or repairing any part of the system 1 Engage the trigger safety latch 2 Tum the sprayer off 3 Disconnect the electrical supply 4 Shut off the water supply 5 Disengage the trigger safety latch and trigger the gun to relieve pressure and then engage the trigger safety latch again 6 Before long term ovemight storage disconnect the water supply and disconnect the electricity 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 Flush the pressure washer before using it again to remove the anti freeze NOTE An anti freeze flush kit P N 802 327 is available to make flushing easier CAUTION lf water does freeze in the pressure washer thaw it
16. in a warm room before trying to start it DO NOT pour hot water on or into the pump it may crack the ceramic plungers 2 After each use wipe all surfaces of the pressure washer with a clean damp cloth 3 Perform the appropriate maintenance See the maintenance chart 8 308 522 Observing regular maintenance intervals helps ensure that you get maximum performance and life from the pressure washer There is a break in period for the pump After changing the oil initially the interval between required changes is longer 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 before proceeding Clean water inlet screen and filter Check pump oil level Fill as necessary After first 50 hours of operation Each 500 hours Change pump oil Use SAE 20 or of operation or 30 non detergent oil 6 months Change pump break in oil Use SAE 20 or 30 non detergent oil TROUBLESHOOTING CHART 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 before proceeding PROBLEM CAUSE SOLUTION Low pressure and or Worn or wrong size tip Replace with tip of proper size pump runs rough Inlet fi
17. ing cavities and examine for debris and damage 6 Lightly grease the packing cavities and then replace the packings in the following order head ring v packing intermediate ring head ring v packing and packing retainer with the o ring installed in the retainer groove CAUTION Install the parts in the proper order and facing the correct direction Improperly installed parts will cause a malfunction 7 Reassemble the manifold as instructed in Servicing the Plungers 308 522 17 ACCESSORI ES EEE Must be purchased separately DOWNSTREAM CHEMICAL INJECTOR KIT 800 649 For injecting harsh cleaning chemicals downstream from the pump Stainless steel construction UPSTREAM CHEMICAL INJECTOR KIT 800 257 For injecting mild cleaning chemicals upstream into the pump BACKFLOW PREVENTOR 801 133 Prevent back up of contaminated water into fresh supply Install upstream of pump TECHNICAL DATA iss WATER SANDBLASTING KIT 800 120 For abrasive cleaning of stubbom dirt and paint Requires a spray tip 801 600 which is not included in kit ANTI FREEZE FLUSH KIT 802 327 For flushing system with 5096 anti freeze solution prior to transporting or storing pressure washer in below freezing temperatures INLET PRESSURE REGULATOR 800 258 Regulates inlet water pressure to 60 psi 4 bar maximum Motor Totally Enclosed Fan Cooled Dimensions Length 43 in 1092 mm Width 24 in 610 mm Height 19 in
18. kcase If leaking is obvious replace the oil seals Otherwise DO NOT remove these seals as they cannot be reused An oil seal kit is available to replace the seals 5 Lightly grease the oil seal if it is being replaced and the flinger and replace them on the plunger shaft Then install the plunger 6 Lightly grease the retaining screw and the outer end of the plunger Place the washer o ring and backup ring around the screw and install the screw through the plunger Torque to 14 4 ft lb 19 5 Nm NOTE If you plan to replace the packings refer to Servicing the V Packings 7 Lubricate the outside of each plunger Slide the manifold onto the crankcase being careful not to damage the seals 8 Install the capscrews and washers finger tight Torque the screws to 21 7 ft Ib 29 Nm following the tightening pattem Figure 4 Uneven tightening may cause the manifold to bind or jam Figure 4 Servicing the V Packings NOTE There are two types of packing kits one is packings only the other includes the packings rings and retainers 1 Remove the manifold as outlined in the Pumping Section 2 Carefully pull the packing retainer from the manifold Examine the o ring and replace it if it is cut or damaged 3 Remove the v packing and head ring Pull out the intermediate retainer ring Remove the second v packing and second head ring 4 Inspect all parts and replace as necessary 5 Thoroughiy clean the pack
19. lter clogged Clean Check more frequently Wom packings abrasives in water or Check filter Replace packings See PUMP SERVICE naturai wear Inadequate water supply Coupling slippage Fouled or dirty inlet or discharge valves Even a small particle can cause the valve to stick Restricted inlet Check water flow rate to pump Tighten or replace Clean inlet and discharge valve assemblies Check filter Check garden hose may be collapsed or kinked Worn inlet or discharge valves Replace worn valves Leaking high pressure hose Replace high pressure hose Water leakage from Worm packings Install new packings See PUMP SERVICE under pump manifold Water in pump Humid air condensing inside crankcase Change oil as specified in MAINTENANCE Wom packings Install new packings See PUMP SERVICE Oil seals leaking Install new oil seals See PUMP SERVICE Frequent or scored damaged or wom plungers Install new plungers See PUMP SERVICE Ihe back o Of Abrasive material in the fluid being pumped Install proper filtration on pump inlet plumbing Inlet water temperature too high Check water temperature may not exceed 160 F Overpressurizing pump EO jos mody Se A adjustments See Excessive pressure due to partially plugged 1 Clean or replace tip See Installing and Changing Spray or damaged tip Tips Pump running too long without spraying Never run pump more than 10 mi
20. nutes without spraying Do not run pump without water Running pump dry Strong surging at the Foreign particles in the inlet or discharge Clean or replace valves See PUMP SERVICE inlet and low pressure valve or worn inlet and or discharge valves on the discharge side Unit will not start Unit not plugged in Check power cord Electrical service off GFCI activated Check fuse circuit breaker Check for proper Thermal overload has tripped grounding Press stop button on the motor starter 308 522 9 MP zs Ze wee St ha va uon a zx heers ata Ts mm Te P ux Aet va zu er X uS en I Dos Dn e Do ete ndu M es x eee S aT tT es TEN NM um A M anta stats eee I T IM TS AM Ie TM D mt E d Mata Mt MER eL viz qum ue atate e iat eet mA A Alan hht aerate alata EE alta ere iS IA IM I I I ue Mex qu 0 han x 0 2 o ten o a o tes A e sf e lt t c q o 9 Ke wW af e e e eo see page 14 For wiring diagram 10 308 522 800 345 si Br rg 4040 pressure Washer REF PART NO NO 1 800 579 2 803 554 3 801 382 4 803 263 9 159 239 6 802 732 7 802 731 8 803 484 9 803 517 10 800 427 11 800 450 12 801 009 13 154 594 14 801 568 15 802 534 16 803 141 17 803 395 18 803 519 19 800 429 20 803 157 21 156 082 22 402 278 23 804 051 24 801 110 25 801 111 27 801 106 28
21. old using an M30 wrench 2 Examine the o ring under the hex plug and replace It if it is cut or distorted 3 Remove the valve assembly from the cavity the assembly may come apart 4 Install the new valve install the o ring and hex plug torque to 75 ft Ib 103 Nm NOTE Retorque the plug after 5 hours of operation Pumping Section 1 Remove the eight capscrews and lockwashers from the manifold using an M13 wrench 2 Carefully separate the manifold from the crankcase NOTE Itmaybe necessary to tap the manifold lightly with a soft mallet to loosen CAUTION Keep the manifold properly aligned with the ceramic plungers when removing to avoid damage to the plunger or seals 3 Carefully examine each plunger for any scoring or Cracking and replace as necessary 16 308 522 Servicing the Plungers NOTE Plunger repair kit P N 803 510 is available to replace retainers o rings washers and backup rings for three cylinders 1 Loosen the plunger retaining screw five to six tums using an M10 wrench Push the plunger towards the crankcase to separate the plunger and retaining screw 2 Remove the screw from the plunger and examine the o ring backup ring and copper bearing gasket washer Replace these parts if necessary using kit 803 510 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 cran
22. or exactly what fluid was injected NOTE TO PHYSICIAN injection 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 is a concern with some exotic coatings injected directly into the bloodstream Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable 2 308 522 mo X 2 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 stop spraying for more than 10 minutes when shutting down and before checking or repairing any part of the system 1 Engage the trigger safety latch Tum the sprayer oft Disconnect the electrical supply Shut off the water supply Disengage the trigger safety latch and trigger the gun to relieve pressure and then engage the trigger safety latch again 6 Before long term ovemight storage disconnect the water supply and disconnect the electricity 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 bodily injury SAFETY LATCH Whenever you stop spraying for a moment always set the gun safety latch in the engaged or safe position making the gun inoperative Failure to properly set the safety latch
23. s This warranty does not cover and Graco shall not be liable for any malfunction damage or wear caused by faulty 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 made at a reasonable charge which charges may include the costs of parts labor and transportation DISCLAIMERS AND LIMITATIONS THE TERMS OF THIS WARRANTY CONSTITUTE THE 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 LIABILITI
24. sediment out of the pump which could clog or scratch the pump Keep this screen clean DO NOT pump caustic materials such materials may corrode the pump components 7 See the chemical injector or sandblaster kit manual for detailed cleaning information if these accessories are used 6 308 522 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 spraying stops even for a moment In the engaged position the trigger safety latch prevents the gun from being triggered accidentally by hand or if it is dropped or bumped Be sure the latch is pushed fully down when engaging it or it cannot prevent the gun from being triggered See Figure 2 TRIGGER SAFETY LATCH SHOWN ENGAGED TRIGGER SAFETY LATCH SHOWN DISENGAGED Figure 2 Installing and Changing Spray Tips WARNING To reduce the risk of serious bodily injury including fluid injection or splashing in the eyes or onto the skin use extreme caution when changing spray tips ALWAYS follow the procedure below 1 Follow the Pressure Rellef Procedure 2 Point the gun and wand away from yourself and anyone else 3 Without holding your hand over the spray tip A pull back the quick coupler ring B remove the tip and then release the ring See Figure 3 4 Be sure the tip is secure before startin
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