Graco Inc. 308-517 Pressure Washer User Manual
Contents
1. DO NOT operate the pressure washer with the inlet water screen removed This screen helps keep abrasive 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 Chemical Injector 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 inside back cover Always read the chemical manufacturer s literature before using any chemical in this pressure washer WARNING Observe chemical manufacturer s safety precautions regarding use of goggles protective clothing or respirators A downstream chemical injector is provided with the pressure washer There is a three position selector valve for no chemical off chemical 1 or chemical 2 Chemical 1 and chemical 2 cannot be applied simultaneously There are also metering valves to control the flowrate of each chemical The chemical adjustment knob on the injector under the hood should be a full two turns counterclockwise from the closed clockwise position Insert each chem cal filter attached with clear tubing to the chemica metering valves into a container of chemical Turn the control ring on the adjustable nozzle clockwise This causes a drop in pressure that actuates the chemical injector Closing the adjustable nozzle deactivates the chemical injector2. Repair Kit Qty Part No Description Incl O ring Seat valve Plate valve Spring Guide valve 801 472 Valve 11 Valve Assy 802 306 O ring Valve Cap Cap O ring Ring backup ONO OO OO 9 9 Washer Screw piston 801 662 Packing Packing 23 801 658 Seal oil Oil Seal 27 801 664 Packing Packing amp Retainer packing Retainer Ring head Retainer packing O ring 308 517 15 PARTS DRAWING i 802 629 Pump Assem y 16 308 517 PARTS LIST 802 629 Pump Assembly 1200 psi REF PART REF PART NO NO DESCRIPTION QTY NO NO DESCRIPTION QTY 1 802 319 MANIFOLD 1200 psi 1 26 802 526 COVER Crankcase 1 2 801 651 SCREW Cap socket hd 8 27 803 273 SCREW Cap socket hd 5 3 801 652 WASHER Lock 8 28 KIT 6 O RING 4 KIT 1 O RING 29 802 345 GAUGE Sight 1 5 KIT 1 SEAT Valve 30 802 793 PLUG Oil Drain 1 6 KIT 1 PLATE Valve 31 803 329 CRANKSHAFT 1 7 KIT 1 SPRING 32 803 275 PIN Wrist 3 8 KIT 1 GUIDE Valve 33 802 794 KEY 1 9 KIT 4 O RING 34 803 276 ROD Connecting 3 10 KIT 4 CAP 35 803 277 WASHER Fiat 6 11 KIT 1 VALVE ASSEMBLY 36 803 278 WASHER Lock 6 12 KIT 19 27 PACKING 37 803 279 SCREW Cap socket hd 6 13 KIT 27 RETAINER Packing 38 803 330 GUIDE Piston 3 14 KIT 27 RING Head 39 801 660 WASHER Flinger 3 15 KIT 27 RETAINER Packing 40 801 661 PLUNGER Ceramic 3 16 KIT 27 O RING 41 KIT 6 RING Backup 17 KIT 23 SEAL Oil 42 KIT 6 WASHER 18 803 265 SCREW C
3. and produces high pressure for rinsing WARNING DO NOT attempt to open or close the adjustable nozzle when the spray gun is in use Be sure that the trigger safety latch on the gun is in the ON position before adjusting to avoid serious bodily injury or fluid injection Check the distance that you will need to hold the spray nozzle from the surface by test spraying on a scrap of similar material For soft surfaces such as wood hold the nozzle about 3 ft 1 m from the surface and gradually bring it closer checking to see if the high pressure spray is damaging the surface Mist wet the surface with cleaning solution Let it soak briefly then use the high pressure rinse to chisel off the soil Keep the nozzle at an angle to the surface and at a distance determined to be best for the surface If some soil remains repeat the procedure letting the chemical soak a little longer Stubborn soil can be cleaned off better with a stronger heated cleaning solution Protect surfaces that might be damaged by the cleaning solution or the high pressure spray Rinse the solution before it dries 308 517 7 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
4. CORDS Use only 3 wire extension cords that have 3 prong grounding type plugs and 3 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 appliances store indoors while not in use Use only extension cords having an electrical rating not less than the rating of the product Do notuse damaged extension cords Examine extension cord before using and replace if damaged Do not abuse extension cord and do not yank or pull on any cord to 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 CAUTION DO NOT use the switch on the GFCI cord to start the unit This may cause premature failure of the GFCI ALWAYS turn the machine off at the switch before resetting the GFCI receptacle that is protected by a ground fault circuit interrupter GFC disconnect Keep cord away from heat and sharp edges Always disconnect the extension cord from the receptacle before disconnecting the product from the extension cord WARNING To reduce the risk of electrocutio
5. 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 H 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 LIABILITIES BASED ON NEGLIGENCE OR STRICT LIA
6. Hose 4 801 223 SWITCH Motor 1 50 802 735 HOSE ASSEMBLY inlet 5 801 894 SCREW Ground self tapping 1 51 801 683 FILTER Chemical 6 801 893 BOX Switch 1 52 801 023 WASHER Flat 1 4 7 801 931 GRIP Cord 2 53 800 246 CHASSIS 8 802 704 CORD 14 3 40 in 54 802 669 HOSEBARB 1 8 x 1 4 802 153 CORD 12 3 40 in 55 802 683 VALVE Metering g 802 685 PLATE Instruction 56 801 937 NUT Lock electrical 57 802 686 LABEL Control Panel 58 802 843 LABEL Knob 59 802 733 SCREW Machine 6 32 x 1 2 60 802 731 WASHER Lock 6 802 732 WASHER Flat 6 62 801 547 WASHER Flat 3 4 63 801 606 WASHER Flat 10 64 802 684 VALVE 3 Way 17 803 396 LABEL Caution Warning 65 801 733 HOSEBARB 1 4 x 1 4 18 801 103 NIPPLE Hex 3 8 x 1 4 66 802 636 PANEL Control 19 800 396 GUN AND WAND ASSEMBLY 67 802 627 ADAPTER 10 800 118 NOZZLE Adjustable 11 802 664 HOOD 12 e 801 666 TIP Spray 15 x 801 883 TIP Spray 15 13 802 751 PANEL End 14 801 935 WAND 20 15 801 957 SLEEVE 18 16 803 350 GUN Spray _ mk ek sch sch h mad mb sch med sech pes incl 10 14 15 16 18 20 1 68 e 803 165 LABEL Voltage 115V 20 801 009 COUPLER Female 1 4 incl 21 1 801 445 LABEL Voltage 230V 21 801 202 O RING Female Coupler 1 4 1 69 e 802 765 GRIP Cord 22 801 090 COUPLER Male 1 4 1 x 801 931 GRIP Cord 1 23 801 967 HOSE High Pressure 30 70 801 226 CONNECTOR Wire pow zt mak xm nk k _ NR N P SE 24 801 605 SCREW Machine 410 24 x 3 4 10 see page
7. any fluid appears to penetrate your skin qet EMERGENCY MEDICAL TREATMENT AT ONCE DO NOT TREAT AS A SIMPLE CUT Tell the doctor exactly what fluid was injected NOTE TO PHYSICIAN Injection in the skin is a traumatic injury lt 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 2 308 517 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 Turn the sprayer off 2 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 overnight 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
8. expose Graco hose to temperatures above 200 F 93 C or below 40 F 40 C Pressure Relief Procedure before checking or servicing the pressure washer to prevent discharging high pressure fluid from the gun TERMS WARNING or DANGER Alerts user to avoid or correct CAUTION Alerts user to avoid or correct conditions conditions that could cause bodily injury that could cause damage to or destruction of 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 308 517 INSTALLATION CHEMICAL STORAGE TRAY PUMP OIL LEVEL INDICATOR WINDOW MOTOR SWITCH CHEMICAL METERING VALVE Figure 1 Check for Shipping Damage Check the unit for any damage that may have occurred in shipping Note any damage and notify the carrier immediately 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 suppiy cord into a grounded GFCl protected outlet 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
9. 12 25 801 875 WASHER Lock 10 10 71 801 304 TERMINAL Ring see page 12 26 801 025 WASHER Lock 5 16 4 x 801 221 TERMINAL Ring see page 12 27 801 546 SCREW Cap hex hd 72 801 866 HOSE ASSEMBLY Bypass 3 8 16 x 1 1 4 2 incl 67 28 801 015 WASHER Flat 5 16 12 73 803 083 LABEL Keep from Freezing 29 801 363 WASHER Lock 3 8 10 74 800 115 VALVE Thermal Relief 30 801 214 SCREW Cap hex hd 75 802 665 ELBOW Street 1 2 x 45 3 8 16 x 1 3 4 2 76 801 622 CROSS 1 2 31 801 813 TUBING PVC 1 4 16 ft 77 801 178 ELBOW Street 1 2 x 90 32 e 801 941 SCREW Cap hex hd 78 801 523 NIPPLE 1 2 x2 5 16 18 x 1 4 79 e 800 154 PUMP AND MOTOR ASSEMBLY 801 818 SCREW Cap hex hd see page 12 1 3 8 16 x 1 4 x 800 248 PUMP AND MOTOR ASSEMBLY 33 801 025 WASHER Lock 5 16 4 see page 13 x 801 363 WASHER Lock 3 8 4 80 801 891 NIPPLE Hex 34 e 801 023 WASHER Flat 1 4 4 3 8 x 3 8 NPSM m 1 x 801 015 WASHER Flat 5 16 4 81 801 890 SWIVEL 3 8 x 3 8 NPSM f 1 35 802 729 HANDLE 1 82 e 801 865 UNLOADER 800 PSI 1 36 801 878 NUT Hex 3 8 16 4 x 802 842 UNLOADER 1200 PSI 1 37 801 818 SCREW Cap hex hd 83 801 907 WASHER Aluminum 1 3 8 16 x 1 6 84 801 905 ADAPTER 3 8 x 3 8 G 1 38 108 179 WHEEL 2 85 803 486 CHEMICAL INJECTOR 1 39 801 235 WASHER Fiat 5 8 4 86 e 801 900 GROMMET Rubber 1 40 801 880 PIN Cotter 1 8 x 1 1 2 2 87 801 901 SUPPORT Unloader 1 41 801 857 AXLE 1 88 801 881 SWIVEL 3 8 x 1 4 1 42 802 648 SPACER Pivot 2 89 801 620 ELBOW Stree
10. ANCE Install new packings See PUMP SERVICE Install new oil seals See PUMP SERVICE Install new plungers See PUMP SERVICE Install proper filtration on pump inlet plumbing Check water temperature may not exceed 160 F 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 SERVICE Check power cord Check fuse circuit breaker Check for proper grounding Press reset button on motor Disassemble chemical valve and clean chemical hose and filter Turn control ring on nozzle clockwise to cause drop in pressure Check level of chemical 308 517 Install new packings See PUMP SERVICE 9 PARTS DRAWING SE 800 232 Hydra Clean 826 Pressure Washer Wiring Diagram see page 12 800 233 Hydra Ciean 1235 Pressure Washer Wiring Diagram see page 13 10 308 517 PARTS LIST 800 232 Hydra Clean 826 Pressure Washer 800 233 Hydra Clean 1235 Pressure Washer REF PART REF PART NO NO DESCRIPTION QTY NO NO DESCRIPTION 1 802 760 COVER Switch 1 45 802 703 CASTER Ze 803 155 CORD SET GFCI 115V 1 46 800 247 BRACKET Caster x 803 149 CORD SET 230V 1 47 802 730 BUMPER 3 e 803 185 LABEL Warning GFCI 1 48 402 278 PLUG Plastic x 803 186 LABEL Warning cord set 1 49 801 112 STRAINER Garden
11. BILITY 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 cali 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 GRACO INC PO BOX 1441 MINNEAPOLIS MN 55440 1441 PRINTED IN U S A 308 517 2 90
12. EXTENSION CORD section and is no more than 100 ft 30 m long Added length of cord will affect current draw of unit Connect the high pressure hose between the pump outlet and the gun inlet CAUTION Up to 100 ft 30 m of high pressure hose may be used Longer hoses may affect sprayer performance and chemical injector performance 6 308 517 TWO CHEMICAL SELECTOR VALVE ADJUSTABLE QUICK COUPLER __ j HIGH PRESSURE SPRAY HOSE 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 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 temperature F 70 C inlet water 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 flow rate equal to that of the unit see Technical Data inside back cover STARTUP Use this procedure whenever starting the pressure washer to help insure that the unit is ready to operate and starting is done safely 1 Check the oil level Pump Add SAE 20 or 30 weight non detergent oil as neces
13. INSTRUCTIONS PARTS LIST CS 308 517 RevA GRACO This manual contains IMPORTANT sn w ne E WARNINGS and INSTRUCTIONS READ AND RETAIN FOR REFERENCE HYDRA CLEAN 826 1235 Pressure Washers HYDRA CLEAN 826 Model 800 232 Series B 800 psi 55 bar OPERATING PRESSURE 1100 psi 76 bar MAXIMUM WORKING PRESSURE HYDRA CLEAN 1235 Model 800 233 Series A 1200 psi 82 bar OPERATING PRESSURE 1500 psi 103 bar MAXIMUM WORKING PRESSURE GRACO INC P O Box 1441 MINNEAPOLIS MN 55440 1441 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
14. Ipm 3 5 gpm 13 Ipm Unit Weight 100 Ibs 46 kg 150 Ibs 68 kg Dimensions Length 38 in 965 mm 38 in 965 mm Width 19 in 482 mm 19 in 482 mm Height 33 in 838 mm 33 in 838 mm Maximum Inlet Water 160 F 70 C 160 F 70 C Temperature inlet Hose Connection Wetted Parts High Pressure Hose 3 4 in garden hose f 3 4 in garden hose f Acrylonitrile and Buna N cover and tube Bypass Hose Synthetic yarn and EPDM Pressure Washer Anodized aluminum Aluminum or Bronze alloys Brass Copper Nylo PTFE composite including fittings Ceramic Buna N Cotton Phenolic 303 304 and 316 Stainless Steel Polymide 12 Thermoplastic PTFE Carbon Steel Zinc with or without Yellow Chromate Plate PTFE is a registered trademark of the DuPont Company 308 517 19 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 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
15. always set the gun safety latch in the engaged or safe position making the gun inoperative Failure to properly set the safety latch 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 Relief Procedure and then remove the spray tip to clean it GROUNDING INSTRUCTIONS This product must be grounded If it should maifunction 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 outlet that is properly installed and grounded in accordance with all local codes and ordinances GROUND FAULT CIRCUIT INTERRUPTER PROTECTION 826 The 826 pressure washer is provided with a ground fault circuit interrupter GFCI built into the power supply cord This device provides additional protection from the risk of electric shock Should replacement of the cord become necessary use only identical replacement parts that include GFCI protection GROUND FAULT CIRCUIT INTERRUPTER PROTECTION 1235 To comply with the National Electrical Code NFPA 70 and to provide additional protection from the risk of electric shock connect the 1235 pressure washer to a EXTENSION
16. ap hex hd 8 43 KIT 6 SCREW Piston 19 803 266 COVER Crankcase 2 44 803 281 SPACER 1 20 803 267 SPACER 1 45 803 282 SEAL Crankshaft 1 21 803 268 O RING 2 49 801 484 PLUG Hex 1 22 803 269 BEARING Ball 2 50 801 482 PLUG Hex 1 23 803 326 CRANKCASE 1 51 801 483 WASHER Flat 1 24 801 659 DIPSTICK 1 52 801 485 WASHER Flat 1 25 803 327 GASKET Cover 1 Repair Kit Qty Part No Description Incl 1 801 472 4 O ring Valve 5 Seat valve 6 Plate valve 7 Spring 8 Guide valve 1 Valve Assy 4 802 306 9 O ring Valve Cap 10 Cap 28 O ring 41 Ring backup OO 9 Om On _ Washer Screw piston 19 801 662 12 Packing Packing 23 801 658 17 Seal oil Oil Seal 12 13 14 15 16 ht aon 27 801 664 Packing amp Retainer Packing Retainer packing Ring head Retainer packing O ring 308 517 17 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 all 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 o
17. 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 MAINTENANCE 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 8 308 517 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 stop spraying for more than 10 minutes when shutting down and before checking or repairing any part of the system Engage the trigger safety latch Turn the sprayer off 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 overnight storage disconnect the wate
18. e page SWITCH BOX 308 517 13 PARTS LIST 802 265 Pump Assembly 800 psi REF PART NO NO DESCRIPTION QTY 1 801 899 MANIFOLD Aluminum 1 802 795 MANIFOLD Brass 1 2 801 651 SCREW Cap socket hd 6 3 801 652 WASHER Lock 6 4 KIT 1 O RING 5 KIT 1 SEAT Valve 6 KIT 1 PLATE Valve 7 KIT 1 SPRING 8 KIT 1 GUIDE Valve 9 KIT 4 O RING 10 KIT 4 CAP _ _ KIT 1 VALVE ASSEMBLY 12 KIT 19 27 PACKING 13 KIT 27 RETAINER Packing 14 KIT 27 RING Head 15 KIT 27 RETAINER Packing 16 KIT 27 O RING 17 KIT 23 SEAL Oil 18 803 265 SCREW Cap hex hd 8 19 803 266 COVER Crankcase 2 20 803 267 SPACER 1 21 803 268 O RING 2 22 803 269 BEARING Bail 2 23 803 270 CRANKCASE 1 24 801 659 DIPSTICK 1 REF PART NO NO 25 803 271 26 803 272 27 803 273 28 KIT 6 29 802 345 30 802 793 31 803 274 32 803 275 33 802 794 34 803 276 35 803 277 36 803 278 37 803 279 38 803 280 39 801 489 40 801 661 41 KIT 6 42 KIT 6 43 KIT 6 44 803 281 45 803 282 49 801 484 50 801 482 51 801 483 52 801 485 DESCRIPTION GASKET Cover COVER Crankcase SCREW Cap socket hd O RING GAUGE Sight PLUG Oil Drain CRANKSHAFT PIN Wrist KEY ROD Connecting WASHER Flat WASHER Lock SCREW Cap socket hd GUIDE Piston WASHER Flinger PLUNGER Ceramic RING Backup WASHER SCREW Piston SPACER SEAL Crankshaft PLUG Hex PLUG Hex WASHER Flat WASHER Flat ang M h PHN AHHH HK mk mak ech sch sch
19. e 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 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 Ib 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 pattern Figure 3 Uneven tightening may cause the manifold to bind or jam Figure 3 Servicing the V Packings 5 Thoroughly clean the packing cavities and NOTE There are two types of packing kits one is just a packings the other includes the packings 6 Lightly grease the packing cavities and then rings and retainers replace the packings in the following order head ring v packing intermediate ring head rin
20. f packings P N 800 271 includes the items in 800 298 and tools to aid in the removal of packing retainers Valves NOTE Fora set of six valves order P N 801 472 1 Remove the hex plug from the manifold 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 lb 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 it may be 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 Servicing the Plungers NOTE Plunger repair kit P N 801 474 is available to replace retainers o rings washers and backup rings for three cylinders 18 308 517 1 Loosen the plunger retaining screw five to six turns using an M10 wrench Push the piunger 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 thes
21. g 1 Remove the manifold as outlined in the Pumping v packing and packing retainer with the o ring Section installed in the retainer groove 2 Carefully pull the packing retainer from the manifold Examine the o ring and replace it if it is cut or damaged CAUTION Be very sure the parts are installed in the proper order and facing the correct direction Improperly installed parts will cause a malfunction 3 Remove the v packing and head ring Pull out the intermediate retainer ring Remove the second v packing and second head ring 7 Reassemble the manifold as instructed in Servicing the Plungers 4 Inspect all parts and replace as necessary ACCESSORIES Must be purchased separately UPSTREAM CHEMICAL INJECTOR KIT ANTI FREEZE FLUSH KIT 802 327 800 257 For flushing system with 50 anti freeze solution prior For injecting mild cleaning chemicals upstream into the to transporting or storing pressure washer in below pump freezing temperatures BACKFLOW PREVENTOR 801 133 INLET PRESSURE REGULATOR 800 258 Prevent back up of contaminated water into fresh Regulates inlet water pressure to 60 psi 4 bar supply Install upstream of pump maximum TECHNICAL DATA Pe te O O Model 800 232 Model 800 233 Motor Totally Enclosed 1 5 hp 1 phase 3 0 hp 1 phase Fan Cooled Electrical Service 115 volts 15 amps 60 Hz 230 volt 20 amp 60 Hz Water Pump Maximum 800 psi 55 bar 1200 psi 82 bar Working Pressure 2 6 gpm 10
22. n keep all connections dry and off the ground Do not touch plug with wet hands 308 517 3 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 a chemical injector read and follow the chemical manufacturer s literature for recommendations on additional protective equipment such as a respirator 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 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 all
23. ow high pressure spray to be emitted from the coupling MOVING PARTS HAZARD 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 4 308 517 System Pressure This sprayer can develop high operating pressure Be sure that all soray 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 inside back cover Always read the chemical manufacturer s literature before using any chemical in this pressure washer 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
24. r supply and disconnect the electricity ao pon Be 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 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 Clean water inlet screen and filter Check pump oil level Fill as necessary After first 50 hours of operation Each 500 hours of operation or 6 months Change pump break in oil Use SAE 20 or 30 non detergent oil Change pump 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 Low pressure and or pump runs rough Worn or wrong size tip iniet filter clogged Worn packings abrasives in water or na
25. sary 2 Turn 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 turned 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 a proper grounded GFC 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 Most pressure washer spraying is done at full pressure On this pressure washer there is an adjustable unloader valve that permits operation at less than maximum pressure To reduce pressure for special cleaning applications turn the pressure control knob on the unloader counterclockwise as needed 7 ALWAYS observe the 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 ary which will quickly damage the pump Be sure the water supply is fully turned on before starting the pump
26. t 1 4 1 43 801 024 NUT Hex 5 16 18 4 90 801 709 PLUG Squarehead 1 4 1 44 801 940 SCREW Cap hex hd 91 801 129 LABEL Warning 1 5 16 18 x 3 4 4 e 800 232 Hydra clean 826 Pressure Washer x 800 233 Hydra clean1235 Pressure Washer 308 517 11 PARTS DRAWING 800 154 Pump and Motor Assembly PARTS LIST 800 154 Pump and Motor Assembly REF PART NO NO DESCRIPTION 1 801 862 MOTOR 1 5 hp TEFC 1 phase incl 12 2 801 864 PUMP 800 psi see parts drawing page 14 3 801 870 HOUSING Coupler 4 801 871 COUPLER incl 11 5 801 872 SCREW Cap hex hd M6 x 20 6 801 023 WASHER Flat 1 4 7 801 139 WASHER Lock 1 4 8 801 015 WASHER Flat 5 16 9 801 363 WASHER Lock 3 8 10 802 818 SCREW Cap hex hd 11 801 887 SPIDER 12 801 137 KEY 12 308 517 QTY 4 _ zt GP bb B HA WIRING DIAGRAM 115 Volt 1 Phase see page 11 SWITCH BOX MOTOR WIRING BOX 70 PARTS DRAWING 800 248 Pump and Motor Assembly 800 248 Pump and Motor Assembly PARTS LIST REF PART NO NO 1 802 625 2 802 629 3 802 633 4 802 698 5 802 786 6 801 139 7 802 784 8 802 785 9 801 887 10 801 137 DESCRIPTION MOTOR 3 0 hp TEFC 1 phase incl 10 PUMP 1200 psi see parts drawing page 16 HOUSING Coupler COUPLER incl 9 SCREW Cap hex hd M6 x 16 WASHER Lock 1 4 WASHER Lock 1 2 SCREW Cap socket hd 1 2 13 x 1 1 4 SPIDER KEY QTY 1 1 1 4 4 4 4 1 1 WIRING DIAGRAM S 230 Volt 1 Phase se
27. tural wear Inadequate water supply Coupling slippage Fouled or dirty inlet or discharge valves Even a smal particle can cause the valve to stick Restricted inlet Worn inlet or discharge valves Leaking high pressure hose Water leakage from under pump manifold Water in pump Humid air condensing inside crankcase Worn packings Oil seals leaking Frequent or premature failure of the packings 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 Strong surging at the Foreign particles in the inlet or discharge inlet and low pressure valve or worn inlet and or discharge valves on the discharge side Unit will not start Unit not plugged in Electrical service off GFC activated Thermal overload has tripped Chemical injector will T Chemical injector clogged not siphon Adjustable nozzle completely closed Low chemical level Replace with tip of proper size Clean Check more frequently Check filter Replace packings See PUMP SERVICE 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 Replace worn valves Repiace high pressure hose Change oi as specified in MAINTEN
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