Graco Inc. 2104E Pressure Washer User Manual
Contents
1. Proper size inlet plumbing check for airtight seal Pump runs extremely rough Restricted inlet or air entering pressure low the inlet plumbing Inlet restrictions and or air leaks Stuck inlet or discharge valve Clean out foreign material replace worn valves Leaking H P seals Replace seals Water leakage from under Worn packing Install new packing the manifoid l I May be caused by humid air Change oil at 3 month or 500 hour intervals using condensing into water inside the Graco Crankcase Oil other approved oil every crankcase month or 200 hours P N 801 144 Water in pump crankcase Frequent or premature Scored plungers failure of the packing Replace plungers Over pressure to inlet manifoid Reduce inlet pressure Damaged or worn plungers Replace plungers Abrasive material in the fluid install proper filtration on pump inlet plumbing being pumped Excessive pressure and or tem Check pressures and fluid inlet temperature be perature of fluid being pumped sure they are within specified range Over pressure of pumps Reduce pressure Do not run pump without water Running pump dry Check for smooth lap surfaces on inlet and discharge valve seats Discharge valve seats and inlet valve seats may be lapped on a very fine oil stone Foreign particles in the inlet or discharge va2. re INSTRUCTIONS PARTS LIST This manual contains IMPORTANT WARNINGS and INSTRUCTIONS READ AND RETAIN FOR REFERENCE HYDRA CLEAN 2104E 2104E MODEL 800 053 SERIES A 2750 psi 150 bar OPERATING PRESSURE 2250 psi 7 55 bar MAXIMUM WORKING PRESSURE GRACO INC P O Box 1441 MINNEAPOLIS MN 55440 1444 OCOPYRIGHT 1982 GRACO INC WARNING HIGH PRESSURE SPR AY CAN CAUSE SERIOUS INJURY FOR PROFE SSIONAL USE ONLY OESERVE ALL WARNINGS Read anc understand all instruction manuals before operating equipment INJECTION HAZARD SEE Fluids under high pressure from spray or leaks can penetrate the skin and cause extremely serious injury including the need for amputation NEVER point the spray gun at anyone or any Pan of the body NEVER put hand or saver the spray tip NEVER try to stop or deflect leaks with your hand or body ALWAYS have the tip guard in place when spraying MEDICAL TR BAY MENTE H any fluid appears to penetrate your skin get EMERGENCY MEDICAL CARE AT ONCE DO ROT TREAT AS A SIMPLE CUT Tell the doctor exactiy what fluid was injected For treatment instructions have your doctor call the NATIONAL POISON CENTER NETWORK 412 881 6669 AVOID COMPONENT RUPTURE Even after you shut off the gasoline engine there is high pressure in the pump hose and gun until you release it by triggering the gun So before removing the spray tip or servicing t
3. Before starting be sure to read the safety warnings and setup instructions Turn on the water supply Trigger the gun to release any back pressure DO NOT wire or tie ihe gun trigger into the open or triggered position CAUTION Never run the cleaning unit dry Costly damage to the pump will result Always be sure water supply is completely turned on before operating Inspect all connections for any leaks Tighten if necessary Cleaning For Hydra Clean technique see the Chemical Injector manual 801 192 i For abrasive cleaning see the Water Sandblaster manual 801 190 Follow these precautions when removing and installing nozzles 1 Shut off the cleaning unit and trigger the gun to relieve pressure Engage the trigger safety Keep the nozzle and the tube pointed away from you and everyone else Do not put your hand over the tip to push the nozzle into place Grasp it from the side and keep your fingers away from the tip Do not let anyone else touch the spray valve while you are cleaning nozzles Be sure the slip ring is pushed forward to lock the nozzle in place before triggering the spray gun Shutdown and Care Of Unit When unit is not in use turn off water supply When shutting down for the day or weekend shut off unit shut off water supply valve and trigger gun to release pressure Wipe off the unit with a damp rag 4 801 392 PRU NES ei
4. 4 69 801 106 TEE brass 1 2 NPT 1 22 801 298 SCREW machine hex hd 70 801 236 NIPPLE hex steel 1 2 x 3 8 NPT 1 T hd 5 16 18 NC x 2 1 2 1 71 801 108 NIPPLE hex brass 1 4 x 1 2 NPT 1 vo 23 801 302 SCREW machine hex hd 72 801 109 PLUG hex brass 3 8 NPT 1 i 57 16 18 NC x 1 4 73 801 110 ADAPTER 1 2 hose 1 24 801 082 SCREW machine hex hd 74 801 111 NUT brass adapter 1 M6 x 30 mm 4 75 801 112 SCREEN inlet 1 25 801 081 SCREW machine hex hd 76 801 113 ry ae aed 1 2 NPT MBE 2 17 172 lg M8 x 20 mm 801 392 9 ELECTRICAL SCHEMATIC PARTS LIST continued REF PART DESCRIPTION QTY NO NO Items 77 90 are pump internal replacement parts See exploded view of pump for details 77 801 027 CAP 78 801 028 O RING cap 79 801 267 DISCHARGE MANIFOLD 80 801 030 WASHER 81 801 031 SEAL 82 801 032 RETAINER 83 801 033 WASHER 84 801 034 WICK 85 801 035 RING retaining 86 801 036 PLUNGER 87 801 037 STUD 88 801 038 RING backup 89 801 039 O RING 90 801 040 RETAINER plunger Y Y Y 00 0002 Y C2 C0 1 Order parts by name and number Always give the model number and series letter of the assembly for which you are ordering 801 042 SEAL KIT INCLUDES 3 SETS OF PARTS 801 041 VALVE KIT INCLUDES 3 SETS OF _ PARTS 2 kits needed to repair all 6 vaives 86 SERVICE TOOLS KEY WRENCH 801 044 EXTRACTOR TOOL 801 205 10 801
5. 392 PARTS DRAWING Gun and Hose Assembly o e PARTS LISTE REF PART DESCRIPTION OTY NO NO 1 801 007 SPRAY HOSE 3 8 ID 50 ft 15 m lg 1 Repair Kit 801 083 includes items A B C D E and F pe RE See o ae i 3 801 244 HANDLE teft 1 E Boone HANDLE right 1 E 01 249 SPRING SERVIC i 6 801 254 LEVER i 1 Remove the 8 screws from the body halves 3 and i 201 208 HE AOA 1 4 See the Parts Drawing Separate the body 9 801 261 DISCHARGE FITTING 1 halves 10 801 247 VALVE BODY 1 i 11 801 253 GUIDE SLEEVE 1 2 Remove the plug 14 spring 5 and ball A from 1 Ses ies FITTING I the valve body G 14 801 250 CAP 1 x 12 SUL UR SCREW 1 3 Remove the snap ring B Then remove the valve 801 265 SCREW Arteta ra d 17 801 134 TUBE 32 1 seat C and o ring D 18 801 029 GRIP 1 ipe 19 801 009 COUPLER female quick disconnect 3 4 Remove the sleeve nut 11 and o ring E with the 20 801 090 COUPLER male quick disconnect 1 actuator rod P 21 801 073 HOUSING nozzle 2 22 801 010 TIP blasting 0 1 inn o 5 After installing the new seat C and ball A tap the 23 801 011 TIP cleaning 15 i X 24 801 074 GUARD tip 2 ball lightly with a hammer to assure a proper 25 801 076 PLATE warning 1 EU seating between the ball and seat 26 801 077 RIVET 2 go 27 801 103 NIPPLE hex 1 4 x 3 8 npt brass 1 28 801 091 COUPLER male quick disconnect 2 6
6. Reassemble in reverse order using the remaining new parts from the repair kit Order parts by name and series letter of the assembly for which you are ordering Recommended tool box spare parts 801 392 11 A naa A A no A A A A SRNR A A ab A A ananas A A A A A A ENN O DAS A O A AA A COM RS aasian VE ia NSE ii d ACCESSORIES Must be purchased separately CHECK VALVE 801 133 CHEMICAL INJECTOR KIT 800 102 Prevent back up of contaminated water into fresh For injecting harsh cleaning chemicals downstream supply Install upstream from pump from pump WATER SANDBLASTER 800 103 ADJUSTABLE SAND SAVER 800 Ost For abrasive cleaning of stubborn dirt and paint For adjusting sand flow TECHNICAL DATA MOTOR 5 hp 3 phase 220 V 60 Hz 17 Amp WATER PUMP 2150 PSI 150 bar max pressure 4 GPM 15 liter min WETTED PARTS Stainless Steel Aluminum Phenolic Plastic Ceramic Liners Nitrile Rubber WEIGHT 140 Ibs OVERALL DIMENSION Length 36 in 914 mm Width 18 in 457 mm Height 17 in 432 mm MAX WATER TEMPERATURE 160 F 70 C INLET HOSE CONNECTION 3 4 in garden hose f THE GRACO WARRANTY Graco Inc warrants all equipment manufacturedby itand bearing its name to be free from defects in material and workmanship under normal use and service This warranty extends to the origina purchaser for a period of 12 months from the date of purchase and applies only when the equipment ts installed and op
7. 135 HUB pulley 1 20 B 137 al 2 Ig 1 i 1 018 BRACKET tensioner PARTS LIST 41 801 364 BELTGUARD cover 1 42 801 365 BELTGUARD baseplate 1 REF PART DESCRIPTION QTY 44 801 132 RIVET drive 2 NO NO 46 801 008 LABEL identification 1 1 HOSE amp GUN ASSY see gun 47 801 388 LABEL warning f 1 detail for parts 1 48 801 389 LABEL identification 1 2 801 001 PUMP REPLACEMENT PARTS 50 801 084 UNLOADER includes items 51 66 1 includes items 77 90 1 51 801 045 CAGE valve 1 3 800 015 ANTI VIBRATION FOOT 4 52 801 046 O RING 2 4 800 036 CHASSIS 1 53 801 047 SPRING 1 5 800 037 ELECTRIC MOTOR ASSY 1 54 801 048 BALL 1 6 801 390 BRACKET spacer T 55 801 049 SEAT 1 8 801 285 BELT drive 2 56 801 050 O RING 2 9 801 231 LABEL warning 2 57 800 012 UNLOADER SUB 1 10 801 140 LABEL identification 1 58 801 059 O RING 1 11 801 129 LABEL warning 1 59 801 060 HOUSING 1 13 801 131 PLATE serial no 1 60 801 0861 CYLINDER 1 14 801 221 CONNECTOR crimp 2 61 801 062 O RING 1 16 801 379 SWITCH starter 1 62 801 063 PLUG i i 2 17 801 382 CORD power 8 ft lg 1 63 801 068 HOUSING VALVE 1 18 801 380 STRAIN RELIEF 2 64 801 069 SPRING 1 19 801 292 SCREW self tapping 65 801 070 VALVE 1 no 6 32 NC x 172 2 66 801 071 SEAT 1 20 801 021 BOLT carriage 67 801 090 COUPLER male quick disconnect 1 5 16 18NCx 5 2 68 801 105 NIPPLE straight brass 21 801 088 SCREW machine hex hd 1 2 NPT x 3 1 2 1 hd 5 16 18 NC x 1 1 2
8. Replace valve parts with service kit 801 041 including retainer spring valve valve seat o ring and back up ring 5 Replace valve cover and torque to 75 ft ib 100 N m Pumping Section Photo 3 f 1 Remove the four 4 hex nuts from the manifold 2 Separate the manifold from the crankcase NOTE It may be necessary to tap manifold lightiy with mallet to loosen CAUTION Keep manifold properly aligned with ceramic plungers when removing to avoid damage to either plungers or seals 3 Carefully examine each plunger for any scoring and replace if necessary 6 801 392 Plungers Photo 4 I I 1 Using an M11 wrench remove the piunger retainer 2 Slide out the seal retainer with oil wick and rubber barrier slinger 3 With a slight twisting motion loosen the plunger from the pl nger rod and remove NOTE The stud may remain with the retainer when removed Disassemble and screw stud into plunger rod finger tight 4 Replace o ring and back up ring on plunger retainer l 5 Saturate new oil wick by soaking in oil 6 Install new plunger 7 Replace plunger retainer and torque to 80 in ib 9 N m 8 Install new oil wick in seal retainer 9 Replace barrier slinger over new plunger 10 Lubricate each plunger sleeve and carefully slide manifold onto crankcase Seals or V Packings Photo 5 6 7 and 8 1 Remove C ring from seal case 2 Then remove the low pressure seal f
9. c o Ret eg A PEN mr CAUTION Shut off cleaning unit when not actually spraying for longer pump life The pump will overheat if left running for over 10 minutes without spraying Check the filter screen in the water inlet connection as often as necessary at least daily Do not operate the unit with the inlet and filter screen removed DO NOT try to adjust the unloader valve or change the engine speed Changing these settings may cause excessive pressure intermittent unloader operation wasted fuel and increased wear on parts and will void the warranty PUMP MUST NOT BE RUN DRY and must be drained of water prior to exposure to freezing temperatures Use and store the unit where it will not be subjected to freezing temperatures If water does freeze in the unit thaw before trying to start A 50 anti freeze solution may be pumped prior to cold weather Storage Use only spray tips that are matched to the unit to avoid excessive cycling and wear of the unioader valve See Accessories CAUTION Let a frozen pump thaw in a warm place Don t pour hot water on a frozen pump A sudden temperature change may crack the ceramic plungers Do not pump caustic materials Before extended storage flush the pump with light oil Avoid dragging hose over an abrasive surface such as cement This causes excessive wear and shorter hose life Clean the intake line strainer daily Lubrication and Care Fill pump crankcase to
10. dot on oil gauge window with 25 oz 0 75 liters of crankcase oil part no 801 144 or equivalent SAE 40 weight hydraulic oil with antiwear and rust inhibitor additives Change initial fill after 50 hour running period Change oil every 3 months or at 500 hour intervals WARNING NEVER alter adjustment or modify the unloader vaive Aitering or adjusting unloader will not increase _ Performance of unit RA TA i a ii it e a SERVICE TROUBLESHOOTING PROBLEM Low pressure CAUSE SOLUTION Replace with nozzle of proper size Worn nozzle Tighten or replace use correct belts and replace both at same time Belt slippage Disassemble reseal and reassemble Air leak in inlet plumbing Relief valve stuck partially Clean and adjust relief valve check for worn plugged or improperly adjusted and dirty valve seats Kit available valve seat worn Inlet suction strainer clogged or Clean Use adequate size Check more improper size frequently Install proper filter Check flow available to pump Worn packing Abrasives in pumped fiuid or severe cavita tion Inadequate water supply Clean inlet and discharge valve assemblies Fouted or dirty inlet or discharge valves Replace worn valves valve seats and or discharge hose Worn inlet or discharge valves Leaky discharge hose
11. erated in accordance with written factory recommendations This warranty does not cover damage or wear which in the reasonable judgment of Graco arises from misuse abrasion corrosion negligence accident substitution of non Graco parts fauity installation or tampering 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 workmanship or material repairs will be made ata reasonable charge and return transportation will charge THIS LIMITED WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FORA 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 EQUIPMENT NOT COVERED BY GRACO WARRANTY Accessories or components of equipment sold by Graco that are not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in mak
12. he unit a ways shut off the unit and trigger the gun to release pressure Be sure that all accessory items and system components will withstand the pressure developed NEVER exceed the pressure rating of any component in system WEVER alter or modify equipment your personal safety as well as the function of the equipment ts at stake Before each use check hose for weak worn or damaged conditions caused by traffic sharp corners pinching or kinking Tighten all fiuid connections securely before each use Replace any damaged hose GENERAL Do not use chemicals or agents which are not compatible with Buna N and PVC or neoprena cover of hose Do not leave a pressurized unit unattended Shut off the unit and release pressure before leaving FIRE Do not spray flammable liquids Do not opefate the engine where combustible fumes or d st may be present NEVER run the unit with the belt guard removed Kaep clear of moving parts when the unit is running Observe detergent Mira Super s safety precautions Avoid getting detergent or other liquids in your eyes Follow the directions on the container regarding contact with eyes nose and skin breathing fumes etc Always wear full goggles to protect your eyes from the spray as well as any debris dislodged by the spray if necessary wear gloves or other protective clothing if antidotes or treatment are recommended be prepared to use them DONT spray t
13. i f install Hose and Spray Gun Connect the spray hose to the spray gun by inserting the pin at the end of the hose into the quick disconnect coupler on the gun Connect the hose to the fluid outlet in the same way Remove the tape from the cap on top of the pump Cleaning Accessories For spraying detergent or other cleaning solution we recommend using a chemical injector kit See Accessories and instruction manual 801 192 for installation and operation For removing rust and old paint we recommend using a water sandblaster See Accessories and instruction manual 801 190 for installation and operation REMOVE TAPE FROM PUMP CAP STARTER SWITCH SPRAY GUN SPRAY HOSE Connect To Water Supply CAUTION Before attaching to water supply check local plumbing code regarding cross connection to water supply Backflow check valve 801 133 Do not exceed 160 F 70 C water temperature to pump in a direct supply system Connect a hose with at least a 3 4 in 19 mm ID from your city water supply to the unit s 3 4 in garden hose threaded inlet The supply hose should not be more than 50 ft 15 m long NOTE For a direct supply system your water source at the unit must have a flow rate of AT LEAST 5 GPM 19 LITER MIN If your operating conditions are different from above contact our Customer Service Department for assistance 801 392 3 AA A EPA is di io E a OPERATION Startup
14. ing such claims Factory Branches Atlanta Dallas Detroit Los Angeles West Caidweil N J Subsidiary and Affiliate Companies Canada England Switzerland France Germany Hong Kong Japan GRACO INC P O BOX 1441 MINNEAPOLIS MIN 55440 1444 PRINTED IN U S A 801 392 9 82 45 10043A
15. lve or worn inlet and or discharge valves Strong surging at the inlet and low pressure on the discharge side 801 392 5 CAUSE SOLUTION Check replace PROBLEM Electric motor won t run Power cord unplugged or building circuit fuse blown Unplug power cord decrease pressure Overload switch has opened Power cord unplugged or Electric motor stops while building circuit fuse blown I Check replace spraying a Unplug power cord relieve pressure allow to cool Overload breaker has opened Don t use more than 100 ft of 12 ga extension cord Extension cord Tip plugged Remove and clean Electric motor runs but Displacement pump frozen or Thaw no output gear train damage i This unit has an overload breaker built into the switch assembly If it opens unplug power cord and let sprayer cool for 30 to 60 minutes Also try to correct the cause of overheating Always use the lowest pressure setting needed NOTE A M11 and M30 metric wrenches are required for servicing pump PUMP Valves Photo 1 and 2 1 Remove the hex plug using an M30 wrench 2 Examine o ring under plug and replace if evidence of cuts or distortion 3 Remove valve assembly including retainer spring valve and valve seat from valve cavity NOTE Valve assembly may come apart during removal i 4
16. oxic chemicals such as insecticide or weed killer This unit is supplied with an 8 foot power cord made up of four AWG No 12 wires The green wire of the electric cord is connected to the unit chassis and motor frame The other three wires are connected to the starter switch Be sure to connect the power cord to the appropriate approved plug to fit your requirements The starter switch has a built in circuit breaker that will shut off the power to the unit whenever the circuit is overloaded Always check to be sure the switch is off and thatthe hoses and electric cord are clear of moving parts before plugging in the power cord IMPORTANT United States Government safety standards have been adopted under the Occupational Safety and Health AS These standards particularly the General Standards Part 1910 and the Construction Standards Part 1926 should be consulted in conriection with your use of airless spray equipment 2 801 392 A O AI NR A A 0 A A A A RT i I INSTALLATION FLUID OUTLET FLUID INLET 3 4 IN GARDEN HOSE THREAD Check Electrical Service and Plug In Before plugging in the sprayer be sure the electrical service is 3 phase 220 V 60 HzAC 20 Amp With the ON OFF switch in the OFF position plug the power supply cord into a grounded outlet If you use an extension cord it must have 4 wires of at least 12 gauge 2 5 mm and should not be over 100 ft 30 3 m long
17. rom the seal case 3 Unscrew the seal case from the manifold using a special key wrench 801 044 4 Remove the high pressure seal and ex mine Before replacing lubricate ID and OD of new high pressure seal and press into manifold NOTE A socket and exten sion may be used to pressure seal from manifold 5 install new o ring on sealcase and lubricate OD of o ring 6 Screw seal case into manifold 7 Lubricate ID and OD of low pressure seal and press into seal case 8 Replace C ring holding low pressure seal in place 9 Lubricate each plunger sieeve and carefully slide manifold onto crankcase NOTE When replacing manifold onto plungers exireme caution should be exercised to avoid damage to the seals 10 Torque all four 4 bolts to 240 in ib 27 N m NOTE Carefully study the order of respective parts and note position of seals to assure proper re assembly and opera tion 801 392 7 A A NR A A A AI PARTS DRAWING In Detail Ref No s 67 76 Are Not Shown See Parts List 50 Sl pS D VN yj Yo omy 8 801 392 A as A A AA A AL o 4 REF PART DESCRIPTION NO NO 26 801 023 WASHER flat 1 4 8 27 801 015 WASHER flat 5 16 16 28 801 139 WASHER lock 1 4 4 29 801 025 WASHER lock 5 16 10 30 801 024 NUT hex 5 16 18 NC 7 31 801 012 GROMMET 4 32 801 367 BUMPER 1 34 801 004 PULLEY pump 1 35 801 381 PULLEY motor 1 36 801
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