Graco Inc. 1204E Pressure Washer User Manual
Contents
1. No NN AN AA CAN PART NO NO 54 800 004 800 014 801 012 801 013 800 015 801 231 801 240 801 293 801 241 801 214 801 291 801 022 801 023 801 024 801 025 801 298 801 363 801 177 801 139 801 170 801 137 801 173 801 087 801 015 801 132 801 131 801 130 801 129 801 141 801 204 801 008 801 242 811 292 801 235 801 243 801 225 801 296 801 294 801 295 801 290 801 376 Piston kit 801 322 Includes Ref No s 7 12 18 Valve kit 801 196 Includes Ref No s 13 18 Cup kit 801 321 Includes Ref No s 8 12 18 DESCRIPTION SPRAY GUN ASSEMBLY see parts on page 9 CHASSIS GROMMET HANDLE FOOT LABEL caution AXLE TENSIONER belt WHEEL BOLT hex hd 3 8 16 x 1 3 4 BOLT carriage 5 16 18 x 3 5 SCREW hex hd 5 16 18 x 1 3 4 WASHER flat 1 4 NUT hex 5 16 LOCKWASHER 5 16 BOLT hex hd 5 16 18 x 2 1 2 WASHER lock 3 8 COVER belt guard LOCKWASHER 1 4 uu SCREW hex hd mach M6 x 25 mm KEY pulley KEY pulley SCREW mach cross recessed 1 4 20 1 3 4 WASHER flat 5 16 RIVET PLATE serial LABEL warning LABEL warning LABEL warning LABEL identification LABEL identification CAP hub SCREW self tpg fiat hd 6 32 x 1 2 WASHER flat PIN cotter STRAIN RELIEF CONNECTOR fiexible conduit CORD power SWITCH starter BOLT carriage 5 16 12. 1 Shut off the cleaning unit and trigger the gun to relieve pressure Engage the trigger safety 2 Keep the nozzle and the tube pointed away from you and everyone else 3 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 4 Do not let anyone else touch the spray valve while you are changing nozzles 5 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 the unit is not in use turn off the water supply When shutting down for the day or weekend shut off the unit shut off the water supply valve and trigger the gun to relieve pressure Wipe off the unit with a damp rag CAUTION Shut off the cleaning unit when not actually spraying for longer pump life The pump could 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 ex cessive pressure intermittent unloader operation wasted fuel and increased wear on parts and will void the warranty THE PUMP MUST NOT BE RUN DRY and must be drained of water before exposure to freezing temperatures Use and store the unit where it wil
3. DIAGNOSIS AND MAINTENANCE CONT PROBLEM PROBABLE CAUSE SOLUTION Fouled or dirty inlet or discharge valves Clean inlet and discharge valve assemblies Low pressure Cont Worn inlet or discharge valves Leaky Replace worn valves valve seats and or discharge hose discharge hose Inlet restriction and or air leaks Damag Replace worn cup or cups clean out Pump runs extremely foreign material replace worn valves rough pressure very ed cup or stuck inlet or discharge valve low Worn inlet manifold seals Replace worn seals Check for plugged nozzle closed valves Cylinder o rings blown Pressures in excess of rated PSI or improperly adjusted by pass valve next to discharge manifold Warped manifold Replace manifold Leakage at the cylinder Loose cylinders Cylinder motion caused Exchange middle and outboard cylinder O Rings at the by improper shimming of the discharge 5 discharge manifold and manifold black powdery substance in the area of the O Rings Worn iniet manifold seals Install new seals If piston rod sleeves are scored replace sleeves and sleeve Water leakage from under the inlet manifold Leaking sleeve O Ring O Rings Oil leak between Worn crankcase piston rod seals Replace crankcase piston rod seals crankcase and pump ing section Oil leaking in the area Worn crankcase seal or improperly instali Remove oil seal retainer and replace of crankc
4. INSTRUCTIONS PARTS LIST 5 2123 GRACO This manual contains IMPORTANT WARNINGS and INSTRUCTIONS READ AND RETAIN FOR REFERENCE HYDRA CLEAN 1204 1200 psi 83 OPERATING PRESSURE 7350 psi 93 bar MAXIMUM WORKING PRESSURE MODEL 800 051 SERIES B GRACO VANGARD rd GRACO INC Box 1441 MINNEAPOLIS 55440 1444 COPYRIGHT 1982 GRACO INC EE HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY FOR PROFESSIONAL USE ONLY OBSERVE ALL WARNINGS Read and understand all instruction manuals before operating equipment INJECTION HAZARD 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 part of the body NEVER put hand or fingers over 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 TREATMENT 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 For treatment instructions have your doctor call the NATIONAL POISON CENTER NETWORK 412 681 6669 AVOID COMPONENT RUPTURE Even after you shut off the electric motor there is high pressure in the pump hose and gun until you relieve it by triggering the gun So before removing the spray tip or servicing the unit a ways shu
5. Replace seal assembly Tighten nut Replace hose Water leaking from Loose stuffing box Tighten valve stem Short piston seal life Scored piston sleeve Abrasives in water Power cord unplugged or building circuit fuse blown Electric motor won t run Overload switch has opened Power cord unplugged or building circuit fuse blown Electric motor stops while spraying Overload breaker has opened Extension cord Tip plugged Electric motor runs but no output Electric motor labors Capacitor failure when starting blows fuses Replace piston sleeve Flush with clean water Check replace Unplug power cord decrease pressure Check replace Unplug power cord relieve pressure allow to cool Don t use more than 100 ft of 12 ga ex tension cord Remove and clean Displacement pump frozen or gear train Thaw damage Replace capacitor 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 8 801 238 eae mene PARTS DRAWING Gun and Hose Assembly 27 18 LN ey 15 4 Vai VL PARTS LIST amp REF PART DESCRIPTION NO NO Repair Kit 801 083 Includes items A B C D E and F 1 801 007 3 8 ID 50 ft 1 2 800 017 SPRAY GU
6. 801 202 901 288 _ 9 PARTS DRAWING STARTER SWITCH 10 80258 PARTS LIST 8 REF PART NO NO 1 800 016 2 800 009 801 270 e 801 198 801 028 B01 356 801 273 801 181 801 111 801 112 801 106 801 105 801 178 801 269 801 090 801 108 801 182 801 110 801 203 801 045 801 046 801 047 801 048 801 049 801 050 800 013 801 143 801 059 801 060 801 061 801 062 801 063 801 068 801 069 801 070 801 071 801 176 801 375 801 300 801 299 SSTS B555RASA5ORUSSEHEUS DN oona DESCRIPTION MOTOR 3 hp PUMP ASSEMBLY includes items 3 49 PUMP Ref No 4 6 are replaceable parts Ref No 7 19 are sold in kits only 4 CAP O RING STUD HOSE 1 2 nptimbe 19 long PROTECTOR shaft NUT brass garden hose adapter SCREEN inlet 1 2 TEE brass 1 2 npt NIPPLE straight brass 1 2 npt x 3 1 2 ELBOW street 90 1 2 npt PLUG hex brass 3 8 npt COUPLER male quick disconnect BUSHING hex reducing brass 1 4 x 1 2 npt NIPPLE straight steel 1 2 npt x 2 1 2 ADAPTER 1 2 garden hose UNLOADER includes items 33 49 CAGE valve O RING SPRING BALL SEAT O RING UNLOADER TAG O RING HOUSING CYLINDER GASKET PLUG HOUSING valve SPRING VALVE SEAT BASE belt guard BELT drive PULLEY pump PULLEY motor
7. 8 x 3 HUB pulley QTY OONA lt a lt Order parts by and series letter of the assembly for which you are ordering 801 238 n ACCESSORIES Must be purchased separately CHECK VALVE 801 133 CHEMICAL INJECTOR KIT 800 102 Prevents back up of contaminated water into fresh For injecting harsh cleaning chemicals downstream supply Install upstream from pump from pump TECHNICAL DATA ELECTRIC MOTOR WATER PUMP 1200 PSI max pressure 15 liter min 4 GPM WETTED PARTS Stainless Steel Aluminum Phenolic Plastic Nitrile Rubber WEIGHT 165 Ib OVERALL DIMENSION Length 30 810 mm Width 28 710 mm Height 25 5 650 mm MAX WATER TEMPERATURE 160 70 C INLET HOSE CONNECTION 3 4 garden hose f LIMITED WARRANTY We warranty each new machine sold by us to be free from manufac turing defects in normal service for period of one 1 year com mencing with delivery of the machine to the original owner Our obligation under this warranty is expressly limited at our option to the replacement or repair at Vangard Mfg Minneapolis Minnesota or a service facility designated by us of such part or parts as inspection shall disclose to have been defective This warranty does not apply to defects caused by damage or unreasonable use including failure to provide reasonable and necessary m
8. D 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 4 119 LITER MIN If your operating conditions are different from above contact our Customer Service Department for assistance Trigger the gun to release any back pressure WARNING DO NOT wire tie the gun trigger into the open or triggered position 801 238 3 Turn on the water supply CAUTION Never run the cleaning unit dry Costly damage to the pump will result Always be sure the water supply is completely turned on before operating Inspect all connections for any leaks Tighten if necessary Cleaning For cleaning with harsh chemicals see the Chemical In jector Kit manual 801 192 For cleaning with clear water test the distance you will need to hold the spray nozzle from the surface on a scrap piece of similar material For soft surfaces such as wood hold the nozzle about 3 ft 1 mm from the sur face and gradually bring it closer checking to see if the high pressure spray is damaging the surface Always hold the nozzle at an angle to the surface and chisel off the dirt When you have finished cleaning shut off the unit and trigger the spray gun to relieve pressure WARNING Follow these precautions when removing and in stalling nozzles
9. N replaceable parts 1 include items 3 1 SERVICE 801244 HANDLE left 1 4 801 245 HANDLE right 1 1 Remove the 8 screws from the body halves 3 and 5 801 249 SPRING 1 4 See the Parts Drawing Separate the body 6 801 254 LEVER 1 halves 7 801 256 NEEDLE 1 8 801 262 HEX PLUG 1 2 Remove the plug 14 spring 5 and ball A from 9 801 261 DISCHARGE FITTING 1 the valve body 10 801 247 VALVE BODY 1 11 801 253 GUIDE SLEEVE 1 3 Remove the snap ring B Then remove the valve 3 501263 NET FITTING 1 seat C and o ring D 14 801 250 1 15 801 264 SCREW 7 4 the sleeve nut 11 and o ring E with the 16 801 265 SCREW 1 actuator rod F 17 801 134 TUBE 32 1 18 801 029 GRIP o 1 5 After installing the new seat and ball tap the 19 7801 009 COUPLER female quick disconnect ball lightly with a hammer to assure a proper seating 2 801 090 HOUSING male quick disconnect H between the ball and seat 20 801 374 blasting 0 1 2 23 801 373 TIP cleaning 15 1 6 Reassemble in reverse order using the remaining 24 801 074 GUARD tip 2 new parts from the repair kit 25 801 076 PLATE warning 1 26 801 077 RIVET 2 27 801 103 NIPPLE hex 1 4 x 3 8 npt brass 1 28 801 091 COUPLER male quick disconnect 2 ML Order parts by name and series letter of the assembly for which you are ordering Recommended tool box spare parts Heplacement O Ring for Coupler Part No
10. aintenance while in the possession of the consumer THIS WARRANTY DOES NOT APPLY TO THE WATER NOZZLE OR V BELTS WE NOT BE LIABLE FOR CONSEQUENTIAL DAMAGES OF ANY THING including but not limited to consequential labor costs or transportation charges in connection with the replacement or repair of defective parts We make no warranty with respect to trade accessories They are subject to the warranties of their manufacturers ANY IMPLIED OR STATUTORY WARRANTIES INCLUDING ANY WARRANTY OF MERCHANTIBILITY OR FITNESS FOR A PAR TICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURA TION OF THIS WRITTEN WARRANTY We make no other express warranty nor is anyone authorized to make any in our behalf Factory Branches Atianta Dallas Detroit Los Angeles West Caldwell N J 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 801 238 5 82 45 100208
11. as insecticide or weed killer This unit has a 3 prong grounding plug to protect you from electric shock Be sure to plug the unit into a pro grounded outlet that will accept the 3 prong plug Do not remove the third prong The green wire of the electric cord is connected to the unit chassis and motor frame and the other two wires are connected to the motor switch for grounding continuity The electric motor has an overload protection device which automatically shuts off the motor if it overheats So before examining or working on a motor which has stopped shut off the unit relieve pressure and pull out the electrical plug This will avoid the hazard of the motor starting unexpectedly ALWAYS CHECK to be sure the switch is OFF and that the hoses and electric cord are clear of moving parts before plugging in the power cord e 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 in connection with your use of airless spray equipment 2 801 238 INSTALLATION HANDLE FLUID OUTLET SPRAY HOSE Fig 1 Check Electrical Service and Plug In Before plugging in the sprayer be sure the electrical service is 220 V 60 HzAC 20 Amp With the ON OFF Switch in the OFF position plug the power supply cord into grounded ou
12. ase ed oil seal retainer packing damaged gasket and or seals Bad bearing Replace bearing Excessive play in the Worn main ball bearing from excessive Replace ball bearing Properly tension end of the crankcase tension to drive belt belt Check shaft shims pulley Water in crankcase May be caused by humid air condensing Change oil every month or 200 hours into water inside the crankcase Leakage of manifold inlet seals and or Replace seals sleeve and O Rings piston rod sleeve O Ring Oil leakage from under May be caused by excessive oiling of the Wipe free of oil Do not oil lubricators side of crankcase wick lubricators for a short period If leakage continues Worn crankcase piston rod seals replace the crankcase piston rod seals Oil leaking at the rear Damaged or improperly installed oil gauge Replace oil gauge or cover O Ring and portion of the or crankcase rear cover O Ring and drain drain plug O Ring crankcase plug O Ring Oil leakage from drain Loose drain plug or worn drain plug Tighten drain plug or replace O Ring plug O Ring Loud knocking noise in Pulley loose on crankshaft Check key and tighten set screw pump Broken or worn bearing Replace bearings Frequent or premature Scored rods or sleeves rods and sleeves failure of the inlet manifold seals Overpressure to inlet manifold Reduce inlet pressure per instructions Short cup life Damaged or worn chrome plating of the Replace
13. ifoid with GARTER SPRING DOWN and drive into place 7 Examine sleeves for scoring or other damage before removing 8 If worn grasp sleeve with pliers and pull off NOTE This procedure will mar the sleeve so use only if sleeve is to be replaced 9 Remove o ring and backup rings from piston rod Reassembly 1 Place barrier slinger on rod 2 Lubricate new o rings and backup rings Install first o ring in the o ring groove on the piston rod Position backup ring against the shoulder in front of the first o ring then the second o ring Be careful to avoid damaging the o rings when slipping them over the piston rod threaded ends 3 Immerse Sleeve in oil carefully twist and push onto rod Machined counter bore end first 4 Replace seal retainers 5 Be careful when replacing inlet manifold so the in let seals are not damaged by the threaded rod ends 6 Replace locking nuts on studs 7 Reassembie piston assemblies and discharge mani fold as described Consult factory for your loca distributor for crank case servicing DIAGNOSIS AND MAINTENANCE PROBLEM PROBABLE CAUSE SOLUTION Low pressure Worn nozzle Belt slippage Inlet suction strainer clogged Replace nozzle of proper size Tighten or replace use correct belt Clean Check more frequently Worn plunger cups Abrasives in pumped Install proper filter fluid or severe cavitation Inadequate water supply 801 238
14. l 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 unloader 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 coment This causes excessive wear and shorter hose ife Clean the intake line strainer daily Lubrication and Care Fill the pump crankcase to the dot on the oil gauge win dow with 25 oz 0 75 liters of crankcase oil 801 144 or equivalent SAE 40 weight hydraulic oil with antiwear and rust inhibitor additives Change the oil after the first 50 hours of operation and then every 3 months or at 500 hour intervals WARNING NEVER alter adjustment or modify the unioader valve Altering or adjusting unloader wil not increase performance of unit DISCHARGE VALVES amp VALVE SEATS Disassembly 1 Loosen the 2 locking nuts about one turn 2 Then remove the 2 flange nuts 3 Grasp the discharge manifold with 3 fingers on the underside and tap with a soft mallet to remove 4 Valve asse
15. lace and lubricate NOTE CUP INSTALLATION Wipe cup inserter lightly with oil Slip backup ring onto piston Force cup over inserter and square with all surfaces Faulty cup installa tion causes premature failure 3 Next replace piston spacer and retainer 4 Slip washer onto rod screw on nut and torque to 60 in Ib ALWAYS USE NEW COTTER PIN 5 Examine cylinder walls for scoring or etching These conditions will cause premature wear of piston assemblies Replace if worn or damaged 6 Lubricate cylinder and replace o rings and backup rings if defective 7 Position cylinders in their original order into manifold chambers and carefully slip over rod ends onto the pump 8 Replace flange nuts on studs and hand tighten both sides Then torque each side to 125 in Ib 9 Hand tighten locking nuts BAC CUP BACKUP RING PISTON SPACER PISTON RETAINER COTTER PIN BAC CUP PISTON INLET VALVE O RINGS CYLINDER PISTON ROD SLEEVE PUMPING SECTION CUTAWAY SEALS AND SLEEVES FS Disassembly 1 Remove discharge manifold and piston assemblies as described 2 Remove both 8 locking nuts from studs 3 With soft mallet tap inlet manifold loose from crank case 4 Place inlet manifold on pair of clearance blocks with crankcase side down and drive out seals 5 Invert inlet manifold with CRANKCASE SIDE UP 6 Lubricate circumference of new Prrrrrm A Lube seals position in man
16. mblies will remain with the manifold In vert manifold and discharge valve assemblies should fall out 5 inspect discharge valves for wear of ridges Spheri cal valves must be replaced when worn Reassembly 1 Place retainer in manifold chamber 2 Next insert spring into center of retainer 3 Place valve over spring with side down 4 Next insert the valve seat 5 Position manifold back onto pump NOTE Exercise caution when inserting cylinders into manifold to avoid damaging cylinder o rings 6 Replace flange nuts on studs and hand tighten both sides torque each side to 125 7 Hand tighten locking nut CAUTION When restarting the pump check to see that there is no cylinder motion as this will cause premature failure of the cylinder o rings Center cylinder motion can be eliminated by switching with one of the end cylinders PUMPING SECTION Ez Disassembly 1 Remove discharge manifold as described above 2 Slip cylinders out of inlet manifold NOTE Identify cylinders so they will be replaced in their original position Front to back 3 Remove cotter pin nut and washer 4 Next remove piston retainer spacer and piston assembly 5 Remove inlet valve 801 238 5 Reassembly 1 Examine inlet valve surface and reverse if damaged Both sides lap surfaces 2 Examine piston assembly for clean inlet surface If damaged rep
17. t off the unit and trigger the gun to release pressure Be sure that all accessory items and system com ponents will withstand the pressure developed NEVER exceed the pressure rating of any component in system NEVER alter or modify equipment your personal as well as the function of the equipment is at stake Before each use check hose for weak worn or damag ed conditions caused by traffic sharp corners pinching or kinking Tighten all fluid connections securely before each use Replace any damaged hose Do not use chemicals or agents which are not compati ble with Buna N and PVC or neoprene cover of hose Do not leave a pressurized unit unattended Shut off the unit and relieve pressure before leaving FIRE aan cena Do not spray flammable liquids Do not operate the unit where combustible fumes or dust may be present GENERAL NEVER tun the unit with the belt guard removed Keep clear of moving parts when the unit is running Observe detergent manufacturer 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 DON T spray toxic chemicals such
18. the cylinders cylinders DIAGNOSIS AND MAINTENANCE CONT PROBLEM PROBABLE CAUSE SOLUTION Abrasive material in the fluid being Short cup life Cont pumped Excessive pressure and or temperature of fluid being pumped Improper installation of cups Overpressure of pumps Running pump dry Front edge of piston sharp Chrome plating of cylinders damaged causing excessive wear of cups May be caused by pumping acid solution Foreign particles in the inlet or discharge valve or worn inlet and or discharge valves Strong surging a the inlet and low pressure on the discharge side Unloader cycling Worn piston seal Loose cleanout port nut Leak in discharge hose Install proper filtration of pump inlet plumbing Check pressures and fluid inlet temperature be sure they are within specified range Properly install lip of new cup into groove on the piston If not properly in stalled the cup will be extruded past the piston Piston wili run eccentric premature failure will result Reduce pressure Do not run pump without water Replace with new piston Install new cups and cylinders Pump only fluid compatible with chrome Check for smooth lap surfaces on inlet and discharge valve seats Discharge valve seats and inlet valve seats Discharge valve seats and inlet valve seats may be lapped on a very fine oil stone damaged cups and discharge valves cannot be lapped but must be replaced
19. tlet Do not remove the third prong of the plug you use an extension cord it must have 3 wires of at least 12 gauge 2 5 mm2 and should not be over 100 ft 30 3 m long Install Wheels and Handle Slide the axle through the frame Slide the wheels onto the axle and secure with the cotter pins provided Install the hub caps Using the two lowest holes on each leg of the frame at tach the handle with the 4 screws flat washers lockwashers and nuts provided Instali Hose and Spray Gun Connect the quick coupler on the end of the tubetothe tip assembly Connect the hose assembly to the quick coupler at the fluid inlet of the gun Then connect the hose to the Hydra Clean unit Rernove the tape from the cap on the top of the pump Clean Accessories For spraying detergent or other cleaning solution we OPERATION Startup Before starting be sure to read the safety warnings and setup instructions REMOVE TAPE FROM CAP SPRAY GUN recommend using a chemical injector kit See Ac cessories and instruction manual 801 192 for installation and operation Connect To Water Supply CAUTION Before attaching to the water supply check local plumbing code regarding cross connection to water supply If backflow prevention is needed use accessory check valve 801 133 Do not exceed 160 F 70 C water temperature to the pump in a direct supply system Connect a hose with a least a 3 4 in 19 mm I
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