Graco Inc. 800-064 Pressure Washer User Manual

1 i t.

This manual contains

WARNINGS and

IMPORTANT lMSTAUCTlQNS

READ AND RETAIN FOR REFERENCE

P/N

800-064 SERIES A

1500 psi(103 bar) OPERATING

PRESSURE

1800

psi

(124

bar) MAXIMUM WORKING

QRllCO

Rev D

bR]$ECTIoN

HAZARD

~~~~~~~~~~~~~~~~~~~~~~~~~

1

, ~ ~ ~ ~ , ~ ~ ~ ~ ~ ~ ~ " ~ ~ ~ ~ ~ , ~ ~ ~ * ~ ~ ~ ~ ~ ~ ~ ' ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ F i

Fluids under high pressure from spray or leaks can penetrate the skin and cause extremely serious injury, including the need for amputation.

Do not spray flammable liquids.

Do

not operate the engine where combustible fumes or dust may present. be

NEVER point the spray gun at anyone or any part of the body.

G A S

~ W E ~ A ~ K

NEVER put hand or fingers over the spray tip,

NEVER fill fuel tank while engine is running

or

hot.

Avoid the possibility of spilled fuel causing a fire.

Always refuel slowly to avoid spillage.

NEVER try to stop or deflect leaks with your hand or body.

ALWAYS

have the tip guard in place when spraying.

NEVER operate engine in a closed building unlessthe exhaust is piped outside. The exhaust contains carbon monoxide, a poisonous, odorlessand invisible

MEDICAL

~ ~ ~ ~ ~ F \ m E ~ ~

~~~~~~~~~~~~~~~~~~ possibly death.

S O ~ $ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

If any fluid appears to penetrate your skin,

EMERGENCY MEDICAL

CARE

ONCE. get

D O NOT

TREAT

&S A SIMPLE GUT.

Tell the doctor exactly what fluid was iniected. For treatment instruction's have your doctor call the

NATIONAL

POISON CENTER NETWORK

AVOID

COMPONENT RUQBWWE

~~~~~~~

NEVER make adjustments on machinery while it is connected to the engine; first remove the ignition cable from the spark plug. Turning over the machinery by hand during adjusting might start the engine and machinery. causing serious injury to the operator. or cleaning

NEVER run the engine with governor disconnected. or operats a t speeds in excess of

3600

RPM

load.

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 the unit, always shut offthe unit and trigger the gun to release pressure.

When starting the engine, maintain from moving parts of the equipment. a safe distance g:

E A h

p""v@%7"":

~ " ~

Be sure that all accessory items and system components will withstand the pressure developed.

NEVER exceed the pressure rating of any component in system..NEVER alter or modify equipment -your personal safety, as well as the function of the equipment, isatstake. Maximum working pressure

1800 PSI (124 bar).

Before each use, check hose for weak, worn or damaged conditions caused by traffic, sharp corners, pinching or kinking. Tighten all fluid connections securely before each use. Replace any damaged hose.

NEVER run the unit with the belt guard removed. 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 wejl as any debris dislodged by the spray. If necessary. wear gloves or other protective clothing. If antidotes or treatment are recommended, be prepared

use them.

not use chemicalsor agentswhich are not compatible with Buna-N and PVC or neoprene cover of hose.

D O N 1

spray toxic chemicals such as insecticide or weed killer.

Do not leave a pressurized off the

IMPORTANT

~ ~ ~

~ ~ .

~ ~ ~ ~ ~ ~

~ , ~ ~

~ ~ ~

~ ~

These standards

1910. 1926-

should be consulted in connection with your use of airless spray equipment.

801-641

.~ .. . . .

. .

...

~ ~ ~ ~ ~ ~ ~ ~ ~ * ~ ~ ?

~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

ENGINE KILL LEVER

Refer to the engine instruction booklet provided with the unit.

Connect To Water Supply

Install Hose and Spray Gun

Connect the spray hose to the spray gun by inserting the pin a t the end of the hose into the quick disconnect coupler the fluid outlet on the gun. Connect the hose t o in the same way.

CAUTION

Before attaching to water supply. check local plumbing code regarding cross-connection to water supply.

Do not exceed 1 60°F (70%) water temperature to pump in a direct supply system.

Cleaning Accessories

For spraying detergent

other cleaning solution, we recommend using a chemical injector kit.

Accessories and instruction manual 801-645 for

See

Connect a hose w i t h 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 5 0 ft.

(15

m)

installation and operation.

NOTE:

For a direct supply system. your wafer source at the unit

must

have a flow rate of

For removing rust and old paint we recommend using a water sandblaster. See Accessoriesand instruction manual 801-646 for installation and operation.

LEAST 5 GPM (19 LITER/MINJ.

contact our Customer Service Department for assistance.

801-641

Startup

-. setup instructions.

Check the oil and gasoline levels daily.

Turn on the water supply

Trigger the gun to release any back pressure

NOT wire or tie the gun

Set the choke and open the fuel valve.

NOTE:

For easier starting, hold the gun trigger open while pulling the rope.

Put your foot on the frame or wheel to steady the unit when you pull the starter rope. Hold the gun in your left hand with the trigger open while starting the engine.

Grasp the starter rope grip and rapidly pull out the cord two or three feet (1 m). Repeat if necessary with the choke opened slightly. When the engine starts, im- mediately release the gun trigger. Open the choke gradually.

CAUTION

Never run the cleaning unit dry. Costlydamage to is completely turned on before operating.

Inspect all connections for necessary. any leaks. Tighten if

Cleaning

For Hydra-Clean technique. see the Chemical Injector manual, 801 -645.

For abrasive cleaning, manual,

801 -646. see the Water Sandblaster

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.

Do not let anyone else touch the spray valve while you are cleaning nozzles.

5. Be sure the slip ring is pushed forward to lock the nozzle in place before triggering the spray

~~~ ~~~ ~

S h u t d o w n a n d 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.

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 sive pressure, interminent unloader operation, wasted fuel and increased wear on parts and will void the warranry.

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 unloader valve. See

ACCESSORIES. temperature change plungers.

~~ ~~ ~~ may crack

Do not pump caustic materials. the ceramic

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

Change the engine oil after every 100 hoursof operation. Drain oil with e'ngine warm. Engine requires

3

pints (1.4 liters) 30W oil. See separate instruction manual for maintenance procedures.

Fill pump crankcase to dot on oil gauge window with

02.

(0.47 liters) of crankcase oil (part no.

801-14441 or equivalent SAE 40 weight hydraulic oil with antiwear and rust inhibitor additives. Change initial fill after 50 hour running period. Change oil &ery

3 months or a t

XI0 hour intervals.

NEVER

alter valve.

4

801-641

. .-

. .

.,-

'ROBLEM

ingine Will Not Start

)r Hard To Start.

Engine Misses Or Lacks

'ower

.ow Pressure

CAUSE

No gasoline in fuel tank or carburetor.

Water in gasoline or old fuel.

SOLUTION

Fill the tank with gasoline, open fuel shut-off valve.

Check fuel line and carburetor.

Drain fuel tank and carburetor.

Use new fuel and dry spark plug.

Choked improperly. Flooded engine.

Dirty carburetor air filter.

Spark plug dirty or improper gap.

Spray gun closed. clear out the gas.

Remove and clean.

Clean, adjust the gap or replace.

Partially plugged air filter.

Spark plug dirty, wrong gap, or wrong type.

Incorrect ignition timing.

Trigger spray gun.

Remove and clean.

Clean, adjust the gap, or replace.

Time engine.

Worn nozzle.

Belt slippage.

Replace w i t h nozzle of proper size.

Tighten or replace; use correct beltsand replace both at same time.

Disassemble, reseal, and reassemble.

Relief valve stuck, partially plugged or improperly adjusted; valve seat worn.

Clean, and adjust relief valve; check for worn and dirty valve seats. Kit available.

Inlet suction strainer clogged

01 improper size.

Clean. Use adequate size. Check more frequently.

Worn packing. Abrasives in pumped fluid or severe cavita- tion. Inadequate water supply.

Install proper filter. Check flow available to pump.

Nater kaka he manifolcf! e from under valves.

Worn inlet or discharge valves.

Leakv discharge hose

Replace worn valves, valve seats and/or discharge hose.

'ump runs extremely rough

)ressure low.

Restricted inlet or air entering the inlet plumbing.

Inlet restrictions and/or air leaks. Stuck inlet or discharge valve.

Leaking H.P. seals.

Worn packing.

Pro er size inlet plumbing; check for air tight sear

ReDlace seals.

Install new packing.

Nater in pump crankcase. May be caused by humid air the crankcase.

Change oil at

Crankcase

3

Oil month or

200 hours) P.N.

5CO

Hour intervals using

(other ap roved oil every month or

801-r44.

'requent orprematurefailurl

)f the packmg.

Scored plungers.

Over pressure

inlet manifold

Damaged or worn plungers.

Abrasive material being pumped. in the fluid

Excessive pressure and./or temperature of fluld bemg pumped.

Over pressure of pumps.

Running pump dry.

Replace plungers.

Reduce inlet pressure.

Replace plungers.

Install proper filtration on pump inletplumbing. jure they are w i t h i n specifled range.

?educe pressure.

30

not run pump without water. strong surging at the inlet nnd low pressure on the lischarge side.

Foreign particles in the inlet or discharge valve, or worn inlet and/or discharge valves.

:heck for smooth lap surfaces on inlet and

$ischar e valve seats. Discharge valve seats and

;tone

801-641

.. . .

. .~~

...

". .

...

. .

6

801-641

.. .,,"..

..,,

~~.

. .

Pressure Washer Assembly,

REF.

PART

NO. No.

800-130

'801-665

'801.666

800-081

801-230

801-129

7 801-141

801-542

801-131

801-594

801-087

12 801-942

13 801.022

14 801-941

15 801-531

16 801-546

17 801.872

18 801-023

19 801-015

20 801-139

21 801-025

801-363

23 801-024

24 801-499

25 801-020

26 801-701

27 801-548

801-007

29 801-591

30 801-934

31 801-137

32 *801-069

800-064

DESCRIPTION

GUN ASSEMBLY,

see parts drawing/list page

TIP. 0006 MEG, 1/4

thd..

Oo

TIP, 1506 MEG, 1/4

thd..

15O

PUMP ASSEMBLY.

see Darts

drawing/list page

BELT,

drive

LABEL,

warning

DECAL,

caution

LABEL

identification

PLATE.

serial

no.

ENGINE. 7

h.0.

SCREW,

'md.

kt., 1 x 1 -3/4"

SCREW,

hex hd.,

5/16-18 x

3

SCREW, hexhd..5/16-18~1-3/4

SCREW,

hex

hd..

5/16-18 x 1"

SCREW.

hex hd.,

31818

7"

SCREW,

hex hd..

3/6-16 x 1-1/4"

SCREW,

hex hd..

x 20 MM

WASHER,

flat.

1/4

WASHER,

flat.

5/16

WASHER,

lock,

WASHER,

lock,

5/16

WASHER,

lock,

3/8

NUT, 5/16-18

NUT.

lockino.

3/8-16

NUT;

locking;

1/2-13

CITY.

SCREW,

hex

hd.,

1 /4-20 NC x

GROMMET

HOSE, H.P.. 1/4 x 50 ft.

1 /2

PULLEY,

pump

PULLEY,

KEY,

pulley

QUICK COUPLE,

female

REF. PART

NO. NO.

33 '801-090

34 '801 -552

35 801-723

800-080

37 801-529

38 801-177

39 801-541

40 801-539

41 801-537

42 801-505

43 801-506

801-573

801.504

46 801-132

47 801-593

48 801-550

49 "801-553

801-130

51 801.605

52 801-606

53 801-612

54 801-875

55 801-367

56 801-608

57 801.609

58 801-555

801-103

60 801-521

61 801.520

DESCRIPTION

OUICK COUPLE.

male

TIP. 2506 M E G I 1/4

thd..

2Fo

LABEL.

Model

1535

CHASSIS WELDMENT

BELTGUARD.

base

BELTGUARD,

cover

HANDLE

BUMPER

WELDMENT,

leg support

FOOT RETAINER

BOOT.

lea

AXLE

FOOT

RIVET.

drive

SPRING

WHEEL

TIP. 4006 MEG. 1/4

thd..

40°

LABEL,

warning

SCREW.

hex hd..

#lo-24 NC

WASHER,

flat,

3/16

WASHER.

flat.

7/16

WASHER;

IO&,

#IO

BUMPER

PIN, roll

8RACKET.

suppon

chk. oil

RAIL STIFFNER

BRACKET

Order p a r k b y name and series letter of the assembly for which you are ordering.

QTY.

'Recommended "tool bow" spare parts.

PARTS DRAWING

Unloader Assembly,

1500

PSI (103 bar) Max.

PARTS

LIST

Unloader Assembly, 800-132'

NO. NO. DESCRIPTION

5 801-049

REF. PART

801-045

801-046

3

801-047

801-048

801-050

7 800-123

801-059

801-412

10 801-432

11 801-062

12 801-063

13 801-068

14 801-069

15 801-070

16 801-071

17 801-939

CAGE,

valve

O-RING

SPRING

BALL

SEAT

O-RING

UNLOADER SUB-ASSEMBLY

O-RING

HOUSING

CYLINDER

O-RING

PLUG

HOUSING VALVE

SPRING

VALVE

SEAT

O-RING

QTY.

Order parts by name and series letter

of the assembly for

which you are ordering.

. . . .

. ~ . . ~ . ,

. . . . . .

801-641

. .

NOTE:

Three sizes of metric wrenches are necessary for servicing the

M10 and M 6 Allen wrench. pump;

M30,

Valves:

1 .

wrench.

2. Examine O-ring

(4) under plug and replace if cuts or distortion exist.

3. Remove valve unit and O-ring

NOTE:

Valve unit may comeapartduring removal.

4. Replace valve unit with P/N 801 -472.

5. Replace hex plug and torque t o 7 5 f t . Ibs.

(10.3

K/m).

NOTE:

Hex plug should be re-torqued after 5 hours operation.

Pumping

Section:

1. Remove the eight Allen head cap screws (1) from the manifold using the M6 Allen wrench.

Lubricate each plunger and carefully slide manifold onto crankcase.

9. Replace the eight capscrews and snug them

Torque to

ft.

Ibs.

(2.2 K/m). up.

NOTE:

The eight capscrews must be torqued evenly to apply equal pressure on the manifold

so that it seats properly and doesn't bind or jam. This is best done by torquing bolts closest to the center of the manifold first and then working out from those bolts.

Servicing V-Packings:

NOTE:

Use packing repair kit PIN 801-662.

After removing the eight capscrews and the manifold carefully pull packing retainer (14) from the manifold. Examine O-ring (15) and replace if necessary.

Remove low pressure packing (12) and head ring

(11).

Pull intermediate retainer ring(l3)from manifold,

NOTE:

It may be necessary to tap manifold lightly with mallet to loosen.

Carefully examine each plunger (21) for any scoring and replace if necessary.

Servicing Plungers:

Loosen plunger retaining screw (17) 5-6 turns, using "10 wrench. Push plunger towards crankcase. This retaining screw. will separate plunger and

2. Remove retaining screw from plunger and examine O-ring (1

9).

bearing/gasket washer (18). Replace if necessary using plunger repair kit P/N 801-663.

Remove plunger from plunger rod and remove copper flinger (22). Clean or replace if necessary. on plunger rod.

5. Replace plunger.

6. Lightly grease retaining screw assembly to avoid cutting O-ring. Lightly grease outer end of plunger.

7. Install retaining screw assembly into plunger and torque to 14.4 ft.

Ibs. (2 K/m).

Inspect all parts and replace if necessary.

NOTE:

If just the packings are'needed use kit

801-662. If rings or retainers need replacement use kit 801

-664.

5 . Thoroughly clean packing cavity in manifold and examine. Lightly grease packing cavity.

Replace packing assembly in the following order:

headring(ll),packing(12),intermediatering(l3),

head ring

1). packing (12), packing retainer(l41 and O-ring (15).

CAUTION

Carefully study the location of each part and the position of the seals to assure proper reassembly and operation.

Lubricate each plunger and carefully slide manifold onto crankcase.

NOTE:

When replacing .the manifold onto plungers, extreme caution should be exercised

avoid damage

the seals.

8. Replace the eight capscrews in the manifold and tighten as previously described (step

9 under servicing plungers).

... .

. .

. :

. .

801-641

. .

. . . . -. . . .

TIl)

L11'-12-14

VALVE UNIT OIL SEAL KIT

KIT

801 -472 801 -658

Includes: Includes: Includes:

REF.

NO.

REF.

QTY NO.

6 16

QTY

~ 1 5 ~ 1 6

PACKING KIT

801-662

REF.

NO.

QTY

PLUNGER REPAIR

KIT

801

-474

Includes:

REF.

NO.

1 7 '

QTY

"PACKING

RETAINER

KIT

801-664

Includes:

REF.

NO.

1 1

1 4

1 5

QTY

*Three kits needed

for

entire pump.

NO.

N O .

1 801-651

2 801-652

3 801-852

4 801-470

801-471

801-650

7 801-485

8 801-484

9 801-482

10 801-483

11 801-655

12 801-653

13 801-654

14 801-656

801-657

16 801-778

17 801-493

18 801-492

19 801.488

20 801-491

21 801-661

DESCRIPTION

SCREW. M8 x

60 MM

WASHER,

8.4

0.8

VALVE UNIT

O-RING

HEX PLUG,

MANIFOLD

WASHER

M24

x 16

CAP,

3/8

NPT

CAP,

1/2

WASHER

NPT

HEAD RING

PACKING

INTERMEDIATE RING

PACKING RETAINER

O-RING

OIL SEAL

PLUNGER RETAINING SCREW

WASHER

O-RING

BACK-UP RING

PLUNGER

QTY

REF. PART

NO. NO.

801-660

801-659

24 801.108

25 801-913

27 801-106

801-110

29 801-11

DESCRIPTION

FLINGER

OIL DiPSTlCK

QTY

26 801.105

HEX REDUCER

REDUCER BUSHING

NIPPLE,

TEE,

1/2

NPT x

3-1/2"

NPT

HOSE ADAPTER.

HOSE CONN. NUT

31 801.597

32 800.132

801-112

INLET SCREEN

HOSE, low pressure

UNLOADER ASSEMBLY. see parts drawing/list. page

33 801 -090

34 801-575

35 801-560

36 801.910

QUICK COUPLE, male

TENSIONER, belt

PUMP

PLUG, Dlastic

37 801-907

WASHER, aluminum

38 801-143

TAG, caution

39 801 -524

LABEL, pump

Order parrs by name and series letter of the assembly for

which you are ordering.

801-641

9

PART$

Gun

Assembly, 800-130

SERVICE

Gun,

Cartridge Replacement

access plate (14) by sliding plate backwards.

Remove cartridge

19 m m socket wrench.

by

" i

..eA8,8!*

using a

Check inside housing to be

sure

all

O-rings came out when cartridge was removed. If O-ring can be seen inside the housing, remove it, being careful not to damage internal threads in housing.

3. Throw away old cartridgeand install newcartridge using a small amount of pipe sealant on threads.

sure totighten cartridgefirmlyagainst housing.

4. Slide access plate into place and install access pin.

REF. PART

NO.

801-134

801-674

801-009

801-638

801-639

801-671

801-670

801-256

801-424

10 801-672

801-673

12 801-428

13 801-419

14 801-427

15 801-420

16 801-423

17 '801 -202

DESCRIPTION

TUBE. 32"

QTY

GRIP 1

COUPLER, female

quick

disconnect 1

SPRAY GUN, lreDlaceable

pans include items

5-18)

CARTRIDGE

1 HOUSING

HEX PLUG

TRIGGER PIN

TRIGGER

OUTLET

PIN COVER

ACCESS PIN

HANDLE

ACCESS P M T E

TUBE

INLET FllTlNG

O-RING. quick couple

Order parrs

by name and series letter

which you are ordering.

*Recommended

"tool box" spare parts.

the assembly for

ENGINE BRIGGS

STRATTON

4 cycle, single cylinder air cooled, 7 hp

GASOLINE TANK 4 quarts (3.79 liter) capacity

WATER PUMP: 1500 PSI (103 bar) mar. pressure; 3-1 /2 GPM

(13.25 liter/min).

WEITED PARTS: Stainless Steel. Aluminum.

Phenolic Plastic. Ceramic

Liners, Nitrile Rubber.

UNIT WEIGHT: 156 Ib I71 kg1

Widlh: 28" (711 mm)

Height:

24" (610 mm)

MAX. WATER TEMPERATURE: 160°

(70" CI

INLET HOSE CONNECTION: 3 / 4 garden hose (I)

THE GRACO WARRANTY

Gracolnc.warrantsallequipmentmanufacturedbyitandbear~ngitsnametobefreefromdefectsin

material and workmanshlp under

normal use

and

Seivtce.

This warranty extends to the ortglnal

purchaSerforaperiodaf12monthsframthedateofpurchaseandappliesonlywhentheequipment

is installed and operated

accordance with written factory recommendations

This warrantydoes not

cover

damage

wear which. in the reasonable judgment of Graco, awes from misuse. abrasion.

corrosmn.

negligence. accident, SubstltUtion of "on-Gram parts. faulty installation or tampering.

Thts warranty is conditmned upon the prepad return equipment clalmed

be defectwe

for examlnallon

by Graco to verify the claimed defect. If the claimed defect is

or replace free of charge. any defective parts. verified.

Graco will repam

The equipment will be returned to the origlnal purchaser transportation prepald. If mspection of the equpment does not disclose any defect in warkmanshipor material, repam will bemadeatareasonablechargeandreturntransportation will be charged.

OR IMPLIED) INCLUDING WARRANTY OF MERCHANTABILITY OR WARRANTY

FITNESS

FOR

PARTICULAR PURPOSE AND

ANY NON-CONTRACTUAL LIABILITIES INCLUDING PRODUCT

LIABILITIES BASED O N NEGLIGENCE OR STRICT LIABILITY. EVERY FORM OF L l A B l L l N FOR

DIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES

LOSS IS EXPRESSLY EXCLUDED AND

DENIED.

EOUIPMENT NOT COVERED BY GRACO WARRANTY. Accessor~es components of equcpment sold

G r a m that are

not