Instructions/Parts Hydraulic Hydraulic Hydraulic Hydra Hydra Hydra-Clean® Clean® Clean® Packages Packages Packages 334187F EN A package package package solution solution solution for for for pressure pressure pressure washing washing washing applications applications applications without without without an an an air air air supply. supply. supply. For For For use use use only only only with with with water water water and and and cleaning cleaning cleaning solutions. solutions. solutions. For For For professional professional professional use use use only. only. only. Important Important Important Safety Safety Safety Instructions Instructions Instructions Read all warnings and instructions in this manual. Save Save Save these these these instructions. instructions. instructions. See page 3 for model information, including the maximum fluid working pressure. PROVEN QUALITY. LEADING TECHNOLOGY.
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
ImportantImportantImportant SafetySafetySafety InstructionsInstructionsInstructionsRead all warnings and instructions in this manual. SaveSaveSave thesethesetheseinstructions.instructions.instructions.
See page 3 for model information,including the maximum fluid workingpressure.
Disconnect the Displacement Pump .............. 17Service the Displacement Pump ................... 17Reconnect the Displacement Pump............... 18Disconnect the Hydraulic Motor..................... 19Service the Hydraulic Motor .......................... 19Reconnect the Hydraulic Motor ..................... 19
311827 Dura-Flo™ Displacement Pump; 600, 750, 900, and 1200
308511 Hydra-Clean® Spray Gun
307158 Viscount® II Hydraulic Motor
334187F 3
Warnings
WarningsWarningsWarningsThe following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. Theexclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specificrisks. When these symbols appear in the body of this manual or on warning labels, refer back to theseWarnings. Product-specific hazard symbols and warnings not covered in this section may appear throughoutthe body of this manual where applicable.
Flammable fumes, such as solvent and paint fumes, in workworkwork areaareaarea can ignite or explode. To helpprevent fire and explosion:
• Use equipment only in well ventilated area.• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, andplastic drop cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.• Do not plug or unplug power cords, or turn power or light switches on or off when flammablefumes are present.
• Ground all equipment in the work area. See GroundingGroundingGrounding instructions.• Use only grounded hoses.• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unlessthey are antistatic or conductive.
• StopStopStop operationoperationoperation immediatelyimmediatelyimmediately if static sparking occurs or you feel a shock... Do not useequipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierceskin. This may look like just a cut, but it is a serious injury that can result in amputation. GetGetGetimmediateimmediateimmediate surgicalsurgicalsurgical treatment.treatment.treatment.
• Engage trigger lock when not dispensing.• Do not point dispensing device at anyone or at any part of the body.• Do not put your hand over the fluid outlet.• Do not stop or deflect leaks with your hand, body, glove, or rag.• Follow the PressurePressurePressure ReliefReliefRelief ProcedureProcedureProcedure when you stop dispensing and before cleaning,checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.• Check hoses and couplings daily. Replace worn or damaged parts immediately.
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.• Do not operate equipment with protective guards or covers removed.• Pressurized equipment can start without warning. Before checking, moving, or servicingequipment, follow the PressurePressurePressure ReliefReliefRelief ProcedureProcedureProcedure and disconnect all power sources.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.• Do not exceed the maximum working pressure or temperature rating of the lowest ratedsystem component. See TechnicalTechnicalTechnical DataDataData in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Datain all equipment manuals. Read fluid and solvent manufacturer’s warnings. For completeinformation about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.• Turn off all equipment and follow the PressurePressurePressure ReliefReliefRelief ProcedureProcedureProcedure when equipment is not in use.• Check equipment daily. Repair or replace worn or damaged parts immediately with genuinemanufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvalsand create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.• Use equipment only for its intended purpose. Call your distributor for information.• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.• Do not kink or over bend hoses or use hoses to pull equipment.• Keep children and animals away from work area.• Comply with all applicable safety regulations.
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,inhaled, or swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.• Store hazardous fluid in approved containers, and dispose of it according to applicableguidelines.
Wear appropriate protective equipment when in the work area to help prevent serious injury,including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protectiveequipment includes but is not limited to:
• Protective eyewear, and hearing protection.• Respirators, protective clothing, and gloves as recommended by the fluid and solventmanufacturer.
6 334187F
Installation
InstallationInstallationInstallationWhen cleaning in enclosed areas, such as storagetanks, locate the pump and hydraulic supply outsidethe area. Provide adequate ventilation.
GroundingGroundingGrounding
The equipment must be grounded to reduce therisk of static sparking. Static sparking can causefumes to ignite or explode. Grounding provides anescape wire for the electric current.
Pump:Pump:Pump: Use the ground screw (GS) and lock washer(LW) to attach the ground wire (L) to the motor plate.Connect the other end of the ground wire to a trueearth ground.
FluidFluidFluid andandand hydraulichydraulichydraulic hoses:hoses:hoses: Use only electricallyconductive hoses with a maximum of 500 ft (150 m)combined hose length to ensure grounding continuity.Check electrical resistance of hoses. If totalresistance to ground exceeds 25 megohms, replacehose immediately.
SpraySpraySpray Gun:Gun:Gun: Ground through connection to a properlygrounded fluid hose and pump.
ObjectObjectObject beingbeingbeing sprayed:sprayed:sprayed: Follow local code.
MaterialMaterialMaterial supplysupplysupply container:container:container: Follow local code.
Container(s)Container(s)Container(s) thatthatthat receivereceivereceive material:material:material: Follow local code.
SolventSolventSolvent pailspailspails usedusedused whenwhenwhen flushing:flushing:flushing: Follow localcode. Use only conductive metal pails, placed ona grounded surface. Do not place the pail on anonconductive surface, such as paper or cardboard,which interrupts grounding continuity.
ToToTo maintainmaintainmaintain groundinggroundinggrounding continuitycontinuitycontinuity whenwhenwhen flushingflushingflushing orororrelievingrelievingrelieving pressure:pressure:pressure: Hold metal part of the gun firmlyto the side of a grounded metal pail, then trigger thegun.
1. Ensure the wall is strong enough to support theweight of the pump assembly and accessories,fluid, hoses, and stress caused during pumpoperation.
2. Ensure that the mounting location has sufficientclearance for easy operator access.
3. Position the wall bracket at a convenient heightensuring that there is sufficient clearance forthe fluid suction line and for servicing thedisplacement pump.
4. Drill four 7/16 in (11 mm) holes using thebracket as a template. Use any of the threemounting hole groupings in the bracket. SeeMounting Hole Layout, page 34.
5. Bolt the bracket securely to the wall using boltsand washers.
6. Attach the pump assembly to the mountingbracket.
1. Connect the suction hose (G) between the pumpfluid inlet and the suction tube (H), using threadsealant on the male threads.
2. Screw on the suction tube strainer.
3. Place the suction tube in the supply drum, andadjust it so it is 1 in (25 mm) off the bottom ofthe drum. Tighten the thumbscrew of the pipehanger onto the drum.
4. Connect the spray hose (J) to the pump outletmanifold.
NOTE:NOTE:NOTE: For two–gun spraying, remove the plug inthe manifold and connect another spray hose.
NOTICENOTICENOTICEThe hydraulic supply system must be kept cleanat all times to avoid damage to the motor andhydraulic power supply. Blow out all hydrauliclines with air and flush thoroughly with compatiblesolvent before connecting the lines to the motor.
Always plug the hydraulic inlets, outlets, and lineswhen disconnecting them for any reason, to avoidintroducing dirt and other contaminants into thesystem.
1. Connect a 3/4 in (19 mm) minimum ID hydraulicsupply line (E) to the inlet port of the hydraulicmotor (B)
2. Connect a 3/4 in. (19 mm) minimum ID hydraulicreturn line (D) to the outlet port of the hydraulicmotor (B).
Figure 1
AllAllAll OtherOtherOther Models:Models:Models:
1. Connect a 3/4 in (19 mm) minimum ID hydraulicsupply line (E) to the supply inlet port of thehydraulic regulator (C). The system is shippedwith a second line (72) connected from the supplyoutlet port of the regulator (C) to the inlet port ofthe hydraulic motor (B).
2. Connect a 3/4 in (19 mm) minimum ID returnline (D) to the return outlet port on the hydraulicregulator (C). The system is shipped with asecond line (73) connected from the return inletport of the regulator (C) to the outlet port on thehydraulic motor (B).
To reduce the risk of overpressurizing your system,which could cause component rupture and seriousinjury, follow these precautions:
• Never exceed 1900 psi (13.1 MPa, 131 bar)hydraulic input to the motor.
• Never exceed the maximum fluid workingpressure of 3000 psi (20.7 MPa, 207 bar) forlow-pressure models or 4300 psi (29.6 MPa,296 bar) for high-pressure models.
• When starting the hydraulic system, open thereturn line shutoff valve (N) first, then open thehydraulic supply line valve (M).
Follow the Pressure Relief Procedurewhenever you see this symbol.
This equipment stays pressurized until pressure isrelieved manually. To help prevent serious injuryfrom moving parts or from pressurized fluid, suchas skin injection or splashing in the eyes or onskin, follow the Pressure Relief Procedure whenyou stop pumping and before you clean, check, orservice the equipment.
1. Engage the gun trigger lock.
2. Close the hydraulic supply shutoff valve (M).
3. Disengage the gun trigger lock.
4. Hold a metal part of the gun firmly to the side of agrounded metal pail. Trigger to relieve pressure.
5. If you suspect the spray tip or hose is clogged orthat pressure has not been fully relieved:
a. VERY SLOWLY loosen the hose endcoupling to relieve pressure gradually.
b. Loosen the coupling completely.
c. Clear hose or tip obstruction.
6. When all pressure is relieved, close the hydraulicreturn shutoff valve (N).
Cleaning chemicals may be toxic. To avoid seriousirritation to your eyes or skin, wear appropriateprotective clothing, such as waterproof outerwearand eye goggles, according to the cleanermanufacturer’s recommendations.
1. Prepare the cleaning solution according to themanufacturer’s instructions.
2. If you are using powdered cleaners, mix themthoroughly in a separate pail before adding themto a supply drum.
To reduce the risk of fluid injection injury, staticsparking, or splashing, relieve the pressure andremove the spray tip before flushing.
NOTE:NOTE:NOTE: Use the lowest possible fluid pressure duringflushing.
BeforeBeforeBefore FirstFirstFirst UseUseUseThe pump was tested in lightweight oil, which isleft in the fluid passages to protect parts. To avoidcontaminating your fluid with oil, flush the equipmentwith a compatible solvent before using the equipment.
1. Engage the trigger lock.
2. Place the suction tube into solvent supply.
3. Hold a metal part of the gun/valve firmly to theside of a grounded metal pail.
4. Disengage the trigger lock. Trigger the gun untilclean solvent comes from the gun.
5. Engage the trigger lock.
6. Place the suction tube in the prepared cleaningsolution.
7. Hold a metal part of the gun/valve firmly to theside of a grounded metal pail.
8. Disengage the trigger lock. Trigger the gun untilcleaning solution comes from the gun.
BeforeBeforeBefore ShutdownShutdownShutdown1. Place the suction tube into the water supply.
2. Hold a metal part of the gun/valve firmly to theside of a grounded metal pail.
3. Disengage the trigger lock. Trigger the gun untilclear water with no cleaning solution comes fromthe gun.
NOTE:NOTE:NOTE: If the pump is not immersed in fluid, fill thewet-cup 1/3 full with Graco Throat Seal Liquid (TSL)or a compatible solvent. The TSL prevents fluid fromdrying on the displacement rod and damaging thepump packings. Check the tightness of the packingnut/wet-cup weekly. Before adjusting, relieverelieverelieve thethethepressurepressurepressure. The nut should be tight enough to preventleakage, but no tighter.
1. Check the hydraulic fluid level before each use.Add fluid as needed to the fill lines.
2. Turn on the hydraulic power supply.
3. Open the hydraulic return shutoff valve (N).
4. Slowly open the hydraulic supply shutoff valve(M).
5. Run the pump slowly until all air is pushed out ofthe lines and fluid is flowing smoothly.
6. Close the spray gun. The pump will stall.
NOTE:NOTE:NOTE: Use the lowest pressure possible to getthe desired results. Higher pressures will causepremature tip and pump wear.
NOTICENOTICENOTICENever allow the hydraulic fluid temperatureto exceed 130°F (54°C). The pump seals willwear faster and leaking may occur at highertemperatures.
ShutdownShutdownShutdown
To reduce the risk of overpressurizing your system,which could cause component rupture and seriousinjury, always shut off the hydraulic supply lineshutoff valve (M) first, and then the return lineshutoff valve (N).
Follow the Shutdown Procedure at the end of thework shift and before you check, adjust, clean, orrepair the system.
1. Flush the pump with water. SeeFlush the Pump, page 14.
2. After flushing, flush the pump again with acompatible solvent, such as mineral spirits.
3. Follow the Pressure Relief Procedure, page 13.
4. Always stop the pump at the bottom of its stroketo prevent fluid from drying on the rod anddamaging the throat packings.
5. Leave a coating of solvent in the pump andhoses.
NOTICENOTICENOTICETo help prevent corrosion of the pump, never leavethe pump filled with water or water-based fluids,or air, during non-use.
334187F 15
Troubleshooting
TroubleshootingTroubleshootingTroubleshooting
1. Follow the Pressure Relief Procedure, page 13. 2. Check all possible problems and solutions beforedisassembling the pump.
ProblemProblemProblem CauseCauseCause SolutionSolutionSolutionRestricted hydraulic line orinadequate hydraulic supply;closed or clogged valves.
Clear any obstructions; checkthat all valves are open; increasehydraulic supply pressure.
Obstructed fluid hose or gun; fluidhose ID is too small.
Open, clear*; use a hose with alarger ID.
Fluid has dried on the displacementrod.
Clean; always stop the pump atthe bottom of the stroke; keep thewet cup 1/3 filled with compatiblesolvent.
Pump fails to operate.
Dirty, worn, or damaged motorparts.
Clean or repair. See Manual307158.
Restricted hydraulic line orinadequate hydraulic supply;closed or clogged valves.
Clear any obstructions; checkthat all valves are open; increasehydraulic supply pressure.
Obstructed fluid hose or gun; fluidhose ID is too small.
Open, clear*; use a hose with alarger ID.
Bleeder valve is open. Close.
Pump operates, but the output islow on both strokes.
Worn packings in the displacementpump.
Replace packings. Seedisplacement pump manual311825 or 311827.
Pump operates, but the output islow on the downstroke.
Held open or worn intake valve. Clear valve; service. Seedisplacement pump manual311825 or 311827.
Pump operates, but the output islow on the upstroke.
Held open or worn piston valve orpackings.
Clear valve; replace packings.See displacement pump manual311825 or 311827.
Exhausted fluid supply. Refill and prime.Held open or worn piston valve orpackings.
Clear valve; replace packings.See displacement pump manual311825 or 311827.
Erratic or accelerated pump speed.
Held open or worn intake valve. Clear valve; service. Seedisplacement pump manual311825 or 311827.
* To determine if the fluid hose or gun is obstructed, follow the Pressure Relief Procedure, page 13.Disconnect the fluid hose and place a container at the pump fluid outlet to catch any fluid. Open the hydraulicsupply valve just enough to start the pump. If the pump starts, the obstruction is in the fluid hose or gun.
16 334187F
Repair
RepairRepairRepair
To help prevent injury from a falling pump,use at least two people when lifting, moving ordisconnecting the motor and/or the displacementpump.
1. Flush the pump, if possible. Stop the pump atthe bottom of its stroke.
2. Follow the Pressure Relief Procedure, page 13.
3. Disconnect the fluid and suction hoses.
NOTE:NOTE:NOTE: Before disconnecting the displacementpump from the motor, note the relative positionof the pump’s fluid outlet to the hydraulic inlet ofthe motor. If the motor does not require service,leave it attached to its mounting.
4. Unscrew the coupling nut (29) from theconnecting rod adapter (30). Remove thecoupling collars (28). Do not lose or drop them.
5. Securely brace the displacement pump (6), orhave two people hold it. Hold the tie rod flats witha wrench to keep the rods from turning. Unscrewthe nuts (23). Remove the displacement pump.Remove the tie rods (24).
1. Install the connecting rod adapter (30) onthe motor shaft. Torque to 115–126 ft-lb(156–170 N•m)
2. Lubricate the threads of the tie rods (24) andtighten them securely into the motor (1).
3. Make sure the coupling nut (29) and couplingcollars (28) are in place on the displacement rod.
4. Use at least two people to hold thedisplacement pump while another reconnectsit to the motor. Orient the pump's fluidoutlet to the hydraulic inlet as noted underDisconnect the Displacement Pump, page 17.Place the displacement pump (6) on the tie rods(24).
5. Screw the nuts (23) onto the tie rods (24) andtorque to 50-60 ft-lb (68-81 N•m).
6. Screw the coupling nut (29) onto the connectingrod adapter (30) loosely. Hold the connecting rodadapter flats with a wrench to keep it from turning.Use an adjustable wrench to tighten the couplingnut. Torque to 145–155 ft-lb (197–210 N•m).
7. Reconnect all hoses. Reconnect the ground wireif it was disconnected. Fill the wet-cup 1/3 full ofGraco Throat Seal Liquid or compatible solvent.
8. Open the hydraulic return shutoff valve (N). Thisvalve must be opened before the supply valve(M).
9. Slowly open the hydraulic supply shutoff valve(M). Run the pump slowly to ensure that itoperates properly.
— — — Part is not sold separately.† The first two digits designate the fan angle.The last three digits designate the orifice size inthousandths of an inch.� Replacement Danger and Warning labels, tags,and cards are available at no cost.
— — — Part is not sold separately.† The first two digits designate the fan angle. The lastthree digits designate the orifice size in thousandths ofan inch.� Replacement Danger and Warning labels, tags, andcards are available at no cost.
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing itsname to be free from defects in material and workmanship on the date of sale to the original purchaser foruse. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for aperiod of twelve months from the date of sale, repair or replace any part of the equipment determinedby Graco to be defective. This warranty applies only when the equipment is installed, operated andmaintained in accordance with Graco’s written recommendations.This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction,damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or impropermaintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shallGraco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipmentwith structures, accessories, equipment or materials not supplied by Graco, or the improper design,manufacture, installation, operation or maintenance of structures, accessories, equipment or materialsnot supplied by Graco.This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to anauthorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Gracowill repair or replace free of charge any defective parts. The equipment will be returned to the originalpurchaser transportation prepaid. If inspection of the equipment does not disclose any defect in materialor workmanship, repairs will be made at a reasonable charge, which charges may include the costs ofparts, labor, and transportation.THISTHISTHIS WARRANTYWARRANTYWARRANTY ISISIS EXCLUSIVE,EXCLUSIVE,EXCLUSIVE, ANDANDAND ISISIS INININ LIEULIEULIEU OFOFOF ANYANYANY OTHEROTHEROTHER WARRANTIES,WARRANTIES,WARRANTIES, EXPRESSEXPRESSEXPRESS ORORORIMPLIED,IMPLIED,IMPLIED, INCLUDINGINCLUDINGINCLUDING BUTBUTBUT NOTNOTNOT LIMITEDLIMITEDLIMITED TOTOTO WARRANTYWARRANTYWARRANTY OFOFOF MERCHANTABILITYMERCHANTABILITYMERCHANTABILITY OROROR WARRANTYWARRANTYWARRANTYOFOFOF FITNESSFITNESSFITNESS FORFORFOR AAA PARTICULARPARTICULARPARTICULAR PURPOSE.PURPOSE.PURPOSE.Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above.The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damagesfor lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shallbe available. Any action for breach of warranty must be brought within two (2) years of the date of sale.GRACOGRACOGRACO MAKESMAKESMAKES NONONO WARRANTY,WARRANTY,WARRANTY, ANDANDAND DISCLAIMSDISCLAIMSDISCLAIMS ALLALLALL IMPLIEDIMPLIEDIMPLIED WARRANTIESWARRANTIESWARRANTIES OFOFOFMERCHANTABILITYMERCHANTABILITYMERCHANTABILITY ANDANDAND FITNESSFITNESSFITNESS FORFORFOR AAA PARTICULARPARTICULARPARTICULAR PURPOSE,PURPOSE,PURPOSE, INININ CONNECTIONCONNECTIONCONNECTION WITHWITHWITHACCESSORIES,ACCESSORIES,ACCESSORIES, EQUIPMENT,EQUIPMENT,EQUIPMENT, MATERIALSMATERIALSMATERIALS OROROR COMPONENTSCOMPONENTSCOMPONENTS SOLDSOLDSOLD BUTBUTBUT NOTNOTNOT MANUFACTUREDMANUFACTUREDMANUFACTURED BYBYBYGRACO.GRACO.GRACO. These items sold, but 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 reasonableassistance in making any claim for breach of these warranties.In no event will Graco be liable for indirect, incidental, special or consequential damages resulting fromGraco supplying equipment hereunder, or the furnishing, performance, or use of any products or othergoods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, orotherwise.FOR GRACO CANADA CUSTOMERSThe Parties acknowledge that they have required that the present document, as well as all documents,notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly orindirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction duprésente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés,donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procéduresconcernées.
GracoGracoGraco InformationInformationInformationFor the latest information about Graco products, visit www.graco.com.For patent information, see www.graco.com/patents.ToToTo placeplaceplace ananan order,order,order, contact your Graco Distributor or call to identify the nearest distributor.Phone:Phone:Phone: 612-623-6921 ororor TollTollToll Free:Free:Free: 1-800-328-0211 Fax:Fax:Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.Original Instructions. This manual contains English. MM 334187
GracoGracoGraco Headquarters:Headquarters:Headquarters: MinneapolisInternationalInternationalInternational Offices:Offices:Offices: Belgium, China, Japan, Korea