Graco_Inc._Pressure_Washer

INSTRUCTIONS

Rev. D

Supersedes Rev. B

and PCN C

Hydra-Clean) Pressure Washers

42 bar, 4.2 MPa (600 psi) Maximum Working Pressure

For Mounting on Open 55 Gallon Supply Drum

(Can be wall mounted with accessory bracket)

Model 205???985, Series C

Includes 5:1 Ratio Monark Pump with Neoprene and UHMWPE packings, drum mounting bracket, suction hose, air line lubricator, 40 ft. spray hose, Hydra???Clean gun and spray tip.

Model 207???860, Series B

Includes 5:1 Ratio Monark Pump with UHMWPE and PTFEpackings, drum mounting bracket, suction hose and air line lubricator.

The Graco warranty will not apply if abrasive or corrosive materials, other than those Graco recom- mends are used with this unit.

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440???1441

http://www.graco.com

Graco Inc. is registered to I.S. EN ISO 9001

Table of Contents

Symbols

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

WARNING

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

Use this pump only for pumping water and water???diluted cleaning solutions in a pressure washing sys- tem. Never use the pump for paint or any other coatings. Any misapplication of the pump may cause dangerous operating conditions which can result in serious injury and substantial property damage.

DThis equipment is for professional use only.

DRead all instruction manuals, tags, and labels before operating the equipment.

DUse the equipment only for its intended purpose. If you are not sure, call your Graco distributor.

DDo not alter or modify this equipment. Use only Graco parts and accessories.

DCheck equipment daily. Repair or replace worn or damaged parts immediately.

DDo not exceed the maximum working pressure stated on the equipment or in the Technical Data for your equipment. Do not exceed the maximum working pressure of the lowest rated component in your system.

DUse fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech- nical Data section of all equipment manuals. Read the fluid and solvent manufacturer???s warnings.

DHandle hoses carefully. Do not pull on hoses to move equipment.

DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 66_C (150_F) or below ???40_C (???40_F).

DWear hearing protection when operating this equipment.

DDo not move or lift pressurized equipment.

DComply with all applicable local, state, and national fire, electrical, and safety regulations.

WARNING

INJECTION HAZARD

Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause an extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin can also cause a serious injury.

D Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi- cal attention.

DDo not point the spray gun at anyone or at any part of the body.

DDo not put hand or fingers over the spray tip.

DDo not stop or deflect fluid leaks with your hand, body, glove, or rag.

DDo not ???blow back??? fluid; this is not an air spray system.

DAlways have the tip guard and the trigger guard on the spray gun when spraying.

DCheck the gun diffuser operation weekly. Refer to the gun manual.

DBe sure the gun trigger safety operates before spraying.

DLock the gun trigger safety when you stop spraying.

DFollow the Pressure Relief Procedure on page 8 whenever you: are instructed to relieve pres- sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.

DTighten all the fluid connections before operating the equipment.

DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately. Do not repair high pressure couplings; replace the entire hose.

DFluid hoses must have spring guards on both ends, to help protect them from rupture caused by kinks or bends near the couplings.

MOVING PARTS HAZARD

Moving parts, such as the air motor piston, can pinch or amputate your fingers.

DKeep clear of all moving parts when starting or operating the pump.

DNever operate the pump with the air motor plates removed.

DBefore checking or servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the equipment from starting unexpectedly.

3???6???993 3

WARNING

FIRE AND EXPLOSION HAZARD

Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and re- sult in a fire or explosion and serious injury.

DGround the equipment and the object being sprayed. Refer to Grounding on page 5.

DIf there is any static sparking or you feel an electric shock while using this equipment, stop spray- ing immediately. Do not use the equipment until you identify and correct the problem.

DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being sprayed.

DKeep the spray area free of debris, including solvent, rags, and gasoline.

DElectrically disconnect all equipment in the spray area.

DExtinguish all open flames or pilot lights in the spray area.

DDo not smoke in the spray area.

DDo not turn on or off any light switch in the spray area while spraying or while operating if fumes are present.

DDo not operate a gasoline engine in the spray area.

TOXIC FLUID HAZARD

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or swallowed.

DKnow the specific hazards of the fluid you are using.

DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.

DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.

43???????????????3

Setup

Grounding

WARNING

FIRE AND EXPLOSION HAZARD

Before operating the pump, ground the system as explained below. Also read the section FIRE OR EXPLOSION HAZARD on page 4.

Although water generally provides a natural electrical ground, the following equipment must be grounded if the cleaning chemical are volatile.

1.When cleaning in enclosed areas, such as storage tanks, locate the pump and air compressor outside the area and well away from it. Provide adequate ventilation. If the area you are cleaning has stored flammable materials. take appropriate precautions to avoid static sparking. Consult your local codes.

2.Pump: use a ground wire and clamp. See Fig. 1. Loosen the grounding lug locknut (W) and washer

(X). Insert one end of a 1.5 mm@ (12 ga) minimum ground wire (Y) into the slot in lug (Z) and tighten the locknut securely. Connect the other end of the wire to a true earth ground. Order Part No.

237???569 Ground Wire and Clamp.

???864

Fig. 1

3.Air and fluid hoses: use only electrically conductive hoses.

4.Air compressor: follow manufacturer???s recommen- dations.

5.Spray gun: ground through connection to a prop- erly grounded fluid hose and pump.

6.Fluid supply container: follow your local code.

7.Object being sprayed: follow your local code.

8.Solvent pails used when flushing: follow your local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts the grounding continu- ity.

9.To maintain grounding continuity when flushing or relieving pressure, hold a metal part of the spray gun firmly to the side of a grounded metal pail, then trigger the gun.

General Information

The typical setup shown in Figure 2 is only a guide to selecting and installing required and optional compo- nents. For assistance in designing a system to suit your needs, contact your Graco representative. Refer to Figure 2 for callouts in parentheses.

3???????????????3 5

Setup

Connect Hoses and Mount Pump

Connect hoses and pump as follows:

NOTE: This pump is supplied with a bracket (D) which holds it to the side of a drum. If you want to install the pump on a wall, do not install the hanging bracket. Use Graco Wall Mounting Bracket 206???778 or equivalent for wall setup.

1.Screw the hose stud (A) of the suction hose (B) into the pump???s intake housing (C) using LoctiteR Pipe Sealant. Assemble the hanging bracket (D) to the pump with the screw, lockwasher, and nut (E) provided.

2.Remove the ball valve (17, see Parts) from Model 205???985. It is not used in this setup. Hang the pump on your empty cleaning solution drum.

NOTE: A pump runaway valve (F) may be installed near the pump air inlet. This valve senses when the pump is running too fast and shuts off the air to the pump.

3.Connect the air line lubricator (G) to the pump air inlet using pipe sealant. Install a pump air bleed valve (H) and air regulator and gauge (J) to the air line lubricator. Connect an air line filter (K) to the regulator. From the air line filter, install an air drain valve (L), bleed???type air valve (M), and connect to the air supply using electrical conductive air supply hose (N).

4.Close to the pump???s 1/2 npt(f) fluid outlet, install a tee (P) and a fluid drain valve (R). Then install a fluid hose (S) and Hydra???Clean gun (T). The hose and gun are supplied with Model 205???985, but must be purchased separately for Model 207???860.

CAUTION

Oils containing phosphate ester or chlorinated hydro- carbons are not compatible with the plastic bowl of the lubricator ??? be sure that oil used to lubricate the compressor is free of these additives.

63???6???993

Operation

General Information

The following instructions are for operation of the Monark 5:1 Ratio Hydra???Clean Pressure Washers Model 205???985 and Model 207???860. Callouts in parentheses refer to Figure 2.

Pressure Relief Procedure

WARNING

INJECTION HAZARD

Fluid under high pressure can be in- jected through the skin and cause serious injury. To reduce the risk of an

injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you:

Dare instructed to relieve the pressure,

Dstop spraying,

Dcheck or service any of the system equipment,

Dor install or clean the spray nozzles.

1.Lock the gun trigger safety.

2.Close the bleed-type master air valve (H, required in your system)

3.Unlock the gun trigger safety.

4.Hold a metal part of the gun firmly to the side of a grounded metal pail, and trigger the gun to relieve pressure

5.Lock the gun trigger safety.

6.Open the drain valve (R, required in your system), having a container ready to catch the drainage.

7.Leave the drain valve open until you are ready to spray again.

If you suspect that the spray tip or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, very slowly loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip or hose.

83???6?????????3

Operation

WARNING

To avoid serious injury, including fluid injection and splashing in the eyes or on the skin, never point the gun at yourself or anyone else.

Before Using

See Fig. 2. Prepare cleaning solution as instructed, observing all safety precautions. Pre-mix powered cleaners in a separate bucket of hot water before adding to water in the supply drum.

WARNING

Take care not to get spray containing cleaning chemicals into your eyes, ears, or nose. If any spray does get on your skin or in your eyes, flush immediately and thoroughly with water. Seek immediate medical attention.

Open the bleed???type air valve (M), hold the spray valve trigger (T) open and slowly open the pump air bleed valve (H) until the pump is running slowly. After solution is coming from the spray nozzle, open the pump air bleed valve all the way and adjust the air line lubricator (G) to deliver about 1 drop per minute. Refer to the separate lubricator instruction manual.

Release the spray valve trigger and let the pump run.

NOTE: Protect surfaces that might be damaged by the cleaning solution and rinse off before the solution dries. For removing stubborn dirt, use a strong, heated solution.

Useful Hints

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 8.

Hold the spray nozzle about 2 feet (0.6 m) from the surface you are cleaning and mist-wet it completely. Let it soak briefly, then use the spray to ???chisel??? the dirt off. Keep the nozzle at an angle, about 6 in. (150 mm) from the surface. If some dirt remains, wet the surface again. Let the object soak a little longer, then hold the nozzle as close as possible and spray to blast the dirt off.

After the dirt is removed, through rinse off the remain- ing solution with clear, cold water. When you are done cleaning, close the pump air bleed valve and relieve the pressure.

Shutdown and Care of Unit

CAUTION

To reduce the risk of damaging your pump. never allow the pump to run dry of fluid. Keep liquid in the container to prevent the pump from running away.

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 8.

When shutting down for the day or weekend, shut off both the bleed???type air valve and pump air bleed valve. Relieve the pressure. Rinse off any solution remaining on equipment with clear, cold water. Shut off the water supply valve and relieve the water pressure.

After shutdown, check the air line lubricator (G) often and keep it filled with oil. Also check the pump packing nut regularly and keep it just tight enough to stop leakage, but no tighter. Use a 1/4 in. diameter rod to tighten.

3???6???993 9

Service

General

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 8.

See Parts illustration for referenced items. Shut off the air supply to the pump and relieve the pressure.

Check the air line lubricator often and keep it filled with oil. Also check the pump packing nut regularly to keep it just tight enough to stop leakage, but no tighter. Use a 1/4 in. (6.3 mm) diameter rod to tighten.

To manually lubricate the motor, disconnect the air line at the motor and place 10 to 15 drops of oil in the inlet. Reconnect the air line and turn on the air to blow oil into the motor. Shut off the air supply to the pump and relieve the pressure.

Proper packing nut take-up will stop leakage. However, all the packings should be replaced after 1000 hours of operation or delivery of 120,000 gallons of solution at 2 gpm. Refer to separate pump manual.

Clean the air line filter regularly.

Remove the inlet filter (2) daily and clean it. Check it for damage that may allow contaminants to enter the pump, and replace if necessary.

Refer to the separate instruction manuals supplied with the components of your system for complete trouble- shooting and service instructions.

????????????????????? 11

Dimensions

11.75??? (298 mm)

24.5??? (622 mm)

???6771

Technical Data

Air pressure range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 to 120 psi (2.8 to 8.4 bar, .28 to .84 MPa) Air volume requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 cfm (0.23 m3/min.) at 100 psi (7 bar, 0.7 MPa), Pump ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5:1 Max. recommended pump speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 cycles per min. Pump discharge pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 psi (41.4 bar, 4.14 MPa) Weight27 lb (12.26 kg) Model 207???860

37 lb (16.80 kg) Model 205???985 Maximum operating temperature of fluid pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480_F (249_C) Maximum operating temperature of air motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200_F (90_C)

Loctiter is registered trademarks of the Loctite Corp.

PTFE is registered trademarks of the DuPont Co.

??????6???99??? 15

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco???s written recommendations.

This warranty does not cover, and 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 improper maintenance, negligence, accident, tampering, or sub- stitution of non???Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of 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 material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT

NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR 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 damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR

A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY 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 reasonable assistance in mak- ing any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The 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 or indirectly hereto, be drawn up in English. Les parties reconnais- sent avoir convenu que la r??daction du pr??sente document sera en Anglais, ainsi que tous documents, avis et proc??dures judiciaires ex??cut??s, donn??s ou intent??s ?? la suite de ou en rapport, directement ou indirectement, avec les procedures concern??es.

Graco Phone Number

TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:

1???800???367???4023

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.

Sales Offices: Minneapolis, Detroit, Los Angeles

Foreign Offices: Belgium, Canada, England, Korea, France, Germany, Hong Kong, Japan

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440???1441

http://www.graco.com

PRINTED IN U.S.A. 306???993 November 1968, Revised September 1997

1??? ?????????????????????