804573 & 804578 Pump Service - Graco Hydra-clean 1535 Instructions-Parts List Manual

800573 & 804578 Pump Service
WARNING
To reduce risk of serious bodily injury, including
fluid injection, splashing in eyes or on skin or injury
from moving parts, always follow Pressure Relief
Procedure on page 6 before proceeding.
NOTE:
The following metric wrenches are needed: 5
mm, 13 mm and 22 mm. Repair kits are
available. Refer to individual repair sections
and pump parts page for details. For best
results, use all parts in kits.
NOTE:
Use tool kit, 800271, to aid in servicing pump.
Kit includes tools to remove packing
retainers.
Valves
NOTE:
For six valve set, order 801472.
1. Remove hex plug from manifold using 22 mm
socket.
2. Examine o–ring under hex plug. Replace if cut or
distorted.
3. Remove valve assembly from cavity with care to
avoid assembly coming apart.
4. Install new valve. Install o–ring and hex plug.
Torque to 33 ft–lb (45 NSm).
NOTE:
Re–torque plug after 5 hours of operation.
Pumping Section
1. Remove eight capscrews and lockwashers from
manifold using 5 mm wrench.
2. Carefully separate manifold from crankcase.
NOTE: It may be necessary to tap manifold lightly
with a soft mallet to loosen.
CAUTION
Keep manifold properly aligned with ceramic plung-
ers when removing to avoid damage to plunger or
seals.
3. Carefully examine each plunger for any scoring or
cracking and replace as necessary.
Servicing Plungers
NOTE:
Use plunger repair kit, 801474 to replace
retainers, o–rings, washers and backup rings
for three cylinders.
1. Loosen plunger retaining nut five to six turns using
13 mm wrench. Push plunger towards crankcase
to separate plunger and retaining screw.
2. Remove nut from plunger and examine o–ring,
backup ring, and copper bearing/gasket washer. If
necessary, replace using parts from kit 801474.
3. Remove plunger and flinger from plunger shaft.
Clean, examine, and replace parts as necessary.
4. Inspect plunger shaft for oil leakage from
crankcase. If leaking, replace oil seals. Use oil seal
kit to replace seals. DO NOT remove seals unless
necessary. Removed seals must be replaced with
new and not reused.
5. Lightly grease flinger and oil seal. Replace on
plunger shaft. Install plunger.
308736 13