Graco Inc. 308-530 Pressure Washer User Manual
Contents
1. Description O RING Valve Seat SEAT Valve VALVE SPRING Valve RETAINER Valve Spring O RING Valve Cap RING Backup valve cap O RING Plunger Retainer O RING Packing Retainer PACKING Low Pressure PACKING High Pressure REF NO 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 PART NO 804 234 801 038 KIT C21 801 040 804 214 804 222 KIT C21 804 217 KIT C21 804 118 KIT C21 804 120 KIT C3 KIT C3 KIT C3 KIT C3 KIT C3 KIT C3 KIT C3 804 221 802 178 804 232 804 077 804 075 101 754 100 361 DESCRIPTION STUD Retaining 6mm x 64 5mm RING Backup plunger retainer O RING Plunger Retainer RETAINER Plunger WASHER Keyhole MANIFOLD O RING Packing Retainer RETAINER Packing PACKING Low Pressure ADAPTER Male PACKING High Pressure ADAPTER Female O RING Valve Seat SEAT Valve VALVE SPRING Valve RETAINER Valve Spring O RING Valve Cap RING Backup valve cap CAP Valve WASHER Lock 10mm SCREW Cap socket head 10mm x 35mm WASHER Lock 6mm WASHER Flat 6mm PLUG Hex socket 3 8 PLUG Hex socket 1 2 308 530 25 QTY Ww _ 12 12 PUMP SERVICE Model 1535 EN Servicing the Valves Disassembly 1 NOTE Remove the four 4 socket head bolts and spring washers from end of manifold Support the discharge manifold from the underside and tap with a soft mallet to separate from the2. 2 Turn the sprayer off 3 Remove the ignition cable from the spark plug 4 Shut off the water supply Disengage the trigger safety latch and trigger the gun to relieve pressure and then engage the trigger safety latch again Before long term overnight storage or transporting of unit disconnect the water supply and turn off the fuel supply valve 1 If the pressure washer will be exposed to freezing temperatures drain all water out of the pump If it must be stored in freezing temperatures flush the unit with a 50 anti freeze solution Relieve pressure Flush the pressure washer before using it again to remove the anti freeze NOTE An anti freeze flush kit P N 802 327 is available to make flushing easier CAUTION If water does freeze in the pressure washer thaw it in a warm room before trying to start it DO NOT pour hot water on or into the pump it may crack the ceramic plungers 2 After each use wipe all surfaces of the pressure washer with a clean damp cloth 3 Perform the appropriate maintenance See maintenance chart 8 308 530 MAINTENANCE NN Observing regular maintenance intervals helps ensure that you get maximum performance and life from the pressure washer There is a break in period for the engine pump and gear reducer if used After changing the oil in these components following their respective break in periods the interval between required changes is longer If the unit
3. bodily injury SAFETY LATCH Whenever you stop spraying for a moment always set the gun safety latch in the engaged or safe position making the gun inoperative Failure to properly set the safety latch can result in accidental triggering of the gun SPRAY TIP SAFETY Use extreme caution when cleaning or changing spray tips If a spray tip clogs while spraying engage the gun safety latch immediately ALWAYS follow the Pressure Relief Procedure and then remove the spray tip to clean it MOVING PARTS HAZARD D Moving parts can pinch or amputate fingers or other body parts KEEP CLEAR of moving parts when starting or operating the pressure washer NEVER operate the pressure washer without all guards and interlocks installed and functioning Follow the Pressure Relief Procedure before checking or servicing the pressure washer to prevent discharging high pressure fluid from the gun Warnings continued on page 4 308 530 3 EQUIPMENT MISUSE HAZARD E General Safety Any misuse of the pressure washer or accessories such as overpressurizing modifying parts using incompatible chemicals and fluids or using worn or damaged parts can cause them to rupture and result in fluid injection splashing in the eyes or on the skin or other serious bodily injury fire explosion or property damage NEVER alter or modify any part of this equipment doing so could cause it to malfunction CHECK all spray equipment regularly and rep
4. 402 278 27 156 082 28 154 594 29 802 579 30 801 569 31 800 392 32 800 661 33 803 925 34 800 175 DESCRIPTION ENGINE 8 hp Briggs amp Stratton I C PUMP amp GEAR REDUCER ASSEMBLY incl 3 13 QTY 1 GEAR REDUCER see page 19 1 SCREW Cap hex hd 5 16 18 x 1 3 4 WASHER Flat 5 16 BRACKET Support BUMPER Rubber NIPPLE Hex 3 8 UNLOADER Preset 2000 psi PUMP ASSEMBLY 2000 psi see page 22 PLUG Square hd 1 4 GUARD Muffler QUICK COUPLER Male 3 8 NIPPLE Hex 3 8 NPSM x 1 4 NPT HOSE Bypass CROSS 1 2 NIPPLE 1 2 x 2 VALVE Thermal Relief ADAPTER 1 2 NUT Garden Hose ADAPTER Garden Hose STRAINER FILTER PLUG Plastic O RING Quick Coupler 3 8 O RING Quick Coupler 1 4 HOSE High Pressure 3 8 x 50 QUICK COUPLER Female 3 8 incl 27 GUN amp WAND ASSEMBLY incl 11 59 60 61 63 CHASSIS HANDLE FRONT LEG ASSEMBLY incl 35 36 50 51 67 Nm ch ch ch ch haa oa NS E AN PART NO 801 546 100 023 802 139 154 636 106 062 101 545 104 811 801 539 801 941 111 040 801 012 800 174 800 173 801 858 801 504 179 885 801 137 803 083 181 867 804 272 802 363 804 274 801 009 801 134 801 674 803 350 801 090 801 730 801 729 101 566 800 377 DESCRIPTION SCREW Cap hex hd 3 8 16 x 1 1 4 WASHER Flat 3 8 AXLE WASHER Flat 5 8 WHEEL amp TIRE ASSEMBLY PIN Cotter 1 8 x 1 1 2 HUB CAP BUMPER SCREW Cap hex
5. PIN Rod 3 50 101 754 PLUG Hex socket 3 8 1 25 801 031 SEAL Oil plunger 3 51 100 361 PLUG Hex socket 1 2 1 Kit Repair Kit Ref No Part No No Description Qty 804 100 RING Backup Valve valve seat O RING Valve Seat SEAT Valve VALVE SPRING Valve RETAINER Valve Spring O RING Cap PACKING High Pressure O RING Packing Retainer PACKING Low Pressure C20 804 096 Packing 308 530 23 PARTS DRAWING 804 246 Pump Assembly 2500 psi 24 308 530 PARTS LIST IT 804 246 Pump Assembly 2500 psi REF PART NO NO 1 804 093 2 804 154 3 801 028 4 804 181 5 804 189 6 804 155 7 804 171 8 804 150 9 802 189 10 804 089 11 804 237 12 804 224 13 804 080 14 804 109 15 804 124 16 804 137 17 804 193 18 804 213 19 804 219 20 804 223 21 804 126 22 801 031 23 804 121 24 804 208 25 804 216 26 804 220 DESCRIPTION KEY CRANKCASE O RING Oil Fill Cap CAP Oil Fill O RING Crankshaft Cover COVER Crankcase GASKET Oil Sight Gauge GAUGE Sight O RING Drain Plug PLUG Drain SCREW Cap hex hd cross recess 6mm x 16mm CRANKSHAFT BEARING SEAL Oil crankshaft O RING Crankshaft Cover COVER Crankshaft COVER Crankshaft RETAINER Packing front ROD Assembly Connecting ROD Plunger PIN Plunger Rod SEAL Oil plunger WASHER Slinger RETAINER Packing rear PLUNGER Ceramic GASKET Plunger Repair Kit Part No 804 098 Valve 804 097 Packing
6. PURPOSE WITH RESPECT T O ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motor switches hose etc are subject to the warraniy if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties Ms IMPORTANT PHONE NUMBERS DS TO PLACE AN ORDER contact your Graco distributor or call this number to identify the distributor closest to you 1 800 328 0211 Toll Free FOR TECHNICAL ASSIST ANCE service repair information or assistance regarding the application of Graco equipment 1 800 543 0339 Toll Free Factory Branches Atlanta Chicago Dallas Detroit Los Angeles West Caldwell N J Subsidiary and Affiliate Companies Canada England Switzerland France Germany Hong Kong Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 PRINTED IN U S A 308 530 1 91 32 308 530
7. inlet manifold Carefully place discharge manifold on working surface with valve chambers up From the three 3 smaller diameter and shallow inlet chambers remove the inlet valve adapters with inner and outer o rings These adapters are not held securely in position and may fall out as the discharge manifold is removed Next remove the valve seats valves springs and retainers from the inlet chambers From the three 3 larger diameter and deeper discharge chambers remove the discharge valve spacers with o rings These brass spacers generally remain with the discharge manifold as it is removed A reverse pliers fitted into the center bore and hooked onto the side ports of the spacer will assist the removal Next remove the valve seats valves springs and retainers from the discharge chambers The inlet and discharge use the same retainers springs valve seats and valves The o rings and valve spacers adapters are different Keep parts in order as they are removed Reassembly DISCHARGE 1 With crankcase side of discharge manifold facing up insert the springs into the retainers over the plastic center guide Place valve spring retainers in deeper valve chambers They will rest on the machined ridge in each chamber Examine the valves for wear or pitting and replace if necessary Install valves over the springs with recessed dish side down Examine valve seat o rings for wear and replace Lubricate and place
8. o rings on lip of retainers Carefully square o rings in valve chamber to avoid cutting o ring when valve seat is installed Examine valve seats for pitting scale or ridges and replace if necessary Install valve seat with grooved side down so o ring fits snugly into groove on seat 26 308 530 6 Examine both o rings on the discharge valve spacer and replace if necessary Lubricate o rings and fit into grooves on outside of spacer Lubricate spacer and carefully press into valve chambers with small diameter side down until spacer snaps tightly into position Reassembly INLET 1 10 Place valve spring retainers into the shallow valve chambers They will rest on the machined ridge in each chamber Insert valve springs into retainers over plastic center guide Inspect the valves for wear ridges or pitting and replace if necessary Insert valves over the springs with recessed dish side down Examine valve seat o rings for wear and replace Lubricate and place o rings on lip of retainers Carefully square o rings in valve chamber to avoid cutting o ring when valve seat is installed Examine valve seats for pitting scale or ridges and replace if necessary Install valve seat with grooved side down so o ring fits snugly into groove on seat Examine the adapter inner o rings and replace if worn Lubricate and install o rings into inlet valve adapters Examine the adapter outer o rings and replace if
9. properly before each use Medical Treatment If any fluid appears to penetrate your skin get EMERGENCY MEDICAL TREATMENT AT ONCE DO NOT TREAT AS A SIMPLE CUT Tell the doctor exactly what fluid was injected NOTE TO PHYSICIAN njection in the skin is a traumatic injury It is important to treat the injury surgically as soon as possible Do not delay treatment to research toxicity Toxicity is a concern with some exotic coatings injected directly into the bloodstream Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable Pressure Relief Procedure To reduce the risk of serious bodily injury including fluid injection and splashing in the eyes or on the skin always follow this procedure whenever you stop spraying for more than 10 minutes when shutting down and before checking or repairing any part of the system 1 Engagethe trigger safety latch 2 Turn the sprayer off 3 Remove the ignition cable from the spark plug 4 Shutoff the water supply 5 Disengage the trigger safety latch and trigger the gun to relieve pressure and then engage the trigger safety latch again 6 Before long term overnight storage or transporting of the unit disconnect the water supply and turn off the fuel supply valve Spray Gun Safety Devices Be sure all gun safety devices are operating properly before each use Do not remove or modify any part of the gun this can cause a malfunction and result in serious
10. ring for ease of installation and to avoid damage to o rings NOTE First install NEW copper gaskets on plunger retainers then back up rings and o rings 4 Install short threaded end of stud into plunger retainer 5 Thread plunger retainer and stud assembly into plunger rod and torque per chart Long threaded end of stud into plunger rod NOTE Exercise caution not to over torque the plunger retainer 6 Rotate shaft so the two 2 outside plungers are extended and lined up Then lubricate plungers 7 Replace all four 4 discharge manifold socket head bolts and washers and hand tighten 8 Then carefully slip manifold assembly onto plungers and tap with soft mallet until flush with crankcase 9 Replace the two 2 inlet manifold socket head bolts and washers and hand tighten Then torque per chart 10 Then torque the four 4 discharge manifold socket head bolts per chart Servicing Crankcase Section 1 While inlet manifold plungers and seal retainers are removed examine crankcase seals for wear 2 Check oil level and for evidence of water in oil 3 Rotate crankshaft by hand to feel for smooth bearing movement 4 Examine crankshaft oil seal externally for drying cracking or leaking 5 Consult factory or your local distributor if crankcase service is required Torque Chart Thread Tool Size Torque 11 mm hex 80 in lbs 8 mm allen 132 in lbs Pump Part Plunger Retainer M5 Inlet Man
11. spray to be emitted from the coupling NEVER use a damaged hose Before each use check entire hose for cuts leaks abrasion bulging cover or damage or movement of the hose couplings If any of these conditions exist replace the hose immediately DO NOT try to recouple high pressure hose or mend it with tape or any other device A repaired hose cannot contain the high pressure fluid HANDLE AND ROUTE HOSES CAREFULL Y Do not pull on hoses to move the pressure washer Do not use chemicals which are not compatible with the inner tube and cover of the hose DO NOT expose Graco hose to temperatures above 200 F 93 C or below 40 F 40 FUEL AND EMISSION HAZARDS IEE NEVER fill the fuel tank while the unit is running or hot The fuel used in this unit is combustible and when spilled on a hot surface can ignite and cause a fire ALWAYS fill tank slowly to avoid spilling NEVER operate the unit in a closed building The exhaust contains carbon monoxide a poisonous odorless invisible gas which can cause serious injury or death if inhaled NEVER alter the throttle setting which is factory set Tampering with this adjustment can damage the pressure washer and will void the warranty 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 c
12. to remove the manifold assembly CAUTION Keep manifold properly aligned with ceramic plungers when removing to avoid damage to either plungers or seals 3 Remove oil pan and slide out seal retainer with wicks 4 Using a wrench loosen the plunger retainer Grasp ceramic plunger and push toward crankcase until plunger retainer pops out 5 Remove plunger retainer with copper gasket back up Ring and o ring 6 Remove plunger from plunger rod 28 308 530 Reassembly 1 Carefully examine each ceramic plunger for scoring or cracks replace if worn and slip onto plunger rod Note Ceramic plunger can only be installed one direction front to back Do not force onto rod 2 Examine plunger retainer and stud and replace if worn Note Thread stud into plunger retainer 3 Examine o ring back up ring and gasket on plunger retainer and replace if worn or cut Lubricate o ring for ease of installation and to avoid damaging o rings Note First install gasket then back up ring and o ring 4 Thread plunger retainer and stud assembly into plunger rod Exercise caution not to over torque 5 Saturate new oil wick by soaking in oil place in seal retainer and slip retainer over ceramic plunger 6 Replace oil pan 7 Turn shaft by hand to line up plungers so end plungers are parallel 8 Carefully slip manifold onto plungers keeping manifold level and tap with mallet to bring manifold flush with cran
13. worn Lubricate and install o rings onto inlet valve adapters Lubricate inlet valve adapter and press into chamber Carefully square inlet valve adapter into chamber to avoid cutting or extruding o ring Replace discharge manifold over plunger ends matching discharge valve spacers with inlet chambers and press into position T ap with a soft mallet until completely seated in chambers Replace all four 4 washers and socket head bolts Hand tighten each Then torque per chart Servicing the Seals Disassembly 1 With discharge manifold removed from the pump remove the two 2 socket head bolts and spring washers from end of inlet manifold Rotate crankshaft to loosen inlet manifold Support inlet manifold from underside and tap with a soft mallet to separate manifold from crankcase 4 With crankcase side of manifold down remove hi pressure seals using a reverse pliers 5 Invert manifold so crankcase side is up and with reverse pliers remove low pressure seals Reassembly 1 Examine low pressure seal for seal wear or spring failure and replace if necessary With crankcase side of inlet manifold up lubricate seal and press into valve chamber with garter spring down Carefully square seal into position 2 Examine hi pressure seal for wear and replace if necessary Invert inlet manifold with crankcase side down lubricate seal and press into chamber with v side up Carefully square into position 3 Rotate shaf
14. 01 566 NUT Lock 3 8 16 3 66 803 301 LABEL Model 2540 1 33 800 661 CHASSIS 1 67 801 137 KEY Square 1 4 x 2 1 308 530 15 GEAR REDUCER SERVICE Model 1535 EEE WARNING To reduce the risk of serious bodily injury including fluid injection splashing in the eyes or on the skin or injury from moving parts always follow the Pressure Relief Procedure Warning on page 2 before proceeding Replacing the O Ring 5 Replacing the Oil Seal 10 1 Remove the four bolts lockwashers and washers NOTE The oil seal MUST be replaced if removed Pull the pump and gear reducer assembly of f the engine 1 Follow steps 1 and 2 under Replacing the O Ring 2 Pry the oil seal out of the gear case Be careful not to 2 Drain the gear reducer oil by placing a container damage the gear case under it and removing the drain plug with a 22 mm wrench Replace the o ring 16 if damaged 3 Wipe the inner surface of the gear case clean then lightly coat it with grease Place the oil seal into the gear case Use a socket placed against the surface 3 Remove the four screws and lockwashers with a of the seal to push the seal into the case until its top 6 mm wrench and pull the gear Case of fthe gear surface is past the ridge in the bore cover 4 Follow steps 4 through 6 under Assembling the Gear 4 Remove the old o ring 5 Clean the gear cover and Reducer if this is all the service required case surface Lightly coat the new o ring with grease and
15. 2 127 N SE Wes hd j 42 800 128 TIP ASSEMBLY 2505 a incl 39 55 1 9 801 674 SLEEVE 28 1 2 10 100 527 WASHER Flat 5 16 20 Da is AEM 1 11 111 040 NUT Lock 5 16 18 12 n aK 12 801 539 BUMPER 44 800 129 TIP ASSEMBLY 4005 z incl 39 59 1 13 801 568 COUPLER Male 3 8 2 14 802 579 HOSE High Pressure 3 8 x 50 1 er Ze an A 15 801 569 COUPLER Female 3 8 incl 16 2 47 156 849 NIPPLE Hex 3 8 3 16 156 082 O RING Female Coupler 3 8 2 48 801 709 PLUG Square 1 17 801 009 COUPLER Female 1 4 incl 19 1 49 800 655 UNLOADER 2500 psi 1 n SEK ee 50 802 627 NIPPLE Hex 3 8 x 1 4 1 ni x 19 154 594 O RING Female Coupler 1 4 1 a se pees NEL i 20 154 636 WASHER Flat 5 8 4 7 Ax z x 53 801 622 CROSS 1 2 1 21 101 545 PIN Cotter 1 8 x 1 1 2 2 i 22 801 504 BUMPER Rubber 2 54 800 115 VALVE Thermal Relief 1 23 803 740 WHEEL amp TIRE ASSEMBLY 2 F Ti T he j 24 803 741 AXLE 1 25 IOT Me SCHEN ce ei ce Gedo AWE Kayan ose 3 8 16 x 1 1 4 4 Zi 26 100 023 WASHER Flat 3 8 10 59 801 615 TIP Spray 4005 1 27 801 819 SCREW Cap hex hd 60 801 367 BUMPER Rubber 2 3 8 16 x 3 1 61 804 251 BRACKET Support 1 28 801 858 BRACKET Front Leg 1 62 804 073 ADAPTER 1 2 1 29 803 925 HANDLE 1 63 800 377 HOSE ASSEMBLY w Couplers 30 800 641 FRONT LEG ASSEMBLY incl 13 14 15 incl 22 26 27 28 32 1 64 804 246 PUMP ASSEMBLY see page 24 1 31 804 273 LABEL Graco Cleaning 65 804 249 GEAR REDUCER ASSEMBLY Systems 1 see page 19 1 32 1
16. 222 i 54 803 083 LABEL Keep From Freezing 1 21 800 115 VALVE Thermal Relief 1 55 804 274 LABEL Graco Cleaning 22 804 073 ADAPTER 1 2 1 2 sea ge whose j 56 801 723 LABEL Model 1535 24 801 110 ADAPTER Garden Hose 1 57 802 363 LABEL Caution 1 25 804 051 STRAINER FILTER 1 58 181 867 LABEL Warning 1 26 402278 PLUG Plastic 1 59 801 009 QUICK COUPLER 27 156 082 O RING Quick Coupler 3 8 2 Female 1 4 incl 28 1 28 154 594 O RING Quick Coupler 1 4 1 60 801 134 WAND 32 1 29 802 579 HOSE High Pressure 3 8 x 50 1 61 801 674 SLEEVE 28 4 30 801 569 QUICK COUPLER Female 3 8 63 803 350 GUN Spray see Instruction incl 27 2 Manual 308 511 1 31 800 392 GUN amp WAND ASSEMBLY 64 801 090 QUICK COUPLER Male 1 4 4 incl 11 59 60 61 63 1 65 801 730 TIP Spray 00055 1 32 800 661 CHASSIS 1 66 801 729 TIP Spray 15055 1 33 803 925 HANDLE 1 67 101 566 NUT Lock 3 8 16 5 34 800 175 FRONT LEG ASSEMBLY 68 800 377 HOSE ASSEMBLY w Quick incl 35 36 50 51 67 1 Couplers incl 16 29 30 1 308 530 11 PARTS DRAWING 800 699 Hydra Clean 2040 Pressure Washer 12 308 530 PARTS LIST I 800 699 Hydra Clean 2040 Pressure Washer REF PART NO NO 1 802 141 800 696 2 3 804 249 4 802 127 6 7 8 100 527 804 251 801 367 11 156 849 12 802 315 13 804 245 14 801 709 15 802 257 16 801 568 17 802 627 18 803 869 19 801 622 20 801 523 21 800 115 22 804 073 23 801 111 24 801 110 25 804 051 26
17. 8 29 804 107 30 804 239 31 804 134 32 804 106 DESCRIPTION SCREW Cap socket head 6mm x 20mm O RING Housing GEAR Driven helical KEY Square 6mm x 27mm WASHER Flat retaining WASHER Lock 8mm SCREW Cap hex hd cross recess KEY Square 1 4 x 55mm WASHER Flat M10 WASHER Lock 10mm SCREW Cap hex hd 3 8 16 x 35mm SCREW Cap hex hd cross recess WASHER Flat 8mm SPACER 308 530 19 2 lt A Ahah QIZA ZA E 1 4 4 PARTS DRAWING 804 244 Pump Assembly 1500 psi 20 308 530 PARTS LIST BT 804 244 Pump Assembly 1500 psi REF PART REF PART NO NO DESCRIPTION QTY NO NO DESCRIPTION QTY 1 802 312 KEY Square 1 28 804 133 GASKET Copper 3 2 804 180 CRANKCASE 1 29 801 038 RING Backup 3 3 804 077 WASHER Lock 12 30 801 039 O RING Retainer 3 4 804 171 GASKET Oil Sight Gauge 1 31 801 040 RETAINER Plunger 3 5 801 028 O RING Oil Fill Cap 1 32 802 206 WASHER Flat 3 6 801 027 CAP Oil Fill 1 33 804 092 RETAINER Seal 3 7 804 150 GAUGE Sight 1 34 804 145 MANIFOLD Inlet 1 8 804 123 O RING Crankcase Cover 1 35 KIT C19 PACKING Low Pressure 9 804 122 COVER Crankcase 1 36 KIT C19 PACKING High Pressure 10 802 189 O RING Drain Plug 1 37 804 088 PLUG Hex Hd 1 2 1 11 804 089 PLUG Oil Drain 1 38 804 075 WASHER Flat 6mm 12 12 804 238 SCREW Cap hex hd cross 39 802 178 WASHER Lock 10mm 6 recess 6mm x 20mm 4 40 804 232 SCREW Cap socket head 13 804 198 CRANKSHAFT 1 10
18. INSTRUCTIONS PARTS LIST 308 530 Rev A GRACO This manual contains IMPORTANT WARNINGS and INSTRUCTIONS READ AND RETAIN FOR REFERENCE HYDRA CLEAN 1535 2040 2540 Pressure Washers HYDRA CLEAN 1535 5 HP ENGINE P N 800 698 Series A 1500 psi 103 bar OPERATING PRESSURE 1900 psi 131 bar MAXIMUM WORKING PRESSURE HYDRA CLEAN 2040 8 HP ENGINE P N 800 699 Series A 2000 psi 138 bar OPERATING PRESSURE 2400 psi 165 bar MAXIMUM WORKING PRESSURE HYDRA CLEAN 2540 9 HP ENGINE P N 800 700 Series A 2500 psi 172 bar OPERATING PRESSURE 3000 psi 207 bar MAXIMUM WORKING PRESSURE 4 Wy 7 LL N y NY RR N y 7 GRACO INC P O Box 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1991 GRACO INC INDEX EN Wamings s MS a el a a all ka daa si ee hae cbs af Entre Se 3 e UC Le Ir NEES 5 RSJ E gt TE e 6 Shutdown Flushing and Storage 8 BUNA FIGS EE 8 Troubleshooting Chart as nrg alla ka a steeped ENN 9 Hydra Glean 15395 25a 120 40 bara tle acs Ian Dias n DER et as 10 Hydra Clean 2040 12 Hydra Clean 2540 14 Gear Reducer Model 1535 16 Gear Reducer Models 2040 amp 2540 18 Pump Model 1535 s na nikam 44er sche 20 Pump Model 2040 E cheddar KK KK KK KK ter KK KK ihn 22 Pu
19. air or replace worn or damaged parts immediately ALWAYS wear protective eyewear and appropriate clothing If using a chemical injector read and follow the chemical manufacturer s literature for recommendations on additional protective equipment such as a respirator System Pressure This sprayer can develop high operating pressures Be sure that all spray equipment and accessories are rated to withstand the maximum working pressure of this sprayer DO NOT exceed the maximum working pressure of any component or accessory used in the system Chemical Compatibility BE SURE that all chemicals used in the chemical injector are compatible with the wetted parts of the hose gun wand and tip as given in the Technical Data inside back cover Always read the chemical manufacturer s literature before using any chemical in this pressure washer HOSE SAFETY EEE High pressure fluid in the hoses can be very dangerous If the hose develops a leak split or rupture due to any kind of wear damage or misuse the high pressure spray emitted from it can cause a fluid injection injury or other serious bodily injury or property damage ALL FLUID HOSES MUST HA VE STRAIN RELIEFS ON BOTH ENDS The strain reliefs help protect the hose from kinks or bends at or close to the coupling which can result in hose rupture TIGHTEN all fluid connections securely before each use High pressure fluid can dislodge a loose coupling or allow high pressure
20. ck garden hose may be collapsed or kinked Worn inlet or discharge valves Replace worn valves Leaking high pressure hose Replace high pressure hose Water leakage from Worn packings Install new packings See PUMP SERVICE under pump manifold Water in pump Humid air condensing inside crankcase Change oil as specified in MAINTENANCE Worn packings Install new packings See PUMP SERVICE Oil seals leaking Install new oil seals See PUMP SERVICE Frequent or premature Scored damaged or worn plungers Install new plungers See PUMP SERVICE failure of the packings Abrasive material in the fluid being pumped Install proper filtration on pump inlet plumbing Inlet water temperature too high Check water temperature may not exceed 160 F Overpressurizing pump Do not modify any factory set adjustments See EQUIPMENT MISUSE HAZARD Excessive pressure due to partially plugged Clean or replace tip See Installing and Changing or damaged tip Spray Tips Pump running too long without spraying Never run pump more than 10 minutes without spraying Running pump dry Do not run pump without water Strong surging at the Foreign particles in the inlet or discharge Clean or replace valves See PUMP SERVICE inlet and low pressure valve or worn inlet and or discharge valves on the discharge side Oil leakage between Worn gasket Replace the gasket See SERVICE SECTION the gear reducer cover and case Oil leakage between Worn oil
21. e risk of fluid injection or splashing in the eyes or on the skin if the gun is bumped or triggered accidentally 8 ALWAYS observe the following CAUTIONS to avoid costly damage to the pressure washer CAUTION DO NOT allow the pressure washer to idle for more than 10 minutes Doing so may cause the recirculating water to overheat and seriously damage the pump Turn off the pressure washer if it will not be spraying or cleaning at least every 10 minutes If heated inlet water is used reduce this time further DO NOT run the pump dry which will quickly damage the pump Be sure the water supply is fully turned on before starting the pump DO NOT operate the pressure washer with the inlet water screen removed This screen helps keep abrasive sediment out of the pump which could clog or scratch the pump Keep this screen clean DO NOT pump caustic materials such materials may corrode the pump components 9 See the chemical injector or sandblaster kit manual for detailed cleaning information if these accessories are used Trigger Safety Latch WARNING To reduce the risk of serious bodily injury including fluid injection splashing in the eyes or on the skin ALWAYS engage the trigger safety latch whenever spraying stops even for a moment In the engaged position the trigger safety latch prevents the gun from being triggered accidentally by hand or if it is dropped or bumped Be sure the latch is push
22. eam into the pump BACKFLOW PREVENTOR 801 133 Prevent back up of contaminated water into fresh supply Install upstream of pump 30 308 530 ANTI FREEZE FLUSH KIT 802 327 For flushing system with 50 anti freeze solution prior to transporting or storing pressure washer in below freezing temperatures INLET PRESSURE REGULATOR 800 258 Regulates inlet water pressure to 60 psi 4 bar maximum WATER SANDBLASTING KIT 800 120 For abrasive cleaning of stubborn dirt and paint Requires a spray tip which is not included in kit 2040 uses 801 729 2540 uses 801 667 TECHNICAL DATA HEHE Model 800 698 Model 800 699 Model 800 700 Engine air cooled 4 cycle 5 hp Briggs amp Stratton UC J 8 hp Briggs amp Stratton UC 9 hp Briggs amp Stratton OHV Gasoline Tank Capacity 3 quarts 2 8 liter 6 quarts 5 7 liter 5 quarts 4 8 liter Water Pump Maximum Working 1500 psi 103 bar 2000 psi 138 bar 2500 psi 172 bar Pressure Water Pump Maximum Flow 3 5 gpm 13 lpm 4 gpm 15 lpm 4 gpm 15 Ipm Inlet Hose Connection 3 4 garden hose f 3 4 garden hose f 3 4 garden hose f Weight 105 Ib 48 kg 152 Ib 68 kg 158 Ib 70 kg Dimensions Length 37 940 mm 36 914 mm 36 914 mm Width 19 483 mm 21 533 mm 21 533 mm Height 20 508 mm 22 5 572 mm 23 584 mm Maximum Inlet Water 160 F 70 C 160 F 70 C 160 F 70 C Temperature Wetted Parts High Pressure Hose Acrylonitrile and B
23. ed fully down when engaging it or it cannot prevent the gun from being triggered See Figure 2 TRIGGER SAFETY LATCH SHOWN ENGAGED TRIGGER SAFETY LATCH SHOWN DISENGAGED Figure 2 Installing and Changing Spray Tips WARNING To reduce the risk of serious bodily injury including fluid injection or splashing in the eyes or onto the skin use extreme caution when changing spray tips ALWAYS follow the procedure below 1 Follow the Pressure Relief Procedure 2 Point the gun and wand away from yourself and anyone else 3 Without holding your hand over the spray tip A pull back the quick coupler ring B Remove the old tip and or install a new one and then release the ring See Figure 3 4 Be sure the tip is secure before starting to spray again 5 Tip holding holes are provided on the chassis CAUTION To avoid blowing the o ring out of the quick coupler due to the high pressure in the system never operate the pressure washer without a tip securely mounted in the quick coupler Figure 3 308 530 7 SHUTDOWN FLUSHING ME AND STORAGE WARNING Pressure Relief Procedure To reduce the risk of serious bodily injury including fluid injection and splashing in the eyes or on the skin always follow this procedure whenever you stop spraying for more than 10 minutes when shutting down and before checking or repairing any part of the system 1 Engage the trigger safety latch
24. er key on the engine shaft and slide the gear reducer onto the shaft up to the engine s shoulder 5 Follow the instructions under Assembling the Gear 6 Secure the gear reducer to the engine with the four Reducer if this is all the service required 16 308 530 bolts and lockwashers PARTS DRAWING Gear Reducer Model 1535 PARTS LIST Gear Reducer Model 1535 REF PART REF PART NO NO DESCRIPTION QTY NO NO DESCRIPTION QTY 1 804 236 SCREW Cap hex hd cross 14 804 231 SCREW Cap hex hd cross recess 4 recess 4 2 804 201 HOUSING Gear Reducer 1 i 3 804 202 GEAR Pinion 3 4 1 15 ez 66 GEAR Driven spur 1 16 804 229 KEY Square 3 16 x 13 16 1 4 804 082 BEARING 1 ni SC 17 804 090 WASHER Flat retaining 1 5 804 225 RING Retaining internal 1 19 804 230 SCREW C hex hd 6 804 226 RING Retaining external 1 Gier 20mm 7 804 203 SEAL Oil pinion 1 gt 8 804 165 KEY Square 3 16 x 1 3 4 1 20 804 188 PLUG Oil Drain 1 9 804 167 GASKET Flange 1 21 802 189 O RING Drain Plug 1 10 804 176 FLANGE Housing 1 22 804 134 WASHER Flat 8mm 4 11 804 177 O RING Housing 1 23 802 175 WASHER Lock 8mm 9 12 804 075 WASHER Flat 6mm 4 24 804 168 SCREW Cap hex hd 13 804 077 WASHER Lock 6mm 4 5 16 18 x 25 mm 4 308 530 17 GEAR REDUCER SERVICE Models 2040 amp 2540 I Replacing the Gasket 9 NOTE To maintain a good seal the gasket must be replaced whenever the gear reducer is disassembled Remo
25. ge to the pump will result Always be sure the water supply is completely turned on before operating 4 Trigger the gun until water sprays from the tip indicating that the air is purged from the system 5 Open the fuel shutoff valve Be sure the spark plug ignition cable is pushed firmly onto the spark plug On those units equipped with an ignition shutoff switch put the switch in the on position and put the throttle in the run position 6 Start the engine NOTE For easier starting have one person start the pressure washer while another person triggers the spray gun 6 308 530 If the engine is cold completely close the engine choke Grasp the starter rope brace one foot on the pressure washer chassis and pull rope rapidly and firmly Continue holding the rope as it returns Pull and return the rope until the engine starts In cool weather the choke may have to be kept closed for 10 to 30 seconds before opening it to keep the engine running Otherwise open the choke as soon as the engine starts If the engine is warm leave the choke open or just partly close it Start the engine as described in the preceding paragraph When it starts be sure to open the choke completely CAUTION On recoil start engines never let the starter rope return by itself It could jam the recoil system 7 ALWAYS engage the gun s trigger safety latch whenever you stop spraying even for a moment to reduce th
26. hd 5 16 18 x 1 NUT Lock 5 16 18 GROMMET Rubber TIP ASSEMBLY 00055 incl 64 65 TIP ASSEMBLY 15055 incl 64 66 BRACKET Front Leg BUMPER Rubber LABEL Chassis KEY Square 1 4 x 2 LABEL Keep From Freezing LABEL Warning LABEL Model 2040 LABEL Caution LABEL Graco Cleaning Systems QUICK COUPLER Female 1 4 incl 28 WAND 32 SLEEVE 28 GUN Spray see Instruction Manual 308 511 QUICK COUPLER Male 1 4 TIP Spray 00055 TIP Spray 15055 NUT Lock 3 8 16 HOSE ASSEMBLY w Quick Couplers incl 16 29 30 O o7 J Ek zk ak AA A zk sch ARO _ NIN N A Via Dai 308 530 13 PARTS DRAWING 800 700 Hydra Clean 2540 Pressure Washer A 14 308 530 PARTS LIST Mee 800 700 Hydra Clean 2540 Pressure Washer REF PART REF PART NO NO DESCRIPTION QTY NO NO DESCRIPTION QTY 1 800 392 GUN amp WAND ASSEMBLY 34 801 012 GROMMET Rubber 4 incl 2 5 9 15 17 47 1 35 800 131 TIP ASSEMBLY 0005 2 803 350 GUN Spray see Instruction incl 39 40 1 Manual 308 511 1 36 800 137 TIP ASSEMBLY 1505 3 181 867 LABEL Warning ventilation 1 incl 39 41 1 4 802 363 LABEL Caution 1 37 402 278 PLUG Plastic 1 5 801 134 WAND 32 1 38 803 083 LABEL Keep From Freezing 1 6 179 885 LABEL Warning chassis 1 39 801 090 COUPLER Male 1 4 4 7 803 901 ENGINE 9 hp Briggs A 40 801 640 TIP Spray 0005 1 Stratton OHV 1 41 801 667 TIP Spray 1505 1 8 80
27. ifold M10 Bolts Discharge M10 Manifold Bolts 8 mm allen 180 in lbs 308 530 27 PUMP SERVICE Models 2040 amp 2540 DIT Servicing the Valves 1 Remove the hex valve plug 2 Examine the o ring under the plug for cuts or distortion and replace if worn Lubricate new o ring before installing 3 Grasp valve retainer by tab at the top with pliers and remove from valve chamber Valve parts usually separate during removal Note A special tool will be needed to remove the seat from the manifold A reverse pliers or a standard vise grip and a 1 4 x 3 bolt to fit I D of seat inserted under the edge of the seat will pry the valve seat out easily 4 Examine all valve parts for wear and replace with preassembled valve assembly in service kit containing retainer spring valve valve seat o ring and back up ring 5 Grasp new valve assembly by tab at top with pliers immerse in oil and push into valve chamber Be certain valve assembly is square in valve chamber 6 Apply Loctite 242 to valve plug thread into manifold port and torque per chart Note Corrosion Resistant models require the coil spring installed in the Valve Plug Servicing the Pumping Section Disassembly 1 Remove the four 4 hex nuts or two 2 bolts from the manifold varies with model 2 Rotate crankshaft by hand to start separation of manifold from crankcase Support the underside of the manifold and tap lightly with a mallet
28. ign 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 for examination by Graco to verify 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 DISCLAIMERS AND LIMITATIONS THE TERMS OF THIS WARRANTY CONSTITUTE THE PURCHASER S SOLE AND EXCLUSIVE REMEDY AND ARE IN LIEU OF ANY OTHER W ARRANTIES EXPRESS OR IMPLIED INCLUDING WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND OF ANY NON CONTRACTUAL LIABILITIES INCLUDING PRODUCT LIABILITIES BASED ON NEGLIGENCE OR STRICT LIABILITY EVERY FORM OF LIABILITY FOR DIRECT SPECIAL OR CONSEQUENTIAL DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND DENIED IN NO CASE SHALL GRACO S LIABILITY EXCEED THE AMOUNT OF THE PURCHASE PRICE ANY ACTION FOR BREACH OF WARRANTY MUST BE BROUGHT WITHIN THREE 3 YEARS OF THE DATE OF SALE EQUIPMENT NOT COVERED BY GRACO WARRANTY GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED W ARRANTIES OF MERCHANTABILITY AND FITNESS FOR A P ARTICULAR
29. install it in the gear case Assembling Mhe Gear Reducer 1 Make sure the gasket is properly placed on the gear i cover Refer to step 4 under Replacing the Gasket 5 Follow steps 4 through 6 under Assembling the Gear Then install the gear cover on the pump shaft Reducer if this is all the service required 2 Align the holes in the gear cover with the holes in the pump Apply low strength Loctite blue on the Replacing the Gasket 1 screw threads and secure the cover with the four 1 Follow steps 1 through 3 under Replacing the screws and lockwashers T ighten them oppositely O Ring and evenly 3 Align the gear s slot with the key on the pump shaft 2 Using a4 mm wrench remove retaining bolt and slide the gear onto the shaft up to the pump s lockwasher flat washer and pull the gear 4 off the shoulder Tighten the retaining bolt lockwasher and pump with a gear puller flat washer to lock the gear on the shaft 4 Make sure the o ring is in place Refer to step 4 3 Remove the four screws and lockwashers from the under Replacing the O Ring Install the gear case on gear Cover the cover aligning the holes and secure it with the four screws and lockwashers T ighten them 4 Remove the gear cover and gasket 1 from the oppositely and evenly pump Clean the gear cover and pump surface Lightly coat both sides of the gasket with grease and 5 Grease the engine shaft Align the gear s slot with the install it on the gear cov
30. is operating in dusty conditions these maintenance checks should be made more often WARNING To reduce the risk of serious bodily injury including fluid injection splashing in the eyes or on the skin or injury from moving parts always follow the Pressure Relief Procedure Warning before proceeding Interval ist do Daily Clean water inlet screen and filter Check engine and pump oil levels Fill as necessary Check gasoline level Fill as necessary After first 5 hours of operation Each 25 hours of operation Change engine break in oil Drain oil when warm Use SAE 30 or 10W 30 detergent oil Clean and remove air cleaner foam Wash with water and detergent Dry thoroughly Rub with oil and squeeze to distribute oil After first 50 hours of operation Change pump break in oil Use SAE 20 or 30 non detergent oil or genuine Cat pump oil Change gear reducer oil Use SAE 90 gear oil on 2040 and 2540 The 1535 uses the oil in pump crankcase Each 100 hours of operation or 3 months Clean or replace paper air cleaner cartridge Tap gently to remove dirt Change engine oil Use SAE 30 or 10W 30 detergent oil Change pump oil Use SAE 20 or 30 non detergent oil or genuine Cat pump oil Change gear reducer oil on 2040 and 2540 Use SAE 90 gear oil The 1535 uses the oil in pump k Each 500 hours of operation or 6 months TROUBLESHOOTING CHART SN WARNING To reduce the risk of seriou
31. kcase 9 Replace washers and nuts or bolts and torque per chart Servicing the Seals and V Packings Disassembly 1 Remove the manifold as described 2 With crankcase side of manifold facing up unscrew the seal case from the manifold using a special key wrench 3 Remove o ring from seal case 4 Remove snap ring and low pressure seal from the seal case Seals are generally removed easily without any tools 5 High Pressure Seal Models The high pressure seal is generally easily removed from the manifold without any tools If extremely worn a reverse pliers may be used 6 V Packing Models The female adapter two v packings and male adapter are easily removed from manifold without tools If extremely worn a reverse pliers may be used Reassembly V Packing Models 1 2 Lubricate high pressure packing area in manifold Insert male adapter with notches down and v side up Lubricate v packings and install one at a time with grooved side down Next install female adapter with grooved side down Examine seal case o ring and replace if worn Lubricate new o ring before installing Thread seal case into manifold and tighten with key wrench High Pressure Seal Models 1 2 Lubricate seal area in manifold Carefully square seal into position by hand with the metal grooved side up Examine seal case o ring and replace if worn Lubricate new o ring before installing Next secure high press
32. mm x 35mm 2 14 804 081 BEARING 2 41 804 146 MANIFOLD Discharge 1 15 802 193 SEAL Oil crankshaft 1 42 KIT C1 RETAINER Valve Spring 16 802 201 O RING Crankshaft Cover 2 43 KIT C1 SPRING Valve 17 804 197 COVER Crankshaft 1 44 KITC1 VALVE 18 804 237 SCREW Cap hex hd cross 45 KIT C1 O RING Valve Seat recess 6mm x 16mm 8 46 KIT C1 SEAT Valve 19 804 214 WASHER Lock 18mm 3 47 801 148 SPACER Discharge Valve 3 20 804 241 ROD Assembly Connecting 3 48 KIT C1 or O RING Spacer 21 804 142 ROD Plunger 3 KIT C19 22 804 083 PIN Rod 3 49 804 147 ADAPTER Inlet Valve 3 23 802 185 WASHER Flat 3 50 KIT C1 or O RING Adapter 24 802 194 SEAL Oil Plunger 3 KIT C19 25 804 143 WASHER Slinger 3 51 KIT C1 or O RING Adapter 26 804 144 PLUNGER Ceramic 3 KIT C19 27 804 127 STUD Retaining SST 52 804 128 SCREW Cap socket head 6mm x 40mm 3 10mm x 55mm 4 Repair Kit Part No Description Qty 804 102 RETAINER Valve Valve Spring 6 43 SPRING valve 6 44 VALVE 6 45 O RING Valve Seat 6 46 SEAT Valve 6 48 O RING Spacer 3 50 O RING Adapter 3 51 O RING Adapter 3 C19 804 101 35 PACKING Low Packing Pressure 3 36 PACKING High Pressure 3 48 O RING Spacer 3 50 O RING Adapter 3 51 O RING Adapter 3 308 530 21 PARTS DRAWING 804 245 Pump Assembly 2000 psi 22 308 530 PARTS LIST DT 800 245 Pump Assembly 2000 psi REF PART REF PART NO NO DESCRIPTION QTY NO NO DESCRIPTION QTY 1 802 178 WASHER L
33. mp If inlet water pressure is over 60 psi 4 1 bar a regulating water valve P N 800 258 must be installed at the garden hose connection Do not exceed 160 F 70 C inlet water temperature Connect a hose with at least a 3 4 inch 19 mm ID from the water supply to the unit s 3 4 inch garden hose inlet The supply hose should not be more than 50 ft 15 m long NOTE The water source at the unit must have a minimum flow rate equal to that of the unit see Technical Data inside back cover 308 530 5 STARTUP IT Always use this startup procedure to ensure that the unit is started safely and properly 1 Check oil levels Engine Add SAE 30 or 10W 30 weight detergent oil as necessary Pump Add SAE 20 or 30 weight non detergent oil or genuine Cat pump oil as necessary Gear Reducer 2040 and 2540 Add SAE 90 gear oil as necessary The 1535 uses the oil in pump crankcase NOTE All units are equipped with a low oil sensor that shuts the engine off if the oil level falls below a certain level If the unit stops unexpectedly check both the oil and the fuel levels Check the oil level each time the unit is refueled 2 Check fuel level WARNING DO NOT refuel a hot engine Refueling a hot engine could cause a fire Use only fresh clean regular or unleaded gasoline Close the fuel shutoff valve during refueling 3 Turn on the water supply CAUTION Never run the unit dry Costly dama
34. mp Model 2540 u kk kk a KK KK ae 24 Pump Service Model 1535 26 Pump Service Models 2040 amp 2540 28 FAC COSS ONES ee Pe dolente 30 dJechnical Data EE 31 Warranty se n a a CE d dakin EE don dank Back Cover TERMS Eee WARNING Alerts user to avoid or correct conditions NOTE Identifies helpful procedures and information that could cause bodily injury CAUTION Alerts user to avoid or correct conditions that could cause damage to the equipment 2 308 530 WARNING HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY FOR PROFESSIONAL USE ONLY OBSERVE ALL WARNINGS Read and understand all instruction manuals before operating equipment FLUID INJECTION HAZARD 4 we x AS vSvp gt NRSv General Safety This pressure washer generates very high fluid pressure Spray from the gun leaks or ruptured components can inject fluid through your skin and into your body and cause extremely serious bodily injury including the need for amputation Also fluid injected or splashed into the eyes or on the skin can cause serious damage NEVER point the spray gun or wand at anyone or at any part of the body NEVER put hand or fingers over the spray tip ALWAYS follow the Pressure Relief Procedure before cleaning or servicing any part of the sprayer NEVER try to stop or deflect leaks with your hand or body Be sure equipment safety devices are operating
35. ngth Loctite on the setscrew threads and tighten the setscrew to lock the gear on the shaft 5 Make sure the gasket is in place refer to step 4 under Replacing the Gasket Install the gear cover on the case aligning the holes and secure it with the nine screws and lockwashers Tighten the screws evenly in a crisscross pattern Grease the engine shaft Align the gear s slot with the key on the engine shaft and slide the gear reducer onto the shaft up to the engine s shoulder 7 Secure the gear reducer to the engine with the four bolts lockwashers and washers PARTS DRAWING Gear Reducer Models 2040 amp 2540 Gear Reducer Models 2040 amp 2540 PARTS LIST REF PART NO NO 1 804 182 2 804 183 3 804 228 4 804 227 5 804 243 6 804 184 7 802 189 8 804 089 9 804 171 10 804 150 11 804 170 12 804 169 13 802 206 14 804 185 15 804 215 16 804 186 17 804 082 18 804 077 DESCRIPTION HOUSING Gear Reducer GEAR Pinion 1 BEARING RING Retaining internal RING Retaining external SEAL Oil pinion O RING Drain Plug PLUG Oil Drain GASKET Oil Sight Gauge GAUGE Sight oil level GASKET Oil Filler Cap CAP Oil Filler WASHER Shim used on Model 2540 only SEAL Oil housing GASKET Flange FLANGE Housing WASHER Flat 6mm WASHER Lock 6mm AK P A da da er REF PART NO NO 19 804 231 20 804 078 21 804 187 22 804 242 23 804 090 24 802 175 25 804 240 26 804 172 27 804 076 28 804 17
36. ock 10mm 2 26 804 121 WASHER Slinger 3 2 804 154 CRANKCASE 1 27 804 208 RETAINER Packing rear 3 3 801 028 O RING Oil Fill Cap 1 28 804 157 WICK Round 3 4 801 027 CAP Oil Fill 1 29 804 129 PLUNGER Ceramic 3 5 804 137 COVER Crankshaft 1 30 804 133 GASKET Copper 3 6 804 123 O RING Crankcase Cover 1 31 804 234 STUD Retaining 3 7 804 155 COVER Crankcase 1 32 801 038 RING Backup 3 8 804 171 GASKET Oil Sight Gauge 1 33 801 039 O RING Plunger 3 9 804 150 GAUGE Sight 1 34 801 040 RETAINER Plunger 3 10 802 189 O RING Drain Plug 1 35 804 214 WASHER Split SST 3 11 804 089 PLUG Drain 1 36 804 200 MANIFOLD 1 12 804 075 WASHER Flat 6mm 12 37 KIT C20 PACKING High Pressure 13 804 077 WASHER Lock 6mm 12 38 KIT C20 O RING Packing Retainer 14 804 238 SCREW Cap hex hd 39 804 207 RETAINER Packing 3 40 KIT C20 PACKING Low Pressure 41 804 232 SCREW Cap socket head 10mm x 35mm 2 42 KIT C2 RING Backup valve seat cross recess 6mm x 20mm 15 804 194 CRANKSHAFT 16 804 080 BEARING 17 804 109 SEAL Oil crankshaft 18 804 124 O RING Crankshaft Cover 43 KIT C2 O RING Valve Seat 19 804 193 COVER Crankshaft 44 KIT C2 SEAT Valve 20 804 237 SCREW Cap hex hd 45 KIT C2 VALVE NN h A cross recess 6mm x 16mm 8 46 KIT C2 SPRING Valve 21 804 209 RETAINER Packing front 3 47 KITC2 RETAINER Valve Spring 22 804 125 ROD Assembly Connecting 3 48 KIT C2 O RING Cap 23 804 156 ROD Plunger 3 49 804 153 CAP Valve 6 24 804 126
37. onsulted 4 308 530 INSTALLATION ZA eg N a Q SK N e L N Sd LT PRESSURE HOSE CONNECTION INLET WATER CONNECTION 3 4 GARDEN HOSE HIGH PRESSURE HOSE CONNECTION INLET WATER CONNECTION 3 4 GARDEN HOSE Figure 1 Check for Shipping Damage Check the unit for any damage that may have occurred in shipping Notify the carrier immediately if there is any damage Set Up If you are using a downstream chemical injector install it between the pump unloader and the high pressure hose using the quick couplers provided Connect the high pressure hose between the pump outlet and the gun inlet Both of these connections are made with quick couplers CAUTION Up to 100 ft 30 m of high pressure hose may be used Longer hoses may af fect sprayer performance and chemical injector performance if used Install the appropriate spray tip on the wand See Installing and Changing Spray T ips If you are using a sandblaster kit see its separate manual for installation instructions HIGH PRESSURE CONNECTION HOSE INLET WATER CONNECTION 3 4 GARDEN HOSE Connect to Water Supply CAUTION Before attaching to the water supply check your local plumbing code regarding cross connection to the water supply A backflow preventer P N 801 133 is available to prevent backflow of contaminated water into the fresh water supply Install it upstream from the pu
38. r injury from moving parts always follow the Pressure Relief Procedure Warning on page 2 before proceeding Replacing the Oil Seal 14 NOTE The oil seal MUST be replaced if removed 1 Follow steps 1 and 3 under Replacing the Gasket 2 Remove the snap ring 6 from the gear case using a snap ring pliers Pull the gear and bearing 3 Push the seal from the inside to the outside of the gear case by placing screwdriver against the seal and lightly tapping it with hammer 4 Wipe the inner surface of the case clean then lightly coat it with grease Place the oil seal into the gear case Use a socket placed against the surface of the seal to push the seal into the case until its top surface is past the ridge in the bore 5 Place the gear and bearing back into the gear case and install the snap ring 6 6 Follow steps 4 through 7 under Assembling the Gear Reducer if this is all the service required Assembling the Gear Reducer 1 Grease the o ring and make sure it s properly placed on the gear cover 2 Placethe four oil seals and screws in the gear cover Place the o ring on the screw to hold it in the cover 3 Apply low strength Loctite blue on the screw threads align the screws with the holes in the pump and tighten the screws oppositely and evenly 4 Grease the pump shaft Align the gear s slot with the key on the pump shaft and slide the gear onto the shaft up to the pump s shoulder Apply low stre
39. s bodily injury including fluid injection splashing in the eyes or on the skin or injury from moving parts always follow the Pressure Relief Procedure Warning before proceeding PROBLEM Engine will not start or J No gasoline in fuel tank or carburetor Fill the tank with gasoline open fuel shut off valve is hard to start Check fuel line and carburetor Low oil Add to proper level Start Stop switch in Stop position Move switch to start position Water in gasoline or old fuel Drain fuel tank and carburetor Use new fuel and dry spark plug Choked improperly Flooded engine Open choke and crank engine several times to clear out gas Dirty air cleaner filter Remove and clean Spark plug dirty wrong gap or wrong type Clean adjust the gap or replace Spray gun closed Trigger spray gun Engine misses or Partially plugged air cleaner filter Remove and clean lacks power Spark plug dirty wrong gap or wrong type Clean adjust the gap or replace Low pressure and or Worn or wrong size tip Replace with tip of proper size pump runs rough Inlet filter clogged Clean Check more frequently Worn packings abrasives in water or Check filter Replace packings See PUMP SERVICE natural wear Inadequate water supply Check water flow rate to pump Fouled or dirty inlet or discharge valves Clean inlet and discharge valve assemblies Check Even a small particle can cause the valve filter to stick Restricted inlet Che
40. seals and or o ring Replace oil seals and or o ring See SERVICE the gear reducer cover SECTION and the pump Oil leakage between Worn oil seal Replace oil seal See SERVICE SECTION the gear reducer case and the engine 308 530 9 PARTS DRAWING 800 698 Hydra Clean 1535 Pressure Washer 10 308 530 PARTS LIST BT 800 698 Hydra Clean 1535 Pressure Washer REF PART REF PART NO NO DESCRIPTION QTY NO NO DESCRIPTION QTY 1 802 239 ENGINE 5 hp Briggs amp 35 801 546 SCREW Cap hex hd Stratton UC 1 3 8 16 x 1 1 4 5 2 800 695 PUMP amp GEAR REDUCER 36 100 023 WASHER Flat 3 8 10 ASSEMBLY incl 3 13 1 39 802 139 AXLE 1 3 804 248 GEAR REDUCER see page 17 1 40 154 636 WASHER Flat 5 8 4 4 802 127 SCREW Cap hex hd 41 106 062 WHEEL amp TIRE ASSEMBLY 2 5 16 18 x 1 3 4 4 42 101 545 PIN Cotter 1 8 x 1 1 2 2 6 100 527 WASHER Flat 5 16 20 43 104 811 HUB CAP 2 7 804 250 BRACKET Support 1 44 801 539 BUMPER 1 8 801 367 BUMPER Rubber 2 45 801 941 REN SU hex hd 11 156 849 NIPPLE Hex 3 8 3 12 802 316 UNLOADER Preset 1500 psi 1 46 111 040 NUT Lock 5 16 18 12 13 804 244 PUMP ASSEMBLY 1500 psi s Een N Se 4 see page 20 1 E incl 64 65 1 is Bn Botoen 7 uo mora ne ASS oss incl 64 16 801 568 QUICK COUPLER Male 3 8 2 50 801 858 BRACKET Front Leg 17 801 620 ELBOW Street 1 4 x 90 1 21 38012504 SEI Kubbur Ee EE 1 52 179 885 LABEL Chassis 1 53 802 781 KEY Square 3 16 x 2 1 20 801 SES NIPPLE
41. t so the two 2 outside plungers are extended and med up 4 Lubricate plungers and discharge valve adapter o rings 5 Carefully line up and join the inlet and discharge manifolds by pressing the protruding discharge valve adapters into the inlet manifold seal chambers 6 Replace all four 4 discharge manifold socket head bolts and washers and hand tighten 7 Then carefully slip manifold assembly onto plungers and tap with soft mallet until flush with crankcase 8 Replace the two 2 inlet manifold socket head bolts and washers and hand tighten Then torque per chart 9 Then torque the four 4 discharge manifold socket head bolts per chart Servicing the Plungers Disassembly 1 Remove discharge and inlet manifold as described 2 Using a wrench loosen plunger retainers approximately three 3 to four 4 turns 3 Grasp ceramic plunger and push towards crankcase until plunger retainers with stud pop out 4 Remove plunger retainer and copper gasket 5 Remove ceramic plunger from plunger rod 6 Remove barrier slinger from plunger rod Reassembly 1 Replace barrier slinger if necessary and onto plunger rod position 2 Carefully examine ceramic plunger for scoring or cracks and replace if worn Slip onto rod NOTE Ceramic plunger can only be installed one direction front to back Do not force onto rod 3 Examine o ring and back up ring on plunger retainer and replace if worn or cut Lubricate o
42. una N cover and tube Bypass Hose Synthetic yarn and EPDM Pressure Washer Anodized aluminum Aluminum or bronze alloys Brass Copper Nylon PTFE e including fittings composite Ceramic Buna N Cotton phenolic 303 304 and 316 Stainless steel Polymide 12 thermoplastic PTFE Carbon steel Zinc with or without yellow chromate plate PTFE isa registered trademark of the DuPont Company 308 530 31 THE GRACO WARRANTY WARRANTY AND DISCLAIMERS Graco warrants all equipment manufactured by it 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 As purchaser s sole remedy for breach of this warranty Graco will for a period of twenty four months from date of sale repair or replace any part of the equipment proven 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 any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility with Graco equipment of structures accessories equipment or materials not supplied by Graco or the improper des
43. ure seal into position by threading seal case into manifold Tighten seal case with key wrench Low Pressure Seal All Models 1 Examine seal for wear or broken spring and lace if necessary Install low pressure seal in seal case with garter spring down Reinstall snap ring Be certain snap ring is a tight fit Replace if it can be easily turned Replace manifold on pump as described and torque per chart Servicing Crankcase Section 1 While manifold plungers and seal retainers are removed examine crankcase seals for wear Check oil level and for evidence of water in oil Rotate crankshaft by hand to feel for smooth bearing movement Examine crankshaft oil seal externally for drying cracking or leaking Consult factory or your local distributor if crankcase service is evidenced Torque Chart Pump Part Thread Tool Size Torque Plunger M5 11 mm hex 80 in lbs Retainer Manifold M8x1 25 13mm hex 125 in Ibs M10 x 1 25 17 mm hex 217 in Ibs M10 17mm hex 217 in lbs Valve 24 mm 75 ft lbs Covers 27 mm 75 ft lbs 308 530 29 ACCESSORIES IT im l L_pz lt p lt upILZL _ _ L L lt LIL I DS Must be purchased separately DOWNSTREAM CHEMICAL INJECTOR KIT 800 117 amp 800 649 For injecting harsh cleaning chemicals downstream from the pump 800 649 is stainless steel construction UPSTREAM CHEMICAL INJECTOR KIT 800 257 For injecting mild cleaning chemicals upstr
44. ve the four bolts lockwashers and washers Pull the pump and gear reducer assembly of f the engine Drain the gear reducer oil by placing a container under it and removing the drain plug with a 22 mm wrench Replace the o ring 15 if damaged Remove the nine screws with a 6 mm wrench and pull the gear case off the gear cover Remove the old gasket 9 Clean the gear cover and case surface Lightly coat the new gasket with grease and install it in on the gear case Follow steps 5 through 7 under Assembling the Gear Reducer if this is all the service required Replacing the Oil Seals 21 1 Follow steps 1 through 3 under Replacing the Gasket Loosen the setscrew using a 4 mm wrench and pull the gear 4 off the pump with a gear puller Using a 6 mm wrench remove the four screws Keep them separate from the other nine screws removed previously Remove the four oil seals 21 and replace them Follow steps 2 through 7 under Assembling the Gear Reducer if this is all the service required Replacing the O Ring 1 1 Follow the instructions under Replacing the Gasket and Replacing the Oil Seals to disassemble the gear reducer Pull the gear cover of f the pump and replace the o ring 1 Follow instructions under Assembling the Gear Reducer if this is all the service required 18 308 530 WARNING To reduce the risk of serious bodily injury including fluid injection splashing in the eyes or on the skin o
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