Graco Inc. 1535 Pressure Washer User Manual
Contents
1.2. Model 2040 800 290 11 308 505 PARTS DRAWING 800 165 8 800 367 Hydra Clean 1535 Pressure Washer 308 505 12 PARTS LIST Emma 800 165 8 800 367 Hydra Clean 1535 Pressure Washer REF PART NO NO 1 800 394 2 179 885 3 802 366 4 802 373 5 802 264 803 239 6 801 024 7 801 025 8 801 023 9 801 090 10 801 007 11 801 009 12 801 202 13 800 184 14 800 374 15 801 499 16 801 015 17 802 277 18 802 127 19 802 269 20 802 266 21 802 265 22 800 173 23 800 174 24 402 278 25 803 083 26 801 729 27 801 730 28 801 957 29 801 935 30 802 363 13 308 505 DESCRIPTION GUN amp WAND ASSEMBLY incl 11 28 29 32 49 LABEL Warning chassis LABEL Identification 1535 LABEL Identification 1535 ENGINE 5 hp Honda OHV ENGINE 5 hp Briggs amp Stratton I C NUT Hex 5 16 18 WASHER Lock 5 16 WASHER Flat 5 16 COUPLER Male 1 4 HOSE High Pressure 50 COUPLER Female 1 4 incl 12 O RING Female Coupler 1 4 HANDLE HOSE ASSEMBLY w Couplers incl 9 10 11 NUT Lock 3 8 16 WASHER Flat 3 8 SCREW Cap hex hd 5 16 18 x 2 1 2 SCREW Cap hex hd 5 16 18 x 1 3 4 CHASSIS GEAR REDUCER see page 15 PUMP ASSEMBLY 1500 psi see page 20 TIP ASSEMBLY 15 Degree incl 9 26 TIP ASSEMBLY 0 Degree incl 9 27 PLUG Plastic LABEL Keep From Freezing TIP Spray 15 Degree TIP Spray 0 Degree SLEEVE 18 WAND 20 LABEL Caution 2 lt lt m
3. Replacing the O Ring 1 Remove the four bolts and lockwashers and the four washers bumpers and bolts Then pull the pump and gear reducer assembly off 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 if damaged Remove the four screws and lockwashers with a 6 mm wrench and pull the gear case of fthe gear cover Remove the old o ring Clean the gear cover and case surface Lightly coat the new o ring with grease and install it in the gear case Follow steps 4 through 6 under Assembling the Gear Reducer if this is all the service required Replacing the Gasket 1 Follow steps 1 through 3 under Replacing the O Ring Using a 4 mm wrench loosen the setscrew and pull the gear off the pump with a gear puller Remove the four screws and lockwashers from the gear cover Remove the gear cover and gasket from the pump Clean the gear cover and pump surface Lightly coat both sides of the gasket with grease and install it on the gear cover Follow the instructions under Assembling the Gear Reducer if this is all the service required Replacing the Oil Seal NOTE The oil seal MUST be replaced if removed 1 2 Follow steps 1 and 2 under Replacing the O Ring Pry the oil seal out of the gear case Be careful not to damage the gear case Wipe the inner surface of the gear case clean then lightly coat it with grease Place
4. Section 2 Carefully pull the packing retainer from the manifold Examine the o ring and replace it if it is cut or damaged 3 Remove the v packing and head ring Pull out the intermediate retainer ring Remove the second v packing and second head ring 4 Inspect all parts and replace as necessary 5 Thoroughly clean the packing cavities and examine 6 Lightly grease the packing cavities and then replace the packings in the following order head ring v packing intermediate ring head ring v packing and packing retainer with the o ring installed in the retainer groove CAUTION Be very sure the parts are installed in the proper order and facing the correct direction See Pump assembly on pages 18 and 20 Improperly installed parts will cause a malfunction 7 Reassemble the manifold as instructed in Servicing the Plungers ACCESSORIES Eta Must be purchased separately DOWNSTREAM CHEMICAL INJECTOR KIT 1535 800 139 DOWNSTREAM CHEMICAL INJECTOR KIT 2040 800 111 For injecting harsh cleaning chemicals downstream from the pump UPSTREAM CHEMICAL INJECTOR KIT 800 257 For injecting mild cleaning chemicals upstream into the pump TECHNICAL DATA BACKFLOW PREVENTOR 801 133 Prevent back up of contaminated water into fresh supply Install upstream of pump ANTI FREEZE FLUSH KIT 802 327 For flushing system with 50 anti freeze solution prior to transporting or storing pressure washer in below
5. 15 1 45 801 907 WASHER Flat 1 11 801 024 NUT Hex 5 16 18 6 46 801 905 ADAPTER 3 8 G x 3 8 NPT 1 12 801 539 BUMPER 1 47 801 868 NIPPLE Hex 3 8 1 13 801 090 COUPLER Male 1 4 4 48 802 315 UNLOADER 2000 psi 1 14 801 007 HOSE High Pressure 50 1 49 801 103 NIPPLE Hex 3 8 x 1 4 2 15 801 009 COUPLER Female 1 4 incl 16 3 50 801 137 KEY Square 1 4 x 2 1 16 801 202 O RING Female Coupler 1 4 3 51 802 124 HOSE Bypass incl 59 1 17 803 350 GUN Spray 1 52 801 523 NIPPLE 1 2 x 2 1 18 801 941 SCREW Cap hex hd 53 801 622 CROSS 1 2 1 5 16 18 x 1 4 54 800 115 VALVE Thermal Relief 1 19 801 935 WAND 20 1 55 800 113 FILTER 1 20 801 235 WASHER Flat 5 8 4 56 801 111 NUT Garden Hose 1 21 801 880 PIN Cotter 1 8 x 1 1 2 2 57 801 110 ADAPTER Garden Hose 1 22 104 811 HUB CAP 2 58 801 112 STRAINER Garden Hose 1 23 106 062 WHEEL amp TIRE ASSEMBLY 2 59 802 627 NIPPLE Hex 3 8 NPSM x 24 802 139 AXLE 1 1 4 NPT 1 25 801 546 SCREW Cap hex hd 60 801 367 BUMPER Rubber 2 3 8 16 x 1 1 4 5 61 802 140 BRACKET Support 1 26 801 015 WASHER Flat 3 8 6 62 801 499 NUT Lock 3 8 16 1 27 801 957 SLEEVE 18 1 63 801 504 BUMPER Rubber 1 28 803 405 PUMP ASSEMBLY 2000 psi 64 801 858 BRACKET Front Leg 1 see page 18 1 65 801 023 WASHER Flat 5 16 14 29 801 541 HANDLE 1 66 100 078 SCREW Cap hex hd 4 30 800 175 FRONT LEG ASSEMBLY incl 25 26 62 63 64 1 31 801 363 WASHER Lock 3 8 4 Model 2040 800 164 32 801 878 NUT Hex 3 8 16 4
6. 2 Remove the screw from the plunger and examine the o ring backup ring and copper bearing gasket washer Replace these parts if necessary using kit 801 474 3 Remove the plunger and flinger from the plunger shaft Clean examine and replace parts as necessary 4 Inspect the plunger shaft for oil leakage from the crankcase If leaking is obvious replace the oil seals Otherwise DO NOT remove these seals as they cannot be reused An oil seal kit is available to replace the seals 5 Lightly grease the flinger and oil seal if it is being replaced and replace them on the plunger shaft Then install the plunger 6 Lightly grease the retaining screw and the outer end of the plunger Place the washer o ring and backup ring around the screw and install the screw through the plunger Torque to 14 4 ft lb 19 5 Nm NOTE f you plan to replace the packings refer to Servicing the V Packings 7 Lubricate the outside of each plunger Slide the manifold onto the crankcase being careful not to damage the seals 8 Install the capscrews and washers finger tight Torque the screws to 21 7 ft Ib 29 Nm following the tightening pattern Figure 4 Uneven tightening may cause the manifold to bind or jam Figure 4 308 505 22 Servicing the V Packings NOTE There are two types of packing kits one is just packings the other includes the packings rings and retainers 1 Remove the manifold as outlined in the Pumping
7. SCREW Cap socket hd Part of kit 1 801 472 Valve Kit Part of kit 2 801 473 Oil Seal Kit Part of kit 3 802 511 Crankshaft Seal Kit Part of kit 4 802 306 Valve Cap Kit Part of kit 6 801 474 Plunger Repair Kit Part of kit 8 801 486 Packing Kit Part of kit 28 801 487 Packing and Retainer Kit 308 505 QTY 1 8 8 N N O1 CO Q O i i A PART NO 803 321 802 345 802 793 vr 803 294 801 652 801 489 801 490 vr vr vr 803 295 803 296 DESCRIPTION COVER Crankcase 2000 psi GAUGE Sight PLUG Oil Drain O RING SCREW Cap socket hd WASHER Lock WASHER Flinger PLUNGER Ceramic RING Backup WASHER SCREW Piston COVER Crankcase SHIM SEAL Oil O RING RETAINER Packing PACKING RING Head RETAINER Packing RING Long Life NOT USED 802 305 802 304 801 482 801 483 801 484 801 485 SCREW Cap socket hd WASHER Lock PLUG Hex WASHER Flat PLUG Hex WASHER Flat QTY 1 1 1 WO O NN PUMP SERVICE Ew WARNING To reduce the risk of serious bodily injury 1 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 NOTE The following metric wrenches are needed M10 M13 and M30 Repair kits are available Refer to the individual repair sections and the pump parts page for more details For the best results use all parts in the k
8. 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 consulted 308 505 4 INSTALLATION HIGH PRESSURE HOSE CONNECTION INLET WATER CONNECTON 3 4 GARDEN HOSE HIGH PRESSURE HOSE CONNECTION INLET WATER CONNECTON 3 4 GARDEN HOSE Figure 1 Check for Shipping Damage The unit should be checked for any damage that may have occurred in shipping Any damage should be noted and the carrier notified immediately 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 Tips If you are using a sandblaster kit see its separate manual for installation instructions 5 308 505 COUPLER SPRAY GUN QUICK SPRAY HOSE Connect to Water Supply CAUTION Before attaching to the water supply check your local plumbing code regarding cross connection to the water sup
9. down and before checking or repairing any part of the system Engage the trigger safety latch Turn the sprayer off Remove the ignition cable from the spark plug 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 MAINTENANCE HEEE 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 respe
10. freezing temperatures INLET PRESSURE REGULATOR 800 258 Regulates inlet water pressure to 60 psi 4 bar maximum Model 800 165 Model 800 367 Model 800 164 Model 800 290 Engine air cooled 4 cycle 5 hp Honda OHV 5 hp Briggs amp 8 hp Briggs amp 8 hp Honda OHV Stratton I C Stratton I C Gasoline Tank Capacity 3 8 quarts 3 6 liter 3 quarts 2 8 liter 6 quarts 5 7 liter 6 2 quarts 6 liter Working Pressure Dimensions Length 37 940 mm Width 19 483 mm Height 20 508 m 37 940 mm 19 483 mm 20 508 mm 36 914 mm 21 533 mm 22 5 572 mm 36 914 mm 21 533 mm 22 5 572 UM Maximum Inlet Water 160 F 70 160 F 70 160 F 70 160 F 70 Temperature Wetted Parts High Pressure Hose Bypass Hose Synthetic yarn and EPDM Pressure Washer including fittings Acrylonitrile and Buna N cover and tube Anodized aluminum Aluminum or bronze alloys Brass Copper Nylon PTFE composite Ceramic Buna N Cotton phenolic 303 304 and 316 Stainless steel Polymide 12 thermoplastic PTFE e Carbon steel Zinc with or without yellow chromate plate PTFE isa registered trademark of the DuPont Company 23 308 505 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 purc
11. 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 308 505 2 EQUIPMENT MISUSE HAZARD SEEN 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 repair 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
12. 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 seals and or o ring Replace oil
13. 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 9 308 505 Da SEN PS E NO AAU NC 903 A N a 4 D PARTS DRAWING i ia 800 164 amp 800 290 Hydra Clean 2040 Pressure Washer 10 308 505 PARTS LIST E 800 164 amp 800 290 Hydra Clean 2040 Pressure Washer REF PART REF PART NO NO DESCRIPTION QTY NO NO DESCRIPTION QTY 1 800 394 GUN 8 WAND ASSEMBLY 33 800 176 CHASSIS 1 incl 15 17 19 27 49 1 34 801 548 GROMMET Rubber 4 2 802 257 GUARD Muffler Briggs amp 35 800 173 TIP ASSEMBLY 15 Degree Stratton 1 incl 13 39 3 802 367 LABEL Identification 2040 1 36 800 174 TIP ASSEMBLY 0 Degree 4 802 363 LABEL Caution 1 incl 13 40 1 5 802 368 LABEL Identification 2040 1 37 402 278 PLUG Plastic 1 6 179 885 LABEL Warning chassis 1 38 803 083 LABEL Keep From Freezing 1 7 802 141 ENGINE 8 hp Briggs 39 801 729 TIP Spray 15 Degree 1 Stratton I C 1 40 801 730 TIP Spray 0 Degree 1 802 998 ENGINE 8 hp Honda OHV 1 41 802 143 GEAR REDUCER see page 17 1 8 802 127 SCREW Cap hex hd 42 181 867 LABEL Warning ventilation 1 5 16 18 x 1 3 4 4 43 802 299 PUMP 8 GEAR REDUCER 9 801 025 WASHER Lock 5 16 10 ASSEMBLY incl 28 41 1 10 800 374 HOSE ASSEMBLY w Couplers 44 801 709 PLUG Square hd 1 4 1 incl 13 14
14. 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 Follow steps 4 through 6 under Assembling the Gear Reducer if this is all the service required Assembling the Gear Reducer 1 Make sure the gasket is properly placed on the gear cover Refer to step 4 under Replacing the Gasket Then install the gear cover on the pump shaft Align the holes in the gear cover with the holes in the pump Apply low strength Loctite blue on the screw threads and secure the cover with the four screws and lockwashers T ighten them oppositely and evenly 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 strength Loctite 9 on the setscrew threads and tighten the setscrew to lock the gear on the shaft Make sure the o ring is in place Refer to step 4 under Replacing the O Ring Install the gear case on the cover aligning the holes and secure it with the four screws and lockwashers T ighten them oppositely and evenly 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 Secure the gear reducer to the engine with the four bolts and lockwashers 308 505 14 PARTS DRAWING 802 266 Gear Reducer 1535 PARTS LIST 802 266 Gear Reducer 1535 RE
15. 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 Ew 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 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 h
16. 0 803 267 SPACER 1 46 NOT USED 21 803 268 O RING 2 47 802 317 WASHER Lock 2 22 803 269 BEARING Ball 2 48 802 318 SCREW Cap socket hd 2 23 803 326 CRANKCASE 1 49 801 484 PLUG Hex 1 24 801 659 DIPSTICK 1 50 801 482 PLUG Hex 1 25 803 327 GASKET Cover 1 51 801 483 WASHER Flat 1 26 802 526 COVER Crankcase 1 52 801 485 WASHER Flat 1 Part of kit 1 801 472 Valve Kit Part of kit 4 802 306 Valve Cap Kit Part of kit 6 801 474 Plunger Repair Kit Part of kit 19 801 662 Packing Kit Part of kit 23 801 658 Oil Seal Kit Part of kit 27 801 664 Packing and Retainer Kit alex 19 308 505 PARTS DRAWING 803 405 Pump Assembly 2000 psi Fee 308 505 20 PARTS LIST ann 803 405 Pump Assembly 2000 psi REF a PAPKA z 0 N 9 01 Q N OQ 9 N 9 0I N 6 N NN N WN N ND DP N NOO R x e 21 PART NO 801 467 801 468 801 469 803 283 803 284 802 500 803 285 803 286 802 895 801 475 803 144 803 332 803 288 802 794 803 289 803 323 803 291 803 273 DESCRIPTION MANIFOLD 2000 psi SCREW Cap hex hd WASHER Lock O RING SEAT Valve PLATE Valve SPRING GUIDE Valve O RING CAP VALVE ASSEMBLY SCREW Cap socket hd COVER Crankcase O RING Crankcase Cover BEARING Tapered Roller SEAL Oil BUSHING Piston CRANKCASE DIPSTICK GASKET Cover CRANKSHAFT 2000 psi RING Retaining KEY PIN Wrist GUIDE Piston 2000 psi ROD Connecting
17. F PART NO NO DESCRIPTION 1 802 350 GASKET 2 802 351 COVER Mounting 3 802 334 SCREW Set 4 802 352 GEAR Pump 5 802 353 O RING 6 801 659 DIPSTICK 7 802 354 CASE Mounting 8 801 023 WASHER Lock 9 802 342 SCREW 10 802 355 SEAL Oil 11 802 356 RING Snap 12 802 357 RING Snap 13 802 358 BEARING 14 802 359 GEAR Engine 15 801 484 CAP G 3 8 BSP 16 802 344 O RING 17 802 345 GAUGE Sight 18 802 331 BOLT 5 16 24 x 1 19 802 360 SCREW 20 801 139 WASHER Lock 15 308 505 O GEAR REDUCER SERVICE 2040 Ez 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 Gasket NOTE To maintain a good seal the gasket must be replaced whenever the gear reducer is disassembled Remove the four bolts and lockwashers washers and 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 if damaged Remove the nine screws with a 6 mm wrench and pull the gear case off the gear cover Remove the old gasket 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 al
18. INSTRUCTIONS PARTS LIST 308 505 Rev A GRACO Supersedes 802 133 amp This manual contains IMPORTANT 802 278 WARNINGS and INSTRUCTIONS READ AND RETAIN FOR REFERENCE HYDRA CLEAN 1535 2040 Pressure Washer P N 800 165 Series B P N 800 367 Series A 1500 psi 103 bar OPERATING PRESSURE 1900 psi 131 bar MAXIMUM WORKING PRESSURE P N 800 164 Series C P N 800 290 Series B 2000 psi 138 bar OPERATING PRESSURE 2400 psi 165 bar MAXIMUM WORKING PRESSURE GRACO INC P O Box 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1989 GRACO INC 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 iii 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 proper
19. Pump 1 5 802 336 GEAR Engine 1 6 802 337 RING Snap 1 7 802 338 BEARING 1 8 802 339 RING Snap 1 9 802 340 GASKET 1 10 801 475 DIPSTICK 1 11 802 341 CASE Mounting 1 12 801 023 WASHER Lock 13 13 802 342 SCREW 9 14 802 343 SEAL Oil 1 15 802 344 O RING 1 16 801 484 CAP G 3 8 BSP 1 17 802 345 GAUGE Sight 1 18 801 025 WASHER Flat 4 19 802 331 BOLT 5 16 24 x 1 4 20 802 346 SCREW 4 21 802 347 SEAL Oil 4 17 308 505 PARTS DRAWING aa 802 265 Pump Assembly 1500 psi 308 505 18 PARTS LIST an 802 265 Pump Assembly 1500 psi REF PART REF PART NO NO DESCRIPTION QTY NO NO DESCRIPTION QTY 1 802 319 MANIFOLD 1500 psi 1 27 803 273 SCREW Cap socket hd 5 2 801 651 SCREW Cap socket hd 8 28 vr O RING 3 801 652 WASHER Lock 8 29 802 345 GAUGE Sight 1 4 O RING 30 802 793 PLUG Oil Drain 1 5 SEAT Valve 31 803 328 CRANKSHAFT 1 6 PLATE Valve 32 803 275 PIN Wrist 3 7 SPRING 33 802 794 KEY 1 8 GUIDE Valve 34 803 276 ROD Connecting 3 9 e O RING 35 803 277 WASHER Flat 6 10 e CAP 36 803 278 WASHER Lock 6 11 VALVE ASSEMBLY 37 803 279 SCREW Cap socket hd 6 12 He PACKING 38 803 330 GUIDE Piston 3 13 RETAINER Packing 39 801 489 WASHER Flinger 3 14 RING Head 40 801 661 PLUNGER Ceramic 3 15 RETAINER Packing 41 vr RING Backup 16 O RING 42 vr WASHER 17 SEAL Oil 43 vr SCREW Piston 18 803 265 SCREW Cap hex hd 8 44 803 281 SPACER 1 19 803 266 COVER Crankcase 2 45 803 282 SEAL Crankshaft 1 2
20. WW m mi A QO QO QO 1 1 2 6 2 1 1 1 mm m m gt gt REF NO 31 PART NO 803 245 803 350 181 867 801 504 801 546 802 273 801 235 106 062 801 880 104 811 802 267 801 012 802 300 801 709 801 868 801 905 801 907 802 316 801 103 802 124 801 523 801 622 800 115 800 113 801 111 801 110 801 112 802 627 801 137 DESCRIPTION GUARD Muffler Briggs amp Stratton GUN Spray LABEL Warning ventilation BUMPER Rubber SCREW Cap hex hd 3 8 16 x 1 1 4 AXLE WASHER Flat 5 8 WHEEL amp TIRE ASSEMBLY PIN Cotter 1 8 x 1 1 2 HUB CAP BRACKET Support GROMMET Rubber PUMP 8 GEAR REDUCER ASSEMBLY incl 20 21 PLUG Square hd 1 4 NIPPLE Hex 3 8 ADAPTER 3 8 G x 3 8 NPT WASHER Flat UNLOADER 1500 psi NIPPLE Hex 3 8 x 1 4 HOSE Bypass incl 58 NIPPLE 1 2 x 2 CROSS 1 2 VALVE Thermal Relief FILTER NUT Garden Hose ADAPTER Garden Hose STRAINER Garden Hose NIPPLE Hex 3 8 NPSM x 1 4 NPT KEY Square 1 4 x 2 Model 1535 800 367 Model 1535 800 165 2 lt A NIN IN Sn ss fl ak lt k mm GEAR REDUCER SERVICE 1535 ia 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
21. ap ring 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 placed on the gear cover s properly Place the four oil seals and screws in the gear cover Place the o ring on the screw to hold it in the cover 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 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 strength Loctite on the setscrew threads and tighten the setscrew to lock the gear on the shaft 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 T ighten 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 Secure the gear reducer to the engine with the four bolts lockwashers and washers 308 505 16 PARTS DRAWING 802 143 Gear Reducer 2040 KR DA 20 5 PARTS LIST 802 143 Gear Reducer 2040 REF PART NO NO DESCRIPTION QTY 1 802 332 O RING 1 2 802 333 COVER Mounting 1 3 802 334 SCREW Set 1 4 802 335 GEAR
22. atch whenever you stop spraying even for a moment to reduce the 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 T urn of fthe 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 308 505 6 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 t
23. ctive break in periods the interval between required changes is longer If the unit 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 What to 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 Change gear reducer oil Use SAE 90 gear oil Each 100 hours Clean or replace paper air of operation cleaner cartridge Tap gently to or 3 months remove dirt Change engine oil Use SAE 30 or 10W 30 Each 500 hours Change pump oil Use SAE 20 of operation or 30 non detergent oil Change or 6 months gear reducer oil Use SAE 90 gear oil 308 505 8 TROUBLESHOOTING CHART Ez WARNING To reduce the risk of serious bodily injury including fluid injection splashing in the eyes
24. haser 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 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 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 transportatio
25. he gun from being triggered accidentally by hand or if it is dropped or bumped Be sure the latch is pushed 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 7 308 505 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 Pointthe 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 anew 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 SHUTDOWN FLUSHING AND STORAGE WARNING PRESSURE RELIEF PROCEDURE To reduce the risk of serious bodily injury A 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
26. its There are two dif ferent tool kits to aid in servicing the pump P N 800 298 is used to ease installation of packings P N 800 271 includes the items in 800 298 and tools to aid in the removal of packing retainers NOTE Valves NOTE Fora set of six valves order P N 801 472 1 Remove the hex plug from the manifold using an M30 wrench 2 Examine the o ring under the hex plug and replace itif itis cut or distorted 3 Remove the valve assembly from the cavity the assembly may come apart 4 Install the new valve Install the o ring and hex plug torque to 75 ft Ib 103 Nm NOTE Retorque the plug after 5 hours of operation Pumping Section 1 Remove the eight capscrews and lockwashers from the manifold using an M13 wrench 2 Carefully separate the manifold from the crankcase NOTE It may be necessary to tap the manifold lightly with a soft mallet to loosen CAUTION Keep the manifold properly aligned with the ceramic plungers when removing to avoid damage to the plunger or seals 3 Carefully examine each plunger for any scoring or cracking and replace as necessary Servicing the Plungers NOTE Plunger repair kit P N 801 474 is available to replace retainers o rings washers and backup rings for three cylinders 1 Loosen the plunger retaining screw five to six turns using an M10 wrench Push the plunger towards the crankcase to separate the plunger and retaining Screw
27. l the service required Replacing the Oil Seals 1 Follow steps 1 through 3 under Replacing the Gasket Loosen the setscrew using a 4 mm wrench and pull the gear off the pump with a gear puller Using a 6 mm wrench remove the four screws Be sure to keep them separate from the other nine Screws removed previously Remove the four oil seals 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 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 Follow instructions under Assembling the Gear Reducer if this is all the service required Replacing the Oil Seal NOTE The oil seal MUST be replaced if removed 1 2 Follow steps 1 and 3 under Replacing the Gasket Remove the snap ring from the gear case using a snap ring pliers Pull the gear and bearing 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 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 Place the gear and bearing back into the gear case and install the sn
28. ly 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 Injection 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 Engage the 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 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 bodily
29. n DISCLAIMERS AND LIMITATIONS THE TERMS OF THIS W ARRANTY CONSTITUTE THE PURCHASER S SOLE AND EXCLUSIVE REMEDY AND ARE IN LIEU OF ANY OTHER WARRANTIES 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 EXPRESSL Y 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 NOW ARRANTY AND DISCLAIMS ALL IMPLIED W ARRANTIES OF MERCHANTABILITY AND FITNESS FORA P ARTICULAR PURPOSE WITH RESPECTT 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 warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties Factory Branches Atlanta Chicago Dallas Detroit Los Angeles West Caldwell N J Subsidiary and Affiliate Companies Canada England Switzerland France Germany Hong Kong Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 PRINTED IN U S A 308 505 10 89 308 505 24
30. n the water supply CAUTION Never run the unit dry Costly damage 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 and be sure the spark plug ignition cable is pushed firmly onto the spark plug On those units equipped with an ignition shutoff switch the switch should be in the on position Throttle should be in the run position 6 Startthe engine NOTE For easier starting have one person start the pressure washer while another person triggers the spray gun 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 7 ALWAYS engage the gun s trigger safety l
31. or on the skin or injury from moving parts always follow the Pressure Relief Procedure Warning before proceeding PROBLEM Engine will not start or 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 on units with low oil sensor 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 drv spark plug Choked improperiv Flooded engine Open choke and crank engine several times to clear out gas Dirtv 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 Check garden hose may be collapsed
32. oses 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 orbelow 40 F 40 C FUEL AND EMISSION HAZARDS iii 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 3 308 505 NEVER alter the throttle setting which is factory set Tampering with this adjustment can damage the pressure washer and will void the warranty MOVING PARTS HAZARD Eta Moving parts can pinch or amputate fingers or other Pressure Relief Procedure before checking or body parts KEEP CLEAR of moving parts when starting servicing the pressure washer to prevent discharging or operating the pressure washer high pressure fluid from the gun NEVER operate the pressure washer without all guards and interlocks installed and functioning Follow the aa 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 or destruction of equipment IMPORTANT United
33. ply 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 pump 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 temperature F 70 O inlet water 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 STARTUP Ez Use this procedure whenever starting the pressure washer to help insure that the unit is ready to operate and starting is done safely 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 as necessary NOTE Some units are equipped with a low oil sensor that shuts the engine of fif 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 o
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