Graco 1535, 2030, 2540, 3040, 2835 Instructions-parts List Manual

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Page 1

INSTRUCTIONS–PARTS LIST

308572

This manual contains important warnings and information. READ AND KEEP FOR REFERENCE.

INSTRUCTIONS

Direct-Drive Pressure Washers

1535

Model 804506, Series A

1500 psi (102 bar, 10.2 MPa) Operating Pressure 1900 psi (131 bar, 13.1 MPa) Maximum Working Pressure

2030

Model 804532, Series A

2000 psi (138 bar, 13.8 MPa) Operating Pressure 2400 psi (165 bar, 16.5 MPa) Maximum Working Pressure

2540

Model 804507, Series A

2500 psi (172 bar, 17.2 MPa) Operating Pressure 2900 psi (200 bar, 20.0 MPa) Maximum Working Pressure

Rev. P

First choice when

quality counts.t

2835

Model 804583, Series A

2800 psi (193 bar, 19.3 MPa) Operating Pressure 3200 psi (221 bar, 22.1 MPa) Maximum Working Pressure

3040

Model 804508, Series A

3000 psi (210 bar, 21.0 MPa) Operating Pressure 3400 psi (234 bar, 23.4 MPa) Maximum Working Pressure

Related Manual

Hydra-CleanR Gun 308511. . . . . . . . . . . . . . . .

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

7329B

1535 Pressure Washer

Model 804506

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

Page 2

Table of Contents

Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Relief Procedure 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Service

1535 and 2030 Pressure Washers 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2540, 2835, and 3040 Pressure Washers 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Lists and Drawings

1535 and 2030 Pressure Washers 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2540 and 3040 Pressure Washers 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2835 Pressure Washer 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Assembly for 1535 and 2030 Pressure Washers 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Assembly for 2540, 2835, and 3040 Pressure Washers 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessories 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Warranty 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Phone Number 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning Symbol

WARNING

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

WARNING

INJECTION HAZARD

Spray from the gun, leaks, or ruptured components can inject fluid into your body and cause serious injury. Fluid splashed in the eyes or on the skin can also cause serious injury.

D Fluid injected into the skin might look like just a cut, but it is a serious injury. Get emergency

medical attention.

D Do not point the gun at anyone or at any part of the body.

D Do not stop or deflect leaks with hand, body, glove, or rag.

D Do not put your hand or fingers over the spray tip.

D Tighten fluid connections before you start this equipment.

Caution Symbol

CAUTION

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

D Engage the gun trigger safety whenever you stop spraying.

D Follow Pressure Relief Procedure on page 5 if the spray tip clogs and before you clean, check,

or service this equipment.

D Repair or replace worn or damaged parts immediately.

D Check hoses, tubes, and coupling daily. Do not repair high-pressure couplings. Replace the entire

hose. Fluid hoses must have spring guards on both ends to prevent kinks and rupture.

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WARNING

HAZARDOUS FLUIDS

Improper handling of hazardous fluids can cause serious injury or death due to splashing in eyes, ingestion, or bodily contamination.

D Know the specific hazards of the fluid being used.

D Store hazardous fluids in approved containers. Dispose of hazardous fluids per local, state, and

national guidelines.

D Wear protective eye wear, gloves, clothing, and respirator as recommended by the fluid

manufacturer.

FUEL HAZARD

The fuel used in this pressure washer is combustible. When spilled on a hot surface, it can ignite and cause a fire.

Do not fill the fuel tank while the engine is running or hot.

EXHAUST HAZARD

The exhaust contains poisonous carbon monoxide, which is colorless and odorless.

Do not operate this equipment in a closed building.

EQUIPMENT MISUSE HAZARD

Misuse of the pressure washer or accessories could cause them to rupture and result in fluid injection, splashing in the eyes or on the skin, or other serious injury.

D Do not alter or modify any part or factory-set adjustment of this equipment.

D Do not exceed the maximum working pressure of any component or accessory in the system.

D Do not use any chemicals that are incompatible with the wetted parts as stated in Technical Data

on page 25.

D Do not alter the throttle setting.

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gun

Setup

hose rack

wand

high-pressure hose

inlet water connection:

Check for Shipping Damage

Check the pressure washer for shipping damage. Notify the carrier immediately if there is any damage.

Connect High-Pressure Hose and Gun

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 could affect pressure washer and chemical injector performance.

Install Spray Tip

Install the appropriate spray tip on the wand. See Installing and Changing Spray Tips on page 6. If you are using a Sandblaster Kit, see its separate manual for installation instructions.

7329B

high-pressure hose connection

3/4-in. garden hose

Connect to Water Supply

CAUTION

Before you connect the garden hose to the pressure washer, check your local plumbing code regarding cross-connection to the water supply. If required, install a backflow preventer.

If the inlet water pressure is over 60 psi (4.1 bar), a regulating water valve 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-in. (19 mm) ID from the water supply to the 3/4 in. garden hose inlet on the pressure washer. The supply hose should not be more than 50 ft (15 m) long.

NOTE: The water source must have a minimum flow rate equal to that of the pressure washer. See Technical Data on page 25.

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Pressure Relief Procedure

WARNING

INJECTION HAZARD

The system pressure must be manually relieved to prevent the system from

starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you

D Are instructed to relieve the pressure D Stop spraying for more than 10 minutes D Check or service any of the system equipment D Install or clean the spray nozzle

Operation

Startup

Always use this startup procedure to ensure that the pressure washer is started safely and properly.

D Always engage the gun trigger safety latch when

you stop spraying even for a moment. This reduces the risk of fluid injection or splashing in the eyes or on the skin if the gun is bumped or triggered accidentally.

D Always observe the CAUTIONS in this section to

avoid costly damage to the pressure washer.

D If you use the Sandblaster Kit, see the Sandblaster

Kit manual for detailed cleaning information.

1. Check the oil level.

NOTE: All pressure washers are equipped with a low-oil sensor that shuts the engine off if the oil level falls below a certain level. If the engine stops unexpectedly, check the oil and the fuel levels. Check the oil level each time you add fuel.

2. Check fuel level.

WARNING

FIRE HAZARD

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.

1. Engage the trigger safety latch.

2. Turn the pressure washer off, and remove the ignition cable from the spark plug.

4. Shut off the water supply.

5. Disengage the trigger safety latch, and trigger the gun to relieve pressure. Then engage the trigger safety latch.

If you suspect that the spray tip or hose is clogged or that pressure has not been fully relieved after following the steps above: Disengage the trigger safety latch,

and trigger the gun to relieve pressure. Wrap a rag around the hose end coupling, and VERY SLOWLY loosen the coupling to relieve pressure gradually. Then loosen it completely. Then clear the tip or hose.

3. Turn on the water supply.

CAUTION

Never run the pressure washer without water. Costly damage to the pump will result. Always be sure the water supply is completely turned on before you run the pressure washer.

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. Put the switch in the START position, and put the throttle in the RUN position.

CAUTION

Do not allow the pressure washer to idle for more than 10 minutes. Doing so could cause the recirculating water to overheat and seriously damage the pump. Turn off the pressure washer if it will not be spraying at least every 10 minutes. If heated inlet water is used, reduce this time more. 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 the pump or damage the cylinders. Keep the screen clean. Do not pump caustic materials; such materials could corrode the pump components.

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Operation

6. Pull the starter rope to start the engine. Brace one foot on the pressure washer chassis, and pull the starter rope out quickly. Pull and return the rope until the engine starts.

CAUTION

Do not allow the starter rope to snap back against the engine. Let the rope recoil gently to prevent damage to the recoil.

NOTE: For easier starting, have one person start the pressure washer while another person triggers the gun.

If the engine is cold, start the engine with the choke completely closed. In cool weather, you might have to let the engine run with the choke closed for the first 10 to 30 seconds. In warm weather, open the choke completely as soon as the engine starts.

If the engine is warm, start the engine with the choke completely open or partially closed. When the engine starts, open the choke completely.

Trigger Safety Latch

WARNING

To reduce the risk of serious bodily injury, including fluid injection and splashing in the eyes or on the skin, always engage the trigger safety latch when you stop spraying even for a moment. When engaged, the trigger safety latch prevents the gun from being triggered accidentally by hand or when dropped or bumped. Be sure the latch is pushed fully down, or it will not prevent the gun from being triggered. See Fig. 1.

Chemical Injector Operation

2. Insert the chemical filter (attached with clear tubing to the chemical injector) into the container of chemical.

3. Install the black large-orifice chemical tip. See Installing and Changing Spray Tips below.

The large orifice of the chemical tip causes a drop in pressure that actuates the chemical injector. Changing back to a small-orifice spray tip deactivates the chemical injector and produces high pressure for rinsing. The chemical filter can be left in the chemical container during high-pressure use. To regulate the flow rate of the chemical, turn the chemical adjustment knob on the injector. Maximum chemical flow is a full two turns counterclockwise from the CLOSED (clockwise) position.

Relieve the pressure.

See page 5.

Installing and Changing Spray Tips

Spray tips have 4- or 5-digit numbers on them. The first two digits are the spray angle. Select the spray tip appropriate for your application. Tip holding holes are provided on the chassis.

Spray Tip Number

00XXX 0_ blaster (red)

15XXX 15_ (yellow)

25XXX 25_ (green)

40XXX 40_ (white)

NOTE: The chemical injector tip is brass and has a large opening and a black plastic cap.

Spray Pattern Fan Angle

Trigger Safety Latch

engaged

Fig. 1

6 308572

disengaged

04612

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 current tip, and install a different one. Then push back the ring. See Fig. 2.

Relieve the pressure.

See page 5.

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Operation

4. Pull on the tip to be sure the tip is secure before you spray again.

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.

04929

Fig. 2

Shutdown, Flushing, and Storage

CAUTION

If water freezes in the pressure washer, thaw it in a warm room before you try to start it. Do not pour hot water on or into the pump; it could crack the ceramic plungers.

D 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 pressure washer with a 50% antifreeze solution, and relieve the pressure. Flush the pressure washer before you use it again to remove the antifreeze.

D Before you store the pressure washer overnight or

transport it, disconnect the water supply, and turn off the fuel supply valve.

Maintenance

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 and pump. After you change the oil in these components following their respective break-in periods, the interval between required changes is longer.

If the pressure washer operated in dusty conditions, these maintenance checks should be made more often.

Maintenance Chart

Relieve the pressure

(see page 5) before you proceed with maintenance.

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

After every 25 hours of operation

After first 50 hours of operation

After every 100 hours of operation, or every 3 months

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.

Change pump break-in oil. Use SAE 20 or 30 non-detergent oil.

Clean or replace paper air cleaner cartridge. Tap gently to remove dirt. Change engine oil. Use SAE 30 or 10W–30 detergent oil.

D After each use, wipe all surfaces of the pressure

washer with a clean, damp cloth.

D Perform the appropriate maintenance. See

Maintenance Chart at right.

After every 500 hours of operation, or every 6 months

Change pump oil. Use SAE 20 or 30 non-detergent oil.

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Troubleshooting

Relieve the pressure (see page 5) before you proceed with troubleshooting.

Problem Cause Solution

Engine will not start or is hard to start.

Engine misses or lacks power.

Pressure is too low, and/or pump runs roughly.

No gasoline in fuel tank or carburetor Fill the tank with gasoline, and open fuel shutoff valve.

Check fuel line and carburetor.

Low oil Add oil to proper level.

Start/Stop switch in STOP position Move switch to START position.

Water in fuel, or old fuel Drain fuel tank and carburetor. Use new fuel, and

make sure spark plug is dry.

Engine flooded or improperly choked Open choke, and pull engine starter rope several

times to clear out fuel. Make sure spark plug is dry.

Dirty air cleaner filter Remove and clean.

Spark plug dirty, wrong gap, or wrong type

Gun not triggered Trigger gun while starting engine.

Partially plugged air cleaner filter Remove and clean.

Spark plug dirty, wrong gap, or wrong plug type

Worn or wrong size tip Replace with tip of proper size.

Clean, adjust the gap, or replace.

Water leaks from under pump manifold.

There is water on oil side of pump.

Inlet filter clogged Clean. Check more frequently.

Worn packings, abrasives in water, or 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

Restricted inlet Garden hose might be collapsed or kinked.

Worn inlet or discharge valves Replace worn valves. See Pump Service on pages

Leaking high-pressure hose Replace high-pressure hose.

Worn packings Install new packings. See Pump Service on pages

Humid air condensing inside crankcase Change oil as specified in Maintenance Chart on

Worn packings Install new packings. See Pump Service on pages

Oil seals leaking Install new oil seals. See Pump Service on pages

Check filter. Replace packings. See Pump Service on pages 10 and 12.

filter.

10 and 12.

page 7.

10 and 12.

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Page 9

Troubleshooting

Problem Cause Solution

Packings are failing frequently or prematurely.

There is strong surging at inlet and low pressure on discharge side.

Scored, damaged, or worn plungers Install new plungers. See Pump Service on pages

10 and 12.

Abrasive material in the fluid being pumped

Inlet water temperature too high Check water temperature. It should not exceed 160_F

Overpressurizing pump Do not modify any factory-set adjustments. See

Excessive pressure due to partially plugged or damaged tip

Pump running too long without spraying Never run pump more than 10 minutes without

Running pump dry Do not run pump without water.

Foreign particles in inlet or discharge valve, or worn inlet and/or discharge valves

Install proper filtration on pump inlet plumbing.

(70_C).

Equipment Misuse Hazard on page 3.

Clean or replace tip. See Installing and Changing Spray Tips on page 6.

spraying.

Clean or replace valves. See Pump Service on pages 10 and 12.

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Page 10

Pump Service: 1535 and 2030 Pressure Washers

Repair kits are available. See the individual repair sections, the Parts Lists on pages 15 to 23, and Pump Repair Kits on pages 21 and 23. For the best results, use all parts in the kits.

Relieve the pressure

(see page 5) before you proceed with service.

NOTES:

D The following metric wrenches are needed: 5 mm,

13 mm, and 22 mm.

D There is a tool kit to aid in servicing the pump.

Tool Kit 800271 includes tools to aid in removing packing retainers.

Valves

NOTE: For a set of six valves, order Valve Assembly

Kit 801472.

1. Remove the hex plug from the manifold using a 22 mm socket.

2. Examine the O-ring under the hex plug, and replace if cut or distorted.

3. Remove the valve assembly from the cavity; the assembly might come apart.

4. Install the new valve. Install the O-ring and hex plug. Torque to 33 ft-lb (45 NSm).

NOTE: Retorque the plug after 5 hours of operation.

Servicing the Plungers

NOTE: Plunger Repair Kit 801474 is available to

replace retainers, O-rings, washers, and backup rings for three cylinders.

1. Loosen the plunger retaining nut five or six turns using a 13 mm wrench. Push the plunger towards the crankcase to separate the plunger and retaining screw.

2. Remove the nut from the plunger, and examine the O-ring, backup ring, and copper bearing/gasket washer. Replace these parts if necessary using Plunger Repair Kit 801474.

3. Remove the plunger and flinger from the plunger shaft. Clean 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, because they cannot be reused. Oil Seal Kits are available for replacing the seals. See Pump Repair Kits on page 21.

5. Lightly grease the flinger (and oil seal if it is being replaced), and replace on the plunger shaft. Then install the plunger.

Pumping Section

1. Remove the eight capscrews and lockwashers from the manifold using a 5 mm wrench.

2. Carefully separate the manifold from the crankcase.

NOTE: You might have to tap the manifold lightly with a soft mallet to loosen it.

CAUTION

To avoid damage to the plunger or seals, keep the manifold properly aligned with the ceramic plungers when you remove it.

3. Carefully examine each plunger for any scoring or cracking, and replace as necessary.

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Page 11

Pump Service: 1535 and 2030 Pressure Washers

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 nut through the plunger. Torque to 11 ft-lb (15 NSm).

NOTE: If you plan to replace the packings, see Servicing the V-packings at right.

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 8.8 ft-lb (12 NSm) following the tightening pattern (Fig. 3). Uneven tightening could cause the manifold to bind or jam.

Fig. 3

9278

Servicing the V-Packings

NOTE: There are two types of packing kits: One is

packings only. The other includes the packings, rings, and retainers.

1. Remove the manifold as outlined in Pumping Section on page 10.

2. Carefully pull the packing retainer from the manifold. Examine the O-ring, and replace if 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 for debris or damage.

6. Lightly grease the packing cavities, and replace the packings in the following order: head ring, V-packing, intermediate ring, head ring, V-packing, packing retainer. Install the O-ring in the retainer groove.

CAUTION

Install the parts in the proper order and facing the proper direction. Improperly installed parts will cause a malfunction.

7. Reassemble the manifold as instructed in Servicing the Plungers on page 10.

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Pump Service: 2540, 2835, and 3040

Pressure Washers

Repair kits are available. See the individual repair sections, the Parts Lists on pages 15 to 23, and Pump Repair Kits on pages 21 and 23. For the best results, use all parts in the kits.

Relieve the pressure

(see page 5) before you proceed with service.

NOTES:

D The following metric wrenches are needed: 6 mm,

13 mm, and 27 mm.

D There is a tool kit to aid in servicing the pump.

Tool Kit 800271 includes tools to aid in removing packing retainers.

Valves

NOTE: For a set of six valves, order Valve Assembly

Kit 804402.

1. Remove the hex plug from the manifold using a 27 mm socket.

2. Examine the O-ring under the hex plug, and replace if cut or distorted.

3. Remove the valve assembly from the cavity; the assembly might come apart.

Servicing the Plungers

NOTE: Plunger Repair Kit 243430 is available to

replace retainers, O-rings, washers, and backup rings for three cylinders.

1. Loosen the plunger retaining nut five or six turns using a 13 mm wrench. Push the plunger towards the crankcase to separate the plunger and retaining screw.

2. Remove the nut from the plunger, and examine the O-ring, backup ring, and copper bearing/gasket washer. Replace these parts if necessary using Plunger Repair Kit 243430.

3. Remove the plunger and flinger from the plunger shaft. Clean and replace parts as necessary.

4. Install the new valve. Install the O-ring and hex plug. Torque to 73 ft-lb (99 NSm).

NOTE: Retorque the plug after 5 hours of operation.

Pumping Section

1. Remove the eight capscrews and lockwashers from the manifold using a 6 mm wrench.

2. Carefully separate the manifold from the crankcase.

NOTE: You might have to tap the manifold lightly with a soft mallet to loosen it.

CAUTION

To avoid damage to the plunger or seals, keep the manifold properly aligned with the ceramic plungers when you remove it.

3. Carefully examine each plunger for any scoring or cracking, and replace as necessary.

5. Lightly grease the flinger (and oil seal if it is being replaced), and replace on the plunger shaft. Then install the plunger.

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Page 13

Pump Service: 2540, 2835, and 3040

Pressure Washers

NOTE: If you plan to replace the packings,see Servicing the V-packings at right.

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 22 ft-lb (30 NSm) following the tightening pattern (Fig. 4). Uneven tightening could cause the manifold to bind or jam.

Servicing the V-Packings

NOTE: There are two types of packing kits: One is

packings only. The other includes the packings, rings and retainers.

1. Remove the manifold as outlined in Pumping Section on page 12.

2. Carefully pull the packing retainer from the manifold. Examine the O-ring, and replace if 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 for debris or damage.

Fig. 4

9278

CAUTION

Install the parts in the proper order and facing the proper direction. Improperly installed parts will cause a malfunction.

7. Reassemble the manifold as instructed in Servicing the Plungers on page 12.

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Page 14

Parts: 1535 and 2030 Pressure Washers

Model 804506, Series A: 1535 Pressure Washer Model 804532, Series A: 2030 Pressure Washer

25,26,27,42,43

161011

1 Apply sealant to threads

Supplied with pump

Supplied with engine

Supplied with unloader

32b

32e

32d

32c

32f

32a

04999A

04999

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Page 15

Parts: 1535 and 2030 Pressure Washers

USE ONLY GENUINE GRACO PARTS AND ACCESSORIES

Model 804506, Series A: 1535 Pressure Washer Model 804532, Series A: 2030 Pressure Washer

Ref. No. Part No. Description Qty.

1 802264 ENGINE, 5.5 hp 1 3 804510 HANDLE, lift 1 4 804533 SCREW, cap, flange, 5/16–18 6 5 804523 WASHER, handle 2 6 111040 NUT, lock 5/16–18 14 7 101545 PIN, cotter 1/8 dia. x 1 in. 2 8 154636 WASHER, plain, 1–3/16 4 9 804511 WHEEL, pneumatic 2 10 804512 SPACER 2 11 804554 AXLE 1 12 804516 PLATE, motor mounting 1 13 100527 WASHER, plain 2 14 804509 HANDLE 1 15 804514 PLATE, pump 1 16 114412 SCREW, flange, hex hd 8 17 804515 PLATE, bottom 1 18 100643 SCREW, cap, sch, 14–20 x .75 4 19 109059 PAD, rubber 2 20 100086 WASHER, plain, 3/16 4 21 102040 NUT, lock, hex, 1/4–20 4 22 804530 SCREW, mach, flthd, 3/8–16 1 23 108789 KNOB 1 24 801012 GROMMET, rubber 6 25 TIP, spray 1

805555 1535 pressure washer

0_ (red), 00055 1

805543 2030 pressure washer

0_ (red), 0004 1

26 TIP, spray 1

805556 1535 pressure washer

15_ (yellow), 15055 1

805544 2030 pressure washer

15_ (yellow), 1504 1

27 TIP, spray 1

805557 1535 pressure washer

25_ (green), 25055 1

805545 2030 pressure washer

25_ (green), 2504 1

28 LABEL 1

290139 1535 pressure washer 1 290142 2030 pressure washer 1

Ref. No. Part No. Description Qty.

29 804479 HOSE, high pressure 3/8 x 50’ 1 30 801569 QUICK COUPLER, 3/8 female 1 31 801568 QUICK COUPLER, 3/8 male 1 32 800392 GUN / WAND ASSEMBLY

800740 1535 pressure washer 1

804544 2030 pressure washer 1 37 290130 LABEL 1 38 802363 LABEL, caution 1 40 290131 LABEL, warning 1 41 290133 LABEL 1 42 TIP, spray 1

805558 1535 pressure washer

40_ (white), 40055 1

805546 2030 pressure washer

,40_ (white), 4004 1

43 TIP, spray, chemical injector 1

805634 1535 pressure washer (black) 1

805634 2030 pressure washer (black) 1 44 803885 STRAINER 1 45 803857 COUPLER, sst 1 46 801112 SCREEN 1 47 KIT, unloader/injector 1

804542 1535 pressure washer 1

804543 2030 pressure washer 1 48 801210 SCREW 2 49 100214 WASHER, lock 2 51 800742 VALVE, thermal relief 1 53 VALVE, relief 1

804534 1535 pressure washer 1

804546 2030 pressure washer 1 55 804570 GASKET 4 56 244350 KIT, repair, chemical injector 1

15308572

Page 16

Parts: 2540 and 3040 Pressure Washers

Model 804507, Series A: 2540 Pressure Washer Model 804508, Series A: 3040 Pressure Washer

25,26,27,42,43

52 51

32b

32d

32c

1 Apply sealant to threads

2 Supplied with pump

16 308572

32e

32f

32a

04996C

Page 17

Parts: 2540 and 3040 Pressure Washers

USE ONLY GENUINE GRACO PARTS AND ACCESSORIES

Model 804507, Series A: 2540 Pressure Washer Model 804508, Series A: 3040 Pressure Washer

Ref. No. Part No. Description Qty.

1 803900 ENGINE, 9 hp

2540 pressure washer 1

803158 ENGINE, 11 hp

3040 pressure washer 1 3 804510 HANDLE, lift 1 4 110837 SCREW, cap, flange, 5/16–18 6 5 804523 WASHER, handle 2 6 111040 NUT, Lock 5/16–18 14 7 101545 PIN, cotter 1/8 dia. x 1 in. 2 8 154636 WASHER, plain, 1–3/16 4 9 804511 WHEEL, pneumatic 2 10 804512 SPACER 2 11 804554 AXLE 1 12 804516 PLATE, motor mounting 1 13 100527 WASHER, plain 4 14 804509 HANDLE 1 15 804514 PLATE, pump 1 16 114412 SCREW, flange, hex hd 8 17 804515 PLATE, bottom 1 18 100643 SCREW, cap, sch, 14–20 x .75 4 19 109059 PAD, rubber 2 20 100086 WASHER, plain, 3/16 4 21 102040 NUT, lock, hex, 1/4–20 4 22 804530 SCREW, mach, flthd, 3/8–16 1 23 108789 KNOB 1 24 801012 GROMMET, rubber 6 25 TIP, spray 1

805551 2540 pressure washer

0_ (red), 0005 1

805547 3040 pressure washer

0_ (red), 00045 1 26 TIP, spray 1

805552 2540 pressure washer

15_ (yellow), 1505 1

805548 3040 pressure washer

15_ (yellow), 15045 1 27 TIP, spray 1

805553 2540 pressure washer

25_ (green), 2505 1

805549 3040 pressure washer

25_ (green), 25045 1

Ref. No. Part No. Description Qty.

28 LABEL 1

290140 2540 pressure washer 1

290141 3040 pressure washer 1 29 804479 HOSE, high pressure 3/8 x 50’ 1 30 801569 QUICK COUPLER, 3/8 female 1 31 801568 QUICK COUPLER, 3/8 male 2 32 800392 GUN / WAND ASSEMBLY

805554 2540 pressure washer

40_ (white), 4005 1

805550 3040 pressure washer

40_ (white), 40045 1 43 TIP, spray, chemical injector 1

805634 2540 pressure washer (black) 1

805634 3040 pressure washer (black) 1 44 804547 KIT, repl, relief valve 1 46 804051 SCREEN 1 47 801210 SCREW 4 48 100214 WASHER, lock 4 50 804397 VALVE, thermal relief 1 51 804569 GASKET, unloader 1 52 804570 GASKET 1 53 UNLOADER/INJECTOR 1

804527 2540 pressure washer 1

804528 3040 pressure washer 1 54 801137 KEY, square 1 55 244350 KIT, repair, chemical injector 1

17308572

Page 18

Parts: 2835 Pressure Washer

Model 804583, Series A

25,26,27,28,42

40 16

161011

1 Apply sealant to threads

2 Supplied with pump

3 Supplied with engine

32e

32b

32d

32c

32f

32a

05923A

18 308572

Page 19

Parts: 2835 Pressure Washer

USE ONLY GENUINE GRACO PARTS AND ACCESSORIES

Model 804583, Series A

Ref. No. Part No. Description Qty.

1 803900 ENGINE, 9 hp 1 3 804510 HANDLE, lift 1 4 110837 SCREW, cap, flange, 5/16–18 6 5 804523 WASHER, handle 2 6 111040 NUT, lock 5/16–18 14 7 101545 PIN, cotter 1/8 dia. x 1 in. 2 8 154636 WASHER, plain, 1–3/16 4 9 804511 WHEEL, pneumatic 2 10 804512 SPACER 2 11 804554 AXLE 1 12 804516 PLATE, motor mounting 1 13 100527 WASHER, plain 4 14 804509 HANDLE 1 15 804514 PLATE, pump 1 16 114412 SCREW, flange, hex hd 8 17 804515 PLATE, bottom 1 18 100643 SCREW, cap, sch, 14–20 x .75 4 19 109059 PAD, rubber 2 20 100086 WASHER, plain, 3/16 4 21 102040 NUT, lock, hex, 1/4–20 4 22 804530 SCREW, mach, flthd, 3/8–16 1 23 108789 KNOB 1 24 801012 GROMMET, rubber 6 25 805543 TIP, spray; 0_ (red), 0004 1 26 805544 TIP, spray; 15_ (yellow), 1504 1 27 805545 TIP, spray; 25_ (green), 2504 1 28 805546 TIP, spray; 40_ (white), 4004 1 29 804479 HOSE, high pressure 3/8 x 50’ 1

Ref. No. Part No. Description Qty.

30 801569 QUICK COUPLER, 3/8 female 1 31 801568 QUICK COUPLER, 3/8 male 2 32 800392 GUN / WAND ASSEMBLY

(includes 32a to 32f) 1 32a 801569 SQUICK COUPLER, female 3/8 1 32b 801009 SQUICK COUPLER, female 1/4 1 32c 801134 SWAND, 32 in. 1 32d 801674 SSLEEVE, 28 in. 1 32e 803350 SGUN (see manual 308511) 1 32f 801603 SNIPPLE, hex, 3/8 npt x 3/8 npt 1 33 804529 HOLDER, gun 1 34 804559 PUMP ASSEMBLY (see page 22) 1 37 290013 LABEL 1 38 802363 LABEL, caution 1 39 820137 LABEL 1 40 290131 LABEL, warning 1 41 290557 LABEL 1 42 805634 TIP, spray, chemical injector 1 44 804536 VALVE, relief 1 46 804051 SCREEN 1 47 801210 SCREW 4 48 100214 WASHER, lock 4 50 804397 VALVE, thermal relief 1 51 804567 KIT, unloader/injector 1 52 244350 KIT, repair, chemical injector 1 56 804275 TUBE, chemical 1 57 801683 STRAINER 1 58 804569 GASKET, unloader 1 59 804570 GASKET 1

19308572

Page 20

Parts: Pump Assembly for 1535 and 2030

Pressure Washers

Pump Models 800740 and 804544

20 308572

05001

Page 21

Parts: Pump Assembly for 1535 and 2030

Pressure Washers

USE ONLY GENUINE GRACO PARTS AND ACCESSORIES

Pump Models 800740 and 804544

Ref. Part No. No. Description Qty.

1 CRANKCASE 1 2 801484 PLUG 2 3 O-RING 1 4 PROTECTOR 1 5 KIT 83 SEAL, oil 6 801753 PLUG 1 7 MANIFOLD 1 8 803278 WASHER 8 9 804027 SCREW 8 10 KIT 1 O-RING 11 KIT 1 SEAT, valve 12 KIT 1 PLATE, valve 13 KIT 1 SPRING 14 KIT 1 CAGE, valve 15 KIT 84 O-RING 16 KIT 84 CAP, valve 17 KIT 1 VALVE ASSEMBLY 18 KIT 96,97 RING, head 19 KIT 96,97 PACKING 20 KIT 96 RETAINER, packing 21 KIT 96,97 O-RING 22 KIT 96,97 O-RING 23 802345 GAUGE, sight 1 24 804021 BEARING 1

Ref Part No. No. Description Qty.

25 801659 DIPSTICK 1 26 803920 NUT 3 27 803921 WASHER 3 28 804011 PLUNGER 3 29 803918 O-RING 3 30 803919 RING, backup 3 31 803922 WASHER, flinger 3 32 PIN, connecting rod 3 33 COVER, crankcase 1 34 SCREW 4 35 GASKET, cover 1 36 804010 END, connecting rod 3 37 804012 ROD, connecting 3 49 804028 SCREW 4 50 801652 WASHER 4 51 FLANGE 1 52 SCREW 4 53 WASHER 4 54 803281 SPACER 1 55 803268 O-RING 1 56 804018 SEAL, oil 1 57 RING, snap 1 58 BEARING 1 59 CRANKSHAFT 1

Pump Repair Kits

Kit No. Repair Kit Part No. Ref. No. Description Qty.

1 801472 Valve Assembly 10

11 12 13 14 or

O-RING SEAT, valve PLATE, valve SPRING CAGE, valve

VALVE ASSEMBLY

6 6 6 6 6

Entire Pump

One Cylinder

83 804033 Oil Seal 5 SEAL, oil 3

84 804034 Valve Cap 15

96 804036

Packing Assembly

97 804037 Packing 18

* Item 17 consists of items 10 to 14. See Pump Assembly illustration on facing page. ** Designates whether kit contains parts for entire pump or for only one cylinder.

18 19 20 21 22

19 21 22

O-RING CAP, valve

RING, head PACKING RETAINER, packing O-RING O-RING

RING, head PACKING O-RING O-RING

6 6

1 1 1 1 1

3 3 3 3

21308572

Page 22

Parts: Pump Assembly for 2540, 2835, and 3040

Pressure Washers

Pump Models 804540 and 804559

1512

22 308572

2825

4998A

Page 23

Parts: Pump Assembly for 2540, 2835, and 3040

Pressure Washers

USE ONLY GENUINE GRACO PARTS AND ACCESSORIES

Pump Models 804540 and 804559

Ref. Part No. No. Description Qty.

1 HEAD, pump 1 2 801651 SCREW 8 3 801652 WASHER 8 4 KIT 123 O-RING 5 KIT 123 SEAT, valve 6 KIT 123 VALVE 7 KIT 123 SPRING 8 KIT 123 CAGE, valve 9 KIT 124 O-RING 10 KIT 124 CAP 11 KIT 123 VALVE ASSEMBLY 12 SCREW 8 13 COVER, bearing 2 14 SPACER 1 15 803268 O-RING 1 16 BEARING 2 17 KIT 23 SEAL, oil 18 CRANKCASE 1 19 801659 DIPSTICK 1 22 GUIDE, piston 3 23 ROD, connecting 3 24 O-RING 1 25 COVER, rear 1 26 SCREW 5 27 801488 O-RING 1 28 SCREW, cap 1 29 PIN 3

Ref. Part No. No. Description Qty.

30 804414 WASHER 3 31 803919 RING, anti extrusion 3 32 803918 O-RING 3 33 804415 PISTON 3 34 803921 WASHER 3 35 803920 NUT 3 40 KIT 130 O-RING 41 KIT 130 RETAINER, packing 42 KIT 130 RING, intermediate 43 KIT 130 PACKING 44 KIT 130 PACKING 45 KIT 130 RING, head 46 SCREW, cap 1 47 801482 SCREW, cap 1 48 801485 WASHER 1 49 WASHER 1 51 115709 SEAL, low pressure 1 75 RING, retaining 1 76 CRANKSHAFT 1 77 BEARING 1 78 O-RING 1 79 SCREW 4 80 WASHER 4 81 FLANGE 1 82 804422 SEAL, oil 1 83 WASHER 4 84 SCREW 4

Pump Repair Kits

Kit No. Repair Kit Part No. Ref. No. Description Qty.

23 801658 Oil Seal 17 SEAL, oil 3

123 804402

Valve Assembly

124 804403 Valve Cap 9

130 804404

Packing Assembly

243430

Plunger Repair

4 5 6 7 8 or

40 41 42 43 44 45

30 31 32 34 35

O-RING SEAT, valve VALVE SPRING CAGE, valve

VALVE ASSEMBLY

O-RING CAP

O-RING RETAINER, packing RING, intermediate PACKING PACKING RING, head

WASHER RING, anti extrusion O-RING WASHER NUT

6 6 6 6 6

6 6

1 1 1 1 2 2

3 3 3 3 3

Entire Pump

One Cylinder

* Item 11 consists of items 4 to 8. See Pump Assembly illustration on facing page. ** Designates whether kit contains parts for entire pump or for only one cylinder.

23308572

Page 24

Notes

24 308572

Page 25

Accessories

PTFE

Water Sandblasting Kit 800120

For abrasive cleaning of stubborn dirt and paint. Requires a sandblasting tip, sold separately as follows:

D 1535 pressure washer uses sandblasting tip 805325.

D 2030 pressure washer uses sandblasting tip 805313.

D 2540 pressure washer uses sandblasting tip 805321.

D 2835 pressure washer uses sandblasting tip 805313.

D 3040 pressure washer uses sandblasting tip 805317.

Technical Data

1535

Model 804506

Engine

(4 cycle, air cooled)

Gasoline tank capacity 3.8 quarts

Maximum operating pressure 1500 psi

Water pump maximum working pressure

Water pump maximum flow 3.5 gpm

Inlet hose connection 3/4-in. garden

Weight (without gun and hose) 79 lb (36 kg) 79 lb (36 kg) 110 lb (50 kg) 110 lb (50 kg) 128 lb (58 kg)

Dimensions

Length

Width

Height

Maximum inlet water temperature 160_F

Sound data (per ISO 3744)

Sound pressure Sound level

Wetted parts

High-pressure hose Bypass hose Pressure washer

(including fittings)

5.5 HP

Hondat OHV

(3.6 liters)

(102 bar,

10.2 MPa)

1900 psi (131 bar,

13.1 MPa)

(13 lpm)

hose (f)

34.5 in.

(940 mm)

22 in.

(483 mm)

23.5 in.

(508 mm)

(70_C)

93.1 dB(A)

103.5 dB(A)

acrylonitrile and buna-N cover and tube synthetic yarn and EPDM

anodized aluminum; aluminum or bronze alloys; brass copper; Nylon-PTFErcomposite;

ceramic; buna-N; cotton phenolic; 303, 304, and 316 stainless steel; polymide–12

thermoplastic; PTFE; rcarbon steel; zinc with or without yellow chromate plate

2030

Model 804532

5.5 HP

Honda OHV

3.8 quarts (3.6 liters)

2000 psi (138 bar,

13.8 MPa)

2400 psi (165 bar,

16.5 MPa)

3 gpm

(11 lpm)

3/4-in. garden

hose (f)

34.5 in.

(914 mm)

22 in.

(533 mm)

23.5 in.

(572 mm)

160_F

(70_C)

93.1 dB(A)

103.5 dB(A)

2540

Model 804507

9 HP

Honda OHV

6.2 quarts (6.1 liters)

2500 psi (172 bar,

17.2 MPa)

2900 psi (200 bar,

20.0 MPa)

4 gpm

(15 lpm)

3/4-in. garden

hose (f)

34.5 in.

(914 mm)

22 in.

(533 mm)

23.5 in.

(572 mm)

160_F

(70_C)

94.3 dB(A)

104.7 dB(A)

2835

Model 804583

9 HP

Honda OHV

6.2 quarts (6.1 liters)

2800 psi (193 bar,

19.3 MPa)

3200 psi (221 bar,

22.1 MPa)

3.5 gpm (13 lpm)

3/4-in. garden

hose (f)

34.5 in.

(914 mm)

22 in.

(533 mm)

23.5 in.

(572 mm)

160_F

(70_C)

94.3 dB(A)

104.7 dB(A)

3040

Model 804508

11 HP

Honda OHV

6.9 quarts (6.5 liters)

3000 psi (210 bar,

21.0 MPa)

3400 psi (234 bar,

23.4 MPa)

4 gpm

(15 lpm)

3/4-in. garden

hose (f)

34.5 in.

(914 mm)

22 in.

(533 mm)

23.5 in.

(572 mm)

160_F

(70_C)

95.8 dB(A)

106.3 dB(A)

r is a registered trademark

Hondat is a trademark of the Honda Corporation.

25308572

Page 26

Graco Warranty

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

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance or structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, gas engines,

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.

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

FOR GRACO CANADA CUSTOMERS

The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

ADDITIONAL WARRANTY COVERAGE

Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment Warranty Program”.

Graco Phone Number

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

1–800–690–2894 Toll Free

All written and visual data contained in this document reflect the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

International Offices: Belgium, Korea, Hong Kong, Japan

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

PRINTED IN USA 308572 05/1995, Revised 9/2003

26 308572

Sales Offices: Minneapolis, Detroit

www.graco.com