INSTRUCTIONS–PARTS LIST
Parts
308524
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
Belt-Drive Pressure Washers
2545
Model 800629, Series B
2500 psi (17.2 MPa, 172 bar) Operating Pressure
2900 psi (20 MPa, 200 bar) Maximum Working Pressure
3040
Model 800632, Series B
3000 psi (20.6 MPa, 206 bar) Operating Pressure
3400 psi (23.4 MPa, 234 bar) Maximum Working Pressure
Rev. K
3235
Model 800634, Series B
3200 psi (22.1 MPa, 221 bar) Operating Pressure
3600 psi (24.8 MPa, 248 bar) Maximum Working Pressure
04607
3040 Pressure Washer
Model 800632
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1995, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 5. . . . . . . . . . . . . . . . . . . . . . .
Pump Service 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
WARNING
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.
Pressure Washer Parts Drawing and List 10. . . . . . . . .
Pump Parts Drawing and List 12. . . . . . . . . . . . . . . . . . .
Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 16. . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 16. . . . . . . . . . . . . . . . . . . . . . . . . .
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 Fluid injected into the skin may 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.
D Engage the gun trigger safety when 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 couplings daily. Do not repair high-pressure couplings; you must replace
the entire hose. Fluid hoses must have spring guards on both ends to prevent kinks and rupture.
2 308524
WARNING
WARNING
MOVING PARTS HAZARD
Moving parts, such as the drive belt, can pinch or amputate fingers.
D Keep clear of moving parts when you start or operate this equipment.
D Do not operate the pressure washer without all guards and interlocks installed and functioning.
HAZARDOUS FLUIDS
Improper handling of hazardous fluids can cause serious injury or death from splashing in the
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 and
solvent 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 may 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 the Technical
Data on page 15.
D Do not alter the throttle setting.
308524 3
gun
Setup
high-pressure hose
connection
hose
hose
rack
inlet water
connection
3/4” garden
hose
Check for Shipping Damage
Check the pressure washer for shipping damage. If
anything is damaged, notify the carrier immediately.
Set Up
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 affect sprayer and
chemical injector performance.
TI1262A
Connect to Water Supply
CAUTION
Before you connect to the water supply, check
your local plumbing code regarding cross
connection to the water supply. Backflow
Preventer 801133 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 (414 kPa,
4.1 bar) Regulating Water Valve 800258 must be
installed at the garden hose connection.
Do not exceed 160_ F (70_ C) inlet water
temperature.
Install the appropriate spray tip on the wand. See
Installing and Changing Spray Tips on page 6. If
you use a sandblaster kit, see its separate manual for
installation instructions.
4 308524
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. 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 15.
Pressure Relief Procedure
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
spraying accidentally. To reduce the risk
of an injury from accidental spray from the gun,
splashing fluid, or moving parts, follow the
Pressure Relief Procedure when 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
1. Engage the trigger safety latch.
2. Turn off the pressure washer, and remove the
ignition cable from the spark plug.
3. Shut off the water supply.
4. Disengage the trigger safety latch, trigger the gun
to relieve the pressure, and 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.
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.
D See manual 308513 for chemical injector operation
and service.
1. Check the oil level.
NOTE: This pressure washer is 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 refuel.
2. Check the 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.
3. Turn on the water supply.
CAUTION
Never run the pressure washer dry. 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 engine switch in the ON 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 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 operate the pressure washer
with the inlet water screen removed. This screen
helps keep abrasive sediment, which could clog
the pump or damage the pump cylinders, out of the
pump. Keep this screen clean. Do not pump
caustic materials; such materials could corrode the
pump components.
308524 5
Operation
6. Pull the starter rope to start the engine. Brace one
foot on the pressure washer cart, and pull the
starter rope out quickly.
CAUTION
Do not allow the starter rope to snap back against
the engine. Let the rope recoil gently to prevent
damage to the recoil mechanism.
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.
Spray Tip Number Spray Pattern Fan Angle
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.
1.
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/or install a different one. Then push
back the ring. See Fig. 2.
4. Pull on the tip to be sure it is secure before you
spray again.
Relieve the pressure.
See page 5.
Trigger Safety Latch
WARNING
To reduce the risk of serious bodily injury, including
fluid injection or splashing in the eyes or on the
skin, always engage the trigger safety latch when
you stop spraying 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
pushed fully down, or it will not prevent the gun
from being triggered. See Fig. 1.
Trigger Safety Latch
engaged
disengaged
0412B
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.
B
A
Fig. 2
04929
Fig. 1
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.
6 308524
Operation
Water Sandblasting
Water Sandblasting Kit 244766 is available for
abrasive cleaning of stubborn dirt and paint. The kit
requires a sandblasting tip, sold separately as follows:
D 2545 pressure washer uses sandblasting
tip 805325.
D 3040 pressure washer uses sandblasting
tip 805317.
D 3235 pressure washer uses sandblasting
tip 805313.
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 may 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 it
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.
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.
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 is 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.
After every
500 hours of
operation, or
every 6 months
Change pump oil. Use SAE 20 or
30 non-detergent oil.
308524 7
Pump Service
Repair kits are available. See Pump Repair Kits on page 13. 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:
10 mm, 13 mm, and 30 mm.
D There are two tool kits to aid in servicing the pump.
Kit 800298 is used to ease installation of packings.
Kit 800271 includes the items in 800298 and tools
to aid in the removal of packing retainers.
Valves
NOTE: For a set of six valves, order 801472.
1. Remove the hex plug from the manifold using a
30 mm wrench.
2. Examine the o-ring under the hex plug and replace
it if it is 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-lb (103 NSm).
NOTE: Retorque the plug after 5 hours of operation.
Pumping Section
1. Remove the eight capscrews and lockwashers
from the manifold using a 13 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.
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 screw five to six turns
using a 10 mm wrench. Push the plunger towards
the crankcase to separate the plunger and
retaining screw.
2. Remove the screw from the plunger, and examine
the o-ring, backup ring, and copper bearing/gasket
washer. Replace these parts, if necessary.
8 308524
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
because they cannot be reused. Oil Seal Kit
801473 is available for replacing the seals.
5. Lightly grease the flinger (and the oil seal if it is
being replaced), and replace on the plunger shaft.
Then install the plunger.
Pump Service
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 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 21.7 ft-lb (29 NSm) following
the tightening pattern in Fig. 3. Uneven tightening
can cause the manifold to bind or jam.
5
8
14
3
2
7
6
Servicing the V-Packings
NOTE: There are two types of packing kits:
801486 contains packings only.
801487 contains packings, rings, and retainers.
1. Remove the manifold as outlined in Pumping
Section on page 8.
2. Carefully pull the packing retainer (43) from the
manifold. Examine the o-ring (42), and replace if
cut or damaged.
3. Remove intermediate ring (46). Pull out restop
v-packing (47). Remove the second V-packing (44)
and ring head (45).
4. Inspect all parts, and replace as necessary.
5. Thoroughly clean the packing cavities, and
examine for debris or damage.
6. Lightly grease packing cavities, and replace packings
in following order: ring head (45), V-packing (44),
restop packing (47), intermediate ring (46). Install
o-ring (42) in retainer groove and then install retainer
ring (43) with low pressure seal (57).
Fig. 3
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 8.
308524 9
Pressure Washer Parts
Model 800629, Series B: 2545 Pressure Washer
Model 800632, Series B: 3040 Pressure Washer
Model 800634, Series B: 3235 Pressure Washer
88
89
21
19
77
87
79
76
78
93
82
51
71
29
30
31
32
33
80
73
70
69
81
9
22
34
74
84
38
36
84
83
94
95
7
28
26
25
55
84
9
84
39
4
37
49
55
41
84
96
67
84
48
85
47
46
55
84
67
2
42
45
67
86
43
15
44
67
6
5
18c
18e
18g
18f
10 308524
18h
18a
18
18d
18b
13
86
17
15
55
14
10
11
12
23
1
04604B
2
Pressure Washer Parts
Ref.
No. Part No. Description Qty.
1 244450 GUN & WAND ASSEMBLY 1
2 100023 WASHER, flat; 3/8 4
4 801539 BUMPER 1
5 803926 BELT GUARD 1
6 803534 LABEL, ID 1
7 800676 CHASSIS 1
9 100214 WASHER, lock; 5/16 3
10 801550 WHEEL, pneumatic 2
11 801612 WASHER, flat; 1/2 2
12 801020 NUT, lock; 1/2–13 2
13 801556 AXLE 1
14 800678 BRACKET, rail stiffener 1
15 801546 SCREW, cap, hex hd. 4
3/8–16 x 1–1/4
17 LABEL, ID 1
803303 Model 800629 1
803161 Model 800632 1
803904 Model 800634 1
18 800160 FRONT LEG ASSEMBLY 1
(includes 18a to 18h)
18a 801537 @ LEG, Front 1
18b 801506 @ BOOT 1
18c 801593 @ SPRING 1
18d 801505 @ RETAINER, spring 1
18e 801504 @ BUMPER, rubber 1
18f 801531 @ SCREW, cap, hex hd; 3/8–16 x 7 1
18g 100132 @ WASHER, flat 1
18h 101566 @ NUT, lock; 3/8–16 1
19 803925 HANDLE 1
21 804498 QUICK COUPLER, 3/8 male 1
22 803298 SCREW, cap, hex hd. 1
5/16–18 x 3–1/2
23 244449 HOSE ASSEMBLY 1
25 802016 BRACKET, rail stiffener 1
26 804500 LABEL, Warning 1
28 801012 GROMMET, rubber 5
29 to 32 TIP ASSEMBLIES
Model 800629
29 805555 00055 (blasting) 1
30 805556 15055 (15_) 1
31 805557 25055 (25_) 1
32 805558 40055 (40_) 1
Model 800632
29 805547 00045 (blasting) 1
30 805548 15045 (15_) 1
31 805549 25045 (25_) 1
32 805550 40045 (40_) 1
Ref.
No. Part No. Description Qty.
29 805543 0004 (blasting) 1
30 805544 1504 (15_) 1
31 805545 2504 (25_) 1
32 805546 4004 (40_) 1
33 805634 TIP ASSY, (chemical injector) 1
34 PUMP (page 18) 1
803297 Model 800629 1
803737 Models 800632 and 800634 1
36 802127 SCREW, cap, hex hd. 4
37 802363 LABEL, Caution 1
38 290013 LABEL, Warning 1
39 803158 ENGINE, 11 hp
41 804356 BUMPER, rubber 1
42 804376 SCREW, cap, hex hd; 1
43 801285 BELT, drive 2
44 801898 HUB, engine 1
45 SHEAVE, engine 1
801911 Models 800629 and 800634 1
803941 Model 800632 1
46 801135 HUB, pump 1
47 SHEAVE, pump 1
801004 Model 800629 1
803890 Models 800632 and 800634 1
48 804495 LABEL, Warning 1
49 803531 PLATE, back 1
51 801522 SCREW, cap, hex hd; 2
55 111040 NUT, lock; 5/16–18 13
67 110963 SCREW, flange, hex hd; 5
69 801526 BRACKET, pump 2
70 156849 NIPPLE 1
71 UNLOADER ASSEMBLIES 1
800323 Model 800629 (2500 psi) 1
800324 Model 800632 (3000 psi) 1
800325 Model 800634 (3200 psi) 1
73 803142 NIPPLE 1
74 803141 BYPASS HOSE 1
76 801111 NUT, garden hose 1
77 801110 ADAPTER, garden hose 1
78 804051 FILTER 1
79 402278 PLUG, plastic 1
80 801622 TEE 1
81 801523 NIPPLE 1
82 116461 VALVE, thermal relief 1
83 804382 BUSHING 4
84 100527 WASHER, flat; 5/16 20
85 100450 BOLT, hex hd; 5/16 x 18 x 1.0 4
86 100133 WASHER, lock; 3/8 4
87* 804388 CHEMICAL INJECTOR 1
88 804275 TUBE, chemical injector 1
89 801683 STRAINER, chemical injector 1
93 162024 COUPLING 1
94 802304 WASHER, lock 4
95 802305 SCREW, cap, socket head 4
96 801137 KEY, square 1
* Chemical Injector Repair Kit – 244351
Model 800634
5/16–18 x 1–3/4
5/16–18 x 3/8
5/16–18 x 6–1/2
5/16–18 x 3/4
Honda OHV 1
,
308524 11
Pump Parts
Pump Model 803297 used on 2545 Pressure Washer
Pump Model 803737 used on 3040 and 3235 Pressure Washers
27
28
22
26
24
22
33
12
13
32
25
31
14
34
35
15
36
37
38
30
29
23
31
21
20
18
56
19
15
41
14
40
12
39
12 308524
17
16
42
Kit 28
43
57
46
47
44
11
45
10
54
9
53
51
3
2
10
04608b
8
7
6
5
4
1
11
52
9
Pump Parts
Ref.
No. Part No. Description Qty
1 801467 MANIFOLD 1
2 801468 SCREW, cap, hex hd 8
3 801469 WASHER, lock 8
4 KIT 1 O-RING
5 KIT 1 SEAT, valve
6 KIT 1 PLATE, valve
7 KIT 1 SPRING
8 KIT 1 GUIDE, valve
9 KIT 4 O-RING
10 KIT 4 CAP
11 KIT 1 VALVE ASSEMBLY (includes 4 to 8)
12 803283 SCREW, cap, socket hd 8
13 803284 COVER, crankcase 1
14 802500 O-RING, crankcase cover 2
15 803285 BEARING, tapered roller 2
16 KIT 2 SEAL, oil
17 803286 BUSHING, piston 1
18 802895 CRANKCASE 1
19 801475 DIPSTICK 1
20 803144 GASKET, cover 1
21 CRANKSHAFT
803287 Pump 803297 1
803332 Pump 803737 1
22 803288 RING, retaining 6
23 802794 KEY 1
24 803289 PIN, wrist 3
25 803290 GUIDE, piston 3
26 803291 ROD, connecting 1
27 803292 SCREW, cap, socket hd 5
28 803293 COVER, crankcase 1
Ref.
No. Part No. Description Qty
29 802345 GAUGE, sight 1
30 802793 PLUG, oil drain 1
31 KIT 6 O-RING
32 803294 SCREW, cap, socket hd 6
33 801652 WASHER, lock 6
34 801660 WASHER, flinger 3
and KIT 6
35 801490 PLUNGER, ceramic 3
36 KIT 6 RING, backup
37 KIT 6 WASHER
38 KIT 6 SCREW, piston
39 803295 COVER, crankcase 1
40 803296 SHIM 2
41 KIT 3 SEAL, oil
42 KIT 28 O-RING
43 KIT 28 RETAINER, packing
44 KIT 8, 28 PACKING
45 KIT 28 RING, head
46 KIT 28 RING, intermediate
47 KIT 28 RESTOP, packing
48 801526 BRACKET, pump 2
49 802305 SCREW, cap, socket hd 2
50 802304 WASHER, lock 2
51 801482 PLUG, hex 1
52 801483 WASHER, flat 1
53 801484 PLUG, hex 1
54 801485 WASHER, flat 1
56 803083 LABEL, prevent freezing 1
57 KIT 28 SEAL, low pressure 1
Pump Repair Kits
Kit
No.
1
2
3
4
Repair Kit
Part No.
801472
Valve
801473
Oil Seal
802511
Crankshaft
Seal
802306
Valve
Cap
Ref.
No. Description Qty
11
4
5
6
7
8
16 SEAL, oil 3
41 SEAL, oil 2
9
10
VALVE ASSEMBLY
(includes 4 to 8)
O-RING
SEAT, valve
PLATE, valve
SPRING
GUIDE, valve
O-RING
CAP
Kit
Repair Kit
No.
Part No.
6
6
6
6
6
6
6
6
6
8
28
801474
Plunger
Repair
801486
Packing
801487
Packing
and
Retainer
Ref.
No. Description Qty
31
O-RING
34
WASHER, flinger
36
RING, backup
37
WASHER
38
SCREW, piston
44 PACKING 6
42
O-RING
43
RETAINER, ring
44
PACKING
45
RING, head
46
RING, intermediate
47
RESTOP, packing
57
SEAL, low pressure
3
3
3
3
3
1
1
1
1
1
1
1
308524 13
Troubleshooting
Relieve the pressure (see page 5) before you proceed with troubleshooting.
PROBLEM CAUSE SOLUTION
Engine not starting or
hard to start
Engine missing or
lacking power
Pressure too low
and/or pump running
roughly
Water leaking from
under pump manifold
Water in pump oil Humid air condensing inside crankcase
Packings failing
frequently or
prematurely.
Strong surging at inlet,
and low pressure on
discharge side
No gasoline in fuel tank or carburetor
Low oil
Start/Stop switch in STOP position
Water in fuel, or old fuel
Engine flooded or improperly choked
Dirty air cleaner filter
Spark plug dirty, wrong gap, or wrong type
Gun not triggered
Partially plugged air cleaner filter
Spark plug dirty, wrong gap, or wrong type
Worn or wrong size tip
Inlet filter clogged
Worn packings, abrasives in water, or
natural wear
Inadequate water supply
Belts slipping
Fouled or dirty inlet or discharge valves
Restricted inlet
Worn inlet or discharge valves
Leaking high-pressure hose
Worn packings Install new packings. See Pump Service on page 8.
Worn packings
Oil seals leaking
Scored, damaged, or worn plungers
Abrasive material in the fluid being
pumped
Inlet water temperature too high
Overpressurizing pump
Excessive pressure due to partially
plugged or damaged tip
Pump running too long without spraying
Running pump dry
Foreign particles in the inlet or discharge
valve, or worn inlet and/or discharge
valves
Fill the tank with gasoline, and open fuel shut off valve.
Check fuel line and carburetor.
Add oil to proper level.
Move switch to START position.
Drain fuel tank and carburetor. Use new fuel, and make
sure dry spark plug is dry.
Open choke, and crank engine several times to clear
out gas. Make sure spark plug is dry.
Remove and clean.
Clean, adjust the gap, or replace.
Trigger gun while starting engine.
Remove and clean.
Clean, adjust the gap, or replace.
Replace with tip of proper size.
Clean. Check more frequently.
Check filter. Replace packings. See Pump Service on
page 8.
Check water flow rate to pump.
Tighten or replace; use correct belts, and replace both
at same time.
Clean inlet and discharge valve assemblies. Check filter.
Check if garden hose is collapsed or kinked.
Replace worn valves. See Pump Service on page 8.
Replace high-pressure hose.
Change oil as specified in Maintenance on page 7.
Install new packings. See Pump Service on page 8.
Install new oil seals. See Pump Service on page 8.
Install new plungers. See Pump Service on page 8.
Install proper filtration on pump inlet plumbing.
Check water temperature. It should not exceed
160_F (70_C).
Do not modify any factory-set adjustments. See
EQUIPMENT MISUSE HAZARD on page 3.
Clean or replace tip. See Installing and Changing
Spray Tips on page 6.
Never run pump more than 10 minutes without spraying.
Do not run pump without water.
Clean or replace valves. See Pump Service on
page 8.
14 308524
Technical Data
2545
Model 800629
Engine
(4 cycle, air cooled)
Gasoline tank capacity 6.9 quarts (6.5 liters) 6.9 quarts (6.5 liters) 6.9 quarts (6.5 liters)
Water pump maximum operating pressure 2500 psi
Water pump maximum flow 4.5 gpm (17 lpm) 4 gpm (15 lpm) 3.5 gpm (13 lpm)
Inlet hose connection 3/4” garden hose (f) 3/4” garden hose (f) 3/4” garden hose (f)
Weight 219 lb (100 kg) 219 lb (100 kg) 219 lb (100 kg)
Dimensions
Length
Width
Height
Maximum inlet water temperature 160_ F (70_ C) 160_ F (70_ C) 160_ F (70_ C)
Wetted parts
High-pressure hose
Bypass hose
Pressure washer (including fittings)
11 HP Honda OHV 11 HP Honda OHV 11 HP Honda OHV
(17.2 MPa, 172 bar)
46” (1168mm)
30” (762mm)
26” (660mm)
Acrylonitrile and Buna–N cover and tube
Synthetic yarn and EPDM
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; carbon steel; zinc plate with or without yellow chromate
3040
Model 800632
3000 psi
(21 MPa, 207 bar)
46” (1168mm)
30” (762mm)
26” (660mm)
3235
Model 800634
3200 psi
(22.1 MPa, 221 bar)
46” (1168mm)
30” (762mm)
26” (660mm)
308524 15
Graco Standard 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 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.
16 308524
International Offices: Belgium, Korea, Hong Kong, Japan
Sales Offices: Minneapolis
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
www.graco.com
PRINTED IN USA 308524 06/1997, Revised 04/2004
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