Graco Inc Hydra-Clean 800-639, Hydra-Clean 800-638, Hydra-Clean 800-690, Hydra-Clean 308-529, Hydra-Clean 2540 User Manual

INSTRUCTIONS-PAR

This

manual contains

WARNINGS

AND

RET

and

AIN FOR REFERENCE

IMPORTANT

INSTRUCTIONS

READ

TS LIST

308–529

Rev

A

HYDRA-CLEAN
Pressure W

HYDRA–CLEAN

P/N 800–638, Series A
P/N 800–690, Series A

2500 psi (172 bar) OPERA

3000 psi (207 bar) MAXIMUM WORKING PRESSURE

HYDRA–CLEAN 3040, 1

P/N 800–639, Series A

3000 psi (207 bar) OPERA

3400 psi (234 bar) MAXIMUM WORKING PRESSURE

2540, 9 HP ENGINE

asher

TING PRESSURE

1 HP ENGINE

TING PRESSURE



2540, 3040

GRACO INC. P

.O. Box 1441 MINNEAPOLIS, MN 55440–1441

COPYRIGHT

1990, GRACO INC.

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

WARNING

General Safety

This pressure washer generates very high fluid
pressure. Spray from the gun, leaks or ruptured
components
your body and cause extremely serious bodily injury
including
splashed
damage.

NEVER

part of the body.
spray

ALWAYS
before

NEVER

body.

Be sure equipment safety devices are operating
properly

can inject fluid through your skin and into

the

need for amputation. Also, fluid injected or

into the eyes or on the skin can cause serious

point the spray gun or wand at anyone or at any

NEVER

tip.

follow the Pressure Relief Procedure ,

cleaning or servicing any part of the sprayer

try to stop or deflect leaks with your hand or

before each use.

put hand or fingers over the

.

Medical Treatment

If any fluid appears to penetrate your skin, get

EMERGENCY MEDICAL TREA TMENT A T ONCE.
DO NOT TREAT AS A SIMPLE CUT . Tell the doctor

exactly

what fluid was injected.

NOTE TO PHYSICIAN:

traumatic injury .

injury surgically as soon as possible.

It is important to treat the

Injection in the skin is a

Do not
delay treatment to research toxicity. Toxicity is a
concern with some exotic coatings injected

into

directly

the bloodstream. Consultation with a

plastic surgeon or reconstructive hand surgeon

be advisable.

may

Pressure Relief Procedure

To

reduce the risk of serious bodily
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

and before checking or repairing any part of the

down,
system.

1. Engage

2. T

3.

Remove the ignition cable from the spark plug.

4.

Shut of

5. Disengage the trigger safety latch and trigger the

gun to relieve pressure, and then engage the
trigger

6. Before long–term (overnight) storage or

transporting of the unit, disconnect the water
supply

the trigger safety latch.

urn the sprayer of

f the water supply

safety latch again.

and turn of

f.

f the fuel supply valve.

injury

, including fluid

.

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

SAFETY LATCH: Whenever you stop spraying for a
moment,
or “safe” position, making the gun inoperative. Failure
to
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.

Procedure

bodily injury

always set the gun safety latch in the engaged

properly set the safety

and then remove the spray tip to clean it.

.

ALWAYS

latch can result in accidental

follow the Pressure Relief



308–529

EQUIPMENT MISUSE HAZARD

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
fluid injection, splashing in the eyes or on the skin, or
other serious bodily injury , fire, explosion or property
damage.

NEVER

doing

CHECK

replace

ALWAYS

clothing. If using a chemical injector , read and follow
the chemical manufacturer ’s literature for
recommendations on additional protective equipment,
such

parts, can cause them to rupture and result in

alter or modify any part of this equipment;

so could cause it to malfunction.

all spray equipment regularly and repair or

worn or damaged parts immediately

wear protective eyewear and appropriate

as a respirator

.

.

HOSE SAFETY

High

pressure fluid in the hoses can be very dangerous.

If

the hose develops a

kind of wear , damage or misuse, the high pressure

emitted from it can cause a fluid injection injury or

spray
other

serious bodily injury or property damage.

ALL FLUID HOSES MUST HAVE STRAIN RELIEFS
ON BOTH ENDS.

hose from kinks or bends at or close to the coupling,

can result in hose rupture.

which

TIGHTEN

use.
or allow high pressure spray to be emitted from the
coupling.

all fluid connections securely before each

High pressure fluid can dislodge a loose coupling

leak, split or rupture due to any

The strain reliefs help protect the

System

This
sure
to withstand the maximum working pressure of this
sprayer.
pressure of any component or accessory used in the
system.

Pressure

sprayer can develop high operating pressures. Be
that all spray equipment and accessories are rated

DO NOT

exceed the maximum working

Chemical Compatibility

BE SURE

injector are compatible with the wetted parts of the
hose,
(inside back cover). Always read the chemical
manufacturer’s
this pressure washer

NEVER

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

with tape or any other device. A repaired hose cannot
contain

HANDLE

pull

on hoses to move the pressure washer
chemicals
and
temperatures above 200 _ F (93 _ C) or below
–40_ F (–40_ C).

that all chemicals used in the chemical

gun, wand and tip, as given in the T

literature before using any chemical in

.

use a damaged hose. Before

try to recouple high

the high pressure fluid.

pressure hose or mend it

AND ROUTE HOSES CAREFULL

which are not compatible with the inner

cover of the hose.

DO NOT

expose

echnical Data

each use, check

Y.

Do not

. Do not

Graco hose to

use

tube

FUEL AND EMISSION HAZARDS

NEVER

The fuel used in this unit is combustible and when
spilled on a hot surface can ignite and cause a fire.

ALWAYS

NEVER

exhaust contains carbon monoxide, a poisonous,

fill the fuel tank while the unit is

fill tank slowly to avoid spilling.

operate the unit in a closed building. The

running or hot.

odorless, invisible gas which can cause serious injury

death if inhaled.

or

NEVER

Tampering with this adjustment can damage the
pressure

alter the throttle setting, which is factory set.

washer and will void the warranty

.

308–529

3

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers or other
body parts.
starting

NEVER

and interlocks installed and functioning. Follow the

KEEP CLEAR

or operating the pressure washer

operate the

pressure washer without all guards

of moving parts when

.

Pressure Relief Procedure before checking or
servicing the pressure washer to prevent discharging

pressure fluid from the gun.

high

TERMS

WARNING: Alerts user to avoid or correct conditions

could cause bodily injury

that

CAUTION: Alerts user to avoid or correct conditions

could cause damage to the equipment.

that

.

NOTE: Identifies

helpful

procedures and information.

IMPORTANT

United

States Government safety standards have been adopted under the Occupational Safety and Health Act. These
standards—particularly the General Standards, Part 1910, and the Construction Standards, Part 1926—should be
consulted.

4

308–529

INSTALLATION

QUICK

COUPLER

SPRAY

GUN

QUICK

COUPLER

HIGH

PRESSURE HOSE

CONNECTION

Figure

INLET W

CONNECTION 3/4”

GARDEN HOSE

1

ATER

Check for Shipping Damage

Check

the unit for any

in shipping. Notify the carrier immediately if there is

damage.

any

damage that may have occurred

Set Up

If

you are using a downstream chemical injector

it between the pump unloader and the high pressure

using the quick couplers provided.

hose,

Connect the high pressure hose between the pump

and the gun inlet. Both of these connections are

outlet
made

with quick couplers.

, install

CAUTION

Up to 100 ft (30 m) of high pressure hose may
be used.
performance,
if

used.

Install the appropriate spray tip on the wand. See
Installing and Changing Spray Tips. If you are using a
sandblaster
instructions.

Longer hoses may af fect sprayer

and chemical injector

kit, see

its separate manual for installation

performance,

SPRAY

HOSE

Connect to Water Supply

CAUTION

Before attaching to the water supply, check your

plumbing code regarding cross–

local
to the water supply . A backflow preventer , P/N
801–133, is available to prevent backflow of
contaminated water into the fresh water supply .

it upstream from the pump.

Install

If inlet water pressure is over 60 psi (4.1 bar) a
regulating water valve, P/N 800–258, must be
installed

Do not exceed 160 _ F (70_ C) inlet water
temperature.

Connect
the

water supply to the unit’

The

supply hose

long.

NOTE: The water source at the unit

at the garden hose connection.

a hose with at least a 3/4 inch (19

s 3/4 inch garden hose inlet.

should not be more than 50 ft (15 m)

minimum flow rate equal to that of the unit

echnical Data, inside back cover).

(see T

connection

mm) ID from

must

have a

308–529

5

STARTUP

Always use this startup procedure to ensure that the

is started safely and properly

unit

1.

Check oil levels.

Engine: Add SAE 30 or 10W–30 weight detergent
oil as necessary

Add SAE 20 or 30 weight non–detergent

Pump:
as

necessary

NOTE: Some units are equipped with a low–oil

sensor
falls below a certain level. If the unit stops
unexpectedly,
levels.
refueled.

2. Check

fuel level.

.

.

that shuts the engine of

check both the oil and the fuel

Check the oil level each time the unit is

.

f if the oil level

WARNING

DO NOT

engine could cause a fire. Use only fresh, clean
regular or unleaded gasoline. Close the fuel
shutoff

3. T

refuel a hot engine. Refueling a hot

valve during refueling.

urn on the water supply

.

oil

If the engine is cold, completely close the engine
choke. Grasp the starter rope, brace one foot on

pressure washer chassis and pull rope rapidly

the
and

firmly

. Continue holding the rope as it returns.

Pull and return the rope until the engine starts. In

weather

cool
for

10 to 30 seconds before opening it to keep the

engine running. Otherwise, open the choke as

as the engine starts.

soon

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

the choke completely

open

, the choke may

have to be kept closed

.

CAUTION

On

recoil start engines, never let the starter rope

return by itself. It could jam the recoil system.

7.

ALWAYS

whenever
reduce
eyes
accidentally.

ALWAYS

8.
avoid

engage the gun’ s trigger safety latch

you stop spraying, even for a moment, to

the risk of fluid injection or splashing in the

or on the skin if the gun is bumped or triggered

observe the following CAUTIONS to

costly damage to the pressure washer

.

CAUTION

Never

run the unit dry
will result. Always be sure the water supply is
completely

4. Trigger the gun until water sprays from the tip
indicating

5. Open
ignition
On those units equipped with an ignition shutof f
switch, put the switch in the “on” position and put
the

6.

Start the engine.

NOTE: For

turned on before operating.

that the air is purged from the system.

the fuel shutof

cable is pushed firmly onto the spark

throttle in the “run” position.

easier starting, have one person start the
pressure washer while another person
triggers

. Costly damage to the pump

f valve. Be sure the spark plug

the spray gun.

plug.

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
will not be spraying or cleaning at least every 10
minutes. If heated inlet water is used, reduce this
time further.

DO NOT

damage
turned

DO

water screen removed. This screen helps keep
abrasive sediment out of the pump, which could
clog

DO NOT

may

9. See

the pump. T

run the pump dry , which will quickly

the pump. Be sure

on before starting the pump.

NOT

operate the pressure washer

or scratch the pump. Keep this screen clean.

pump caustic materials; such materials

corrode the pump components.

the chemical injector or sandblaster kit
for detailed cleaning information if these
accessories

urn of

are used.

f the pressure washer if it

the water supply is fully

with the inlet

manual

6

308–529

Trigger Safety Latch

WARNING

To reduce the risk of serious bodily injury ,
including fluid injection, splashing in the eyes or
on the skin,
latch whenever spraying stops, even for a
moment.

In the engaged position, the trigger safety latch
prevents the gun from being triggered
accidentally
Be sure the latch is pushed fully down when
engaging
triggered.

ALWAYS

by hand or if it is dropped or bumped.

it or it cannot

See Figure 2.

engage the trigger safety

prevent the gun from being

Installing and Changing Spray Tips

WARNING

To

reduce the risk of serious bodily injury
fluid injection or splashing in the eyes or onto the
skin, use extreme caution when changing spray

ALWAYS

tips.

1.

Follow the

2. Point the gun and wand away from yourself and
anyone

3. Without holding your hand over the spray tip (A),

back the quick coupler ring (B). Remove the old

pull
tip and/or install a new one, and then release the

See Figure 3.

ring.

4. Be sure the tip is secure before starting to spray
again.

follow the procedure below

Pressure Relief Procedure

else.

, including

.

.

TRIGGER SAFETY LA

TRIGGER SAFETY LA

DISENGAGED

Figure 2

TCH SHOWN ENGAGED

TCH SHOWN

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

Figure 3

mounted in the quick coupler

.

B

A

308–529

7

SHUTDOWN, FLUSHING
AND STORAGE

MAINTENANCE

WARNING

Pressure

To reduce the risk of serious bodily injury ,
including
or on the skin, always follow this procedure
whenever you stop spraying for more than 10
minutes, when shutting down, and before
checking

1.

2. T

3. Remove the ignition cable from the spark

4. Shut

5. Disengage

6. Before long–term (overnight) storage or

1. If the pressure washer will be exposed to freezing
temperatures, drain all water out of the pump. If it
must
unit with a 50% anti–freeze solution. Relieve
pressure.
it

again to remove the anti–freeze.

NOTE: An anti–freeze flush kit, P/N 802–327, is

Relief Procedure

fluid injection

or repairing any part of the system.

Engage the trigger safety latch.

urn the sprayer of

plug.

of

f the water supply

the trigger safety latch and trigger

the

gun to relieve pressure, and then engage

the

trigger safety latch again.

transporting of unit, disconnect the water
supply,

and turn of

be stored in freezing temperatures, flush the

Flush the pressure washer before

available

and splashing in the eyes,

f.

.

f the fuel supply valve.

to make flushing easier

.

using

CAUTION

If

water does freeze in the

it

in a

warm room before trying to start it.

pour hot water on or into the pump; it may crack

ceramic plungers!

the

2. After each use, wipe all surfaces of the pressure
washer

3. Perform the appropriate maintenance. See
maintenance

with a clean, damp cloth.

chart.

pressure washer

DO NOT

, thaw

Observing
that you get maximum performance and life from the
pressure

There is a break–in period for the engine, pump and
gear reducer (if used). After changing the oil in these
components following their respective break–in
periods, the interval between required changes is
longer.

If the unit is operating in dusty conditions, these
maintenance

regular maintenance intervals helps ensure

washer

.

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

proceeding.

before

Interval

Daily

After first 5
hours of
operation

Each 25 hours
of operation

After first 50
hours of
operation

Each 100 hours
of operation
or 3 months

Each 500 hours
of operation
or 6 months

What to do

Clean water inlet screen and
filter

. Check engine and pump oil
levels. Fill as necessary
gasoline level. Fill as necessary

Change
oil when warm. Use SAE 30 or
10W–30 detergent oil.

Clean and remove air cleaner
foam. Wash with water and
detergent. Dry thoroughly
with oil and squeeze to distribute
oil.

Change pump break–in oil. Use
SAE 20 or 30 non–detergent oil.
Change gear reducer oil. Use
SAE 90 gear oil.

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

Change pump oil. Use SAE 20 or
30 non–detergent oil. Change
gear reducer oil. Use SAE 90
gear oil.

engine break–in oil. Drain

. Check

. Rub

ap gently to

.

8

308–529

TROUBLESHOOTING CHART

To

reduce the risk of serious bodily injury

moving

parts, always follow the

Pressure Relief Procedure W

WARNING

, including fluid injection, splashing in the eyes or on

arning

before proceeding.

the skin or injury from

PROBLEM

Engine will not start or
is hard to start

Engine misses or
lacks power

Low

pressure and/or

pump runs rough

W

ater leakage from

under pump manifold

W

ater in pump

Frequent or premature
failure of the packings

Strong surging at the
inlet and low pressure
on the discharge side

Oil leakage between
the gear reducer cover
and case

Oil leakage between
the gear reducer cover
and the pump

Oil leakage between
the gear reducer case
and the engine

CAUSE SOLUTION

No gasoline in fuel tank or carburetor

Low oil (on units with low oil sensor).

Start/Stop switch in Stop position.

W

ater in gasoline or old fuel.

Choked improperly

Dirty air cleaner filter

Spark plug dirty

Spray gun closed.

Partially plugged air cleaner filter

Spark plug dirty

W

orn or wrong size tip.

Inlet filter clogged.

W

orn packings, abrasives in water or

natural wear

Inadequate water supply

Fouled or dirty inlet or discharge valves.
Even a small particle can cause the valve
to stick.

Restricted inlet.

W

orn inlet or discharge valves.

Leaking high pressure hose.

orn packings.

Humid air condensing inside crankcase.

W

orn 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.

W

orn gasket.

W

orn oil seals and/or o-ring.

W

orn oil seal.

. Flooded engine.

.

, wrong gap or wrong type.

, wrong gap or wrong type.

.

.

.

.

.

Fill the tank with gasoline, open fuel shut of
Check fuel line and carburetor

Add to proper level.

Move switch to start position.

Drain fuel tank and carburetor
spark plug.

Open choke and crank engine several times to clear
out gas.

Remove and clean.

Clean, adjust the gap or replace.

T

rigger spray gun.

Remove and clean.

Clean, adjust the gap or replace.

Replace with tip of proper size.

Clean. Check more frequently

filter

Check

Check water flow rate to pump.

Clean inlet and discharge valve assemblies. Check
filter.

Check garden hose, may be collapsed or kinked.

Replace worn valves.

Replace high pressure hose.

Install new packings. See PUMP SER

Change oil as specified in MAINTENANCE.

Install new packings. See PUMP SER

Install new oil seals. See PUMP SER

Install new plungers. See PUMP SER

Install proper filtration on pump inlet plumbing.

Check water temperature; may not exceed 160

Do not modify any factory–set adjustments. See
EQUIPMENT MISUSE HAZARD.

Clean or replace tip. See Installing and Changing
Spray Tips.

Never run pump more than 10 minutes without
spraying.

Do not run pump without water

Clean or replace valves. See PUMP SER

Replace the gasket. See SER

Replace oil seals and/or o-ring. See SER
SECTION.

Replace oil seal. See SER

. Replace packings. See PUMP SER

.

. Use new fuel and dry

.

.

VICE SECTION.

VICE SECTION.

f valve.

VICE.

VICE.W

VICE.

VICE.

VICE.

F.

VICE.

VICE

308–529

9

PARTS DRAWING

800–638 & 800–690 Hydra–Clean 2540 Pressure Washer

48

51

50 47

47

13

51

3

4

10

7

65

8

49

62

38

45

46

52

61

54

43

64

11

10

60

3

7

8

10

4

37

58

53

56

57

29

3
0

35
36
42
44

31

33

32
26

39
40
41
55
59

34

6

24

26

25

11

20

10

11

10

23

10

12

18

20

21

17
19

14

1

9

5

2

47

15
16

13

15
16

32

10

26

308–529

22

26
27

28

63

PARTS LIST

800–638 & 800–690 Hydra–Clean 2540 Pressure Washer

REF PART
NO. NO. DESCRIPTION QTY

1 800–392

2 803–350

3 181–867
4 802–363
5 801–134 W
6 179–885
7 803–900

8 802–127 SCREW

9 801–674
10 100–527 W
11 111–040 NUT
12 801–539 BUMPER 1
13 801–568
14 802–579
15 801–569
16 156–082
17 801–009
18 801–941 SCREW

19 154–594
20 154–636 W
21 101–545
22 801–504
23 803–740
24 803–741 AXLE 1
25 801–546 SCREW

26 100–023 W
27 801–819 SCREW

28 801–858 BRACKET, Front Leg 1
29
30 800–641

31 803–301

GUN & W

(incl. 2, 5, 9, 15, 17, 47)

GUN, Spray (see Instruction

Manual 308–51
LABEL, W
LABEL, Caution

AND, 32”
LABEL, W
ENGINE, 9 hp, Honda OHV

(used on 800–638 only)

803–901

803–925 HANDLE 1

ENGINE, 9 hp, Briggs &

Stratton OHV (used on

800–690 only)

5/16–18 x 1-3/4
SLEEVE, 28”

ASHER, Flat 5/16

COUPLER, Male 3/8
HOSE, High Pressure, 3/8 x 50’
COUPLER, Female 3/8 (incl. 16)
O–RING, Female Coupler 3/8
COUPLER, Female 1/4 (incl. 19)

5/16–18 x 1
O–RING, Female Coupler 1/4

ASHER, Flat 5/8
PIN, Cotter 1/8 x 1-1/2
BUMPER, Rubber
WHEEL & TIRE ASSEMBL

3/8–16 x 1-1/4

ASHER, Flat 3/8

3/8–16 x 3

FRONT LEG ASSEMBL

(incl. 22, 26, 27, 28, 32)
LABEL, Model 2540

AND ASSEMBL

1) 1

arning, ventilation

arning, chassis

, Cap, hex hd.

, Lock 5/16–18

, Cap, hex hd.

, Cap, hex hd.

, Cap, hex hd.

Y

Y2

Y

1

1
1
1
1

1

1

4

1
18
10

2

1

2

2

1

4

1

4

2

2

4
10

1

1

1

REF P
NO. NO. DESCRIPTION QTY

32 101–566 NUT
33 800–661 CHASSIS 1
34 801–012 GROMMET
35 800–131

36 800–137

37 402–278
38 803–083
39 801–090
40 801–640 TIP
41 801–667 TIP
42 800–128

43 803–739

44 800–129

45 801–907 W
46 801–905
47 156–849
48 801–709
49 800–655
50 802–627
51 803–869
52 801–523
53 801–622
54 800–115 VAL
55 801–614 TIP
56 801–111 NUT
57 801–110
58 804–051 FILTER/STRAINER 1
59 801–615 TIP
60 801–367
61 802–140 BRACKET
62 804–073
63 800–377

64 803–737 PUM
65 802–143

ART

, Lock 3/8–16

, Rubber

TIP ASSEMBLY, 0005

(incl. 39, 40)

TIP ASSEMBLY, 1505

(incl. 39, 41)
PLUG, Plastic
LABEL, Keep From Freezing
COUPLER, Male 1/4

, Spray 0005
, Spray 1505

TIP ASSEMBLY, 2505

(incl. 39, 55)
PUMP & GEAR REDUCER

ASSEMBL
TIP ASSEMBLY, 4005

(incl. 39, 59)

ASHER, Flat
ADAPTER, 3/8 G x 3/8 NPT
NIPPLE, Hex 3/8
PLUG, Square
UNLOADER, 2500 psi
NIPPLE, Hex 3/8 x 1/4
HOSE, Bypass
NIPPLE, 1/2 x 2
CROSS, 1/2

VE, Thermal Relief

, Spray 2505

, Garden Hose

ADAPTER, Garden Hose

, Spray 4005

BUMPER, Rubber

ADAPTER, 1/2
HOSE ASSEMBLY, w/Couplers

(incl. 13, 14, 15)

P A

GEAR REDUCER ASSEMBL

(see page 15)

Y (incl. 64, 65)

, Support

SSEMBL

Y (see page 1

Y

3

4

1

1
1
1
4
1
1

1

1

1
1
1
2
1
1
1
1
1
1
1
1
1
1

1
2
1
1

1

6) 1

1

308–529

11

PARTS DRAWING

800–639 Hydra–Clean 3040 Pressure Washer

13

37

58

51

57

50

56

48

51

47

53

46

52

54

38

49

61

55

22

10

43

60

3

7

8

10

4

30

32

26

29

35
36
42
44

34

32
26

62

19

26
27

31
39
40
41
45

28

12

33

6

26

25

24

10

22

20

22

10

23

10

18

59

20

11
17

14

1

9

5

2

21

47

15
16

13

15
16

12

308–529

PARTS LIST

800–639 Hydra–Clean 3040 Pressure Washer

REF PART
NO. NO. DESCRIPTION QTY

1 800–392

2 803–350

3 181–867
4 802–363
5 801–134 W
6 179–885
7 803–158
8 802–127 SCREW

9 801–674
10 100–527 W
11 801–009
12 801–539 BUMPER 1
13 801–568
14 802–579
15 801–569
16 156–082
17 154–594
18 801–941 SCREW

19 801–504
20 154–636 W
21 101–545
22 111–040 NUT
23 803–740
24 803–741 AXLE 1
25 801–546 SCREW

26 100–023 W
27 801–819 SCREW

28 801–858 BRACKET, Front Leg 1
29
30 800–641

31 801–090
32 101–566 NUT

GUN & W

(incl. 2, 5, 9, 1

GUN, Spray (see Instruction

Manual 308–51
LABEL, W
LABEL, Caution

AND, 32”
LABEL, W
ENGINE, 1

5/16–18 x 1-3/4
SLEEVE, 28”

ASHER, Flat 5/16
COUPLER, Female 1/4 (incl. 17)

COUPLER, Male 3/8
HOSE, High Pressure, 3/8 x 50’
COUPLER, Female 3/8 (incl. 16)
O–RING, Female Coupler 3/8
O–RING, Female Coupler 1/4

5/16–18 x1
BUMPER, Rubber

ASHER, Flat 5/8
PIN, Cotter 1/8 x 1-1/2

WHEEL & TIRE ASSEMBL

3/8–16 x 1-1/4

ASHER, Flat 3/8

3/8–16 x 3

803–925 HANDLE 1

FRONT LEG ASSEMBL

(incl. 19, 26, 27, 28, 32)
COUPLER, Male 1/4

AND ASSEMBL

1, 15, 47)

1) 1

arning, ventilation

arning, chassis

1 hp, Honda OHV

, Cap, hex hd.

, Cap, hex hd.

, Lock 5/16–18

, Cap, hex hd.

, Cap, hex hd.

, Lock, 3/8–16

Y

Y2

Y

1

1
1
1
1
1

4
1

18

1

2
1
2
1
1

4
2
4
2

10

4

10

1

1
4
5

REF P
NO. NO. DESCRIPTION QTY

33 800–661 CHASSIS 1
34 801–012 GROMMET
35 800–314

36 800–315

37 402–278
38 803–083
39 803–106 TIP
40 803–107 TIP
41 803–108 TIP
42 800–316

43 803–739

44 800–317

45 803–109 TIP
46 804–073
47 156–849
48 800–324
49 802–140 BRACKET
50 803–142

51 803–141
52 801–523
53 801–622
54 800–115 VAL
55 801–367
56 801–111 NUT
57 801–110
58 804–051 FILTER/STRAINER 1
59 800–377

60 803–737 PUM
61 802–143

62 803–161

ART

, Rubber

TIP ASSEMBLY, 00045

(incl. 31, 39)

TIP ASSEMBLY, 15045

(incl. 31, 40)
PLUG, Plastic
LABEL, Keep From Freezing

, Spray 00045
, Spray 15045
, Spray 25045

TIP ASSEMBLY, 25045

(incl. 31, 41)
PUMP & GEAR REDUCER

ASSEMBL
TIP ASSEMBLY, 40045

(incl. 31, 45)

, Spray 40045
ADAPTER, 1/2
NIPPLE, Hex 3/8
UNLOADER, 3000 psi

NIPPLE, Hex

1/2 NPSM x 3/8 NPT
HOSE, Bypass
NIPPLE, 1/2 x 2
CROSS, 1/2

VE, Thermal Relief

BUMPER, Rubber

, Garden Hose

ADAPTER, Garden Hose

HOSE ASSEMBLY, w/Couplers

(incl. 13, 14, 15)

P A

GEAR REDUCER ASSEMBL

(see page 15)
LABEL, Model 3040

Y (incl. 60, 61)

, Support

SSEMBL

Y (see page 1

Y

4

1

1
1
1
1
1
1

1

1

1
1
1
2
1
1

1
1
1
1
1
2
1
1

1

6) 1

1
1

308–529

13

GEAR REDUCER SERVICE

To

reduce the risk of serious bodily injury

from

moving parts, always follow the

WARNING

, including fluid injection, splashing in the eyes or on the

Pressure Relief Procedure W

arning

on page 2 before proceeding.

skin or injury

Replacing the Gasket (9)

NOTE: To maintain a good seal, the gasket must be

replaced whenever the gear reducer is
disassembled.

the

1. Remove
Pull the pump and gear reducer assembly of f the
engine.

2. Drain the gear reducer oil by placing a container
under
wrench.

3. Remove
pull

the gear case of

4. Remove the old gasket (9). Clean the gear cover

case surface. Lightly coat the new gasket with

and
grease

5. Follow steps 5 through 7 under Assembling the

Reducer if this is all the service required.

Gear

four bolts, lockwashers and washers.

it

and removing the drain plug with a 22 mm

Replace the o–ring (15) if damaged.

the nine screws with a 6 mm wrench and

f the gear cover

and install it in on the gear case.

.

Replacing the Oil Seals (21)

1. Follow steps 1 through 3 under Replacing the
Gasket.

2. Loosen the setscrew, using a 4 mm wrench, and

the gear of

pull

3. Using

4.

5. Follow steps 2 through 7 under Assembling the

a 6 mm wrench, remove the
sure to keep them separate from the other nine
screws

Remove the four oil seals and replace them.

Gear

removed previously

Reducer if this is all the service required.

f the pump with a gear puller

four screws. Be

.

.

Replacing the O–Ring (1)

1. Follow

2. Pull the gear cover of f the pump and replace the

3. Follow instructions under Assembling the Gear

the instructions under Replacing the
and Replacing the Oil Seals to disassemble the
gear reducer.

o–ring (1).

Reducer

if this is all the service required.

Gasket

Replacing the Oil Seal (14)

NOTE: The oil seal MUST be replaced with a new

if removed.

one

1. Follow

2. Remove

3. Push the seal from the inside to the outside of the

4. Wipe the inner surface of the case clean, then

5. Place

6. Follow steps 4 through 7 under Assembling the

steps 1 and 3 under Replacing the

the snap ring (6) from the gear case,

a

snap ring pliers. Pull the gear and bearing.

gear case by placing screwdriver against the seal

lightly tapping it with hammer

and

coat it with grease. Place the oil

lightly
gear case. Use a socket, placed against the
surface of the seal, to push the seal into the case

its top surface is past the ridge in the bore.

until

the gear and bearing back into the gear case

and

install the snap ring (6).

Reducer if this is all the service required.

Gear

.

Gasket.

using

seal into the

Assembling the Gear Reducer

1. Grease the o–ring and make sure it’ s properly
on the gear cover

placed

2. Place the four oil seals and screws in the gear

Place the o–ring on the screw to hold it in the

cover.
cover.

3. Apply low strength Loctite  (blue) on the screw

threads, align the screws with the holes in the
pump, and tighten the screws oppositely and
evenly.

4. Grease the pump shaft. Align the gear ’s slot with

the key on the pump shaft and slide the gear onto
the shaft, up to the pump’ s shoulder . Apply low
strength Loctite  on the setscrew threads and

the setscrew to lock the gear on the shaft.

tighten

5. Make sure the gasket is in place (refer to step 4

Replacing the Gasket). Install the gear cover

under
on the case, aligning the holes, and secure it with
the nine screws and lockwashers. T ighten the
screws

6. Grease

the key on the engine shaft and slide the gear
reducer

evenly in a crisscross pattern.

the engine shaft. Align the gear’s slot

onto

the shaft, up to the engine’

.

with

s shoulder

.

14

308–529

7.

Secure the gear reducer to the engine with the four
bolts,

lockwashers and washers.

PARTS DRAWING
802–143 Gear Reducer

21

1

20

2

3

4

10

5

6

7

8

9

17

11

12

13

14

PARTS LIST
802–143 Gear Reducer

REF PART
NO. NO. DESCRIPTION QTY

1 802–332 O–RING 1
2 802–333
3 802–334 SCREW
4 802–335
5 802–336
6 802–337
7 802–338 BEARING 1
8 802–339

9 802–340 GASKET 1
10 801–475 DIPSTICK 1
11 802–341
12 100–527 W
13 802–342 SCREW 9
14 802–343
15 802–344 O–RING 1
16 801–484 CAP
17 802–345
18 100–214 W
19 802–331 BOLT
20 802–346 SCREW 4
21 802–347

COVER, Mounting

GEAR, Pump
GEAR, Engine
RING, Snap

RING, Snap

CASE, Mounting

ASHER, Lock

SEAL, Oil

, G 3/8 BSP

GAUGE, Sight

ASHER, Flat

, 5/16–24 x 1”

SEAL, Oil

, Set

1
1
1
1
1

1

1

13

1

1
1
4
4

4

19

12

18

15

16

308–529

15

PARTS DRAWING

803–737 Pump Assembly

10

9

8

18

19

20

11

2

10

45

53

12

44

13

43

14

42

16

40

17

15

41

14

50

49

39

12

7

6

5

4

3

11

9

1

52

45

51

44

47

46

54

16

308–529

38

37

31

36

21

35

34

23

25

22

24

26

33

32

28

29

27

31

30

PARTS LIST

803–737 Pump Assembly

REF PART
NO. NO. DESCRIPTION QTY

1 801–467

MANIFOLD, 2000 psi
2 801–468 SCREW
3 801–469 W

KIT 1

4

KIT 1

5

KIT 1

6

KIT 1

7

KIT 1

8

KIT 4

9

KIT 4

10

KIT 1

11

ASHER, Lock
O–RING
SEAT

, V

PLA

TE, V
SPRING
GUIDE, V
O–RING
CAP
VAL

VE ASSEMBL
12 803–283 SCREW
13 803–284
14 802–500
15 803–285

KIT 2

16
17 803–286

COVER, Crankcase
O–RING, Crankcase Cover
BEARING, T
SEAL, Oil
BUSHING, Piston

, Cap, hex hd.

alve

alve

alve

Y

, Cap, socket hd.

apered Roller

1
8
8

8
1
2
2

1
18 802–895 CRANKCASE 1
19 801–475 DIPSTICK 1
20 803–144 GASKET

, Cover

1
21 803–332 CRANKSHAFT 1
22 803–288

RING, Retaining

6
23 802–794 KEY 1
24 803–289
25 803–290
26 803–291

PIN, W
GUIDE, Piston
ROD, Connecting

27 803–292 SCREW

rist 3

, Cap, socket hd

3

3

5

REF P

ART

NO. NO. DESCRIPTION QTY

28 803–293
29 802–345
30 802–793

KIT 6

31

COVER, Crankcase
GAUGE, Sight
PLUG, Oil Drain

O–RING
32 803–294 SCREW
33 801–652 W
34 801–660 W
35 801–490

KIT 6

36
37

KIT 6
KIT 6

38
39 803–295

ASHER, Lock

ASHER, Flinger
PLUNGER, Ceramic
RING, Backup
WASHER
SCREW
COVER, Crankcase

, Cap, socket hd

, Piston

1
1
1

6
6
3
3

1

40 803–296 SHIM 2

KIT 3

41
42

KIT 28
KIT 28

43
44

KIT 8,28
KIT 28

45
46

KIT 28

47

KIT 28
49 802–305 SCREW
50 802–304 W
51 801–482
52 801–483 W
53 801–484
54 801–485 W

SEAL, Oil
O–RING
RET

AINER, Packing
PACKING
RING, Head
RET

AINER, Packing
RING, Long Life

, Cap, socket hd.

ASHER, Lock

PLUG, Hex

ASHER, Flat

PLUG, Hex

ASHER, Flat

2
2
1
1
1
1

Kit

Repair Kit

No.

Part No.

1 801–472

Valve

2 801–473

Oil Seal Kit

3 802–511

Crankshaft
Seal Kit

4 802–306

6 801–474

8 801–486

28 801–487

alve Cap Kit

V

Plunger Repair
Kit

Packing Kit

Packing and
Retainer Kit

Ref.

Description Qty.

No.

4

O–RING

, V

5

SEAT
PLA

6

SPRING

7

GUIDE, Valve

8

VALVE ASSEMBLY

11

16

SEAL, Oil

41

SEAL, Oil

910O–RING

CAP

31

O–RING

36

RING, Backup

37

WASHER

38

SCREW

44 PACKING 6

42

O–RING

43

RETAINER,
PACKING

44

RING,

45

RETAINER,

46

RING,

47

alve

TE, V

alve

, Piston

Head

Long Life

Packing

Packing

6
6
6
6
6
6

3

2

6
6

3
3
3
3

1
1
2
1
1
1

308–529

17

PUMP

SER

VICE

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

proceeding.

before

NOTE: The following metric wrenches are needed:

M13 and M30. Repair kits are available.

M10,
Refer

to the individual repair sections and

pump parts page for more details. For the

results, use all parts in the kits.

best

NOTE: 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

the

includes
in

the removal of packing retainers.

items in 800–298 and tools to aid

the

Valves

NOTE:

1. Remove the hex plug from the manifold using an

2. Examine

3. Remove the valve assembly from the cavity; the

4. Install the new valve. Install the o–ring and hex

NOTE: Retorque

For a set of six valves, order P/N 801–472.

wrench.

M30

the

o–ring under the hex plug and replace

it

if it is cut or distorted.

assembly

plug;

may come apart.

torque to 75 ft–lb (103 Nm).

the plug after 5 hours of operation.

Servicing the Plungers

NOTE: Plunger

replace retainers, o–rings, washers and
backup

1. Loosen
using an M10 wrench. Push the plunger towards
the crankcase to separate the plunger and
retaining

2. Remove the screw from the plunger and examine

o–ring, backup ring

the
washer.
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

Otherwise, DO

seals.
they

cannot be reused. An oil seal kit

replace

5. Lightly grease the flinger and oil seal, if it is being
replaced and replace them on the plunger shaft.

install the plunger

Then

6. Lightly grease the retaining screw and the outer
end of the plunger . Place the washer, o–ring and
backup
through

NOTE: If you plan to replace the packings, refer to

Servicing

repair kit, P/N 801–474 is available to

rings for three cylinders.

the plunger retaining screw five to six turns,

screw

.

and copper bearing/gasket

Replace these parts, if necessary

NOT remove these seals as

the seals.

.

ring

around the screw and install the screw

the plunger

. T

orque to 14.4 ft–lb (19.5 Nm).

the V–Packings.

, using kit

is available to

Pumping Section

1. Remove the eight capscrews and lockwashers
the manifold using an M13 wrench.

from

2. Carefully separate the manifold from the

crankcase.

may

NOTE: It

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

3. Carefully

18

to the plunger or seals.

examine each plunger for

cracking

and replace as necessary

308–529

any scoring or

.

7. Lubricate the outside of each plunger . Slide the
manifold onto the crankcase, being careful not to
damage

8. Install the capscrews and washers finger–tight.
Torque the screws to 21.7 ft–lb (29 Nm) following
the
may

Figure 4

the seals.

tightening pattern (Figure 4). Uneven

cause the manifold to bind or jam.

5

8

14

3

2

7

6

tightening

Servicing the V–Packings

PTFE

PTFE

PTFE

PTFE

PTFE

PTFE

PTFE

PTFE

PTFE

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

packings only , the other includes the
packings,

1. Remove the manifold as outlined in the Pumping
Section.

rings and retainers.

clean

5. Thoroughly
for

debris and damage.

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.

2. Carefully pull the packing retainer from the
manifold. Examine the o–ring and replace it if it is

or damaged.

cut

3. Remove

the v–packing and head ring. Pull out

the
intermediate retainer ring. Remove the second
v–packing

4.

Inspect all parts and replace as necessary

and second head ring.

.

ACCESSORIES

(Must be purchased separately)

DOWNSTREAM CHEMICAL INJECT
800–117

For injecting harsh cleaning chemicals downstream

the pump.

from

UPSTREAM CHEMICAL INJECTOR KIT
800–257

For

injecting mild cleaning chemicals upstream into the

pump.

BACKFLOW

Prevent back–up of contaminated water into fresh
supply.

Install upstream of pump.

PREVENT

OR 801–133

OR KIT

CAUTION

Install

the parts in the proper order and facing the

correct direction. Improperly installed parts will

a malfunction.

cause

7. Reassemble the manifold as instructed in
Servicing

the Plungers.

ANTI–FREEZE FLUSH KIT 802–327

For

flushing system with 50% anti–freeze solution prior
to transporting or storing pressure washer in below
freezing

INLET

Regulates inlet water pressure to 60 psi (4 bar)
maximum.

temperatures.

PRESSURE REGULA

TOR 800–258

TECHNICAL DATA

Engine (air–cooled, 4 cycle)

Gasoline T

W

ater Pump Maximum W

Pressure

W

ater Pump Maximum Flow

Inlet Hose Connection

Weight

Dimensions

Maximum Inlet W

Wetted Parts

ank Capacity

Length
Width
Height

ater T

High Pressure Hose

Bypass Hose

Pressure Washer
(including fittings)

emperature 160_ F

orking

Model

800–638

9 hp Honda OHV

6.2 quarts (6 liters) 5 quarts (4.8 liters)

2500 psi (172 bar) 2500 psi (172 bar) 3000 psi (207 bar)

4 gpm (15 lpm) 4 gpm (15 lpm) 4 gpm (15 lpm)

3/4” garden hose (f) 3/4” garden hose (f) 3/4” garden hose (f)

158 lb (70 kg) 158 lb (70 kg) 172 lb (78 kg)

36” (914 mm)
21” (533 mm)

23.5” (597 mm)

(70

_ C) 160_ F

Acrylonitrile and Buna–N cover and tube

Synthetic yarn and EPDM

Anodized aluminum, Aluminum or bronze alloys, Brass Copper
composite, Ceramic, Buna–N, Cotton phenolic, 303, 304, and 316 Stainless steel,
Polymide–12 thermoplastic,
chromate plate

is a registered trademark of the DuPont Company

Model 800–690 Model 800–639

9 hp Briggs & Stratton OHV11 hp Honda OHV

6.9 quarts (6.5 liters)

36” (914 mm)
21” (533 mm)
23” (584 mm)

(70

_ C) 160_ F

r

, Carbon steel, Zinc with or without yellow

36” (914 mm)
21” (533 mm)
24” (610 mm)

, Nylon–

.

(70

_ C)

r

308–529

19

THE GRACO WARRANTY

WARRANTY

Graco
workmanship
purchaser’s
of

sale, repair or replace any part of the equipment proven defective. This warranty applies only when the

equipment

This

warranty does not cover
faulty
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,
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,
labor

DISCLAIMERS AND LIMIT

THE TERMS OF THIS W ARRANTY CONSTITUTE THE PURCHASER’S SOLE AND EXCLUSIVE
REMEDY
WARRANTY
AND
NEGLIGENCE OR STRICT LIABILITY . EVER Y FORM OF LIABILITY FOR DIRECT , SPECIAL OR
CONSEQUENTIAL DAMAGES OR LOSS IS EXPRESSL Y EXCLUDED AND DENIED. IN NO CASE
SHALL
BREACH

EQUIPMENT

GRACO MAKES NO W ARRANTY, AND DISCLAIMS ALL IMPLIED W ARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A P ARTICULAR PURPOSE, WITH RESPECT T O
ACCESSORIES,

GRACO. These items sold, but not manufactured by Graco (such as electric motor

BY
are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable
assistance

AND DISCLAIMERS

warrants all equipment manufactured by it and bearing its

on the date of sale by an authorized Graco distributor

sole remedy for breach of this warranty

is installed, operated and maintained in accordance with Graco’

installation, misapplication, abrasion, corrosion, inadequate or improper maintenance,

operation or maintenance of structures, accessories, equipment or materials not supplied by

and transportation.

OF ANY NON–CONTRACTUAL LIABILITIES, INCLUDING PRODUCT LIABILITIES, BASED ON

repairs will be

AND ARE IN LIEU OF ANY OTHER W

OF MERCHANT

GRACO’S LIABILITY EXCEED THE AMOUNT OF THE PURCHASE PRICE.

OF W

ARRANTY MUST BE BROUGHT WITHIN THREE (3) YEARS OF THE DA

NOT COVERED BY GRACO W

EQUIPMENT

in making any claim for breach of these warranties.

, and Graco shall not be liable for

made at a reasonable charge, which charges may include the costs of parts,

ATIONS

ABILITY OR W

, MA

TERIALS OR COMPONENTS SOLD BUT NOT MANUF

, Graco will, for a period of twenty four months from date

ARRANTIES (EXPRESS OR IMPLIED), INCLUDING

ARRANTY OF FITNESS FOR A P

ARRANTY

name to be free from defects in material and

to the original purchaser for use. As

s written recommendations.

, any malfunction, damage or wear caused by

ARTICULAR

, switches, hose,

negligence,

PURPOSE,

ANY ACTION FOR

TE OF

SALE.

ACTURED

etc.)

20

TO PLACE AN ORDER ,

distributor

closest to you:

FOR TECHNICAL ASSIST ANCE,

application

Subsidiary and Affiliate Companies:

of Graco equipment:

Factory

Branches:

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

308–529

IMPORTANT PHONE NUMBERS

contact your Graco distributor , or call this number to identify the

1–800–328–021

1–800–543–0339 T

Atlanta, Chicago, Dallas, Detroit, Los Angeles, W

Canada; England; Switzerland; France; Germany; Hong Kong; Japan; Korea

PRINTED

1 T

oll Free

service repair information or assistance regarding the

oll Free

est Caldwell (N.J.)

IN U.S.A. 308–529 1/91