Graco Inc Hydra-Clean 800-668, Hydra-Clean 800-666 User Manual

INSTRUCTIONS-PARTS

This

manual

contains IMPORTANT

WARNINGS

READ AND

and

INSTRUCTIONS

RETAIN FOR REFERENCE

LIST

HYDRA-CLEAN

@

251

Pressure Washer

HYDRA-CLEAN@
PIN 800-666,

2500psi (172 bar) OPERATING PRESSURE

2900psi (200 bar)

HYDRA-CLEAN@'
P/N 800-668,

3000

psi

(207 bar) OPERATING PRESSURE

psi

3400

(234 bar)

2510

Series

Series

A

MAXIMUM

3009

A

MAXIMUM

WORKING PRESSURE

WORKING PRESSURE

0.3009

I

GRACO INC.

RO.

BOX

1441 MINNEAPOLIS, MN 55440-1441

@COPYRIGHT

1991,

GRACO

INC.

WARNING

HIGH

FOR PROFESSIONAL

PRESSURE SPRAY

USE

CAN

ONLY. OBSERVE ALL

Read and understand all instruction manuals before operating equipment.

FLUID

General Safety

This pressure washer generates very high
pressure. Spray from

components can inject fluid through your skin and into

your body and cause extremely serious bodily injury

including the need for amputation.
splashed into the eyes or on the skin can cause serious

damage.

NNER

part of the body.
spray tip.

ALWAYS

cleaning or servicing any part of the sprayer.

NNER

body.

INJECTION

point the spray gun or wand at anyone or at any

follow the Pressure Rellef Procedure, before

try to stop or deflect leaks with your hand or

the

NNER

HAZARD

gun,

Also,

put hand

leaks or ruptured

fluid injected or

or

fingers over the

fluid

CAUSE SERIOUS INJURY.

WARNINGS.

Pressure Relief Procedure

To

reduce the risk of serious bodily injury, including
injection and splashing in the eyes or on the skin,
always follow this procedure whenever you stop

10

sprayingfor more than
and before checking or repairing any part of the system.

1.

Engage the trigger safety latch.

2.

Tum the sprayer

3.

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, and then engage the trigger
safety latch again.

minutes, when shuttingdown,

off.

fluid

Be sure equipment safety devices are operating
properly before each use.

Medical Treatment

If

any fluid appears to penetrate your skin, get
EMERGENCY
NOT TREAT AS A SIMPLE

what fluid was injected.

NOTE TO PHYSICIAN: Injection

traumatic
surgically
treatment to research toxicity Toxicity is
concern with some exotic coatings injected

directly into the bloodstream. Consultation with a
plastic surgeon or reconstructive hand surgeon
may be advisable.

MEDlCALTREATMENTATONCE.DO

CUT.

Tell

the doctor exactly

in

the skin is

injuv.

It

is

as

soon

Important

as

to treat

posslble.

the

Do

not delay

Injury

a

a

6.

Before long-term (overnight) storage or
transporting of the unit, disconnect the water supply
and disconnect the fuel supply.

Spray

Be sure all gun safety devices are operating properly
before each
the gun; this can cause a malfunction and result
sefious bodily injury.

SAFETY

moment, always set the gun safety latch
or "safe" position, making the gun inoperative. Failure
properly

triggering of the gun.

SPRAY

cleaning or changing spray tips.

while spraying, engage the gun safety latch

immediately.
Procedure and then remove the spray tip

Gun

Safety

use.

LATCH:

set

the safety latch can result in accidental

TIP

SAFEPI:

ALWAYS

Devices

Do

not remove or modify any part of

Whenever you stop spraying for a

in

the engaged

Use extreme caution when

If

a spray tip clogs

follow the Pressure Relief

to

clean

in

to

it,

2

308-528

FUEL AND

EMISSION

HAZARDS

NNER

me

spilled on a hot surface can ignite and cause a fire.

ALWAYS

NNER

exhaust contains carbon monoxide, a poisonous,

fill the fuel tank while the unit is running or hot.

fuel used in this unit is combustible and when

fill tank slowly

operate the unit in a closed building. The

to

avoid spilling.

EQUIPMENT MISUSE HAZARD

General Safety

Any misuse of the pressure washer or accessories,

such as overpressurizing, modifying parts, using
incompatible chemicals and fluids,

damaged parts, can cause them
fluid injection, splashing in the eyes or on the skin, or
other serious bodily injury, fire, explosion or property

damage.

NNER

so

CHECK

replace wom or damaged parts immediately.

ALWAYS

clothing.

the

alter

or

modify any part of this equipment; doing

could cause it to malfunction.

all spray equipment regularly and repair or

wear protective eyewear and appropriate

If

using a chemical injector, read and follow manufacturer's literature before using any chemical in

chemical manufacturer's literature for

or

using wom

to

rupture and result

or

in

odorless, invisible gas which can cause serious injury

if

or death

NNER

factory

the

pressure washer and will void the warranty.

recommendations on additional protective equipment,

such as

System

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

to

withstand
sprayer.
pressure of any component or accessory
system.

inhaled.

alter the maximum throttle setting, which is

set.

Tampering with this adjustment can damage

a

respirator.

Pressure

the

maximum working pressure of this

DO

NOT

exceed the maximum working

used

in

the

Chemical Compatibility

BE

SURE

injector are compatible with
hose, gun, wand and tip, as given in the Technical Data
(inside back cover). Always read the chemical

this pressure washer.

that ail chemicals used in the chemical

the

wetted parts

of

the

~..

HOSE SAFETY

High pressure fluid in
If the hose develops a leak, split or rupture due

kind of wear, damage or misuse, the high pressure
spray emitted from
other serious bodily injury or property damage.

ALL FLUID HOSES MUST HAVE STRAIN RELIEFS ON
BOTH ENDS.

from

kinks

or

bends

can result in hose rupture.

TIGHTEN

use. High pressure fluid can dislodge a

or allow high pressure spray

coupling.

all fluid connections securely before each

the

hoses

can

be very dangerous.

it

can cause a fluid injection injury or

The

strain reliefs help protect the hose

ai

or close to the coupling, which

loose

to

be emitted from the

to

any

coupling

NNEfl

entire hose for cuts, leaks, abrasion, bulging cover, or
damage

these conditions exist, replace

DO

with tape or any other device.

contain the high pressure fluid.

HANDLEAND ROVTEHOSES CAREFULLY

on

chemicals which are not compatible with the inner tube
and cover of the hose.
temperatures above

(-400

use a damaged hose. Before each

or

movement of the hose couplings.

the

hose immediately.

NOT

try

to

recouple high pressure hose

A

repaired hose cannot

hoses

to

move the pressure washer. Do not use

DO

NOT

expose Graco hose

200"

F

(93'

C)

C).

use,

or

Do

or below

check

If

any

mend it

not pull

-40"

of

to

F

308-528

3

MOVING

PARTS

HAZARD

Moving parts can pinch or amputate fingers or other
body parts.
or operating the pressure washer. high pressure fluid from

NEVER

and interlocks installed and functioning. Follow the

KEEP

operate

CLEAR

Ihe

of moving parts

pressure washer without all guards

when

starting

Pressure Relief Procedure

servicing the pressure washer to prevent discharging

the

before checking or

gun.

TERMS

WARNING:

that could cause bodily injury. that could cause damage

NOTE

Alerts

user

to avoid or correct conditions

Identifies helpful procedures and information.

CAUTION

Alefts

user to avoid or correct conditions

to

the equipment.

IMPORTANT

United States Government safety standards have been adopted under the Occupational Safety and Health
standards-particularly the General Standards, Part 1910, and the Construction Standards, Part 1926-should be

consulted.

Act.

These

4

308-528

INSTALLATION

HIGH

PRESSURE

HOSE

CONNECflON

QUICK

COUPLER

Figure

Check

Check the unit for any damage that may have occurred
in shipping. Notify
any damage.

Set
Fill the battery cells with electrolyte and water. Charge

the

and secure. Connect the fuel line
quick coupler provided. Squeeze the priming
times.
install it between the pump unloader and the high
pressure hose, using

Connect the high pressure hose between the pump
outlet and the gun inlet. Both of these connections are
made with quick couplers.

1

for

Shipping

Damage

the

carrier immediately

if

there

is

Up

battery. Be sure the battery connections are correct

to

the engine using the

bulb

3

to

5

If

you are using a downstream chemical injector,

the

quick couplers provided.

CAUTION

lo

100

fl

Up
beused. Longer hoses may affect sprayer
performance, and chemical injector performance,

if

used.

InStall the appropriate spray tip on the wand. See

Installing and Changing Spray Tips. If you are using a
sandblaster kit, see its separate manual for installation
instructions.

(30 m) of high pressure hose may

Connect

to

Water Supply

CAUTION

Before attaching

local plumbing code regarding cross-connection

to

the water supply.
801-133, is available to prevent backflow of
contaminated water into the fresh water supply.
Install it upstream from the pump.

If inlet water pressure is over
regulating water valve,
installed at the garden hose connection.

Do not exceed 160° F

temperature.

Connect a hose with at leasl a 3/4 inch (19 mm) ID from

the water supply

supply hose should not be more than
NOTE: The water source at the unit

minimum flow rate equal
Technical Data, inside back cover).
not possible, a water holding tank must be
added

to

the water supply, check your

A

backflow preventer, P/N

60

psi

P/N

800-258, must be

(70"

C) inlet water

to

the

unit's 3/4

to

prevent pump damage.

inch

NPT inlet. The

50

to

that

(4.1

bar) a

fl(l5

m) long.

must

have a

of

the unit (see

If

this is

308-528

5

Always

is started safely and properly.

1.

NOTE:

2.

use

this startup procedure

Check oil levels.
Engine: Add SA€

as necessary.
Pump: Add SAE

as necessary.

This pressure washer is equipped with a
low-oil sensor that shuts the engine
oil level falls below a certain level. If the unit
stops unexpectedly, check both the oil and
the fuel levels. Check the oil level each time
the unit

Check

fuel

is

refueled.

level.

30

or 1 OW-3OweigM detergent oil

20

or

30

to

ensure that the Unit

weight non-detergent oil

off

WARNING

DO

NOT refuel a hot engine. Refueling a hot
engine could cause a fire. Use only fresh, clean
regular or unleaded gasoline. Close the fuel

shutoff valve during refueling.

3.

Turn on the water supply.

if the

If

the engine is cold, completely close the engine
choke. Press
choke may have
seconds before opening it to keep the engine
running. Otherwise, open the choke as soon as the
engine starts.

If the engine is warm, leave the choke open or
partially closed. Start the engine as described in the
preceding paragraph. When the engine starts. be
sure

to

open the choke completely.

7.

ALWAYS

whenever you stop spraying, even for a moment,
reduce the risk of fluid injection or splashing
eyes or on the skin if the gun is bumped or triggered

accidentally.

8.

ALWAYS

costly damage

7

DONOTaliowthe pressure washer
than

10

recirculating water to overheat and seriously
damage the pump. Tum
will not be spraying or cleaning at least every
minutes.
time further.

If

the

start button.

to

be kept closed for

engage the gun's trigger safety latch

observe the following

to

the pressure washer

in

cool weather, the

10

CAUTIONS

to avoid

CAUTION

to

idle for more

minutes. Doing

heated inlet water is used, reduce this

so

may cause the

off

the pressure washer

to

in

if

10

30

to

the

it

Never run the unit dry, Costly damage to the pump
completely tumed on before operating.

I

will result. Always be sure the

4.

Trigger the gun until water sprays from the tip

indicating that the air is purged from the system.

5.

Be

sure the spark plug ignition cables are pushed
firmly onto the spark plugs. The ignition shutoff
switch should be in the "on" position. The throttle
should be in

6.

Start

NOTE

the engine.

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

triggers the spray

the

"run" position.

1

water supply is

gun.

DO

NOT run the pump dry, which will quickly
damage the pump.
fully tumed on before starting the pump.

DO

NOT operate the pressure washer without an

inlet water screen. This screen helps keep
abrasive sediment
clog or scratch the pump. Keep this screen clean.

DO

NOT pump caustic materials; such materials

may corrode the pump components.

9.

See the chemical injector or sandblaster kit manual

for detailed cleaning information

accessories are used.

Be

sure the water supply is

out

of the pump, which could

if

these

6

308-528

-

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 Nom being triggered accidentally
by hand or if
latch is pushed fully down when engaging
cannot prevent the gun
Figure

2.

ALWAYS

it

is

engage

the

trigger safety

dropped or bumped. Be sure the

from

being triggered. See

it

or it

Installing and Changing Spray

Tips

WARNING

1.

Follow the

2.

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

3.

Without holding your hand over the spray tip
pull back the quick coupler ring (e). Remove the old
tip and/or install a new one, and then release the
ring. See Figure

4.

Be sure the tip

again.

5.

Tip holding holes are provided on the chassis.

TO

avoid blowing the O-ring out
coupler, due
never operate the pressure washer without a tip
securely mounted in the quick coupler.

Pressure

to

Relief Procedure.

3.

is

secure before starting to spray

of

the quick

the high pressure in the system,

(A),

TRIGGER SAFETY LATCH SHOWN ENGAGED

TRIGGER SAFETY LATCH SHOWN DISENGAGED

Figure

2

Figure

3

308-528

7

SHUTDOWN, FLUSHING

'AND STORAGE

WARNING

Pressure

To reduce the risk of serious bodily injury,
including fluid injection and splashing

or

on the skin, always follow this procedure
whenever you stop spraying for more than
minutes, when shutting down, and before
checking or repairing any part of the system.

1.

2.

3. Remove the ignition cable from the spark

4.

5. Disengage the trigger safety latch and trigger

6.

If

the pressure washer will be exposed

temperatures, drain all water
must be stored in freezing temperatures, flush the

unit with a
pressure. Flush the pressure washer before using it
again to remove the anti-freeze.

NOTE:

Rellef

Procedure

in

the eyes,

10

Engage the trigger safety latch.

Turn

the sprayer

plugs.

Shut

off

the water supply.

the gun
the trigger safety latch again.

Before long-term (overnight) storage or
transporting of the unit, disconnect the water
supply, and disconnect the fuel supply.

to

An

anti-freeze flush kit, P/N 802-327,

available

off.

relieve pressure, and then engage

to

freezing

out

of the pump. If it

50%

anti-freeze solution. Relieve

to

make flushing easier.

is

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
After changing the oil
their respective break-in periods, the interval between
required changes is longer.

If

the unit is operating in dusty conditions, these

maintenance checks should be made more often.

in

WARNING

To reduce the risk of serious bodily iniury,

including fluid injection, splashing in the eyes or
on the skin or injury from moving parts, always
follow the
before proceeding.

Daily

After first 5
hours of

Each 25 hours
of operation

After first
hours of

Pressure

50

Relief

What to

Clean water inlet screen and
filter. Check engine and pump
levels. Fill as necessary. Check
oasoline level. Fill as necessarv.

Change engine break-in oil.
Drain

30 or 1OW-30 detergent oil.
Clean and remove air cleaner

foam. Wash with water and
detergent. Dry thoroughly.
with oil and squeeze
oil.

Change pump break-in oil.
SAE

20

tne

engine and pump.

these components following

Procedure Warnlng

1

do

oil

oil

when warm.

or 30 non-detergent oil.

Use

SAE

Rub

to

distribute

Use

If

water does freeze in the pressure washer, thaw it

to

in a warm room before trying

pour

hot

water on or into the pump;

ceramic plungers!

2.

After each

washer with a clean, damp cloth.

3. Perform the appropriate maintenance. See
maintenance chart.

6

308-528

use,

wipe all surfaces of the pressure

start it.

it

may crack the

DO

NOT

Each

100

hours
of operation
or 3 months

Each

500

hours
of operation

Clean or replace paper air
cleaner cartridae. TaD aentlv
remove

Use

dirt.

Cfiange'.eEgine'oil.

SAE 30 or 1OW-30

to

I
I

TROUBLESHOOTING

To

reduce the riskof

moving

parts,

serious

always

follow the

CHART

WARNING

bodily

injury,

includingfluid injection,

Pressure Relief Procedure Warnlng

splashing

before

inthe

eyes

proceeding.

or

on

the skin

or

injury

from

Problem

Engine will

IS

hard to start

Engine misses or
lacks power

COW

pump runs rough

Water leakage

under pump manifold

Water in pump

Frequent or
premature failure of
the packings

Strong

inlet and low pressure

3n

the discharge side

not

start

pessure andlor

from

surging

at

the

M

Cause

No gasoline

Low oil level.
StarVStop switch in Stop position.
Water

Lwse

Battery not properly charged.

Choked improperly. Flooded engine.

Dirty air cleaner filter.
Spark
Spray gun closed.
Partially plugged air cleaner filter.
Spark plug dirty, wrong gap or wrong type.

lnconecl

Worn

Inlet filter Clogged.

Worn packings, abrasives

wear.
Inadequate water suppiy.
Belt slippage.

Fouled or dirty inlet
a smaii particle can

Restricted inlet.
Worn inlet
Leaking

Wom packings.

Humid air condensing inside crankcase.

Worn

Oil seals leaking.
Scored, damaged or wom plungers.

Abrasive material in the fluid being pumped.
Inlet water temperature
Overpressurizing pump.

Excessive pressure due
damaged

Pump running too long without spraying.

Running pump dry.
Foreign

valve or wom inlet and/or discharge valves.

in

fuel

tank or carburetor.

in

gasoline or old fuel.

or wrong battery connection.

plug

dirty, wrong gap or wrong type.

ignition timing.

or

wrong

size

tip.

in

water or natural

or

discharge valves. Even

cause

the valve to stick.

or discharge vaives.

high

pressure

packings.

hose.

too

high.

to partially plugged or

tip.

particles

in the inlet or discharge

Solution

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

Add

to proper level.
Move switch
Drain fuel tank

dry spark plug.
Check and tighten battery connections.
Check electrolyte level of cells, recharge battery.
Open choke and crank engine several times to

clear out gas.
Remove and ciean.
Clean, adjust the gap or replace.

Trigger spray gun.

Remove and ciean.
Clean. adjust the gap or replace.

Time engine.
Replace

Clean. Check'more frequently.
Check filter. Replace packings.

SERVICE.
Check water flow rate

Tighten or replace;

both at same time.
Clean inlet and discharge valve assemblies. Check

filter.

Check garden hose. may
Replace wom valves.
Replace'high pressure hose.
Install new packings.

3hange oil as specified in MAINTENANCE.

nStali new packings.

nstail new oil seals.
Install new plungers.
Install proper filtration on pump Inlet plumbing.
Check watertemperature; may not exceed

Do

not

EQUIPMENT MISUSE HAZARD.
Clean or replace

Spray
Never

spraying.

not

Do
Clean or replace valves.

to

start position.

and

carburetor. Use new fuel and

with tip of proper size.

See

to pump.

USB

wrrect

belts

be

collapsed or kinked.

See

PUMP SERVICE.

See

PUMP SERVICE.

See

PUMP SERVICE.

See

PUMP SERVICE.

modify any factory-set adjustments.

tip.

See

Installing and Changing

Tips.

run

pump more than

run

pump without water.

10

minutes

See

PUMP SERVICE.

off

valve.

PUMP

and replace

16OOF.

See

without

308-528

9

PARTS

800-666

DRAWING

Hydra-Clean@

2510

Pressure

Washer

10

308-528

PARTS

800-666

LIST

Hydra-Clean@

2510

Pressure Washer

REF

NO.

1
2
3

4

5

6
7

8

9

10
11
12
13
14
15
16

17

18
19

20

21

22

23
24
25

26
27

28

29

30

31
32

33
34

35
36
37

38
39

40

41

42

43

44

PART
NO.

800-643
803-788
801-940

100-214
100-023

803-872

102-547

802-784

803-591

802-026

804-049

801 -823

803-812
803-806
803-797
801 -790
803-517
802-084

HUB, Engine
BELT. Drive

HUB,'

SHEAVE, Pump
PUMP, 2500 psi
LABEL, Keep From Freezing

NIPPLE.

TEE., -3~4

801 -787

802-096
803-141

803-1 42
802-025

801 -71 6
801

-008

801-568
800-323

803-791

156-849
803-787
803-781

100-321
800-642
803-817

100-307

100-133

100-132
802-845
803-881
801-571

172-981

BUSHING, 314 x 112

HOSE,

NIPPLE, Hex,
TANK. Fuel.

LABEL, WainiG,
LABEL, Graco G
QUICK COUPLER, Male 318
UNLOADER, 2500 psi

CAPLUG,

NIPPLE, Hex 3/8
BRACKET. Pumo mountina
NBE, pump mounting
NUT, Lock, 1/2-13

BRACKET, Rail stiffener
BOLT, Eye
NUT, Hex, 3/8-16
WASHER, Lock, 318
WASHER, Flat, 3/8

FOOT, Rubber
FUEL LINE, w/Connector,

HOSE, High pressure, 318
LABEL. Wamina. chassis

176-250

800-652
801 -569

318 NPT

Pump 1

314

_.

~ ~ ~

Bypass

x

Inlet,

x 2 1

112

6

aallon

3/4

(see

NPSM 1

fuel

page 14) 1

tank

'

114

X

50'

ON

1

1

6

6

6
1

4

6

14

1

1

1

2

1
1

1

1

1

1

2
2

1

2
6

6

10

4

1

1

1

REF
NO.

45

46
47

48

49

50

51

52

53

54

55

56
57
58
59

60

61
62
63

64

65

66

67

68

69
70

71
72

73
74
75
76

n

78
79

80
81
82
83
84

85

PART
NO.

156-082
803-350
801-134
801 -674
801-009

154-594
801 -972
803-525
107-069
801 -954
100-527
100-01 6

100-015
801 -960
801-959
801 -958
803-867

803-077

802-408

181 -867
802-363
802-908
801-919
803-891
801 -971
800-375

800-392
801

-548

800-404
800-405
800-493
800-494
803-894

803-868
801 -090

801 -759
801 -758
803-697
803-698

155-665
803-781

DESCRIPTION

QN

O-RING, Quick couDler. 3/8
GUN, Spray

(see

3d8-511) 1
WAND. 32l
SLEEVE, 28" 1
QUICK COUPLER, Female, 1/4

O-RING, (incl.
PAD. Banem

5ob

utck ' coupler, 114 1

-~,

BOLT, Battery
BRACKET, Battery
BATTERY, 12 Volt,
WASHER. Flat.

.

~,

BOLT, Carriage, 1/4-20

30

amp

1/4

.

~.

x

1

TERMINAL PROTECTOR, Black
TERMINAL PROTECTOR,

Red

CABLE. 26 Lona 1

CABEL,'

ElectTolyie

CABLE. 32 Lono

LABEL,'w~~~~~­LABEL, Caution
CONNECTOR, Fuel
BRACKET. Fuel Connector

LINE.

Fuei~

.

1/4

-.

,

.

Hose

,

.

-.

.

.

-,

CLAMP,

HOSE ASSEMBLY, w/Quick

couplers (incl. 26,

GUN & WAND ASSEMBLY

(incl. 29,44,46,47,

~"

40,

44)

48,

49)

GROMMET. Rubber 4

TIP

ASSEMBLY

0013

(incl. 79, 80)

TIP

ASSEMBLY 1513

(incl. 79,81) 1

TIP

ASSEMBLY 2513

(incl. 79, 82)

TIP ASSEMBLY 4013

(incl.

CAPLUG,

70, 83) 1

Ouilet,

318

ENGINE, 24 Hp Onan,

electric

statt

QUICK COUPLER, Male, 114 4

TIP, Spray 0013 1

TIP,

Spray 1513

TIP. SDrav 2513 1

TIP;

Sprai

4013

SWIVEL, 318

SPACER, Pump Bracket 2

1

1

1

1

2

1

1

2

2

1

1

1

3

1

1

1

1

1

1

1

1

1

308-528

11

PARTS

800-668

DRAWING

Hydra-Clean6

3009

Pressure Washer

12

308-528

PARTS

800-668

LIST

Hydra-Clean@

3009

Pressure Washer

REF
NO.

1

2

3
4

5

6

7

8

9

10

11
12
13
14
15
16
17

18

19
20
21

22

23

24

25

26

27

28

29

30
31
32
33
34
35
36
37
38
39

40

41

42

43

44

PART
NO.

800-643

803-788
801 -940

100-214
100-023

803-872

102-547

802-784

803-591

802-026
802-1 17

801

-823
803-812
803-806

803-797

803-814

803-517
802-084

801 -787

802-096

803-141

803-142
802-025

801

-71 6

801

-008

801

-568
800-324
803-791

156-849

803-787

803-781

100-321
800-642
803-817

100-307

100-133

.100-132

802-845

803-881

801-571

172-981
176-250

800-652
801

-569

DESCRIPTION

CHASSIS
BELT GUARD

SCREW. Can

5/16-i8 ~'314
WASHER, Lock, 5/16
WASHER, Flat, 5/16

LABEL, Graco G
SCREW, Cap, hex hd

5116-18X 1-1/2

WASHER, Lock, 1/2

WASHER, Flat, 1/2

BARB. Hose. 114
SHiiVE, Engine

HUB, Engine

BELT, Drive

HUB. PumD

SHGVE.

PUMP, 3000 psi
LABEL, Keep From Freezing
NIPPLE. 314

TEE, 314

BUSHING. 314
HOSE, Bypass
NIPPLE,

3/8 NPT x 1/2 NPSM

TANK, Fuel, 6 gallon

LABEL, Warnin
LABEL, Graco
QUICK COUPLER, Male 3/8
UNLOADER, 3000 psi

CAPLUG, Inlet, 3/4

NIPPLE,

BRACKn,

TUBE, Pump mounting

NUT, Lock, 1/2-13
BRACKET, Rail stiffener

BOLT,

Eye

NUT, Hex, 3/8-16

WASHER, Lock, 3/8
WASHER, Flat, 3/8

FOOT, Rubber
FUEL LINE, w/Connector, 1/4
HOSE, High pressure, 3/8

LABEL, Warning, chassis
LABEL, Warning, chassis
FUEL TANK ASSEMBLY

10,

(incl.

QUICK

COUPLER,

(incl. 45)

hex

hd.

X

5/16

.

Pump

(see

page 16)

X

2

X

112

Hex,

fuel

tank

8

Hex

3/8

Pump mounting

23,

24, 25,39, 69)

Female,

x

3/8

50'

QTY

1

1

6
6

6

1

4
6

14

1

1

1

2

1

1

1

1

1

1
1
1

1

1
1
1

2

1
1

2

1

2
2

1

2

6
6

10

4

1
1

1

1
1

2

REF

NO.

45

46
47
48
49

50

51

52

53

54

55

56
57

58

59

60

61
62

63

64

65
66
67
68
69

70

71

72
73

74
75
76

n

.78

79

80

81
82
83
84

85

PART
NO.

156-082

803-350
801-134
801-674

801 -009

154-594

801

-972
803-525
107-069

801

-954
100-527
100-01 6
100-015

801-960

801

-959

801 -958

803-867

803-077

802-408

181-867

802-363

802-908
801-919.
803-891

801

-971

800-375
800-392
801 -548

800-478
800-479

800-480
800-481

803-894
803-868

801

-090

803-687
801 -994
803-686
803-689

155-665

603-781

308-528

13

PARTS

801-790

DRAWING

Pump Assembly,

2500

psi

14

41

308-528

PARTS

801-790

LIST

Pump

Assembly,

2500

psi

REF PART

NO.

NO.

1 ~ 801-781

2

801-468
3 801-469
4 Kit 1
5 Kit 1
6 Kit 1

7

Kit 1

8

Kit 1
9 Kit 1
10 Kit 4
11 Kit 4
12 803-419
13 803-273
14 803-424

15

803-433

16 803-423
17 803-421
18 802-793

19 801-488

20

801-782

21 803-414

22

803-429

23 803-430
24 802-345
25 803-437
26 803-435
27 803-427
28 803-416

29

803-436

30 803-434

31 802-357

DESCRIPTION

MANIFOLD

SCREW, Cap, hex hd
WASHER, Lock
O-RING

SEAT, Valve

PLATE, Valve
SPRING, Valve
GUIDE, Valve
VALVE ASSEMBLY
O-RING
CAP
COVER, Crankcase
SCREW, Cap, socket

hd

GASKET, Cover
BEARING, Tapered roller

GASKET, Cover
COVER, Crankcase

CAP

O-RING

DIPSTICK
CRANKCASE
O-RING

O-RING
GAUGE, Sight
SCREW, Cap, socket hd
WASHER, Lock
YOKE, Crankshaft

ROD,

Connecting

PIN, Wrist
BEARING, Ball
RING, Snap

QTY

2

16
16

1

32

1

1
1
1
1

1

1

1
4
4
1
6

6
6
3
6

1

1

REF

PART

NO.

NO.

32 803-418
33 803-283
34 803-420
35 803-428
36 803-415
37 803-426
38 803-432
39

Kit

6

40

803-417
41 803-425
42 803-422

44

802-304

45

803-438
46 803-431
47 Kit 24

48

Kit 6

49 801-783

50

Kit

29

51

Kit

29

52 Kit 29

53

Kit 29 or
54

Kit 29

55

Kit 6

56 Kit6
57 Kit 6
58 801-482
59 801-483

60

801-484
61 801-485
62 Kit 29

DESCRIPTION

COVER, Crankcase
SCREW, Cap, socket hd
GASKFl; Cover
SEAL, Oil
CRANKSHAFT
RING, Connecting rod

KEY

WASHER. Flat

GUIDE,

piston

COVER, Crankcase
GASKET, Cover
WASHER, Lock
SCREW, Cap, socket hd
BUSHING
SEAL, Oil

WASHER, Flinger
PLUNGER, Ceramic

O-RING
RETAINER, O-ring

RING, Intermediate
PACKING

12

RING;

Head
RING, Backup
O-RING
SCREW. Piston

CAP

WASHER,

Flat

CAP

WASHER, Flat

RING, Long life

QTY

1

4

1

1

1
6
1

6

1
1

4
4
8

6

6

4

4
3
3

Packing
Packing

Retainer

&

62

RING, Long life

~ ~

A

-

6

3

308-528

15

PARTS

803-814

DRAWING

Pump

Asse

16

4i

308-528

PARTS

803-814

LIST

Pump Assembly,

REF PART

NO. NO.

1 801-781

2

801-468
3 801-469
4

Kit

1

Kit

5

6

7

8
9

10

11

12

1

Kit

1

Kit

1

Kit

1

Kit

1

Kit

4

Kit

4

803-419

13 803-273

14

803-424

15 803-433
16 803-423
17 803-421
18 802-793

19 801-488
20 801-782
21 803-414

22

803-429

23 803-430

24 802-345
25 803-437
26 803-435
27 803-427

28

803-416

29

803-436
30 803-434
31 802-357

3000

psi

DESCRIPTION
MANIFOLD
SCREW, Cap, hex

hd

WASHER, Lock
O-RING

SEAT. Valve

".

~~,

~

PLATE, Valve
SPRING, Valve
GUIDE, Valve

VALVE ASSEMBLY

O-RING
CAP
COVER, Crankcase
SCREW, Cap, socket hd
GASKET, Cover
BEARING, Tapered foller
GASKET, Cover
COVER. Crankcase
CAP

O-RING

DIPSTICK
CRANKCASE

O-RING

.~.

"

O-RING

GAUGE, Sight
SCREW, Cap, socket hd
WASHER. Lock

~~

-.

~~

~.

YOKE, Crankshaft

ROD.

PIN.

wrist

Connectina

~~

"

BEARING. Ball

RING, Snap

QTY

2

16

16

1

32

1

1

1
1

1

1

1

1

4
4

1'

6
6
6

3

6

1

1

REF

PART

NO. NO.

32 803-418
33

803-283

34 803-420
35 803-428
36 803-415
37 803-426

803-432

38

39

Kit

6

40

803-417

41

803-425

42 803-422

44

802-304

45

803-438
46 803-431
47

Kit

24

48

Kit6
49 801-490

50

Kit

29

51

Kit

29

52

Kit

53

54

55

56
57

58

59

60

61

62

29

Kit

29or

Kit

29

Kit

6

Kit

6

Kit

6

801-482
801-483
801-484

801-485

Kit

29

DESCRIPTION

COVER. Crankcase

..

~~

SCREW,

Cap, socket

GASKET. Cover

SE~L,

o'il

CRANKSHAFT
RING, Connecting rod

KEY
WASHER, Flat
GUIDE,

Piston

COVER, Crankcase
GASKET, Cover
WASHER, Lock
SCREW, Cap, socket hd
BUSHING
SEAL, Oil
WASHER, Flinger
PLUNGER, Ceramic
O-RING

RETAINER, O-ring

RING, Intermediate

PACKING

12

RING, Head

RING, Backup

O-RING
SCREW, Piston

CAP
WASHER, Flat
CAP
WASHER, Flat

RING, Long life

hd

QTY

1

4

1

1

1

6

1

6

1

1

4

4

6
6

6

4

4
3
3

KltRepair

Part

NO.

1

801-472

Kn-

NO.

Valve

4

802-306

Valve

Cap

6

801-474

Plunger Repair

8

801-468

Parkino

. ". . . . .

Packing

Retainer

&

Ref

No.

Descrlptlon

4

O-RING

SEAT,

5

PLATE.

6

7

SPRING

8

GUIDE,

VALVE

9

10

O-RING

11

CAP

39

WASHER, Flat

48

WASHER, Flinger

55

RING,

56

O-RING

57

SCREW.

PACKING

53

Valve

Valve

Valve

ASSEMBLY

Backup

Piston

Qty.

Incl.

6
6
6
6
6
6

6

6

3
3

3

3

3

6

308-528

17

PUMP

SERVICE

WARNING

To

reduce the risk of serious bodily injury,
including fluid injection, splashing in the eyes or
on the skin, or injury from moving parts, always
follow the

Pressure Relief Procedure

Warning

before proceeding.

-

NOTE

NOTE

Valves

NOTE:

1. Remove the hex plug from the manifold using an

2.

3. Remove the valve assembly from the cavity; the

4. Install the newvalve. Install the O-ring and hex plug;

NOTE:

The following metric wrenches are needed:

M30.

M10, M13 and
Refer

to

the individual repair sections and the

Repair kits are available.

pump parts page for more details. For the best
results, use all parts in the kits.

two

There are

different

servicing the pump. P/N

tool

kits

800-298

to

aid in

is used

to

ease installation of packings. P/N 800-271
includes the items in

800-298

and

tools

to

aid

in the removal of packing retainers.

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

M30 wrench.
Examine the O-ring under the hex plug and replace

it

if it is cut or distorted.

assembly may come apart.

torque

to

75

It-lb

(103 Nm).

Retorque the plug after 5 hours of operation.

Servicing the Plungers

NOTE

1,

2.

3.

4.

5.

6.

NOTE

Plunaer reDair kit. P/N 801-474 is available

I.

..

to

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

Loosen the plunger retaining screw five

to

six turns,
using an MlOwrench. Push the plungertowards the
crankcase to separate the plunger and retaining
screw.

Remove the screw from the plunger and examine

the O-ring, backup ring and copper bearinggasket
washer. Replace these parts,

if

necessary, using kit

801-474.
Remove the plunger and flinger from the plunger

shaft. Clean, examine and replace parts as
necessary.

Inspect the

plunger shaft

crankcase. If leaking is

seals. Otherwise,

DO

they cannot be reused.

for oil leakage from the

obvious, replace the

NOT

remove these seals as

An

oil seal kit

is

available to

oil

replace the seals.

Lightly grease the flinger and oil seal,

if

it is being
replaced and replace them on the plunger shaft.
Then install the plunger.

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

If

you plan

to

14.4 ft-lb (19.5 Nm).

to

replace the packings, refer

to

Servicing the V-Packings.

Pumping Section

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

2.

Carefully separate the manifold from the crankcase.

NOTE

It

may be necessary

with a

soft

mallet

to

tap the manifold lightly

to

loosen.

CAUTION

Keep the manifold properly aligned with the
ceramic plungers when removing
damage

3.

Carefully examine each plunger for any scoring or

to

the plunger or seals.

cracking and replace as necessary.

to

avoid

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.

Torquethe screws

to

21.7 ft-lb

(29

Nm)

following the
tightening pattern (Figure 4). Uneven tightening
may cause the manifold

I

Flgure

4

to

bind or jam.

I

18

308-528

Servicing the V-Packings

NOTE:

There are

packings

two

only,

types

of packing kits: one

the

Other includes the

is

5.

Thoroughly clean the packing cavities and examine
for debris and damage.

6.

Lightly grease the packing cavities and then

packings, rings and retainers. replace the packinas in the followina order: head

ring, v-packing, ihrmediate ring: head ring,

1.

Remove the manifold as outlined in the Pumping
Section.

2.

Carefully pull

the

packing retainer from the
manifold. Examine the O-ring and replace it
cut or damaged.

3.

Remove the v-packing and head ring.

Puli

if

out

it is

the

v-packing and packing retainer with the O-ring
installed in the retainer groove.

CAUTION

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

intermediate retainer ring. Remove the second

7.

v-packing and second head ring.

4.

Inspect all parts and replace as necessary.

Reassemble the manifold as instructed in Servicing

the

Plungers.

ACCESSORIES

(Must

DOWNSTREAM CHEMICAL INJECTOR KIT ANTI-FREEZE FLUSH KIT 802-327
800-425

For injecting harsh cleaning chemicals downstream
from the pump.

be purchased separately)

50%

For flushing system with

to

transporting or storing pressure washer in below

anti-freeze solution prior

freezing temperatures.

BACKFLOW PREVENTOR 801 -1 33 INLET PRESSURE REGULATOR 800-258

Prevent back-up
supply. Install upstream

of

contaminated water into fresh

of

pump. maximum.

Regulates

WATER SANDBLASTING KIT 800-120

For abrasive cleaning
Requires a spray tip which is not included in kit

uses

801-758,3009

uses

of

stubborn

801-994).

dirt

and paint.

(2510

TECHNICAL DATA

Model

800-666

Enaine ftwin cvlinder,
Battery

Gasoline Tank Capacity

Water Pump Maximum Working Pressure

Water

Pump Maximum

Inlet

Hme

Connection

Weight

Dimensims

Length

Width

Height

Maximum

Wend

I

Inlet

Parts

High Pressure
BypassHose

~.

Pressure Washer (including fittings)

4

Cvcle. air-cooiedl

Flow

Water Temperature

Hose

I

24

HP

Onan

12

volt,

30

amp,

250

CCA

25500

psi

(172 bar)

gpm

(38

Ipm)

3/4"

NFT

(f)

343

Ibs

(156

kg)

48"

(1219 mm)

30"

(762 mm)

25'

(635

I

1

160' F

mm)

(70'

C)

I

Acrylonitrile and Buna-N cover and

I

Svnthetic yam and EPDM

Anodized aluminum, Aluminum or

composite. Ceramic, Buna-N. Colton phenolic,

steel.

Polymide-12 thermoplastic. TeflonQ, Carbon

yellow chromate plate

TeflonQ

is a registered trademark

inlet water pressure

i

24HPOnan

12 volt,

6 gallon (23 liter) 6 gallon (23 liter)

30500

psi

9

gpm

3/4"

NPT

343

Ibs

48"

(1219 mm)

30"

(762 mm)

25"

1635

.-"

1-

I

160' F (70'

tube

bronze

aiioys, Brass Copper,

303,304,

of

the

DuPont

Company.

Model

30

amp,

(207

(34

ipm) 10

(r)

(156

mml

~

steel.

to

60

psi

800-668

2%

CCA

bar)

kg)

I

C)

Nylon-TeflonQ

and 316 Stainless

Zinc with or without

(4

bar)

I

I

308-528

19

THE GRACO WARRANTY

WARRANTY AND

Gram warrants

and

workmanship on

DISCLAIMERS

ail

equipment manufactured

the

date

of

sale

by

by

an

authorized

A

and beating

Gm disbibutor

its

name

io

be

free

horn

to

the

defects

original purohas8r for

in material

usa.

Aspurohaser'ssoleremedyiorbreachofmiswarranty,Grau,will,faraperiodoftwentyfaurmonthshom

&~ofsaie,repairorrepiaceanypartoftheequipmentpmvendefective.Thiswarrantysppiiesonlywhen

me

equlpment

is

installed.

operated

and

maintained in

acwrdance

with

Gram's written

recommendations.

This

warranty

does not cover.

and

Graw

shall

not

be

liable

for,

any malfunction. damage

M

WBT

caused

by fauiiy installation. misapplication, abrasion. corrosion, inadequate or improper maintenance.
negligence, accident. tampering.

liable for maifunction. damage or
accessories. equipment or materials not supplid by Graco. or
installation. operation or maintenance

or

suWon

mar

caused by

of

sbuctures. accessories. equipment

of

non-Graco component parts. Nor shall Graco

the

incompatibility wim Graco equipment

me

improper design, manufacture.

or

materials not supplied by

ofsbuctures,

be

Graco.

This

warranty is conditioned upon
examination by Gram
repiace

free

of charge

to

verity

any

transportation prepaid. If inspection
workmanship.

repairs

will

be

the

the

claimed

defeotive

parts.

of

made at a reasonable charge, which charges may include

prepaid

return of

defecl.

The

equipment

me

equipment does not disclose

me

If

the

equipment clrumed

claimed defect is verified. Gram will repair or

will

be

returned

to

be d&Wm for

to

me original purchaser

any

defect In

the

mntelial

costs

of

or

parts,

labor and transportation.
DISCLAIMERS

AND LIMITATIONS

THETERMS OFTHIS WARRANTYCONSTIWTETHE PURCHASERS SOLE AND EXCLUSIVE REMEDY

ANDAREINLiEUOFANYDTHERWARRANTiES(EXPRESSORIMPLIED),lNCLUDlNGWARRANTYOF

MERCHANTABiLiTY

NON-CONTRACTUALLIABILITiES.

STRICT LlABiLlTY. EVERY
DAMAGES

OR

LIABILITY EXCEED THE AMOUNT OF THE PURCHASE PRICE. ANY ACTION FOR BREACH
WARRANTY MUST BE BROUGHT WITHIN THREE

LOSS

OR

WARRANTY OF FITNESS FOR

A

PARTICULAR PURPOSE, AND

iNCWDlNG PRODUCTLIABIUTiES. BASEDON NEGLIGENCE

FORM

OF

IS

EXPRESSLY EXCLUDED AND DENIED. IN NO CASE SHALL GRACO'S

LIABILITY FOR DIRECT, SPECIAL

(3)

YEARS OF THE DATE OF SALE,

OR

CONSEQUENTIAL

OF

ANY

OR

OF

EOUIPMENT

- -

-

. .

GRACOMAKESN0WARRANTY;ANDOlSCLAlMSALLlMPLlEDWARRANTlESOFMERCHAMABlLlTY

NOT

.

. .

.

-

.

COVERED

- -

...

"

RV

.

-_

-

.

GRACO

"

.

"

WARRANN

..

.

- -

. .

. . . .

. .

. .

. . . .

AND FITNESS FOR A PARTICULAR PURPOSE, WITH RESPECT TO ACCESSORIES, EOUIPMENS.

MATERIALS

notmanuf~redbyGraa,(suchaselectricmotor,~hes,hose,etc.)aresubjectto~wananiy,~any,

of their manufacturer. Graco will provide purchaser with reasonable assistance
breach

of

OR

COMPONENTS

these

warrantias.

SOLD

BUT

NOT MANUFACTURED BY GRACO.

These

items

sold, but

in

making any olaim for

IMPORTANT PHONE NUMBERS

TO PLACE AN

distributor

FOR

TECHNICAL ASSISTANCE,

application

Subsidiary and

Factory

GRACO INC.

closest

of

Graco

ORDER,

to

you:

equipment:

contact

1-800-328-021

Branches Atlanta. Chicago, Dallas,

Afflilam

Companies: Canada; England: Swherland: France: Germany: Hong Kong;

RO.

BOX 1441 MINNEAPOLIS, MN 55440-1441

PRINTED IN U.S.A.

your Graw distributor,

1

Toll

Free

service

1-800-543-0339

repair information

Toll

Oemi,

Los Angeles. West Caidwell (N.J.)

308-528

or

Free

1/91

call

this number

or

assistance

to

identify the

regarding

Japan:

the

Korea