Graco Inc Hydra-Clean 3540, Hydra-Clean 800-635, Hydra-Clean 800-681, Hydra-Clean 308-525, Hydra-Clean 3050 User Manual
...
INSTRUCTIONS-PAR
This
manual contains
WARNINGS
AND RETAIN FOR REFERENCE
and
IMPORTANT
INSTRUCTIONS
READ
TS LIST
308–525
Rev
A
HYDRA-CLEAN
Pressure W
HYDRA-CLEAN
P/N 800–681, Series A
3000 psi (207 bar) OPERA
3400 psi (234 bar) MAXIMUM WORKING PRESSURE
HYDRA-CLEAN
P/N 800–635, Series A
P/N 800–636, Series A
3500 psi (241 bar) OPERA
3900 psi (269 bar) MAXIMUM WORKING PRESSURE
HYDRA-CLEAN
P/N 800–637, Series A
4000 psi (276 bar) OPERA
4300 psi (296 bar) MAXIMUM WORKING PRESSURE
3050, 13 HP ENGINE
3540, 13 HP ENGINE
4043, 16 HP ENGINE
asher
TING PRESSURE
TING PRESSURE
TING PRESSURE
3050, 3540, 4043
GRACO INC. P
.O. Box 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT
1991, 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 can inject fluid through your skin and into
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
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
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
any
.
Medical Treatment
If any fluid appears to penetrate your skin, get
EMERGENCY
NOT
TREA
what
fluid was injected.
NOTE TO PHYSICIAN:
traumatic
surgically as soon as possible.
treatment
with
some exotic coatings injected
MEDICAL TREA
T AS A SIMPLE CUT. T
injury
.
It is important to treat the injury
to research toxicity
bloodstream. Consultation with a plastic surgeon
reconstructive hand surgeon may be advisable.
or
TMENT A
ell the doctor exactly
T ONCE. DO
Injection in the skin is a
Do not delay
. T
oxicity is a concern
directly into the
Pressure Relief Procedure
To
reduce the risk of serious bodily
injection
follow this procedure whenever you stop spraying for
more
checking
1.
2. T
3.
4.
5. Disengage the trigger safety latch and trigger the
6. Before long–term (overnight) storage or
and splashing in the eyes
than 10 minutes, when shutting
or repairing any part of the system.
Engage the trigger safety latch.
urn the sprayer of
Remove the ignition cable from the spark plug.
Shut of
gun
safety
transporting
and
f the water supply
to relieve pressure, and then
latch again.
of the unit, disconnect the water
disconnect the fuel supply
f.
injury
, including fluid
or on the skin, always
down, and before
.
engage the trigger
.
supply
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
properly set the safety latch can result in accidental
triggering
SPRAY TIP SAFETY: Use extreme caution when
cleaning
spraying, engage the gun safety latch immediately.
ALWAYS
then
bodily injury
always set the gun safety latch in the engaged
“safe” position, making the gun inoperative. Failure to
of the gun.
or changing spray
follow the Pressure Relief Procedure and
remove the spray tip to clean it.
.
tips. If a spray tip clogs while
FUEL AND EMISSION HAZARDS
NEVER
The
on
tank
NEVER
exhaust contains carbon monoxide, a poisonous,
fill the fuel tank while the
fuel used in this unit
a hot surface can ignite and cause a fire.
slowly to avoid spilling.
operate the unit in a closed building. The
is combustible and when spilled
unit is running or hot.
ALWAYS
fill
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
so
could cause it to malfunction.
CHECK
replace
ALWAYS
clothing.
chemical manufacturer’s literature for
parts, can cause them to rupture and result in
alter or modify any part of this equipment; doing
all spray equipment regularly and repair or
worn or damaged parts immediately
wear protective eyewear and appropriate
If using
a chemical injector
, read and follow the
.
odorless,
death
NEVER
factory
the
recommendations on additional protective equipment,
such
System
This
sure
to withstand the maximum working pressure of this
sprayer.
pressure of any component or accessory used in the
system.
invisible
if inhaled.
alter the maximum throttle setting, which is
set. T
pressure washer and will void the warranty
as a respirator
Pressure
sprayer can develop high operating pressures. Be
that all spray equipment and accessories are
DO NOT
gas which can cause serious injury or
ampering with this adjustment can
.
exceed the maximum working
damage
.
rated
Chemical Compatibility
BE SURE
injector
gun,
back cover). Always read the chemical manufacturer’s
literature before using any chemical in this pressure
washer.
that all chemicals used in the chemical
are compatible with the
wand and tip,
as given in the T
wetted parts of the hose,
echnical Data (inside
HOSE SAFETY
High
pressure fluid in the hoses can be very dangerous.
If the hose develops a leak, split or rupture due to any
kind of wear, damage or misuse, the high pressure
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.
allow high pressure spray to be emitted from the
coupling.
all fluid connections securely before each
High pressure fluid can
The strain reliefs help protect the
dislodge a loose coupling or
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 AND ROUTE HOSES CAREFULLY.
pull
chemicals
and
temperatures
(–40 C).
use
a damaged hose. Before each use, check
try to recouple high pressure hose or mend it
the high pressure fluid.
on hoses to move the pressure washer
which are not
cover of the hose.
above 200
compatible with the inner tube
DO NOT
F
expose Graco hose to
(93
C)
or below –40
Do not
. Do not use
F
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers or other
parts.
body
or
operating the pressure washer
NEVER
and interlocks installed and functioning. Follow the
KEEP CLEAR
operate the pressure washer without all guards
of moving parts when starting
.
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
NOTE: Identifies
helpful procedures and information.
.
CAUTION: Alerts user to avoid or correct conditions
could cause damage to the equipment.
that
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.
4 308-525
INSTALLATION
HIGH
PRESSURE
HOSE
CONNECTION
WA
TER
SUPPL
CONNECTION
Y
SPRAY
HOSE
QUICK
COUPLER
SPRAY
GUN
QUICK
COUPLER
TEE HANDLE
(4043 ONL
Y)
Figure
1
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
Fill the battery cells with electrolyte and water. Charge
battery
the
and
quick
times.
install it between the pump unloader and the high
pressure
Connect the high pressure hose between the pump
outlet and the gun inlet. Both of these connections are
made
. Be sure the battery connections are correct
secure.
Connect the fuel line to the engine using the
coupler provided. Squeeze the priming bulb 3 to 5
If you are using a downstream chemical injector
hose, using the quick couplers provided.
with quick couplers.
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 affect sprayer
and chemical injector
kit, see its separate manual for installation
performance,
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’s 3/4 inch garden hose inlet.
The supply hose should not be more than 50 ft (15 m)
long.
NOTE: The water source at the unit
at the garden hose connection.
a hose with at least a 3/4 inch (19 mm) ID from
minimum
Technical
flow rate equal to that of the unit (see
Data, inside back cover).
connection
must
have a
STARTUP
Always
is
1.
NOTE: This pressure washer is equipped with a
2.
use this startup procedure to ensure
started safely and properly
Check oil levels.
Engine: Add SAE 30 or 10W–30 weight detergent
as necessary
oil
Add SAE 20
Pump:
as
necessary
low–oil sensor that shuts the engine off if the
oil level falls below a certain level. If the unit
stops
fuel levels. Check the oil level each time the
is refueled.
unit
Check fuel level.
.
.
unexpectedly
.
or 30 weight non–detergent oil
, check both the oil and the
that the unit
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
.
CAUTION
Never
run the unit dry
will result. Always be sure the water supply is
completely
turned on before operating.
. Costly damage to the pump
If the engine is cold, completely close the engine
choke. Press the start button. In cool weather
choke may have to be kept closed for 10 to 30
seconds before opening it to keep the engine
running.
engine
If the engine is warm, leave the choke open or
partially
preceding paragraph. When the engine starts, be
sure
7.
ALWAYS
whenever
reduce the risk of fluid injection or splashing in the
eyes
accidentally.
ALWAYS
8.
avoid
Otherwise,
starts.
closed. Start the engine as described in the
to open the choke completely
engage the gun’s trigger safety latch
you stop spraying, even for a moment, to
or on the skin if the gun is bumped or triggered
observe the following CAUTIONS to
costly damage to the pressure washer
open the choke as soon as the
.
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
the pump. T
run the pump dry, which will quickly
the pump. Be sure
on before starting the pump.
urn of
f the pressure washer if it
the water supply is fully
, the
.
4. Trigger the gun until water sprays from the tip
indicating
5. Open
ignition cables are pushed firmly onto the spark
plugs. Put the ignition shutoff switch in the “on”
position
6.
Start the engine.
NOTE: For
that the air is purged from the system.
the fuel shutoff valve. Be sure the spark plug
and the throttle in the “run” position.
easier starting, have one person start the
pressure washer while another person
triggers
the spray gun.
DO
NOT
operate the pressure washer
water screen removed. This screen helps keep
abrasive sediment out of the pump, which could
or scratch the pump. Keep this screen clean.
clog
DO NOT
may
9. See
for detailed cleaning information if these
accessories
pump caustic materials; such materials
corrode the pump components.
the chemical
injector or sandblaster kit manual
are used.
with the inlet
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
back
the quick coupler ring (B). Remove
and/or install a
See
Figure 3.
4. Be sure the tip is secure before starting to spray
again.
follow the procedure below
Pressure Relief Procedure
else.
holding your hand over the spray tip (A), pull
new one, and then release the ring.
, including
.
.
the old tip
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
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 be stored in freezing temperatures, flush the
unit with a 50% anti–freeze solution. Relieve
pressure.
again
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
supply,
and disconnect the fuel supply
Flush the pressure washer before using it
to remove the anti–freeze.
available
and splashing in the eyes,
f.
.
of the unit, disconnect the water
to make flushing easier
.
.
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
with a clean, damp cloth.
pressure washer
DO NOT
, thaw
Observing regular maintenance intervals helps ensure
that you get maximum performance and life from the
pressure
There is a break–in period for the engine and pump.
After changing the oil in these components following
their respective break–in periods, the interval between
required
If the unit is operating in dusty conditions, these
maintenance
washer
changes is longer
.
.
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 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
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. 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.
. Check
. Rub
ap gently to
.
3. Perform the appropriate maintenance. See
maintenance
chart.
TROUBLESHOOTING CHART
WARNING
To
reduce the risk of serious bodily injury
moving
parts, always follow the
Pressure Relief Procedure W
Problem Cause Solution
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
No gasoline in fuel tank or carburetor
Low oil level.
Start/Stop switch in Stop position.
W
ater in gasoline or old fuel.
Loose or wrong battery connection.
Battery not properly charged.
Choked improperly
Dirty air cleaner filter
Spark plug dirty
Spray gun closed.
Partially plugged air cleaner filter
Spark plug dirty
Incorrect ignition timing.
W
orn or wrong size tip.
Inlet filter clogged.
W
orn packings, abrasives in water or natural
wear.
Inadequate water supply
Belt slippage.
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.
W
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.
, including fluid injection, splashing in the eyes or on the skin or injury from
arning
.
. 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
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 clean.
Clean, adjust the gap or replace.
T
rigger spray gun.
Remove and clean.
Clean, adjust the gap or replace.
T
ime engine.
Replace with tip of proper size.
Clean. Check more frequently
Check filter
SERVICE.
Check water flow rate to pump.
T
ighten or replace; use correct belts and replace
both at same time.
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
before proceeding.
f valve.
.
. Use new fuel and
.
.
. Replace packings. See PUMP
VICE.
VICE.
VICE.
VICE.
F.
.
VICE.
PARTS DRAWING
800–635 & 800–636 Hydra–Clean 3540 Pressure Washer
76
89
37
87
85
70
31
63
5
47
60
58
57
32
59
64
15
88
38
33
34
35
36
2
71
72
73
74
29
5
87
86
28
30
56
45
46
77
1
63
5
1
2
62
5
2
48
49
61
58
57
2
5
5
6
53
52
54
55
9
11
10
76
51
77
3
27
65
48
37
4
7
44
5
6
50
8
67
24
22
79
5
78
81
80
10 308-525
83
25
66
68
5
2
20
19
18
84
82
21
91
5
23
89
92
90
17
16
40
87
12
39
13
75
14
69
26
42
43
69
26
42
41
PARTS LIST
800–635 & 800–636 Hydra–Clean 3540 Pressure Washer
REF PART
NO. NO. DESCRIPTION QTY
1 100–188 NUT
2 100–214 W
3 803–945 BELT
4 803–800 SHEA
5 100–023 W
6 801–941 SCREW
7 803–534
8 803–926 BEL
9 803–525 BOLT
10 804–282 BRACKET
11 801–972 P
12 801–550
13 801–612 W
14 801–020 NUT
15 800–676 CHASSIS 1
16 801–556 AXLE 1
17 800–678 BRACKET
18 801–546 SCREW
19 100–133 W
20 100–132 W
21 800–160
22 803–905
23 111–040 NUT
24 803–925 HANDLE 1
25 803–298 SCREW
26 156–082
27 154–594
28 802–016 BRACKET
29 801–522 SCREW
30 176–250
31 801–548 GROMMET
32 172–981
33 800–314
34 800–315
35 800–316
36 800–317
37 803–883
38
39 800–652
40 801–733
41 801–571
42 801–569
43 801–568
44 800–392
45 100–023 W
46 801–217
LABEL, Belt Guard
WHEEL & TIRE ASSEMBL
FRONT LEG ASSEMBL
LABEL, Model 3540
O–RING, Quick Coupler 3/8
O–RING, Quick Coupler 1/4
LABEL, Chassis
LABEL, Chassis
TIP ASS’Y
TIP ASS’Y
TIP ASS’Y
TIP ASS’Y
ENGINE, 12.5 HP
803–967
803–526 SP
ENGINE, 13 HP
PUMP ASS’Y (see page 16)
FUEL T
BARB, Hose 1/4
HOSE, High Pressure 3/8 x 50’
QUICK COUPLER, Female 3/8
QUICK COUPLER, Male 3/8
GUN & W
BUMPER, Rubber
, Hex 5/16–18
ASHER, Lock 5/16
, Drive
VE, Engine
ASHER, Flat 5/16
, Cap, Hex hd
5/16–18 x 1
T GUARD
, Battery
, Battery
AD, Battery
ASHER, Flat 1/2
, Lock 1/2–13
, Rail Stif
, Cap, Hex hd
3/8–16 x 1–1/4
ASHER, Lock 3/8
ASHER, Flat 3/8
(incl. 5, 78 through 84)
, Lock 5/16–18
, Cap, Hex hd
5/16–18 x 3–1/2
, Rail Stif
, Cap, Hex hd
, Rubber
, 00045 (incl. 70, 71)
, 15045 (incl. 70, 72)
, 25045 (incl. 70, 73)
, 40045 (incl. 70, 74)
Stratton V
(used on 800–635 only)
(used on 800–636 only)
(incl 40, 87, 89, 90, 91, 92)
(used on 800–635 only)
(used on 800–635 only)
(incl. 26)
(incl. 42, 65, 66, 67, 68, 69)
ASHER, Flat 5/16
(used on 800–635 only)
ACER (used on
800–636 only)
anguard OHV
ANK ASSEMBL
AND ASSEMBL
fener 1
Y
fener 1
, Briggs &
, Honda OHV
Y
Y
11
13
2
1
26
9
1
1
2
1
1
Y2
2
2
4
4
4
1
1
4
1
2
1
2
1
5
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
REF P
NO. NO. DESCRIPTION QTY
47 177–144
48 803–535 SCREW
49 803–942 SHEA
50 801–898
51 801–135
52 801–959
53 801–945
54 803–077
55 801–954 BATTERY
56 100–527 W
57 100–016 W
58 100–015 NUT
59 801–964 BOLT
60 801–946
61 801–958
62 803–531 BASEPLA
63 801–022 SCREW
64 107–069 BRACKET
65 801–009
66 801–134 W
67 801–674
68 803–350
69 156–849
70 801–090
71 803–106 TIP
72 803–107 TIP
73 803–108 TIP
74 803–109 TIP
75 800–375
76 802–363
77 181–867
78 801–531 SCREW
79 801–504
80 801–505 RET
81 801–593 SPRING 1
82 801–506 BOOT 1
83 801–537
84 801–499 NUT
85 802–907 CONNECT
86 801–919 BRACKET
87 801–971 CLAMP
88 801–629
89 801–716
90 803–881
91 802–025 T
92 801–008
ART
LABEL, Belt Guard
(used on 800–635 only)
801–559 SCREW
(used on 800–636 only)
VE, Pump
HUB, Engine
HUB, Pump
TERMINAL PROTECT
CABLE, Battery 12” Long
LABEL, BA
ASHER, Flat 1/4
ASHER, Lock 1/4
, Hex 1/4–20
, Carriage 1/4–20 x 1
CABLE, Battery 24” Long
TERMINAL PROTECT
5/16–18 x 3/4
QUICK COUPLER, Female 1/4
(incl. 27)
AND, 32”
SLEEVE, 28”
GUN, Spray (see Instruction
Manual 308–51
NIPPLE, Hex 3/8
QUICK COUPLER, Male 1/4
, Spray 00045
, Spray 15045
, Spray 25045
, Spray 40045
HOSE ASSEMBL
COUPLERS (incl 41, 42, 43)
LABEL, Caution
LABEL, W
3/8–16 x 7
BUMPER, Rubber
AINER, Spring
LEG, Front
, Lock 3/8–16
(used on 800–635 only)
(used on 800–635 only)
(used on 800–635 only)
LINE, Fuel
(used on 800–635 only)
LABEL, W
(used on 800–635 only)
LINE, Fuel w/Squeeze Bulb
(used on 800–635 only)
ANK, Fuel
(used on 800–635 only)1
LABEL, Graco G
(used on 800–635 only)
, Cap, Hex hd
, Cap, Hex hd
OR, Black
TTERY 1
, 12 V
olt, 30 Amp
OR, Red
TE, Belt Guard
, Cap, Hex hd
, Battery
1) 1
Y W/QUICK
arning 1
, Cap, Hex hd
OR, Fuel
, Fuel Connector
, Hose
arning
1
1
1
1
1
1
1
1
1
2
4
4
2
1
1
1
4
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
2
1
1
11308-525
PARTS DRAWING
800–637 Hydra–Clean 4043 Pressure Washer
76
89
37
87
85
70
31
63
5
47
60
58
57
32
59
64
15
88
87
38
33
34
35
36
2
29
71
72
73
74
28
5
86
30
56
46
77
1
1
58
2
62
5
2
48
53
52
54
55
9
11
10
6
51
27
65
3
4
7
44
5
6
50
8
67
45
2
49
61
57
2
5
5
24
22
79
5
78
81
80
12 308-525
83
25
66
68
5
2
20
19
18
84
82
21
91
5
23
89
92
90
17
16
12
40
87
39
13
75
14
69
26
42
43
69
26
42
41
PARTS LIST
800–637 Hydra–Clean 4043 Pressure Washer
REF PART
NO. NO. DESCRIPTION QTY
1 100–188 NUT
2 100–214 W
3 803–889 BELT
4 803–943 SHEA
5 100–023 W
6 801–941 SCREW
7 803–534
8 803–926 BEL
9 803–525 BOLT
10 803–530 BRACKET
11 801–972 P
12 801–550
13 801–612 W
14 801–020 NUT
15 800–676 CHASSIS 1
16 801–556 AXLE 1
17 800–678 BRACKET
18 801–546 SCREW
19 100–133 W
20 100–132 W
21 800–160
22 803–906
23 111–040 NUT
24 803–925 HANDLE 1
25 803–298 SCREW
26 156–082
27 154–594
28 802–016 BRACKET
29 801–522 SCREW
30 176–250
31 801–548 GROMMET
32 172–981
33 800–314
34 800–315
35 800–316
36 800–317
37 803–884
38
39 800–652
40 801–733
41 803–519
42 803–157
43 801–568
44 800–429
45 802–851
, Hex 5/16–18
ASHER, Lock 5/16
, Drive
VE, Engine
ASHER, Flat 5/16
, Cap, Hex hd
5/16–18 x 1
LABEL, Belt Guard
T GUARD
, Battery
, Battery
AD, Battery
WHEEL & TIRE ASSEMBL
ASHER, Flat 1/2
, Lock 1/2–13
, Rail Stif
, Cap, Hex hd
3/8–16 x 1–1/4
ASHER, Lock 3/8
ASHER, Flat 3/8
FRONT LEG ASSEMBL
(incl. 5, 78 thru 84)
LABEL, Model 4043
, Lock 5/16–18
, Cap, Hex hd
5/16–18 x 3–1/2
O–RING, Quick Coupler 3/8
O–RING, Quick Coupler 1/4
, Rail Stif
, Cap, Hex hd
LABEL, Chassis
, Rubber
LABEL, Chassis
TIP ASS’Y
TIP ASS’Y
TIP ASS’Y
TIP ASS’Y
ENGINE, 16 HP
Stratton V
PUMP ASS’Y (see page 16)
FUEL T
(incl. 40, 87, 89, 90, 91, 92)
BARB, Hose 1/4
HOSE, High Pressure 3/8 x 50’
QUICK COUPLER, Female 3/8
(incl. 26)
QUICK COUPLER, Male 3/8
GUN & W
(incl. 42, 45, 65 thru 69)
HANDLE, T
, 00045 (incl. 70, 71)
, 15045 (incl. 70, 72)
, 25045 (incl. 70, 73)
, 40045 (incl. 70, 74)
, Briggs &
anguard OHV
ANK ASSEMBL
AND ASSEMBL
ee 1
11
13
2
1
26
9
1
1
2
1
1
Y2
2
2
fener 1
4
4
4
Y
1
1
4
1
2
1
fener 1
2
1
5
1
1
1
1
1
1
1
Y
1
1
1
2
2
Y
1
REF P
NO. NO. DESCRIPTION QTY
46 801–217
47 177–144
48 803–535 SCREW
49 803–944 SHEA
50 801–898
51 801–135
52 801–959
53 801–945
54 803–077
55 801–954 BATTERY
56 100–527 W
57 100–016 W
58 100–015 NUT
59 801–964 BOLT
60 801–946
61 801–958
62 803–531 BASEPLA
63 801–022 SCREW
64 107–069
65 801–009
66 801–134 W
67 801–674
68 803–351
69 156–849
70 801–090
71 803–106 TIP
72 803–107 TIP
73 803–108 TIP
74 803–109 TIP
75 800–450
76 802–363
77 181–867
78 801–531 SCREW
79 801–504
80 801–505 RET
81 801–593 SPRING 1
82 801–506 BOOT 1
83 801–537
84 801–499 NUT
85 802–907 CONNECT
86 801–919 BRACKET
87 801–971 CLAMP
88 801–629
89 801–716
90 803–881
91 802–025 T
92 801–008
ART
BUMPER, Rubber
LABEL, Belt Guard
, Cap, Hex hd
VE, Pump
HUB, Engine
HUB, Pump
TERMINAL PROTECT
CABLE, Battery 12” Long
LABEL, BA
ASHER, Flat 1/4
ASHER, Lock 1/4
CABLE, Battery 24” Long
TERMINAL PROTECT
5/16–18 x 3/4
BRACKET Battery
QUICK COUPLER, Female 1/4
(incl. 27)
AND, 32”
SLEEVE, 28”
GUN, Spray (see Instruction
Manual 308–51
NIPPLE, Hex 3/8
QUICK COUPLER, Male 1/4
, Spray 00045
, Spray 15045
, Spray 25045
, Spray 40045
HOSE ASSEMBL
COUPLERS (incl. 41, 42, 43)
LABEL, Caution
LABEL, W
3/8–16 x 7
BUMPER, Rubber
LEG, Front
LINE, Fuel
LABEL, W
LINE, Fuel w/Squeeze Bulb
ANK, Fuel
LABEL, Graco G
TTERY 1
, 12 V
olt, 30 Amp
, Hex 1/4–20
, Carriage 1/4–20 x 1
TE, Belt Guard
, Cap, Hex hd
arning 1
, Cap, Hex hd
AINER, Spring
, Lock 3/8–16
OR, Fuel
, Fuel Connector
, Hose
arning 2
OR, Black
OR, Red
1) 1
Y W/QUICK
1
1
1
1
1
1
1
1
1
2
4
4
2
1
1
1
4
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
13308-525
PARTS DRAWING
800–681 Hydra–Clean 3050 Pressure Washer
77
76
63
5
37
1
2
62
58
47
60
59
64
57
15
45
56
46
5
2
48
49
61
58
57
1
2
5
5
6
53
52
54
55
9
11
10
51
3
27
65
4
66
7
44
5
6
68
50
8
67
38
33
34
35
36
2
29
71
72
73
74
28
5
70
32
31
30
24
22
79
5
78
81
80
14 308-525
83
25
5
2
20
19
18
84
82
21
5
23
17
16
12
13
69
26
42
14
43
69
26
42
41
75
PARTS LIST
800–681 Hydra–Clean 3050 Pressure Washer
REF PART
NO. NO. DESCRIPTION QTY
1 100–188 NUT
2 100–214 W
3 801–285 BELT
4 803–941 SHEA
5 100–023 W
6 801–941 SCREW
7 803–534
8 803–926 BEL
9 803–525 BOLT
10 804–282 BRACKET
11 801–972 P
12 801–550
13 801–612 W
14 801–020 NUT
15 800–676 CHASSIS 1
16 801–556 AXLE 1
17 800–678 BRACKET
18 801–546 SCREW
19 100–133 W
20 100–132 W
21 800–160
22 803–949
23 111–040 NUT
24 803–925 HANDLE 1
25 803–298 SCREW
26 156–082
27 154–594
28 802–016 BRACKET
29 801–522 SCREW
30 176–250
31 801–548 GROMMET
32 172–981
33 800–135
34 800–134
35 800–060
36 800–061
37 803–967
38
41 801–571
42 801–569
43 801–568
44 800–392
, Hex 5/16–18
ASHER, Lock 5/16
, Drive
VE, Engine
ASHER, Flat 5/16
, Cap, Hex hd
5/16–18 x 1
LABEL, Belt Guard
T GUARD
, Battery
, Battery
AD, Battery
WHEEL & TIRE ASSEMBL
ASHER, Flat 1/2
, Lock 1/2–13
, Rail Stif
, Cap, Hex hd
3/8–16 x 1–1/4
ASHER, Lock 3/8
ASHER, Flat 3/8
FRONT LEG ASSEMBL
(incl. 5, 78 thru 84)
LABEL, Model 3050
, Lock 5/16–18
, Cap, Hex hd
5/16–18 x 3–1/2
O–RING, Quick Coupler 3/8
O–RING, Quick Coupler 1/4
, Rail Stif
, Cap, Hex hd
LABEL, Chassis
, Rubber
LABEL, Chassis
TIP ASS’Y
TIP ASS’Y
TIP ASS’Y
TIP ASS’Y
ENGINE, 13 HP
PUMP ASS’Y (see page 16)
HOSE, High Pressure 3/8 x 50’
QUICK COUPLER, Female 3/8
(incl. 26)
QUICK COUPLER, Male 3/8
GUN & W
(incl. 42, 65, 66, 67, 68, 69)
, 0006 (incl. 70, 71)
, 1506 (incl. 70, 72)
, 2506 (incl. 70, 73)
, 4006 (incl. 70, 74)
, Honda OHV
AND ASSEMBL
11
13
2
1
26
9
1
1
2
1
1
Y2
2
2
fener 1
4
4
4
Y
1
1
4
1
2
1
fener 1
2
1
5
1
1
1
1
1
1
1
1
2
2
Y
1
REF P
NO. NO. DESCRIPTION QTY
45 803–526 SPACER 1
46 801–217
47 177–144
48 801–559 SCREW
49 801–004 SHEA
50 801–898
51 801–135
52 801–959
53 801–945
54 803–077
55 801–954 BATTERY
56 100–527 W
57 100–016 W
58 100–015 NUT
59 801–964 BOLT
60 801–946
61 801–958
62 803–531 BASEPLA
63 801–022 SCREW
64 107–069 BRACKET
65 801–009
66 801–134 W
67 801–674
68 803–350
69 156–849
70 801–090
71 801–665 TIP
72 801–666 TIP
73 801–552 TIP
74 801–553 TIP
75 800–375
76 802–363
77 181–867
78 801–531 SCREW
79 801–504
80 801–505 RET
81 801–593 SPRING 1
82 801–506 BOOT 1
83 801–537
84 801–499 NUT
ART
BUMPER, Rubber
LABEL, Belt Guard
, Cap, Hex hd
VE, Pump
HUB, Engine
HUB, Pump
TERMINAL PROTECT
CABLE, Battery 12” Long
LABEL, BA
ASHER, Flat 1/4
ASHER, Lock 1/4
CABLE, Battery 24” Long
TERMINAL PROTECT
5/16–18 x 3/4
QUICK COUPLER, Female 1/4
(incl. 27)
AND, 32”
SLEEVE, 28”
GUN, Spray (see Instruction
Manual 308–51
NIPPLE, Hex 3/8
QUICK COUPLER, Male 1/4
, Spray 0006
, Spray 1506
, Spray 2506
, Spray 4006
HOSE ASSEMBL
COUPLERS (incl. 41, 42, 43)
LABEL, Caution
LABEL, W
3/8–16 x 7
BUMPER, Rubber
LEG, Front
TTERY 1
, 12 V
olt, 30 Amp
, Hex 1/4–20
, Carriage 1/4–20 x 1
TE, Belt Guard
, Cap, Hex hd
, Battery
arning 1
, Cap, Hex hd
AINER, Spring
, Lock 3/8–16
OR, Black
OR, Red
1) 1
Y W/QUICK
1
1
1
1
1
1
1
1
1
2
4
4
2
1
1
1
4
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
15308-525
PARTS DRAWING
Pump Assembly, 3000 psi (used on Model 3050), 3500 & 4000 psi (used on Models 3540 & 4043)
10
9
8
11
2
7
6
5
4
3
1
45
44
47
54
46
53
60
61
62
67
59
65
64
57
58
66
63
55
10
43
42
52
16
51
13
17
14
19 56 20
18
21
23
40
22
15
24
41
26
14
33
48
39
28
32
11
9
12
44
45
50
49
12
29
16 308-525
38
37
31
36
35
34
25
27
31
30
PARTS LIST
Pump Assembly, 3000 psi (used on Model 3050), 3500 & 4000 psi (used on Models 3540 & 4043)
REF PART
NO. NO. DESCRIPTION QTY
1 801–467
2 801–468 SCREW
3 801–469 WASHER, Lock 8
4
5
6
7
8
9
10
11
12 803–283 SCREW
13 803–284 COVER, Crankcase
14 802–500 O–RING, Crankcase cover 2
15 803–324 BEARING, T
16
17 803–286 BUSHING, Piston 3
18 802–895 CRANKCASE, 3000 psi 1
19 801–475 DIPSTICK 1
20 803–144 GASKET, Cover 1
21 803–287 CRANKSHAFT 1
22 803–288
23 802–794 KEY 1
24 803–289 PIN, Wrist 3
25 803–325
26 803–291 ROD, Connecting 3
27 803–292 SCREW
28 803–293 COVER, Crankcase
29 802–345 GAUGE, Sight 1
30 802–793
31
32 803–294 SCREW
33 803–652 WASHER, Lock 6
34
35 801–490 PLUNGER, Ceramic 3
36
37
38
39 803–295 COVER, Crankcase
40 803–296 SHIM 2
41
42
43
44
45
46
47
48 801–526 BRACKET
49 802–305 SCREW
50 802–304 WASHER, Lock 2
51 801–482 PLUG, Hex 1
52 801–483 WASHER, Flat 1
53 801–484 PLUG, Hex 1
54 801–485 WASHER, Flat 1
MANIFOLD, 3000 psi
803–504
MANIFOLD, 3500 & 4000 psi
, Cap, hex hd
Kit 1
Kit 1
Kit 1
Kit 1
Kit 1
Kit 4 or 106
Kit 4 or 106
Kit 1
O–RING
SEAT
, V
TE, V
alve
alve
PLA
SPRING
GUIDE, Valve
O–RING
CAP
VALVE ASSEMBLY
, Cap, socket hd
, 3000 p
si 1
803–506 COVER, Crankcase,
3500 & 4000 psi
apered roller
Kit 2
SEAL, Oil
803–501 CRANKCASE,
3500 & 4000 psi
RING, Retaining
GUIDE, Piston, 3000 psi
803–503 GUIDE, Piston,
3500 & 4000 psi
, Cap, socket hd
, 3000 p
si 1
803–507 COVER, Crankcase,
3500 & 4000 psi
PLUG, Oil drain
Kit 6 or 107
O–RING
, Cap, socket hd
Kit 6 or 107
W
ASHER, Flinger
803–502 PLUNGER, Ceramic 3
Kit 6 or 107
Kit 6 or 107
Kit 6 or 107
RING, Backup
WASHER
SCREW
, Piston
, 3000 p
si 1
803–505 COVER, Crankcase,
3500 & 4000 psi
Kit 3
Kit 28 or 109
Kit 28 or 109
Kit 28 or 109
Kit 8 or 1
Kit 28 or 109
Kit 28 or 109
Kit 28 or 109
SEAL, Oil
O–RING
RETAINER, Packing
PACKING
12
RING, Head
RETAINER, Packing
RING, Long Life
, Pump
, Cap, socket hd
REF PART
NO. NO. DESCRIPTION QTY
1
1
8
55 801–624 PUMP
803–508 PUMP
56 803–083
803–517
57 802–085
58 801–106
, 3000 psi
, 3500 & 4000 psi
LABEL, Keep From Freezing,
3000 psi
LABEL, Keep From Freezing,
3500 & 4000 psi
NIPPLE 1/2
TEE 1/2
1
1
1
1
1
1
59 800–113 FILTER (see Instruction
60 801–111 NUT
Manual 801–744)
, Garden hose
1
1
61 801–110 ADAPTER, Garden hose 1
8
62 801–112 STRAINER, Garden hose 1
63 803–141 HOSE, Bypass 1
64 803–142 NIPPLE, Hex 1/2 NPSM x
1
3/8 NPT 3000 psi
1
802–534 NIPPLE, Hex 1/2 NPSM x
2
1/2 NPT
, 3500 & 4000 psi
1
65 800–325 UNLOADER, 3000 psi 1
800–689 UNLOADER, 3500 psi
800–427 UNLOADER, 4000 psi 1
1
801–236
66 801–868
NIPPLE, Hex 3/8, 3000 psi
NIPPLE, Hex 1/2x3/8,
3500 & 4000 psi
67 801–568
6
3
Kit
Repair
No.
Part No.
1 801–472
Valve
Kit
3
5
2 801–473
Oil Seal
1
1
6
1
2
3 802–511
Crankshaft Seal
4 802–306
V
alve Cap, 3000 psi
6 801–474
Plunger Repair
3000 psi
8 801–468
Packing, 3000 psi
28 801–487
Packing & Retainer
3000 psi
106
803–509
V
alve Cap,
3500 & 4000 psi
107 803–510
Plunger Repair
3500 & 4000 psi
4
109 803–511
Packing & Retainer
3500 & 4000 psi
112 803–512
Packing,
3500 & 4000 psi
COUPLER, Male 3/8
,
,
,
,
Ref
No.
Description Qty.
4
O–RING
5
SEAT
, V
6
7
8
11
16
41
910O–RING
31
34
36
37
38
44 PACKING 6
42
43
44
45
46
47
910O–RING
31
34
36
37
38
42
43
44
45
46
47
44 PACKING 6
alve
PLA
TE, V
SPRING
GUIDE, V
VAL
SEAL, Oil
SEAL, Oil
CAP
O–RING
W
RING, Backup
WASHER
SCREW
O–RING
RETAINER,
Packing
PACKING
RING, Head
RETAINER,
Packing
RING, Long Life
CAP
O–RING
W
RING, Backup
WASHER
SCREW
O–RING
RETAINER,
Packing
PACKING
RING, Head
RETAINER,
Packing
RING, Long Life
alve
alve
VE ASSEMBL
ASHER, Flinger
, Piston
ASHER, Flinger
, Piston
1
2
1
6
6
6
6
6
6
Y
3
2
6
6
1
1
1
1
1
1
1
2
1
1
1
6
6
1
1
1
1
1
1
1
2
1
1
1
17308-525
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 the
pump
parts page for more details. For the
results,
NOTE: There are two different tool kits to aid in
servicing the pump. P/N 800–298 is used to
ease installation of packings. P/N 800–271
includes
in
use all parts in the kits.
the items in 800–298 and tools to aid
the removal of packing retainers.
best
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
NOTE:
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
torque
may come apart.
the new
to 75 ft–lb (103 Nm).
Retorque the plug after 5 hours of operation.
valve. Install the o–ring and hex plug;
Servicing the Plungers
NOTE: Plunger
available to replace retainers, o–rings,
washers
1. Loosen
using
an M10 wrench. Push the
crankcase to separate the plunger and retaining
screw.
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
seals. Otherwise, DO NOT remove these seals as
cannot be reused. An oil seal kit is available to
they
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
of the plunger
ring
around
the
plunger
NOTE: If you plan to replace the packings, refer to
Servicing
repair kit, P/N 801–474 or 803–510 is
and backup rings for three cylinders.
the plunger retaining screw five to six
plunger towards the
and copper bearing/gasket
Replace these parts, if
or 803–510.
the seals.
.
grease the retaining screw and the outer
. Place the washer
the screw and install the screw through
. T
orque to 14.4 ft–lb (19.5 Nm).
the V–Packings.
necessary
, o–ring and backup
turns,
, using kit
end
Pumping Section
1. Remove
the
2. Carefully
NOTE: It
the eight capscrews
manifold using an M13 wrench.
separate the manifold from the
may be necessary to tap the manifold lightly
with
a soft mallet to loosen.
and lockwashers from
crankcase.
CAUTION
Keep the manifold properly aligned with the
ceramic plungers when removing to avoid
damage
3. Carefully examine each plunger for any scoring or
to the plunger or seals.
cracking
and replace as necessary
.
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
18 308-525
Servicing the V–Packings
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.
6. Lightly
grease the packing cavities and then replace
the packing cavities and examine
the packings in the following order: head ring,
v–packing,
and
packing retainer with the o–ring installed in the
retainer
intermediate ring, head ring,
groove.
v–packing
2. Carefully pull the packing retainer from the
manifold.
or
damaged.
Examine the o–ring and replace it if it is 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
OR KIT
800–117 (3540)
800–649 (3540 & 4043)
For injecting harsh cleaning chemicals downstream
the pump. 800–649 is stainless steel
from
construction.
UPSTREAM CHEMICAL INJECTOR KIT
800–257
For
injecting mild cleaning chemicals
pump.
BACKFLOW
PREVENT
OR 801–133
Prevent back–up of contaminated water into fresh
supply.
Install upstream of pump.
upstream into the
TECHNICAL DATA
CAUTION
Install
the parts in the proper order and facing the
correct direction. Improperly installed parts will
a malfunction.
cause
7. Reassemble
the
Plungers.
the manifold as
instructed in Servicing
WATER SANDBLASTING KIT 800–120
For abrasive cleaning of stubborn dirt and paint.
Requires a spray tip which is not included in kit (3245
801–667, 4040 uses 801–600).
uses
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
Engine (4 cycle, air–cooled)
Battery
Gasoline T
W
ater Pump Maximum W
Pressure
W
ater Pump Maximum Flow
Inlet Hose Connection
Weight
Dimensions
Maximum Inlet W
Temperature
W
etted Parts
ank Capacity
Length
Width
Height
ater
High Pressure Hose
Bypass Hose
Pressure W
(including fittings)
asher
orking
Model
800–681
13 HP Honda OHV
12 V
olt, 30 AMP
250 CCA
2 Gallon (7.6 Liter) 6 Gallon (23 Liter) 2 Gallon (7.6 Liter) 6 Gallon (23 Liter)
3000 psi (207 bar) 3500 psi (241 bar) 3500 psi (241 bar) 4000 psi (276 bar)
5 gpm (19 lpm) 4 gpm (15 lpm) 4 gpm (15 lpm)
3/4” garden hose (f) 3/4” garden hose (f) 3/4” garden hose (f) 3/4” garden hose (f)
255 lbs (1
49” (1245 mm)
30” (762 mm)
26.5” (673 mm)
160
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, PTFE, Carbon steel, Zinc with or without yellow chromate
plate
16 kg)
F (70
C) 160
Model 800–635 Model 800–636 Model 800–637
12.5 HP Briggs &
Stratton OHV
12 V
olt, 30 AMP
250 CCA
255 lbs (1
49” (1245 mm)
30” (762 mm)
26.5” (673 mm)
16 kg)
F (70
C) 160
13 HP Honda OHV
12 V
olt, 30 AMP
250 CCA
255 lbs (1
49” (1245 mm)
30” (762 mm)
26.5” (673 mm)
16 kg)
F (70
C) 160
16 HP Briggs &
Stratton OHV
12 V
olt, 30 AMP
250 CCA
4.25 gpm (16 lpm)
255 lbs (1
49” (1245 mm)
30” (762 mm)
26.5” (673 mm)
F (70
, Nylon–PTFE
16 kg)
C)
19308-525
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 WARRANTY CONSTITUTE THE PURCHASER’S SOLE AND EXCLUSIVE
REMEDY
WARRANTY
AND
NEGLIGENCE OR STRICT LIABILITY. EVERY FORM OF LIABILITY FOR DIRECT, SPECIAL OR
CONSEQUENTIAL DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND DENIED. IN NO CASE
SHALL
BREACH
EQUIPMENT
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WITH RESPECT TO
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.)
Subsidiary and Affiliate Companies:
IMPORTANT PHONE NUMBERS
TO PLACE AN ORDER,
distributor
closest to you:
FOR TECHNICAL ASSISTANCE,
application
of Graco equipment:
Factory
Branches:
contact your Graco distributor, or call this number to identify the
1–800–328–021
1 T
oll Free
service repair information or assistance regarding the
1–800–543–0339 T
Atlanta, Chicago, Dallas, Detroit, Los Angeles, W
Canada; England; Switzerland; France; Germany; Hong Kong; Japan; Korea
oll Free
est Caldwell (N.J.)
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
PRINTED
IN U.S.A. 308–525 1/91
3X8–525
Á
Á
Á
Á
Á
Á
Á
Á
Á
Rev. D
Parts
Change Notice
Some parts in Rev. A of manual 308–525 have changed but have not yet been changed in the
instruction manual. Please note the changes below and mark them in your manual or keep
this sheet with your manual.
The
following pressure washers have been obsoleted and are no longer covered by this manual:
800–681
800–635
800–637
The following changes apply to the page1
Series
Assembly No.
Model 800–636
Letter
Change
B
Part That
Changed
176–250
801–548
172–981
БББББÁÁÁÁÁÁÁ
801–571
801–568
177–144
181–867
800–314
800–315
БББББ
БББББÁÁÁÁÁÁÁ
БББББÁÁÁÁÁÁÁ
ÁÁ
800–316Á35
ÁÁÁ
800–317
803–106
803–107
803–108
803–109
NEW
NEW
NEW
NEW
NEW
1 parts list for 800–636:
Ref
No.
30
31
32
41
43
47
77
33
34
36
71
72
73
74
–
–
–
–
–
Part Description
Label
Rubber grommet
Label
Hose, high pressure,
Á
ББББББББ
3/8” x 50’
Quick coupler
Label
Label
T
ip assembly
T
ip assembly
T
ip assembly
ББББББББ
T
Á
Á
ip assembly
ББББББББ
Spray tip, 00045
ББББББББ
Spray tip, 15045
Spray tip, 25045
Spray tip, 40045
Chemical injector
T
ube, chemical injector
Strainer
T
ip, chemical injector
Adapter
, chemical injector
, male, 3/8”
, 00045
, 15045
, 25045
, 40045
Description of Change
Replaced by 804–500
Replaced by 801–012
Deleted
Replaced by 804–427
БББББББББ
Replaced by 804–498
Replaced by 804–495
Replaced by 290–013
Replaced by 805–547
Replaced by 805–548
Replaced by 805–549
БББББББББ
Replaced by 805–550
БББББББББ
Deleted
БББББББББ
Deleted
Deleted
Deleted
Added 804–388
Added 804–275
Added 801–683
Added 805–634
Added 100–081
The following two pages replace page 17 of manual 308–525:
3X8–525 Rev
. D
1/30/95
Pump
Assembly – Parts
USE ONLY GENUINE GRACO PARTS AND ACCESSORIES
Ref.
No. Part
1 801–467 MANIFOLD 1
2 801–468 SCREW
3 801–469 W
4
5
6
7
8
9
10
11
12 803–283 SCREW
13 803–284
14 802–500
15 803–324
16
17 803–286
18 802–895 CRANKCASE 1
19 801–475 DIPSTICK 1
20 803–144 GASKET
21 803–287
22 803–288
23 802–794 KEY 1
24 803–289
25 803–325
26 803–291
27 803–292 SCREW
28 803–293
29 802–345
30 802–793
31
32 803–294 SCREW
33 8033–652 W
34
35 801–490
36
No.
803–504
KIT 1
KIT 1
KIT 1
KIT 1
KIT 1
KIT 4 or 106
KIT 4 or 106
KIT 1
803–506
KIT 2
803–501
803–503
803–507
KIT 6 or 107
KIT 6 or 107WASHER, Flinger
803–502
KIT 6 or 107
Description Qty
MANIFOLD, 3500 & 4000 psi
, Cap, hex hd
ASHER, lock
O-RING
SEAT
, V
alve
PLA
TE, V
alve
SPRING
GUIDE, V
O-RING
CAP
VAL
COVER, Crankcase.
COVER, Crankcase,
3500 & 4000 psi
O–RING, Crankcase Cover
BEARING, T
SEAL, Oil
BUSHING, Piston
CRANKCASE,
3500 & 4000 psi
CRANKSHAFT
RING, Retaining
PIN, W
GUIDE, Piston, 3000 psi
GUIDE, Piston,
3500 & 4000 psi
ROD, Connecting
COVER, Crankcase
COVER, Crankcase,
3500 & 4000 psi
GAUGE, Sight
PLUG, Oil Drain
O-RING
ASHER, Lock
PLUNGER, Ceramic
PLUNGER, Ceramic
RING, Backup.
alve
VE ASSEMBL
, Cap, socket hd
apered Roller
, Cover
rist 3
, Cap, socket hd
, Cap, socket hd
Y
Ref.
No.
Part No.
37
KIT 6 or 107
1
8
8
8
1
1
2
2
1
1
1
1
6
3
3
3
5
1
1
1
1
6
6
3
3
3
KIT 6 or 107
38
39 803–295
803–505
40 803–296 SHIM 2
KIT 3
41
42
KIT 28 or 1
KIT 28 or 1
43
44
KIT 28 or 1
Kit 8 or 109
45
KIT 28 or 112RING, Head
46
KIT 28 or 1
47
KIT 28 or 112RING, Long Life
48 801–526 BRACKET
49 802–305 SCREW
50 802–304 W
51 801–482
52 801–483 W
53 801–484
54 801–485 W
55 801–624 PUMP
803–508 PUMP
56 803–083
803–517
57 802–085
58 801–106
59 800–113 FIL
60 801–111 NUT
61 801–110
62 801–112
63 803–141
64 803–142
802–534
65 800–325
800–689
800–427
66 801–868
801–236
67 801–568
Description Qty
WASHER
SCREW
COVER, Crankcase
COVER, Crankcase,
3500 & 4000 psi
SEAL, Oil
12O-RING
12RET
12PACKING
12RET
PLUG, Hex
PLUG, Hex
LABEL, Keep From Freezing
3000 psi
LABEL, Keep From Freezing
3500 & 4000 psi
NIPPLE 1/2
TEE 1/2
Manual 801–744)
ADAPTER, Garden Hose
STRAINER, Garden Hose
HOSE, Bypass
NIPPLE, Hex 1/2 NPSM x
3/8 NPT 3000 psi
NIPPLE, Hex 1/2 NPSM x
1/2 NPT
UNLOADER, 3000 psi
UNLOADER, 3500 psi
UNLOADER, 4000 psi
NIPPLE, Hex 3/8, 3000 psi
NIPPLE, Hex 1/2x3/8,
3500 & 4000 psi
COUPLER, Male 3/8
, Piston
AINER, Packing
AINER, Packing
, Pump
, Cap, socket hd
ASHER, Lock
ASHER, Flat
ASHER, Flat
, 3000 psi
, 3500 & 4000 psi
TER (see Instruction
, Garden Hose
, 3500 & 4000 psi
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
3X8–525 Rev
. D
1/30/95
Kit
Á
Á
Á
Á
Á
Á
Á
Á
Á
Á
Á
Á
Á
Á
Á
Repair
No.
Part No.
1 801–472
Valve
2 801–473
Oil Seal
3 802–511
Crankshaft Seal
4 802–306
V
alve Cap, 3000 psi
6 801–474
Plunger Repair
3000 psi
8 801–486
Packing, 3000 psi
28 801–487
Packing & Retainer
3000 psi
106
803–509
V
alve Cap,
3500 & 4000 psi
107 803–510
Plunger Repair
3500 & 4000 psi
109 803–511
Packing, 4000 psi
112 803–512
Packing &
Retainer
Kit
,4000 psi
Ref
No.
Description Qty.
4
O–RING
5
SEAT
, V
6
7
8
11
16
41
910O–RING
,
31
34
36
37
38
alve
PLA
TE, V
SPRING
GUIDE, V
VAL
alve
alve
VE ASSEMBL
SEAL, Oil
SEAL, Oil
CAP
O–RING
W
ASHER, Flinger
RING, Backup
WASHER
SCREW
, Piston
6
6
6
6
6
6
Y
3
2
6
6
1
1
1
1
1
44 PACKING 6
42
,
,
O–RING
43
RET
44
45
46
47
910O–RING
31
34
36
37
38
44
47
–
42
43
44
45
46
47
–
AINER, Packing
PACKING
RING, Head
RET
AINER, Packing
RING, Long Life
CAP
O–RING
W
ASHER, Flinger
RING, Backup
WASHER
SCREW
PACKING
RING, Long life
PACKING
O-RING
RET
AINER, packing
PACKING
RING, head
RET
AINER, packing
RING, Long life
PACKING
, Piston
1
1
2
1
1
1
6
6
1
1
1
1
1
3
3
3
1
1
1
2
1
1
1
The
following changes apply to the page17 parts list for pump asssembly of Models 3540 and 4043 only:
Series
Assembly No.
Pump asssembly
БББББ
for Models 3540
БББББ
and 4043 only
БББББ
Letter
Change
–
ÁÁ
ÁÁ
ÁÁ
Part That
Changed
804–497
ÁÁÁ
ÁÁÁ
ÁÁÁ
Ref
No.
Part Description
Unloader outlet fitting
Á
Á
Á
ББББББББ
ББББББББ
ББББББББ
Description of Change
Added replacement part no.
БББББББББ
804–497 for the unloader out
БББББББББ
let fitting.This outlet fitting is
only used on Pressure W
БББББББББ
er Models 3540 and 4043
-
ash-
3X8–525 Rev
. D
1/30/95
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