Graco Inc Hydra-Clean 800-700, Hydra-Clean 800-699, Hydra-Clean 308-530, Hydra-Clean 800-698 User Manual

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Page 1

INSTRUCTIONS-PAR

This

manual contains

WARNINGS

AND RETAIN FOR REFERENCE

and

IMPORTANT

INSTRUCTIONS

READ

TS LIST

308–530

Rev

HYDRA-CLEAN Pressure W

HYDRA-CLEAN

P/N 800–698, Series A

1500 psi (103 bar) OPERA

1900 psi (131 bar) MAXIMUM WORKING PRESSURE

HYDRA-CLEAN 2040, 8 HP ENGINE

P/N 800–699, Series A

2000 psi (138 bar) OPERA

2400 psi (165 bar) MAXIMUM WORKING PRESSURE

HYDRA-CLEAN 2540, 9 HP ENGINE

P/N 800–700, Series A

2500 psi (172 bar) OPERA

3000 psi (207 bar) MAXIMUM WORKING PRESSURE

1535, 5 HP ENGINE

ashers

TING PRESSURE



1535, 2040, 2540

1535

2040 2540

GRACO INC. P

.O. Box 1441 MINNEAPOLIS, MN 55440–1441

COPYRIGHT

1991, GRACO INC.

Page 2

INDEX

Warnings 3.

Installation 5

Startup 6

Shutdown, Flushing and Storage 8.

Maintenance 8

Troubleshooting Chart 9.

Hydra–Clean 1535 10.

Hydra–Clean 2040 12.

Hydra–Clean 2540 14.

Gear Reducer (Model 1535) 16.

Gear Reducer (Models 2040 & 2540) 18.

Pump (Model 1535) 20.

Pump (Model 2040) 22.

Pump (Model 2540) 24.

Pump Service (Model 1535) 26.

Pump Service (Models 2040 & 2540) 28.

Accessories 30

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data 31.

Warranty Back Cover.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TERMS

WARNING: Alerts user to avoid or correct conditions

could cause bodily injury

that

CAUTION:

could

Alerts

user to avoid or correct conditions that

cause damage to the equipment.

NOTE:

Identifies helpful procedures and information.

 308–530

Page 3

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 Spray from the gun, leaks or ruptured components can inject fluid through your skin and into your body and

extremely serious bodily injury including the need

cause for amputation. Also, fluid injected or splashed into the

or on the skin can cause serious damage.

eyes

NEVER

part of the body . spray

ALWAYS

cleaning

NEVER

body.

Be before

point the

tip.

follow the

or servicing any part of the sprayer

try to stop or deflect leaks with your hand or

sure equipment safety devices are operating properly

each use.

generates very high fluid pressure.

spray gun or wand at anyone or at any

NEVER

put hand or fingers over the

Pressure Relief Procedure

before

Medical Treatment

If any fluid appears to penetrate your skin, get

EMERGENCY MEDICAL TREATMENT AT ONCE. DO

TREA

NOT

what

NOTE TO PHYSICIAN:

traumatic

surgically as soon as possible.

treatment with bloodstream. reconstructive

T AS A SIMPLE CUT. T

fluid was injected.

Injection in the skin is a

injury

It is important to treat the injury

to research toxicity

some exotic coatings injected directly into the

Consultation with a plastic surgeon or

hand surgeon may be advisable.

ell the doctor exactly

Do not delay

. T

oxicity

is a concern

Pressure Relief Procedure

reduce the risk of serious bodily injury injection follow this procedure whenever you stop spraying for more than 10 minutes, when shutting down, and before checking

2. T

5. Disengage

6. Before

and splashing in the eyes or on the skin, always

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

to relieve pressure, and then engage the trigger safety

of the unit, disconnect the water supply and turn off the

f the water supply

the trigger safety latch and

latch again.

long–term (overnight)

fuel supply valve.

storage or transporting

, including

trigger the gun

fluid

Spray Gun Safety Devices

Be sure all gun safety devices are operating properly

each use. Do not remove or modify any part of the

before gun; this can cause a malfunction and result in serious

injury

bodily

SAFETY LA TCH: Whenever you stop spraying for a moment, or

“safe” 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

remove the spray tip to clean it.

then

always set the gun safety latch in the engaged

position, making the gun inoperative. Failure to

of the gun.

or changing spray tips. If a spray tip clogs

follow the Pressure Relief Procedure and

while

MOVING PARTS HAZARD

Moving parts. operating

NEVER

and interlocks installed and functioning. Follow the Pressure Relief Procedure before checking or

parts can pinch or amputate fingers or other body

KEEP CLEAR

the pressure washer

operate the pressure washer

of moving parts when starting or

without all guards

servicing the pressure washer to prevent discharging

pressure fluid from the gun.

high

arnings continued on page 4.

3308–530

Page 4

EQUIPMENT MISUSE HAZARD

General Safety

Any

misuse of the as overpressurizing, modifying chemicals and fluids, or using worn or damaged parts, can cause them to rupture and result in fluid injection, splashing in the eyes or on the skin, or other serious

injury

bodily

NEVER

CHECK

replace

ALWAYS

clothing. chemical manufacturer’s literature for recommendations on

alter or modify any part of this equipment; doing

could cause it to malfunction.

all spray equipment regularly and repair or

worn or damaged parts immediately

wear protective eyewear and appropriate

If using a chemical injector

additional protective equipment, such as a respirator

pressure washer or accessories, such

parts, using incompatible

, fire, explosion or property damage.

, read and follow

the

HOSE SAFETY

High

pressure fluid in the hoses can be very dangerous. If

the

hose develops a leak, split or of wear , damage or misuse, the high pressure spray emitted from it can cause a fluid injection injury or other serious bodily injury or property damage.

ALL FLUID HOSES MUST HA VE STRAIN RELIEFS

BOTH ENDS.

from kinks or bends at or close to the coupling, which can result

in hose rupture.

TIGHTEN

High high

all fluid connections securely before each use.

pressure fluid can dislodge a loose coupling or allow

pressure spray to be emitted from the coupling.

The strain

rupture due to any kind

reliefs help protect the hose

System

This sprayer can develop high operating pressures. Be sure to withstand the maximum working pressure of this sprayer. pressure of any component or accessory used in the system.

Pressure

that all spray equipment and accessories are rated

DO NOT

exceed the maximum working

Chemical Compatibility

SURE

that all chemicals used in the chemical

are compatible with the wetted parts of the hose, gun,

and tip, as given in the T

wand cover). Always read the chemical manufacturer ’s literature before using any chemical in this pressure washer.

NEVER

entire hose for cuts, leaks, abrasion, bulging cover , or damage or movement of the hose couplings. If any of these

NOT

tape the

use a damaged hose. Before each use, check

conditions exist, replace the

try to recouple high pressure hose or mend it with

or any

other device. A repaired hose cannot contain

high pressure fluid.

echnical Data (inside back

hose immediately

HANDLE AND ROUTE HOSES CAREFULL Y.

pull on hoses to move the pressure washer. Do not use chemicals which are not compatible with the inner tube and cover of the hose. temperatures (–40_ C).

above 200

DO NOT

_ F

expose Graco hose to

(93

_ C)

or below –40

injector

Do not

_ F

FUEL AND EMISSION HAZARDS

NEVER

The on tank

NEVER

contains carbon monoxide, a poisonous, odorless,

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

fuel used in this unit is combustible and when spilled

a hot surface can ignite and cause a fire.

slowly to avoid spilling.

operate the unit in a closed building. The exhaust

ALWAYS

fill

invisible gas which can cause serious injury or death if inhaled.

NEVER

Tampering with this adjustment can damage the pressure

alter the throttle setting, which is factory set.

washer and will void the warranty

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.

4 308–530

Page 5

INSTALLATION

2540

HIGH

PRESSURE

HOSE

CONNECTION

CONNECTION 3/4”

INLET WATER

GARDEN HOSE

1535

HIGH PRESSURE

HOSE

CONNECTION

INLET WATER

CONNECTION 3/4”

GARDEN HOSE

QUICK

COUPLER

2040

HIGH PRESSURE

HOSE CONNECTION

INLET WATER

CONNECTION 3/4”

GARDEN HOSE

Figure

Check for Shipping Damage

Check

the unit for any damage that may have occurred

shipping. Notify

the carrier immediately

if there is any

damage.

Set Up

you are using a downstream chemical injector between using

Connect

the pump unloader and the high pressure hose,

the quick couplers provided.

the high pressure hose between the pump

, install it

outlet

and the gun inlet. Both of these connections are made

quick couplers.

with

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 T ips. If you are using a sandblaster kit, see its separate manual for installation instructions.

Longer hoses may af fect sprayer

and chemical injector

performance,

SPRAY

GUN

QUICK

COUPLER

SPRAY

HOSE

Connect to Water Supply

CAUTION

Before attaching to the water supply, check your local plumbing code regarding 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

at the garden hose connection.

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

Connect

a hose with at least a 3/4 inch (19 mm) ID from the water supply to the unit’ The supply hose should not be more than 50 ft (15 m) long.

NOTE: The water source at the unit

minimum Technical

flow rate equal to that of the unit (see

Data, inside back cover).

cross–connection

s 3/4 inch garden hose inlet.

must

have a

5308–530

Page 6

STARTUP

Always is

NOTE:

use this startup procedure to ensure that the

started safely and properly

Check oil levels.

Engine: as

Pump: genuine

Gear as necessary . The 1535 uses the oil in pump crankcase.

Check fuel level.

Add SAE 30 or 10W–30 weight detergent oil

necessary

Reducer (2040 and 2540): Add SAE 90 gear oil

All shuts certain level. If the unit stops unexpectedly , check oil

Add SAE 20 or 30 weight non–detergent oil or

Cat pump oil as necessary

units are equipped with a low–oil sensor that

the engine of

both the oil and the fuel levels. Check the

level each time the unit is refueled.

f if the oil level

falls below a

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

unit

If the engine is cold, completely close the engine

Grasp the starter rope, brace one foot on the

choke. pressure washer chassis and pull rope rapidly and firmly. Continue holding the rope as it returns. Pull and return the rope until the engine starts. In cool

the

weather, to 30 seconds before opening it to keep the engine running. Otherwise, open the choke as soon as the engine

If the engine is warm, leave the choke open, or just partly close it. Start the engine as described in the preceding the

choke completely

choke may have to be kept closed for 10

starts.

paragraph. When it starts, be sure to open

CAUTION

recoil start engines, never let the starter rope

return by itself. It could jam the recoil system.

ALWAYS

whenever reduce the risk of fluid injection or splashing in the eyes accidentally.

ALWAYS

8. costly

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

damage to the pressure washer

CAUTIONS

CAUTION

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.

the pump. T

urn of

f the pressure washer if it

to avoid

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

5. Open the fuel shutoff valve. Be sure the spark plug ignition those put in

the “run” position.

Start the engine.

NOTE: For easier starting, have one person start the

that the air is purged from the system.

cable is pushed firmly onto the

units equipped with an

the

switch in the “on” position and put the throttle

pressure the

washer while

spray gun.

ignition shutof

another person triggers

spark plug. On

f switch,

DO NOT

damage turned

NOT

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

DO NOT

may

9. See the chemical injector or sandblaster kit manual for are

run the pump dry , which will quickly

the pump. Be sure

on before starting the pump.

operate the pressure washer

or scratch the pump. Keep this screen clean.

pump caustic materials; such materials

corrode the pump components.

detailed cleaning information if these accessories

used.

the water supply is fully

with the inlet

6 308–530

Page 7

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

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.

Follow the

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

3. Without back the quick coupler ring (B). Remove the old tip and/or install a new one, and then release the ring. See

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

Figure 3.

, including

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

7308–530

Page 8

SHUTDOWN, FLUSHING AND STORAGE

WARNING

Pressure

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

Relief Procedure

, including

injection and splashing in the eyes, or on

part of the system.

the

MAINTENANCE

Observing regular maintenance intervals helps ensure that you get maximum performance and life from the pressure

There reducer (if used). After changing the oil in these components the

If the unit is operating in dusty conditions, these maintenance

washer

is a break–in period for

interval between required changes is longer

the engine, pump and gear

following their respective break–in periods,

checks should be made more often.

Engage the trigger safety latch.

2. T

urn the sprayer of

3. Remove

4. Shut

5. Disengage

the the

6. Before long–term (overnight) storage or

transporting of unit, disconnect the water supply,

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

the ignition cable from the spark plug.

f the water supply

the gun to relieve pressure, and then engage trigger safety latch again.

and turn of

Flush the pressure washer before using it

to remove the anti–freeze.

available

to make flushing easier

trigger safety latch and trigger

f the fuel supply valve.

CAUTION

water does freeze in the

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

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 or genuine Cat pump oil. Change gear reducer oil. Use SAE 90 gear oil on 2040 and

2540. The 1535 uses the oil in pump crankcase.

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 or genuine Cat

pump oil. Change gear reducer oil on 2040 and 2540. Use SAE 90 gear oil. The 1535 uses the oil in pump crankcase.

. Check

. Rub

ap gently to

8 308–530

Page 9

TROUBLESHOOTING CHART

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 the skin or injury from

arning

before proceeding.

PROBLEM

Engine will not start or is hard to start

Engine misses or lacks power

pressure and/or

Low pump runs rough

ater leakage from

under pump manifold

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

Start/Stop switch in Stop position.

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

orn or wrong size tip.

Inlet filter clogged.

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.

orn inlet or discharge valves.

Leaking high pressure hose.

orn packings.

Humid air condensing inside crankcase.

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.

orn gasket.

orn oil seals and/or o-ring.

orn oil seal.

. Flooded engine.

, 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.

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.

f valve.

VICE.

VICE.W

VICE.

F.

VICE.

VICE

9308–530

Page 10

PARTS DRAWING

800–698 Hydra–Clean 1535 Pressure Washer

27 30

28 59

65 66

48 49

67 36

50 51

36 35

10 308–530

Page 11

PARTS LIST

800–698 Hydra–Cleanr 1535 Pressure Washer

REF PART NO. NO. DESCRIPTION QTY

1 802–239

2 800–695

3 804–248 GEA 4 802–127 SCREW

6 100–527 W 7 804–250 BRACKET

8 801–367 11 156–849 12 802–316 13 804–244

14 801–709 15 803–245 16 801–568 17 801–620 ELBOW 18 801–866 19 801–622 20 801–523 21 800–115 VAL 22 804–073 23 801–111 NUT 24 801–110 25 804–051 STRAINER/FILTER 1 26 402–278 27 156–082 28 154–594 29 802–579 30 801–569

31 800–392

32 800–661 CHASSIS 1 33 803–925 HANDLE 1 34 800–175

ENGINE, 5 hp, Briggs &

Stratton I/C

PUMP & GEAR REDUCER

ASSEMBL

R R

5/16–18 x 1-3/4

ASHER, Flat 5/16

BUMPER, Rubber NIPPLE, Hex 3/8 UNLOADER, Preset 1500 psi PUMP ASSEMBLY, 1500 psi

(see page 20) PLUG, Square hd. 1/4 GUARD, Muf QUICK COUPLER, Male 3/8

HOSE, Bypass CROSS, 1/2 NIPPLE, 1/2 x 2

VE, Thermal Relief

ADAPTER, 1/2

, Garden Hose

ADAPTER, Garden Hose

PLUG, Plastic O–RING, Quick Coupler 3/8 O–RING, Quick Coupler 1/4 HOSE, High Pressure, 3/8 x 50’ QUICK COUPLER, Female 3/8

(incl. 27) GUN & W

(incl. 1

FRONT LEG ASSEMBL

(incl. 35, 36, 50, 51, 67)

Y (incl. 3, 13)

EDUCE

, Cap, hex hd.

, Street 1/4 x 90

1, 59, 60, 61, 63)

R (see page 1

, Support

fler 1

AND ASSEMBL

7) 1

1 2 3 1

1 1

_ 1

1 1 1 1 1 1 1

1 2 1 1

REF P NO. NO. DESCRIPTION QTY

35 801–546 SCREW

36 100–023 W 39 802–139 AXLE 1 40 154–636 W 41 106–062 42 101–545 43 104–811 44 801–539 BUMPER 1 45 801–941 SCREW

46 111–040 NUT 47 801–012 GROMMET 48 800–174

49 800–173

50 801–858 BRACKET 51 52 179–885 53 802–781 KEY 54 803–083 55 804–274

56 801–723 57 802–363 58 181–867 59 801–009

60 801–134 W 61 801–674 63 803–350

64 801–090 65 801–730 TIP 66 801–729 TIP 67 101–566 NUT 68 800–377

ART

801–504

, Cap, hex hd. 3/8–16 x 1-1/4 ASHER, Flat 3/8

ASHER, Flat 5/8

WHEEL & TIRE ASSEMBL PIN, Cotter 1/8 x 1-1/2 HUB CAP

, Cap, hex hd. 5/16–18 x 1

, Lock 5/16–18

, Rubber

TIP ASSEMBLY, 00055

(incl. 64, 65)

TIP ASSEMBLY, 15055

(incl. 64, 66)

, Front Leg 1 BUMPER, Rubber LABEL, Chassis

, Square 3/16 x 2 LABEL, Keep From Freezing LABEL, Graco Cleaning

Systems 1 LABEL, Model 1535 LABEL, Caution LABEL, W QUICK COUPLER,

Female 1/4 (incl. 28)

AND, 32” SLEEVE, 28” GUN, Spray (see Instruction

Manual 308–51 QUICK COUPLER, Male 1/4

, Spray 00055 , Spray 15055

HOSE ASSEMBL Couplers (incl. 16, 29, 30)

arning 1

1) 1

, Lock 3/8–16

Y w/Quick

2 2

1 1 1 1

1 1

1 1 1

4 1 1 5

11308–530

Page 12

PARTS DRAWING

800–699 Hydra–Clean 2040 Pressure Washer

27 30

28 59

65 66

48 49

67 36

50 51

36 35

12 308–530

Page 13

PARTS LIST

800–699 Hydra–Clean 2040 Pressure Washer

REF PART NO. NO. DESCRIPTION QTY

1 802–141

2 800–696

3 804–249 4 802–127 SCREW

6 100–527 W 7 804–251 BRACKET

8 801–367 11 156–849 12 802–315 13 804–245

14 801–709 15 802–257 16 801–568 17 802–627

18 803–869 19 801–622 20 801–523 21 800–1 22 804–073 23 801–111 NUT 24 801–110 25 804–051 STRAINER/FILTER 1 26 402–278 27 156–082 28 154–594 29 802–579 30 801–569

31 800–392

32 800–661 CHASSIS 1 33 803–925 HANDLE 1 34 800–175

ENGINE, 8 hp, Briggs &

Stratton I/C

PUMP & GEAR REDUCER

ASSEMBL

GEAR REDUCER (see page 19)

5/16–18 x 1-3/4

ASHER, Flat 5/16

BUMPER, Rubber NIPPLE, Hex 3/8 UNLOADER, Preset 2000 psi PUMP ASSEMBLY, 2000 psi

(see page 22) PLUG, Square hd. 1/4 GUARD, Muf QUICK COUPLER, Male 3/8 NIPPLE, Hex 3/8 NPSM x

1/4 NPT HOSE, Bypass CROSS, 1/2 NIPPLE, 1/2 x 2

VAL

VE, Thermal Relief

ADAPTER, 1/2

, Garden Hose

ADAPTER, Garden Hose

PLUG, Plastic O–RING, Quick Coupler 3/8 O–RING, Quick Coupler 1/4 HOSE, High Pressure, 3/8 x 50’ QUICK COUPLER,

Female 3/8 (incl. 27) GUN & W

(incl. 1

FRONT LEG ASSEMBL

(incl. 35, 36, 50, 51, 67)

Y (incl. 3, 13)

, Cap, hex hd.

, Support

fler 1

AND ASSEMBL

1, 59, 60, 61, 63)

1 1

1 2 3 1

1 1

1 1 1 1 1 1 1 1

1 2 1 1

REF P NO. NO. DESCRIPTION QTY

35 801–546 SCREW

36 100–023 W 39 802–139 AXLE 1 40 154–636 W 41 106–062 42 101–545 43 104–811 44 801–539 BUMPER 1 45 801–941 SCREW

46 111–040 NUT 47 801–012 GROMMET 48 800–174

49 800–173

50 801–858 BRACKET 51 52 179–885 53 801–137 KEY 54 803–083 55 181–867 56 804–272 57 802–363 58 804–274

59 801–009

60 801–134 W 61 801–674 63 803–350

64 801–090 65 801–730 TIP 66 801–729 TIP 67 101–566 NUT 68 800–377

ART

801–504

, Cap, hex hd. 3/8–16 x 1-1/4 ASHER, Flat 3/8

ASHER, Flat 5/8

WHEEL & TIRE ASSEMBL PIN, Cotter 1/8 x 1-1/2 HUB CAP

, Cap, hex hd. 5/16–18 x 1

, Lock 5/16–18

, Rubber

TIP ASSEMBLY, 00055

(incl. 64, 65)

TIP ASSEMBLY, 15055

(incl. 64, 66)

, Front Leg 1 BUMPER, Rubber LABEL, Chassis

, Square 1/4 x 2 LABEL, Keep From Freezing LABEL, W LABEL, Model 2040 LABEL, Caution LABEL, Graco Cleaning

Systems 1

QUICK COUPLER,

Female 1/4 (incl. 28)

AND, 32” SLEEVE, 28” GUN, Spray (see Instruction

Manual 308–51 QUICK COUPLER, Male 1/4

, Spray 00055 , Spray 15055

HOSE ASSEMBL Couplers (incl. 16, 29, 30)

arning 1

1) 1

, Lock 3/8–16

Y w/Quick

2 2

1 1 1 1

1 1

1 1 1

4 1 1 5

13308–530

Page 14

PARTS DRAWING

800–700 Hydra–Clean 2540 Pressure Washer

40 41 55 59

35 36 42 44

32 26

17 19

15 16

14 308–530

Page 15

PARTS LIST

800–700 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 7 803–901

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

31 804–273

32 101–566 NUT 33 800–661 CHASSIS 1

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, Briggs &

Stratton OHV

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

803–925 HANDLE 1

FRONT LEG ASSEMBL

(incl. 22, 26, 27, 28, 32)

LABEL, Graco Cleaning

Systems 1

AND ASSEMBL

1) 1

arning, ventilation

arning, chassis

, Cap, hex hd.

, Lock 5/16–18

, Cap, hex hd.

, Lock 3/8–16

1 1 1 1

1 20 12

4 10

REF P NO. NO. DESCRIPTION QTY

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

43 800–697

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 61 804–251 BRACKET 62 804–073 63 800–377

64 804–246 PUM 65 804–249

66 803–301 67 801–137 KEY

ART

, 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 19) LABEL, Model 2540

, Square 1/4 x 2

Y (incl. 64, 65)

, Support

SSEMBL

Y (see page 2

1 1 1 4 1 1

1 1 1 3 1 1 1 1 1 1 1 1 1 1

1 2 1 1

4) 1

1 1 1

15308–530

Page 16

GEAR REDUCER SERVICE (Model 1535)

reduce the risk of serious bodily injury

moving

parts, always follow the

Pressure Relief Procedure W

, including fluid injection,

WARNING

splashing in the eyes or on the skin or injury from

arning

on page 2 before proceeding.

Replacing the O–Ring (5)

1. Remove the four bolts, lockwashers and washers. Pull the pump and gear reducer assembly of f the engine.

2. Drain the gear reducer oil by placing a container under it and removing the drain plug with a 22 mm wrench.

3. Remove the four screws and lockwashers with a 6 mm wrench and pull the gear case of f the gear cover.

4. Remove case and

5. Follow Reducer

Replace the o–ring (16) if damaged.

the old o–ring (5). Clean the gear cover and

surface. Lightly coat the new o–ring with grease

install it in the gear case.

steps 4 through 6 under

if this is all the service required.

Assembling the Gear

Replacing the Gasket (1)

1. Follow steps 1 through 3 under Replacing the O–Ring.

Replacing the Oil Seal (10)

NOTE: The

Follow steps 1 and 2 under Replacing the O–Ring.

2. Pry damage

3. Wipe the inner surface of the gear case clean, then lightly coat it with grease. Place the oil seal into the gear of

the seal, to push the seal into the case until its top

surface

4. Follow Reducer

oil seal MUST be replaced if removed.

the oil seal out of the gear case. Be careful not to

the gear case.

case. Use a socket, placed against the surface

is past the ridge in the bore.

steps 4 through 6 under

if this is all the service required.

Assembling the Gear

Assembling the Gear Reducer

1. Make

2. Align

sure the gasket is properly placed

cover. Refer to step 4 under Replacing the Gasket.

install the gear cover on the pump shaft.

Then,

the holes in the gear cover with the pump. Apply low strength Loctite  (blue) on the screw threads and secure the cover with the four screws and lockwashers. T ighten them oppositely and

evenly

on the gear

holes in the

2. Using a 4 mm wrench, remove retaining bolt, lockwasher, flat washer and pull the gear (4) off the

with a gear puller

pump

3. Remove the four screws and lockwashers from the

cover

gear

4. Remove the gear cover and gasket (1) from the pump. Clean the gear cover and pump surface. Lightly install

5. Follow the instructions under Assembling the Gear Reducer

coat both

it on the gear cover

if this is all the service required.

sides of the gasket with grease and

3. 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. flat

washer to lock the gear on the shaft.

4. Make sure the o–ring is in place. Refer to step 4 under the cover, aligning the holes, and secure it with the four screws and lockwashers. T ighten them oppositely

5. Grease key on the engine shaft and slide the gear reducer onto

6. Secure the gear reducer to the engine with the four bolts

ighten the retaining bolt, lockwasher

Replacing the O–Ring. Install the gear case on

and evenly

the engine shaft. Align the gear’s slot with the

the shaft, up to the engine’

and lockwashers.

s shoulder

and

16 308–530

Page 17

PARTS DRAWING

Gear Reducer (Model 1535)

PARTS LIST

Gear Reducer (Model 1535)

REF PART NO. NO. DESCRIPTION QTY

1 804–236 SCREW

2 804–201 3 804–202 4 804–082 BEARING 1 5 804–225 6 804–226 7 804–203 8 804–165 KEY

9 804–167 GASKET 10 804–176 11 804–177 12 804–075 W 13 804–077 W

, Cap, hex hd./cross

recess 4 HOUSING, Gear Reducer GEAR, Pinion, 3/4

RING, Retaining, internal RING, Retaining, external SEAL, Oil, pinion

, Square, 3/16 x 1–3/4

, Flange FLANGE, Housing O–RING, Housing

ASHER, Flat, 6mm ASHER, Lock, 6mm

1 1

1 1 1 1 1 1 1 4 4

REF P

ART

NO. NO. DESCRIPTION QTY

14 804–231 SCREW

, Cap, hex hd./cross

recess 4 15 804–166 16 804–229 KEY 17 804–090 W 19 804–230 SCREW

GEAR, Driven, spur

, Square, 3/16 x 13/16

ASHER, Flat, retaining

, Cap, hex hd.

1 1 1

(8mm x 20mm) 1 20 804–188 21 802–189 22 804–134 W 23 802–175 W

PLUG, Oil Drain O–RING, Drain Plug

ASHER, Flat, 8mm

ASHER, Lock, 8mm 24 804–168 SCREW

5/16–18 x 25 mm

, Cap, hex hd.

1 1 4 9

17308–530

Page 18

GEAR REDUCER SERVICE (Models 2040 & 2540)

WARNING

reduce the risk of serious bodily injury

moving

parts, always follow the

Pressure Relief Procedure W

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

arning

on page 2 before proceeding.

or injury from

Replacing the Gasket (9)

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

replaced whenever the gear reducer is disassembled.

1. Remove the four bolts, lockwashers and washers. Pull the pump and gear reducer assembly of f the engine.

2. Drain the gear reducer oil by placing a container under it and removing the drain plug with a 22 mm wrench.

3. Remove the nine screws with a 6 mm wrench and pull

4. Remove case surface. Lightly coat the new gasket with grease

5. Follow Reducer

Replace the o–ring (15) if damaged.

the gear case of

the old gasket (9). Clean the gear cover and

and install it in on the gear case.

steps 5 through 7 under

if this is all the service required.

f the gear cover

Assembling the Gear

Replacing the Oil Seals (21)

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

2. Loosen the gear (4) of

3. Using them separate from the other nine screws removed previously.

4. Remove

5. Follow Reducer

the setscrew, using a 4 mm wrench, and pull

f the pump with a gear puller

a 6 mm wrench, remove the four screws. Keep

the four oil seals (21) and replace them.

steps 2 through 7 under

if this is all the service required.

Assembling the Gear

Replacing the O–Ring (1)

1. Follow the instructions under Replacing the Gasket

Replacing the Oil Seals to disassemble the gear

and reducer.

2. Pull the gear cover of f the pump and replace the o–ring (1).

Replacing the Oil Seal (14)

NOTE: The oil seal MUST be replaced if removed.

Follow steps 1 and 3 under Replacing the Gasket.

2. Remove snap

3. Push the seal from the inside to the outside of the gear case by placing screwdriver against the seal and

4. Wipe coat it with grease. Place the oil seal into the gear case. seal, to push the seal into the case until its top surface

Place the and

6. Follow Reducer

the snap ring

ring pliers. Pull the gear and bearing.

lightly tapping it with hammer

the inner surface of

Use a socket, placed against the surface of the

is past the ridge in the bore.

gear and bearing back into the gear case

install the snap ring (6).

steps 4 through 7 under

if this is all the service required.

(6) from the gear case, using a

the case clean, then lightly

Assembling the Gear

Assembling the Gear Reducer

1. Grease on

2. Place Place

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

4. Grease key on the pump shaft and slide the gear onto the shaft, Loctite on the setscrew threads and tighten the setscrew

5. Make Replacing case, aligning the holes, and secure it with the nine screws in

6. Grease key on the engine shaft and slide the gear reducer onto

the o–ring and make sure it’

the gear cover

the four oil seals and the o–ring on the screw to hold it

align the

tighten the screws oppositely and evenly

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

up to the pump’

to lock the gear on the shaft.

sure the gasket is

the Gasket). Install the gear cover on the

and lockwashers. T

a crisscross pattern.

the engine shaft. Align the gear’s slot with the

the shaft, up to the engine’

screws in the gear cover

screws with the holes in the pump,

s shoulder

in place (refer to step 4 under

ighten the screws

s properly placed

in the cover

. Apply low strength

s shoulder

evenly

. .

3. Follow instructions under Assembling the Gear Reducer

18 308–530

if this is all the service required.

7. Secure the gear reducer to the engine with the four lockwashers and washers.

bolts,

Page 19

PARTS DRAWING

Gear Reducer (Models 2040 & 2540)

PARTS LIST

Gear Reducer (Models 2040 & 2540)

REF PART NO. NO. DESCRIPTION QTY

1 804–182 2 804–183 3 804–228 BEARING 1 4 804–227 5 804–243 6 804–184 7 802–189 8 804–089

9 804–171 GASKET 10 804–150 11 804–170 GASKET 12 804–169 CAP 13 802–206 W

14 804–185 15 804–215 GASKET 16 804–186 17 804–082 W 18 804–077 W

HOUSING, Gear Reducer GEAR, Pinion, 1”

RING, Retaining, internal RING, Retaining, external SEAL, Oil, pinion O–RING, Drain Plug PLUG, Oil Drain

, Oil Sight Gauge

GAUGE, Sight, oil level

, Oil Filler Cap

, Oil Filler

ASHER, Shim (used on

Model 2540 only)

SEAL, Oil, housing

, Flange

FLANGE, Housing

ASHER, Flat, 6mm ASHER, Lock, 6mm

1 1

1 1 1 1 1 1 1 1 1

1 1 1 1 4 4

REF P

ART

NO. NO. DESCRIPTION QTY

19 804–231 SCREW

20 804–078 21 804–187

O–RING, Housing

GEAR, Driven, helical 22 804–242 KEY 23 804–090 W 24 802–175 W 25 804–240 SCREW

, Cap, socket head,

6mm x 20mm

, Square, (6mm x 27mm) ASHER, Flat, retaining ASHER, Lock, 8mm

, Cap, hex hd./cross

4 1 1 1 1 5

recess 4

26 804–172 KEY 27 804–076 W 28 804–178 W

, Square, 1/4 x 55mm ASHER, Flat, M10 ASHER, Lock, 10mm

29 804–107 SCREW

3/8–16 x 35mm

30 804–239 SCREW

, Cap, hex hd.,

, Cap, hex hd./cross

1 4 4

recess 1

31 804–134 W

ASHER, Flat, 8mm

32 804–106 SPACER 4

19308–530

Page 20

PARTS DRAWING

804–244 Pump Assembly, 1500 psi

20 308–530

Page 21

PARTS LIST

804–244 Pump Assembly, 1500 psi

REF PART NO. NO. DESCRIPTION QTY

1 802–312 KEY 2 804–180 CRANKCASE 1 3 804–077 W 4 804–171 GASKET 5 801–028 6 801–027 CAP 7 804–150 8 804–123

9 804–122 10 802–189 11 804–089 12 804–238 SCREW

13 804–198 CRANKSHAFT 1 14 804–081 BEARING 2 15 802–193 16 802–201 17 804–197 18 804–237 SCREW

19 804–214 W 20 804–241 21 804–142 22 804–083 23 802–185 W 24 802–194 25 804–143 W 26 804–144 27 804–127

, Square

ASHER, Lock

, Oil Sight Gauge

O–RING, Oil Fill Cap

, Oil Fill GAUGE, Sight O–RING, Crankcase Cover COVER, Crankcase O–RING, Drain Plug PLUG, Oil Drain

, Cap, hex hd./cross

recess (6mm x 20mm)

SEAL, Oil, crankshaft O–RING, Crankshaft Cover COVER, Crankshaft

, Cap, hex hd./cross

recess (6mm x 16mm)

ASHER, Lock, 18mm ROD, Assembly Connecting ROD, Plunger PIN, Rod

ASHER, Flat SEAL, Oil Plunger

ASHER, Slinger PLUNGER, Ceramic STUD, Retaining, SST

(6mm x 40mm) 3

1 1 1 1 1 1 1 1

1 2 1

8 3 3 3 3 3 3 3 3

REF P NO. NO. DESCRIPTION QTY

28 804–133 GASKET 29 801–038 30 801–039 31 801–040 RET 32 802–206 W 33 804–092 RET 34 804–145 35 36 37 804–088 38 804–075 W 39 802–178 W 40 804–232 SCREW

41 804–146 42 43 44 45 46 47 801–148 SP 48

49 804–147 50

52 804–128 SCREW

ART

, Copper RING, Backup O–RING, Retainer

AINER, Plunger

ASHER, Flat

AINER, Seal

MANIFOLD, Inlet

KIT C19PACKING, Low Pressure KIT C19PACKING, High Pressure

PLUG, Hex Hd., 1/2

ASHER, Flat, 6mm ASHER, Lock, 10mm

, Cap, socket head

(10mm x 35mm) 2

MANIFOLD, Discharge

KIT C1 KIT C1 KIT C1 KIT C1 KIT C1

KIT C1 or KIT C19

KIT C1 or KIT C19 KIT C1 or KIT C19

RET

AINER, V SPRING, V VALVE O–RING, V SEAT

, V

ACER, Discharge V

O–RING, Spacer

ADAPTER, Inlet V O–RING, Adapter

O–RING, Adapter

10mm x 55mm

alve Spring

alve

alve Seat

alve

, Cap, socket head,

alve 3

3 3 3 3 3 3 1

Kit

Repair Kit Part No.

No.

C1 804–102

Valve

C19 804–101

Packing

Ref

Description Qty.

No.

RET

AINER, V

Spring

SPRING, valve VALVE

O–RING, V

Seat

, V

SEAT O–RING, Spacer

O–RING, Adapter

P Pressure

O–RING, Spacer

O–RING, Adapter

alve

ACKING, Low

ACKING, High

alve

6 6 6

alve

6 6 3 3 3

3 3 3 3

21308–530

Page 22

PARTS DRAWING

804–245 Pump Assembly, 2000 psi

 308–530

Page 23

PARTS LIST

800–245 Pump Assembly, 2000 psi

REF PART NO. NO. DESCRIPTION QTY

1 802–178 W 2 804–154 CRANKCASE 1 3 801–028 4 801–027 CAP 5 804–137 6 804–123 7 804–155 8 804–171 GASKET

9 804–150 10 802–189 11 804–089 12 804–075 W 13 804–077 W 14 804–238 SCREW

15 804–194 CRANKSHAFT 1 16 804–080 BEARING 2 17 804–109 18 804–124 19 804–193 20 804–237 SCREW

21 804–209 RET 22 804–125 23 804–156 24 804–126 25 801–031

ASHER, Lock, 10mm

O–RING, Oil Fill Cap

, Oil Fill COVER, Crankshaft O–RING, Crankcase Cover COVER, Crankcase

, Oil Sight Gauge GAUGE, Sight O–RING, Drain Plug PLUG, Drain

ASHER, Flat, 6mm ASHER, Lock, 6mm

, Cap, hex hd./

cross recess (6mm x 20mm)

SEAL, Oil, crankshaft O–RING, Crankshaft Cover COVER, Crankshaft

, Cap, hex hd./

cross recess (6mm x 16mm)

AINER, Packing, front ROD, Assembly Connecting ROD, Plunger PIN, Rod SEAL, Oil, plunger

1 1 1 1 1 1 1 1

1 12 12

REF P NO. NO. DESCRIPTION QTY

26 804–121 W 27 804–208 RET 28 804–157 29 804–129 30 804–133 GASKET 31 804–234 32 801–038 33 801–039 34 801–040 RET 35 804–214 W 36 37 38 39 804–207 RET 40 41 804–232 SCREW

42 43 44 45 46 47 48 49 804–153 CAP 50 101–754 51 100–361

ART

ASHER, Slinger

AINER, Packing, rear WICK, Round PLUNGER, Ceramic

, Copper STUD, Retaining RING, Backup O–RING, Plunger

AINER, Plunger

ASHER, Split, SST 804–200 KIT C20 PACKING, High Pressure KIT C20

KIT C20PACKING, Low Pressure

KIT C2 KIT C2 KIT C2 KIT C2 KIT C2 KIT C2 KIT C2

MANIFOLD 1

O–RING, Packing Retainer

AINER, Packing

, Cap, socket head

(10mm x 35mm) 2

RING, Backup, valve seat O–RING, V SEAT VALVE SPRING, V RET

AINER, V

O–RING, Cap

, V PLUG, Hex socket 3/8 PLUG, Hex socket 1/2

alve Seat

, V

alve

alve Spring

alve 6

3 3 3 3 3 3 3 3 3 3

1 1

Kit

Repair Kit Part No.

No.

C2 804–100

Valve

C20 804–096

Packing

Ref

Description Qty.

No.

RING, Backup, valve seat

O–RING, V

Seat 44 45 46 47

, V

SEAT

VALVE

SPRING, V

RETAINER,

O–RING, Cap

Pressure

O–RING, Packing

Retainer

Pressure

alve

alve Spring

ACKING, High

ACKING, Low

alve

3 3 3 3

3 3

23308–530

Page 24

PARTS DRAWING

804–246 Pump Assembly, 2500 psi

24 308–530

Page 25

PARTS LIST

804–246 Pump Assembly, 2500 psi

REF PART NO. NO. DESCRIPTION QTY

1 804–093 KEY 1 2 804–154 CRANKCASE 1 3 801–028 4 804–181 CAP 5 804–189 6 804–155 7 804–171 GASKET 8 804–150

9 802–189 10 804–089 11 804–237 SCREW

12 804–224 CRANKSHAFT 1 13 804–080 BEARING 2 14 804–109 15 804–124 16 804–137 17 804–193 18 804–213 RET 19 804–219 20 804–223 21 804–126 22 801–031 23 804–121 W 24 804–208 RET 25 804–216 26 804–220 GASKET

O–RING, Oil Fill Cap

, Oil Fill O–RING, Crankshaft Cover COVER, Crankcase

, Oil Sight Gauge GAUGE, Sight O–RING, Drain Plug PLUG, Drain

, Cap, hex hd./cross

recess (6mm x 16mm)

SEAL, Oil, crankshaft O–RING, Crankshaft Cover COVER, Crankshaft COVER, Crankshaft

AINER, Packing, front ROD, Assembly Connecting ROD, Plunger PIN, Plunger Rod SEAL, Oil, plunger

ASHER, Slinger

AINER, Packing, rear PLUNGER, Ceramic

, Plunger

1 1 1 1 1 1 1 1

1 2 1 1 3 3 3 3 3 3 3 3 3

REF P NO. NO. DESCRIPTION QTY

27 804–234

28 801–038 29 30 801–040 RET 31 804–214 W 32 804–222 MANIFOLD 1 33 34 804–217 RET 35 36 804–118 37 38 804–120 39 40 41 42 43 44 45 46 804–221 CAP 47 48

49 804–077 W 50 804–075 W 51 101–754 52 100–361

ART

STUD, Retaining

(6mm x 64,5mm) 3

RING, Backup, plunger retainer

KIT C21

KIT C21PACKING, Low Pressure

KIT C21 PACKING, High Pressure

KIT C3 KIT C3 KIT C3 KIT C3 KIT C3 KIT C3 KIT C3

802–178 WASHER, Lock, 10mm 804–232

O–RING, Plunger Retainer

AINER, Plunger

ASHER, Keyhole

O–RING, Packing Retainer

AINER, Packing

ADAPTER, Male

ADAPTER, Female O–RING, V SEAT VALVE SPRING, V RET

AINER, V O–RING, V RING, Backup, valve cap

, V

SCREW

(10mm x 35mm) 2 ASHER, Lock, 6mm

ASHER, Flat, 6mm PLUG, Hex socket 3/8 PLUG, Hex socket 1/2

alve Seat

, V

alve

alve Spring

alve Cap

alve 6

, Cap, socket head

3 3

12 12

1 1

Kit

Repair Kit Part No.

No.

C3 804–098

Valve

C21 804–097

Packing

Ref

Description Qty.

No.

O–RING, V

Seat 40 41 42 43

, V

SEAT

VALVE

SPRING, V

RET

Spring

O–RING, V

Cap

RING, Backup,

valve cap

O–RING, Plunger

Retainer

O–RING, Packing

Retainer

Pressure

alve

AINER, V

ACKING, Low

ACKING, High

alve

3 3 3 3

alve

25308–530

Page 26

PUMP

SER

VICE (Model 1535)

Servicing the Valves

Disassembly:

1. Remove the four (4) socket head bolts and spring washers

2. Support the discharge manifold from the underside and tap with a soft mallet to separate from the inlet manifold.

3. Carefully place discharge manifold on working surface

4. From chambers and outer o–rings. These adapters are not held securely manifold

5. Next remove the valve seats, valves, springs and retainers

6. From the three (3) larger diameter and deeper discharge chambers remove the discharge valve spacers remain A reverse pliers fitted into the center bore and hooked onto the side ports of the spacer will assist the

from end of manifold.

with valve chambers up.

the three (3) smaller diameter and shallow inlet

remove the inlet valve adapters with inner

in position and may fall out as the discharge

is removed.

from the inlet chambers.

with o–rings. These

with the discharge manifold as it is removed.

removal.

brass spacers generally

6. Examine and replace if necessary . Lubricate o–rings and fit into

7. Lubricate spacer and carefully press into valve chambers snaps

Reassembly: (INLET)

1. Place valve spring retainers into the shallow valve chambers. They will rest on the machined ridge in each

2. Insert guide.

3. Inspect the valves for wear , ridges or pitting and replace if necessary. Insert valves over the springs with

4. Examine valve seat o–rings for wear and replace. Lubricate and place o–rings on lip of retainers. Carefully square o–rings in valve chamber to avoid cutting

5. Examine valve seats for pitting, scale or ridges and replace side

both o–rings

grooves on outside of spacer

with small diameter side down until spacer

tightly into position.

chamber

valve springs into retainers

recessed (dish) side down.

o–ring when valve seat is installed.

down, so o–ring fits snugly into groove on seat.

if necessary

on the discharge valve spacer

over plastic center

. Install valve

seat with grooved

7. Next remove the valve seats, valves, springs and retainers

NOTE: The inlet and discharge use the same

Reassembly:

1. With insert the springs into the retainers over the plastic center

2. Place valve spring retainers in deeper valve chambers. They will rest on the machined ridge in each

3. Examine necessary. Install valves over the springs with recessed

4. Examine valve seat o–rings for wear and replace. Lubricate and place o–rings on lip of retainers. Carefully square o–rings in valve chamber to avoid cutting

5. Examine valve seats for pitting, scale or ridges and replace side

from the discharge chambers.

retainers, o–rings and valve spacers/adapters are different. Keep parts in order as they are removed.

crankcase side of discharge manifold facing

guide.

chamber

o–ring when valve seat is installed.

if necessary

down, so o–ring fits snugly into groove on seat.

springs, valve seats and valves. The

(DISCHARGE)

up,

the valves for wear or pitting and replace if

(dish) side down.

. Install valve

seat with grooved

6. Examine the adapter inner o–rings and replace if worn. Lubricate and install o–rings into inlet valve adapters.

7. Examine the adapter outer o–rings and replace if worn. Lubricate and install o–rings onto inlet valve adapters.

8. Lubricate Carefully avoid

9. Replace discharge manifold over plunger ends matching discharge valve spacers with inlet chambers and press into position. T ap with a soft mallet

10. Replace Hand tighten each. Then torque per chart.

inlet valve adapter and press into

square inlet valve adapter into chamber to

cutting or extruding o–ring.

until completely seated in chambers.

all four (4) washers and socket head bolts.

chamber

Servicing the Seals

Disassembly:

1. With discharge manifold removed from the pump remove the two (2) socket head bolts and spring washers

Rotate crankshaft to loosen inlet manifold.

3. Support soft

from end of inlet manifold.

inlet manifold from

mallet to separate manifold from crankcase.

underside and tap with a

26 308–530

Page 27

4. With crankcase side of manifold down remove hi–pressure

seals using a reverse pliers.

NOTE: Ceramic plunger can only be installed one

(front

direction

to back). Do not force onto rod.

5. Invert manifold so crankcase side is up and with reverse

Reassembly:

1. Examine low pressure seal for seal wear or spring failure of inlet manifold up, lubricate seal and press into valve chamber with garter spring down. Carefully square

2. Examine hi–pressure seal for wear and replace if necessary. down, lubricate seal and press into chamber with v–side

3. Rotate shaft so the two (2) outside plungers are extended

4. Lubricate plungers and discharge valve adapter o–rings.

5. Carefully line–up and join the inlet and discharge manifolds adapters

6. Replace bolts

7. Then and

8. Replace and washers and hand tighten. Then torque per chart.

9. Then torque the four (4) discharge manifold socket head

pliers remove low pressure seals.

and replace if necessary. With crankcase side

seal into position.

Invert inlet manifold

up. Carefully square into position.

and lined–up.

by pressing the protruding discharge valve

into the inlet manifold seal chambers.

all four (4) discharge

and washers and hand tighten.

carefully

tap with soft mallet until flush with crankcase.

bolts per chart.

slip manifold assembly onto plungers

the two (2)

inlet manifold socket head bolts

with crankcase side

manifold socket head

3. Examine o–ring and back–up ring on plunger retainer and replace if worn or cut. Lubricate o–ring for ease of installation and to avoid damage to o–rings.

NOTE: First install NEW copper gaskets on plunger

retainers,

4. Install short threaded end of stud into plunger retainer.

5. Thread plunger retainer and stud assembly into plunger of

NOTE: Exercise

6. Rotate shaft so the two (2) outside plungers are extended

7. Replace bolts

8. Then and

9. Replace and washers and hand tighten. Then torque per chart.

10. Then torque the four (4) discharge manifold socket head bolts per chart.

rod and torque per chart. (Long threaded end

stud into plunger rod.)

retainer.

and washers and hand tighten.

carefully

tap with soft mallet until flush with crankcase.

then back–up rings and o–rings.

caution not to over torque the plunger

and lined–up. Then lubricate plungers.

all four (4) discharge

slip manifold assembly onto plungers

the two (2)

inlet manifold socket head bolts

manifold socket head

Servicing Crankcase Section

Servicing the Plungers

Disassembly:

1. Remove

2. Using a wrench loosen plunger retainers approximately three (3) to four (4) turns.

3. Grasp until

Remove plunger retainer and copper gasket.

Remove ceramic plunger from plunger rod.

Remove barrier slinger from plunger rod.

Reassembly:

1. Replace barrier slinger if necessary and position onto

2. Carefully examine ceramic plunger for scoring or cracks

discharge and inlet manifold as described.

ceramic

plunger retainers with stud pop out.

plunger rod.

and replace if worn. Slip onto rod.

plunger and push towards crankcase

1. While

3. Rotate

4. Examine crankshaft oil seal externally for drying,

5. Consult factory or your local distributor if crankcase

Pump Part

Plunger Retainer Inlet Manifold

Bolts

Discharge Manifold Bolts

inlet manifold, plungers and seal retainers are

removed,

Check oil level and for evidence of water in oil.

movement.

cracking

service is required.

examine crankcase seals for wear

crankshaft by hand to feel for smooth

or leaking.

orque Chart

Thread T

M5 1 M10

M10

ool Size

1 mm hex

8 mm a

Torque

80 in. lbs.

llen 13

llen

180 in. lbs.

2 in. l

bearing

bs.

27308–530

Page 28

PUMP

SER

VICE (Models 2040 & 2540)

Servicing the Valves

1. Remove

2. Examine the o–ring under the plug for cuts or distortion and replace if worn. Lubricate new o–ring before

3. Grasp remove from valve chamber . Valve parts usually separate

Note: A

4. Examine all valve parts for wear and replace with preassembled valve assembly in service kit containing and

5. Grasp immerse in oil and push into valve chamber . Be certain

the hex valve plug.

installing.

valve

retainer by tab at the top with pliers and

during removal.

special tool will be needed to remove the seat from the manifold. A reverse pliers or a standard seat inserted under the edge of the seat, will pry the

back–up ring.

new valve assembly by tab at top with pliers,

valve assembly is square in valve chamber

vise grip and

valve seat out easily

retainer

, spring, valve, valve seat,

a 1/4” x 3” bolt to fit I.D. of

o–ring,

Reassembly:

1. Carefully or

cracks, replace if worn and slip onto plunger rod.

Note: Ceramic plunger can only be installed one

2. Examine plunger retainer and stud and replace if worn.

Note: Thread

3. Examine retainer and replace if worn or cut. Lubricate o–ring for ease of installation and to avoid damaging o–rings.

Note: First install gasket, then back–up ring and

4. Thread plunger retainer and stud assembly into plunger

5. Saturate

retainer

examine each ceramic plunger for scoring

(front

direction

stud into plunger retainer

o–ring, back–up ring and gasket on plunger

o–ring.

rod. Exercise caution not to over torque.

new oil

and slip retainer over ceramic plunger

to back). Do not force onto rod.

wick by soaking in oil, place in seal

6. Apply

Note: Corrosion Resistant models require the coil

Loctite 242 to

port

and torque per chart.

installed in the V

spring

valve plug, thread into manifold

alve Plug.

Servicing the Pumping Section

Disassembly:

1. Remove manifold

2. Rotate crankshaft by hand to start separation of manifold from crankcase. Support the underside of the manifold and tap lightly with a mallet to remove the

the four (4) hex nuts or two (2) bolts from the

(varies with model).

manifold assembly

CAUTION

Keep manifold properly aligned with ceramic plungers when removing to avoid damage to

plungers or seals.

either

3. Remove

4. Using a wrench, loosen the plunger retainer. Grasp ceramic plunger and push toward crankcase until plunger

5. Remove plunger retainer with copper gasket, back–up

Remove plunger from plunger rod.

28 308–530

oil pan and slide out seal retainer with

retainer pops out.

Ring and o–ring.

wicks.

Replace oil pan.

7. Turn shaft by hand to line up plungers so end plungers

8. Carefully slip manifold onto plungers, keeping manifold level, and tap with mallet to bring manifold flush with crankcase.

9. Replace washers and nuts or bolts and torque per chart.

are parallel.

Servicing the Seals and V–Packings

Disassembly:

1. Remove

2. With the seal case from the manifold using a special key wrench.

3. Remove

4. Remove snap ring and low pressure seal from the seal case. Seals are generally removed easily without

5. High Pressure Seal Models: The high pressure seal is generally easily removed from the manifold without may be used.

6. V–Packing Models: The female adapter , two v–packings and male adapter are easily removed from manifold without tools. If extremely worn a reverse

the manifold as described.

crankcase side of manifold facing up, unscrew

o–ring from seal case.

any tools.

any tools. If extremely worn a reverse pliers

pliers may be used.

Page 29

Reassembly:

V–Packing Models:

Lubricate high pressure packing area in manifold.

2. Insert male adapter with notches down and “v” side up.

Servicing Crankcase Section

1. While manifold, plungers and seal retainers are removed,

examine crankcase seals for wear

3. Lubricate grooved

4. Next

5. Examine seal case o–ring and replace if worn. Lubricate

6. Thread wrench.

High Pressure Seal Models:

Lubricate seal area in manifold.

2. Carefully square seal into position by hand with the metal

3. Examine seal case o–ring and replace if worn. Lubricate

4. Next secure high pressure seal into position by threading with

Low Pressure Seal–All Models:

1. Examine seal for wear or broken spring and lace if necessary.

2. Install low pressure seal in seal case with garter spring

v–packings and install one–at–a–time with

side down.

install female adapter with grooved side down.

new o–ring before installing.

seal case into manifold and tighten with key

grooved side up.

new o–ring before installing.

seal case into manifold. T

key wrench.

down.

ighten seal case

Check oil level and for evidence of water in oil.

3. Rotate

4. Examine crankshaft oil seal externally for drying,

5. Consult factory or your local distributor if crankcase

Pump Part

Plunger Retainer

Manifold

crankshaft by hand to feel for smooth

movement.

cracking

service is evidenced.

or leaking.

orque Chart

Thread T

M5 1

M8 x 1.25

M10 x 1.25

ool Size

1 mm hex

13 mm hex

17 mm hex

bearing

Torque

80 in. lbs.

125 in. lbs.

217 in. lbs.

3. Reinstall Replace

4. Replace per

chart.

snap ring. Be

if it can be easily turned.

manifold on pump as described and

certain snap ring is a tight fit.

torque

Valve Covers

M10

—

17 mm hex

24 mm

27 mm

217 in. lbs.

75 ft. lbs.

29308–530

Page 30

ACCESSORIES

(Must be purchased separately)

DOWNSTREAM CHEMICAL INJECT

OR KIT

800–117 & 800–649

For

injecting harsh cleaning chemicals downstream from

the

pump. 800–649 is stainless steel construction.

UPSTREAM CHEMICAL INJECTOR KIT 800–257

For injecting mild cleaning chemicals upstream into the pump.

BACKFLOW PREVENT

Prevent back–up of contaminated water into fresh supply.

Install upstream of pump.

OR 801–133

ANTI–FREEZE FLUSH KIT 802–327

For

flushing system with 50% anti–freeze solution prior to transporting temperatures.

INLET

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

or storing

pressure washer in below freezing

PRESSURE REGULA

TOR 800–258

WATER SANDBLASTING KIT 800–120

For abrasive cleaning of stubborn dirt and paint. Requires a spray tip which is not included in kit (2040

801–729, 2540 uses 801–667).

uses

30 308–530

Page 31

TECHNICAL DATA

PTFE

Engine (air–cooled, 4 cycle)

Gasoline Tank Capacity

ater Pump Maximum W

Pressure

ater Pump Maximum Flow

Inlet Hose Connection

Weight

Dimensions

Length Width Height

Maximum Inlet W Temperature

Wetted Parts

High Pressure Hose

Bypass Hose

Pressure W

(including fittings)

ater

asher

orking

Model

800–698

5 hp Briggs & Stratton I/C

3 quarts (2.8 liter) 6 quarts (5.7 liter) 5 quarts (4.8 liter)

1500 psi (103 bar) 2000 psi (138 bar) 2500 psi (172 bar)

3.5 gpm (13 lpm) 4 gpm (15 lpm) 4 gpm (15 lpm)

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

105 lb (48 kg) 152 lb (68 kg) 158 lb (70 kg)

37” (940 mm) 19” (483 mm) 20” (508 mm)

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

(70

_ C) 160_ F

is a registered trademark of the DuPont Company

Model 800–699 Model 800–700

8 hp Briggs & Stratton I/C

36” (914 mm) 21” (533 mm)

22.5” (572 mm)

(70

_ C) 160_ F

, Carbon steel, Zinc with or without yellow

hp Briggs & Stratton OHV

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

, Nylon–

(70

_ C)

31308–530

Page 32

THE GRACO WARRANTY

WARRANTY

Graco workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser’s sale, repair or replace any part of the equipment proven defective. This warranty applies only when the equipment

This

warranty does not cover faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, damage materials of

structures, accessories, equipment or materials not supplied by Graco.

This

warranty is conditioned upon the prepaid return of the equipment claimed to be defective for by

Graco to verify the claimed defect. If the claimed defect is verified, Graco any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection reasonable

DISCLAIMERS AND LIMIT

THE TERMS OF THIS W ARRANTY CONSTITUTE THE PURCHASER’S SOLE AND EXCLUSIVE REMEDY AND ARE IN LIEU OF ANY OTHER W ARRANTIES (EXPRESS OR IMPLIED), INCLUDING WARRANTY AND OF ANY NON–CONTRACTUAL LIABILITIES, INCLUDING PRODUCT LIABILITIES, BASED ON NEGLIGENCE OR STRICT LIABILITY . EVER Y FORM OF LIABILITY FOR DIRECT , SPECIAL OR CONSEQUENTIAL GRACO’S OF WARRANTY MUST BE BROUGHT WITHIN THREE (3) YEARS OF THE DA

EQUIPMENT NOT COVERED BY GRACO W

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

making any claim for breach of these warranties.

AND DISCLAIMERS

warrants all equipment manufactured by it and bearing its name to

sole remedy for breach of this warranty

is installed, operated and maintained in accordance with Graco’

, and Graco shall not be liable for

tampering, or substitution of non–Graco component parts. Nor shall Graco be liable for malfunction,

or wear caused by the incompatibility with Graco equipment of structures, accessories, equipment or

not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance

of the equipment does not disclose any defect in material or workmanship, repairs will be made at a

charge, which charges may include the costs of parts, labor and transportation.

ATIONS

OF MERCHANTABILITY OR W

LIABILITY EXCEED THE AMOUNT OF THE PURCHASE PRICE. ANY ACTION FOR BREACH

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

to the warranty

DAMAGES OR LOSS IS EXPRESSL

EQUIPMENT

, if any

, MA

TERIALS OR COMPONENTS SOLD BUT NOT MANUF

, of their manufacturer

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

, any malfunction, damage or wear caused by

ARRANTY OF FITNESS FOR A PAR

Y EXCLUDED AND DENIED. IN NO CASE SHALL

ARRANTY

. Graco will provide purchaser with reasonable assistance

be free from defects in material and

s written recommendations.

examination

will repair or replace free of charge

TICULAR PURPOSE,

TE OF SALE.

ACTURED BY

, switches, hose, etc.) are

32 308–530

IMPORTANT PHONE NUMBERS

TO PLACE AN ORDER ,

distributor

closest to you:

FOR TECHNICAL ASSIST ANCE,

application

Subsidiary and Affiliate Companies:

of Graco equipment:

Factory

Branches:

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

1–800–328–021

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

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

1 T

oll Free

service repair information or assistance regarding the

1–800–543–0339 T

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

PRINTED

IN U.S.A. 308–530 1/91

oll Free

est Caldwell (N.J.)

Graco Inc Hydra-Clean 800-700, Hydra-Clean 800-699, Hydra-Clean 308-530, Hydra-Clean 800-698 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual