Graco Inc. 800-666 Pressure Washer User Manual
Contents
1. CONNECTOR Fuel BRACKET Fuel Connector LINE Fuel 1 4 CLAMP Hose HOSE ASSEMBLY w Quick couplers incl 26 40 44 GUN amp WAND ASSEMBLY incl 29 44 46 47 48 49 GROMMET Rubber TIP ASSEMBLY 0010 incl 79 80 TIP ae 1510 incl 79 81 TIP ASSEMBLY 2510 incl 79 82 TIP ASSEMBLY 4010 incl 79 83 CAPLUG Outlet 3 8 ENGINE 24 Hp Onan electric start QUICK COUPLER Male 1 4 TIP Spray 0010 TIP Spray 1510 TIP Spray 2510 TIP Spray 4010 SWIVEL 3 8 SPACER Pump Bracket PQ s sch i A sch Po wesch sch zech l AS LAN sch sch sch ek et st al md NO P P NI a A3 amd ud wb aaa 308 528 13 PARTS DRAWING ESS 801 790 Pump Assembly 2500 14 308 528 PARTS LIST CTT 801 790 Pump pop sr 2500 psi REF PART NO NO 1 801 781 2 801 468 3 801 469 4 Kit 1 5 Kit 1 6 Kit 1 7 Kit 1 8 Kit 1 9 Kit 1 10 Kit4 11 Kit4 12 803 419 13 803 273 14 803 424 15 803 433 16 803 423 17 803 421 18 802 793 19 801 488 20 801 782 21 803 414 22 803 429 23 803 430 24 802 345 es 803 437 26 803 435 27 803 427 28 803 416 29 803 436 30 803 434 31 602 357 DESCRIPTION MANIFOLD SCREW Cap hex hd WASHER Lock O RING SEAT Valve PLATE Valve SPRING Vaive GUIDE Valve VALVE ASSEMBLY O RING CAP COVER Crankcase SCREW Cap socket hd GASKET Cover BEARING Tapered roller GASKET Cover COVER Crankcase CAP O RING DIPSTICK CRANKCASE O RING O RING GAUG2. and Buna N cover and tube Synthetic yarn and EPDM Anodized aluminum Aluminum or bronze alloys Brass Copper Nylon Teflon composite Ceramic Buna N Cotton phenolic 303 304 and 316 Stainless steel Polymide 12 thermoplastic Teflon Carbon steel Zinc with or without yellow chromate plate Teflon is a registered trademark of the DuPont Company 308 528 19 THE GRACO WARRANTY WARRANTY AND DISCLAIMERS Graco warrants ail equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use As purchaser s sole remedy for breach of this warranty Graco will for a period of twenty four months from date of sale repair or replace any part of the equipment proven defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility with Graco equipment of structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation
3. operation or maintenance 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 examination by Graco to verify the claimed defect H the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation DISCLAIMERS AND LIMITATIONS THE TERMS OF THIS WARRANTY CONSTITUTE THE PURCHASER S SOLE AND EXCLUSIVE REMEDY AND ARE IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND OF ANY NON CONTRACTUAL LIABILITIES INCLUDING PRODUCT LIABILITIES BASED ON 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 GRACO S LIABILITY EXCEED THE AMOUNT OF THE PURCHASE PRICE ANY ACTION FOR BREACH OF WARRANTY MUST BE BROUGHT WITHIN THREE 3 YEARS OF THE DATE OF SALE EQUIPMENT NOT COVERED BY GRACO WARRANTY GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO ACCESSORIES E
4. the engine is warm leave the choke open or partially closed Start the engine as described in the preceding paragraph When the engine starts be Sure to open the choke completely 7 ALWAYS engage the gun s trigger safety latch whenever you stop spraying even for a moment to reduce the risk of fluid injection or splashing in the eyes or on the skin if the gun is bumped or triggered accidentally 8 ALWAYS observe the following CAUTIONS to avoid costly damage to the pressure washer CAUTION DO NOT allow the pressure washer to idle for more than 10 minutes Doing so may cause the recirculating water to overheat and seriously damage the pump Tum off the pressure washer if it will not be spraying or cleaning at least every 10 minutes If heated inlet water is used reduce this time further DO NOT run the pump dry which will quickly damage the pump Be sure the water supply is fully turned on before starting the pump DO NOT operate the pressure washer without an inlet water screen This screen helps keep abrasive sediment out of the pump which could clog or scratch the pump Keep this screen clean DO NOT pump caustic materials such materials may corrode the pump components 9 See the chemical injector or sandblaster kit manual for detailed cleaning information if these accessories are used Trigger Safety Latch WARNING To reduce the risk of serious bodily injury including fluid injection splashing in the eye
5. to 100 ft 30 m of high pressure hose may be used Longer hoses may affect sprayer performance and chemical injector performance if used Install the appropriate spray tip on the wand See installing and Changing Spray Tips if you are using a sandblaster kit see its separate manual for installation instructions CAUTION Before attaching to the water supply check your local plumbing code regarding cross connection to the water supply A backflow preventer P N 801 133 is available to prevent backflow of contaminated water into the fresh water supply Install it upstream from the pump lf 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 s 3 4 inch NPT inlet The supply hose should not be more than 50 ft 15 m long NOTE The water source at the unit must have a minimum flow rate equal to that of the unit see Technical Data inside back Cover if this is not possible a water holding tank must be added to prevent pump damage 308 528 5 Kee EE EE EE Ee NA CON x PE E CNN NEEN EC Nd EEEO EE GE k S E r Ka Always use this startup procedure to ensure that the unit is started safely and properly 1 Check oil levels Engine Add SAE 30 or 10W 30 weight detergent
6. 2513 incl 79 82 TIP ASSEMBLY 4013 incl 79 83 CAPLUG Outlet 3 8 ENGINE 24 Hp Onan electric Start QUICK COUPLER Male 1 4 TIP Spray 0013 TIP Spray 1513 TIP Spray 2513 TIP Spray 4013 SWIVEL 3 8 SPACER Pump Bracket wech Pa Al sch mi sch coh zb mt och sch t sch NO D P A3 sech ND wech ed sch 22205 wh zech IN sch ch sch sch JS 308 528 11 PESO ing E e EE 12 308 528 PARTS LIST ss GE 800 668 H tu 3009 pressure Washer REF PART NO NO 2 803 788 3 801 940 4 100 214 5 100 023 6 803 872 7 102 547 8 802 784 9 803 591 10 802 026 11 802 117 12 801 823 13 803 812 14 803 806 15 803 797 16 803 814 17 803 517 18 802 084 19 801 787 20 802 096 21 803 141 22 803 142 23 802 025 24 801 716 25 801 008 26 801 568 27 800 324 28 803 791 29 156 849 30 803 787 31 803 781 32 100 321 33 800 642 34 803 817 35 100 307 36 100 133 37 100 132 38 802 845 39 803 881 40 801 571 41 172 981 42 176 250 43 800 652 44 801 569 DESCRIPTION CHASSIS BELT GUARD SCREW Cap hex hd 5 16 18 x 3 4 WASHER Lock 5 16 WASHER Flat 5 16 LABEL Graco G SCREW Cap hex hd 5 16 18 x 1 1 2 WASHER Lock 1 2 WASHER Flat 1 2 BARB Hose 1 4 x 5 16 SHEAVE Engine HUB Engine BELT Drive HUB Pump SHEAVE Pump PUMP 3000 psi see page 16 LABEL Keep From Freezing NIPPLE 3 4 x 2 TEE 3 4 BUSHING 3 4 x 1 2 HOSE Bypass NIPPLE Hex 3 8 NPT x 1 2 NPSM TANK Fuel 6 g
7. 308 528 Rev A INSTRUCTIONS PARTS LIST d GRACO This manual contains IMPORTANT WARNINGS and INSTRUCTIONS READ AND RETAIN FOR REFERENCE HYDRA CLEAN 2510 3009 Pressure Washer HYDRA CLEAN 2510 P N 800 666 Series A 2500 psi 172 bar OPERATING PRESSURE 2900 psi 200 bar MAXIMUM WORKING PRESSURE HYDRA CLEAN 3009 P N 800 668 Series A 3000 psi 207 bar OPERATING PRESSURE 3400 psi 234 bar MAXIMUM WORKING PRESSURE GRACO INC P O Box 1441 MINNEAPOLIS MN 55440 1441 COPYRIGHT 1991 GRACO INC WARNING 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 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 the need for amputation Also fluid injected or splashed into the eyes or on the skin can cause serious damage NEVER point the spray gun or wand at anyone or at any part of the body NEVER put hand or fingers over the spray tip ALWAYS follow the Pressure Relief Procedure before cleaning or servicing any part of the sprayer NEVER try to stop or deflect leaks with your hand or body Be sure equipment safety devices are operating properly before each use Medical Treatment
8. E Sight SCREW Cap socket hd WASHER Lock YOKE Crankshaft ROD Connecting PIN Wrist BEARING Ball RING Snap QTY 16 16 A OD t O Dpt ca mi iB a REF PART NO 803 418 803 283 803 420 803 428 803 415 803 426 803 432 Kit 6 803 417 803 425 803 422 802 304 803 438 803 431 Kit 24 Kit 6 801 783 Kit 29 Kit 29 Kit 29 Kit 29 or 12 Kit 29 Kit 6 Kit 6 Kit 6 801 482 801 483 801 484 801 485 Kit 29 DESCRIPTION COVER Crankcase SCREW Cap socket hd GASKET Cover SEAL Oil CRANKSHAFT RING Connecting rod KEY WASHER Flat GUIDE Piston COVER Crankcase GASKET Cover WASHER Lock SCREW Cap socket hd BUSHING SEAL Oil WASHER Flinger PLUNGER Geramic O RING RETAINER O ring RING intermediate PACKING RING Head RING Backup O RING SCREW Piston CAP WASHER Flat CAP WASHER Flat RING Long life gt D k d d eh dO Cp P P A sch CD Goh P 801 472 Valve MES GE Cap 801 474 Plunger Repair 48 2 801 769 Packing 801 770 Retainer Packing amp O RING SEAT Valve PLATE Valve SPRING GUIDE Vaive NOON P 39 WASHER Flat WASHER Flinger RING Backup O RING a SCREW Piston 62 RING Long life VALVE ASSEMBLY 3 O RING 11 CAP Repair Kit Part No Description RD DD O PACKING E 308 528 15 16 308 528 PARTS LI ST EE EE 803 814 Pump Poser 3000 ps
9. E STRAIN RELIEFS ON BOTH ENDS The strain reliefs help protect the hose from kinks or bends at or close to the coupling which can result in hose rupture TIGHTEN all fluid connections securely before each use High pressure fluid can dislodge a loose coupling or allow high pressure spray to be emitted from the coupling NEVER use a damaged hose Before each use check 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 try to recouple high pressure hose or mend it with tape or any other device A repaired hose cannot contain the high pressure fluid HANDLE AND ROUTE HOSES CAREFULLY Do not 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 DO NOT expose Graco hose to temperatures above 200 F 93 C or below 40 F 40 C 308 528 3 MOVING PARTS HAZARD Moving parts can pinch or amputate fingers or other Pressure Relief Procedure before checking or body parts KEEP CLEAR of moving parts when starting servicing the pressure washer to prevent discharging or operating the pressure washer high pressure fluid from the gun NEVER operate the pressure washer without all quards and interlocks installed and functioning Follow the TERMS WARNING Alerts user to avoid or corect conditions CAUTION Alerts user to avoid or correct cond
10. Flat 48 WASHER Fiinger 55 RING Backup 56 O RING 57 SCREW Piston O RING PACKING RING Head RING Long life VALVE ASSEMBLY RETAINER O ring RING intermediate Repair Kit Part No Description D D Or Oo 802 306 O RING Valve Cap CAP 801 474 Plunger Repair e PACKING LE 308 528 17 PUMP SERVICE WARNING To reduce the risk of serious bodily injury including fluid injection splashing in the eyes or on the skin or injury from moving parts always follow the Pressure Relief Procedure Warning before proceeding NOTE The following metric wrenches are needed M10 M13 and M30 Repair kits are available Refer to the individual repair sections and the pump parts page for more details For the best results use all parts in the kits 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 the items in 800 298 and tools to aid in the removal of packing retainers Valves NOTE For a set of six valves order P N 801 472 1 Remove the hex plug from the manifold using an M30 wrench 2 Examine the o ring under the hex plug and replace it if it is cut or distorted 3 Remove the valve assembly from the cavity the assembly may come apart 4 Install the new valve install the o ring and hex plug torque to 75 ft lb 103 Nm NOTE Retorque the plug after 5 hours of operation Pumpi
11. H any fluid appears to penetrate your skin get EMERGENCY MEDICAL TREATMENT AT ONCE DO NOT TREAT AS A SIMPLE CUT Tell the doctor exactly wnat fluid was injected NOTE TO PHYSICIAN injection in the skin is a traumatic injury itis important to treat the Injury surgically as soon as possible Do not delay treatment to research toxicity Toxicity is a concern with some exotic coatings injected directly into the bloodstream Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable 2 308 528 Pressure Relief Procedure To reduce the risk of serious bodily injury including fluid injection and splashing in the eyes or on the skin aiways follow this procedure whenever you stop spraying for more than 10 minutes when shutting down and before checking or repairing any part of the system 1 Engage the trigger safety latch Turn the sprayer off 2 3 Remove the ignition cable from the spark plug 4 Shut off the water supply 5 Disengage the trigger safety latch and trigger the gun to relieve pressure and then engage the trigger safety latch again 6 Before long term overnight storage or transporting of the unit disconnect the water supply and disconnect the fuel supply Spray Gun Safety Devices Be sure all gun safety devices are operating property before each use Do not remove or modify any part of the gun this can cause a malfunction and result in serious bodily injury SAFETY LATCH Wh
12. QUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motor switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties IMPORTANT PHONE NUMBERS TO PLACE AN ORDER contact your Graco distributor or call this number to identify the distributor closest to you 1 800 328 0211 Toll Free FOR TECHNICAL ASSISTANCE service repair information or assistance regarding the application of Graco equipment 1 800 543 0339 Toll Free Factory Branches Atlanta Chicago Dallas Detroit Los Angeles West Caldwell N J Subsidiary and Affiliate Companies Canada England Switzerland France Germany Hong Kong Japan Korea GRACO INC PO BOX 1441 MINNEAPOLIS MN 55440 1441 PRINTED IN U S A 308 528 1 91
13. allon LABEL Waring fuel tank LABEL Graco QUICK COUPLER Male 3 8 UNLOADER 3000 psi GAPLUG Inlet 3 4 NIPPLE Hex 3 8 BRACKET Pump mounting TUBE Pump mounting NUT Lock 1 2 13 BRACKET Rail stiffener BOLT Eye NUT Hex 3 8 16 WASHER Lock 3 8 WASHER Flat 3 8 FOOT Rubber FUEL LINE w Connector 1 4 HOSE High pressure 3 8 x 50 LABEL Waming chassis LABEL Waming chassis FUEL TANK ASSEMBLY incl 10 23 24 25 39 69 QUICK COUPLER Female 3 8 2 incl 45 REF PART NO NO 45 156 082 46 803 350 47 801 134 48 801 674 49 801 009 50 154 594 51 801 972 52 803 525 53 107 069 54 801 954 56 100 527 56 100 016 57 100 015 58 801 960 59 801 959 60 801 958 61 803 867 62 803 077 63 802 408 64 181 867 65 802 363 66 802 908 67 801 919 68 803 891 69 801 971 70 800 375 71 800 392 72 801 548 73 800 478 74 800 479 75 800 480 76 800 481 77 803 894 78 803 868 79 801 090 80 803 687 81 801 994 82 803 688 83 803 689 84 155 665 85 803 781 DESCRIPTION O RING Quick coupler 3 8 GUN Spray See 308 511 WAND 2 SLEEVE 28 QUICK COUPLER Female 1 4 inct 50 O RING Quick coupler 1 4 PAD Battery BOLT Battery BRACKET Battery BATTERY 12 Volt 30 amp WASHER Flat 1 4 WASHER Lock 1 4 NUT Hex 1 4 20 BOLT Carriage 1 4 20 x 1 TERMINAL PROTECTOR Black TERMINAL PROTECTOR Red CABLE 26 Long LABEL Electrolyte CABLE 32 Long LABEL Waming LABEL Caution
14. 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 changes is longer If the unit is operating in dusty conditions these maintenance 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 before proceeding Interval Lues do Daily Clean water inlet screen and filter Check engine and pump oil levels Fill as necessary Check gasoline level Fill as necessary After first 5 Change engine break in oil hours of Drain oil when warm Use SAE operation 30 or 10W 30 detergent oil Each 25 hours Clean and remove air cleaner of operation foam Wash with water and detergent Dry thoroughly Rub with oil and squeeze to distribute oil Change pump break in oil Use SAE 20 or 30 non detergent oil After first 50 hours of operation Each 100 hours Clean or replace paper air of operation Cleaner cartridge Tap gently to or 3 months remove dirt Change engine oil Use SAE 30 or 10W 30 detergent oil Each 500 hours Change pump oil Use SAE 20 or of operation 30 non detergent oil or 6 months TROUBLESHOOTING CHART WARNING To reduce the risk of serious bodily
15. cking and second head ring r a PSEA the manifold as instructed in Servicing e Plungers 4 Inspect all parts and replace as necessary ACCESSORIES Ge Must be purchased separately DOWNSTREAM CHEMICAL INJECTOR KIT ANTI FREEZE FLUSH KIT 802 327 800 425 For flushing system with 50 anti freeze solution prior For injecting harsh cleaning chemicals downstream to transporting or storing pressure washer in below from the pump freezing temperatures BACKFLOW PREVENTOR 801 133 INLET PRESSURE REGULATOR 800 258 Prevent back up of contaminated water into fresh Regulates iniet water pressure to 60 psi 4 bar supply Install upstream of pump maximum WATER SANDBLASTING KIT 800 120 For abrasive cleaning of stubbom dirt and paint Requires a spray tip which is not included in kit 2510 uses 801 758 3009 uses 801 994 NM ENNER ENK KEEN DR CC SES EE CP TO CO TC ene a alah y VOOR RE A RERO LORS e EEE TIRE OR ENTREE PE TEE OD AE RAA DN da DNK NENNEN d NENNEN EC ENN SO A ENN NN E EE CNN DNK E MER NEEN MAKE CNN NN PORC CCC ER REC MCK ed SS Neien EE UC j x Ca ANITA x La x E r ONG H d 4 s Va e Engine twin cylinder 4 cycle air cooled 24 HP Onan Dimensions Length 48 1219 mm 48 1219 mm Width 30 762 mm 30 762 mm Height 25 635 mm 25 635 mm Son EMMG Wetted Parts High Pressure Hose Bypass Hose Pressure Washer including fittings Acrylonitrile
16. crew and the outer end of the plunger Place the washer o ring and backup ring around the screw and install the screw through the plunger Torque to 14 4 ft lb 19 5 Nm NOTE If you plan to replace the packings refer to Servicing the V Packings 7 Lubricate the outside of each plunger Slide the manifold onto the crankcase being careful not to damage the seals 8 Install the Capscrews and washers finger tight Torque the screws to 21 7 ft lb 29 Nm following the tightening pattern Figure 4 Uneven tightening may cause the manifold to bind or jam Figure 4 Servicing the V Packings 5 Thoroughly clean the packing cavities and examine NOTE There are two types of packing kits one is for debris and damage packings only the other includes the 6 Lightly grease the packing cavities and then packings rings and retainers replace the packings in the following order head fing v packing intermediate ring head ring 1 Remove the manifold as outlined in the Pumping v packing and packing retainer with the o ring Section installed in the retainer groove CAUTION install the parts in the proper order and facing the correct direction Improperly installed parts will cause a malfunction 2 Carefully pull the packing retainer from the manifold Examine the o ring and replace it if it is cut or damaged 3 Remove the v packing and head ring Pull out the intermediate retainer ring Remove the second v pa
17. enever you stop spraying for a moment always set the gun safety latch in the engaged or safe position making the gun inoperative Failure ta properly set the safety latch can result in accidental triggering of the gun SPRAY TIP SAFETY Use extreme caution when cleaning or changing spray tips If a spray tip clogs while spraying engage the gun safety latch immediately ALWAYS foilow the Pressure Relief Procedure and then remove the spray tip to clean it FUEL AND EMISSION HAZARDS NEVER fill the fuel tank while the unit is running or hot The fuel used in this unit is combustible and when spilled on a hot surface can ignite and cause a fire ALWAYS fill tank slowly to avoid spilling NEVER operate the unit in a closed building The exhaust contains carbon monoxide a poisonous odorless invisible gas which can cause serious injury or death if inhaled NEVER alter the maximum throttle setting which is factory set Tampering with this adjustment can damage the pressure washer and will void the warranty EQ U P M E NT M S U S E H AZAR D GE General Safety Any misuse of the pressure washer or accessories such as overpressurizing modifying parts using incompatible chemicals and fluids or using worm or damaged parts can cause them to rupture and result in fluid injection splashing in the eyes or on the skin or other serious bodily injury fire explosion or property damage NEVER alter or modify any part
18. i REF PART 803 419 803 273 803 424 803 433 803 423 803 421 802 793 801 488 801 782 803 414 803 429 803 430 802 345 803 437 803 435 803 427 803 416 803 436 803 434 802 357 DESCRIPTION MANIFOLD SCREW Cap hex nd WASHER Lock O RING SEAT Valve PLATE Valve SPRING Valve GUIDE Valve VALVE ASSEMBLY O RING CAP COVER Crankcase SCREW Cap socket hd GASKET Cover BEARING Tapered roller GASKET Cover COVER Crankcase CAP O RING DIPSTICK CRANKCASE O RING O RING GAUGE Sight SCREW Cap socket hd WASHER Lock YOKE Crankshaft ROD Connecting PIN Wrist BEARING Ball RING Snap QTY 16 16 E EE EE EE REF PART NO NO 53 Kit 29 or 12 54 Kit 29 55 Kit6 56 Kit6 57 Kit6 58 801 482 59 801 483 60 801 484 61 801 485 62 Kit 29 DESCRIPTION COVER Crankcase SCREW Cap socket hd GASKET Cover SEAL Oil CRANKSHAFT RING Connecting rod KEY WASHER Flat GUIDE Piston COVER Crankcase GASKET Cover WASHER Lock SCREW Cap socket hd BUSHING SEAL Oil WASHER Flinger PLUNGER Ceramic O RING RETAINER O ring RING Intermediate PACKING RING Head RING Backup Q RING SCREW Piston CAP WASHER Flat CAP WASHER Fiat RING Long life DD Arh A OD mms 5 CO O PZ 801 472 Valve 801 468 Packing 801 487 Retainer Packing amp O RING S SEAT Valve 6 PLATE Valve 7 SPRING E GUIDE Valve a WASHER
19. ing in the eyes or on the skin always follow this procedure whenever you stop spraying for more than 10 minutes when shutting down and before checking or repairing any part of the system 1 2 3 Engage the trigger safety latch Tum the sprayer off Remove the ignition cable from the spark plugs Shut off the water supply Disengage the trigger safety latch and trigger the gun to relieve pressure and then engage the trigger safety latch again Before long term overnight storage or transporting of the unit disconnect the water supply and disconnect the fuel supply 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 Flush the pressure washer before using it again to remove the anti freeze NOTE An anti freeze flush kit P N 802 327 is if water does freeze in the pressure washer thaw it in a warm room before trying to start it DO NOT pour hot water on or into the pump it may crack the ceramic plungers available to make flushing easier CAUTION After each use wipe all surfaces of the pressure washer with a clean damp cloth Perform the appropriate maintenance See maintenance chart 308 528 Observing regular maintenance intervals helps ensure that you get maximum performance and life from the pressure washer There is a
20. injury including fluid injection splashing in the eyes or onthe skin or injury from moving parts always follow the Pressure Relief Procedure Warning before proceeding EE CE EE Engine will not start or No gasoline in fuel tank or carburetor Fil the tank with gasoline open fuel shut off valve is hard to start Check fuel line and carburetor Add to proper level Move switch to start position Drain fue tank and carburetor Use new fuel and dry spark plug Check and tighten battery connections Check electrolyte level of ceils recharge battery Open choke and crank engine severai times to clear out gas Remove and clean Clean adjust the gap or replace Trigger spray gun Remove and clean Clean adjust the gap or replace Time engine Low oil level Start Stop switch in Stop position Water in gasoline or old fuel Loose or wrong battery connection Battery not properly charged Choked improperly Flooded engine Dirty air Cleaner filter Spark plug dirty wrong gap or wrong type Spray gun closed Partially plugged air cleaner filter Spark plug dirty wrong gap or wrong type incorrect ignition timing Worn or wrong size tip Inlet filter clogged Wom packings abrasives in water or natural wear Inadequate water supply Belt slippage Engine misses or lacks power Replace with tip of proper size Clean Check more frequen
21. itions that Could cause bodily injury that could cause damage to the equipment NOTE identifies helpful procedures and information IMPORTANT United States Government safety standards have been adopted under the Occupational Safety and Health Act These standards particularly the General Standards Part 1910 and the Construction Standards Part 1926 should be consulted 4 308 528 SNE Deh di DECH EENS EA e ENEE EE ECC a E Dell va haen Belle ale eu ka Baba rte e Se elef Lal nt s r DO D CEE PONS PA CR CPE SC EN a a tt a a WC e a WK m a a e e CM E Ge LOC PIECE SE EC TC CU CC ER CO CG GO SO SC SCOR CES HIGH PRESSURE HOSE CONNECTION WATER SUPPLY QUICK COUPLER GUN QUICK COUPLERS HOSE Figure 1 Check for Shipping Damage Connect to Water Supply Check the unit for any damage that may have occurred in shipping Notify the carrier immediately if there is any damage Set Up Fill the battery cells with electrolyte and water Charge the battery Be sure the battery connections are correct and secure Connect the fuel line to the engine using the quick Coupler provided Squeeze the priming bulb 3 to 5 times if you are using a downstream chemical injector install it between the pump unloader and the high pressure hose using the quick couplers provided Connect the high pressure hose between the pump outlet and the gun inlet Both of these connections are made with quick couplers CAUTION Up
22. ng Section 1 Remove the eight capscrews and lockwashers from the manifold using an M13 wrench 2 Carefully separate the manifold from the crankcase NOTE Itmay be necessary to tap the manifold lightly with a soft mailet to loosen CAUTION Keep the manifold properly aligned with the ceramic plungers when removing to avoid damage to the plunger or seals 3 Carefully examine each plunger for any scoring or cracking and replace as necessary 18 308 528 Servicing the Plungers NOTE Plunger repair kit P N 801 474 is available to replace retainers o rings washers and backup rings for three cylinders 1 Loosen the plunger retaining screw five to six turns using an M10 wrench Push the plunger towards the crankcase to separate the plunger and retaining screw 2 Remove the screw from the plunger and examine the o ring backup ring and copper bearing gasket washer Replace these parts ifnecessary using kit 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 seats Otherwise DO NOT remove these seals as they cannot be reused An ail seal kit is available to replace the seals 5 Lightly grease the flinger and oil seat if it is being replaced and replace them on the plunger shaft Then install the ptunger 6 Lightly grease the retaining s
23. of this equipment doing so could cause it to malfunction CHECK all spray equipment regularly and repair or replace wom or damaged parts immediately ALWAYS wear protective eyewear and appropriate clothing if using a chemical injector read and follow the chemical manufacturer s literature for recommendations on additional protective equipment such as a respirator System Pressure This sprayer can develop high operating pressures Be sure that all spray equipment and accessories are rated to withstand the maximum working pressure of this sprayer DO NOT exceed the maximum working pressure of any component or accessory used in the system Chemical Compatibility BE SURE that all chemicals used in the chemical injector are compatible with the wetted parts of the hose gun wand and tip as given in the Technical Data inside back cover Always read the chemical manufacturer s literature before using any chemical in this pressure washer NM ENNEN SCHEER OC NN NNN ENKEN ANA ee pesa ta Pata a ata tada Pa AEN NENNEN gt qa pa CART O TA Ta eee CS K d deefe NR no SA ae Ee EC EE NNEN OR RO EDP KN SENTE OK CECR RO DDS O A NENNEN NENNEN 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 spray emitted from it can cause a fluid injection injury or other serious bodily injury or property damage ALL FLUID HOSES MUST HAV
24. oil as necessary Pump Add SAE 20 or 30 weight non detergent oil as necessary NOTE This pressure washer is equipped with a low oil sensor that shuts the engine off if the oil level falls below a certain level If the unit stops unexpectedly check both the oil and the fuel levels Check the oil level each time the unit is refueled 2 Check fuel level WARNING DO NOT refuel a hot engine Refueling a hot engine could cause a fire Use only fresh clean reguiar or unleaded gasoline Close the fuel shutoff valve during refueling 3 Tum on the water supply CAUTION Never run the unit dry Costly damage to the pump will result Always be sure the water supply is completely tumed on before operating 4 Trigger the gun until water sprays from the tip indicating that the air is purged from the system 5 Be sure the spark plug ignition cables are pushed firmly onto the spark plugs The ignition shutoff switch should be in the on position The throttle should be in the run position 6 Start the engine NOTE For easier starting have one person start the pressure washer while another person triggers the spray gun 6 308 528 If the engine is cold completely close the engine choke Press the start button In cool weather the choke may have to be kept closed for 10 to 30 seconds before opening it to keep the engine running Otherwise open the choke as soon as the engine starts If
25. p mounting NUT Lock 1 2 13 BRACKET Rail stiffener BOLT Eye NUT Hex 3 8 16 WASHER Lock 3 8 WASHER Flat 3 8 FOOT Rubber FUEL LINE w Connector 1 4 HOSE High pressure 3 8 x 50 LABEL Warning chassis LABEL Warning chassis FUEL TANK ASSEMBLY incl 10 23 24 25 39 69 QUICK COUPLER Female 3 8 P incl 45 AC PART NO 156 082 803 350 801 134 801 674 801 009 154 594 801 972 803 525 107 069 801 954 100 527 100 016 100 015 801 960 801 959 801 958 803 867 803 077 802 408 181 867 802 363 802 908 801 919 803 891 801 971 800 375 800 392 801 548 800 404 800 405 800 493 800 494 803 894 803 868 801 090 801 759 801 758 803 697 803 698 155 665 803 781 DESCRIPTION O RING Quick coupler 3 8 GUN Spray see 308 511 WAND 32 SLEEVE 28 QUICK COUPLER Female 1 4 incl 50 O RING Quick coupler 1 4 PAD Battery BOLT Battery BRACKET Battery BATTERY 12 Volt 30 amp WASHER Flat 1 4 WASHER Lock 1 4 NUT Hex 1 4 20 BOLT Carriage 1 4 20 x 1 TERMINAL PROTECTOR Black TERMINAL PROTECTOR Red CABLE 26 Long LABEL Electrolyte CABLE 32 Long LABEL Warning LABEL Caution CONNECTOR Fuel BRACKET Fuel Connector LINE ae CLAMP H HOSE ASSEMBLY w Quick couplers incl 26 40 44 GUN amp WAND ASSEMBLY incl 29 44 46 47 48 49 GROMMET Rubber TIP ASSEMBLY 0013 incl 79 80 TIP ASSEMBLY 1513 incl 79 81 TIP ASSEMBLY
26. s or on the skin ALWAYS engage the trigger safety latch whenever spraying stops even for a moment In the engaged position the trigger safety latch prevents the gun from being triggered accidentally by hand or if it is dropped or bumped Be sure the latch is pushed fully down when engaging it or it cannot prevent the gun from being triggered See Figure 2 TRIGGER SAFETY LATCH SHOWN DISENGAGED Figure 2 Installing and Changing Spray Tips WARNING To reduce the risk of serious bodily injury including fluid injection or splashing in the eyes or onto the skin use extreme caution when changing spray tips ALWAYS follow the procedure below 1 Follow the Pressure Relief Procedure 2 Point the gun and wand away from yourself and anyone else 3 Without holding your hand over the spray tip A pull back the quick coupler ring B Remove the old tip and or install a new one and then release the ring See Figure 3 4 Be sure the tip is se ure before starting to spray again 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 mounted in the quick coupler 308 528 7 SHUTDOWN FLUSHING HE AND STORAGE WARNING Pressure Rellef Procedure To reduce the risk of serious bodily injury including fluid injection and splash
27. tly Check filter Replace packings See PUMP SERVICE Check water flow rate to pump Tighten or replace use correct belts and replace both at same time Clean intet and discharge valve assemblies Check filter Check garden hose may be collapsed or kinked Replace worn valves Low pressure and or pump runs rough Fouled or dirty inlet or discharge valves Even a small particle can cause the valve to stick Restricted inlet Worn inlet or discharge valves Leaking high pressure hose Replace high pressure hose Water leakage from Worn packings Instali new packings See PUMP SERVICE under pump manifold Water in pump Humid air condensing inside crankcase Change oil as specified in MAINTENANCE Install new packings See PUMP SERVICE install new oil seals See PUMP SERVICE Install new plungers See PUMP SERVICE Install proper filtration on pump inlet plumbing Check water temperature may not exceed 160 F Do not modify any factory set adjustments See EQUIPMENT MISUSE HAZARD Excessive pressure due to partially plugged or Clean or replace tip See Installing and Changing damaged tip Spray Tips Pump running too long without spraying Never run pump more than 10 minutes without spraying Running pump dry Do not run pump without water Strong surging atthe Foreign particles in the iniet or discharge Ciean or replace vaives See PUMP SERVICE inlet and low press
28. ure valve or worn inlet and or discharge valves on the discharge side 308 528 9 Worn packings Oil seals leaking Frequent or premature failure of the packings Scored damaged or worn plungers Abrasive material in the fluid being pumped Inlet water temperature too high Overpressurizing pump a a B 10 308 528 PARTS LIST EM SE EE 800 666 Hydra Cieans 2 2510 mengen Washer PART NO 800 643 803 788 801 940 100 214 100 023 803 872 102 547 802 784 803 591 802 026 804 049 801 823 803 812 803 806 803 797 801 790 803 517 802 084 801 787 802 096 803 141 803 142 802 025 801 716 801 008 801 568 800 323 803 791 156 849 803 787 803 781 100 321 800 642 803 817 100 307 100 133 100 132 802 845 803 881 801 571 172 981 176 250 800 652 801 569 DESCRIPTION CHASSIS BELT GUARD SCREW Cap hex hd 5 16 18 x 3 4 WASHER Lock 5 16 WASHER Flat 5 16 LABEL Graco G SCREW Cap hex hd 5 16 18 x 1 1 2 WASHER Lock 1 2 WASHER Flat 1 2 BARB Hose 1 4 x 5 16 SHEAVE Engine HUB Engine BELT Drive HUB Pump SHEAVE Pump PUMP 2500 psi see page 14 LABEL Keep From Freezing NIPPLE 3 4 x 2 TEE 3 4 BUSHING 3 4 x 1 2 HOSE Bypass NIPPLE Hex 3 8 NPT x 1 2 NPSM TANK Fuel 6 gallon LABEL Warning fuel tank LABEL Graco G QUICK COUPLER Male 3 8 UNLOADER 2500 psi CAPLUG Inlet 3 4 NIPPLE Hex 3 8 BRACKET Pump mounting TUBE Pum
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