Graco Inc. 308-532 Pressure Washer User Manual
Contents
1. 800 706 Hydra Clean 3540 Pressure Washer REF PART NO NO 1 100 188 2 100 214 3 801 285 4 804 136 5 100 023 6 801 941 7 803 534 8 803 926 9 803 525 10 804 282 11 801 972 12 801 550 13 801 612 14 801 020 15 800 676 16 801 556 17 800 678 18 801 546 19 100 133 20 100 132 21 800 160 22 803 905 23 111 040 24 803 925 25 803 298 26 156 082 27 154 594 28 802 016 29 801 522 30 176 250 31 801 548 32 172 981 33 800 314 34 800 315 35 800 316 36 800 317 37 803 883 38 39 800 652 40 802 026 41 801 571 42 801 569 43 801 568 44 800 392 DESCRIPTION NUT Hex 5 16 18 WASHER Lock 5 16 BELT Drive SHEAVE Engine WASHER Flat 5 16 SCREW Cap Hex hd 5 16 18 x 1 LABEL Belt Guard BELT GUARD BOLT Battery BRACKET Battery PAD Battery WHEEL amp TIRE ASSEMBLY WASHER Flat 1 2 NUT Lock 1 2 13 CHASSIS AXLE BRACKET Rail Stiffener SCREW Cap Hex hd 3 8 16 x 1 1 4 WASHER Lock 3 8 WASHER Flat 3 8 FRONT LEG ASSEMBLY incl 5 78 through 84 LABEL Model 3540 NUT Lock 5 16 18 HANDLE SCREW Cap Hex hd 5 16 18 x 3 1 2 O RING Quick Coupler 3 8 O RING Quick Coupler 1 4 BRACKET Rail Stiffener SCREW Cap Hex hd LABEL Chassis GROMMET Rubber LABEL Chassis ASS Y 00045 incl 70 71 ASS Y 15045 incl 70 72 ASS Y 25045 incl 70 73 TIP ASS Y 40045 incl 70 74 ENGINE 12 5 HP Briggs amp Stratton Vanguard OHV PUMP ASS Y2. recharge battery Open choke and crank engine several 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 Replace with tip of proper size Clean Check more frequently 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 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 SERVICE 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 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 Strong surging at the Foreign particles in the inlet or discharge Clean or replace valves See PUMP SERVICE inlet and low pressure valve or worn inlet and or discharge valves on the discharge side 308 532 9 PARTS DRAWING 800 706 Hydra Clean 3540 Pressure Washer a 10 308 532 PARTS LIST EN
3. see page 14 FUEL TANK ASSEMBLY incl 40 87 89 90 91 92 BARB Hose 1 4 HOSE High Pressure 3 8 x 50 QTY 11 13 2 1 27 NN N N A A EI ABA lt _ QUICK COUPLER Female 3 8 incl 26 QUICK COUPLER Male 3 8 GUN amp WAND ASSEMBLY incl 42 65 66 67 68 69 _ REF NO 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 PART NO 801 217 177 144 803 535 803 796 801 898 801 135 801 959 801 945 803 077 801 954 100 527 100 016 100 015 801 964 801 946 801 958 803 531 801 022 107 069 801 009 801 134 801 674 803 350 156 849 801 090 803 106 803 107 803 108 803 109 800 375 802 363 181 867 801 531 801 504 801 505 801 593 801 506 801 537 801 499 802 907 801 919 801 971 801 629 801 716 803 881 802 025 801 008 DESCRIPTION BUMPER Rubber LABEL Belt Guard SCREW Cap Hex hd SHEAVE Pump HUB Engine HUB Pump TERMINAL PROTECTOR Black CABLE Battery 12 Long LABEL 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 CABLE Battery 24 Long TERMINAL PROTECTOR Red BASEPLATE Belt Guard SCREW Cap Hex hd 5 16 18 x 3 4 BRACKET Battery QUICK COUPLER Female 1
4. 30 Amp 1 10 803 530 BRACKET Battery 1 56 100 527 WASHER Flat 1 4 2 11 801 972 PAD Battery 1 57 100 016 WASHER Lock 1 4 4 12 801 550 WHEEL amp TIRE ASSEMBLY 2 58 100 015 NUT Hex 1 4 20 4 13 801 612 WASHER Flat 1 2 2 59 801 964 BOLT Carriage 1 4 20 x 1 2 14 801 020 NUT Lock 1 2 13 2 60 801 946 CABLE Battery 24 Long 1 15 800 676 CHASSIS 1 61 801 958 TERMINAL PROTECTOR Red 1 16 801 556 AXLE 1 62 803 531 BASEPLATE Belt Guard 1 17 800 678 BRACKET Rail Stiffener 1 63 801 022 SCREW Cap Hex hd 18 801 546 SCREW Cap Hex hd 5 16 18 x 3 4 4 3 8 16 x 1 1 4 4 64 107 069 BRACKET Battery 1 19 100 133 WASHER Lock 3 8 4 65 801 009 QUICK COUPLER Female 1 4 20 100 132 WASHER Flat 3 8 4 incl 27 1 21 800 160 FRONT LEG ASSEMBLY 66 801 134 WAND 32 1 incl 5 78 thru 84 1 67 801 674 SLEEVE 28 1 22 803 906 LABEL Model 4043 1 68 803 351 GUN Spray see Instruction 23 111 040 NUT Lock 5 16 18 4 Manual 308 511 1 24 803 925 HANDLE 1 69 156 849 NIPPLE Hex 3 8 1 25 803 298 SCREW Cap hd 70 801 090 QUICK COUPLER Male 14 4 5 16 18 x 3 1 2 1 71 803 106 Spray 00045 1 26 156 082 O RING Quick Coupler 3 8 2 72 803 107 TIP Spray 15045 1 27 154 594 O RING Quick Coupler 1 4 1 73 803 108 TIP Spray 25045 1 28 802 016 BRACKET Rail Stiffener 1 74 803 109 TIP Spray 40045 1 29 801 522 SCREW Cap Hex hd 2 75 800 450 HOSE ASSEMBLY W QUICK 30 176 250 LABEL Chassis 1 COUPLERS incl 41 42 43 1 31 801 548 GROMMET Rubber 5
5. Detroit Los Angeles West Caldwell N J Subsidiary and Affiliate Companies Canada England Switzerland France Germany Hong Kong Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 PRINTED IN U S A 308 532 3 91 3X8 532 Rev D Parts Change Notice Some parts in Rev A of manual 308 532 have changed but have not yet been changed in the instruction manual Please note the changes below and mark them in your manual or keep this sheet with your manual Pressure washer 800 706 has been obsoleted and is no longer covered by this manual The following changes apply to the page 13 parts list for 800 707 Series Letter Part That Ref Assembly No Change Changed Part Description Description of Change Model 800 707 B 801 814 3 Drive belt Replaced by 803 889 803 160 4 Sheave engine Replaced by 803 943 803 530 10 Battery bracket Replaced by 804 282 176 250 30 Label Replaced by 804 500 801 548 31 Rubber grommet Replaced by 801 012 172 981 32 Label Deleted 803 519 41 Hose high Replaced by 804 427 pressure 3 8 x 50 801 568 43 Quick coupler male Replaced by 804 498 3 8 177 144 47 Label Replaced by 804 495 803 068 49 Sheave pump Replaced by 803 944 804 141 51 Hub pump Replaced by 801 135 800 450 75 Hose assembly with Replaced by 800 375 quick couplers 181 867 77 Label Replaced by
6. KIT 28 or 112 RETAINER Packing KIT 28 or 112 PACKING Kit 8 or 109 KIT 28 or 112 RING Head KIT 28 or 112 RETAINER Packing KIT 28 or 112 RING Long Life 801 526 802 305 802 304 801 482 801 483 801 484 801 485 801 624 803 508 803 083 803 517 802 085 801 106 800 113 801 111 801 110 801 112 803 141 803 142 802 534 800 325 800 689 800 427 801 868 801 236 801 568 BRACKET Pump SCREW Cap socket hd WASHER Lock PLUG Hex WASHER Flat PLUG Hex WASHER Flat PUMP 3000 psi PUMP 3500 amp 4000 psi LABEL Keep From Freezing 3000 psi LABEL Keep From Freezing 3500 amp 4000 psi NIPPLE 1 2 TEE 1 2 FILTER see Instruction Manual 801 744 NUT Garden Hose ADAPTER Garden Hose STRAINER Garden Hose HOSE Bypass NIPPLE Hex 1 2 NPSM x 3 8 NPT 3000 psi NIPPLE Hex 1 2 NPSM x 1 2 NPT 3500 amp 4000 psi UNLOADER 3000 psi UNLOADER 3500 psi UNLOADER 4000 psi NIPPLE Hex 3 8 3000 psi NIPPLE Hex 1 2x3 8 3500 amp 4000 psi COUPLER Male 3 8 3X8 532Rev D 1 30 95 Qty kh sch N DN N ech mk mk o Kit Repair Kit Ref 801 487 O RING No Part No No Description Qty Packing amp Retainer RETAINER Packing 1 801 472 4 O RING S000 psi BIN e Valve 5 SEAT Valve PLATE Valve SPRING GUIDE Valve 1 RING Head RETAINER Packing VALVE ASSEMBLY 2 801 473 6 SEAL Oil Oil Seal RING Long Life 803 509 O RING Valve
7. each use Medical Treatment If any fluid appears to penetrate your skin get EMERGENCY MEDICAL TREA TMENT AT ONCE DO NOT TREAT AS A SIMPLE CUT Tell the doctor exactly what fluid was injected NOTE TO PHYSICIAN njection in the skin is a traumatic injury It is 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 2 308 532 Pressure Relief Procedure To reduce the risk of serious bodily injury including fluid injection and splashing in the eyes or on the skin always follow this procedure whenever you stop spraying for more than 10 minutes when shutting down and before checking or repairing any part of the system 1 Engage the trigger safety latch 2 Turn the sprayer off 3 Remove the ignition cable from the spark plug 4 Shutoff 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 properly before each use Do not remove or modify any part of the gun this can cause a malfunction and result in serious b
8. only fresh clean regular or unleaded gasoline Close the fuel shutoff valve during refueling 3 Turn 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 turned on before operating 4 Trigger the gun until water sprays from the tip indicating that the air is purged from the system 5 Openthe fuel shutoff valve Be sure the spark plug ignition cables are pushed firmly onto the spark plugs Put the ignition shutof f switch in the on position and the throttle in the run position 6 Startthe engine NOTE For easier starting have one person start the pressure washer while another person triggers the spray gun 6 308 532 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 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 CAUTI
9. or on the skin or injury from moving parts always follow the Pressure Relief Procedure Warning before proceeding What to 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 hours of operation Each 25 hours of operation 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 Rub with oil and squeeze to distribute oil After first 50 Change pump break in oil Use hours of SAE 20 or 30 non detergent oil operation or genuine CAT pump oil Each 100 hours Clean or replace paper air of operation or 3 months cleaner cartridge Tap gently to remove dirt Change engine oil Use SAE 30 or 10W 30 q gent o Each 500 hours Change pump oil Use SAE 20 of operation or 30 non detergent oil or or 6 months genuine CAT9 pump oil TROUBLESHOOTING CHART NEN 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 Problem 894m Engine will not start or is hard to start No gasoline in fuel tank or carburetor Low oil level Start Stop switch in Stop position Water in gas
10. 25 803 503 803 291 803 292 803 293 803 507 802 345 802 793 KIT 6 or 107 803 294 8033 652 KIT 6 or 107 801 490 803 502 KIT 6 or 107 GRACO Pump Assembly Parts USE ONLY GENUINE GRACO PARTS AND ACCESSORIES Description MANIFOLD MANIFOLD 3500 amp 4000 psi SCREW Cap hex hd WASHER lock O RING SEAT Valve PLATE Valve SPRING GUIDE Valve O RING CAP VALVE ASSEMBLY SCREW Cap socket hd COVER Crankcase COVER Crankcase 3500 amp 4000 psi O RING Crankcase Cover BEARING Tapered Roller SEAL Oil BUSHING Piston CRANKCASE CRANKCASE 3500 amp 4000 psi DIPSTICK GASKET Cover CRANKSHAFT RING Retaining KEY PIN Wrist GUIDE Piston 3000 psi GUIDE Piston 3500 amp 4000 psi ROD Connecting SCREW Cap socket hd COVER Crankcase COVER Crankcase 3500 amp 4000 psi GAUGE Sight PLUG Oil Drain O RING SCREW Cap socket hd WASHER Lock WASHER Flinger PLUNGER Ceramic PLUNGER Ceramic RING Backup Qty QO _ _ CA dv ao O1 9 Ref No 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 Part No KIT 6 or 107 KIT 6 or 107 803 295 803 505 803 296 KIT 3 Description WASHER SCREW Piston COVER Crankcase COVER Crankcase 3500 amp 4000 psi SHIM SEAL Oil KIT 28 or 112 O RING
11. 290 013 800 314 33 Tip assembly 00045 Replaced by 805 547 800 315 34 Tip assembly 15045 Replaced by 805 548 800 316 35 Tip assembly 25045 Replaced by 805 549 800 317 36 Tip assembly 40045 Replaced by 805 550 803 106 71 Spray tip 00045 Deleted 803 107 72 Spray tip 15045 Deleted 803 108 73 Spray tip 25045 Deleted GRACO 3X8 532 Rev D 1 30 95 The following changes apply to the page 13 parts list for 800 707 Model 800 707 Assembly No Series Letter Change Part That Ref Changed No Part Description Description of Change 803 109 74 Spray tip 40045 Deleted NEW Chemical injector Added 804 388 NEW Tube chemical Added 804 275 injector NEW Strainer chemical Added 801 683 injector NEW Tip chemical Added 805 634 injector NEW Adapter Added 100 081 The following three pages replace pages 14 and 15 of manual 308 532 GRACO 3X8 532 Rev D Pump Assembly Parts GRACO 3X8 532 Rev D 1 30 95 Ref No N O O1 gt N mr CONO 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Part No 801 467 803 504 801 468 801 469 KIT 1 KIT 1 KIT 1 KIT 1 KIT 1 KIT 4 or 106 KIT 4 or 106 KIT 1 803 283 803 284 803 506 802 500 803 324 KIT 2 803 286 802 895 803 501 801 475 803 144 803 287 803 288 802 794 803 289 803 3
12. 4 incl 27 WAND 32 SLEEVE 28 GUN Spray see Instruction Manual 308 511 NIPPLE Hex 3 8 QUICK COUPLER Male 1 4 TIP Spray 00045 TIP Spray 15045 TIP Spray 25045 TIP Spray 40045 HOSE ASSEMBLY W QUICK COUPLERS incl 41 42 43 LABEL Caution LABEL Warning SCREW Cap Hex hd 3 8 16 x 7 BUMPER Rubber RETAINER Spring SPRING BOOT LEG Front NUT Lock 3 8 16 CONNECTOR Fuel BRACKET Fuel Connector CLAMP Hose LINE Fuel LABEL Warning LINE Fuel w Squeeze Bulb TANK Fuel LABEL Graco G o lt ns ch NB EN a a ch sch qc ND nn om ak 308 532 11 PARTS DRAWING 800 707 Hydra Clean 4043 Pressure Washer 12 308 532 PARTS LIST WR 800 707 Hydra Clean 4043 Pressure Washer REF PART REF PART NO NO DESCRIPTION QTY NO NO DESCRIPTION QTY 1 100 188 NUT Hex 5 16 18 11 46 801 217 BUMPER Rubber 1 2 100 214 WASHER Lock 5 16 13 47 177 144 LABEL Belt Guard 1 3 801 814 BELT Drive 2 48 803 535 SCREW Cap Hex hd 1 4 803 160 SHEAVE Engine 1 49 803 068 SHEAVE Pump 1 5 100 023 WASHER Flat 5 16 26 50 801 898 HUB Engine 1 6 801 941 SCREW Cap Hex hd 51 804 141 HUB Pump 1 5 16 18 x 1 9 52 801 959 TERMINAL PROTECTOR Black1 803 534 LABEL Belt Guard 1 53 801 945 CABLE Battery 12 Long 1 8 803 926 BELT GUARD 1 54 803 077 LABEL BATTERY 1 9 803 525 BOLT Battery 2 55 801 954 BATTERY 12 Volt
13. 76 802 363 LABEL Caution 1 32 172 981 LABEL Chassis 1 77 181 867 LABEL Warning 1 33 800 314 TIP ASS Y 00045 incl 70 71 1 78 801 531 SCREW Cap Hex hd 34 800 315 TIP ASS Y 15045 incl 70 72 1 3 8 16 x 7 1 35 800 316 TIP ASS Y 25045 incl 70 73 1 79 801 504 BUMPER Rubber 1 36 800 317 TIP ASS Y 40045 incl 70 74 1 80 801 505 RETAINER Spring 1 37 803 884 ENGINE 16 HP Briggs amp 81 801 593 SPRING 1 Stratton Vanguard OHV 1 82 801 506 BOOT 1 38 PUMP ASS Y see page 14 1 83 801 537 LEG Front 1 39 800 652 FUEL TANK ASSEMBLY 84 801 499 NUT Lock 3 8 16 1 incl 40 87 89 90 91 92 1 85 802 907 CONNECTOR Fuel 1 40 801 733 BARB Hose 1 4 1 86 801 919 BRACKET Fuel Connector 1 41 803 519 HOSE High Pressure 3 8 x 50 1 87 801 971 CLAMP Hose 3 42 803 157 QUICK COUPLER Female 3 8 88 801 629 LINE Fuel 1 incl 26 2 89 801 716 LABEL Warning 2 43 801 568 QUICK COUPLER Male 39 8 2 90 803 881 LINE Fuel w Squeeze Bulb 1 44 800 429 GUN amp WAND ASSEMBLY 91 802 025 TANK Fuel 1 incl 42 45 65 thru 69 92 801 008 LABEL Graco G 1 _ 45 802 851 HANDLE Tee 308 532 13 PARTS DRAWING Pump Assembly 53 4 3 16 14 308 532 PARTS LIST NEN Pump Assembly REF PART REF PART NO DESCRIPTION NO NO DESCRIPTION QTY 804 175 CRANKCASE 804 132 RING Backup valve cap 804 196 COVER Crankshaft 801 028 O RING Oil Fill Cap 801 027 CAP Oil Fill 804 190 O RING Crankcase Cover 804 158 COVER Cran
14. 800 706 Model 800 707 Engine 4 cycle air cooled 12 5 HP Briggs amp Stratton OHV 16 HP Briggs amp Stratton OHV Battery 12 Volt 30 AMP 12 Volt 30 AMP 250 CCA 250 CCA Gasoline Tank Capacity 6 Gallon 23 Liter 6 Gallon 23 Liter Water Pump Maximum Working 3500 psi 241 bar 4000 psi 276 bar Pressure Water Pump Maximum Flow 4 gpm 15 Ipm 4 25 gpm 16 lpm Inlet Hose Connection 3 4 garden hose f 3 4 garden hose f Weight 55 Ibs 116 kg 255105 116 kg Dimensions Length 49 1245 mm 49 1245 mm Width 30 762 mm 30 762 mm Height 26 5 673 mm 26 5 673 mm Maximum Inlet Water 160 F 70 C 160 F 70 C Temperature Wetted Parts High Pressure Hose Acrylonitrile and Buna N cover and tube Bypass Hose Synthetic yarn and EPDM Pressure Washer Anodized aluminum Aluminum or bronze alloys Brass Copper Nylon PTFE9 including fittings composite Ceramic Buna N Cotton phenolic 303 304 and 316 Stainless steel Polymide 12 thermoplastic PTFE e Carbon steel Zinc with or without yellow chromate plate PTFE isa registered trademark of the DuPont Company 308 532 19 THE GRACO WARRANTY WARRANTY AND DISCLAIMERS Graco warrants all 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
15. CH 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 Besure the tip is secure 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 Figure 3 308 532 7 SHUTDOWN FLUSHING ESS AND STORAGE WARNING Pressure Relief Procedure To reduce the risk of serious bodily injury including fluid injection and splashing in the eyes or on the skin always follow this procedure whenever you stop spraying for more than 10 minutes when shutting down and before checking or repairing any part of the system Engage the trigger safety latch Turn the sprayer off Remove the ignition cables from the spark plugs Shut off the water supply Disengage the trigger safety latch and trigger the gun
16. CHASER 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 EXPRESSL Y 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 NOW ARRANTY AND DISCLAIMS ALL IMPLIED W ARRANTIES OF MERCHANTABILITY AND FITNESS FOR A P ARTICULAR PURPOSE WITH RESPECT T ACCESSORIES EQUIPMENT 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 Ew IMPORTANT PHONE NUMBERS NW 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 ASSIST ANCE service repair information or assistance regarding the application of Graco equipment 1 800 543 0339 Toll Free Factory Branches Atlanta Chicago Dallas
17. Cap CAP 3500 amp 4000 psi 3 802 511 41 SEAL Oil Crankshaft Seal 803 510 O RING Plunger Repair WASHER Flinger 3500 amp 4000 psi RING Backup WASHER 4 802 306 9 O RING SCREW Piston Valve Cap 3000 psi 10 CAP 803 511 PACKING 6 801 474 31 O RING 1 Packing 4000 psi RING Long life Plunger Repair 34 WASHER Flinger 1 PACKING 3000 psi 36 RING Backup 1 803 512 O RING 37 WASHER 1 Packing amp RETAINER packing 38 SCREW Piston 1 Retainer 4000 psi PACKING 801 486 44 PACKING RING head Packing 3000 psi RETAINER packing RING Long life PACKING GRACO 3X8 532 Rev D 1 30 95
18. INSTRUCTIONS PARTS LIST lt 308 532 Rev A GRACO This manual contains IMPORTANT WARNINGS and INSTRUCTIONS READ AND RETAIN FOR REFERENCE HYDRA CLEAN 3540 4043 Pressure Washers HYDRA CLEAN 3540 12 5 HP ENGINE P N 800 706 Series A 3500 psi 241 bar OPERATING PRESSURE 3900 psi 269 bar MAXIMUM WORKING PRESSURE HYDRA CLEAN 4043 16 HP ENGINE P N 800 707 Series A 4000 psi 276 bar OPERATING PRESSURE 4300 psi 296 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
19. ONS 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 Turn 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 with the inlet water screen removed 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 Seethe 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 eyes 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 ENGAGED TRIGGER SAFETY LAT
20. dge of the seat will pry the valve seat out easily 4 Examine all valve parts for wear and replace with preassembled valve assembly in service kit containing retainer spring valve valve seat o ring and back up ring 5 Grasp new valve assembly by tab at top with pliers immerse in oil and push into valve chamber Be certain valve assembly is square in valve chamber 6 Apply Loctite 242 to valve plug thread into manifold port and torque per chart Note Corrosion Resistant models require the coil spring installed in the Valve Plug Servicing the Pumping Section Disassembly 1 Remove the four 4 hex nuts or two 2 bolts from the manifold varies with model 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 manifold assembly CAUTION Keep manifold properly aligned with ceramic plungers when removing to avoid damage to either plungers or seals 3 Remove oil pan and slide out seal retainer with wicks 4 Using a wrench loosen the plunger retainer Grasp ceramic plunger and push toward crankcase until plunger retainer pops out 5 Remove plunger retainer with copper gasket back up Ring and o ring 6 Remove plunger from plunger rod 16 308 532 Reassembly 1 Carefully examine each ceramic plunger for scoring or cracks replace if worn and slip onto plunger rod Note Ceramic plunge
21. efore 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 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 temperature F 70 inlet water Connect a hose with at least a 3 4 inch 19 mm ID from the water supply to the unit s 3 4 inch garden hose inlet The supply hose should not be more than 50 ft 15 m long NOTE The water source at the unit musthavea minimum flow rate equal to that of the unit see Technical Data inside back cover 308 532 5 STARTUP NN Always use this startup procedure to ensure that the unit is started safely and properly 1 Check oil levels Engine Add SAE 30 10W 30 weight detergent oil as necessary Pump Add SAE 20 or 30 weight non detergent oil or genuine CAT pump 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
22. 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 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 If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship 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 W ARRANTY CONSTITUTE THE PUR
23. ft by hand to feel for bearing movement smooth 4 Examine crankshaft oil seal externally for drying cracking or leaking 5 Consult factory or your local distributor if crankcase service is evidenced Torque Chart Pump Part Thread Plunger Retainer Manifold Valve Covers M5 M8 x 1 25 M10 x 1 25 M10 Tool Size 11 mm hex 13 mm hex 17 mm hex 17 mm hex 24 mm 27 mm Torque 80 in Ibs 125 in lbs 217 in lbs 217 in lbs 75 ft lbs 75 ft lbs 308 532 17 ACCESSORIES NEN Must be purchased separately DOWNSTREAM CHEMICAL INJECTOR KIT 800 117 3540 800 649 3540 amp 4043 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 PREVENTOR 801 133 Prevent back up of contaminated water into fresh supply Install upstream of pump 18 308 532 WATER SANDBLASTING KIT 800 120 For abrasive cleaning of stubborn dirt and paint Requires a spray tip which is not included in kit 3540 uses 803 107 4043 uses 803 107 ANTI FREEZE FLUSH KIT 802 327 For flushing system with 50 anti freeze solution prior to transporting or storing pressure washer in below freezing temperatures INLET PRESSURE REGULATOR 800 258 Regulates inlet water pressure to 60 psi 4 bar maximum TECHNICAL DATA Dn nn Model
24. ited 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 4 308 522 INSTALLATION HIGH PRESSURE HOSE CONNECTION WATER SUPPLY CONNECTION Figure 1 Check for Shipping Damage 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 to 100 ft 30 m of high pressure hose may be used Longer hoses may af fect 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 ped TEE HANDLE 4043 ONLY SPRAY HOSE Connect to Water Supply CAUTION B
25. kcase 804 171 GASKET Sight Gauge 804 150 GAUGE Sight oil level 42 KIT CA RING Back Up 43 KIT CA O RING Valve Seat 44 KIT CA SEAT Valve 45 KIT CA VALVE 46 KIT CA SPRING Valve 47 KIT CA RETAINER Valve Spring 48 KIT C4 O RING Valve Cap ss gt O QO N O O1 gt O No O N 9 N 6 QTY 1 1 1 1 1 1 1 1 1 802 189 O RING Drain Plug 1 49 804 140 Valve 6 804 089 PLUG Drain 1 50 KIT C22 O RING Seal Case 804 238 SCREW Cap hex hd cross 51 804 075 WASHER Flat 6mm 12 recess 6mm x 20mm 4 52 KIT C22 RETAINER Seal front 804 195 CRANKSHAFT 1 53 804 077 WASHER Lock 6mm 12 804 108 BEARING 2 54 804 233 SCREW Cap socket hd 804 109 SEAL Oil crankshaft 1 10mm x 25mm 4 804 074 O RING Crankshaft Cover 2 55 804 214 WASHER SST 18mm 3 SCA oi jenen 1 56 802 178 WASHER Lock 10mm 4 eranksna 57 803 083 LABEL Keep from freezing 1 804 237 SCREW Cap hex hd cross E Ss Gnome g SB BOAZAT pum 20 804 110 ROD Connecting 3 60 801 523 NIPPLE 1 2 2 1 21 804 160 Plunger 3 x 22 804 111 PIN Rod 3 G1 2601106 TEE B2 23 801 030 WASHER Flat 3 62 800 113 FILTER see instruction 24 801 031 SEAL Oil connecting rod 3 manual 801 744 1 25 KIT C22 RETAINER Seal rear 63 801 111 NUT Garden Hose 1 26 804 121 WASHER Flinger 3 64 801 110 ADAPTER Garden Hose 1 27 804 161 WICK Oil 3 65 801 112 STRAINER Garden Hose 1 28 801 036 PLUNGER Ceramic 3 66 100 214 WASHER L
26. ll 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 below 40 F 40 308 532 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 servicing the pressure washer to prevent discharging starting or operating the pressure washer high pressure fluid from the gun NEVER operate the pressure washer without all guards and interlocks installed and functioning Follow the TERMS NEN WARNING Alerts user to avoid or correct conditions CAUTION Alerts user to avoid or correct conditions that could cause bodily injury that could cause damage to the equipment NOTE Identifies helpful procedures and information IMPORTANT Un
27. ock 5 16 4 29 804 133 WASHER Copper 3 67 803 141 HOSE ASSEMBLY Bypass 1 2 SOT OS RING BAD 58mm 68 801 568 QUICK COUPLER Male 3 8 1 32 801 039 O RING Retaining plunger 3 2 Me DELE ds Sex We 2 33 801 040 RETAINER Plunger 3 1 2 NPT 1 2 NPSM 1 34 802 753 PAN 1 x 36 KIT C22 ADAPTER Front 800 427 UNLOADER 4000 PSI 1 37 C22 PACKING High Pressure 72 108 842 SCREW Cap 38 KIT C22 ADAPTER Rear Hex hd 8mm x 16mm 4 39 804 211 CASE Seal 3 73 101 754 PLUG 3 8 1 40 KIT C22 PACKING Low Pressure 74 100 361 PLUG 1 2 1 Kit Repair Kit Ref Kit Repair Kit Ref No Part No No Description No Part No No Description Qty C 801 041 RING Back Up C22 804 099 RETAINER Seal Valve O RING Valve rear Seat i ADAPTER Front SEAT Valve 6 PACKING High VALVE 6 Pressure SPRING Valve 6 ADAPTER Rear RETAINER Valve 6 PACKING Low Spring Pressure O RING Valve 6 O RING Seal Cap Case RETAINER Seal front 308 532 15 PUMP SERVICE ERN Servicing the Valves 1 Remove the hex valve plug 2 Examine the o ring under the plug for cuts or distortion and replace if worn Lubricate new o ring before installing 3 Grasp valve retainer by tab at the top with pliers and remove from valve chamber V alve parts usually separate during removal Note A special tool will be needed to remove the seat from the manifold A reverse pliers or a standard vise grip and a 1 4 x 3 bolt to fit I D of seat inserted under the e
28. odify any part of this equipment doing so could cause it to malfunction CHECK all spray equipment regularly and repair or replace worn 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 HOSE SAFETY IE 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 HAVE 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 a
29. odily injury SAFETY LATCH Whenever you stop spraying for a moment always set the gun safety latch in the engaged or safe position making the gun inoperative Failure to 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 follow 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 EQUIPMENT MISUSE HAZARD SN General Safety Any misuse of the pressure washer or accessories such as overpressurizing modifying parts using incompatible chemicals and fluids or using worn or damaged 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 m
30. oline 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 Engine misses or lacks power Partially plugged air cleaner filter Spark plug dirty wrong gap or wrong type Incorrect ignition timing Low pressure and or pump runs rough Worn or wrong size tip Inlet filter clogged Worn packings abrasives in water or natural wear Inadequate water supply Belt slippage Fouled or dirty inlet or discharge valves Even a small particle can cause the valve to stick Restricted inlet Worn inlet or discharge valves Leaking high pressure hose Water leakage from under pump manifold Worn packings Water in pump Humid air condensing inside crankcase 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 Excessive pressure due to partially plugged or damaged tip Pump running too long without spraying Running pump dry Fill the tank with gasoline open fuel shut off valve Check fuel line and carburetor Add to proper level Move switch to start position Drain fuel tank and carburetor Use new fuel and dry spark plug Check and tighten battery connections Check electrolyte level of cells
31. r can only be installed one direction front to back Do not force onto rod 2 Examine plunger retainer and stud and replace if worn Note Thread stud into plunger retainer 3 Examine o ring back up ring and gasket on plunger 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 o ring 4 Thread plunger retainer and stud assembly into plunger rod Exercise caution not to over torque 5 Saturate new oil wick by soaking in oil place in seal retainer and slip retainer over ceramic plunger 6 Replace oil pan 7 Turn shaft by hand to line up plungers so end plungers are parallel 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 Servicing the Seals and V Packings Disassembly 1 Remove the manifold as described 2 With crankcase side of manifold facing up unscrew the seal case from the manifold using a special key wrench Remove o ring from seal case 4 Remove snap ring and low pressure seal from the seal case Seals are generally removed easily without any tools 5 High Pressure Seal Models The high pressure seal is generally easily removed from the manifold without any tools If extremely worn a reverse pliers may be used 6 V Packing Models The female adap
32. ter two v packings and male adapter are easily removed from manifold without tools If extremely worn a reverse pliers may be used Reassembly V Packing Models 1 2 Lubricate high pressure packing area in manifold Insert male adapter with notches down and v side up Lubricate v packings and install one at a time with grooved side down Next install female adapter with grooved side down Examine seal case o ring and replace if worn Lubricate new o ring before installing Thread seal case into manifold and tighten with key wrench High Pressure Seal Models 1 2 Lubricate seal area in manifold Carefully square seal into position by hand with the metal grooved side up Examine seal case o ring and replace if worn Lubricate new o ring before installing Next secure high pressure seal into position by threading seal case into manifold Tighten seal case with key wrench Low Pressure Seal All Models 1 Examine seal for wear or broken spring and lace if necessary Install low pressure seal in seal case with garter spring down Reinstall snap ring Be certain snap ring is a tight fit Replace if it can be easily turned Replace manifold on pump as described and torque per chart Servicing Crankcase Section 1 While manifold plungers and seal retainers are removed examine crankcase seals for wear 2 Check oil level and for evidence of water in oil 3 Rotate cranksha
33. 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 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 Flush the pressure washer before using it again to remove the anti freeze NOTE An anti freeze flush kit P N 802 327 is available to make flushing easier CAUTION If water does freeze in the pressure washer thaw itin a warm room before trying to start it DO NOT pour hot water on or into the pump it may crack the ceramic plungers 2 After each use wipe all surfaces of the pressure washer with a clean damp cloth 3 Perform the appropriate maintenance See maintenance chart 8 308 522 MAINTENANCE NN Observing regular maintenance intervals helps ensure that you get maximum performance and life from the pressure washer There is a break in period for the engine and pump After changing the oil in these components following their respective break in periods the interval between required 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
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