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Graco Inc. 2540 Pressure Washer User Manual

1. Wetted Parts High Pressure Hose Bypass Hose Pressure Washer including fittings 36 914 mm 21 533 mm 21 533 mm 23 584 mm 24 610 mm 160 F 70 C 160 F 70 C 36 914 mm Acrylonitrile and Buna N cover and tube Synthetic yarn and EPDM Anodized aluminum Aluminum or bronze alloys Brass Copper Nylon PTFE composite Ceramic Buna N Cotton phenolic 303 304 and 316 Stainless steel Polymide 12 thermoplastic PTFE Carbon steel Zinc with or without yellow chromate plate PTFE isa registered trademark of the DuPont Company 308 529 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 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 part
2. 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 4 308 529 INSTALLATION HIGH PRESSURE HOSE CONNECTION INLET WATER CONNECTION 3 4 GARDEN HOSE 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 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 QUICK COUPLER SPRAY GUN QUICK COUPLER SPRAY HOSE Connect to Water Supply 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 wa
3. PARTS DRAWING ES 800 639 Hydra Clean 3040 Pressure Washer 12 308 529 PARTS LIST EN 800 639 Hydra Clean 3040 Pressure Washer REF PART NO NO 1 800 392 2 803 350 3 181 867 4 802 363 5 801 134 6 179 885 7 803 158 8 802 127 9 801 674 10 100 527 11 801 009 12 801 539 13 801 568 14 802 579 15 801 569 16 156 082 17 154 594 18 801 941 19 801 504 20 154 636 21 101 545 22 111 040 23 803 740 24 803 741 25 801 546 26 100 023 27 801 819 28 801 858 29 803 925 30 800 641 31 801 090 32 101 566 DESCRIPTION QTY GUN amp WAND ASSEMBLY incl 2 5 9 11 15 47 GUN Spray see Instruction Manual 308 511 LABEL Warning ventilation LABEL Caution WAND 32 LABEL Warning chassis ENGINE 11 hp Honda OHV SCREW Cap hex hd _ gt 5 16 18 x 1 3 4 4 SLEEVE 28 1 WASHER Flat 5 16 18 COUPLER Female 1 4 incl 17 1 BUMPER 1 COUPLER Male 3 8 2 HOSE High Pressure 3 8 x 50 1 COUPLER Female 3 8 incl 16 2 O RING Female Coupler 3 8 1 O RING Female Coupler 1 4 1 SCREW Cap hex hd 5 16 18 x1 BUMPER Rubber WASHER Flat 5 8 PIN Cotter 1 8 x 1 1 2 NUT Lock 5 16 18 WHEEL amp TIRE ASSEMBLY AXLE SCREW Cap hex hd 3 8 16 x 1 1 4 WASHER Flat 3 8 SCREW Cap hex hd 3 8 16 x 3 BRACKET Front Leg HANDLE FRONT LEG ASSEMBLY incl 19 26 27 28 32 COUPLER Male 1 4 NUT Lock 3 8 16 _ _ of ANONANA _ _ m ana REF P
4. 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 O 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 Em IMPORTANT PHONE NUMBERS SN 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 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 308 529 1 91 20 308 529
5. 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 O FUEL AND EMISSION HAZARDS ME 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 throttle setting which is factory set Tampering with this adjustment can damage the pressure washer and will void the warranty 308 529 3 MOVING PARTS HAZARD ENS 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 I WARNING Alerts user to avoid or correct conditions NOTE Identifies helpful procedures and information that could cause bodily injury CAUTION Alerts user to avoid or correct conditions that could cause damage to the equipment IMPORTANT
6. packings See PUMP SERVICE under pump manifold Water in pump Humid air condensing inside crankcase Change oil as specified in MAINTENANCE Worn packings Install new packings See PUMP SERVICE Oil seals leaking Install new oil seals See PUMP SERVICE Frequent or premature Scored damaged or worn plungers Install new plungers See PUMP SERVICE failure of the packings Abrasive material in the fluid being pumped Install proper filtration on pump inlet plumbing Inlet water temperature too high Check water temperature may not exceed 160 F Overpressurizing pump Do not modify any factory set adjustments See EQUIPMENT MISUSE HAZARD Excessive pressure due to partially plugged Clean or replace tip See Installing and Changing or 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 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 Oil leakage between Worn gasket Replace the gasket See SERVICE SECTION the gear reducer cover and case Oil leakage between Worn oil seals and or o ring Replace oil seals and or o ring See SERVICE the gear reducer cover SECTION and the pump Oil leakage between Worn oil seal Replace oil seal See SERVICE SECTION the gear red
7. 308 529 Replacing the Oil Seal 14 NOTE The oil seal MUST be replaced with a new one if removed Follow steps 1 and 3 under Replacing the Gasket Remove the snap ring 6 from the gear case using a snap ring pliers Pull the gear and bearing Push the seal from the inside to the outside of the gear case by placing screwdriver against the seal and lightly tapping it with hammer Wipe the inner surface of the case clean then lightly coat it with grease Place the oil seal into the gear case Use a socket placed against the surface of the seal to push the seal into the case until its top surface is past the ridge in the bore Place the gear and bearing back into the gear case and install the snap ring 6 Follow steps 4 through 7 under Assembling the Gear Reducer if this is all the service required Assembling the Gear Reducer 1 Grease the o ring and make sure it placed on the gear cover s properly Place the four oil seals and screws in the gear cover Place the o ring on the screw to hold it in the cover Apply low strength Loctite blue on the screw threads align the screws with the holes in the pump and tighten the screws oppositely and evenly Grease the pump shaft 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 Apply low strength Loctite on the setscrew threads and tighten the setscrew to lock the gear on the shaft
8. ART NO NO 33 800 661 34 801 012 35 800 314 36 800 315 37 402 278 38 803 083 39 803 106 40 803 107 41 803 108 42 800 316 43 803 739 44 800 317 45 803 109 46 804 073 47 156 849 48 800 324 49 802 140 50 803 142 51 803 141 52 801 523 53 801 622 54 800 115 55 801 367 56 801 111 57 801 110 58 804 051 59 800 377 60 803 737 61 802 143 62 803 161 DESCRIPTION CHASSIS GROMMET Rubber TIP ASSEMBLY 00045 incl 31 39 TIP ASSEMBLY 15045 incl 31 40 PLUG Plastic LABEL Keep From Freezing TIP Spray 00045 TIP Spray 15045 TIP Spray 25045 TIP ASSEMBLY 25045 incl 31 41 PUMP amp GEAR REDUCER ASSEMBLY incl 60 61 TIP ASSEMBLY 40045 incl 31 45 TIP Spray 40045 ADAPTER 1 2 NIPPLE Hex 3 8 UNLOADER 3000 psi BRACKET Support NIPPLE Hex 1 2 NPSM x 3 8 NPT HOSE Bypass NIPPLE 1 2 x 2 CROSS 1 2 VALVE Thermal Relief BUMPER Rubber NUT Garden Hose ADAPTER Garden Hose FILTER STRAINER HOSE ASSEMBLY w Couplers incl 13 14 15 NN NN kad ak zk GER hak zal RaR 1 PUMP ASSEMBLY see page 16 1 GEAR REDUCER ASSEMBLY see page 15 LABEL Model 3040 308 529 1 1 13 GEAR REDUCER SERVICE SN 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 on page 2 before proceeding Replacing
9. E Valve 9 KIT 4 O RING 10 KIT 4 CAP 11 KIT 1 VALVE ASSEMBLY 12 803 283 SCREW Cap socket hd 8 13 803 284 COVER Crankcase 1 14 802 500 O RING Crankcase Cover 2 15 803 285 BEARING Tapered Roller 2 16 KIT 2 SEAL Oil 17 803 286 BUSHING Piston 1 18 802 895 CRANKCASE 1 19 801 475 DIPSTICK 1 20 803 144 GASKET Cover 1 21 803 332 CRANKSHAFT 1 22 803 288 RING Retaining 6 23 802 794 KEY 1 24 803 289 PIN Wrist 3 25 803 290 GUIDE Piston 3 26 803 291 ROD Connecting 3 27 803 292 SCREW Cap socket hd 5 Kit Repair Kit Part No 801 472 801 473 Oil Seal Kit 802 511 Crankshaft Valve Cap Kit 801 474 Plunger Repair 801 486 Packing Kit 801 487 Packing and Retainer Kit Ref Description O RING SEAT Valve PLATE Valve SPRING GUIDE Valve VALVE ASSEMBLY SEAL Oil SEAL Oil O RING CAP O RING RING Backup WASHER SCREW Piston PACKING Ma O RING RETAINER Packing PACKING RING Head RETAINER Packing RING Long Life REF NO 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 49 50 51 52 53 54 PART NO 803 293 802 345 802 793 KIT 6 803 294 801 652 801 660 801 490 KIT 6 KIT 6 KIT 6 803 295 803 296 KIT 3 KIT 28 KIT 28 KIT 8 28 KIT 28 KIT 28 KIT 28 802 305 802 304 801 482 801 483 801 484 801 485 DESCRIPTION COVER Crankcase GAUGE Sight PLUG Oil Drain O RING SCREW Cap socket hd WASHER Lock WASHER Flinger PL
10. INSTRUCTIONS PARTS LIST 308 529 Rev A GRACO This manual contains IMPORTANT WARNINGS and INSTRUCTIONS READ AND RETAIN FOR REFERENCE HYDRA CLEAN 2540 3040 Pressure Washer HYDRA CLEAN 2540 9 HP ENGINE P N 800 638 Series A P N 800 690 Series A 2500 psi 172 bar OPERATING PRESSURE 3000 psi 207 bar MAXIMUM WORKING PRESSURE HYDRA CLEAN 3040 11 HP ENGINE P N 800 639 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 1990 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 Ez 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 prope
11. Improperly installed parts will cause a malfunction 7 Reassemble the manifold as instructed in Servicing the Plungers ACCESSORIES IE Must be purchased separately DOWNSTREAM CHEMICAL INJECTOR KIT 800 117 For injecting harsh cleaning chemicals downstream from the pump 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 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 ETT Model 800 638 Model 800 690 Model 800 639 5 quarts 4 8 liters 6 9 quarts 6 5 liters Engine air cooled 4 cycle 9 hp Honda OHV 9 hp Briggs amp Stratton OHV 11 hp Honda OHV Gasoline Tank Capacity 6 2 quarts 6 liters Water Pump Maximum Working Pressure Water Pump Maximum Flow Inlet Hose Connection 2500 psi 172 bar 2500 psi 172 bar 3000 psi 207 bar 4 gpm 15 Ipm 4 gpm 15 Ipm 4 gpm 15 Ipm 3 4 garden hose f 3 4 garden hose f 3 4 garden hose f 158 Ib 70 kg 158 Ib 70 kg 172 Ib 78 kg Dimensions Length 36 914 mm Width 21 533 mm Height 23 5 597 mm Maximum Inlet Water Temperature 160 F 70
12. Make sure the gasket is in place refer to step 4 under Replacing the Gasket Install the gear cover on the case aligning the holes and secure it with the nine screws and lockwashers T ighten the screws evenly in a crisscross pattern Grease the engine shaft Align the gear s slot with the key on the engine shaft and slide the gear reducer onto the shaft up to the engine s shoulder Secure the gear reducer to the engine with the four bolts lockwashers and washers PARTS DRAWING 802 143 Gear Reducer Ra ye 20 5 PARTS LIST 802 143 Gear Reducer REF PART NO NO DESCRIPTION QTY 1 802 332 O RING 1 2 802 333 COVER Mounting 1 3 802 334 SCREW Set 1 4 802 335 GEAR Pump 1 5 802 336 GEAR Engine 1 6 802 337 RING Snap 1 7 802 338 BEARING 1 8 802 339 RING Snap 1 9 802 340 GASKET 1 10 801 475 DIPSTICK 1 11 802 341 CASE Mounting 1 12 100 527 WASHER Lock 13 13 802 342 SCREW 9 14 802 343 SEAL Oil 1 15 802 344 O RING 1 16 801 484 CAP G 3 8 BSP 1 17 802 345 GAUGE Sight 1 18 100 214 WASHER Flat 4 19 802 331 BOLT 5 16 24 x 1 4 20 802 346 SCREW 4 21 802 347 SEAL Oil 4 308 529 15 PARTS DRAWING 803 737 Pump Assembly 10 lt r3 16 308 529 PARTS LIST ITE 803 737 Pump Assembly REF PART NO NO DESCRIPTION QTY 1 801 467 MANIFOLD 2000 psi 1 2 801 468 SCREW Cap hex hd 8 3 801 469 WASHER Lock 8 4 KIT 1 O RING 5 KIT 1 SEAT Valve 6 KIT 1 PLATE Valve 7 KIT 1 SPRING 8 KIT 1 GUID
13. UNGER Ceramic RING Backup WASHER SCREW Piston COVER Crankcase SHIM SEAL Oil O RING RETAINER Packing PACKING RING Head RETAINER Packing RING Long Life SCREW Cap socket hd WASHER Lock PLUG Hex WASHER Flat PLUG Hex WASHER Flat 308 529 AMA Ma WO O 17 PUMP SERVICE EN 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 dif ferent 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 Fora 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 Pumping Section 1 Remov
14. cable from the spark plug 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 unit disconnect the water supply and turn off the fuel supply valve 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 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 2 After each use wipe all surfaces of the pressure washer with a clean damp cloth 3 Perform the appropriate maintenance See maintenance chart 8 308 529 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 pump and gear reducer if used 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 maintenan
15. ce checks should be made more often WARNING To reduce the risk of serious bodily injury x 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 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 hours of operation Change pump break in oil Use SAE 20 or 30 non detergent oil Change gear reducer oil Use SAE 90 gear oil 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 Change or 6 months gear reducer oil Use SAE 90 gear oil TROUBLESHOOTING CHART SEEN 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 Engine will not start or No gasoli
16. d 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 NOTE There are two types of packing kits one is packings only the other includes the packings rings and retainers 1 Remove the manifold as outlined in the Pumping Section 2 Carefully pull the packing retainer from the manifold Examine the o ring and replace it if it is cut or damaged 3 Remove the v packing and head ring Pull out the intermediate retainer ring Remove the second v packing and second head ring 4 Inspect all parts and replace as necessary 5 Thoroughly clean the packing cavities and examine for debris and damage 6 Lightly grease the packing cavities and then replace the packings in the following order head ring v packing intermediate ring head ring v packing and packing retainer with the o ring installed in the retainer groove CAUTION Install the parts in the proper order and facing the correct direction
17. e the eight capscrews and lockwashers from the manifold using an M13 wrench 2 Carefully separate the manifold from the crankcase NOTE It may be necessary to tap the manifold lightly with a soft mallet 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 18 308 529 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 if necessary 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 seals Otherwise DO NOT remove these seals as they cannot be reused An oil seal kit is available to replace the seals 5 Lightly grease the flinger and oil seal if it is being replaced and replace them on the plunger shaft Then install the plunger 6 Lightly grease the retaining screw and the outer en
18. ne in fuel tank or carburetor Fill the tank with gasoline open fuel shut off valve is hard to start Check fuel line and carburetor Low oil on units with low oil sensor Add to proper level Start Stop switch in Stop position Move switch to start position Water in gasoline or old fuel Drain fuel tank and carburetor Use new fuel and dry spark plug Choked improperly Flooded engine Open choke and crank engine several times to clear out gas Dirty air cleaner filter Remove and clean Spark plug dirty wrong gap or wrong type Clean adjust the gap or replace Spray gun closed Trigger spray gun Engine misses or Partially plugged air cleaner filter Remove and clean lacks power Spark plug dirty wrong gap or wrong type Clean adjust the gap or replace Low pressure and or Worn or wrong size tip Replace with tip of proper size pump runs rough Inlet filter clogged Clean Check more frequently Worn packings abrasives in water or Check filter Replace packings See PUMP SERVICE natural wear Inadequate water supply Check water flow rate to pump Fouled or dirty inlet or discharge valves Clean inlet and discharge valve assemblies Check Even a small particle can cause the valve filter to stick Restricted inlet Check garden hose may be collapsed or kinked Worn inlet or discharge valves Replace worn valves Leaking high pressure hose Replace high pressure hose Water leakage from Worn packings Install new
19. rking 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 Ew 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 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
20. rly before 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 2 308 529 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 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 turn off the fuel supply valve 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 res
21. s 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 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 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
22. t prevent the gun from being triggered See Figure 2 TRIGGER SAFETY LATCH SHOWN ENGAGED 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 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 3 308 529 7 SHUTDOWN FLUSHING ES 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
23. ter 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 F 70 temperature C 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 must have a minimum flow rate equal to that of the unit see Technical Data inside back cover 308 529 5 STARTUP Ez 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 oil as necessary Pump Add SAE 20 or 30 weight non detergent oil as necessary NOTE Some units are 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 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
24. the Gasket 9 NOTE To maintain a good seal the gasket must be replaced whenever the gear reducer is disassembled Remove the four bolts lockwashers and washers Pull the pump and gear reducer assembly of f the engine Drain the gear reducer oil by placing a container under it and removing the drain plug with a 22 mm wrench Replace the o ring 15 if damaged Remove the nine screws with a 6 mm wrench and pull the gear case off the gear cover Remove the old gasket 9 Clean the gear cover and case surface Lightly coat the new gasket with grease and install it in on the gear case Follow steps 5 through 7 under Assembling the Gear Reducer if this is all the service required Replacing the Oil Seals 21 1 Follow steps 1 through 3 under Replacing the Gasket Loosen the setscrew using a 4 mm wrench and pull the gear off the pump with a gear puller Using a 6 mm wrench remove the four screws Be sure to keep them separate from the other nine screws removed previously Remove the four oil seals and replace them Follow steps 2 through 7 under Assembling the Gear Reducer if this is all the service required Replacing the O Ring 1 1 Follow the instructions under Replacing the Gasket and Replacing the Oil Seals to disassemble the gear reducer Pull the gear cover of f the pump and replace the o ring 1 Follow instructions under Assembling the Gear Reducer if this is all the service required 14
25. ucer case and the engine 308 529 9 Sa ON RENE PARTS DRAWING SE 690 Hydra Clean 2540 Pressure Washer 800 638 amp 800 10 308 529 PARTS LIST Emma 800 638 amp 800 690 Hydra Clean 2540 Pressure Washer REF PART NO NO 1 800 392 2 803 350 3 181 867 4 802 363 5 801 134 6 179 885 7 803 900 803 901 8 802 127 9 801 674 10 100 527 11 111 040 12 801 539 13 801 568 14 802 579 15 801 569 16 156 082 17 801 009 18 801 941 19 154 594 20 154 636 21 101 545 22 801 504 23 803 740 24 803 741 25 801 546 26 100 023 27 801 819 28 801 858 29 803 925 30 800 641 31 803 301 DESCRIPTION QTY GUN amp WAND ASSEMBLY incl 2 5 9 15 17 47 GUN Spray see Instruction Manual 308 511 LABEL Warning ventilation LABEL Caution WAND 32 LABEL Warning chassis ENGINE 9 hp Honda OHV used on 800 638 only ENGINE 9 hp Briggs amp Stratton OHV used on __i WW m EW 800 690 only 1 SCREW Cap hex hd 5 16 18 x 1 3 4 4 SLEEVE 28 1 WASHER Flat 5 16 18 NUT Lock 5 16 18 10 BUMPER 1 COUPLER Male 3 8 2 HOSE High Pressure 3 8 x 50 1 COUPLER Female 3 8 incl 16 2 O RING Female Coupler 3 8 2 COUPLER Female 1 4 incl 19 1 SCREW Cap hex hd 5 16 18 x 1 O RING Female Coupler 1 4 WASHER Flat 5 8 PIN Cotter 1 8 x 1 1 2 BUMPER Rubber WHEEL 8 TIRE ASSEMBLY AXLE SCREW Cap hex hd 3 8 16 x 1 1 4 WASHER Flat 3 8 SCREW Cap he
26. ult in serious bodily 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 EQUIPMENT MISUSE HAZARD SEEN 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 modify 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 wo
27. 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 Open the fuel shutoff valve Be sure the spark plug ignition cable is pushed firmly onto the spark plug On those units equipped with an ignition shutof f switch put the switch in the on position and put the throttle 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 6 308 529 If the engine is cold completely close the engine choke Grasp the starter rope brace one foot on the 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 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 just partly close it Start the engine as described in the preceding paragraph When it starts be sure to open the choke completely CAUTION On recoil start engines never let the starter rope return by itself It could jam the recoil system 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 e
28. x hd 3 8 16 x 3 BRACKET Front Leg HANDLE FRONT LEG ASSEMBLY incl 22 26 27 28 32 LABEL Model 2540 NIN ND BR _ of lt mm m m REF PART NO NO 32 101 566 33 800 661 34 801 012 35 800 131 36 800 137 37 402 278 38 803 083 39 801 090 40 801 640 41 801 667 42 800 128 43 803 739 44 800 129 45 801 907 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 55 801 614 56 801 111 57 801 110 58 804 051 59 801 615 60 801 367 61 802 140 62 804 073 63 800 377 64 803 737 65 802 143 DESCRIPTION NUT Lock 3 8 16 CHASSIS GROMMET Rubber TIP ASSEMBLY 0005 incl 39 40 TIP ASSEMBLY 1505 incl 39 41 PLUG Plastic LABEL Keep From Freezing COUPLER Male 1 4 TIP Spray 0005 TIP Spray 1505 TIP ASSEMBLY 2505 incl 39 55 PUMP amp GEAR REDUCER ASSEMBLY incl 64 65 TIP ASSEMBLY 4005 incl 39 59 WASHER 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 VALVE Thermal Relief TIP Spray 2505 NUT Garden Hose ADAPTER Garden Hose FILTER STRAINER TIP Spray 4005 BUMPER Rubber BRACKET Support ADAPTER 1 2 HOSE ASSEMBLY w Couplers incl 13 14 15 Nm N xak vu Ammum RAO 1 PUMP ASSEMBLY see page 16 1 GEAR REDUCER ASSEMBLY see page 15 308 529 1 11
29. yes 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 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 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 j 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 canno

Graco Inc. 2540 Pressure Washer User Manual

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