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Graco Inc. 308-530 manual

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  • Page 1

    INSTRUCTIONS-P AR TS LIST 308–530 Rev A This manual contains IMPORT ANT W ARNINGS and INSTRUCTIONS READ AND RET AIN FOR REFERENCE HYDRA-CLEAN 1535, 2040, 2540 Pressure W ashers  HYDRA-CLEAN 1535, 5 HP ENGINE P/N 800–698, Series A 1500 psi (103 bar) OPERA TING PRESSURE 1900 psi (131 bar) MAXIMUM WORKING PRESSURE HYDRA-CLEAN 2040, 8 HP ENGINE [...]

  • Page 2

     308–530 INDEX W arnings 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Startup 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 3

    3 308–530 W ARNING HIGH PRESSURE SPRA Y CAN CAUSE SERIOUS INJUR Y . FOR PROFESSIONAL USE ONL Y . OBSER VE ALL W ARNINGS. 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 [...]

  • Page 4

    4 308–530 EQUIPMENT MISUSE HAZARD General Safety Any misuse of the pressure washer or accessories, such as overpressurizing, modifying parts, using incompatible chemicals and fluids, or using worn or damaged 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,[...]

  • Page 5

    5 308–530 INST ALLA TION 1535 2040 2540 Figure 1 SPRA Y GUN SPRA Y HOSE QUICK COUPLER QUICK COUPLER INLET W A TER CONNECTION 3/4” GARDEN HOSE HIGH PRESSURE HOSE CONNECTION HIGH PRESSURE HOSE CONNECTION INLET W A TER CONNECTION 3/4” GARDEN HOSE INLET W A TER CONNECTION 3/4” GARDEN HOSE HIGH PRESSURE HOSE CONNECTION Check for Shipping Damage [...]

  • Page 6

    6 308–530 ST ARTUP 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 or genuine Cat  pump oil as necessary . Gear Reducer (2040 and 2540): Add SAE 90 gear oil as nece[...]

  • Page 7

    7 308–530 T rigger Safety Latch W ARNING T o reduce the risk of serious bodily injury , including fluid injection, splashing in the eyes or on the skin, AL WA YS 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 o[...]

  • Page 8

    8 308–530 SHUTDOWN, FLUSHING AND STORAGE W ARNING 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[...]

  • Page 9

    9 308–530 TROUBLESHOOTING CHART W ARNING 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 W arning before proceeding. PROBLEM CAUSE SOLUTION Low pressure and/or pump runs rough Partially plugged air cleaner filter [...]

  • Page 10

    10 308–530 P ARTS DRA WING 800–698 Hydra–Clean  1535 Pressure W asher 60 63 29 31 61 16 47 64 48 49 6 65 66 33 44 46 6 6 45 41 32 39 36 35 34 67 36 67 36 50 51 36 35 40 52 40 43 42 46 56 27 30 27 30 28 59 8 20 46 6 1 6 7 3 2 15 55 58 57 4 53 22 23 24 25 26 21 12 17 11 11 18 14 13 46 19 16 45 6 54 68 11[...]

  • Page 11

    11 308–530 P ARTS LIST 800–698 Hydra–Clean r 1535 Pressure W asher REF P ART NO. NO. DESCRIPTION QTY 1 802–239 ENGINE, 5 hp, Briggs & Stratton I/C 1 2 800–695 PUMP & GEAR REDUCER ASSEMBL Y (incl. 3, 13) 1 3 804–248 GEA R R EDUCE R ( se e p ag e 1 7) 1 4 802–127 SCREW , Cap, hex hd. 5/16–18 x 1-3/4 4 6 100–527 W ASHER, Flat[...]

  • Page 12

    12 308–530 P ARTS DRA WING 800–699 Hydra–Clean  2040 Pressure W asher 8 20 46 6 60 63 29 31 61 16 1 47 64 48 49 6 6 7 54 3 2 15 65 66 55 58 57 33 44 46 6 6 45 41 32 39 36 35 34 67 36 67 36 50 51 36 35 40 52 4 40 43 42 53 22 23 24 25 26 21 46 56 12 17 11 11 18 14 13 46 19 16 27 30 27 30 28 59 45 6 68 11[...]

  • Page 13

    13 308–530 P ARTS LIST 800–699 Hydra–Clean  2040 Pressure W asher REF P ART NO. NO. DESCRIPTION QTY 1 802–141 ENGINE, 8 hp, Briggs & Stratton I/C 1 2 800–696 PUMP & GEAR REDUCER ASSEMBL Y (incl. 3, 13) 1 3 804–249 GEAR REDUCER (see page 19) 1 4 802–127 SCREW , Cap, hex hd. 5/16–18 x 1-3/4 4 6 100–527 W ASHER, Flat 5/16 [...]

  • Page 14

    14 308–530 P ARTS DRA WING 800–700 Hydra–Clean  2540 Pressure W asher 60 52 11 10 5 2 14 1 9 13 10 61 38 65 43 31 29 12 11 10 10 18 23 33 24 26 25 30 32 26 32 26 28 22 26 27 20 6 20 21 62 56 57 58 37 54 11 66 49 50 47 47 51 48 64 11 53 13 15 16 15 16 17 19 18 10 8 10 4 3 7 63 47 51 67 34 39 35 36 42 44 40 41 55 59[...]

  • Page 15

    15 308–530 P ARTS LIST 800–700 Hydra–Clean  2540 Pressure W asher REF P ART NO. NO. DESCRIPTION QTY 1 800–392 GUN & W AND ASSEMBL Y (incl. 2, 5, 9, 15, 17, 47) 1 2 803–350 GUN, Spray (see Instruction Manual 308–51 1) 1 3 181–867 LABEL, W arning, ventilation 1 4 802–363 LABEL, Caution 1 5 801–134 W AND, 32” 1 6 179–885 L[...]

  • Page 16

    16 308–530 GEAR REDUCER SERVICE (Model 1535) W ARNING 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 W arning on page 2 before proceeding. Replacing the O–Ring (5) 1. Remove the four bolts, lockwashers and wash[...]

  • Page 17

    17 308–530 P ARTS DRA WING Gear Reducer (Model 1535) 1 23 22 20 21 21 20 24 23 22 2 3 4 5 6 7 8 17 23 19 16 11 15 12 13 14 10 9 P ARTS LIST Gear Reducer (Model 1535) REF P ART NO. NO. DESCRIPTION QTY 1 804–236 SCREW , Cap, hex hd./cross recess 4 2 804–201 HOUSING, Gear Reducer 1 3 804–202 GEAR, Pinion, 3/4 1 4 804–082 BEARING 1 5 804–22[...]

  • Page 18

    18 308–530 GEAR REDUCER SER VICE (Models 2040 & 2540) W ARNING 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 W arning on page 2 before proceeding. Replacing the Gasket (9) NOTE: T o maintain a good seal, the[...]

  • Page 19

    19 308–530 P ARTS DRA WING Gear Reducer (Models 2040 & 2540) 19 18 17 16 15 14 13 31 24 25 20 4 3 26 2 5 6 29 30 11 24 23 22 12 32 10 9 7 8 28 27 1 21 P ARTS LIST Gear Reducer (Models 2040 & 2540) REF P ART NO. NO. DESCRIPTION QTY 1 804–182 HOUSING, Gear Reducer 1 2 804–183 GEAR, Pinion, 1” 1 3 804–228 BEARING 1 4 804–227 RING, [...]

  • Page 20

    20 308–530 P ARTS DRA WING 804–244 Pump Assembly , 1500 psi 9 38 3 12 7 11 10 38 3 18 17 6 5 17 20 13 28 29 30 31 32 33 35 34 39 40 36 48 47 48 46 45 44 43 42 41 39 52 42 43 44 45 46 50 49 51 21 23 24 25 19 26 27 8 4 16 15 14 38 3 18 16 14 1 20 22 2 37[...]

  • Page 21

    21 308–530 P ARTS LIST 804–244 Pump Assembly , 1500 psi REF P ART NO. NO. DESCRIPTION QTY 1 802–312 KEY , Square 1 2 804–180 CRANKCASE 1 3 804–077 W ASHER, Lock 12 4 804–171 GASKET , Oil Sight Gauge 1 5 801–028 O–RING, Oil Fill Cap 1 6 801–027 CAP , Oil Fill 1 7 804–150 GAUGE, Sight 1 8 804–123 O–RING, Crankcase Cover 1 9 80[...]

  • Page 22

     308–530 P ARTS DRA WING 804–245 Pump Assembly , 2000 psi 19 18 16 4 3 6 7 12 13 14 8 9 11 10 12 13 20 16 17 18 5 2 23 25 26 35 29 49 42 48 47 46 45 44 43 20 13 12 32 39 40 41 42 43 44 46 24 1 41 15 22 22 27 28 21 31 30 32 33 34 40 39 38 37 45 50 51[...]

  • Page 23

    23 308–530 P ARTS LIST 800–245 Pump Assembly , 2000 psi REF P ART NO. NO. DESCRIPTION QTY 1 802–178 W ASHER, Lock, 10mm 2 2 804–154 CRANKCASE 1 3 801–028 O–RING, Oil Fill Cap 1 4 801–027 CAP , Oil Fill 1 5 804–137 COVER, Crankshaft 1 6 804–123 O–RING, Crankcase Cover 1 7 804–155 COVER, Crankcase 1 8 804–171 GASKET , Oil Sigh[...]

  • Page 24

    24 308–530 P ARTS DRA WING 804–246 Pump Assembly , 2500 psi 17 15 13 4 3 5 6 50 49 11 7 8 10 9 50 49 11 13 14 15 16 2 20 22 23 31 24 18 25 46 45 44 43 42 41 40 39 11 49 50 26 27 28 29 30 35 34 33 36 37 37 38 32 39 40 41 42 43 44 45 46 21 47 48 12 19 19 1 51 52[...]

  • Page 25

    25 308–530 P ARTS LIST 804–246 Pump Assembly , 2500 psi REF P ART NO. NO. DESCRIPTION QTY 1 804–093 KEY 1 2 804–154 CRANKCASE 1 3 801–028 O–RING, Oil Fill Cap 1 4 804–181 CAP , Oil Fill 1 5 804–189 O–RING, Crankshaft Cover 1 6 804–155 COVER, Crankcase 1 7 804–171 GASKET , Oil Sight Gauge 1 8 804–150 GAUGE, Sight 1 9 802–18[...]

  • Page 26

    26 308–530 PUMP SER VICE (Model 1535) Servicing the V alves Disassembly: 1. Remove the four (4) socket head bolts and spring washers from end of manifold. 2. Support the discharge manifold from the underside and tap with a soft mallet to separate from the inlet manifold. 3. Carefully place discharge manifold on working surface with valve chambers[...]

  • Page 27

    27 308–530 4. With crankcase side of manifold down remove hi–pressure seals using a reverse pliers. 5. Invert manifold so crankcase side is up and with reverse pliers remove low pressure seals. Reassembly: 1. Examine low pressure seal for seal wear or spring failure and replace if necessary . With crankcase side of inlet manifold up, lubricate [...]

  • Page 28

    28 308–530 PUMP SER VICE (Models 2040 & 2540) Servicing the V alves 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 durin[...]

  • Page 29

    29 308–530 Reassembly: V–Packing Models: 1. Lubricate high pressure packing area in manifold. 2. Insert male adapter with notches down and “v” side up. 3. Lubricate v–packings and install one–at–a–time with grooved side down. 4. Next install female adapter with grooved side down. 5. Examine seal case o–ring and replace if worn. Lu[...]

  • Page 30

    30 308–530 ACCESSORIES (Must be purchased separately) DOWNSTREAM CHEMICAL INJECT OR KIT 800–1 17 & 800–649 For injecting harsh cleaning chemicals downstream from the pump. 800–649 is stainless steel construction. UPSTREAM CHEMICAL INJECTOR KIT 800–257 For injecting mild cleaning chemicals upstream into the pump. BACKFLOW PREVENT OR 80[...]

  • Page 31

    31 308–530 TECHNICAL DA T A Model 800–698 Model 800–699 Model 800–700 Engine (air–cooled, 4 cycle) 5 hp Briggs & Stratton I/C 8 hp Briggs & Stratton I/C 9 hp Briggs & Stratton OHV Gasoline T ank Capacity 3 quarts (2.8 liter) 6 quarts (5.7 liter) 5 quarts (4.8 liter) W ater Pump Maximum W orking Pressure 1500 psi (103 bar) 2000[...]

  • Page 32

    32 308–530 THE GRACO W ARRANTY W ARRANTY 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 per[...]