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308–530
INSTRUCTIONS-PARTS LIST
Rev A
This manual contains IMPORTANT
WARNINGS and INSTRUCTIONS READ
AND RETAIN FOR REFERENCE
HYDRA-CLEAN 1535, 2040, 2540
Pressure Washers
HYDRA-CLEAN 1535, 5 HP ENGINE
P/N 800–698, Series A
1500 psi (103 bar) OPERATING PRESSURE
1900 psi (131 bar) MAXIMUM WORKING PRESSURE
HYDRA-CLEAN 2040, 8 HP ENGINE
P/N 800–699, Series A
2000 psi (138 bar) OPERATING PRESSURE
2400 psi (165 bar) MAXIMUM WORKING PRESSURE
HYDRA-CLEAN 2540, 9 HP ENGINE
P/N 800–700, Series A
2500
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INDEX Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Shutdown, Flushing and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Maintenance . . . . . . . .
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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 Pressure Relief Procedure This pressure washer generates very high fluid pressure. To reduce the risk of serious bodily injury, including fluid Spray from the gun, leaks or ruptured components can injection and splashing in the eyes or on the skin, always inject fluid through your ski
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EQUIPMENT MISUSE HAZARD General Safety System Pressure Any misuse of the pressure washer or accessories, such This sprayer can develop high operating pressures. Be as overpressurizing, modifying parts, using incompatible sure that all spray equipment and accessories are rated chemicals and fluids, or using worn or damaged parts, to withstand the maximum working pressure of this can cause them to rupture and result in fluid injection, sprayer. DO NOT exceed the maximum working splashing in the ey
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INSTALLATION 1535 2540 HIGH PRESSURE HOSE CONNECTION HIGH PRESSURE INLET WATER HOSE CONNECTION 3/4” CONNECTION GARDEN HOSE INLET WATER CONNECTION 3/4” QUICK GARDEN HOSE COUPLER 2040 SPRAY GUN QUICK COUPLER SPRAY HIGH PRESSURE HOSE HOSE CONNECTION INLET WATER CONNECTION 3/4” GARDEN HOSE Figure 1 Check for Shipping Damage Connect to Water Supply Check the unit for any damage that may have occurred in CAUTION shipping. Notify the carrier immediately if there is any Before attaching to the water su
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STARTUP Always use this startup procedure to ensure that the unit If the engine is cold, completely close the engine is started safely and properly. choke. Grasp the starter rope, brace one foot on the pressure washer chassis and pull rope rapidly and 1. Check oil levels. firmly. Continue holding the rope as it returns. Pull and return the rope until the engine starts. In cool Engine: Add SAE 30 or 10W–30 weight detergent oil weather, the choke may have to be kept closed for 10 to 30 seconds bef
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Trigger Safety Latch Installing and Changing Spray Tips WARNING WARNING To reduce the risk of serious bodily injury , To reduce the risk of serious bodily injury, including fluid injection or splashing in the eyes or onto the including fluid injection, splashing in the eyes or skin, use extreme caution when changing spray on the skin, ALWAYS engage the trigger safety tips. ALWAYS follow the procedure below. latch whenever spraying stops, even for a moment. 1. Follow the Pressure Relief Procedure
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SHUTDOWN, FLUSHING MAINTENANCE AND STORAGE Observing regular maintenance intervals helps ensure that you get maximum performance and life from the pressure washer. WARNING Pressure Relief Procedure There is a break–in period for the engine, pump and gear reducer (if used). After changing the oil in these To reduce the risk of serious bodily injury, including components following their respective break–in periods, fluid injection and splashing in the eyes, or on the the interval between required
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TROUBLESHOOTING CHART 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. CAUSE SOLUTION PROBLEM Engine will not start or No gasoline 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 Add to proper level. Start/Stop switch in Stop position. Move
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PARTS DRAWING 800–698 Hydra–Clean 1535 Pressure Washer 1 57 46 58 7 6 53 2 55 54 3 6 45 8 4 6 18 15 13 17 14 11 46 12 11 16 23 20 24 21 25 26 19 22 44 47 46 28 32 64 59 6 61 56 60 6 63 45 48 52 49 65 66 39 40 31 11 6 36 27 35 46 30 33 41 16 68 67 27 30 36 29 40 42 43 34 67 50 36 51 36 35 308–530
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PARTS LIST 800–698 Hydra–Clean 1535 Pressure Washer REF PART REF PART NO. NO. DESCRIPTION QTY NO. NO. DESCRIPTION QTY 35 801–546 SCREW, Cap, hex hd. 1 802–239 ENGINE, 5 hp, Briggs & Stratton I/C 1 3/8–16 x 1-1/4 5 36 100–023 WASHER, Flat 3/8 10 2 800–695 PUMP & GEAR REDUCER 39 802–139 AXLE 1 ASSEMBLY (incl. 3, 13) 1 40 154–636 WASHER, Flat 5/8 4 3 804–248 GEAR REDUCER (see page 17) 1 41 106–062 WHEEL & TIRE ASSEMBLY2 4 802–127 SCREW, Cap, hex hd. 42 101–545 PIN, Cotter 1/8 x 1-1/2 2 5/16–18 x
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PARTS DRAWING 800–699 Hydra–Clean 2040 Pressure Washer 57 46 7 6 1 58 2 53 6 45 54 3 8 4 6 15 18 17 14 11 13 12 46 11 16 20 23 24 21 25 26 44 19 22 47 46 28 32 64 59 6 61 56 60 6 63 55 45 48 52 49 65 66 39 40 31 11 6 36 27 35 46 30 33 16 68 41 67 27 36 30 29 40 42 34 43 67 50 36 51 36 35 308–530
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PARTS LIST 800–699 Hydra–Clean 2040 Pressure Washer REF PART REF PART NO. NO. DESCRIPTION QTY NO. NO. DESCRIPTION QTY 1 802–141 ENGINE, 8 hp, Briggs & 35 801–546 SCREW, Cap, hex hd. Stratton I/C 1 3/8–16 x 1-1/4 5 2 800–696 PUMP & GEAR REDUCER 36 100–023 WASHER, Flat 3/8 10 ASSEMBLY (incl. 3, 13) 1 39 802–139 AXLE 1 3 804–249 GEAR REDUCER (see page 19) 1 40 154–636 WASHER, Flat 5/8 4 4 802–127 SCREW, Cap, hex hd. 41 106–062 WHEEL & TIRE ASSEMBLY2 5/16–18 x 1-3/4 4 42 101–545 PIN, Cotter 1/8 x
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PARTS DRAWING 800–700 Hydra–Clean 2540 Pressure Washer 31 11 3 10 61 4 7 43 67 10 38 65 18 60 8 10 51 50 48 47 64 51 49 11 47 52 13 56 62 57 54 58 37 12 53 17 19 34 11 33 9 10 66 5 40 2 41 35 10 55 36 18 6 42 59 39 44 24 1 47 20 15 10 16 26 25 11 13 63 29 23 15 32 16 26 14 20 21 32 28 30 26 22 26 27 308–530
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PARTS LIST 800–700 Hydra–Clean 2540 Pressure Washer REF PART REF PART NO. NO. DESCRIPTION QTY NO. NO. DESCRIPTION QTY 1 800–392 GUN & WAND ASSEMBLY 34 801–012 GROMMET, Rubber 4 (incl. 2, 5, 9, 15, 17, 47) 1 35 800–131 TIP ASSEMBLY, 0005 2 803–350 GUN, Spray (see Instruction (incl. 39, 40) 1 Manual 308–511) 1 36 800–137 TIP ASSEMBLY, 1505 3 181–867 LABEL, Warning, ventilation 1 (incl. 39, 41) 1 4 802–363 LABEL, Caution 1 37 402–278 PLUG, Plastic 1 5 801–134 WAND, 32” 1 38 803–083 LABEL, Keep
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GEAR REDUCER SERVICE (Model 1535) 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 the O–Ring (5) Replacing the Oil Seal (10) NOTE: The oil seal MUST be replaced if removed. 1. Remove the four bolts, lockwashers and washers. Pull the pump and gear reducer assembly of f the 1. Follow steps 1 and 2 under Replacin
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PARTS DRAWING Gear Reducer (Model 1535) 1 23 22 8 20 7 21 6 5 4 3 16 21 2 19 14 22 23 13 20 23 17 12 24 10 9 15 11 PARTS LIST Gear Reducer (Model 1535) REF PART REF PART NO. NO. DESCRIPTION QTY NO. NO. DESCRIPTION QTY 1 804–236 SCREW, Cap, hex hd./cross 14 804–231 SCREW, Cap, hex hd./cross recess 4 recess 4 2 804–201 HOUSING, Gear Reducer 1 15 804–166 GEAR, Driven, spur 1 3 804–202 GEAR, Pinion, 3/4 1 16 804–229 KEY, Square, 3/16 x 13/16 1 4 804–082 BEARING 1 17 804–090 WASHER, Flat, retaini
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GEAR REDUCER SERVICE (Models 2040 & 2540) 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 the Gasket (9) Replacing the Oil Seal (14) NOTE: The oil seal MUST be replaced if removed. NOTE: To maintain a good seal, the gasket must be replaced whenever the gear reducer is 1. Follow steps 1 and 3 under Replacing th
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PARTS DRAWING Gear Reducer (Models 2040 & 2540) 29 28 22 12 27 23 24 11 10 30 9 21 32 2 1 26 3 4 7 5 8 6 14 15 31 24 17 16 25 18 19 13 20 PARTS LIST Gear Reducer (Models 2040 & 2540) REF PART REF PART NO. NO. DESCRIPTION QTY NO. NO. DESCRIPTION QTY 1 804–182 HOUSING, Gear Reducer 1 19 804–231 SCREW, Cap, socket head, 2 804–183 GEAR, Pinion, 1” 1 6mm x 20mm 4 3 804–228 BEARING 1 20 804–078 O–RING, Housing 1 4 804–227 RING, Retaining, internal 1 21 804–187 GEAR, Driven, helical 1 5 804–243 RING,
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PARTS DRAWING 804–244 Pump Assembly, 1500 psi 12 18 7 3 3 38 4 38 20 9 1 6 13 8 5 17 16 14 11 10 2 20 21 23 38 24 3 25 18 19 26 14 22 27 15 16 17 28 29 30 31 32 33 35 34 39 40 36 48 47 48 46 45 44 43 37 42 41 39 51 49 52 50 46 45 44 43 42 308–530
