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308–529
INSTRUCTIONS-PARTS LIST
Rev A
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
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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 To reduce the risk of serious bodily injury, including fluid pressure. Spray from the gun, leaks or ruptured injection and splashing in the eyes or on the skin, components can inject fluid through your skin and i
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EQUIPMENT MISUSE HAZARD General Safety System Pressure Any misuse of the pressure washer or accessories, This sprayer can develop high operating pressures. Be such as overpressurizing, modifying parts, using sure that all spray equipment and accessories are rated incompatible chemicals and fluids, or using worn or to withstand the maximum working pressure of this damaged parts, can cause them to rupture and result in sprayer. DO NOT exceed the maximum working fluid injection, splashing in the ey
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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 WARNING: Alerts user to avoid or correct conditions NOTE: Identifies helpful procedures and info
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INSTALLATION QUICK COUPLER SPRAY GUN QUICK COUPLER HIGH SPRAY HOSE PRESSURE 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 CAUTION in shipping. Notify the carrier immediately if there is Before attaching to the water supply, check your any damage. local plumbing code regarding cross– connection to the water supply . A backflow preventer , P/N Set Up 801–133, is available to p
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STARTUP Always use this startup procedure to ensure that the If the engine is cold, completely close the engine unit is started safely and properly. choke. Grasp the starter rope, brace one foot on the pressure washer chassis and pull rope rapidly 1. Check oil levels. and firmly. Continue holding the rope as it returns. Pull and return the rope until the engine starts. In Engine: Add SAE 30 or 10W–30 weight detergent cool weather, the choke may have to be kept closed oil as necessary. for 10 to
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Trigger Safety Latch Installing and Changing Spray Tips WARNING WARNING To reduce the risk of serious bodily injury, including To reduce the risk of serious bodily injury , 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 WARNING that you get maximum performance and life from the pressure washer. Pressure Relief Procedure To reduce the risk of serious bodily injury , There is a break–in period for the engine, pump and including fluid injection and splashing in the eyes, gear reducer (if used). After changing the oil in these or on the skin, always follow this procedure components following their respective break–in whe
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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 (on units with low oil sensor). Add to proper level. Start/St
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PARTS DRAWING 800–638 & 800–690 Hydra–Clean 2540 Pressure Washer 4 3 3 4 7 7 43 65 8 8 38 10 10 48 45 64 51 46 50 47 11 49 47 10 52 13 62 60 51 61 54 53 56 57 39 35 12 40 58 36 41 42 37 55 44 59 17 1 11 19 10 34 9 6 31 5 29 2 33 10 18 24 20 20 47 21 10 15 3 26 16 11 0 25 13 32 15 23 26 16 14 32 28 26 22 63 26 27 308–529
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PARTS LIST 800–638 & 800–690 Hydra–Clean 2540 Pressure Washer REF PART REF PART NO. NO. DESCRIPTION QTY NO. NO. DESCRIPTION QTY 1 800–392 GUN & WAND ASSEMBLY 32 101–566 NUT, Lock 3/8–16 3 (incl. 2, 5, 9, 15, 17, 47) 1 33 800–661 CHASSIS 1 2 803–350 GUN, Spray (see Instruction 34 801–012 GROMMET, Rubber 4 Manual 308–511) 1 35 800–131 TIP ASSEMBLY, 0005 3 181–867 LABEL, Warning, ventilation 1 (incl. 39, 40) 1 4 802–363 LABEL, Caution 1 36 800–137 TIP ASSEMBLY, 1505 5 801–134 WAND, 32” 1 (incl
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PARTS DRAWING 800–639 Hydra–Clean 3040 Pressure Washer 4 3 7 43 61 8 38 10 48 51 47 50 60 52 13 51 53 22 10 56 57 55 49 58 37 46 54 12 31 35 39 36 40 42 33 41 22 44 45 11 10 1 6 17 9 34 62 10 5 18 2 24 20 20 21 10 26 47 29 22 25 15 16 23 30 13 32 15 26 16 14 32 28 26 19 59 26 27 308–529
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PARTS LIST 800–639 Hydra–Clean 3040 Pressure Washer REF PART REF PART NO. NO. DESCRIPTION QTY NO. NO. DESCRIPTION QTY 1 800–392 GUN & WAND ASSEMBLY 33 800–661 CHASSIS 1 (incl. 2, 5, 9, 11, 15, 47) 1 34 801–012 GROMMET, Rubber 4 2 803–350 GUN, Spray (see Instruction 35 800–314 TIP ASSEMBLY, 00045 Manual 308–511) 1 (incl. 31, 39) 1 3 181–867 LABEL, Warning, ventilation 1 36 800–315 TIP ASSEMBLY, 15045 4 802–363 LABEL, Caution 1 (incl. 31, 40) 1 5 801–134 WAND, 32” 1 37 402–278 PLUG, Plastic 1
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GEAR REDUCER SERVICE WARNING To reduce the risk of serious bodily injury, including fluid injection, splashing in the eyes or on the skin or injury from moving parts, always follow the Pressure Relief Procedure Warning on page 2 before proceeding. Replacing the Gasket (9) Replacing the Oil Seal (14) NOTE: To maintain a good seal, the gasket must be NOTE: The oil seal MUST be replaced with a new replaced whenever the gear reducer is one if removed. disassembled. 1. Follow steps 1 and 3 under Repl
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PARTS DRAWING 802–143 Gear Reducer 1 2 3 4 10 21 20 5 11 6 12 7 13 8 9 14 17 19 12 18 15 16 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
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PARTS DRAWING 803–737 Pump Assembly 10 9 20 19 18 8 12 7 13 11 14 6 5 45 46 4 1 47 50 44 45 49 17 3 16 2 42 43 44 54 53 11 9 52 10 51 40 15 41 14 39 12 29 28 21 23 32 33 26 22 24 30 25 31 34 27 35 36 31 37 38 308–529
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PARTS LIST 803–737 Pump Assembly REF PART REF PART NO. NO. DESCRIPTION QTY NO. NO. DESCRIPTION QTY 1 801–467 MANIFOLD, 2000 psi 1 28 803–293 COVER, Crankcase 1 2 801–468 SCREW, Cap, hex hd. 8 29 802–345 GAUGE, Sight 1 3 801–469 WASHER, Lock 8 30 802–793 PLUG, Oil Drain 1 4 KIT 1 O–RING 31 KIT 6 O–RING 5 KIT 1 SEAT, Valve 32 803–294 SCREW, Cap, socket hd 6 6 KIT 1 PLATE, Valve 33 801–652 WASHER, Lock 6 7 KIT 1 SPRING 34 801–660 WASHER, Flinger 3 8 KIT 1 GUIDE, Valve 35 801–490 PLUNGER, Ceramic 3
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PUMP SERVICE Servicing the Plungers WARNING To reduce the risk of serious bodily injury , NOTE: Plunger repair kit, P/N 801–474 is available to including fluid injection, splashing in the eyes or replace retainers, o–rings, washers and on the skin, or injury from moving parts, always backup rings for three cylinders. follow the Pressure Relief Procedure Warning before proceeding. 1. Loosen the plunger retaining screw five to six turns, using an M10 wrench. Push the plunger towards NOTE: The foll
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5. Thoroughly clean the packing cavities and examine Servicing the V–Packings for debris and damage. NOTE: There are two types of packing kits: one is packings only , the other includes the 6. Lightly grease the packing cavities and then packings, rings and retainers. replace the packings in the following order: head ring, v–packing, intermediate ring, head ring, 1. Remove the manifold as outlined in the Pumping v–packing and packing retainer with the o–ring Section. installed in the retainer gr
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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, o
