INSTRUCTIONS-PARTS LIST 308–529 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.
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.
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, explosion or property damage. NEVER alter or modify any part of this equipment; doing so could cause it to malfunction.
MOVING PARTS HAZARD Moving parts can pinch or amputate fingers or other body parts. KEEP CLEAR of moving parts when starting or operating the pressure washer. Pressure Relief Procedure before checking or servicing the pressure washer to prevent discharging 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 that could cause bodily injury.
INSTALLATION QUICK COUPLER SPRAY GUN QUICK COUPLER SPRAY HOSE 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. Connect to Water Supply CAUTION 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.
STARTUP 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.
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.
SHUTDOWN, FLUSHING AND STORAGE WARNING Pressure Relief Procedure MAINTENANCE Observing regular maintenance intervals helps ensure that you get maximum performance and life from the pressure washer. 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.
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. PROBLEM Engine will not start or is hard to start CAUSE No gasoline in fuel tank or carburetor. SOLUTION Dirty air cleaner filter. Spark plug dirty, wrong gap or wrong type. Spray gun closed. Fill the tank with gasoline, open fuel shut off valve.
PARTS DRAWING 800–638 & 800–690 Hydra–Clean 2540 Pressure Washer 4 3 3 4 7 7 43 65 8 8 10 38 10 48 51 50 47 45 11 10 52 62 51 54 57 56 37 60 61 53 39 40 41 55 59 35 36 42 44 58 29 64 49 47 13 46 31 6 12 11 34 10 24 26 32 26 32 26 22 308–529 1 9 20 20 21 10 25 2 18 11 47 15 16 13 23 14 28 26 27 10 10 5 33 3 0 17 19 63 15 16
PARTS LIST 800–638 & 800–690 Hydra–Clean 2540 Pressure Washer REF PART NO. NO. DESCRIPTION QTY 1 800–392 GUN & WAND ASSEMBLY (incl. 2, 5, 9, 15, 17, 47) 1 2 803–350 GUN, Spray (see Instruction Manual 308–511) 1 1 3 181–867 LABEL, Warning, ventilation 1 4 802–363 LABEL, Caution 1 5 801–134 WAND, 32” 1 6 179–885 LABEL, Warning, chassis 7 803–900 ENGINE, 9 hp, Honda OHV (used on 800–638 only) 1 803–901 ENGINE, 9 hp, Briggs & Stratton OHV (used on 800–690 only) 1 8 802–127 SCREW, Cap, hex hd.
PARTS DRAWING 800–639 Hydra–Clean 3040 Pressure Washer 4 3 7 43 61 48 51 8 10 38 47 50 60 13 51 53 52 22 10 56 57 37 55 49 58 46 54 35 36 42 44 34 31 39 40 41 45 12 33 22 6 62 10 24 26 29 25 26 20 26 27 308–529 2 20 21 10 22 47 15 16 13 14 28 19 9 5 32 26 32 1 18 23 30 12 11 17 10 59 15 16
PARTS LIST 800–639 Hydra–Clean 3040 Pressure Washer REF PART NO. NO. DESCRIPTION QTY 1 800–392 GUN & WAND ASSEMBLY (incl. 2, 5, 9, 11, 15, 47) 1 2 803–350 GUN, Spray (see Instruction Manual 308–511) 1 1 3 181–867 LABEL, Warning, ventilation 1 4 802–363 LABEL, Caution 1 5 801–134 WAND, 32” 1 6 179–885 LABEL, Warning, chassis 1 7 803–158 ENGINE, 11 hp, Honda OHV 8 802–127 SCREW, Cap, hex hd. 5/16–18 x 1-3/4 4 1 9 801–674 SLEEVE, 28” 18 10 100–527 WASHER, Flat 5/16 11 801–009 COUPLER, Female 1/4 (incl.
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: NOTE: To maintain a good seal, the gasket must be replaced whenever the gear reducer is disassembled. 1. Remove the four bolts, lockwashers and washers.
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 NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 PART NO.
PARTS DRAWING 803–737 Pump Assembly 10 9 8 12 7 11 13 14 6 5 4 1 45 3 2 20 19 18 44 46 47 45 50 44 54 43 42 16 49 17 53 10 9 11 52 51 40 21 28 23 26 22 38 16 308–529 37 31 36 35 34 15 33 41 14 39 12 29 32 24 25 27 31 30
PARTS LIST 803–737 Pump Assembly REF NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 PART NO. 801–467 801–468 801–469 KIT 1 KIT 1 KIT 1 KIT 1 KIT 1 KIT 4 KIT 4 KIT 1 803–283 803–284 802–500 803–285 KIT 2 803–286 802–895 801–475 803–144 803–332 803–288 802–794 803–289 803–290 803–291 803–292 Kit No. 1 Repair Kit Part No. 801–472 Valve Ref. No. 4 5 6 7 8 11 Description Qty.
PUMP 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 before proceeding. NOTE: 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.
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.
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.