INSTRUCTIONS-PARTS LIST 308–523 Rev A This manual contains IMPORTANT WARNINGS and INSTRUCTIONS READ AND RETAIN FOR REFERENCE HYDRA-CLEAN 1535, 2040 Pressure Washer HYDRA-CLEAN 1535, 5 HP ENGINE P/N 800–670, Series A P/N 800–671, Series A 1500 psi (103 bar) OPERATING PRESSURE 1900 psi (131 bar) MAXIMUM WORKING PRESSURE HYDRA-CLEAN 2040, 8 HP ENGINE P/N 800–672, Series A P/N 800–674, Series A 2000 psi (138 bar) OPERATING PRESSURE 2400 psi (165 bar) MAXIMUM WORKING PRESSURE 1535 2040 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 Pressure Relief Procedure 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 System Pressure 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. This sprayer can develop high operating pressures.
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 2040 SPRAY GUN QUICK COUPLER HIGH PRESSURE HOSE CONNECTION 1535 INLET WATER CONNECTION 3/4” GARDEN HOSE 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.
STARTUP Always use this start-up 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: All 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.
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 MAINTENANCE Observing regular maintenance intervals helps ensure that you get maximum performance and life from the pressure washer. 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.
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 PROBLEM Engine will not start or is hard to start 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 800–672 & 800–674 Hydra–Clean 2040 Pressure Washer 58 57 57 15 55 1 1 58 53 2 4 6 3 54 9 18 17 4 6 10 14 12 11 13 11 18 20 19 46 6 23 16 24 8 7 25 26 22 44 21 28 59 47 64 46 32 66 31 5 6 61 60 62 48 49 6 52 63 45 39 6 36 29 37 36 50 51 36 35 10 308-523 42 46 43 27 30 35 27 30 41 67 36 38 40 40 29 34 10
PARTS LIST 800–672 & 800–674 Hydra–Clean 2040 Pressure Washer 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 28 29 30 31 32 PART NO. DESCRIPTION QTY 802–141 ENGINE, 8 hp, Briggs & Stratton I/C (used on 800–672 only) 1 802–998 ENGINE, 8 hp, Honda OHV (used on 800–674 only) 1 802–299 PUMP & GEAR REDUCER ASSEMBLY (incl. 3, 13) 1 802–143 GEAR REDUCER (see page 17) 1 802–127 SCREW, Cap, hex hd.
PARTS DRAWING 800–670 & 800–671 Hydra–Clean 1535 Pressure Washer 58 57 55 1 57 55 1 53 2 59 54 3 4 6 6 4 67 6 9 18 14 17 58 10 11 15 11 7 12 46 18 16 20 6 23 8 24 25 26 22 44 21 47 46 32 64 6 56 61 60 6 63 48 65 49 66 45 52 39 40 31 36 33 16 6 35 46 41 30 67 36 29 40 42 34 38 37 36 50 51 36 35 12 308-523 43
PARTS LIST 800–670 & 800–671 Hydra–Clean 1535 Pressure Washer 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 28 29 30 31 32 PART NO. DESCRIPTION QTY 803–239 ENGINE, 5 hp, Briggs & Stratton I/C (used on 800–670 only) 1 803–264 ENGINE, 5 hp, Honda OHV (used on 800–671 only) 1 802–300 PUMP & GEAR REDUCER ASSEMBLY (incl. 3, 13) 1 802–266 GEAR REDUCER (see page ) 1 802–127 SCREW, Cap, hex hd.
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) 1. Remove the four bolts, lockwashers and washers. Pull the pump and gear reducer assembly off the engine. NOTE: 2.
PARTS DRAWING 802–266 Gear Reducer (Model 1535) 10 6 9 11 8 12 13 14 20 7 3 19 16 15 5 17 8 18 4 2 1 PARTS LIST 802–266 Gear Reducer (Model 1535) REF NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 PART NO.
GEAR REDUCER SERVICE (Model 2040) 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 (Model 2040) 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 (Model 2040) 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 802–265 Pump Assembly, 1500 psi 10 24 9 23 8 18 19 7 11 20 21 6 22 5 13 4 2 1 14 14 12 47 3 12 15 16 17 48 52 49 51 11 10 50 9 22 45 18 21 44 19 26 29 25 37 33 31 34 35 36 32 28 27 43 42 28 41 18 308-523 40 39 38 30
PARTS LIST 802–265 Pump Assembly, 1500 psi 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 PART NO. DESCRIPTION 802–319 MANIFOLD 801–651 SCREW, Cap, socket hd.
PARTS DRAWING 803–405 Pump Assembly, 2000 psi 10 9 20 19 18 8 12 7 11 13 14 6 5 4 1 45 44 46 47 45 50 3 2 44 54 43 42 16 49 17 53 9 11 52 10 51 40 15 41 14 39 12 29 28 21 23 26 22 37 38 31 36 35 34 33 32 24 25 27 31 30
PARTS LIST 803–405 Pump Assembly, 2000 psi 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 2 803–286 802–895 801–475 803–144 803–332 803–288 802–794 803–289 803–323 803–291 803–273 DESCRIPTION MANIFOLD SCREW, Cap, hex hd. WASHER, Lock O–RING SEAT, Valve PLATE, Valve SPRING GUIDE, Valve O–RING CAP VALVE ASSEMBLY SCREW, Cap, socket hd.
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 just packings only, the other includes the packings, rings and retainers. 1. Remove the manifold as outlined in the Pumping Section. 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.
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.
