308–530
INSTRUCTIONS-PARTS LIST
Rev
A
This manual contains IMPORTANT
WARNINGS and INSTRUCTIONS READ
AND RETAIN FOR REFERENCE
HYDRA-CLEANR 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 psi (172 bar) OPERATING PRESSURE
3000 psi (207 bar) MAXIMUM WORKING PRESSURE
1535
2040
2540
GRACO INC. P.O. Box 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1991, GRACO INC.
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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.
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. Also, fluid injected or splashed into the
eyes or on the skin can cause serious damage.
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.
1. Engage the trigger safety latch.
2. Turn the sprayer off.
NEVER point the spray gun or wand at anyone or at any
part of the body . NEVER put hand or fingers over the
spray tip.
3. Remove the ignition cable from the spark plug.
4. Shut off the water supply
.
ALWAYS follow the Pressure Relief Procedure
cleaning or servicing any part of the sprayer
,
before
.
5. Disengage the trigger safety latch and trigger the gun
to relieve pressure, and then engage the trigger
safety latch again.
NEVER try to stop or deflect leaks with your hand or
body.
6. Before long–term (overnight) storage or transporting
of the unit, disconnect the water supply and turn off
the fuel supply valve.
Be sure equipment safety devices are operating properly
before each use.
Spray Gun Safety Devices
Be sure all gun safety devices are operating properly
before each use. Do not remove or modify any part of the
gun; this can cause a malfunction and result in serious
Medical Treatment
If any fluid appears to penetrate your skin, get
EMERGENCY MEDICAL TREATMENT AT ONCE. DO
bodily injury
.
NOT TREAT AS A SIMPLE CUT
what fluid was injected.
.
T
ell the doctor exactly
SAFETY LATCH: Whenever you stop spraying for a
moment, always set the gun safety latch in the engaged
or “safe” position, making the gun inoperative. Failure to
properly set the safety latch can result in accidental
triggering of the gun.
NOTE TO PHYSICIAN: Injection in the skin is a
traumatic injury It is important to treat the injury
.
surgically as soon as possible. Do not delay
treatment to research toxicity. Toxicity is a concern
with some exotic coatings injected directly into the
bloodstream. Consultation with a plastic surgeon or
reconstructive hand surgeon may be advisable.
SPRAY TIP SAFETY : Use extreme caution when
cleaning or changing spray tips. If a spray tip clogs while
spraying, engage the gun safety latch immediately
.
ALWAYS follow the Pressure Relief Procedure and
then remove the spray tip to clean it.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers or other body
parts. KEEP CLEAR of moving parts when starting or
servicing the pressure washer to prevent discharging
high pressure fluid from the gun.
operating the pressure washer
.
NEVER operate the pressure washer without all guards
and interlocks installed and functioning. Follow the
Pressure Relief Procedure
before checking or
Warnings continued on page 4.
308–530
3
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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. Be
sure that all spray equipment and accessories are rated
to withstand the maximum working pressure of this
sprayer. DO NOT exceed the maximum
pressure of any component or accessory used in the
system.
working
NEVER alter or modify any part of this equipment; doing
so could cause it to malfunction.
Chemical Compatibility
CHECK all spray equipment regularly and repair or
BE SURE that all chemicals used in the chemical injector
are compatible with the wetted parts of the hose, gun,
wand and tip, as given in the Technical Data (inside back
cover). Always read the chemical manufacturer
literature before using any chemical in this pressure
washer.
replace worn or damaged parts immediately
.
ALWAYS wear protective eyewear and appropriate
clothing. If using a chemical injector, read and follow the
’s
chemical manufacturer
’s literature for recommendations
on additional protective equipment, such as a respirator
.
HOSE SAFETY
High pressure fluid in the hoses can be very dangerous. If
the hose develops a leak, split or rupture due to any kind
of wear, damage or misuse, the high pressure spray
emitted from it can cause a fluid injection injury or other
serious bodily injury or property damage.
NEVER use a damaged hose. Before each use, check
entire hose for cuts, leaks, abrasion, bulging cover , or
damage or movement of the hose couplings. If any of
these conditions exist, replace the hose immediately DO
.
NOT try to recouple high pressure hose or mend it with
tape or any other device. A repaired hose cannot contain
the high pressure fluid.
ALL FLUID HOSES MUST HA VE STRAIN RELIEFS
ON BOTH ENDS. The strain reliefs help protect the hose
from kinks or bends at or close to the coupling, which can
result in hose rupture.
HANDLE AND ROUTE HOSES CAREFULL Y. Do not
pull on hoses to move the pressure washer. Do not use
chemicals which are not compatible with the inner tube
and cover of the hose. DO NOT expose Graco hose to
TIGHTEN all fluid connections securely before each use.
High pressure fluid can dislodge a loose coupling or allow
high pressure spray to be emitted from the coupling.
temperatures above 200_ F (93_ C) or below –40_
F
(–40_ C).
FUEL AND EMISSION HAZARDS
NEVER fill the fuel tank while the unit is running or hot.
The fuel used in this unit is combustible and when spilled
on a hot surface can ignite and cause a fire. ALWAYS fill
tank slowly to avoid spilling.
invisible gas which can cause serious injury or death if
inhaled.
NEVER alter the throttle setting, which is factory set.
Tampering with this adjustment can damage the
NEVER operate the unit in a closed building. The exhaust
contains carbon monoxide, a poisonous, odorless,
pressure washer and will void the warranty
.
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These
standards—particularly the General Standards, Part 1910, and the Construction Standards, Part 1926—should be
consulted.
4
308–530
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INSTALLATION
1535
2540
HIGH PRESSURE
HOSE
CONNECTION
HIGH
PRESSURE
HOSE
INLET WATER
CONNECTION 3/4”
GARDEN HOSE
CONNECTION
INLET WATER
CONNECTION 3/4”
GARDEN HOSE
QUICK
COUPLER
2040
SPRAY
GUN
QUICK
COUPLER
SPRAY
HOSE
HIGH PRESSURE
HOSE CONNECTION
INLET WATER
CONNECTION 3/4”
GARDEN HOSE
Figure
1
Check for Shipping Damage
Connect to Water Supply
CAUTION
Check the unit for any damage that may have occurred in
shipping. Notify the carrier immediately if there is any
damage.
Before attaching to the water supply, check your
local plumbing code regarding cross–connection
to the water supply . A backflow preventer , P/N
801–133, is available to prevent backflow of
contaminated water into the fresh water supply .
Install it upstream from the pump.
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.
If inlet water pressure is over 60 psi (4.1 bar) a
regulating water valve, P/N 800–258, must be
installed at the garden hose connection.
Connect the high pressure hose between the pump outlet
and the gun inlet. Both of these connections are made
with quick couplers.
Do not exceed 160 _ F (70 _ C) inlet water
CAUTION
temperature.
Up to 100 ft (30 m) of high pressure hose may
be used. Longer hoses may af
performance, and chemical injector performance,
if used.
fect sprayer
Connect a hose with at least a 3/4 inch (19 mm) ID from
the water supply to the unit’s 3/4 inch garden hose inlet.
The supply hose should not be more than 50 ft (15 m)
long.
Install the appropriate spray tip on the wand. See
Installing and Changing Spray T ips. If you are using a
sandblaster kit, see its separate manual for installation
instructions.
NOTE: The water source at the unit
must have a
minimum flow rate equal to that of the unit (see
Technical Data, inside back cover).
308–530
5
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STARTUP
Always use this startup procedure to ensure that the unit
If the engine is cold, completely close the engine
choke. Grasp the starter rope, brace one foot on the
pressure washer chassis and pull rope rapidly and
firmly. Continue holding the rope as it returns. Pull
and return the rope until the engine starts. In cool
weather, the choke may have to be kept closed for 10
to 30 seconds before opening it to keep the engine
running. Otherwise, open the choke as soon as the
engine starts.
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
R
pump oil as necessary
.
If the engine is warm, leave the choke open, or just
partly close it. Start the engine as described in the
preceding paragraph. When it starts, be sure to open
Gear Reducer (2040 and 2540): Add SAE 90 gear oil
as necessary . The 1535 uses the oil in pump
crankcase.
the choke completely
.
CAUTION
NOTE: All units are equipped with a low–oil sensor that
On recoil start engines, never let the starter rope
return by itself. It could jam the recoil system.
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.
7. ALWAYS engage the gun’ s trigger safety latch
whenever you stop spraying, even for a moment, to
reduce the risk of fluid injection or splashing in the
eyes or on the skin if the gun is bumped or triggered
accidentally.
2. Check fuel level.
WARNING
DO NOT refuel a hot engine. Refueling a hot
engine could cause a fire. Use only fresh, clean
regular or unleaded gasoline. Close the fuel
shutoff valve during refueling.
8. ALWAYS observe the following CAUTIONS to avoid
costly damage to the pressure washer
.
CAUTION
DO NOT allow the pressure washer to idle for more
than 10 minutes. Doing so may cause the
recirculating water to overheat and seriously
damage the pump. Turn off the pressure washer if it
will not be spraying or cleaning at least every 10
minutes. If heated inlet water is used, reduce this
time further.
3. Turn on the water supply
.
CAUTION
Never run the unit dry. Costly damage to the pump
will result. Always be sure the water supply is
completely turned on before operating.
DO NOT run the pump dry , which will quickly
damage the pump. Be sure the water supply is fully
turned on before starting the pump.
4. Trigger the gun until water sprays from the tip
indicating that the air is purged from the system.
5. Open the fuel shutoff valve. Be sure the spark plug
ignition cable is pushed firmly onto the spark plug. On
those units equipped with an ignition shutoff switch,
put the switch in the “on” position and put the throttle
in the “run” position.
DO NOT operate the pressure washer with the inlet
water screen removed. This screen helps keep
abrasive sediment out of the pump, which could
clog or scratch the pump. Keep this screen clean.
DO NOT pump caustic materials; such materials
may corrode the pump components.
6. Start the engine.
NOTE: For easier starting, have one person start the
pressure washer while another person triggers
the spray gun.
9. See the chemical injector or sandblaster kit manual
for detailed cleaning information if these accessories
are used.
6
308–530
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Trigger Safety Latch
WARNING
Installing and Changing Spray Tips
WARNING
To reduce the risk of serious bodily injury, including
fluid injection or splashing in the eyes or onto the
skin, use extreme caution when changing spray
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.
,
tips. ALWAYS follow the procedure below
.
1. Follow the Pressure Relief Procedure
.
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.
2. Point the gun and wand away from yourself and
anyone else.
3. Without holding your hand over the spray tip (A), pull
back the quick coupler ring (B). Remove the old tip
and/or install a new one, and then release the ring.
See Figure 3.
4. Be sure the tip is secure before starting to spray
again.
5. Tip holding holes are provided on the chassis.
CAUTION
To avoid blowing the o–ring out of the quick
coupler, due to the high pressure in the system,
never operate the pressure washer without a tip
securely mounted in the quick coupler
.
TRIGGER SAFETY LATCH SHOWN ENGAGED
A
B
TRIGGER SAFETY LATCH SHOWN
DISENGAGED
Figure 3
Figure 2
308–530
7
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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
There is a break–in period for the engine, pump and gear
reducer (if used). After changing the oil in these
components following their respective break–in periods,
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.
the interval between required changes is longer
.
If the unit is operating in dusty conditions, these
maintenance checks should be made more often.
WARNING
To reduce the risk of serious bodily injury
including fluid injection, splashing in the eyes or
1. Engage the trigger safety latch.
2. Turn the sprayer off.
,
on the skin or injury from moving parts, always
follow the Pressure Relief Procedure Warning
before proceeding.
3. Remove the ignition cable from the spark plug.
4. Shut off the water supply
.
5. Disengage the trigger safety latch and trigger
the gun to relieve pressure, and then engage
the trigger safety latch again.
Interval
What to do
Daily
Clean water inlet screen and
filter. Check engine and pump oil
levels. Fill as necessary. Check
6. Before long–term (overnight) storage or
transporting of unit, disconnect the water
supply, and turn off the fuel supply valve.
gasoline level. Fill as necessary
.
After first 5
hours of
operation
Change engine break–in oil.
Drain oil when warm. Use SAE
30 or 10W–30 detergent oil.
1. If the pressure washer will be exposed to freezing
temperatures, drain all water out of the pump. If it
must be stored in freezing temperatures, flush the
Each 25 hours Clean and remove air cleaner
of operation
foam. Wash with water and
detergent. Dry thoroughly. Rub
with oil and squeeze to distribute
oil.
unit with a 50%
anti–freeze solution. Relieve
pressure. Flush the pressure washer before using it
again to remove the anti–freeze.
After first 50
hours of
operation
Change pump break–in oil. Use
SAE 20 or 30 non–detergent oil
or genuine Cat
R
pump oil.
NOTE: An anti–freeze flush kit, P/N 802–327, is
Change gear reducer oil. Use
SAE 90 gear oil on 2040 and
2540. The 1535 uses the oil in
pump crankcase.
available to make flushing easier
.
CAUTION
Each 100
hours of
operation
or 3 months
Clean or replace paper air
cleaner cartridge. Tap gently to
remove dirt. Change engine oil.
Use SAE 30 or 10W–30
detergent oil.
If water does freeze in the pressure washer, thaw
it in a warm room before trying to start it. DO NOT
pour hot water on or into the pump; it may crack
the ceramic plungers!
Change pump oil. Use SAE 20 or
30 non–detergent oil or genuine
CatR pump oil. Change gear
reducer oil on 2040 and 2540.
Use SAE 90 gear oil. The 1535
uses the oil in pump crankcase.
Each 500
hours of
operation
or 6 months
2. After each use, wipe all surfaces of the pressure
washer with a clean, damp cloth.
3. Perform the appropriate maintenance. See
maintenance chart.
8
308–530
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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.
Check fuel line and carburetor.
is hard to start
Low oil
Add to proper level.
Start/Stop switch in Stop position.
Move switch to start position.
W
ater in gasoline or old fuel.
Choked improperly. Flooded engine.
Dirty air cleaner filter
Drain fuel tank and carburetor. Use new fuel and dry
spark plug.
Open choke and crank engine several times to clear
out gas.
.
Remove and clean.
Spark plug dirty, wrong gap or wrong type.
Spray gun closed.
Clean, adjust the gap or replace.
Trigger spray gun.
Engine misses or
lacks power
Partially plugged air cleaner filter
Spark plug dirty, wrong gap or wrong type.
orn or wrong size tip.
Inlet filter clogged.
orn packings, abrasives in water or
natural wear
Inadequate water supply
.
Remove and clean.
Clean, adjust the gap or replace.
Low pressure and/or
pump runs rough
W
Replace with tip of proper size.
Clean. Check more frequently
.
W
Check filter. Replace packings. See PUMP SERVICE.
.
.
Check water flow rate to pump.
Fouled or dirty inlet or discharge valves.
Even a small particle can cause the valve
to stick.
Clean inlet and discharge valve assemblies. Check
filter.
Restricted inlet.
Check garden hose, may be collapsed or kinked.
Replace worn valves.
W
orn inlet or discharge valves.
Leaking high pressure hose.
orn packings.
Replace high pressure hose.
W
ater leakage from
W
Install new packings. See PUMP SERVICE.
under pump manifold
Water in pump
Humid air condensing inside crankcase.
orn packings.
Oil seals leaking.
Change oil as specified in MAINTENANCE.
Install new packings. See PUMP SERVICE.
Install new oil seals. See PUMP SERVICE.
W
Frequent or premature Scored, damaged or worn plungers.
failure of the packings
Install new plungers. See PUMP SERVICE.
Abrasive material in the fluid being pumped. Install proper filtration on pump inlet plumbing.
Inlet water temperature too high.
Overpressurizing pump.
Check water temperature; may not exceed 160_F.
Do not modify any factory–set adjustments. See
EQUIPMENT MISUSE HAZARD.
Excessive pressure due to partially plugged Clean or replace tip. See Installing and Changing
or damaged tip.
Spray Tips.
Pump running too long without spraying.
Never run pump more than 10 minutes without
spraying.
Running pump dry
.
Do not run pump without water.
Strong surging at the
Foreign particles in the inlet or discharge
Clean or replace valves. See PUMP SERVICE.
inlet and low pressure valve or worn inlet and/or discharge valves.
on the discharge side
Oil leakage between
the gear reducer cover
and case
W
W
W
orn gasket.
Replace the gasket. See SERVICE SECTION.
Oil leakage between
the gear reducer cover
and the pump
orn oil seals and/or o-ring.
orn oil seal.
Replace oil seals and/or o-ring. See SERVICE
SECTION.
Oil leakage between
the gear reducer case
and the engine
Replace oil seal. See SERVICE SECTION.
308–530
9
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PARTS DRAWING
800–698 Hydra–Cleanr 1535 Pressure Washer
1
57
58
46
7
6
53
2
3
55
54
6
45
8
4
6
18
15
13
17
14
11
46
12
20
11
16
23
24
21
25
26
19
22
44
47
46
28
59
32
64
6
56
61
60
6
63
45
48
49
52
65
66
39
40
31
11
6
36
27
30
35
46
33
41
16
68
67
36
27
30
29
40
42
43
34
50
67
36
51
36
35
10 308–530
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PARTS LIST
800–698 Hydra–Cleanr 1535 Pressure Washer
REF PART
REF PART
NO. NO.
DESCRIPTION
QTY
NO. NO.
DESCRIPTION
QTY
35
801–546 SCREW, Cap, hex hd.
3/8–16 x 1-1/4
100–023 WASHER, Flat 3/8
802–139 AXLE
154–636 WASHER, Flat 5/8
106–062 WHEEL & TIRE ASSEMBL
101–545 PIN, Cotter 1/8 x 1-1/2
104–811 HUB CAP
801–539 BUMPER
801–941 SCREW, Cap, hex hd.
5/16–18 x 1
1
802–239 ENGINE, 5 hp, Briggs &
Stratton I/C
800–695 PUMP & GEAR REDUCER
ASSEMBLY (incl. 3, 13)
5
10
1
1
36
39
40
41
42
43
44
45
2
1
4
3
4
804–248 GEAR REDUCER (see page 17) 1
802–127 SCREW, Cap, hex hd.
5/16–18 x 1-3/4
100–527 WASHER, Flat 5/16
804–250 BRACKET, Support
801–367 BUMPER, Rubber
156–849 NIPPLE, Hex 3/8
Y
2
2
4
20
1
2
6
7
8
11
12
13
1
2
6
12
4
3
46
47
48
111–040 NUT, Lock 5/16–18
801–012 GROMMET, Rubber
802–316 UNLOADER, Preset 1500 psi
804–244 PUMP ASSEMBL
1
Y
, 1500 psi
800–174 TIP ASSEMBL , 00055
Y
(see page 20)
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
(incl. 64, 65)
800–173 TIP ASSEMBL
(incl. 64, 66)
1
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
801–709 PLUG, Square hd. 1/4
803–245 GUARD, Muffler
801–568 QUICK COUPLER, Male 3/8
801–620 ELBOW, Street 1/4 x 90_
801–866 HOSE, Bypass
801–622 CROSS, 1/2
801–523 NIPPLE, 1/2 x 2
800–115 VALVE, Thermal Relief
804–073 ADAPTER, 1/2
801–111 NUT, Garden Hose
801–110 ADAPTER, Garden Hose
804–051 STRAINER/FILTER
402–278 PLUG, Plastic
156–082 O–RING, Quick Coupler 3/8
154–594 O–RING, Quick Coupler 1/4
802–579 HOSE, High Pressure, 3/8 x 50’
801–569 QUICK COUPLER, Female 3/8
(incl. 27)
49
Y
, 15055
1
1
1
1
1
1
50
51
52
53
54
55
801–858 BRACKET, Front Leg
801–504 BUMPER, Rubber
179–885 LABEL, Chassis
802–781 KEY, Square 3/16 x 2
803–083 LABEL, Keep From Freezing
804–274 LABEL, Graco Cleaning
Systems
1
1
1
1
56
57
58
59
801–723 LABEL, Model 1535
802–363 LABEL, Caution
181–867 LABEL, Warning
801–009 QUICK COUPLER,
Female 1/4 (incl. 28)
1
1
1
60
61
63
801–134 WAND, 32”
801–674 SLEEVE, 28”
803–350 GUN, Spray (see Instruction
Manual 308–511)
2
1
4
1
1
5
31
800–392 GUN & WAND ASSEMBL
(incl. 11, 59, 60, 61, 63)
800–661 CHASSIS
803–925 HANDLE
Y
64
65
66
67
68
801–090 QUICK COUPLER, Male 1/4
801–730 TIP, Spray 00055
801–729 TIP, Spray 15055
101–566 NUT, Lock 3/8–16
800–377 HOSE ASSEMBLY w/Quick
Couplers (incl. 16, 29, 30)
1
1
1
32
33
34
800–175 FRONT LEG ASSEMBL
Y
(incl. 35, 36, 50, 51, 67)
1
1
308–530 11
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PARTS DRAWING
800–699 Hydra–Cleanr 2040 Pressure Washer
57
46
7
6
1
58
2
3
53
6
45
54
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
59
32
52
64
6
56
61
60
6
63
55
45
48
49
65
66
39
40
31
11
27
6
36
35
46
30
33
16
68
41
67
36
27
30
29
40
42
34
43
67
50
36
51
36
35
12 308–530
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PARTS LIST
800–699 Hydra–Cleanr 2040 Pressure Washer
REF PART
REF PART
NO. NO.
NO. NO.
DESCRIPTION
QTY
DESCRIPTION
QTY
1
2
802–141 ENGINE, 8 hp, Briggs &
Stratton I/C
800–696 PUMP & GEAR REDUCER
ASSEMBLY (incl. 3, 13)
35
801–546 SCREW, Cap, hex hd.
3/8–16 x 1-1/4
100–023 WASHER, Flat 3/8
802–139 AXLE
154–636 WASHER, Flat 5/8
106–062 WHEEL & TIRE ASSEMBL
101–545 PIN, Cotter 1/8 x 1-1/2
104–811 HUB CAP
801–539 BUMPER
801–941 SCREW, Cap, hex hd.
5/16–18 x 1
1
5
10
1
36
39
40
41
42
43
44
45
1
1
3
4
804–249 GEAR REDUCER (see page 19)
802–127 SCREW, Cap, hex hd.
5/16–18 x 1-3/4
4
Y
2
4
20
1
2
6
7
100–527 WASHER, Flat 5/16
804–251 BRACKET, Support
801–367 BUMPER, Rubber
156–849 NIPPLE, Hex 3/8
2
1
8
2
11
12
13
3
6
12
4
802–315 UNLOADER, Preset 2000 psi
1
46
47
48
111–040 NUT, Lock 5/16–18
801–012 GROMMET, Rubber
804–245 PUMP ASSEMBL , 2000 psi
Y
(see page 22)
1
1
1
2
800–174 TIP ASSEMBLY, 00055
14
15
16
17
801–709 PLUG, Square hd. 1/4
802–257 GUARD, Muffler
(incl. 64, 65)
800–173 TIP ASSEMBL
(incl. 64, 66)
1
49
Y
, 15055
801–568 QUICK COUPLER, Male 3/8
802–627 NIPPLE, Hex 3/8 NPSM x
1/4 NPT
1
1
1
1
1
1
1
1
1
50
51
52
53
54
55
56
57
58
801–858 BRACKET, Front Leg
801–504 BUMPER, Rubber
179–885 LABEL, Chassis
801–137 KEY, Square 1/4 x 2
803–083 LABEL, Keep From Freezing
181–867 LABEL, Warning
804–272 LABEL, Model 2040
802–363 LABEL, Caution
804–274 LABEL, Graco Cleaning
Systems
801–009 QUICK COUPLER,
Female 1/4 (incl. 28)
801–134 WAND, 32”
801–674 SLEEVE, 28”
1
1
1
1
1
1
1
1
1
1
2
1
1
18
19
20
21
22
23
24
25
26
27
28
29
30
803–869 HOSE, Bypass
801–622 CROSS, 1/2
801–523 NIPPLE, 1/2 x 2
800–115 VALVE, Thermal Relief
804–073 ADAPTER, 1/2
801–111 NUT, Garden Hose
801–110 ADAPTER, Garden Hose
804–051 STRAINER/FILTER
402–278 PLUG, Plastic
156–082 O–RING, Quick Coupler 3/8
154–594 O–RING, Quick Coupler 1/4
802–579 HOSE, High Pressure, 3/8 x 50’
801–569 QUICK COUPLER,
Female 3/8 (incl. 27)
1
59
1
1
1
60
61
63
803–350 GUN, Spray (see Instruction
Manual 308–511)
2
1
4
1
1
5
31
800–392 GUN & WAND ASSEMBL
(incl. 11, 59, 60, 61, 63)
800–661 CHASSIS
803–925 HANDLE
Y
64
65
66
67
68
801–090 QUICK COUPLER, Male 1/4
801–730 TIP, Spray 00055
801–729 TIP, Spray 15055
101–566 NUT, Lock 3/8–16
800–377 HOSE ASSEMBLY w/Quick
Couplers (incl. 16, 29, 30)
1
1
1
32
33
34
800–175 FRONT LEG ASSEMBL
Y
(incl. 35, 36, 50, 51, 67)
1
1
308–530 13
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PARTS DRAWING
800–700 Hydra–Cleanr 2540 Pressure Washer
31
4
11
3
10
61
7
43
65
67
10
38
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
41
55
59
2
35
36
42
44
10
18
6
39
24
1
47
15
16
20
10
11
26
25
13
63
29
23
15
16
32
26
14
20
21
32
28
30
26
22
26
27
14 308–530
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PARTS LIST
800–700 Hydra–Cleanr 2540 Pressure Washer
REF PART
REF PART
NO. NO.
NO. NO.
DESCRIPTION
QTY
DESCRIPTION
QTY
1
2
800–392 GUN & WAND ASSEMBL
Y
34
35
801–012 GROMMET, Rubber
800–131 TIP ASSEMBL , 0005
4
(incl. 2, 5, 9, 15, 17, 47)
803–350 GUN, Spray (see Instruction
Manual 308–511)
1
Y
(incl. 39, 40)
800–137 TIP ASSEMBL
(incl. 39, 41)
1
1
1
1
1
1
36
Y
, 1505
3
4
5
6
7
181–867 LABEL, Warning, ventilation
802–363 LABEL, Caution
801–134 WAND, 32”
179–885 LABEL, Warning, chassis
803–901 ENGINE, 9 hp, Briggs &
Stratton OHV
802–127 SCREW, Cap, hex hd.
5/16–18 x 1-3/4
801–674 SLEEVE, 28”
100–527 WASHER, Flat 5/16
111–040 NUT, Lock 5/16–18
801–539 BUMPER
801–568 COUPLER, Male 3/8
802–579 HOSE, High Pressure, 3/8 x 50’
801–569 COUPLER, Female 3/8 (incl. 16)
156–082 O–RING, Female Coupler 3/8
801–009 COUPLER, Female 1/4 (incl. 19)
801–941 SCREW, Cap, hex hd.
5/16–18 x 1
1
1
1
4
1
1
37
38
39
40
41
42
402–278 PLUG, Plastic
803–083 LABEL, Keep From Freezing
801–090 COUPLER, Male 1/4
801–640 TIP, Spray 0005
1
801–667 TIP, Spray 1505
800–128 TIP ASSEMBL
8
Y
, 2505
4
1
20
12
1
2
1
2
2
1
(incl. 39, 55)
1
1
9
10
11
12
13
14
15
16
17
18
43
44
800–697 PUMP & GEAR REDUCER
ASSEMBLY (incl. 64, 65)
800–129 TIP ASSEMBL , 4005
Y
(incl. 39, 59)
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
801–907 WASHER, Flat
801–905 ADAPTER, 3/8 G x 3/8 NPT
156–849 NIPPLE, Hex 3/8
801–709 PLUG, Square
800–655 UNLOADER, 2500 psi
802–627 NIPPLE, Hex 3/8 x 1/4
803–869 HOSE, Bypass
801–523 NIPPLE, 1/2 x 2
801–622 CROSS, 1/2
800–115 VALVE, Thermal Relief
801–614 TIP, Spray 2505
801–111 NUT, Garden Hose
801–110 ADAPTER, Garden Hose
804–051 FILTER/STRAINER
801–615 TIP, Spray 4005
6
1
4
2
2
2
1
19
20
21
22
23
24
25
154–594 O–RING, Female Coupler 1/4
154–636 WASHER, Flat 5/8
101–545 PIN, Cotter 1/8 x 1-1/2
801–504 BUMPER, Rubber
803–740 WHEEL & TIRE ASSEMBL
803–741 AXLE
801–546 SCREW, Cap, hex hd.
3/8–16 x 1-1/4
Y
4
10
26
27
100–023 WASHER, Flat 3/8
801–819 SCREW, Cap, hex hd.
3/8–16 x 3
801–367 BUMPER, Rubber
804–251 BRACKET, Support
804–073 ADAPTER, 1/2
1
1
1
28
29
30
801–858 BRACKET, Front Leg
803–925 HANDLE
800–641 FRONT LEG ASSEMBL
(incl. 22, 26, 27, 28, 32)
804–273 LABEL, Graco Cleaning
Systems
800–377 HOSE ASSEMBL
Y, w/Couplers
(incl. 13, 14, 15)
1
Y
64
65
804–246 PUMP ASSEMBLY (see page 24) 1
804–249 GEAR REDUCER ASSEMBL
1
Y
31
(see page 19)
1
1
1
1
3
1
66
67
803–301 LABEL, Model 2540
801–137 KEY, Square 1/4 x 2
32
33
101–566 NUT, Lock 3/8–16
800–661 CHASSIS
308–530 15
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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
engine.
1. Follow steps 1 and 2 under Replacing the O–Ring.
2. Pry the oil seal out of the gear case. Be careful not to
damage the gear case.
2. Drain the gear reducer oil by placing a container
under it and removing the drain plug with a 22 mm
wrench. Replace the o–ring (16) if damaged.
3. Wipe the inner surface of the gear case clean, then
lightly coat it with grease. Place the oil seal into the
gear case. Use a socket, placed against the surface
of the seal, to push the seal into the case until its top
surface is past the ridge in the bore.
3. Remove the four screws and lockwashers with a
6 mm wrench and pull the gear case of f the gear
cover.
4. Follow steps 4 through 6 under Assembling the Gear
Reducer if this is all the service required.
4. Remove the old o–ring (5). Clean the gear cover and
case surface. Lightly coat the new o–ring with grease
and install it in the gear case.
Assembling the Gear Reducer
1. Make sure the gasket is properly placed on the gear
cover. Refer to step 4 under Replacing the Gasket.
Then, install the gear cover on the pump shaft.
5. Follow steps 4 through 6 under Assembling the Gear
Reducer if this is all the service required.
2. Align the holes in the gear cover with the holes in the
pump. Apply low strength Loctite r (blue) on the
screw threads and secure the cover with the four
screws and lockwashers. T ighten them oppositely
Replacing the Gasket (1)
1. Follow steps 1 through 3 under Replacing the
O–Ring.
and evenly
.
3. Align the gear’s slot with the key on the pump shaft
and slide the gear onto the shaft, up to the pump’ s
2. Using a 4 mm wrench, remove retaining
lockwasher, flat washer and pull the gear (4) off the
pump with a gear puller
bolt,
shoulder. Tighten the retaining bolt, lockwasher and
flat washer to lock the gear on the shaft.
.
4. Make sure the o–ring is in place. Refer to step 4
under Replacing the O–Ring. Install the gear case on
the cover, aligning the holes, and secure it with the
3. Remove the four screws and lockwashers from the
gear cover
.
four screws and lockwashers. T
oppositely and evenly
ighten them
.
4. Remove the gear cover and gasket (1) from the
pump. Clean the gear cover and pump surface.
Lightly coat both sides of the gasket with grease and
5. Grease the engine shaft. Align the gear
key on the engine shaft and slide the gear reducer
onto the shaft, up to the engine’s shoulder
’s slot with the
install it on the gear cover
.
.
5. Follow the instructions under Assembling the Gear
Reducer if this is all the service required.
6. Secure the gear reducer to the engine with the four
bolts and lockwashers.
16 308–530
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PARTS DRAWING
Gear Reducer (Model 1535)
1
23
22
8
20
21
7
6
5
4
3
16
21
2
9
19
14
22
23
13
20
23
17
12
24
10
15
11
PARTS LIST
Gear Reducer (Model 1535)
REF PART
REF PART
NO. NO.
NO. NO.
DESCRIPTION
QTY
DESCRIPTION
QTY
1
804–236 SCREW, Cap, hex hd./cross
recess
14
804–231 SCREW, Cap, hex hd./cross
recess
4
1
1
1
1
1
1
1
1
1
1
4
4
4
1
1
1
2
3
804–201 HOUSING, Gear Reducer
804–202 GEAR, Pinion, 3/4
804–082 BEARING
15
16
17
19
804–166 GEAR, Driven, spur
804–229 KEY, Square, 3/16 x 13/16
804–090 WASHER, Flat, retaining
804–230 SCREW, Cap, hex hd.
(8mm x 20mm)
4
5
804–225 RING, Retaining, internal
804–226 RING, Retaining, external
804–203 SEAL, Oil, pinion
804–165 KEY, Square, 3/16 x 1–3/4
804–167 GASKET, Flange
804–176 FLANGE, Housing
804–177 O–RING, Housing
804–075 WASHER, Flat, 6mm
804–077 WASHER, Lock, 6mm
6
1
1
1
4
9
7
20
21
22
23
24
804–188 PLUG, Oil Drain
802–189 O–RING, Drain Plug
804–134 WASHER, Flat, 8mm
802–175 WASHER, Lock, 8mm
804–168 SCREW, Cap, hex hd.
5/16–18 x 25 mm
8
9
10
11
12
13
4
308–530 17
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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
disassembled.
1. Follow steps 1 and 3 under Replacing the Gasket.
2. Remove the snap ring (6) from the gear case, using a
snap ring pliers. Pull the gear and bearing.
1. Remove the four bolts, lockwashers and washers.
Pull the pump and gear reducer assembly of f the
engine.
3. Push the seal from the inside to the outside of the
gear case by placing screwdriver against the seal
2. Drain the gear reducer oil by placing a container
under it and removing the drain plug with a 22 mm
wrench. Replace the o–ring (15) if damaged.
and lightly tapping it with hammer
.
4. Wipe the inner surface of the case clean, then lightly
coat it with grease. Place the oil seal into the gear
case. Use a socket, placed against the surface of the
seal, to push the seal into the case until its top
surface is past the ridge in the bore.
3. Remove the nine screws with a 6 mm wrench and
pull the gear case off the gear cover
.
4. Remove the old gasket (9). Clean the gear cover and
case surface. Lightly coat the new gasket with
grease and install it in on the gear case.
5. Place the gear and bearing back into the gear case
and install the snap ring (6).
6. Follow steps 4 through 7 under Assembling the Gear
Reducer if this is all the service required.
5. Follow steps 5 through 7 under Assembling the Gear
Reducer if this is all the service required.
Assembling the Gear Reducer
Replacing the Oil Seals (21)
1. Grease the o–ring and make sure it’s properly placed
1. Follow steps 1 through 3 under Replacing the
Gasket.
on the gear cover
.
2. Place the four oil seals and screws in the gear cover
.
Place the o–ring on the screw to hold it in the cover
.
2. Loosen the setscrew
,
using a 4 mm wrench, and pull
the gear (4) off the pump with a gear puller
.
3. Apply low strength Loctiter (blue) on the screw
threads, align the screws with the holes in the pump,
3. Using a 6 mm wrench, remove the four screws. Keep
them separate from the other nine screws removed
previously.
and tighten the screws oppositely and evenly
.
4. Grease the pump shaft. Align the gear s slot with the
’
key on the pump shaft and slide the gear onto the
shaft, up to the pump’s shoulder. Apply low strength
Loctiter on the setscrew threads and tighten the
setscrew to lock the gear on the shaft.
4. Remove the four oil seals (21) and replace them.
5. Follow steps 2 through 7 under Assembling the Gear
Reducer if this is all the service required.
5. Make sure the gasket is in place (refer to step 4 under
Replacing the Gasket). Install the gear cover on the
case, aligning the holes, and secure it with the nine
screws and lockwashers. Tighten the screws evenly
in a crisscross pattern.
Replacing the O–Ring (1)
1. Follow the instructions under Replacing the Gasket
and Replacing the Oil Seals to disassemble the gear
reducer.
6. Grease the engine shaft. Align the gear
key on the engine shaft and slide the gear reducer
onto the shaft, up to the engine’s shoulder
’s slot with the
2. Pull the gear cover of f the pump and replace the
o–ring (1).
.
3. Follow instructions under Assembling the Gear
Reducer if this is all the service required.
7. Secure the gear reducer to the engine with the four
bolts, lockwashers and washers.
18 308–530
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PARTS DRAWING
Gear Reducer (Models 2040 & 2540)
29
28
22
12
11
27
23
24
10
30
9
21
32
2
1
26
3
4
7
8
5
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.
NO. NO.
DESCRIPTION
QTY
1
DESCRIPTION
QTY
1
2
804–182 HOUSING, Gear Reducer
804–183 GEAR, Pinion, 1”
804–228 BEARING
804–227 RING, Retaining, internal
804–243 RING, Retaining, external
804–184 SEAL, Oil, pinion
802–189 O–RING, Drain Plug
804–089 PLUG, Oil Drain
804–171 GASKET, Oil Sight Gauge
804–150 GAUGE, Sight, oil level
804–170 GASKET, Oil Filler Cap
804–169 CAP, Oil Filler
802–206 WASHER, Shim (used on
Model 2540 only)
19
804–231 SCREW, Cap, socket head,
6mm x 20mm
1
4
1
1
1
1
5
3
1
20
21
22
23
24
25
804–078 O–RING, Housing
804–187 GEAR, Driven, helical
804–242 KEY, Square, (6mm x 27mm)
804–090 WASHER, Flat, retaining
802–175 WASHER, Lock, 8mm
804–240 SCREW, Cap, hex hd./cross
recess
4
1
5
1
6
1
7
1
8
1
9
1
4
1
4
4
10
11
12
13
1
26
27
28
29
804–172 KEY, Square, 1/4 x 55mm
804–076 WASHER, Flat, M10
804–178 WASHER, Lock, 10mm
804–107 SCREW, Cap, hex hd.,
3/8–16 x 35mm
1
1
1
1
1
1
4
4
4
14
15
16
17
18
804–185 SEAL, Oil, housing
804–215 GASKET, Flange
804–186 FLANGE, Housing
804–082 WASHER, Flat, 6mm
804–077 WASHER, Lock, 6mm
30
804–239 SCREW, Cap, hex hd./cross
recess
1
4
4
31
32
804–134 WASHER, Flat, 8mm
804–106 SPACER
308–530 19
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PARTS DRAWING
804–244 Pump Assembly, 1500 psi
12
18
3
7
3
38
4
38
20
9
1
6
5
13
8
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
20 308–530
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PARTS LIST
804–244 Pump Assembly, 1500 psi
REF PART
REF PART
NO. NO.
NO. NO.
DESCRIPTION
QTY
1
DESCRIPTION
QTY
1
2
802–312 KEY, Square
28
29
30
31
32
33
34
35
36
37
38
39
40
804–133 GASKET, Copper
801–038 RING, Backup
801–039 O–RING, Retainer
801–040 RETAINER, Plunger
802–206 WASHER, Flat
804–092 RETAINER, Seal
804–145 MANIFOLD, Inlet
3
3
3
3
3
3
1
804–180 CRANKCASE
1
3
804–077 WASHER, Lock
804–171 GASKET, Oil Sight Gauge
801–028 O–RING, Oil Fill Cap
801–027 CAP, Oil Fill
12
1
4
5
1
6
1
7
804–150 GAUGE, Sight
1
8
804–123 O–RING, Crankcase Cover
804–122 COVER, Crankcase
802–189 O–RING, Drain Plug
804–089 PLUG, Oil Drain
804–238 SCREW, Cap, hex hd./cross
recess (6mm x 20mm)
1
KIT C19
KIT C19
P
ACKING, Low Pressure
9
1
P
ACKING, High Pressure
10
11
12
1
804–088 PLUG, Hex Hd., 1/2
804–075 WASHER, Flat, 6mm
802–178 WASHER, Lock, 10mm
804–232 SCREW, Cap, socket head
(10mm x 35mm)
1
12
6
1
4
1
2
1
2
1
13
14
15
16
17
18
804–198 CRANKSHAFT
804–081 BEARING
802–193 SEAL, Oil, crankshaft
802–201 O–RING, Crankshaft Cover
804–197 COVER, Crankshaft
804–237 SCREW, Cap, hex hd./cross
recess (6mm x 16mm)
2
1
41
42
43
44
45
46
47
48
804–146 MANIFOLD, Discharge
KIT C1
KIT C1
KIT C1
KIT C1
KIT C1
RETAINER, Valve Spring
SPRING, Valve
VALVE
O–RING, Valve Seat
SEAT, Valve
8
3
3
3
3
3
3
3
3
19
20
21
22
23
24
25
26
27
804–214 WASHER, Lock, 18mm
804–241 ROD, Assembly Connecting
804–142 ROD, Plunger
801–148 SPACER, Discharge Valve
KIT C1 or O–RING, Spacer
KIT C19
3
3
804–083 PIN, Rod
49
50
804–147 ADAPTER, Inlet Valve
KIT C1 or O–RING, Adapter
KIT C19
802–185 WASHER, Flat
802–194 SEAL, Oil Plunger
804–143 WASHER, Slinger
804–144 PLUNGER, Ceramic
804–127 STUD, Retaining, SST
(6mm x 40mm)
51
52
KIT C1 or O–RING, Adapter
KIT C19
804–128 SCREW, Cap, socket head,
10mm x 55mm
3
4
Kit
Repair Kit Ref
No. Part No.
No. Description
Qty.
C1
804–102
42
RETAINER, Valve
Valve
Spring
SPRING, valve
VALVE
O–RING, Valve
Seat
SEAT, Valve
O–RING, Spacer
O–RING, Adapter
O–RING, Adapter
6
6
6
43
44
45
6
6
3
3
3
46
48
50
51
C19 804–101
35
P
ACKING, Low
Pressure
ACKING, High
Packing
3
36
P
Pressure
3
3
3
3
48
50
51
O–RING, Spacer
O–RING, Adapter
O–RING, Adapter
308–530 21
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PARTS DRAWING
804–245 Pump Assembly, 2000 psi
19
18
16
14
9
13
22
12
8
15
7
4
3
20
13
12
11
10
6
22
2
12
23
13
20
25
26
16
27
28
17
18
24
21
35
5
49
48
47
29
31
46
45
30
32
33
34
44
43
42
40
39
38
37
32
45
39
50
40
41
51
42
43
44
46
1
41
22 308–530
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PARTS LIST
800–245 Pump Assembly, 2000 psi
REF PART
REF PART
NO. NO.
NO. NO.
DESCRIPTION
QTY
2
1
1
1
1
1
1
1
1
1
1
12
12
DESCRIPTION
QTY
3
3
3
3
3
3
3
3
1
2
802–178 WASHER, Lock, 10mm
804–154 CRANKCASE
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
804–121 WASHER, Slinger
804–208 RETAINER, Packing, rear
804–157 WICK, Round
804–129 PLUNGER, Ceramic
804–133 GASKET, Copper
804–234 STUD, Retaining
801–038 RING, Backup
801–039 O–RING, Plunger
801–040 RETAINER, Plunger
804–214 WASHER, Split, SST
804–200 MANIFOLD
3
4
801–028 O–RING, Oil Fill Cap
801–027 CAP, Oil Fill
5
6
7
8
804–137 COVER, Crankshaft
804–123 O–RING, Crankcase Cover
804–155 COVER, Crankcase
804–171 GASKET, Oil Sight Gauge
804–150 GAUGE, Sight
9
3
3
1
10
11
12
13
14
802–189 O–RING, Drain Plug
804–089 PLUG, Drain
804–075 WASHER, Flat, 6mm
804–077 WASHER, Lock, 6mm
804–238 SCREW, Cap, hex hd./
cross recess (6mm x 20mm)
804–194 CRANKSHAFT
KIT C20
PACKING, High Pressure
KIT C20 O–RING, Packing Retainer
804–207 RETAINER, Packing
KIT C20
3
2
4
1
2
1
2
1
PACKING, Low Pressure
15
16
17
18
19
20
804–232 SCREW, Cap, socket head
804–080 BEARING
(10mm x 35mm)
804–109 SEAL, Oil, crankshaft
804–124 O–RING, Crankshaft Cover
804–193 COVER, Crankshaft
804–237 SCREW, Cap, hex hd./
cross recess (6mm x 16mm)
804–209 RETAINER, Packing, front
804–125 ROD, Assembly Connecting
804–156 ROD, Plunger
42
43
44
45
46
47
48
49
50
51
KIT C2
KIT C2
KIT C2
KIT C2
KIT C2
KIT C2
KIT C2
RING, Backup, valve seat
O–RING, Valve Seat
SEAT, Valve
VALVE
SPRING, Valve
RETAINER, Valve Spring
O–RING, Cap
8
3
3
3
3
3
21
22
23
24
25
804–153 CAP, Valve
101–754 PLUG, Hex socket 3/8
100–361 PLUG, Hex socket 1/2
6
1
1
804–126 PIN, Rod
801–031 SEAL, Oil, plunger
Kit
Repair Kit Ref
No. Part No.
No. Description
Qty.
C2
804–100
Valve
42
43
RING, Backup,
valve seat
O–RING, Valve
3
Seat
SEAT, Valve
VALVE
3
3
3
3
44
45
46
47
SPRING, Valve
RETAINER,
Valve Spring
3
3
48
37
O–RING, Cap
C20 804–096
PACKING, High
Packing
Pressure
O–RING, Packing
Retainer
PACKING, Low
Pressure
3
3
3
38
40
308–530 23
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PARTS DRAWING
804–246 Pump Assembly, 2500 psi
17
15
13
11
8
49
19
50
7
12
6
4
3
11
49
50
1
10
9
5
19
2
20
50
49
22
11
23
31
24
13
18
14
21
15
25
16
46
45
44
26
43
27
28
29
42
41
30
35
34
33
40
39
36
37
37
32
38
39
51
40
41
42
52
43
44
45
46
47
48
24 308–530
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PARTS LIST
804–246 Pump Assembly, 2500 psi
REF PART
NO. NO.
REF PART
NO. NO.
DESCRIPTION
QTY
DESCRIPTION
QTY
1
1
1
1
1
1
1
1
27
804–234 STUD, Retaining
1
2
804–093 KEY
804–154 CRANKCASE
(6mm x 64,5mm)
3
3
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
801–038 RING, Backup, plunger retainer
KIT C21 O–RING, Plunger Retainer
801–040 RETAINER, Plunger
804–214 WASHER, Keyhole
804–222 MANIFOLD
KIT C21 O–RING, Packing Retainer
804–217 RETAINER, Packing
KIT C21
804–118 ADAPTER, Male
KIT C21 ACKING, High Pressure
804–120 ADAPTER, Female
KIT C3
KIT C3
KIT C3
KIT C3
KIT C3
KIT C3
KIT C3
3
4
801–028 O–RING, Oil Fill Cap
804–181 CAP, Oil Fill
3
3
1
5
6
7
8
804–189 O–RING, Crankshaft Cover
804–155 COVER, Crankcase
804–171 GASKET, Oil Sight Gauge
804–150 GAUGE, Sight
3
3
3
9
10
11
802–189 O–RING, Drain Plug
804–089 PLUG, Drain
804–237 SCREW, Cap, hex hd./cross
recess (6mm x 16mm)
1
1
PACKING, Low Pressure
P
12
1
2
1
2
1
1
3
3
3
3
3
3
3
3
3
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
804–224 CRANKSHAFT
804–080 BEARING
O–RING, Valve Seat
SEAT, Valve
VALVE
804–109 SEAL, Oil, crankshaft
804–124 O–RING, Crankshaft Cover
804–137 COVER, Crankshaft
804–193 COVER, Crankshaft
804–213 RETAINER, Packing, front
804–219 ROD, Assembly Connecting
804–223 ROD, Plunger
804–126 PIN, Plunger Rod
801–031 SEAL, Oil, plunger
804–121 WASHER, Slinger
804–208 RETAINER, Packing, rear
804–216 PLUNGER, Ceramic
804–220 GASKET, Plunger
SPRING, Valve
RETAINER, Valve Spring
O–RING, Valve Cap
RING, Backup, valve cap
804–221 CAP, Valve
802–178 ASHER, Lock, 10mm
804–232 SCREW, Cap, socket head
6
2
W
(10mm x 35mm)
2
12
12
1
49
50
51
52
804–077 WASHER, Lock, 6mm
804–075 WASHER, Flat, 6mm
101–754 PLUG, Hex socket 3/8
100–361 PLUG, Hex socket 1/2
1
Kit
Repair Kit Ref
No. Part No.
No. Description
Qty.
C3
804–098
Valve
39
O–RING, Valve
Seat
3
3
3
3
40
41
42
43
SEAT, Valve
VALVE
SPRING, Valve
RETAINER, Valve
Spring
O–RING, Valve
Cap
3
3
3
44
45
RING, Backup,
valve cap
C21 804–097
29
33
35
37
O–RING, Plunger
Retainer
O–RING, Packing
Packing
3
3
3
6
Retainer
P
ACKING, Low
Pressure
ACKING, High
Pressure
P
308–530 25
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PUMP SERVICE (Model 1535)
6. Examine both o–rings on the discharge valve spacer
and replace if necessary . Lubricate o–rings and fit
Servicing the Valves
Disassembly:
into grooves on outside of spacer
.
1. Remove the four (4) socket head bolts and spring
washers from end of manifold.
7. Lubricate spacer and carefully press into valve
chambers with small diameter side down until spacer
snaps tightly into position.
2. Support the discharge manifold from the underside
and tap with a soft mallet to separate from the inlet
manifold.
Reassembly: (INLET)
1. Place valve spring retainers into the shallow valve
chambers. They will rest on the machined ridge in
3. Carefully place discharge manifold on working
surface with valve chambers up.
each chamber
.
4. From the three (3) smaller diameter and shallow inlet
chambers remove the inlet valve adapters with inner
and outer o–rings. These adapters are not held
securely in position and may fall out as the discharge
manifold is removed.
2. Insert valve springs into retainers over plastic center
guide.
3. Inspect the valves for wear , ridges or pitting and
replace if necessary. Insert valves over the springs
with recessed (dish) side down.
5. Next remove the valve seats, valves, springs and
retainers from the inlet chambers.
4. Examine valve seat o–rings for wear and replace.
Lubricate and place o–rings on lip of retainers.
Carefully square o–rings in valve chamber to avoid
cutting o–ring when valve seat is installed.
6. From the three (3) larger diameter and deeper
discharge chambers remove the discharge valve
spacers with o–rings. These brass spacers generally
remain with the discharge manifold as it is removed.
A reverse pliers fitted into the center bore and
hooked onto the side ports of the spacer will assist
the removal.
5. Examine valve seats for pitting, scale or ridges and
replace if necessary. Install valve seat with grooved
side down, so o–ring fits snugly into groove on seat.
6. Examine the adapter inner o–rings and replace if
worn. Lubricate and install o–rings into inlet valve
adapters.
7. Next remove the valve seats, valves, springs and
retainers from the discharge chambers.
NOTE: The inlet and discharge use the same
retainers, springs, valve seats and valves. The
o–rings and valve spacers/adapters are
different. Keep parts in order as they are
removed.
7. Examine the adapter outer o–rings and replace if
worn. Lubricate and install o–rings onto inlet valve
adapters.
8. Lubricate inlet valve adapter and press into chamber
.
Carefully square inlet valve adapter into chamber to
avoid cutting or extruding o–ring.
Reassembly: (DISCHARGE)
1. With crankcase side of discharge manifold facing up,
insert the springs into the retainers over the plastic
center guide.
9. Replace discharge manifold over plunger ends
matching discharge valve spacers with inlet
chambers and press into position. T ap with a soft
mallet until completely seated in chambers.
2. Place valve spring retainers in deeper valve
chambers. They will rest on the machined ridge in
10. Replace all four (4) washers and socket head bolts.
Hand tighten each. Then torque per chart.
each chamber
.
3. Examine the valves for wear or pitting and replace if
necessary. Install valves over the springs with
recessed (dish) side down.
Servicing the Seals
Disassembly:
4. Examine valve seat o–rings for wear and replace.
Lubricate and place o–rings on lip of retainers.
Carefully square o–rings in valve chamber to avoid
cutting o–ring when valve seat is installed.
1. With discharge manifold removed from the pump
remove the two (2) socket head bolts and spring
washers from end of inlet manifold.
2. Rotate crankshaft to loosen inlet manifold.
5. Examine valve seats for pitting, scale or ridges and
replace if necessary. Install valve seat with grooved
side down, so o–ring fits snugly into groove on seat.
3. Support inlet manifold from underside and tap with a
soft mallet to separate manifold from crankcase.
26 308–530
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4. With crankcase side of manifold down remove
hi–pressure seals using a reverse pliers.
NOTE: Ceramic plunger can only be installed one
direction (front to back). Do not force onto rod.
5. Invert manifold so crankcase side is up and with
reverse pliers remove low pressure seals.
3. Examine o–ring and back–up ring on plunger
retainer and replace if worn or cut. Lubricate o–ring
for ease of installation and to avoid damage to
o–rings.
Reassembly:
1. Examine low pressure seal for seal wear or spring
failure and replace if necessary With crankcase side
.
NOTE: First install NEW copper gaskets on plunger
of inlet manifold up, lubricate seal and press into
valve chamber with garter spring down. Carefully
square seal into position.
retainers, then back–up rings and o–rings.
4. Install short threaded end of stud into plunger
retainer.
2. Examine hi–pressure seal for wear and replace if
necessary. Invert inlet manifold with crankcase side
down, lubricate seal and press into chamber with
v–side up. Carefully square into position.
5. Thread plunger retainer and stud assembly into
plunger rod and torque per chart. (Long threaded end
of stud into plunger rod.)
3. Rotate shaft so the two (2) outside plungers are
extended and lined–up.
NOTE: Exercise caution not to over torque the plunger
retainer.
4. Lubricate plungers and discharge valve adapter
o–rings.
6. Rotate shaft so the two (2) outside plungers are
extended and lined–up. Then lubricate plungers.
5. Carefully line–up and join the inlet and discharge
manifolds by pressing the protruding discharge valve
adapters into the inlet manifold seal chambers.
7. Replace all four (4) discharge manifold socket head
bolts and washers and hand tighten.
6. Replace all four (4) discharge manifold socket head
bolts and washers and hand tighten.
8. Then carefully slip manifold assembly onto plungers
and tap with soft mallet until flush with crankcase.
7. Then carefully slip manifold assembly onto plungers
and tap with soft mallet until flush with crankcase.
9. Replace the two (2) inlet manifold socket head bolts
and washers and hand tighten. Then torque per
chart.
8. Replace the two (2) inlet manifold socket head bolts
and washers and hand tighten. Then torque per
chart.
10. Then torque the four (4) discharge manifold socket
head bolts per chart.
9. Then torque the four (4) discharge manifold socket
head bolts per chart.
Servicing Crankcase Section
1. While inlet manifold, plungers and seal retainers are
Servicing the Plungers
removed, examine crankcase seals for wear
.
Disassembly:
2. Check oil level and for evidence of water in oil.
1. Remove discharge and inlet manifold as described.
2. Using a wrench loosen plunger retainers
approximately three (3) to four (4) turns.
3. Rotate crankshaft by hand to feel for smooth bearing
movement.
3. Grasp ceramic plunger and push towards crankcase
until plunger retainers with stud pop out.
4. Examine crankshaft oil seal externally for drying,
cracking or leaking.
4. Remove plunger retainer and copper gasket.
5. Remove ceramic plunger from plunger rod.
6. Remove barrier slinger from plunger rod.
Reassembly:
5. Consult factory or your local distributor if crankcase
service is required.
Torque Chart
Pump Part
Thread Tool Size Torque
1 mm hex 80 in. lbs.
8 mm allen 132 i . lbs.
Plunger Retainer M5
1
1. Replace barrier slinger if necessary and
onto plunger rod.
position
Inlet Manifold
Bolts
M10
M10
n
Discharge
8 mm allen 180 in. lbs.
2. Carefully examine ceramic plunger for scoring or
cracks and replace if worn. Slip onto rod.
Manifold Bolts
308–530 27
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PUMP SERVICE (Models 2040 & 2540)
Reassembly:
Servicing the Valves
1. Carefully examine each ceramic plunger for scoring
or cracks, replace if worn and slip onto plunger rod.
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.
Note:
Ceramic plunger can only be installed one
direction (front to back). Do not force onto rod.
2. Examine plunger retainer and stud and replace if
worn.
3. Grasp valve retainer by tab at the top with pliers and
remove from valve chamber . Valve parts usually
separate during removal.
Note:
Thread stud into plunger retainer.
Note:
A
special tool will be needed to remove the seat
3. Examine o–ring, back–up ring and gasket on plunger
retainer and replace if worn or cut. Lubricate o–ring
from the manifold. A reverse pliers or a
standard vise grip and a 1/4” x 3” bolt to fit I.D. of
seat inserted under the edge of the seat, will pry
for ease of installation and to avoid
damaging
o–rings.
the valve seat out easily
.
Note:
First install gasket, then back–up ring and
o–ring.
4. Examine all valve parts for wear and replace with
preassembled valve assembly in service kit
containing retainer, spring, valve, valve seat, o–ring,
and back–up ring.
4. Thread plunger retainer and stud assembly into
plunger rod. Exercise caution not to over torque.
5. Grasp new valve assembly by tab at top with pliers,
immerse in oil and push into valve chamber . Be
5. Saturate new oil wick by soaking in oil, place in seal
retainer and slip retainer over ceramic plunger
.
certain valve assembly is square in valve chamber
.
6. Replace oil pan.
6. Apply Loctite 242 to valve plug, thread into manifold
port and torque per chart.
7. Turn shaft by hand to line up plungers so end
plungers are parallel.
Note:
Corrosion Resistant models require the coil
spring installed in the Valve Plug.
8. Carefully slip manifold onto plungers, keeping
manifold level, and tap with mallet to bring manifold
flush with crankcase.
Servicing the Pumping Section
Disassembly:
9. Replace washers and nuts or bolts and torque per
chart.
1. Remove the four (4) hex nuts or two (2) bolts from the
manifold (varies with model).
Servicing the Seals and V–Packings
Disassembly:
2. Rotate crankshaft by hand to start separation of
manifold from crankcase. Support the underside of
the manifold and tap lightly with a mallet to remove
1. Remove the manifold as described.
the manifold assembly
.
2. With crankcase side of manifold facing up, unscrew
the seal case from the manifold using a special key
wrench.
CAUTION
Keep manifold properly aligned with ceramic
plungers when removing to avoid damage to
either plungers or seals.
3. Remove o–ring from seal case.
4. Remove snap ring and low pressure seal from the
seal case. Seals are generally removed easily
without any tools.
3. Remove oil pan and slide out seal retainer with wicks.
4. Using a wrench, loosen the plunger retainer. Grasp
ceramic plunger and push toward crankcase until
plunger retainer pops out.
5. High Pressure Seal Models: The high pressure
seal is generally easily removed from the manifold
without any tools. If extremely worn a reverse pliers
may be used.
5. Remove plunger retainer with copper gasket,
back–up Ring and o–ring.
6. V–Packing Models: The female adapter , two
v–packings and male adapter are easily removed
from manifold without tools. If extremely worn a
reverse pliers may be used.
6. Remove plunger from plunger rod.
28 308–530
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Reassembly:
Servicing Crankcase Section
V–Packing Models:
1. While manifold, plungers and seal retainers are
1. Lubricate high pressure packing area in manifold.
removed, examine crankcase seals for wear
.
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.
2. Check oil level and for evidence of water in oil.
4. Next install female adapter with grooved side down.
3. Rotate crankshaft by hand to feel for smooth bearing
movement.
5. Examine seal case o–ring and replace if worn.
Lubricate new o–ring before installing.
6. Thread seal case into manifold and tighten with key
wrench.
4. Examine crankshaft oil seal externally for drying,
cracking or leaking.
High Pressure Seal Models:
1. Lubricate seal area in manifold.
2. Carefully square seal into position by hand with the
metal grooved side up.
5. Consult factory or your local distributor if crankcase
service is evidenced.
3. Examine seal case o–ring and replace if worn.
Lubricate new o–ring before installing.
4. Next secure high pressure seal into position by
threading seal case into manifold. Tighten seal case
with key wrench.
Torque Chart
Pump Part Thread
Tool Size Torque
Low Pressure Seal–All Models:
Plunger
Retainer
M5
11 mm hex 80 in. lbs.
1. Examine seal for wear or broken spring and lace if
necessary.
Manifold
M8 x 1.25 13 mm hex 125 in. lbs.
M10 x 1.25 17 mm hex 217 in. lbs.
2. Install low pressure seal in seal case with garter
spring down.
3. Reinstall snap ring. Be certain snap ring is a tight fit.
Replace if it can be easily turned.
M10
—
17 mm hex 217 in. lbs.
Valve
Covers
24 mm
27 mm
75 ft. lbs.
75 ft. lbs.
4. Replace manifold on pump as described and torque
per chart.
308–530 29
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ACCESSORIES
(Must be purchased separately)
DOWNSTREAM CHEMICAL INJECTOR KIT
800–117 & 800–649
For injecting harsh cleaning chemicals downstream from
the pump. 800–649 is stainless steel construction.
ANTI–FREEZE FLUSH KIT 802–327
For flushing system with 50% anti–freeze solution prior to
transporting or storing pressure washer in below freezing
temperatures.
UPSTREAM CHEMICAL INJECTOR KIT
800–257
For injecting mild cleaning chemicals upstream into the
pump.
INLET PRESSURE REGULATOR 800–258
Regulates inlet water pressure to 60 psi (4 bar)
maximum.
WATER SANDBLASTING KIT 800–120
For abrasive cleaning of stubborn dirt and paint.
Requires a spray tip which is not included in kit (2040
uses 801–729, 2540 uses 801–667).
BACKFLOW PREVENTOR 801–133
Prevent back–up of contaminated water into fresh
supply. Install upstream of pump.
30 308–530
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TECHNICAL DATA
Model 800–698
5 hp Briggs & Stratton I/C
3 quarts (2.8 liter)
Model 800–699
8 hp Briggs & Stratton I/C
6 quarts (5.7 liter)
Model 800–700
Engine (air–cooled, 4 cycle)
9
hp Briggs & Stratton OHV
Gasoline
ater Pump Maximum Working
Pressure
ater Pump Maximum Flow
Tank Capacity
5 quarts (4.8 liter)
2500 psi (172 bar)
W
1500 psi (103 bar)
2000 psi (138 bar)
W
3.5 gpm (13 lpm)
3/4” garden hose (f)
105 lb (48 kg)
4 gpm (15 lpm)
3/4” garden hose (f)
152 lb (68 kg)
4 gpm (15 lpm)
3/4” garden hose (f)
158 lb (70 kg)
Inlet Hose Connection
Weight
Dimensions
Length
37” (940 mm)
19” (483 mm)
20” (508 mm)
36” (914 mm)
21” (533 mm)
22.5” (572 mm)
36” (914 mm)
21” (533 mm)
23” (584 mm)
Width
Height
Maximum Inlet Water
Temperature
160_
F
(70_
C)
160_
F
(70_
C)
160_
F
(70_
C)
Wetted Parts
High Pressure Hose
Bypass Hose
Acrylonitrile and Buna–N cover and tube
Synthetic yarn and EPDM
Pressure Washer
(including fittings)
Anodized aluminum, Aluminum or bronze alloys, Brass Copper, Nylon–
PTFE
composite, Ceramic, Buna–N, Cotton phenolic, 303, 304, and 316 Stainless steel,
r
Polymide–12 thermoplastic,
chromate plate
r, Carbon steel, Zinc with or without yellow
PTFE
is a registered trademark of the DuPont Company
.
PTFE
308–530 31
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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, operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for, any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence,
accident, tampering, or substitution of non–Graco component parts. Nor shall Graco be liable for malfunction,
damage or wear caused by the incompatibility with Graco equipment of structures, accessories, equipment or
materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance
of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective for examination
by Graco to verify the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge
any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If
inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a
reasonable charge, which charges may include the costs of parts, labor and transportation.
DISCLAIMERS AND LIMITATIONS
THE TERMS OF THIS W ARRANTY CONSTITUTE THE PURCHASER’S SOLE AND EXCLUSIVE
REMEDY AND ARE IN LIEU OF ANY OTHER W ARRANTIES (EXPRESS OR IMPLIED), INCLUDING
WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE,
AND OF ANY NON–CONTRACTUAL LIABILITIES, INCLUDING PRODUCT LIABILITIES, BASED ON
NEGLIGENCE OR STRICT LIABILITY . EVER Y FORM OF LIABILITY FOR DIRECT , SPECIAL OR
CONSEQUENTIAL DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND DENIED. IN NO CASE SHALL
GRACO’S LIABILITY EXCEED THE AMOUNT OF THE PURCHASE PRICE. ANY ACTION FOR BREACH
OF
WARRANTY MUST BE BROUGHT WITHIN THREE (3) YEARS OF THE DATE OF SALE.
EQUIPMENT NOT COVERED BY GRACO WARRANTY
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED W
ARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A P
ARTICULAR PURPOSE, WITH RESPECT T
O
ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY
GRACO. These items sold, but not manufactured by Graco (such as electric motor, switches, hose, etc.) are
subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance
in making any claim for breach of these warranties.
IMPORTANT PHONE NUMBERS
TO PLACE AN ORDER , contact your Graco distributor , or call this number to identify the
distributor closest to you: 1–800–328–0211 Toll Free
FOR TECHNICAL ASSIST ANCE, service repair information or assistance regarding the
application of Graco equipment: 1–800–543–0339 Toll Free
Factory Branches: Atlanta, Chicago, Dallas, Detroit, Los Angeles, West Caldwell (N.J.)
Subsidiary and Affiliate Companies: Canada; England; Switzerland; France; Germany; Hong Kong; Japan; Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
PRINTED IN U.S.A. 308–530 1/91
32 308–530
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