Graco 2525DD Use and care manual

333031F
EN
Operation, Repair, Parts
Pressure Washers
For high pressure water cleaning. For professional use only.
See page 2 for model information and maximum working pressure.
Important Safety Instructions
Read all warnings and instructions in this
manual and in the gas engine manual.
Save these instructions.
ti22506a
ti22505a
Direct-Drive Models
Belt-Drive Models

Models
2333031F
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Symbols and Meanings . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Personal Protective Equipment . . . . . . . . . . . . . . 7
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 8
Nozzle Review . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Nozzle Connection . . . . . . . . . . . . . . . . . . . . . . 10
Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Priming the Pump . . . . . . . . . . . . . . . . . . . . . . . 12
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cleaning with Detergents . . . . . . . . . . . . . . . . . 14
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . 15
Belt Tension Adjustment . . . . . . . . . . . . . . . . . . 15
Winterizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Parts (Belt-Drive Models) . . . . . . . . . . . . . . . . . . . 19
Sprayer Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Sprayer Parts List . . . . . . . . . . . . . . . . . . . . . . . 20
Pump 127382 . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pump 127384 . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Parts (Direct-Drive Models) . . . . . . . . . . . . . . . . . . 23
Sprayer Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Sprayer Parts List . . . . . . . . . . . . . . . . . . . . . . . 24
Pump 127383 . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pump 127417 . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Pump 127385 . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Pump 127420 . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Pump 127419 . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Pump 127418 . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 36
Models
Part No. Model Operating Pressure
PSI MPa Bar
24U618 2525DD 2500 17.2 172
24U626
24U619 2532DD 3200 22 220
24U985
24U620 3027DD 2700 18.6 186
24U986
24U987 3032DD 3200 22 220
24U621
24U988 4040DD 4000 27.6 276
24U622
24U989 4040DDC 4000 27.6 276
24U623
24U990 4040BD 4000 27.6 276
24U624
24U991 4040BDC 4000 27.6 276
24U625

Models
333031F 3
Safety Symbols and Meanings
The following safety symbols appear on the equipment and throughout this manual. It is important that you read the
table below and understand what each symbol means.
Symbol Meaning
Burn Hazard
Ejected Parts Hazard
Electric Shock Hazard
Fall Hazard
Fire and Explosion Hazard
Entanglement Hazard
Recoil Hazard
Skin Injection Hazard
Splash Hazard
Toxic Fluid or Carbon Monoxide Hazard
Do Not Stop Leaks or Deflect Leaks
Do Not Use Flammable Liquids
Do Not Spray People or Animals
Eliminate Ignition Sources
Hold Firmly With Both Hands
Perform Pressure Relief Procedure
Read Manual Before Using Equipment
Wear Personal Protective Equipment
Equipment Misuse Hazard
Symbol Meaning

Warnings
4333031F
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
WARNINGWARNINGWARNING
WARNING
CARBON MONOXIDE HAZARD
Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon
monoxide can cause death.
• Do not operate in an enclosed area.
RECOIL HAZARD
Gun may recoil when triggered. If you are not standing securely, you could fall and be seriously injured.
•Hold onto gun/wand firmly with both hands to avoid kickbacks.
FALL HAZARD
Use of this equipment can create puddles and slippery surfaces. High pressure spray could cause you to fall
if you are too close to the cleaning surface.
•Keep spray nozzle between 8 to 24 inches (20 to 60 cm) away from cleaning surface.
•Always operate equipment on a stable surface.
•Cleaning area should have adequate slopes and drainage to reduce possibility of falls due to slippery
surfaces.
•Be extremely careful if you must operate equipment from ladder, scaffolding, or any other relatively
unstable location.
FIRE AND EXPLOSION HAZARD
Flammable vapors in the work area and can ignite or explode. To help prevent fire and explosion:
•Do not spray flammable liquids.
•Operate pressure washers outdoors only.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static arc).
•When transporting or repairing equipment, transport or repair with the fuel tank empty or with fuel shutoff
valve turned off.
•Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable and
can ignite or explode if spilled on hot surface.
•Keep work area free of debris, including solvent, rags and gasoline.
ELECTRIC SHOCK HAZARD
Spray contact with electrical wiring can result in serious injury or death.
•Keep water spray away from electric wiring.

Warnings
333031F 5
SKIN INJECTION HAZARD
High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event that
injection occurs, get immediate surgical treatment.
•Keep clear of nozzle. Do not spray any person, yourself or any animal.
•Keep hands and other body parts away from the discharge. Do not try to stop leaks with any part of the
body.
•This product is to be used only by trained operators.
•Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs while
spraying, follow the Pressure Relief Procedure for turning off the unit and relieving the pressure before
removing the nozzle tip to clean.
•Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn off
the unit and follow the Pressure Relief Procedure for turning off the unit.
•Check hoses and parts for signs of damage. Replace any damaged hoses or parts.
•Use Graco replacement parts or accessories that are approved for the rated pressure of the pressure
washer.
•Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.
•Verify that all connections are secure before operating the unit.
•Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.
BURN HAZARD
Running engines produce heat and hot exhaust gases. Temperature of muffler and nearby areas can reach
or exceed 150° F (65° C). Fire or severe burns can occur.
•Do not touch hot surfaces.
•Stay clear of exhaust gases.
•Never move equipment while operating.
•Allow equipment to cool before touching.
ENTANGLEMENT HAZARD
Rotating parts can cause serious injury.
•Keep clear of moving parts.
•Do not operate equipment with protective guards or covers removed.
TOXIC FLUID HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
•Do not use pressure washer to dispense hazardous detergents or acid-type cleaners.
•Do not alter chemical injector feature that is listed in the manual.
•Read MSDSs to know the specific hazards of the fluids you are using.
•Route exhaust away from work area.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye
injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not
limited to:
•Protective eyewear, and hearing protection.
•Respirators, protective clothing, and gloves as recommended by the detergent manufacturer.
WARNINGWARNINGWARNING
WARNING

Warnings
6333031F
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Always wear appropriate gloves, eye protection, and a respirator or mask when spraying.
• Do not operate or spray near children. Keep children away from equipment at all times.
• Do not overreach or stand on an unstable support. Keep effective footing and balance at all times.
• Stay alert and watch what you are doing.
• Do not leave the unit energized or under pressure while unattended. When the unit is not in use, turn
off the unit and follow the Pressure Relief Procedure for turning off the unit.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Keep operating area clear of all persons.
• Do not kink or over-bend the hose.
• Do not expose the hose to temperatures or to pressures in excess of those specified by manufac-
turer.
• Do not use the hose as a strength member to pull or lift the equipment.
• Follow the maintenance instructions specified in the manual.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
CALIFORNIA PROPOSITION 65
The engine exhaust from this product contains a chemical known to the State of California to cause
cancer, birth defects or other reproductive harm.
This product contains a chemical known to the State of California to cause cancer, birth defects or other
reproductive harm. Wash hands after handling.
The following instructions are required by California state law, section 4442 of the California Public
Resource Code. Other states may have similar laws. Federal laws apply on federal land.
•A spark arrestor must be added to the muffler of this engine if it is to be used on any forest-covered,
brush-covered, or grass-covered unimproved land.
•See your engine or equipment dealer for spark arrestor muffler options.
WARNINGWARNINGWARNING
WARNING

Installation
333031F 7
Installation
Personal Protective Equipment
Setup
This unit should only be placed on a level surface while
operating to ensure proper lubrication for the engine and
water pump.
Be certain to block wheels to prevent unit from moving
while operating.
Before initial use, make sure the oil cap/dipstick is
inserted into the pump. Because of varying shipping
requirements, the pump may need to be shipped with an
oil travel plug instead of the dipstick in the pump. If your
pump has been shipped with an oil travel plug, you will
need to remove it and replace the plug with the oil dip-
stick provided with the unit.
Once properly installed, check the oil sight glass on the
pump crankcase. Make sure the oil level is in the center
of the sight glass before each use. If the level appears
to be low, add pump oil and fill only to the center of the
oil sight glass. Refer to the Parts List for the correct
pump oil. Do not overfill!
Engine Fuel Tank
A minimum of 86 octane fuel is recommended for use
with this unit. Do not mix oil with gasoline.
Purchase fuel in quantities that may be used within 30
days. Use of clean, fresh lead-free gasoline is recom-
mended. Leaded gasoline may be used if lead-free is
unavailable. Do not use gasoline containing methanol or
alcohol.
Check the engine oil level before starting the engine
(see engine manual).
Fill the fuel tank according to engine manual.
Occasional carburetor and choke adjustments will be
necessary for the engine. Refer to the engine manual
supplied with this unit for proper adjustment procedures.
Review the engine manual accompanying this pressure
washer for correct engine start-up and maintenance pro-
cedures.
INJECTION AND INHALATION HAZARD
Proper attire is essential to your safety. It is advised
to utilize whatever means necessary to protect eyes,
ears and skin. Additional safety attire (such as
respiratory mask) may be required when using
detergent cleaning agents with this washer.
FIRE AND EXPLOSION HAZARD
Do not use unit in an area:
• with insufficient ventilation
• where there is evidence of oil or gas leaks
• where flammable gas vapors may be present
BURST HAZARD
Do not allow unit to be exposed to rain, snow or freez-
ing temperatures. If any part of the unit becomes fro-
zen, excessive pressure may build up which could
cause it to burst and result in possible serious injury.

Pressure Relief Procedure
8333031F
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Engage trigger lock.
2. Turn unit off.
3. Shut off water supply. Disconnect from water.
4. Disengage trigger lock.
5. Trigger gun to relieve pressure.
6. Engage trigger lock.
7. If you suspect the spray tip or hose is clogged or
that pressure has not been fully relieved after follow-
ing the steps above, VERY SLOWLY loosen hose
end coupling to relieve pressure gradually, then
loosen completely. Clear hose or tip obstruction.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury
from pressurized fluid, such as skin injection,
splashing fluid and moving parts, follow the Pressure
Relief Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.

Pressure Relief Procedure
333031F 9
Nozzle Review
Various nozzles may be quick-connected into the end of
the wand to change the spray pattern or use the deter-
gent feature.
To determine spray fan, refer to the number stamped on
the nozzle. The first two digits indicate the spray fan
degrees, i.e.; 0=0°, 25=25°, 40=40°, 65 = detergent/low
pressure.
0° nozzle (RED): This is a blasting nozzle, which deliv-
ers a very concentrated stream of water. Be cautious
when using the straight narrow stream. It is not recom-
mended for use on painted or wood surfaces, or items
attached with adhesive backings. Uses: Removing
weeds from sidewalk cracks, stubborn stains from con-
crete, masonry, aluminum and steal, caked mud from
equipment, and cleaning lawn mower undersides.
15° nozzle (YELLOW): This is a chiseling nozzle. The
spray should be directed at a 45° angle to the surface
and used like a scraper to remove paint, grease and dirt.
Uses: Surface preparation (removing mildew stains and
paint chips).
25° nozzle (GREEN): This is a flushing nozzle. This
pattern is best suited for flushing dirt, mud, and grime.
Uses: Wet sweeping leaves from walks, curbs and
driveways, cleaning stable floors, washing swimming
pool bottoms, and de-greasing engines.
40° nozzle (WHITE): This is a wash nozzle. This wide
spray pattern disperses the water pressure over a larger
area and is recommended for moderate washing. Uses:
Washing down aluminum siding, cleaning windows,
washing vehicles, spraying sidewalks, driveways and
patios. NOTE: Not available for Model 2525.
65° nozzle (BLACK): This is a low pressure detergent
application nozzle. This broad spray pattern distributes
solution over vast areas under low pressure. Uses:
Detergent application, misting or rinsing.
EJECTED PARTS HAZARD
When using Quick Connects, be certain the
connection is securely locked. If connections are not
securely locked, the high pressure water may eject
the nozzle from the wand, causing severe injury or
serious damage.
Always point wand always from you when changing
nozzle. Perform Pressure Relief Procedure
(page 8) before changing nozzle.

Pressure Relief Procedure
10 333031F
Nozzle Connection
1. Perform Pressure Relief Procedure, page 8.
2. Engage trigger lock.
3. The nozzle assembly should be disconnected from
the gun/wand assembly at this time by retracting the
locking ring on the quick-connect fitting to remove
the nozzle.
Water Supply
Select a water supply hose which is a quality grade of
garden hose measure at least 3/4 in. (19.05 mm) ID and
no longer than 50 feet (15.24 m).
Check the water inlet strainer to make sure it is clean
and free of any obstructions. Periodic cleaning of the
water strainer will help prevent pump problems.
1. Unscrew garden hose inlet connection from front of
filter assembly.
2. Remove clear plastic cover and clean filter screen.
Connect the hoses
1. Connect one end of water supply hose to water inlet
of unit.
2. Connect other end of hose to pressurized water
supply. When connecting water inlet to water supply
mains, local regulations of your water company
must be observed. In some areas, the unit must not
be connected directly to public drinking water sup-
ply. This prevents feedback of the detergents into
the water supply. Direct connection is permitted if a
back flow preventer is installed.
3. Quick-connect high pressure discharge hose to
water outlet of unit.
4. Connect other end of discharge hose to gun assem-
bly.
Follow incoming water requirements listed below:
1. Water pressure must be a minimum of 25 psi (0.17
MPa,1.72 bar) and a maximum of 125 psi (0.86
MPa, 8.6 bar). NOTE: A typical outdoor faucet will
generally supply this psi if fully turned on.
2. Incoming GPM must be at least one gallon more
than the outgoing GPM stated on pressure washer
nameplate. NOTE: You can check GPM by timing
how long it takes to fill a 5 gallon container.
NOTICE
As a strainer becomes obstructed, it restricts proper
flow of water to the pump. This can result in cavitation
which will cause premature failure of pump packings.
NOTICE
Incoming water temperature must not exceed 140° F
(60° C). Excessive pump damage may result if the
water temperature exceeds this acceptable level.
Never allow the unit to operate without the incoming
water line attached and the water supply fully turned
on. Damage to the equipment could occur.