Graco HYDRA-CLEAN 1535 Operation manual

308736
Rev. G
First choice when
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INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
HYDRA-CLEANt1535, 2030, 2540, 3040
Pressure Washers
Hydra-clean 1535 (Siphon Feed)
804560 Series B
1500 psi (10.2 MPa, 102 bar) Operating Pressure
1900 psi (13.1 MPa, 131 bar) Maximum Working Pressure
Hydra-clean 2030 (Siphon Feed)
804561 Series B
2000 psi (13.8 MPa, 138 bar) Operating Pressure
2400 psi (16.5 MPa, 165 bar) Maximum Working Pressure
Hydra-clean 2540 (Siphon Feed)
804562, Series B
2500 psi (17.2 MPa, 172 bar) Operating Pressure
2900 psi (20.0 MPa, 200 bar) Maximum Working Pressure
Hydra-clean 3040 (Siphon Feed)
804563, Series B
3000 psi (20.7 MPa, 207 bar) Operating Pressure
3400 psi (23.4 MPa, 234 bar) Maximum Working Pressure
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
http://www.graco.com
ECOPYRIGHT 1997 GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
7010B
Model 804562

2308736
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification and Function 4. . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
804573 & 804578 Pump Service 13. . . . . . . . . . . . . . . .
804565 & 804566 Pump Service 15. . . . . . . . . . . . . . . .
Accessories 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List & Drawing
Hydra-clean 1535, 2030 Pressure Washer 18. . . . . . .
Hydra-clean 2040, 3040 Pressure Washer 20. . . . . . .
Pump Assembly Models 804573 and 804578 22. . . . .
Pump Assembly Model 804565 & 804566 24. . . . . . . .
Warranty 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 26. . . . . . . . . . . . . . . . . . . . . . . . .
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow instruc-
tions.
WARNING
INJECTION HAZARD
Spray from gun, leaks or ruptured components can inject fluid into your body and cause serious injury.
Fluid splashed in eyes or on skin can also cause serious injury.
DFluid injected into skin may look like just a cut, but it is a serious injury. Get emergency medical
attention.
DDo not point gun at anyone or at any part of body.
DDo not stop or deflect leaks with hand, body, glove or rag.
DDo not put hand or fingers over spray tip.
DTighten fluid connections before starting equipment.
DEngage gun trigger safety whenever spraying is stopped.
DFollow Pressure Relief Procedure on page 6 if spray tip clogs and before cleaning, checking or
servicing equipment.
DRepair or replace worn or damaged parts immediately.
DCheck hoses, tubes, and coupling daily. Do not repair high pressure couplings: replace entire hose.
Fluid hoses must have spring guards on both ends to prevent kinks and rupture.

3308736
WARNING
HAZARDOUS FLUIDS
Improper handling of hazardous fluids can cause serious injury, even death, due to splashing in eyes,
ingestion or bodily contamination.
DKnow specific hazards of fluid being used.
DStore hazardous fluids in approved containers. Dispose of hazardous fluids per local, state and
national guidelines.
DWear protective eyewear, gloves, clothing, and respirator as recommended by fluid manufacturer.
FUEL HAZARD
The fuel used in this unit is combustible and when spilled on a hot surface can ignite and cause a fire.
DDo not fill fuel tank while engine is running or hot.
EXHAUST HAZARD
The exhaust contains poisonous carbon monoxide which is colorless and odorless.
DDo not operate this equipment in a closed building.
EQUIPMENT MISUSE HAZARD
Misuse of pressure washer or accessories may cause them to rupture and result in fluid injection,
splashing in eyes or on skin, or other serious injury.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DDo not exceed maximum working pressure of any component or accessory in system.
DDo not use any chemicals that are incompatible with wetted parts as stated in Technical Data.
DDo not alter throttle setting.

4308736
Component Identification and Function
7011A
Typical Installation – Pressure Washer
Fig. 1
F
T
E
G
K
A
B
D
L
C
H
J
M
N
P
R
S
V
7010B
AEngine 5.5 horsepower (models 1535 and 2030), 9 horsepower (model 2540),
11 horsepower (model 3040), operates pump assembly
BPump Assembly Pressurizes fluid to be sprayed through spray gun
CInlet Screen Screens out debris and other material between source and siphon tube
fluid filter
DInlet Filter Filters fluid between screen and fluid inlet
EFluid Inlet Fluid inlet to displacement pump from siphon tube
FFluid Outlet Hose and spray gun connection
GSpray Gun High pressure spray gun with gun safety latch
HSpray TIp Variety of spray tips depending on job needs
JSpray Gun Safety Latch Prevents accidental triggering of spray gun
KSpray Hose 100 ft (30 m), 1/4 in. or 3/8 in. ID, grounded, nylon hose with spring
guards on both ends
LInjector Injects chemical into spray hose and gun during pressure washer op-
eration by syphon action
MInjector Strainer and Tube Strains and routes chemical from source to injector
NUnloader Relieves fluid pressure when open
PUnloader Drain Tube Provides drainage for unloader
REZ Start Valve Provides quick priming and pump operation
SEZ Start Drain Tube Provides drainage for EZ start valve
THose Rack Provides storage for spray hose
VPressure Gauge Measures and displays pump air pressure

5308736
Installation
Check for Shipping Damage
Check unit for any damage that may have occurred in
shipping. Notify carrier immediately if there is any dam-
age.
Set Up
Connect high pressure hose (K) between pump outlet
and gun inlet. Both of these connections are made with
quick couplers.
CAUTION
Up to 100 ft (30 m) of high pressure hose may
be used. Longer hoses may affect sprayer perform-
ance, and chemical injector performance, if used.
Install desired spray tip (H) on spray gun (G). See Install-
ing and Changing Spray T ips. If you are using a
sandblaster kit, see its separate manual for installation
instructions.
Water Supply
CAUTION
Do not exceed 160_F (70_C) inlet water tempera-
ture.
Insert siphon tube (P) in container providing clean water
source.
NOTE: The water supply must be able to provide water
at a minimum flow rate equal to that of unit while
its being used (see Technical Data on
page 17).

6308736
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
System pressure must be manually
relieved to prevent system from starting
or spraying accidentally. Fluid under high
pressure can be injected through skin and cause
serious injury. To reduce risk of injury from injec-
tion, splashing fluid, or moving parts, follow Pres-
sure Relief Procedure whenever you:
Dare instructed to relieve pressure,
Dstop spraying for more than 10 minutes,
Dcheck or service system equipment,
Dinstall or clean spray nozzle.
Pressure Relief Procedure
1. Engage trigger safety latch.
2. Turn sprayer off.
3. Remove ignition cable from spark plug.
4. Remove siphon tube from water supply.
5. Disengage trigger safety latch and trigger gun to
relieve pressure. Engage trigger safety latch.
6. If spray tip or hose is completely clogged, or
pressure has not been fully relieved after following
steps above: Disengage trigger safety latch and
trigger gun to relieve pressure. Wrap rag around
hose end coupling and VERY SLOWLY loosen
coupling to relieve pressure gradually, then loosen
completely. Now clear tip or hose.
Startup
Always use start–up procedure to ensure that unit is
started safely and properly.
1. Check oil level:
NOTE: All units are equipped with a low-oil sensor that
shuts engine off if oil level falls below a certain
level. If unit stops unexpectedly , check both oil
and fuel levels. Check oil level each time unit is
refueled.
2. Check fuel level.
WARNING
FIRE HAZARD
Do not refuel a hot engine. Refueling a
hot engine could cause a fire. Use only
fresh, clean regular or unleaded gaso-
line. Close fuel shutoff valve during refueling.
CAUTION
Never run unit dry. Costly damage to pump will
result. Always be sure water supply is sufficient
before operating.
3. Put siphon tube in water supply. For best perfor-
mance, place siphon tube and water source at the
same or higher level than pressure washer.

7308736
Operation
4. Trigger gun until water sprays from tip indicating
that air is purged from system.
5. Open fuel shutoff valve. Be sure spark plug ignition
cable is pushed firmly onto spark plug. Put switch
in ON position and put throttle in RUN position.
CAUTION
Do not allow pressure washer to idle more than 10
minutes. Doing so may cause recirculating water to
overheat and seriously damage pump. Turn off
pressure washer if not spraying or cleaning at least
every 10 minutes. If heated inlet water is used,
reduce time further. Do not operate pressure
washer with inlet water screen removed. Keep
screen clean. Screen keeps abrasive sediment out
of pump, Abrasive sediment can clog pump or
damage cylinders. Do not pump caustic materials;
such materials may corrode pump components.
CAUTION
Do not allow starter rope to snap back against
engine. Return carefully to prevent damage to
recoil.
6. Start engine.
If engine is cold, completely close engine choke.
Grasp starter rope, brace one foot on pressure
washer chassis and pull rope rapidly and firmly.
Continue holding rope as it returns. Pull and return
rope until engine starts. In cool weather, choke
may have to be kept closed for 10 to 30 seconds
before opening it to keep engine running. Other-
wise, open choke as soon as engine starts.
If engine is warm, leave choke open, or partly
open. Start engine as described in preceding para-
graph. When it starts, open choke completely.
Operate engine at reduced rpm to assist priming.
When water flows from return hoses pump is
primed. Raise engine to full rpm for normal pres-
sure washer operation.
7. Always engage gun’s trigger safety latch when
spraying is stopped, even for a moment. This
reduces risk of fluid injection or splashing in eyes
or on skin if gun is bumped or triggered acciden-
tally.
8. Always observe preceding CAUTIONS to avoid
damage to pressure washer.
9. See sandblaster kit manual for detailed cleaning
information if this accessory is used.

8308736
Operation
Trigger Safety Latch
WARNING
To reduce risk of serious bodily injury, including
fluid injection, splashing in eyes or on skin, always
engage trigger safety latch when spraying is
stopped, even for a moment. In engaged position,
trigger safety latch prevents gun from being trig-
gered accidentally by hand or if dropped or
bumped. Be sure to push down latch fully to en-
gage it. If latch not fully engaged, gun can acciden-
tally trigger. See Figure 2.
Figure 2
TRIGGER SAFETY LATCH SHOWN ENGAGED
TRIGGER SAFETY LATCH SHOWN DISENGAGED
04612
Chemical Injector Operation
WARNING
To reduce risk of serious bodily injury, including
fluid injection or splashing in eyes or onto skin, use
extreme caution when changing spray tips. Always
follow procedure below.
1. Follow Pressure Relief Procedure.
2. Insert chemical filter (attached with clear tubing to
chemical injector) into container of chemical.
3. Install black spray tip for chemicals (see Installing
and Changing Tips).
The large hole of the chemical spray tip causes a drop
in pressure that actuates the chemical injector. Chang-
ing back to a smaller diameter spray tip deactivates
the chemical injector and produces high pressure for
rinsing. The chemical filter can be left in the chemical
container during high pressure use. The flow rate of
the chemical may be regulated by turning the chemical
adjustment knob on the injector. The maximum chemi-
cal flow is a full two turns counterclockwise from the
closed (clockwise) position.

9308736
Operation
Installing and Changing Spray Tips
WARNING
To reduce risk of serious bodily injury, including
fluid injection or splashing in eyes or onto skin, use
extreme caution when changing spray tips. always
follow procedure below.
1. Follow Pressure Relief Procedure.
2. Point gun and wand away from yourself and any-
one else.
3. Spray tips have a 4– or 5–digit number on them.
The first two digits are spray angle. Select spray
tip appropriate for application.
Spray Tip Number Spray Pattern Fan Angle
00XXX 0_, blaster (red)
15XXX 15_ (yellow)
25XXX 25_ (green)
40XXX 40_ (white)
NOTE: The chemical injector spray tip is brass with large
diameter hole and black cap.
4. Point spray tip (A) away from hands and body. Pull
back quick coupler ring (B). Remove tip with fin-
gers and hand to side of spray tip. Replace tip and
push back ring. See Figure 3.
5. Pull on tip to be sure it is secure.
6. Storage for spray tips is provided on chassis next
to pump.
CAUTION
O-ring (801202) may be blown out of quick coupler
(B) due to high pressure in system. Never operate
pressure washer without tip (A) securely mounted
in quick coupler.
04929
Figure 3
A
B

10 308736
Operation
Shutdown, Flushing and Storage
NOTE: For easier flushing, use anti –freeze flush kit
802327.
CAUTION
If water freezes in pressure washer, thaw in warm
room before trying to start it. Do not pour hot water
on or into pump. Hot water may crack ceramic
plungers!
1. If pressure washer is used or stored in freezing
temperatures, drain all water out of pump after
use. Flush with 50% anti–freeze solution. Relieve
pressure. Flush before using to remove anti–
freeze.
2. Before long-term (overnight) storage or transport,
disconnect water supply, and turn off fuel supply
valve.
3. After each use, wipe all surfaces with a clean,
damp cloth.
4. Perform regular maintenance. See maintenance
chart.
Maintenance
Perform regular maintenance at listed intervals to en-
sure maximum life and performance.
There are different break-in periods for engine, pump,
and gear reducer (if used). Follow each respective
break-in period as listed.
If operating pressure washer in dusty conditions, per-
form maintenance checks more frequently.
WARNING
To reduce risk of serious bodily injury, including
fluid injection, splashing in eyes or on skin or injury
from moving parts, always follow Pressure Relief
Procedure on page 6 before proceeding.
Interval What to do
Daily Clean water inlet screen and filter.
Check engine and pump oil levels.
Fill as necessary. Check gasoline
level. Fill as necessary.
After first 5
hours of opera-
tion
Change engine break–in oil. Drain
oil when warm. Use SAE 30 or
10W–30 detergent oil.
Each 25 hours
of operation
Clean and remove air cleaner
foam. Wash with water and deter-
gent. Dry thoroughly. Rub with oil
and squeeze to distribute oil.
After first 50
hours of opera-
tion
Change pump break-in oil. Use
SAE 20 or 30 non-detergent oil.
Each 100
hours of opera-
tion
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.
Each 500
hours of opera-
tion
or 6 months
Change pump oil. Use SAE 20 or
30 non-detergent oil.