Graco HYDRA-CLEAN 1535 Operation manual

308572
Rev. P
First choice when
quality counts.t
INSTRUCTIONS–PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
Direct-Drive Pressure Washers
1535
Model 804506, Series A
1500 psi (102 bar, 10.2 MPa) Operating Pressure
1900 psi (131 bar, 13.1 MPa) Maximum Working Pressure
2030
Model 804532, Series A
2000 psi (138 bar, 13.8 MPa) Operating Pressure
2400 psi (165 bar, 16.5 MPa) Maximum Working Pressure
2540
Model 804507, Series A
2500 psi (172 bar, 17.2 MPa) Operating Pressure
2900 psi (200 bar, 20.0 MPa) Maximum Working Pressure
2835
Model 804583, Series A
2800 psi (193 bar, 19.3 MPa) Operating Pressure
3200 psi (221 bar, 22.1 MPa) Maximum Working Pressure
3040
Model 804508, Series A
3000 psi (210 bar, 21.0 MPa) Operating Pressure
3400 psi (234 bar, 23.4 MPa) Maximum Working Pressure
Related Manual
Hydra-CleanRGun 308511. . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1995 GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
1535 Pressure Washer
Model 804506
7329B

2308572
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Service
1535 and 2030 Pressure Washers 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2540, 2835, and 3040 Pressure Washers 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Lists and Drawings
1535 and 2030 Pressure Washers 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2540 and 3040 Pressure Washers 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2835 Pressure Washer 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Assembly for 1535 and 2030 Pressure Washers 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Assembly for 2540, 2835, and 3040 Pressure Washers 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
INJECTION HAZARD
Spray from the gun, leaks, or ruptured components can inject fluid into your body and cause serious
injury. Fluid splashed in the eyes or on the skin can also cause serious injury.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get emergency
medical attention.
DDo not point the gun at anyone or at any part of the body.
DDo not stop or deflect leaks with hand, body, glove, or rag.
DDo not put your hand or fingers over the spray tip.
DTighten fluid connections before you start this equipment.
DEngage the gun trigger safety whenever you stop spraying.
DFollow Pressure Relief Procedure on page 5 if the spray tip clogs and before you clean, check,
or service this equipment.
DRepair or replace worn or damaged parts immediately.
DCheck hoses, tubes, and coupling daily. Do not repair high-pressure couplings. Replace the entire
hose. Fluid hoses must have spring guards on both ends to prevent kinks and rupture.

3308572
WARNING
HAZARDOUS FLUIDS
Improper handling of hazardous fluids can cause serious injury or death due to splashing in eyes,
ingestion, or bodily contamination.
DKnow the specific hazards of the fluid being used.
DStore hazardous fluids in approved containers. Dispose of hazardous fluids per local, state, and
national guidelines.
DWear protective eye wear, gloves, clothing, and respirator as recommended by the fluid
manufacturer.
FUEL HAZARD
The fuel used in this pressure washer is combustible. When spilled on a hot surface, it can ignite and
cause a fire.
Do not fill the fuel tank while the engine is running or hot.
EXHAUST HAZARD
The exhaust contains poisonous carbon monoxide, which is colorless and odorless.
Do not operate this equipment in a closed building.
EQUIPMENT MISUSE HAZARD
Misuse of the pressure washer or accessories could cause them to rupture and result in fluid injection,
splashing in the eyes or on the skin, or other serious injury.
DDo not alter or modify any part or factory-set adjustment of this equipment.
DDo not exceed the maximum working pressure of any component or accessory in the system.
DDo not use any chemicals that are incompatible with the wetted parts as stated in Technical Data
on page 25.
DDo not alter the throttle setting.

4308572
Setup
7329B
high-pressure hose
connection
hose rack
inlet water connection:
3/4-in. garden hose
gun
high-pressure hose
wand
Check for Shipping Damage
Check the pressure washer for shipping damage.
Notify the carrier immediately if there is any
damage.
Connect High-Pressure Hose and Gun
Connect the high-pressure hose between the pump
outlet and the 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 could affect pressure washer
and chemical injector performance.
Install Spray Tip
Install the appropriate spray tip on the wand. See
Installing and Changing Spray Tips on page 6. If
you are using a Sandblaster Kit, see its separate
manual for installation instructions.
Connect to Water Supply
CAUTION
Before you connect the garden hose to the pressure
washer, check your local plumbing code regarding
cross-connection to the water supply. If required,
install a backflow preventer.
If the inlet water pressure is over 60 psi (4.1 bar), a
regulating water valve must be installed at the
garden hose connection.
Do not exceed 160_F (70_C) inlet water
temperature.
Connect a hose with at least a 3/4-in. (19 mm) ID from
the water supply to the 3/4 in. garden hose inlet on the
pressure washer. The supply hose should not be more
than 50 ft (15 m) long.
NOTE: The water source must have a minimum flow
rate equal to that of the pressure washer. See
Technical Data on page 25.

5308572
Pressure Relief Procedure
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you
DAre instructed to relieve the pressure
DStop spraying for more than 10 minutes
DCheck or service any of the system equipment
DInstall or clean the spray nozzle
1. Engage the trigger safety latch.
2. Turn the pressure washer off, and 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. Then engage the trigger
safety latch.
If you suspect that the spray tip or hose is clogged or
that pressure has not been fully relieved after following
the steps above: Disengage the trigger safety latch,
and trigger the gun to relieve pressure. Wrap a rag
around the hose end coupling, and VERY SLOWLY
loosen the coupling to relieve pressure gradually. Then
loosen it completely. Then clear the tip or hose.
Operation
Startup
Always use this startup procedure to ensure that the
pressure washer is started safely and properly.
DAlways engage the gun trigger safety latch when
you stop spraying even for a moment. This reduces
the risk of fluid injection or splashing in the eyes or
on the skin if the gun is bumped or triggered
accidentally.
DAlways observe the CAUTIONS in this section to
avoid costly damage to the pressure washer.
DIf you use the Sandblaster Kit, see the Sandblaster
Kit manual for detailed cleaning information.
1. Check the oil level.
NOTE: All pressure washers are equipped with a
low-oil sensor that shuts the engine off if the oil level
falls below a certain level. If the engine stops
unexpectedly, check the oil and the fuel levels. Check
the oil level each time you add fuel.
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 gasoline. Close
the fuel shutoff valve during refueling.
3. Turn on the water supply.
CAUTION
Never run the pressure washer without water. Costly
damage to the pump will result. Always be sure the
water supply is completely turned on before you run
the pressure washer.
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.
Put the switch in the START position, and put the
throttle in the RUN position.
CAUTION
Do not allow the pressure washer to idle for more
than 10 minutes. Doing so could cause the recir-
culating water to overheat and seriously damage the
pump. Turn off the pressure washer if it will not be
spraying at least every 10 minutes. If heated inlet
water is used, reduce this time more. Do not oper-
ate the pressure washer with the inlet water screen
removed. This screen helps keep abrasive sediment
out of the pump, which could clog the pump or
damage the cylinders. Keep the screen clean. Do
not pump caustic materials; such materials could
corrode the pump components.

6308572
Operation
6. Pull the starter rope to start the engine. Brace one
foot on the pressure washer chassis, and pull the
starter rope out quickly. Pull and return the rope
until the engine starts.
CAUTION
Do not allow the starter rope to snap back against
the engine. Let the rope recoil gently to prevent
damage to the recoil.
NOTE: For easier starting, have one person start
the pressure washer while another person triggers
the gun.
If the engine is cold, start the engine with the
choke completely closed. In cool weather, you
might have to let the engine run with the choke
closed for the first 10 to 30 seconds. In warm
weather, open the choke completely as soon as
the engine starts.
If the engine is warm, start the engine with the
choke completely open or partially closed. When
the engine starts, open the choke completely.
Trigger Safety Latch
WARNING
To reduce the risk of serious bodily injury, including
fluid injection and splashing in the eyes or on the
skin, always engage the trigger safety latch when
you stop spraying even for a moment. When
engaged, the trigger safety latch prevents the gun
from being triggered accidentally by hand or when
dropped or bumped. Be sure the latch is pushed
fully down, or it will not prevent the gun from being
triggered. See Fig. 1.
Fig. 1
engaged disengaged 04612
Trigger Safety Latch
Chemical Injector Operation
1. Relieve the pressure.
See page 5.
2. Insert the chemical filter (attached with clear tubing
to the chemical injector) into the container of
chemical.
3. Install the black large-orifice chemical tip. See
Installing and Changing Spray Tips below.
The large orifice of the chemical tip causes a drop in
pressure that actuates the chemical injector. Changing
back to a small-orifice 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. To regulate the
flow rate of the chemical, turn the chemical adjustment
knob on the injector. Maximum chemical flow is a full
two turns counterclockwise from the CLOSED
(clockwise) position.
Installing and Changing Spray Tips
Spray tips have 4- or 5-digit numbers on them. The
first two digits are the spray angle. Select the spray tip
appropriate for your application. Tip holding holes are
provided on the chassis.
Spray Tip Number Spray Pattern Fan Angle
00XXX 0_blaster (red)
15XXX 15_(yellow)
25XXX 25_(green)
40XXX 40_(white)
NOTE: The chemical injector tip is brass and has a
large opening and a black plastic cap.
1. Relieve the pressure.
See page 5.
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
current tip, and install a different one. Then push
back the ring. See Fig. 2.

7308572
Operation
4. Pull on the tip to be sure the tip is secure before
you spray again.
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.
04929
A
B
Fig. 2
Shutdown, Flushing, and Storage
CAUTION
If water freezes in the pressure washer, thaw it in a
warm room before you try to start it. Do not pour
hot water on or into the pump; it could crack the
ceramic plungers.
DIf 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
pressure washer with a 50% antifreeze solution,
and relieve the pressure. Flush the pressure
washer before you use it again to remove the
antifreeze.
DBefore you store the pressure washer overnight or
transport it, disconnect the water supply, and turn
off the fuel supply valve.
DAfter each use, wipe all surfaces of the pressure
washer with a clean, damp cloth.
DPerform the appropriate maintenance. See
Maintenance Chart at right.
Maintenance
Observing regular maintenance intervals helps ensure
that you get maximum performance and life from the
pressure washer.
There is a break-in period for the engine and pump.
After you change the oil in these components following
their respective break-in periods, the interval between
required changes is longer.
If the pressure washer operated in dusty conditions,
these maintenance checks should be made more
often.
Maintenance Chart
Relieve the pressure
(see page 5) before you
proceed with maintenance.
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
operation
Change engine break-in oil. Drain
oil when warm. Use SAE 30 or
10W–30 detergent oil.
After every
25 hours of
operation
Clean and remove air cleaner
foam. Wash with water and
detergent. Dry thoroughly. Rub
with oil, and squeeze to distribute
oil.
After first
50 hours of
operation
Change pump break-in oil. Use
SAE 20 or 30 non-detergent oil.
After every
100 hours of
operation, or
every 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.
After every
500 hours of
operation, or
every 6 months
Change pump oil. Use SAE 20 or
30 non-detergent oil.

8308572
Troubleshooting
Relieve the pressure (see page 5) before you proceed with troubleshooting.
Problem Cause Solution
Engine will not start
or is hard to start.
No gasoline in fuel tank or carburetor Fill the tank with gasoline, and open fuel shutoff valve.
Check fuel line and carburetor.
Low oil Add oil to proper level.
Start/Stop switch in STOP position Move switch to START position.
Water in fuel, or old fuel Drain fuel tank and carburetor. Use new fuel, and
make sure spark plug is dry.
Engine flooded or improperly choked Open choke, and pull engine starter rope several
times to clear out fuel. Make sure spark plug is dry.
Dirty air cleaner filter Remove and clean.
Spark plug dirty, wrong gap, or wrong
type
Clean, adjust the gap, or replace.
Gun not triggered Trigger gun while starting engine.
Engine misses or
lacks power.
Partially plugged air cleaner filter Remove and clean.
Spark plug dirty, wrong gap, or wrong
plug type
Clean, adjust the gap, or replace.
Pressure is too low,
and/or pump runs
roughly.
Worn or wrong size tip Replace with tip of proper size.
Inlet filter clogged Clean. Check more frequently.
Worn packings, abrasives in water, or
natural wear
Check filter. Replace packings. See Pump Service on
pages 10 and 12.
Inadequate water supply Check water flow rate to pump.
Fouled or dirty inlet or discharge valves Clean inlet and discharge valve assemblies. Check
filter.
Restricted inlet Garden hose might be collapsed or kinked.
Worn inlet or discharge valves Replace worn valves. See Pump Service on pages
10 and 12.
Leaking high-pressure hose Replace high-pressure hose.
Water leaks from
under pump
manifold.
Worn packings Install new packings. See Pump Service on pages
10 and 12.
There is water on oil
side of pump.
Humid air condensing inside crankcase Change oil as specified in Maintenance Chart on
page 7.
Worn packings Install new packings. See Pump Service on pages
10 and 12.
Oil seals leaking Install new oil seals. See Pump Service on pages
10 and 12.

9308572
Troubleshooting
Problem Cause Solution
Packings are failing
frequently or
prematurely.
Scored, damaged, or worn plungers Install new plungers. See Pump Service on pages
10 and 12.
Abrasive material in the fluid being
pumped
Install proper filtration on pump inlet plumbing.
Inlet water temperature too high Check water temperature. It should not exceed 160_F
(70_C).
Overpressurizing pump Do not modify any factory-set adjustments. See
Equipment Misuse Hazard on page 3.
Excessive pressure due to partially
plugged or damaged tip
Clean or replace tip. See Installing and Changing
Spray Tips on page 6.
Pump running too long without spraying Never run pump more than 10 minutes without
spraying.
Running pump dry Do not run pump without water.
There is strong
surging at inlet and
low pressure on
discharge side.
Foreign particles in inlet or discharge
valve, or worn inlet and/or discharge
valves
Clean or replace valves. See Pump Service on pages
10 and 12.

10 308572
Pump Service: 1535 and 2030 Pressure Washers
Repair kits are available. See the individual repair sections, the Parts Lists on pages 15 to 23,
and Pump Repair Kits on pages 21 and 23. For the best results, use all parts in the kits.
Relieve the pressure
(see page 5) before you
proceed with service.
NOTES:
DThe following metric wrenches are needed: 5 mm,
13 mm, and 22 mm.
DThere is a tool kit to aid in servicing the pump.
Tool Kit 800271 includes tools to aid in removing
packing retainers.
Valves
NOTE: For a set of six valves, order Valve Assembly
Kit 801472.
1. Remove the hex plug from the manifold using a
22 mm socket.
2. Examine the O-ring under the hex plug, and
replace if cut or distorted.
3. Remove the valve assembly from the cavity; the
assembly might come apart.
4. Install the new valve. Install the O-ring and hex
plug. Torque to 33 ft-lb (45 NSm).
NOTE: Retorque the plug after 5 hours of operation.
Pumping Section
1. Remove the eight capscrews and lockwashers
from the manifold using a 5 mm wrench.
2. Carefully separate the manifold from the
crankcase.
NOTE: You might have to tap the manifold lightly
with a soft mallet to loosen it.
CAUTION
To avoid damage to the plunger or seals, keep the
manifold properly aligned with the ceramic plungers
when you remove it.
3. Carefully examine each plunger for any scoring or
cracking, and replace as necessary.
Servicing the Plungers
NOTE: Plunger Repair Kit 801474 is available to
replace retainers, O-rings, washers, and backup rings
for three cylinders.
1. Loosen the plunger retaining nut five or six turns
using a 13 mm wrench. Push the plunger towards
the crankcase to separate the plunger and
retaining screw.
2. Remove the nut from the plunger, and examine the
O-ring, backup ring, and copper bearing/gasket
washer. Replace these parts if necessary using
Plunger Repair Kit 801474.
3. Remove the plunger and flinger from the plunger
shaft. Clean and replace parts as necessary.
4. Inspect the plunger shaft for oil leakage from the
crankcase. If leaking is obvious, replace the oil
seals. Otherwise, DO NOT remove these seals,
because they cannot be reused. Oil Seal Kits are
available for replacing the seals. See Pump
Repair Kits on page 21.
5. Lightly grease the flinger (and oil seal if it is being
replaced), and replace on the plunger shaft. Then
install the plunger.