Graco Hydra-Clean 2510 Operation manual

INSTRUCTIONS-PARTS LIST
This manual contains IMPORTANT
WARNINGS
and INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
HYDRA-CLEAN @ 251 0.3009
PressureWasher
HYDRA-CLEAN@ 2510
PIN 800-666, Series A
2500psi (172bar) OPERATING PRESSURE
2900psi (200 bar)
MAXIMUM WORKING PRESSURE
P/N 800-668, Series A
3000 psi (207 bar) OPERATING PRESSURE
3400
psi (234 bar) MAXIMUM WORKING PRESSURE
HYDRA-CLEAN@' 3009
I
GRACO INC. RO. BOX 1441 MINNEAPOLIS, MN 55440-1441
@COPYRIGHT 1991, GRACO INC.

WARNING
HIGH PRESSURESPRAY CAN CAUSE SERIOUSINJURY.
FOR PROFESSIONAL
USE ONLY. OBSERVEALL WARNINGS.
Read and understand all instruction manuals before operating equipment.
FLUID INJECTION HAZARD
Thispressurewashergeneratesvery high fluid
General Safety
pressure.Sprayfrom the gun, leaks orruptured
your body and causeextremelyserious bodily injury
components can injectfluidthrough yourskinandinto
including theneedfor amputation.
Also, fluidinjectedor
splashedintothe eyesor onthe skincancause serious
damage.
NNER pointthe spray gun or wand at anyone oratany
part of the body.
NNER put hand or fingers over the
spraytip.
ALWAYS followthe PressureRellefProcedure,before
cleaningor servicingany part ofthe sprayer.
NNER try to stop or deflect leaks with your hand or
body.
Be sureequipmentsafetydevicesareoperating
properlybeforeeachuse.
MedicalTreatment
If any fluid appearstopenetrateyourskin,get
EMERGENCY
MEDlCALTREATMENTATONCE.DO
what fluidwas injected.
NOT TREAT AS A SIMPLE
CUT. Tell the doctor exactly
traumatic
injuv. It is Important totreat the Injury
NOTE TO PHYSICIAN: Injection in the skin is a
surgically as soon as posslble. Do not delay
treatmentto research toxicity Toxicity is
a
concern with someexotic coatings injected
plastic surgeonor reconstructivehandsurgeon
directlyintothe bloodstream. Consultation with a
maybeadvisable.
Pressure Relief Procedure
To reducetheriskofseriousbodilyinjury, including fluid
injection and splashing in theeyesor on theskin,
sprayingformore than
10 minutes, when shuttingdown,
alwaysfollowthisprocedure whenever you stop
andbefore checkingor repairinganypartofthesystem.
1. Engagethetriggersafetylatch.
2. Tum the sprayer off.
3. Removethe ignitioncablefrom the spark plug.
4. Shut off thewatersupply.
5. Disengagethetriggersafetylatch and triggerthe
gunto relieve pressure, and then engage the trigger
safety latch again.
6. Beforelong-term (overnight) storage or
transporting of the unit, disconnect the water supply
and disconnectthe fuel supply.
Be sure all gun safety devices areoperatingproperly
Spray Gun Safety Devices
thegun; thiscancauseamalfunctionandresult in
before each use. Do not remove ormodifyany part of
sefiousbodily injury.
SAFETY LATCH: Whenever you stop spraying fora
moment, always set the gun safetylatch
in the engaged
or "safe"position,makingthe gun inoperative. Failure
to
triggering of thegun.
properly
set thesafetylatchcanresult in accidental
SPRAY TIP SAFEPI: Useextreme caution when
cleaning or changing spray tips.
If aspray tip clogs
whilespraying,engagethegunsafety latch
immediately.
ALWAYS follow the Pressure Relief
Procedure and then remove the spraytip
to clean it,
2 308-528

FUEL AND EMISSION HAZARDS
NNER fill the fueltank while the unitis running or hot.
me fuel used in thisunit is combustibleandwhen odorless, invisible gas whichcan cause serious injury
or death
if inhaled.
ALWAYS fill tank slowly to avoid spilling.
spilled on a hot surfacecan ignite and cause a fire.
NNER alterthemaximumthrottlesetting, which is
factory
set. Tamperingwith this adjustment can damage
NNER operatetheunit in a closed building. The
exhaust containscarbonmonoxide,apoisonous,
the pressure washer andwill voidthe warranty.
EQUIPMENT MISUSEHAZARD
General Safety
Any misuse ofthepressurewasheroraccessories,
suchasoverpressurizing,modifyingparts, using
incompatible chemicalsandfluids,
or using wom or
fluid injection, splashing inthe eyes or onthe skin, or
damaged parts, can causethem
to rupture and result in
other serious bodily injury, fire, explosion or property
damage.
NNER alter or modifyanypartofthis equipment; doing
so couldcause itto malfunction.
recommendations on additional protective equipment,
such as
a respirator.
System Pressure
nissprayer candevelophighoperating pressures.Be
to withstand the maximum workingpressureof this
sure thatallspray equipment and accessories arerated
sprayer.
DO NOT exceedthemaximumworking
pressure of any component or accessory
used in the
system.
Chemical Compatibility
replacewom or damaged parts immediately.
CHECK all sprayequipmentregularlyandrepair or BE SURE that ail chemicalsused in thechemical
injector are compatiblewith
the wettedparts of the
ALWAYS wear protective eyewearandappropriate hose,gun, wand andtip, as giveninthe Technical Data
(inside back cover).Alwaysreadthechemical
the chemical manufacturer'sliteraturefor
clothing.
If usingachemical injector, readandfollowmanufacturer'sliteraturebeforeusing any chemical in
this pressure washer.
HOSE SAFETY
~.. Highpressurefluidin the hoses can beverydangerous.
If the hosedevelops a leak, splitor rupture due
to any
kind of wear, damage or misuse,thehighpressure
spray emitted from
it can cause a fluidinjection injuryor
other seriousbodily injury or property damage.
ALL FLUID HOSES MUSTHAVE STRAIN RELIEFSON
BOTH ENDS.
The strain reliefs help protect the hose
from kinks or bends ai or closetothe coupling, which
can resultinhose rupture.
TIGHTEN all fluid connectionssecurelybeforeeach
use.Highpressurefluidcandislodgea
loose coupling
or allow high pressurespray
to be emittedfromthe
coupling.
NNEfl usea damaged hose. Before each use, check
entire hosefor cuts, leaks, abrasion,bulgingcover, or
these conditions exist, replace
the hose immediately.
damage
or movement of thehosecouplings. If any of
DO NOT try to recouplehighpressurehose or mendit
with tape or any other device.
A repairedhosecannot
contain the high pressure fluid.
HANDLEAND ROVTEHOSESCAREFULLY Do notpull
on hoses to movethepressurewasher.Donotuse
chemicals whichare not compatiblewiththe innertube
and cover of the hose.
DO NOT expose Graco hose to
temperaturesabove 200" F (93' C) or below -40" F
(-400 C).
308-528 3

MOVING PARTS HAZARD
bodyparts. KEEP CLEAR of moving parts when starting
Movingpartscanpinch oramputatefingers orother
PressureReliefProcedure beforechecking or
servicing the pressure washer to preventdischarging
or operatingthepressurewasher. highpressurefluidfrom
the gun.
NEVER operate Ihe pressure washer withoutallguards
andinterlocksinstalledandfunctioning.Followthe
TERMS
WARNING: Alerts user to avoid or correct conditions CAUTION Alefts user to avoid or correct conditions
that couldcause bodily injury.that couldcausedamage
to theequipment.
NOTE Identifieshelpfulproceduresandinformation.
IMPORTANT
UnitedStates Government safety standards havebeenadoptedunder theOccupational Safety and Health Act. These
standards-particularly theGeneralStandards,Part1910,andtheConstructionStandards,Part 1926-should be
consulted.
4 308-528

INSTALLATION
QUICK
COUPLER
HOSE CONNECflON
HIGH PRESSURE
Figure
1
Check for Shipping Damage
Check the unit forany damage that may have occurred
in shipping. Notify
the carrier immediately if there is
any damage.
Set
Up
Fillthe batterycellswith electrolyte andwater. Charge
the battery.Besure thebattery connections are correct
andsecure. Connect the fuel line
to the engineusingthe
quickcoupler provided.Squeeze the priming
bulb 3 to 5
times. If youare using a downstream chemical injector,
install itbetweenthepumpunloaderandthe high
pressure hose, using
the quick couplers provided.
Connectthe high pressure hose betweenthe pump
outlet andthe gun inlet. Both of these connections are
madewith quick couplers.
CAUTION
beused. Longerhosesmayaffectsprayer
Up
lo 100 fl (30m)of high pressure hose may
performance, and chemical injector performance,
if used.
InstallingandChanging Spray Tips. Ifyou are usinga
InStalltheappropriatespray tip onthewand.See
sandblasterkit, see itsseparate manual forinstallation
instructions.
Connect
to Water Supply
CAUTION
Before attaching to the water supply, check your
to thewatersupply. A backflow preventer, P/N
localplumbingcoderegarding cross-connection
801-133, is availabletoprevent backflow of
contaminated water into the fresh water supply.
Install itupstream from the pump.
Ifinletwaterpressure is over
60 psi (4.1 bar) a
regulating watervalve,
P/N 800-258, must be
installedat the gardenhoseconnection.
temperature.
Do notexceed160°F
(70" C) inletwater
the water supply
to the unit's 3/4 inch NPT inlet.The
Connect a hose with atleasla 3/4 inch(19 mm)ID from
supply hose should notbemore than
50 fl(l5 m) long.
NOTE:Thewater source at theunit
must havea
minimumflow rate equal
to that of the unit (see
Technical Data, insideback cover).
If this is
not possible, a water holding tankmust be
added
to prevent pump damage.
308-528
5

Always use this startup procedure to ensure that the Unit
isstarted safelyandproperly.
1. Checkoil levels.
Engine: Add SA€
30 or 1 OW-3OweigM detergentoil
as necessary.
Pump: Add SAE
20 or 30 weight non-detergentoil
as necessary.
NOTE: Thispressurewasher is equippedwitha
low-oil sensor that shuts the engine
off if the
oil levelfalls below a certain level. If the unit
the fuel levels. Check theoil level each time
stopsunexpectedly,checkboththe oil and
the unit
is refueled.
2. Check fuel level.
WARNING
DO NOT refuelahotengine.Refuelingahot
enginecould cause a fire. Use only fresh, clean
regular or unleadedgasoline.Closethefuel
shutoff valveduring refueling.
3. Turn onthewatersupply.
I will result. Alwaysbe sure the 1 water supply is
Never run the unit dry, Costly damage to the pump
completelytumed on before operating.
4. Triggerthegununtilwaterspraysfromthe tip
indicatingthat the airis purgedfrom the system.
5. Be sure the spark plug ignitioncables are pushed
firmlyonto thespark plugs. The ignition shutoff
switch shouldbe inthe "on" position. The throttle
shouldbe in
the "run" position.
6. Start theengine.
NOTE For easier starting, have one person start the
pressurewasherwhileanotherperson
triggers the spray
gun.
If the engine is cold, completely close the engine
choke. Press
the start button. in coolweather, the
choke may have
to be kept closed for 10 to 30
secondsbeforeopeningit to keep theengine
running. Otherwise, open thechokeas soonas the
engine starts.
Iftheengine is warm, leave the choke open or
partiallyclosed.Start the engine asdescribedinthe
preceding paragraph. When the engine starts. be
sure
to open thechokecompletely.
7. ALWAYS engagethegun'striggersafety latch
wheneveryoustop spraying, even for a moment,
to
reduce the risk offluid injectionor splashing in the
eyesor onthe skin if the gunisbumpedor triggered
accidentally.
8. ALWAYS observe thefollowing CAUTIONS toavoid
7 CAUTION
costly damage to the pressure washer
DONOTaliowthepressure washer
to idlefor more
than
10 minutes. Doing so maycausethe
recirculating water to overheatandseriously
damage the pump.Tum
off the pressure washer if it
will not be sprayingor cleaningat least every 10
minutes. If heated inletwater isused, reduce this
time further.
DO NOT runthepumpdry, which will quickly
fully tumed on before starting the pump.
damagethe pump.
Be surethewater supply is
DO NOT operate the pressure washer without an
abrasivesediment
out of the pump, whichcould
inletwaterscreen.Thisscreenhelps keep
clog or scratch the pump.Keepthis screen clean.
DO NOTpump caustic materials; such materials
may corrode the pump components.
9. See thechemical injectoror sandblasterkitmanual
for detailed cleaning information
if these
accessoriesare used.
6 308-528

-
Trigger Safety Latch
WARNING
To reducetheriskofserious bodily injury,
includingfluid injection, splashing inthe eyes or
on theskin,
ALWAYS engage the triggersafety
latch wheneversprayingstops,evenfor a
moment.
In the engaged position, the trigger safety latch
byhandor if
it is droppedor bumped. Be sure the
prevents the gun Nombeingtriggered accidentally
cannot prevent the gun
from beingtriggered. See
latch ispushed fully down when engaging
it or it
Figure
2.
TRIGGER SAFETY LATCH SHOWN ENGAGED
TRIGGER SAFETY LATCH SHOWN DISENGAGED
Figure 2
Installing and Changing Spray Tips
WARNING
1. Followthe Pressure Relief Procedure.
2. Pointthegunandwandawayfromyourselfand
anyone else.
3. Withoutholdingyourhandoverthespray tip (A),
tip and/or install a new one, and then release the
pullback the quick coupler ring (e). Remove theold
ring. See Figure
3.
4. Besurethe tip is securebeforestartingtospray
again.
5. Tip holding holes are providedon the chassis.
TO avoid blowing theO-ringout of the quick
coupler, due
to the high pressure in the system,
securely mounted in the quick coupler.
never operate the pressure washer without a tip
Figure
3
308-528 7

'ANDSTORAGE
SHUTDOWN, FLUSHING
WARNING
Pressure Rellef Procedure
To reducetherisk ofserious bodily injury,
or on theskin,alwaysfollowthisprocedure
includingfluidinjection and splashing
in the eyes,
whenever you stop spraying formorethan
10
minutes,whenshuttingdown,andbefore
checkingor repairingany part of the system.
1. Engagethetriggersafetylatch.
2. Turn thesprayer off.
3. Removethe ignition cable fromthespark
plugs.
4. Shut off thewatersupply.
5. Disengage the trigger safety latch and trigger
the trigger safety latch again.
the gun
to relievepressure, and then engage
6. Beforelong-term(overnight)storageor
transportingof the unit,disconnect thewater
supply, and disconnect the fuel supply.
If the pressure washerwill be exposed to freezing
temperatures, drain all water
out of the pump. If it
must bestored infreezing temperatures,flushthe
pressure. Flush the pressure washer before using it
unit with a
50% anti-freezesolution.Relieve
again to removethe anti-freeze.
NOTE: An anti-freezeflushkit,P/N802-327, is
available to make flushingeasier.
If water doesfreezeinthe pressurewasher, thaw it
pour
hot water on orintothe pump; it may crack the
in a warm room before trying
to start it. DO NOT
ceramic plungers!
2. After each use, wipe all surfacesofthepressure
washer with a clean, damp cloth.
3. Performtheappropriatemaintenance.See
maintenance chart.
MAINTENANCE
that you get maximum performance and life from the
Observing regular maintenance intervalshelps ensure
pressurewasher.
There is a break-in period for
tne engine and pump.
After changingthe oil
in these components following
their respective break-in periods, the interval between
required changesis longer.
If theunit is operating in dustyconditions,these
maintenance checks shouldbe made more often.
WARNING
includingfluid injection, splashinginthe eyesor
To reducetheriskofserious bodily iniury,
follow the
Pressure Relief Procedure Warnlng
on the skin or injury from moving parts, always
beforeproceeding.
1
Daily
After first 5
hours of
Each25 hours
of operation
After first
50
hours of
Each
100 hours
of operation
or 3 months
Each
500 hours
of operation
What to do
Clean water inlet screenand
filter. Check engineandpump
oil
oasoline level.Fillas necessarv.
levels. Fillas necessary. Check
Change engine break-inoil.
30 or 1OW-30 detergent oil.
Drain
oil when warm. Use SAE
Clean and remove air cleaner
foam. Washwith water and
with oil and squeeze
to distribute
detergent. Dry thoroughly.
Rub
oil.
Change pump break-inoil.
Use
SAE 20 or 30 non-detergent oil.
Cleanor replace paperair
cleanercartridae. TaD aentlv
to I
remove dirt. Cfiange'.eEgine'oil.
Use SAE 30or 1OW-30 I
6 308-528

TROUBLESHOOTING CHART
WARNING
To reducethe riskof serious bodily injury, includingfluidinjection, splashing inthe eyes or on the skin or injury from
moving parts, always follow the Pressure Relief Procedure Warnlng before proceeding.
Problem
Engine will not start M
IS hardto start
Engine misses or
lackspower
COW pessureandlor
pumpruns rough
Water leakage
from
under pump manifold
Water in pump
prematurefailureof
Frequent or
the packings
Strong surging at the
inletand low pressure
3n the discharge side
Cause
Nogasoline in fuel tank or carburetor.
Low oil level.
StarVStop switchinStop position.
Water
in gasolineor oldfuel.
Lwse or wrong battery connection.
Battery not properly charged.
Chokedimproperly. Flooded engine.
Dirty air cleaner filter.
Spark
plug dirty, wronggapor wrong type.
Spraygunclosed.
Partiallypluggedair cleaner filter.
Spark plugdirty, wronggapor wrong type.
lnconecl ignitiontiming.
Worn
or wrong size tip.
Inlet filter Clogged.
Worn packings, abrasives
in water or natural
wear.
Inadequatewater suppiy.
Belt slippage.
Fouledor dirty inlet
or discharge valves. Even
a smaii particle can
cause the valvetostick.
Restricted inlet.
Worn inletor dischargevaives.
Leaking
high pressure hose.
Wom packings.
Humidair condensing inside crankcase.
Worn packings.
Oilseals leaking.
Scored, damagedor wom plungers.
Abrasive materialinthe fluid beingpumped.
Inletwater temperature
too high.
Overpressurizingpump.
Excessive pressuredueto partiallypluggedor
damaged
tip.
Pumprunningtoo longwithout spraying.
Runningpumpdry.
Foreign
particles inthe inletor discharge
valve or wominlet and/ordischargevalves.
Solution
Fillthe tank withgasoline, openfuelshut off valve.
Check fuellineandcarburetor.
Add to proper level.
Moveswitch
to start position.
dry spark plug.
Drain fuel tank
and carburetor. Use new fueland
Check andtighten battery connections.
Check electrolyte levelofcells, recharge battery.
Openchokeandcrank engineseveraltimesto
clear out gas.
Removeandciean.
Clean, adjust thegap or replace.
Trigger spray gun.
Remove and ciean.
Clean. adjust thegap or replace.
Time engine.
Replacewithtip ofproper size.
Clean. Check'more frequently.
Check filter. Replace packings.
See PUMP
SERVICE.
Check water flow rate
to pump.
Tightenor replace;
USB wrrect belts andreplace
bothat same time.
filter.
Clean inlet and discharge valve assemblies. Check
Check gardenhose. may
be collapsedor kinked.
Replace wom valves.
Replace'highpressure hose.
Installnew packings.
See PUMP SERVICE.
3hangeoilas specified in MAINTENANCE.
nStali new packings.
See PUMP SERVICE.
nstailnew oilseals.
See PUMP SERVICE.
Installnew plungers.
See PUMP SERVICE.
Install properfiltrationon pumpInlet plumbing.
Check watertemperature; may not exceed
16OOF.
Do not modify anyfactory-setadjustments. See
EQUIPMENT MISUSE HAZARD.
Clean or replace
tip. See Installingand Changing
Spray
Tips.
Never run pumpmorethan 10 minutes without
spraying.
Do
not run pumpwithout water.
Clean or replace valves.
See PUMP SERVICE.
308-528 9

PARTS DRAWING
800-666 Hydra-Clean@ 2510 Pressure Washer
10 308-528

PARTS LIST
800-666 Hydra-Clean@ 2510 Pressure Washer
REF
NO.
2
1
3
4
5
6
7
8
10
9
11
12
13
14
15
17
16
18
20
19
21
22
23
24
25
27
26
28
29
30
31
32
33
34
35
36
37
39
38
41
40
43
42
44
PART
NO.
800-643
801-940
803-788
100-214
803-872
100-023
102-547
802-784
803-591
802-026
804-049
801 -823
803-812
803-806
803-797
803-517
801 -790
802-084
801 -787
803-141
802-096
803-1 42
802-025
801 -71 6
801
-008
801-568
803-791
803-787
156-849
803-781
100-321
800-642
803-817
100-307
100-133
802-845
100-132
803-881
801-571
172-981
176-250
800-652
801 -569
800-323
HUB, Engine
BELT. Drive
1
ON
1
6
6
6
1
4
14
6
1
1
1
2
HUB,' Pump1 SHEAVE,Pump
1
PUMP, 2500psi (see page 14)1
LABEL,KeepFromFreezing
1
NIPPLE. 314 x21TEE.,-3~4
_. ~ ~ ~
BUSHING, 314 x 112
HOSE, Bypass
NIPPLE, Hex,
TANK. Fuel.
6 aallon
1
1
1
318NPT
x 112 NPSM1 1
LABEL, WainiG,
fuel tank
LABEL, Graco G
QUICK COUPLER, Male318
UNLOADER, 2500psi
CAPLUG,
Inlet, 3/4
BRACKET. Pumo mountina
NIPPLE, Hex 3/8
NBE, pumpmounting
'
BOLT,Eye
BRACKET, Rail stiffener
NUT, Hex, 3/8-16
WASHER, Lock, 318
WASHER, Flat, 3/8
FOOT,Rubber
FUEL LINE, w/Connector,
HOSE, High pressure,318
LABEL. Wamina. chassis
NUT, Lock, 1/2-13
114
X 50'
2
2
2
1
6
6
10
4
1
1
1
REF
45
NO.
47
46
49
48
50
51
52
53
54
55
57
56
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
n
78
79
80
81
82
83
84
85
PART
NO.
803-350
156-082
801-134
801 -674
801-009
154-594
801 -972
803-525
801 -954
107-069
100-527
100-015
100-01 6
801-959
801 -960
801 -958
803-867
802-408
181 -867
802-363
802-908
801-919
803-891
801 -971
800-375
800-392
800-404
801
-548
800-405
800-493
800-494
803-894
803-868
801 -090
801 -759
801 -758
803-697
803-698
155-665
803-781
803-077
DESCRIPTION QN
O-RING,QuickcouDler. 3/8 1
GUN, Spray (see 3d8-511) 1
1
WAND. 32l
QUICK COUPLER, Female, 1/4
SLEEVE,28"1
O-RING, (incl.
5ob utck ' coupler, 114 1
1
PAD.Banem
1
-~,
BOLT, Battery
BRACKET, Battery
BATTERY, 12Volt,
30 amp
1
WASHER.Flat. 1/4
1
2
2
. ~, . ~.
BOLT, Carriage, 1/4-20 x 1
TERMINALPROTECTOR, Black 1
TERMINALPROTECTOR, Red 1
CABLE. 26Lona1
2
CABEL,' ElectTolyie
CABLE. 32Lono
LABEL,'w~~~~~-
CONNECTOR,Fuel
LABEL, Caution
BRACKET. Fuel Connector
LINE. Fuei~ 1/4 1
-. . . -, . -. , . , .
CLAMP, Hose
HOSE ASSEMBLY,w/Quick
3
GUN & WAND ASSEMBLY
couplers(incl. 26,
40, 44) 1
~"
(incl. 29,44,46,47, 48, 49) 1
GROMMET.Rubber 4
TIP ASSEMBLY 0013
TIP ASSEMBLY 1513
(incl.79,80)
1
TIP ASSEMBLY 2513
(incl.79,81)1
TIP ASSEMBLY 4013
(incl. 79,82)
1
CAPLUG, Ouilet, 318
(incl. 70,83)1
1
ENGINE, 24 Hp Onan,
electric
statt 1
QUICKCOUPLER,Male,114 4
TIP,Spray00131
TIP, Spray1513 1
TIP.SDrav25131
TIP; Sprai 4013
SWIVEL,318
1
1
SPACER,Pump Bracket2
308-528
11

PARTS DRAWING
800-668 Hydra-Clean6 3009 Pressure Washer
12 308-528

PARTS LIST
800-668 Hydra-Clean@ 3009 Pressure Washer
REF
NO.
1
2
3
4
5
7
6
8
9
11
10
12
14
13
15
16
18
17
19
20
21
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23
25
24
26
27
28
29
30
31
32
33
34
35
36
37
38
39
41
40
42
43
44
NO.
PART
800-643
801 -940
803-788
100-214
803-872
100-023
102-547
802-784
803-591
802-026
802-1 17
801 -823
803-812
803-797
803-806
803-517
803-814
802-084
801 -787
802-096
803-141
803-142
802-025
801 -008
801 -71 6
800-324
801 -568
803-791
803-787
156-849
803-781
100-321
800-642
803-817
100-307
100-133
.100-132
802-845
803-881
801-571
172-981
800-652
176-250
801
-569
DESCRIPTION
CHASSIS
BELT GUARD
SCREW. Can
hex hd.
5/16-i8 ~'314
WASHER, Lock, 5/16
WASHER, Flat, 5/16
LABEL, Graco G
SCREW, Cap,hex hd
WASHER,Lock, 1/2
5116-18X 1-1/2
WASHER,Flat, 1/2
BARB. Hose. 114
X 5/16
.
SHiiVE, Engine
HUB, Engine
HUB.PumD
BELT, Drive
SHGVE. Pump
PUMP, 3000psi (see page 16)
LABEL, Keep From Freezing
NIPPLE. 314
X 2
TEE,314
BUSHING.314
X 112
HOSE, Bypass
NIPPLE,
Hex,
3/8 NPT x 1/2 NPSM
TANK, Fuel, 6 gallon
LABEL, Graco
LABEL,Warnin
fuel tank
CAPLUG, Inlet,3/4
UNLOADER, 3000psi
NIPPLE,
Hex 3/8
BRACKn, Pump mounting
TUBE, Pump mounting
BOLT,
Eye
BRACKET, Rail stiffener
NUT, Hex, 3/8-16
WASHER, Lock, 3/8
WASHER, Flat, 3/8
FOOT,Rubber
FUEL LINE, w/Connector, 1/4
HOSE, High pressure, 3/8
x 50'
LABEL, Warning,chassis
LABEL, Warning,chassis
QUICK COUPLER, Female,
3/8
(incl.
10, 23, 24, 25,39, 69)
8
QUICK COUPLER, Male 3/8
NUT,Lock, 1/2-13
FUEL TANK ASSEMBLY
(incl.45)
QTY
1
1
6
6
6
1
4
14
6
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
1
2
1
2
1
2
6
10
6
4
1
1
1
1
1
2
REF
NO.
45
46
47
49
48
51
50
53
52
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
70
69
71
72
73
74
75
76
n
.78
79
80
81
82
83
85
84
PART
NO.
803-350
156-082
801-134
801 -009
801-674
154-594
801 -972
803-525
801 -954
107-069
100-527
100-01 6
801-960
100-015
801 -959
803-867
801 -958
803-077
802-408
181-867
802-363
802-908
801-919.
803-891
801 -971
800-375
800-392
801 -548
800-478
800-479
800-480
800-481
803-894
803-868
801 -090
803-687
801 -994
803-689
803-686
155-665
603-781
308-528
13

PARTS DRAWING
801-790 Pump Assembly, 2500 psi
14 308-528
41

PARTS LIST
801-790 Pump Assembly, 2500 psi
REF PART
NO. NO.
1 ~ 801-781
2 801-468
3801-4694 Kit 1
5 Kit 1
6Kit1
8 Kit1
7 Kit1
9Kit1 10 Kit4
11Kit4
12 803-419
13803-273
14803-424
15 803-433
16803-423
17803-421
18802-793
20 801-782
19801-488
21803-414
22 803-429
24802-345
23803-430
25803-437
26803-435
27 803-427
28803-416
29 803-436
30803-434
31802-357
DESCRIPTION
MANIFOLD
WASHER, Lock
SCREW, Cap, hex hd
O-RING
SEAT, Valve
SPRING, Valve
PLATE, Valve
GUIDE, Valve
VALVE ASSEMBLY
COVER, Crankcase
CAP
SCREW, Cap, socket
hd
GASKET, Cover
BEARING, Tapered roller
GASKET, Cover
COVER, Crankcase
CAP
O-RING
O-RING
DIPSTICK
CRANKCASE
O-RING
O-RING
GAUGE, Sight
WASHER, Lock
SCREW, Cap, socket hd
YOKE, Crankshaft
ROD, Connecting
BEARING, Ball
PIN, Wrist
RING, Snap
QTY
16
2
16
32
1
1
1
1
1
1
1
1
1
4
4
1
6
6
3
6
6
1
1
REF PART
NO. NO.
32 803-418
34 803-420
33803-283
35 803-428
37 803-426
36803-415
38803-432
39
Kit 6
40 803-417
41803-425
42803-422
44 802-304
45 803-438
46803-431
47Kit24
48 Kit6
50 Kit 29
51 Kit 29
52 Kit29
53 Kit29or 12
55
Kit 6
54 Kit 29
56 Kit6
57Kit6
58801-482
59801-483
60 801-484
61801-485
62Kit29
49801-783
COVER, Crankcase
DESCRIPTION
SCREW, Cap, sockethd
GASKFl; Cover
SEAL, Oil
RING, Connecting rod
CRANKSHAFT
KEY
WASHER. Flat
GUIDE, piston
COVER, Crankcase
WASHER, Lock
GASKET, Cover
SCREW, Cap, sockethd
BUSHING
WASHER, Flinger
SEAL, Oil
PLUNGER, Ceramic
RETAINER, O-ring
RING, Intermediate
O-RING
PACKING
RING; Head
RING, Backup
SCREW. Piston
O-RING
CAP
WASHER, Flat
CAP
WASHER,Flat
RING, Longlife
QTY
1
4
1
1
1
6
1
6
1
4
1
4
8
6
6
4
4
3
3
~ ~
Packing
Packing
&
Retainer
A
-
62 RING,Longlife
6
3
308-528 15

PARTS DRAWING
803-814 Pump Asse
4i
16 308-528

PARTS LIST
803-814 Pump Assembly, 3000 psi
REF PART
NO. NO.
1801-781
2 801-468
3801-4694
Kit 1
5
Kit 1
7 Kit 1
6
Kit 1
8
Kit 1
9 Kit 1
11 Kit 4
10 Kit 4
12 803-419
14 803-424
13803-273
15803-433
16803-423
17 803-421
18802-793
19801-488
20801-782
21803-414
22 803-429
23803-430
24802-345
25803-437
26803-435
28 803-416
27803-427
29 803-436
30803-434
31802-357
DESCRIPTION
MANIFOLD
SCREW, Cap, hex
hd
WASHER, Lock
SEAT. Valve
O-RING
PLATE, Valve
GUIDE, Valve
SPRING, Valve
". ~~, ~
VALVE ASSEMBLY
O-RING
CAP
COVER, Crankcase
GASKET, Cover
SCREW, Cap, sockethd
GASKET, Cover
BEARING, Taperedfoller
COVER. Crankcase
CAP
CRANKCASE
DIPSTICK
O-RING
O-RING
O-RING
.~. "
GAUGE, Sight
SCREW, Cap, sockethd
WASHER. Lock
YOKE, Crankshaft
ROD. Connectina
~~ -. ~~ ~.
PIN. wrist
BEARING. Ball
~~
"
RING,Snap
QTY
2
16
16
32
1
1
1
1
1
1
1
1
4
1
4
6
1'
6
3
6
6
1
1
REF PART
NO.NO.
32803-418
34803-420
33
803-283
35 803-428
36803-415
37803-426
38
803-432
40 803-417
41 803-425
42803-422
44 802-304
45 803-438
46803-431
39 Kit 6
47 Kit 24
48 Kit6
50 Kit 29
51 Kit 29
52 Kit 29
53 Kit 29or 12
54 Kit 29
55 Kit 6
56 Kit 6
57
Kit 6
58 801-482
59 801-483
60 801-484
61 801-485
62 Kit 29
49801-490
COVER. Crankcase
DESCRIPTION
SCREW, Cap, socket hd
.. ~~
GASKET. Cover
SE~L, o'il
CRANKSHAFT
RING, Connectingrod
KEY
WASHER, Flat
GUIDE,
Piston
COVER, Crankcase
WASHER, Lock
GASKET, Cover
SCREW, Cap, socket hd
BUSHING
SEAL, Oil
WASHER, Flinger
O-RING
PLUNGER, Ceramic
RING, Intermediate
RETAINER, O-ring
PACKING
RING, Head
RING, Backup
SCREW, Piston
CAP
WASHER, Flat
CAP
WASHER,Flat
RING, Longlife
O-RING
QTY
1
4
1
1
1
6
1
6
1
4
1
4
6
6
6
4
4
3
3
KltRepair Kn-
801-472
1
Descrlptlon
No.
Part NO. NO.
Qty.
Ref
Incl.
Valve
4
O-RING
5
SEAT, Valve
6
6
6
PLATE. Valve 6
7
SPRING
6
8 GUIDE, Valve
6
9
VALVE ASSEMBLY 6
4
802-306
10
O-RING
Valve Cap
11 CAP
6
6
6
801-474
39 WASHER,Flat 3
Plunger Repair 48 WASHER, Flinger
55 RING, Backup
3
3
56 O-RING
57 SCREW. Piston
3
3
8
6
PACKING 53
801-468
Parkino
.". . . . .
Packing &
Retainer
308-528 17

PUMP SERVICE
WARNING
To reducetherisk ofserious bodily injury,
includingfluid injection, splashinginthe eyes or
on the skin, or injury from moving parts, always
follow the
Pressure Relief Procedure Warning
beforeproceeding.
-
NOTE
NOTE
Valves
NOTE:
The following metric wrenches are needed:
M10, M13 and
M30. Repairkitsare available.
Refer
to the individual repair sectionsandthe
pump partspagefor moredetails.Forthe best
results, use all partsinthe kits.
Thereare
two different tool kits to aidin
servicing thepump. P/N
800-298 is used to
easeinstallation of packings.P/N 800-271
includes the itemsin
800-298 and tools to aid
inthe removal ofpackingretainers.
For a set of six valves, order P/N 801-472.
1. Removethehex plug fromthe manifold using an
M30 wrench.
2. Examinethe O-ring under the hexplugandreplace
it if itiscut or distorted.
3. Removethevalveassemblyfromthecavity;the
assembly may comeapart.
4. Install thenewvalve.Install theO-ring and hexplug;
torque
to 75 It-lb (103 Nm).
NOTE: Retorque theplug after 5 hoursofoperation.
Pumping Section
1. Remove the eight capscrews and lockwashers from
the manifoldusingan M13 wrench.
2. Carefully separate themanifoldfrom the crankcase.
NOTE It maybenecessary to tap themanifoldlightly
with a
soft mallet to loosen.
CAUTION
Keepthe manifold properly aligned withthe
ceramicplungers whenremoving
to avoid
damage
to the plunger or seals.
3. Carefully examine each plunger for any scoringor
crackingand replaceas necessary.
Servicing the Plungers
NOTE Plunaer reDairkit. P/N801-474 isavailable to
1,
2.
3.
4.
5.
6.
I.
..
backuprings for three cylinders.
replaceretainers, O-rings, washers and
Loosenthe plunger retaining screwfive
to six turns,
usingan MlOwrench.Push theplungertowardsthe
crankcase to separatetheplunger and retaining
screw.
the O-ring,backup ring and copperbearinggasket
Remove the screw from the plunger and examine
washer. Replace these parts,
if necessary,usingkit
801-474.
Remove the plunger and flinger from the plunger
shaft.Clean,examine and replacepartsas
necessary.
crankcase. Ifleaking is obvious, replace the
oil
Inspect theplunger shaft for oil leakage fromthe
seals. Otherwise,
DO NOT removetheseseals as
they cannotbereused.
An oilsealkit is availableto
replace the seals.
Lightly greasethe flinger andoil seal,
if it is being
replaced and replace them on the plunger shaft.
Then installthe plunger.
of the plunger. Place the washer, O-ringandbackup
Lightly grease the retaining screw and theouter end
the plunger.Torque to 14.4ft-lb (19.5 Nm).
ringaround the screw and install the screw through
NOTE If you plan to replace the packings, refer to
Servicingthe V-Packings.
7. Lubricate the outside of eachplunger.Slidethe
manifoldonto the crankcase, being careful not to
damage the seals.
8. Installthecapscrewsand washersfinger-tight.
Torquethe screws
to 21.7 ft-lb (29 Nm) followingthe
tighteningpattern (Figure4).Uneven tightening
may cause themanifold
to bindor jam.
I I
Flgure 4
18 308-528

ServicingtheV-Packings 5. Thoroughly cleanthe packingcavitiesandexamine
NOTE: Thereare two types of packing kits:one is
packings only, the Other includesthe 6. Lightlygreasethe packing cavitiesandthen
packings,ringsandretainers.replacethepackinas inthefollowinaorder:head
for debris and damage.
1. Removethemanifoldasoutlined in thePumping ring,v-packing, ihrmediate ring: headring,
v-packingand packing retainerwiththeO-ring
installed inthe retainer groove.
Section.
2. Carefully pull the packing retainerfromthe
manifold. Examine the O-ring and replace it
if it is
cut or damaged.
CAUTION
Installthe parts in the proper order andfacingthe
Correct direction.Improperlyinstalledparts will
cause a malfunction.
3. Remove the v-packing and head ring. Puli out the
v-packing and second head ring.
intermediateretainerring.Removethesecond
7. Reassemble themanifoldas instructedinServicing
4. Inspectall parts and replace as necessary.
the Plungers.
ACCESSORIES
(Must be purchased separately)
DOWNSTREAMCHEMICALINJECTOR KIT ANTI-FREEZEFLUSH KIT802-327
For injecting harshcleaningchemicalsdownstream For flushing system with
50% anti-freeze solution prior
from the pump.
to transporting or storingpressurewasherin below
freezing temperatures.
800-425
BACKFLOWPREVENTOR 801-133INLETPRESSUREREGULATOR800-258
Prevent back-up of contaminatedwaterintofresh Regulates inletwaterpressure to 60 psi (4 bar)
supply.Installupstream
of pump.maximum.
WATER SANDBLASTING KIT 800-120
Forabrasivecleaning of stubborn dirt andpaint.
uses 801-758,3009 uses 801-994).
Requires a spray tip which is not included inkit (2510
TECHNICAL DATA
Model 800-666 Model 800-668
Enaineftwincvlinder,
4 Cvcle. air-cooiedl I 24 HP Onan i 24HPOnan I
Battery 12volt,
30 amp, 2% CCA 12 volt, 30 amp, 250 CCA
GasolineTank Capacity
Water Pump Maximum Working Pressure 6 gallon (23 liter) 6gallon(23 liter)
Dimensims
343 Ibs (156 kg)
343 Ibs (156 kg)
Weight
3/4" NPT (r)
3/4" NFT (f)
Inlet Hme Connection
9 gpm (34 ipm)10 gpm (38 Ipm)
Water Pump Maximum Flow
30500 psi (207 bar) 25500 psi (172 bar)
Length
48" (1219 mm)
Width
Height
48" (1219 mm)
30" (762 mm)
25' (635 mm)
25" 1635 mml
30" (762 mm)
I 1-
Maximum Inlet WaterTemperature 1 160' F (70' C) I 160' F (70' C)
.-" ~ I
Wend Parts I I
I BypassHose
HighPressure
Hose
I Svnthetic yam and EPDM
AcrylonitrileandBuna-N cover and
tube
~.
Pressure Washer(includingfittings) Anodizedaluminum, Aluminumor
bronze aiioys, Brass Copper, Nylon-TeflonQ
composite. Ceramic, Buna-N. Coltonphenolic, 303,304, and316 Stainless
steel. Polymide-12 thermoplastic. TeflonQ, Carbon steel. Zinc withor without
yellow chromateplate
TeflonQ is a registered trademark of the DuPont Company.
308-528 19

THE GRACO WARRANTY
WARRANTY AND DISCLAIMERS
Gram warrants
ail equipment manufactured by A and beating its name io be free horn defects in material
and workmanship on the date of sale by an authorized Gmdisbibutor to the original purohas8r for usa.
Aspurohaser'ssoleremedyiorbreachofmiswarranty,Grau,will,faraperiodoftwentyfaurmonthshom
me equlpment is installed. operated and maintained in acwrdance with Gram'swritten
&~ofsaie,repairorrepiaceanypartoftheequipmentpmvendefective.Thiswarrantysppiiesonlywhen
recommendations.
This warranty does not cover. and Graw shall not be liable for, any malfunction. damage M WBT caused
negligence, accident. tampering. or suWon of non-Graco component parts. Nor shall Graco be
byfauiiyinstallation.misapplication,abrasion.corrosion,inadequateorimpropermaintenance.
accessories.equipmentormaterialsnot supplid byGraco.or
me improperdesign,manufacture.
liable for maifunction. damage or
mar caused by the incompatibility wim Graco equipment ofsbuctures,
installation. operation or maintenance of sbuctures. accessories. equipment or materials not supplied by
Graco.
This warranty is conditioned upon the prepaid return of me equipment clrumed to be d&Wm for
examination by Gram
to verity the claimed defecl. If the claimed defect is verified. Gram will repair or
repiace
free of charge any defeotive parts. The equipment will be returned to me original purchaser
transportationprepaid.Ifinspection
of me equipmentdoes not disclose any defect In mntelial or
workmanship. repairs will be made at a reasonable charge, which charges may include the costs of parts,
labor and transportation.
DISCLAIMERS
AND LIMITATIONS
THETERMS OFTHIS WARRANTYCONSTIWTETHE PURCHASERS SOLE AND EXCLUSIVE REMEDY
ANDAREINLiEUOFANYDTHERWARRANTiES(EXPRESSORIMPLIED),lNCLUDlNGWARRANTYOF
MERCHANTABiLiTY OR WARRANTYOFFITNESSFOR A PARTICULARPURPOSE,AND OF ANY
NON-CONTRACTUALLIABILITiES. iNCWDlNG PRODUCTLIABIUTiES. BASEDON NEGLIGENCE OR
STRICTLlABiLlTY.EVERY FORM OF LIABILITYFORDIRECT,SPECIAL OR CONSEQUENTIAL
DAMAGES
OR LOSS IS EXPRESSLYEXCLUDEDANDDENIED.INNOCASESHALLGRACO'S
WARRANTY MUST BE BROUGHT WITHIN THREE
(3) YEARS OF THE DATE OF SALE,
LIABILITYEXCEEDTHEAMOUNTOFTHEPURCHASEPRICE.ANYACTIONFORBREACH
OF
EOUIPMENT NOT COVERED RV GRACO WARRANN
GRACOMAKESN0WARRANTY;ANDOlSCLAlMSALLlMPLlEDWARRANTlESOFMERCHAMABlLlTY
ANDFITNESSFOR A PARTICULARPURPOSE,WITHRESPECTTOACCESSORIES,EOUIPMENS.
MATERIALS
OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but
-- - .. ... " . .. . - . -- . " . -_ - . " .. . -- .. . . .. .. .. . . ..
notmanuf~redbyGraa,(suchaselectricmotor,~hes,hose,etc.)aresubjectto~wananiy,~any,
of their manufacturer. Graco will provide purchaser with reasonable assistance in making anyolaim for
breach
of these warrantias.
IMPORTANT PHONE NUMBERS
TO PLACEAN ORDER, contact your Graw distributor, or call this number to identify the
distributor closest to you: 1-800-328-021 1 Toll Free
FOR TECHNICALASSISTANCE, service repair information or assistance regarding the
application of Graco equipment: 1-800-543-0339 Toll Free
Subsidiary and Afflilam Companies: Canada; England: Swherland: France: Germany: Hong Kong; Japan: Korea
Factory BranchesAtlanta. Chicago, Dallas, Oemi, Los Angeles. West Caidwell (N.J.)
GRACO INC. RO. BOX 1441 MINNEAPOLIS,MN55440-1441
PRINTED IN U.S.A. 308-528 1/91