Graco HYDRA-CLEAN 3540 Operation manual

308525
Rev. H
First choice when
quality counts.t
INSTRUCTIONS–PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
3540 Belt-Drive Pressure Washer
Model 800636, Series C
3500 psi (24 MPa, 241 bar) Operating Pressure
3900 psi (27 MPa, 269 bar) Maximum Working Pressure
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1991, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Parts

2308525
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Service 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts
Pressure Washer 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
DDo not point the gun at anyone or at any part of the body.
DFluid injected into the skin may look like just a cut, but it is a serious injury. Get emergency
medical attention.
WARNING
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.
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 when 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 couplings daily. Do not repair high-pressure couplings; you must replace
the entire hose. Fluid hoses must have spring guards on both ends to prevent kinks and rupture.

3
308525
WARNING
MOVING PARTS HAZARD
Moving parts, such as the drive belt, can pinch or amputate fingers.
DKeep clear of moving parts when you start or operate this equipment.
DDo not operate the pressure washer without all guards and interlocks installed and functioning.
HAZARDOUS FLUIDS
Improper handling of hazardous fluids can cause serious injury or death from splashing in the
eyes, ingestion, or bodily contamination.
DKnow the specific hazards of the fluid being used.
DWear protective eye wear, gloves, clothing, and respirator as recommended by the fluid and
solvent manufacturer.
DStore hazardous fluids in approved containers. Dispose of hazardous fluids per local, state, and
national guidelines.
DDo not alter the throttle setting.
EQUIPMENT MISUSE HAZARD
Misuse of the pressure washer or accessories may 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 the Technical
Data on page 13.
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.
WARNING

4308525
Setup
gun hose
high-pressure
hose connection
water supply
connection TI1265A
Check for Shipping Damage
Check the unit for any damage that may have occurred in
shipping. Notify the carrier immediately if there is any
damage.
Unit Preparation
Charge the battery. Be sure the battery connections are
correct and secure. Connect the fuel line to the engine
using the quick coupler provided. Squeeze the priming
bulb 3 to 5 times. If you are using a downstream chemical
injector, install it between the pump unloader and the high
pressure hose, using the quick couplers provided.
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 may affect sprayer perform-
ance, and chemical injector performance, if used.
Install the appropriate spray tip on the wand. See
Installing and Changing Spray Tips. If you are using a
sandblaster kit, see its separate manual for installation
instructions.
Connect to Water Supply
CAUTION
Before attaching to the water supply, check your local
plumbing code regarding cross connection to the water
supply. A backflow preventer, 801133, is available to
prevent backflow of contaminated water into the fresh
water supply. Install it upstream from the pump.
If inlet water pressure is over 60 psi (4.1 bar) a
regulating water valve, 800258, 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 inch (19 mm) ID
from the water supply to the unit’s 3/4 inch garden
hose inlet. The supply hose should not be more than
50 ft (15 m) long.
NOTE: The water source at the unit must have a
minimum flow rate equal to that of the unit (see
Technical Data on page 13).

5
308525
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.
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 this startup procedure to ensure that the
pressure washer is started safely and properly.
1. Check oil levels.
Engine: Add SAE 30 or 10W–30 weight detergent oil
as necessary.
Pump: Add SAE 20 or 30 weight non-detergent oil as
necessary.
NOTE: This pressure washer is equipped with a
low–oil sensor that shuts the engine off if the oil
level falls below a certain level. If the unit stops
unexpectedly, check both the oil and the fuel
levels. Check the oil level each time the unit is
refueled.
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. Turn on water supply.
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
cables are pushed firmly onto spark plugs. Put
ignition shutoff switch in “on” position and throttle
in “run” position.

6308525
Operation
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.
NOTE: For easier starting, have one person start the
pressure washer while another person triggers
the spray gun.
If the engine is cold, completely close the engine
choke. Press the start button. In cool weather, the
choke may have to be kept closed for 10 to 30
seconds before opening it to keep the engine
running. Otherwise, open the choke as soon as the
engine starts.
If the engine is warm, leave the choke open or
partially closed. Start the engine as described in the
preceding paragraph. When the engine starts, be
sure to open the choke completely.
7. ALWAYS engage gun’s trigger safety latch when-
ever you stop spraying, even for a moment, to
reduce risk of fluid injection or splashing in eyes or
on skin if gun is bumped or triggered accidentally.
8. ALWAYS observe following CAUTIONS to avoid
costly damage to pressure washer.
9. See chemical injector or sandblaster kit manual for
detailed cleaning information if these accessories
are used.
Water Sandblasting
Water Sandblasting Kit 244766 is available for
abrasive cleaning of stubborn dirt and paint. The kit
requires sandblasting tip 805317, which is sold
separately.
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
0412B

7
308525
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 on page 5.
2. Point gun and wand away from yourself and
anyone else.
3. Without holding your hand over spray tip (A), pull
back quick coupler ring (B). Remove old tip and/or
install a new one, and then release ring. See
Figure 3.
4. Be sure tip is secure before starting to spray
again.
5. Tip holding holes are provided on chassis.
CAUTION
O-ring 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.
Figure 3
A
B
Shutdown, Flushing, and Storage
1. If pressure washer will be exposed to freezing
temperatures, drain all water out of pump. If it
must be stored in freezing temperatures, flush unit
with a 50% anti–freeze solution. Relieve pressure.
Flush pressure washer before using it again to
remove anti–freeze.
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!
2. After each use, wipe all surfaces of pressure
washer with a clean, damp cloth.
3. Perform appropriate maintenance. See mainte-
nance chart on page 8.

8308525
Operation
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 changing the oil in these components following
their respective break–in periods, the interval between
required changes is longer.
If the unit is operating in dusty conditions, these main-
tenance checks should be made more often.
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 5 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.

9
308525
Troubleshooting
WARNING
To reduce risk of serious injury, including fluid injection and splashing in eyes, or on skin, always follow Pres-
sure Relief Procedure on page 5 before proceeding.
Problem Cause Solution
Engine will not start
or is hard to start
No gasoline in fuel tank or carburetor. Fill tank with gasoline, open fuel shut off valve. Check
fuel line and carburetor.
Low oil. Add to proper level.
Start/Stop switch in Stop position. Move switch to start position.
Water in gasoline or old fuel. Drain fuel tank and carburetor. Use new fuel and dry
spark plug.
Loose or wrong battery connection. Check and tighten battery connections.
Battery not properly charged. Check electrolyte level of cells, recharge battery.
Choked improperly. Flooded engine. Open choke and pull engine several times to clear out
gas. Use dry spark plug.
Dirty air cleaner filter. Remove and clean.
Spark plug dirty, wrong gap or wrong
type.
Clean, adjust gap or replace.
Spray gun closed. Trigger spray gun while spraying.
Engine misses or
lacks power
Partially plugged air cleaner filter. Remove and clean.
Spark plug dirty, wrong gap or wrong
plug type.
Clean and adjust spark plug gap or replace.
Low pressure and/or
pump runs rough
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,
page 11.
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. Check garden hose, may be collapsed or kinked.
Worn inlet or discharge valves. Replace worn valves. See PUMP SERVICE, page 11.
Leaking high pressure hose. Replace high pressure hose.
Water leakage from
under pump manifold
Worn packings. Install new packings. See PUMP SERVICE, page 11..
Water on oil side of
pump
Humid air condensing inside crankcase. Change oil as specified in Maintenance, page 11.
Worn packings. Install new packings. See PUMP SERVICE, page 11.
Oil seals leaking. Install new oil seals. See PUMP SERVICE, page 11.

10 308525
Troubleshooting
Problem Cause Solution
Frequent or prema-
ture failure of pack-
ings
Scored, damaged or worn plungers. Install new plungers. See PUMP SERVICE, page 11.
Abrasive material in fluid being pumped. Install proper filtration on pump inlet plumbing.
Inlet water temperature too high. Check water temperature; may 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 7.
Pump running too long without spraying. Never run pump more than 10 minutes without spray-
ing.
Running pump dry. Do not run pump without water.
Strong surging at in-
let 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,
page 11.

11
308525
Pump Service
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 5 before proceeding.
NOTE: The following metric wrenches are needed: 5
mm, 13 mm and 22 mm. Repair kits are
available. Refer to individual repair sections
and pump parts page for details. For best
results, use all parts in kits.
NOTE: There are two different tool kits to aid in
servicing the pump. 800298 is used to ease
installation of packings. 800271 includes the
items in 800298 and tools to aid in the removal
of packing retainers.
Valves
NOTE: For a set of six valves, order 801472.
1. Remove hex plug from manifold using an 22 mm
wrench.
2. Examine o–ring under hex plug and replace if cut
or distorted.
3. Remove valve assembly from cavity; assembly
may come apart.
4. Install new valve. Install o–ring and hex plug;
torque to 75 ft–lb (103 Nm).
NOTE: Retorque plug after 5 hours of operation.
Pumping Section
1. Remove eight capscrews and lockwashers from
manifold using an 13 mm wrench.
2. Carefully separate manifold from crankcase.
NOTE: It may be necessary to tap manifold lightly with
a soft mallet to loosen.
CAUTION
Keep manifold properly aligned with ceramic plung-
ers when removing to avoid damage to plunger or
seals.
3. Carefully examine each plunger for any scoring or
cracking and replace as necessary.
Servicing Plungers
NOTE: Plunger repair kit, 801474 or 803510 is
available to replace retainers, o–rings,
washers and backup rings for three cylinders.
1. Loosen plunger retaining screw five to six turns,
using an 5 mm wrench. Push plunger towards
crankcase to separate plunger and retaining
screw.
2. Remove screw from plunger and examine o–ring,
backup ring and copper bearing/gasket washer.
Replace these parts, if necessary, using kit 801474
or 803510.
3. Remove plunger and flinger from plunger shaft.
Clean, examine and replace parts as necessary.
4. Inspect plunger shaft for oil leakage from crank-
case. If leaking is obvious, replace oil seals. Other-
wise, DO NOT remove these seals as they cannot
be reused. An oil seal kit is available to replace
seals.
5. Lightly grease flinger and oil seal, if it is being
replaced and replace them on plunger shaft. Then
install plunger.

12 308525
Pump Service
6. Lightly grease retaining screw and outer end of
plunger. Place washer, o–ring and backup ring
around screw and install screw through plunger.
Torque to 14.4 ft–lb (19.5 Nm).
NOTE: If you plan to replace the packings, refer to
Servicing the V–Packings.
7. Lubricate outside of each plunger. Slide manifold
onto crankcase, being careful not to damage
seals.
8. Install capscrews and washers finger–tight. Torque
screws to 21.7 ft–lb (29 Nm) following the tighten-
ing pattern in Fig. 4. Uneven tightening may cause
manifold to bind or jam.
Figure 4
14
2
3
5
8
7
6
Servicing V–Packings
NOTE: There are two types of packing kits: one is
packings only, the other includes the packings,
rings and retainers.
1. Remove manifold as outlined in Pumping Section.
2. Carefully pull packing retainer from manifold.
Examine o–ring and replace it if it is cut or dam-
aged.
3. Remove v–packing and head ring. Pull out inter-
mediate retainer ring. Remove second v–packing
and second head ring.
4. Inspect all parts and replace as necessary.
5. Thoroughly clean packing cavities and examine for
debris and damage.
6. Lightly grease packing cavities and then replace
packings in following order:
head ring,
v–packing,
intermediate ring,
head ring,
v–packing and packing retainer with o–ring in-
stalled in retainer groove.
CAUTION
Install parts in proper order and facing correct
direction. Improperly installed parts will cause a
malfunction.
7. Reassemble manifold as instructed in Servicing
Plungers.

13
308525
Technical Data
Model 800636
Engine (4 cycle, air–cooled) 13 HP Honda OHV
Battery 12 Volt, 30 AMP
250 CCA
Gasoline Tank Capacity 2 Gallon (7.6 Liter)
Water Pump Maximum Working Pressure 3500 psi (241 bar)
Water Pump Maximum Flow 4 gpm (15 lpm)
Inlet Hose Connection 3/4” garden hose (f)
Weight 255 lbs (116 kg)
Dimensions
Length
Width
Height
49” (1245 mm)
30” (762 mm)
26.5” (673 mm)
Maximum Inlet Water Temperature 160_F (70_C)
Wetted Parts
High Pressure Hose
Bypass Hose
Pressure Washer
(including fittings)
Acrylonitrile and Buna–N cover and tube
Synthetic yarn and EPDM
Anodized aluminum, Aluminum or bronze alloys, Brass Copper, Nylon–PTFE
composite, Ceramic, Buna–N, Cotton phenolic, 303, 304, and 316 Stainless steel,
Polymide–12 thermoplastic, PTFE, Carbon steel, Zinc with or without yellow chromate
plate

14 308525
Notes

15
308525
Pressure Washer – Parts
63
5
76
48
45
547
82
80
81
22
83
84
79
5
78
21
24
59 25
56
12
5
2
25 17
13
14
16
5
23
7
1
7
2
7
3
7
4
31
70
3
3
3
4
3
5
3
6
29
2
528
20 19 18
51
30
77
46
59 2
2
48
50
49
4
56
7
62
57
58
52
53
61
60
9
58
5756
59 55
11
10
8
64
15
3
38
37
93
75
44
3540 Pressure Washer
Model 800636, Series C

16 308525
Pressure Washer -
Parts
3540 Pressure Washer Model 800636, Series C
Ref
No. Part No. Description Qty
2 100214 WASHER, Lock 5/16 4
3 803945 BELT, Drive 2
4 803800 SHEAVE, Engine 1
5 100023 WASHER, Flat 5/16 4
6 100450 SCREW, Cap, Hex hd
5/16–18 x 1 9
7 803534 LABEL, Belt Guard 1
8 803926 BELT GUARD 1
9 803525 BOLT, Battery 2
10 804282 BRACKET, Battery 1
11 801972 PAD, Battery 1
12 801550 WHEEL & TIRE ASSEMBLY 2
13 801612 WASHER, Flat 1/2 2
14 801020 NUT, Lock 1/2–13 2
15 800676 CHASSIS 1
16 801556 AXLE 1
17 800678 BRACKET, Rail Stiffener 1
18 801546 SCREW, Cap, Hex hd
3/8–16 x 1–1/4 4
19 100133 WASHER, Lock 3/8 4
20 100132 WASHER, Flat 3/8 4
21 800160 FRONT LEG ASSEMBLY
(incl. 5, 78 through 84) 1
22 803905 LABEL, Model 3540 1
23 111040 NUT, Lock 5/16–18 4
24 803925 HANDLE 1
25 803298 SCREW, Cap, Hex hd
5/16–18 x 3–1/2 1
28 802016 BRACKET, Rail Stiffener 1
29 801522 SCREW, Cap, Hex hd 2
30 804500 LABEL, Chassis 1
31 801548 GROMMET, Rubber 5
33 800314 TIP ASS’Y, 00045 (incl. 70, 71) 1
34 800315 TIP ASS’Y, 15045 (incl. 70, 72) 1
35 800316 TIP ASS’Y, 25045 (incl. 70, 73) 1
36 805434 TIP ASS’Y, 40045 (incl. 70, 74) 1
37 803883 ENGINE, 12.5 HP, Briggs &
Stratton Vanguard OHV
(used on 800635 only) 1
803967 ENGINE, 13 HP, Honda OHV
(used on 800636 only) 1
38 PUMP ASS’Y (see page 16) 1
39 800652 FUEL TANK ASSEMBLY
(incl 40, 87, 89, 90, 91, 92)
(used on 800635 only) 1
40 801733 BARB, Hose 1/4
(used on 800635 only) 1
Ref
No. Part No. Description Qty
44 244450 GUN & WAND ASSEMBLY 1
45 803526 SPACER 1
46 801217 BUMPER, Rubber 1
47 177144 LABEL, Belt Guard 1
48 803535 SCREW, Cap, Hex hd
(used on 800635 only) 1
801559 SCREW, Cap, Hex hd 1
49 803942 SHEAVE, Pump 1
50 801898 HUB, Engine 1
51 801135 HUB, Pump 1
52 801959 TERMINAL PROTECT., Blk 1
53 801945 CABLE, Battery 12” Long 1
55 115753 BATTERY, 12 Volt, 30 Amp 1
56 100527 WASHER, Flat 1/4 24
57 100016 WASHER, Lock 1/4 4
58 100015 NUT, Hex 1/4–20 4
59 100022 BOLT, Carriage 1/4–20 x 1 2
60 801946 CABLE, Battery 24” Long 1
61 801958 TERMINAL PROTECT., Red 1
62 803531 BASEPLATE, Belt Guard 1
63 801022 SCREW, Cap, Hex hd
5/16–18 x 3/4 4
64 107069 BRACKET, Battery 1
70 801090 QUICK COUPLER, Male 1/4 4
71 803106 TIP, Spray 00045 1
72 803107 TIP, Spray 15045 1
73 803108 TIP, Spray 25045 1
74 803109 TIP, Spray 40045 1
75 244451 HOSE ASSEMBLY 1
76 802363 LABEL, Caution 1
77 290013 LABEL, Warning 1
78 801531 SCREW, Cap, Hex hd
3/8–16 x 7 1
79 801504 BUMPER, Rubber 1
80 801505 RETAINER, Spring 1
81 801593 SPRING 1
82 801506 BOOT 1
83 801537 LEG, Front 1
84 801499 NUT, Lock 3/8–16 1
93 801137 KEY, square 2

17
308525
Pump – Parts
Pump Assembly 803508, 3500 psi (24 MPa, 241 bar)
65
67 66
64
63 55
50
49
48
57
58
98
59
60
61
62
46
47
44
45
10
9
8
7
6
5
4
1
3
2
10 9
11 52
51
54
53
13
14
18
19 56 20
12
43 42 16
17 40 15
41 14
39
12
21 23
22 24
26 33 32
28 29
30
31
27
25
34
35
36
31
37
38
11
44
45
68

18 308525
Pump – Parts
Pump Assembly 803508, 3500 psi (24 MPa, 241 bar)
Ref
No. Part No. Description Qty
1 801467 MANIFOLD, 3000 psi 1
803504 MANIFOLD, 3500, 4000 psi 1
2 801468 SCREW, Cap, hex hd 8
3 801469 WASHER, Lock 8
4 Kit 1 O–RING
5 Kit 1 SEAT, Valve
6 Kit 1 PLATE, Valve
7 Kit 1 SPRING
8 Kit 1 GUIDE, Valve
9 Kit 4 or 106 O–RING
10 Kit 4 or 106 CAP
11 Kit 1 VALVE ASSEMBLY
12 803283 SCREW, Cap, socket hd 8
13 803284 COVER, Crankcs., 3000 psi 1
803506 COVER, Crankcase,
3500 and 4000 psi 1
14 802500 O–RING, Crankcase cover 2
15 803324 BEARING, Tapered roller 2
16 Kit 2 SEAL, Oil
17 803286 BUSHING, Piston 3
18 802895 CRANKCASE, 3000 psi 1
803501 CRANKCASE,
3500 and 4000 psi 1
19 801475 DIPSTICK 1
20 803144 GASKET, Cover 1
21 803287 CRANKSHAFT 1
22 803288 RING, Retaining 6
23 802794 KEY 1
24 803289 PIN, Wrist 3
25 803325 GUIDE, Piston, 3000 psi 3
803503 GUIDE, Piston,
3500 and 4000 psi 3
26 803291 ROD, Connecting 3
27 803292 SCREW, Cap, socket hd 5
28 803293 COVER, Crankcase,
3000 psi 1
803507 COVER, Crankcase,
3500 and 4000 psi 1
29 802345 GAUGE, Sight 1
30 802793 PLUG, Oil drain 1
31 Kit 6 or 107 O–RING
32 803294 SCREW, Cap, socket hd 6
33 803652 WASHER, Lock 6
34 Kit 6 or 107 WASHER, Flinger
35 801490 PLUNGER, Ceramic 3
803502 PLUNGER, Ceramic 3
36 Kit 6 or 107 RING, Backup
Ref Part No. Description Qty
37 Kit 6 or 107 WASHER
38 Kit 6 or 107 SCREW, Piston
39 803295 COVER, Crankcs., 3000 psi 1
803505 COVER, Crankcase,
3500 and 4000 psi 1
40 803296 SHIM 2
41 Kit 3 SEAL, Oil
42 Kit 28 or 109 O–RING
43 Kit 28 or 109 RETAINER, Packing
44 Kit 28 or 109 PACKING Kit 8 or 112
45 Kit 28 or 109 RING, Head
46 Kit 28 or 109 RETAINER, Packing
47 Kit 28 or 109 RING, Long Life
48 801526 BRACKET, Pump 2
49 802305 SCREW, Cap, socket hd 4
50 802304 WASHER, Lock 2
51 801482 PLUG, Hex 1
52 801483 WASHER, Flat 1
53 801484 PLUG, Hex 1
54 801485 WASHER, Flat 1
55 801624 PUMP, 3000 psi 1
803508 PUMP, 3500 and 4000 psi 1
56 803083 LABEL, Keep From Freezing,
3000 psi 1
803517 LABEL, Keep From Freezing,
3500 and 4000 psi 1
57 802085 NIPPLE 1/2 1
58 801622 CROSS 1/2 1
59 800113 FILTER (see Instruction
Manual 801744) 1
60 801111 NUT, Garden hose 1
61 801110 ADAPTER, Garden hose 1
62 801112 STRAINER, Garden hose 1
63 803141 HOSE, Bypass 1
64 803142 NIPPLE, Hex 1/2 NPSM x
3/8 NPT 3000 psi 1
802534 NIPPLE, Hex 1/2 NPSM x
1/2 NPT, 3500 and 4000 psi 1
65 800325 UNLOADER, 3000 psi 1
800689 UNLOADER, 3500 psi
800427 UNLOADER, 4000 psi 1
65a 804487 FITTING, unloader
outlet (not shown) 1
66 801868 NIPPLE, Hex 3/8, 3000 psi 1
801236 NIPPLE, Hex 1/2x3/8,
3500 and 4000 psi 2
67 801568 COUPLER, Male 3/8 1
68 KIT 5 REPAIR KIT
98 116461 VALVE, thermal 1

19
308525
Pump – Parts
Kit
No.
Repair Kit
Part No.
Ref
No. Description Qty.
1801472
Valve
4
5
6
7
8
11
O–RING
SEAT, Valve
PLATE, Valve
SPRING
GUIDE, Valve
VALVE ASSEMBLY
6
6
6
6
6
6
2801473
Oil Seal
16 SEAL, Oil 3
3802511
Crankshaft Seal
41 SEAL, Oil 2
4802306
Valve Cap, 3000 psi
9
10
O–RING
CAP
6
6
5244350
Chemical Injector
Repair Kit
68 O–RING
O–RING
SS ball
Spring
1
1
1
1
6801474
Plunger Repair,
3000 psi
31
34
36
37
38
O–RING
WASHER, Finger
RING, Backup
WASHER
SCREW, Piston
1
1
1
1
1
8801468
Packing, 3500 psi
44 PACKING 6
28 801487
Packing & Retainer,
3000 psi
42
43
44
45
46
47
O–RING
RETAINER,
PACKING
PACKING
RING, Head
RETAINER,
PACKING
RING, Long Life
1
1
2
1
1
1
106 803509
Valve Cap,
3500 & 4000 psi
9
10
O–RING
CAP
6
6
107 803510
Plunger Repair,
3500 & 4000 psi
31
34
36
37
38
O–RING
WASHER, Flinger
RING, Backup
WASHER
SCREW, Piston
1
1
1
1
1
109 803511
Packing & Retainer,
3500 & 4000 psi
42
43
44
45
46
47
O–RING
RETAINER,
PACKING
PACKING
RING, Head
RETAINER,
PACKING
RING, Long Life
1
1
2
1
1
1
112 803512
Packing,
3500 & 4000 psi
44 PACKING 6

20 308525
Graco Standard Warranty
Graco warrants all equipment listed in this manual which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. With the exception of
any special extended or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or
replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed,
operated and maintained in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or
substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance or structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect
in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT
NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, gas engines,
switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance
in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties
reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures
judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
ADDITIONAL WARRANTY COVERAGE
Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment Warranty
Program”.
Graco Phone Number
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1–800–690–2894 Toll Free
All written and visual data contained in this document reflect the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Sales Offices: Minneapolis, Detroit
International Offices: Belgium, Korea, Hong Kong, Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
www.graco.com
PRINTED IN USA 308525 January 1991, Revised September 2002