Graco HYDRA-CLEAN 3540 Operation manual

308525
Rev. H
First choice when
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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

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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.

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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

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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).

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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.

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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

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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.

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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.

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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.