Sherwin-Williams 2800 User manual

OWNER’S MANUAL
820-1 80 Rev A
This manual contains Important
Warnings and Instructions.
Read the
manual and keep
i! for reference.
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9 HP ENGINE Model 2800 PRESSURE WASHER
PIN 820-175, Series A
28OOpsi’(lQB bar) OPERATING PRESSURE
3200 psi
(224 bar) MAXIMUM WORKING PRESSURE
TABLE OF CONTENTS
Warnings ......................... 2
. Installation ....................... 5
startup..
......................... 6.
Shutdown, Flushing and Storage .... 8
Maintenance ...................... 8
PartsDrawing8Lists 10
Troubleshooting Chart
......
.I.. ... 9
Pump Sewice .................... 14
Accessories
.....................
15
Technical Data
................... 15
Warranty
................ Back Cover
v.
....
.............
\ ........ \
.F”
The SHERWIN-WILLIAMS COMPANY, CLEVELAND, OHIO 441 15

HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURY.
FOR PROFESSIONAL USE ONLY OBSERVE ALL WARNINGS.
Read and understand all instruction manuals before operating equipment.
.. .
FLUID lNJECTlON HAZARD
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~;~&$~p~q%qy: ;%
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General Safety
This pressure washer generates very high fluid
components can inject fluid through your skin and into
pressure. Spray from the gun, leaks or ruptured
your body,
and cause extremely serious bodily injuq
including the need for amputation. Also, fluid injected or
damage.
splashed into the eyes or on the skin
can cause serious
NNER point the spray gun or wand at-anyone or at any
part of the body.
NWfR put hand or fingers over the
spray tip.
ALWAYS follow the Pressure Relief Procedure, before
cleaning or selvicing any part
of the sprayer.
NEVER try to stop or deflect leaks with your harid.or
body.
properly before each use.
Be sure equipment safety devices are operating
Medical Treatment
If any fluid appears to penetrate your skin, get
EMERGENCY MEDICAL TREATMENT AT ONCE.
DO
NOT TREAT AS A SIMPLE CUT. Tell the doctor exactly
what fluid was injected.
NOTE TO PHYSICIAN: lnjection
in the skin is a
traumatic
injuv. It is important to treat the injury
surgically
as soon as possible. Do not delay
treatment to research toxicify roxicify
is a concern
bloodstream. Consultation with a plastic surgeon or
with some exotic coatings injected directly into the
reconstnrctive hand surgeon may be advisable.
i
_.? .
..
2
Pressure Relief Procedure
To reduce the risk of serious bodily injury, including fluid
injection and splashing in the eyes or on the skin, always
follow this procedure whenever you stop spraying for
more than 10 minutes, when shutting down, and before
checking.or repairing any part of the system.
1.
2.
3.
4.
5.
6.
Engage the trigger safety latch.
.Turn the sprayer
off.
Remove the ignition cable from the spark plug.
Shut off the water supply.
Disengage the trigger safety latch and trigger the
gun
to relieve pressure, and then engage the trigger
safety latch again.
Before long-term (overnight) storage or transport-
ing
of the unit, disconnect the water supply and turn
off the fuel supply valve.
Spray Gun Safety Devices
Be sure all gun safety devices are operating properly
before each
use. Do not remove or modify any part of
the gun; this can cause a malfunction and result in
serious bodily injury.
SAFETY LATCH: Whenever you
stop spraying for a
or "safe" position, making the gun inoperative. Failure
moment, always set the gun safety latch in the engaged
to properly
set the safety latch can result in accidental
triggering of the gun.
SPRAY TIP SAFETY: Use extreme caution when
cleaning or changing spray tips.
'.
..
820- 180

EQUIPMENT MISUSE HAZARD
General Safety System Pressure
Any misuse of the pressure wisher or accesw)ries,
such
Bs overpressu~~n~, modifying using This sprayer can develop high operating pressures. Be
incompatible chemicals and fluids,
or using or sure that all spray equipment and accessories are rated
damaged
parts, can them to and to withstand the maximum working pressure of this
other serious bodily injury, fire, explosion or property Pressure of any component or accessory used in the
in fluid injection, splashing in the eyes or on the skin, or sprayer.
Do exceed the working
damage. system.
' . NEVER alter or modw any part of this equipment; doing
so could cause it to malfunction.
Chemical Compatibility
CHECK all spray equipment regularly and repair or
replace worn or damaged pm immediately.
BESURE that all chemicals used in the chemical injector
ALWAYS wear protective eyewear and appropriate are compatible with the wetted parts of the hose, gun,
clothing.
If using a chemical injector, read and follow the wand and tip, as given in the Technical Data (inside back
chemical manufacturer's literature for recommenda- cover). Always read the chemical manufacturer's
tions on additional protective equipment, such as a
. literature before using any chemical in this pressure
respirator.
.. washer.
HOSE SAFETY
..
High pressure fluid in the hoses can be very dangerous.
' If the hose develops a leak, split or rupture due to any
spray emitted from it can cause a fluid injection injury or
kind of wear, damage or misuse, the high pressure
other serious bodily injury or property damage.
pJ (..?*, AU FLUID HOSES MUST HAVE STRAIN RELIEFS ON
.<+>?
\i... BOTH ENDS. The strain reliefs help protect the hose
-ui.
from kinks or bends at or close to the coupling, which,
can result in hose rupture.
TlGHTENall fluid connections securely before each use.
High pressure fluid can dislodge a
loose coupling or
allow high pressure spray to be emitted from the
coupling.
NEVER use a damaged hose. Before each use, check
entire hose for cuts;leaks, abrasion, bulging cover, or
damage or movement of the hose couplings.
If any of
these conditions exist, replace the hose immediately.
DO NOT try to recouple high pressure hose or mend it
with tape or any other device. A repaired hose cannot
contain the high pressure fluid.
HANDLEAND ROUTE HOSES CAREFULLY Do not pull
on hoses to move the pressure washer.
Do not use
chemicals which are not compatible with the inner tube
temperatures above
200°F (93°C) or below
-4OaF
and cover of the hose. DO NOT expose Graco hose
lo
(-40°C).
FUEL AND EMISSION HAZARDS
NEVER fill the fuel tank while the unit is running or hot. odorless, invisible gas which can cause serious injury or
The fuel used in this
unit is combustible and when death if inhaled.
ALWAYSfill tank slowly to avoid spilling.
spilled on a hot surface can ignite and cause a fire.
NW€R alter the throttle setting, which is factory set.
NNER operate the unit in a closed building. The Tampering with this adjustment can damage the
exhaust contains carbon monoxide, a poisonous, pressure washer and will void the warranty.
820-180
3

MOVING PARTS HAZARD
body parts. K€€P CLEAR of moving parts when starting Pressure Relief Procedure before checking or
Moving parts
can pinch or amputate fingers or other and interiocks installed and functioning. Follow the
or operating the pressure washer. servicing the pressure washer
to prevent discharging
NNER operate the pressure washer without all guards
TERMS
WARNING: Alerts user to avoid or correct conditions NOTE Identifies helpful procedures and information.
that could cause bodily injuty.
CAUTION Alerts user to avoid or correct conditions
that could cause damage
to the equipment.
high pressure fluid
from the gun.
.. .
IMPORTANT
United States Government safely standards have been adopted under the Occupational Safety and Health Act. These
standardsparticularly the General Standards, Part 1910, and the Construction Standards, Part 1926-should be
consulted.
4
820 - 1 80

INSTALLATION
PRESSURE HOSE
CONNECTION
INLET WATER
COUPLER
CONNECTION
314"
GARDEN HOSE
Figure 1
Check for Shipping Damage
Check the unit for any damage that may have occurred
In shipping. Notify the carrier immediately if there is
Set Up
If you are using a downstream chemical injector, install
it between the pump unloader and the high pressure
hose, using the quick couplers provided.
chemical injector) outlet and the gun inlet. Both of these
Connect the high pressure hose between the pump (or
connections are made with quick couplers.
fi.!?.!,
t';:J
2 any damage.
CAUTION
Up to
100 ft (30 m) of high pressure hose may
performance, and chemical injector performance,
be used. Longer hoses may affect sprayer
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
to the water supply. A backflow preventer, P/N
local plumbing code regarding cross- connection
contaminated water into the fresh water supply.
801-133, is available to prevent backflow 'of
Install it upstream from the pump.
If inlet water pressure is over 60 psi (4.1 bar) a
regulating water valve,
P/N 800-258, 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 314 inch garden hose inlet.
The supply hose should not be more than
50 ff (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, inside back cover).
820- 180
5

STARTUP
Always use this startup procedure to ensure that the unit
is started safely and properly.
1. Check oil levels.
Engine: Add SAE
30 or low30 weight detergent oil as
necessary.
Pump: Add SAE
20 or 30 weight non-detergent oil as
necessary.
NOTE This unit 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 una
is refueled.
2. Check fuel level.
WARNING
DO NOT refuel a hot engine. Refueling a hot
regular or unleaded gasoline. Close the fuel
engine could cause a fire.
Use only fresh, clean
shutoff valve during refueling.
3. Turn on the water supply.
ICAUTION1 will result. Always be sure the water supply is
Never run the unit dry. Costly damage to the pump
completely turned on before operating.
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
On those units equipped with an ignition shutoff
ignition cable
is pushed fiirmly onto the spark plug.
the throttle in the "run" position.
switch, put the switch in the "on" position and put
6. Start the 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.
Grasp the starter rope, brace one foot on the pressure
washer chassis and pull rope rapidly and firmly.
Continue holding the rope as it returns. Pull and return
the rope until the engine
starts. 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.
ifthe engine is warm, leave the choke open, or just partly
close
it. Start the engine as described in the preceding
paragraph. When
it starts, be sure to open the choke
completely.
CAUTION
On recoil start engines, never let the starter rope
return by itself.
It could jam the recoil system.
7. ALWAYS engage the gun's trigger safety latch
whenever you stop spraying, even for a moment,
to
reduce the risk of fluid injection or splashing in the
accidentally.
eyes or on the skin if the gun is bumped or triggered
8. ALWAYS observe the following CAUTIONS to avoid
costly damage
to the pressure washer.
CAUTION
than 10 minutes. Doing so may cause the
DOfiOTallowthe pressure washerto idleformore
recirculating water
to overheat and seriously
damage the pump. Turn
off the pressure washer
if it will not be spraying or cleaning at least every
this time further.
10 minutes. If heated inlet water is used, reduce
DO NOT run the pump dry, which will quickly
damage the pump. Be sure the water supply
is
fully turned on before starting the pump.
DO NOT operate the pressure washer with the
inlet water screen removed. This screen helps
keep abrasive sediment out of the pump, which
could clog or scratch the pump. Keep this screen
clean.
DO NOT pump caustic materials; such materials
may corrode the pump components.
....
9. See the chemical injector or sandblaster kit manual
for detailed cleaning information
if these accesso-
ries are used.
6
820-180

Trigger Safety Latch
WARNING
To reduce the risk of serious bodily injuly,
including fluid injection, splashing in the eyes or
on
the skin, ALWAYS engage the trigger safety
latch whenever spraying stops, even for a
moment.
In the engaged position, the trigger safety latch
tally by hand or
if it is dropped or bumped. Be sure
prevents
the gun from being triggered acciden-
the latch is pushed fully down when engaging it or
1 cannot prevent the gun from being triggered.
See Figure 2.
,.
. ..
TRIGGER SAFETY LATCH SHOWN ENGAGED
TRIGGER SAFEPT LATCH SHOGN
Figure 2
DISENGAGED
installing and Changing Spray Tips
I WARNING 1
To reduce the risk of serious bodily injury,
onto the skin, use extreme caution when
including fluid injection or splashing in the eyes or
changing spray tips.
ALWAYS follow the proce-
dure below.
1. Follow the Pressure Relief Procedure:
2. Point the gun and wand away from yourself and
anyone else.
3. Without holding your hahd over the spray tip (A),
pull back the quick coupler ring (B). Remove the old
tip andlor install a new one, and then
release the
ring.
See Figure 3.
4. Be sure the tip is secure before starting to spray
again.
5. Tip holding holes are provided in the chassis.
CAUTION
To avoid blowing the o-ring out of the quick
coupler, due to the high pressure in the system,
Figure
3
020 - 1 00
7

SHUTDOWN, FLUSHING
AND STORAGE
, .
WARNING
Pressure Relief Procedure
To reduce the' risk of serious bodily injury,
including fluid injection and splashing
in the eyes,
or on the skin, always follow this procedure
whenever you stop spraying for more than
10
minutes, when shutting down, and before
checking or repairing any part of the system.
1. Engage the trigger safety latch.
2. Turn the sprayer off.
3. Remove the ignition cable from the spark
Plug.
4. Shut off the water supply.
5. Disengage the trigger safety latch and trigger
the trigger safety latch again.
the gun to relieve pressure, and then engage
6. Before long-term (overnight) storage or
transporting of unit, disconnect the water
supply, and turn
off the fuel supply valve.
1. If 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
unit with a
50% anti-freeze solution. Relieve
pressure. Flush the pressure washer before using
it again
to remove the anti-freeze.
NOTE
An anti-freeze flush kit, P/N 802-327, is available
to make flushing easier.
CAUTION
If water does freeze in the pressure washer, thaw
it in a warm room before trying to start it. DO NOT
pour hot water on or into the pump; it may crack
2. After each use, wipe all surfaces of the pressure
washer with a clean, damp cloth.
3. Perform the appropriate maintenance. See mainte-
nance chart.
MAINTENANCE
that you get maximum petformance and life from the
Observing regular maintenance intervals helps ensure
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
maintenance checks should be made more often.
-.
. ..
1" WARNING
.. i
I
To reduce the risk of serious bodily injury,
on the skin or injuty from moving palts, always
including fluid injection, splashing in the eyes or
follow the Pressure Relief
Procedure Warning
before proceeding.
I I
Interval What to do
Daily Clean water inlet screen and
filter. Check engine and pump
oil levels. Fill as necessaty.
Check gasoline level. Fill
as
necessary.
After first
5
hours of
Change engine break-in oil.
operation
Drain
oil when warm. Use SAE
30 or low30 detergent oil.
Each 25 hours Clean and remove air cleaner
of operation 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.
Each 100.
hours of
operation
or
3 months
Each
500
hours of
operation
Dr
6 months
Clean or replace paper air
cleaner cartridge. Tap gently
to
remove dirt. Change engine oil.
Use SAE
30 or IOW-30
detergent oil.
Change pump oil. Use
SAE 20
or 30 non-detergent oil.
820- 180

TROUBLESHOOTING CHART
WARNING 1
To reduce the risk of serious bodily injury, including fluid injection, splashing in the eyes or on the skin or injury
from moving parts, always follow the Pressure Relief Procedure Warning before proceeding.
,$,j,:,f;)
/.m
,.,. , .I
.~&,.
, . , ,. , . .
..
PROBLEM
Engine will not stat? or
is hard to start
Engine misses or lacks
power
Low pressure andlor
pump
NnS rough
Water leakage from
underpumpmanifold
Water in pump
Frequent or premature
hilure of the packings
jtrong, surging at the
nletandlowpressureon
he discharge side
CAUSE
No gasoline in fuel tank or carburetor.
Low oil
StarVstOp switch
in Stop position.
Water
in gasoline or old fuel.
Choked improperly. Flooded engine.
Dirty air cleaner filter.
'.
Spark plug dirty, wrong gap or wrong type.
Spray gun closed.
Partially plugged air cleaner filter.
Spark plug dirty, wrong gap
or wrong type.
Worn or wrong size tip.
Inlet filter clogged.
wear.
Wornpackings.abrasivesinwaterornatura1
Inadequate water supply.
Fouledordirtyinletordischargevalves.Even
asmall particle can cause thevahre lo stick.
Restricted inlet.
Worn inlet or discharge valves.
Leaking high pressure hose.
."< .
..
Worn packings,
Humid air condensing inside crankcase.
Worn packings.
Dil seals leaking.
Scored, damaged
or worn plungers.
4brasive material
in the fluid being pumped.
nlet water temperature too high.
3verpressurizing pump.
5cessivepressureduetopartiallypluggedor
iamaged tip.
lump running too long without spraying.
iunnina aumo d~~
'oreign particles in the inlet or discharge
'dve or worn inlet andlor discharge valves.
~ ~~~ ~
SOLUTION
Fill the tank with gasoline, open fuel shut off valve.
Check fuel line and carburetor.
Add to proper level.
Move switch
to Start position.
Drain
fuel tank and carburetor. Use new fuel and dry
spark plug.
Open choke and crank engine several times
to clear
out gas.
Remove and clean.
Clean, adjust the gap or replace.
Trigger spray
gun.
Remove and clean.
Clean, adjust the gap or replace.
Replace with
tip of proper size.
Clean. Check more frequently,
Check filter. Replace packings. See PUMP SERVICE.
Check water flow rate to pump.
Clean inlet and discharge valve assemblies. Check
filter.
See PUMP SERVICE.
Check garden hose, may be collapsed or kinked.
Replace worn valves.
See PUMP SERVICE.
Replace high pressure hose.
Install
new packings. See PUMP SERVICE.
Change pump oil.
Install new packings. See PUMP SERVICE.
Install new oil seals. See PUMP SERVICE.
Install new plungers. See PUMP SERVICE.
nstall proper filtration
on pump inlet plumbing.
:heck water temperature; may not exceed
16OOF.
30 not modify any factory-set adjustments. See
EQUIPMENT MISUSE HAZARD.
:lean or replace tip. See Installing and Changing
spray lips.
Wer
run pump more than 10 minutes without
;praying.
10 not run pump without water.
:lean or replace valves.
See PUMP SERVICE.
9

PARTS DRAWING
820-175 Model 2800 Pressure Washer
!.
!.

PARTS LIST
820-175 Model 2800 Pressure Washer
REF PART
NO. NO. DESCRIPTION ON NO. NO. DESCRIPTION
REF PART
1
2
3
4
5
6
7
8
10
9
11
12
13
15
14
16
17
18
20
19
22
21
24
23
25
26
27
28
800-392
GUNB~WhJD ASSEMBLY
~~
29 803-925 HANDLE
lincl. 17. 191 1 30 800-641 FRONT LEG ASSEMBLY
801-504
, 181-867
801-1 11
NUT, Garden Hose
802-363
1
179-885
LABEL, Wamin
32 101-566 Na Nylon LOck,'3/&16
803-900 ENGINE, 9 hp, a ondaOHV 1
1 33 m1 CHASSIS
802-127 SCREW, Cap, hex hd..
34 801-012 GROMMET, Rubber
35 801-367 BUMPER, Rubber
1 820-137 LABEL, ID . '
1 100-527 WASHER, Flat; 5/16 14
1 37 804-051
FILTEiUSTRAINER
38 803-083 LABEL, Kee From Freezing
804-391 LABEL, Model 2800
801-568
QUICK COUPLER, 3/8 Male , 2
1 41 800-124
RP ASSEMBLY, 0004
802-579
HOSE, High Pressure, 3/8 x 50' 1
42 800-125
TIP ASSEMBLY, 1504
43 800-126
TIP ASSEMBLY, 2504
44 800-127 TIP ASSEMBLY, 4004
111-040
NUT. Nylon Lock, 5/16-16 10 - 45 ' 801-907 WASHER, Flat
803350 GUN, Spray (see 308-51 1) 46 801-905 ADAPTER
801-941 SCREW, Cap. hex hd. 47 156-849 NIPPLE, Hex. 3/8 NPT
801-009 QUICK COUPLER. 114 Female
49 800-745 UNLOADER. Preset. 2800 DSi
154-636
101
-545
. ' 5/16-18~1.75 4 I 36 804-398 BRACKn, Pump Support
801-539 BUMPER
1 40 801-1 10 ADAPTER, garden Hose
801-569 COUPLING 1
5/16-18 x 1 4 48 801-709 . PLUG
BUMPER,'Rubber
LABEL, Warning
LABEL. Caution
2
" .. ~ ~ . . .
1 .31 ' 800-377 H s""'. SEA 2A SEMBLY
1 lincl. 13. 14.15)
WASHER, Flat,;5/8
COlTER PIN
4 50 802-627 NIPPLE, Hex,
2 318 NPT x 1 14 NPT
800-743 PUMP- ~ ~ ~
1
803-740 WHEEL 8 TIRE ASSEMBLY 2
801-546
SCREW, Cap, hex hd.
803-741 AXLE 1
318-16 X 1.25 4
100.023 WASHER, Flat, 3/8 8
154-494 O-RING, Quick Coupler, 1/4
156-082
O-RING, Quick Coupler, 3/8
(not shown) AR
(not shown) AR '
51 803-869
HOSE, Bypa&
52 801-523 NIPPLE. 112 NPT
53 " 8ol~ios T.EE,l/2NpT-~ -
54 804-397
THERMAL RELIEFVALVE
55 801-090 QUICK COUPLER. 1/4 Male
.~
56 801-599 ie Bare, 0004-~ ~'
57 801-600 TIF: Bare, 1504
58 801-601 TIP Bare. 2504
59 801-602
TI+ Bare; 4004
QTY
1
1
4
1
1
4
.1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
820- 180
11

PARTS DRAWING
800-743 Pump Asse
I
,' 81
82
,/
I
I
/

PARTS LIST
800-743 Pump Assembly
REF PART
NO. NO.
2 801-651
1 804-405
4 KIT123
3 801-652
5 KIT123
6 KIT 123
7 KIT123
8 KIT123
9 KIT 124
11 KIT123
10 KIT124
12 803-265
13 803-266
14 804406
16 804407
15 803-268
17 KIT23
19 801459
18 804408
22 804-409
23 804410
25 804-412
24 804-411
26 803-273
28 801-753
27 801-488
29 804413
HEAD, Pump
DESCRIPTION
WASHER
SCREW
VALVE
SEAT, Valve
SPRING
CAGE, Valve
CAP
VALVE ASSEMBLY
SCREW
COVER, Bearing
SPACER
O-RING
BEARING
.
SEAL, Oil
CRANKCASE
DIPSTICK
GUIDE, Piston
ROD, Connecting
COVER, Rear
SCREW
SCREW, Cap
PIN
O-RING
O-RING
5
O-RING
O-RING
OM
REF PART
1
NO. NO.
30 804414
8
8 31 803-919 32 803-918
33 804415
34 803-921
40 KIT130
41 KIT 130
43 KIT130
42 KIT 130
8
44 KIT130
2
45 KIT 130
1 48 801484
1 48 801485
47 801482
2
75 804416
49 801-483
1 76 804417
1
3
77 804-418
3 79 804420
1
1 80 801-469 81 804421
5
1
82 804-422
1 84 803-292
83 803-278
3
35 803-920
7a 804-419
WASHER
DESCRIPTION
RING, Anti-Extrusion
PISTON
WASHER
O-RING
NUT
O-RING
RETAINER, Packing
RING, Intermediate
PACKING
RING, Head
PACKING
SCREW, Cap
SCREW, Cap
WASHER
WASHER.
CRANKSHAFT
RING, Retaining
BEARiNG
SCREW
WASHER
FLANGE, Gas
SEAL, Oil
WASHER
SCREW
O-RING
QN
3
3
3
3
3
3
1
1
1
1
1
1
1
1
4
4
1
1
4
4
Klt
6'
6
SPRING
7
CAGE, Valve
8
6
6
VALVE
6
SEAT, Valve
5
Valve Assembly
6
O-RING
4
804-402 123
Oil Seal
3
SEAL.Oil
17
801458
23
OW._
Descrlpthx
No.
Ref.
Part No. No.
Repalr KR
II I
:!* I VALVE ASSEMBLY II 6
124
Valve Cap
804-403
Packing
804404
130
6
CAP
10
6
O-RING
9
40
O-RING
1
41
RETAINER, Packing
1
Assembly
42
RING, Intermediate
1
43
PACKING
1
44
PACKING
45 RING, Head
2
2
Item 11 consists of items 4 through 8.
-
.
See Pump Assembly illustration on previous page.
820- 180 13

-~
PUMP SERVICE
WARNING
To reduce the risk of serious bodily injury,
including fluid injection, splashing In the eyes or
on the skin, or injury from moving parts, always
follow the Pressure Relief Procedure Warning
before proceeding.
NOTE The following metric wrenches are needed:
the individual repair sections and the pump parts page
M10, M13 and M30. Repair kB are available. Refer to
for more details. For the best results, use all parts in the
kits.
NOTE There are two different tool kits to aid in servicing
the pump. P/N
800-298 is used to ease installation of
packings. P/N
800-271' includes the items in 800-298
and tools to aid in the removal of packing retainers.
Valves
NOTE For a set of six valves, order P/N 8011172.
1.
2.
3.
. .-
. ..
4.
Remove the hex plug from the manifold using an
M30'wrench.
Examine the O-ring under the hex plug and replace
it if it is cut or distorted.
Remove the valve assembly from the cavity; the
assembly may come apart.
torque to 75 ft-lb (103 Nm).
Install the new valve. Install the O-ring and hex plug;
NOTE Retorque the plug after
5 hours of operation.
Pumping Section
1. Remove the eight capscrews and lockwashers from
the manifold using an
M13 wrench.
2. Carefully separate the manifold from the crankcase.
NOTE It may be necessary
to tap the manifold lightly
with a soft mallet
to loosen.
ICA_lD*1
Keep the manifold properly aligned with the
damage
to the plunger or seals.
ceramic plungers when removing
to avoid
3. Carefully examine each plunger for any scoring or
cracking and replace
as necessary.
14
Servicing the Plungers
NOTE: Plunger repair kt, P/N 801-474 is available to
replace retainers, O-rings. washers and backup rings for
three cylinders.
1.
2.
3.
4.
5.
6.
Loosen the plunger retaining screw five to six turns,
using an MlOwrench. Push the plungertowards the
crankcase
to separate the plunger and retaining
screw.
the O-ring. backup ring and copper bearing/gasket
Remove the screw from the plunger and examine
washer. Replace these parts, if necessary, using kit
801474.
Remove the plunger and flinger from the plunger
shaft. Clean, examine and replace parts as
necessary.
Inspect the plunger shaft for oil leakage from the
crankcase.
If leaking is obvious, replace the oil
seals. Otherwise,
DO NOT remove these seals as
they cannot be reused. An oil seal kit is available to
replace the seals.
tightly grease the flinger and oil seal, if
it is being
replaced, and replace them on the plunger shaft.
Then install the plunger.
Lightly grease the retaining screw and the~outer end
of the plunger. Place the washer, O-ring and backup
ring around the screw and install the screw through
the 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.
8.
Lubricate the outside of each plunger. Slide the
damage the seals.
manifold onto the crankcase, being careful not
to
Torque the screws to 21.7 ft-lb (29 Nm) following the
Install the capscrews and washers finger-tight.
tightening pattern (Figure
4). Uneven tightening
may cause the manifold to bind or jam.
I 1
Figure 4
820- 180

Servicing the V-Packings 5.
packings only, the other includes the packings, rings
NOTE: There are two types of packing kits: one is
and retainers. 6.
1.
2.
3.
4.
Remove the manifold as outlined in the Pumping
Section.
for debris and damage.
Thoroughly clean the packing cavities
and examine
Lightly grease the packing cavities and then replace
the packings
in the following order: head ring,
v-packing, intermediate ring, head ring, v-packing
and packing retainer with the O-ring installed in the
retainer groove.
manifold. &amine the o-ring-and replace
it if it is cut
or damaged.
Remove the v-packing and head ring. Pull
out the I
correct direction. Improperly installed parts will
cause a malfunction.
intermediate retainer ring. Remove the second
I
v-packing and second head ring. ..
Inspect all parts and replace as necessaty. the Plungers.
~ ~ ~~ ~~ ~
7. Reassemble the manifold as instructed in Servicing
ACCESSORIES
(Must be purchased separately)
800-1 17
DOWNSTREAM CHEMICAL INJECTOR KIT ANTI-FREEZE FLUSH KIT 802-327
For flushing system with 50% anti-freeze solution prior
For injecting harsh cleaning chemicals downstream
to transporting or storing pressure washer in below
from
the pump. freezing temperatures.
UPSTREAM CHEMICAL INJECTOR KIT
For injecting mild cleaning chemicals upstream into the
pump.
800-257 INLET PRESSURE REGULATOR 800-258
Regulates inlet water pressure to 60 psi (4 bar)
maximum.
BACKFLOW PREVENTOR 801-133
supply. Install upstream of pump.
Prevent back-up of contaminated water into fresh
TECHNICAL DATA
Model 800-638
Engine (air-cooled, 4 cycle) 9 hp Honda OHV
Gasoline Tank Capacity
6.2 quarts (6 liters)
Water Pump Maximum Working Pressure
2800 psi (196 bar)
Water PumD Maximum Flow
3.5 aDm 113.2 Ium)
Inlet Hose Connection
-. .
3/4" garden hose (f)
..
Weight 125 Ib (57 kg)
Dimensions
Width
Length 36" (914 mm)
Height
21 " (533 mm)
23.5" (597 mm)
Maximum Inlet Water Temperature 160-F
(70°C)
Wetted Parts
High Pressure Hose Acrylonitrile and Buna-N cover and tube
Bypass
Hose Synthetic yam and EPDM
Pressure Washer (including fittings) Anodized aluminum, Aluminum
or bronze alloys, Brass Copper, Nylon-
composite, Ceramic, Buna-N on phenolic,
303, 304, and 316 Stainless steel,
Polymide-12 thermoplastic, Carbon steel. Zinc plate, with or without yellow
chromate
is
a registered bademark of the DuPont Cornpaw.
820- 180 15
PTFE
PTFE
PTFE
PTFE
PTFE
PTFE
PTFE
PTFE
PTFE
PTFE

THE SHERWIN-WILLIAMS WARRANTY AND DISCLAIMERS
WARRANTY
Graco warrants all equipment manufactured by it and bearing its name to be free from defects in materiil and workmanship on ths
date of sale by an authorized Gram distributor to the original purchaser for use.
As purchaser's sole remedy for breach of this,,!;,,;:? ) I,
ranty, Graco will, for a period of twenty four months fmm the date of sale, repair or replace any pad of the equipment proven de;S:?:',- I
tiie. This warranty applies onlywhen the equipment is installed, operated and maintained in accordance with Graco's written me ;',
ommendations.
This warranty does not cover, and Graco shall not be liable for, any malfunction, damage or wear caused by
faulty installation, mis- !,,
application, 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 with Graw
!;
\.
equipment of structures,' accessories. equipment or materials not supplied by Graco, or the improper design, manufacture, installa- i;,
tion. operation or maintenance of 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 Gram distributor .'
for verification of the claim. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment
wilt be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any fs
defect in material or workmanship. repairs will be made at a reasonable charge, which charges may include the costs of pam,
labor and transportation.
DISCLAIMERS AND LIMITATIONS
L:./
I;!.
The tens of this warranty constlute purchaser's sole and exclusive remedy and & in lieu of any other warranties (express or [i
implied), lncludlng warranty of merchantablllty or warranty of fitness for a partlcular purpose, and of any non-contractual ;::
liabilities, including product liabilities, based on negligence or strict liability. Every form of liability for direct, special or consequential 1'
damages or loss is expressly excluded and denied. In no case shall Graco's liability exceed the amount of the purchase price. Any
action for breach of warranty must be brought within two (2) years of the date of sale.
! ..
EQUIPMENT NOT COVERED BY GRACO WARRANTY
Graco makes no warranty, and disclaims all implied warranties of merchantablllty and fitness for a partlcular purpose, with i ;
c:
respect to accessories, equipment, materials, or components sold but not manufactured by Gram. These items sold. but not
manufactured by Graco (such as engines, pumps, 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. i., .
...
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The SHERWIN-WILLIAMS COMPANY, CLEVELAND, OHIO 44115
PRIMEDIN USA. 820-180 2-93 Revlsed2-93