Graco Pressure Washer 2500 psi User Manual

INSTRUCTIONS–PARTS LIST  
308524  
Rev. K  
This manual contains important  
warnings and information.  
READ AND KEEP FOR REFERENCE.  
INSTRUCTIONS  
Belt-Drive Pressure Washers  
2545  
Model 800629, Series B  
2500 psi (17.2 MPa, 172 bar) Operating Pressure  
2900 psi (20 MPa, 200 bar) Maximum Working Pressure  
3040  
Model 800632, Series B  
3000 psi (20.6 MPa, 206 bar) Operating Pressure  
3400 psi (23.4 MPa, 234 bar) Maximum Working Pressure  
3235  
Model 800634, Series B  
3200 psi (22.1 MPa, 221 bar) Operating Pressure  
3600 psi (24.8 MPa, 248 bar) Maximum Working Pressure  
04607  
3040 Pressure Washer  
Model 800632  
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441  
ECOPYRIGHT 1995, GRACO INC.  
Graco Inc. is registered to I.S. EN ISO 9001  
 
WARNING  
MOVING PARTS HAZARD  
Moving parts, such as the drive belt, can pinch or amputate fingers.  
D Keep clear of moving parts when you start or operate this equipment.  
D Do 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.  
D Know the specific hazards of the fluid being used.  
D Store hazardous fluids in approved containers. Dispose of hazardous fluids per local, state, and  
national guidelines.  
D Wear protective eye wear, gloves, clothing, and respirator as recommended by the fluid and  
solvent manufacturer.  
FUEL HAZARD  
The fuel used in this pressure washer is combustible. When spilled on a hot surface, it can ignite and  
cause a fire.  
Do not fill the fuel tank while the engine is running or hot.  
EXHAUST HAZARD  
The exhaust contains poisonous carbon monoxide, which is colorless and odorless.  
Do not operate this equipment in a closed building.  
EQUIPMENT MISUSE HAZARD  
Misuse of the pressure washer or accessories may cause them to rupture and result in fluid injection,  
splashing in the eyes or on the skin, or other serious injury.  
D Do not alter or modify any part or factory-set adjustment of this equipment.  
D Do not exceed the maximum working pressure of any component or accessory in the system.  
D Do not use any chemicals that are incompatible with the wetted parts as stated in the Technical  
Data on page 15.  
D Do not alter the throttle setting.  
308524  
3
 
Setup  
high-pressure hose  
connection  
gun  
hose  
hose  
rack  
inlet water  
connection  
3/4” garden  
hose  
TI1262A  
Check for Shipping Damage  
Connect to Water Supply  
Check the pressure washer for shipping damage. If  
anything is damaged, notify the carrier immediately.  
CAUTION  
Before you connect to the water supply, check  
your local plumbing code regarding cross  
connection to the water supply. Backflow  
Preventer 801133 is available to prevent  
backflow of contaminated water into the fresh  
water supply. Install it upstream from the pump.  
Set Up  
Connect the high-pressure hose between the pump  
outlet and the gun inlet. Both of these connections are  
made with quick couplers.  
If inlet water pressure is over 60 psi (414 kPa,  
4.1 bar) Regulating Water Valve 800258 must be  
installed at the garden hose connection.  
CAUTION  
Up to 100 ft (30 m) of high-pressure hose may  
be used. Longer hoses may affect sprayer and  
chemical injector performance.  
Do not exceed 160_ F (70_ C) inlet water  
temperature.  
Connect a hose with at least a 3/4-in. (19 mm) ID from  
the water supply to the 3/4-in. garden hose inlet. The  
supply hose should not be more than 50 ft (15 m) long  
Install the appropriate spray tip on the wand. See  
Installing and Changing Spray Tips on page 6. If  
you use a sandblaster kit, see its separate manual for  
installation instructions.  
NOTE: The water source must have a minimum flow  
rate equal to that of the pressure washer. See  
Technical Data on page 15.  
4
308524  
 
Pressure Relief Procedure  
1. Engage the trigger safety latch.  
WARNING  
INJECTION HAZARD  
2. Turn off the pressure washer, and remove the  
ignition cable from the spark plug.  
The system pressure must be manually  
relieved to prevent the system from  
3. Shut off the water supply.  
4. Disengage the trigger safety latch, trigger the gun  
to relieve the pressure, and engage the trigger  
safety latch.  
spraying accidentally. To reduce the risk  
of an injury from accidental spray from the gun,  
splashing fluid, or moving parts, follow the  
Pressure Relief Procedure when you  
If you suspect that the spray tip or hose is clogged or  
that pressure has not been fully relieved after following  
the steps above: Disengage the trigger safety latch,  
and trigger the gun to relieve pressure. Wrap a rag  
around the hose end coupling, and VERY SLOWLY  
loosen the coupling to relieve pressure gradually. Then  
loosen it completely. Then clear the tip or hose.  
D Are instructed to relieve the pressure  
D Stop spraying for more than 10 minutes  
D Check or service any of the system equipment  
D Install or clean the spray nozzle  
Operation  
Startup  
Always use this startup procedure to ensure that the  
pressure washer is started safely and properly.  
3. Turn on the water supply.  
D Always engage the gun trigger safety latch when  
you stop spraying even for a moment. This reduces  
the risk of fluid injection or splashing in the eyes or  
on the skin if the gun is bumped or triggered  
accidentally.  
CAUTION  
Never run the pressure washer dry. Costly  
damage to the pump will result. Always be sure  
the water supply is completely turned on before  
you run the pressure washer.  
D Always observe the CAUTIONS in this section to  
avoid costly damage to the pressure washer.  
D If you use the Sandblaster Kit, see the Sandblaster  
4. Trigger the gun until water sprays from the tip  
indicating that the air is purged from the system.  
Kit manual for detailed cleaning information.  
D See manual 308513 for chemical injector operation  
and service.  
5. Open the fuel shutoff valve. Be sure the spark plug  
ignition cable is pushed firmly onto the spark plug.  
Put the engine switch in the ON position, and put  
the throttle in the RUN position.  
1. Check the oil level.  
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 engine stops  
unexpectedly, check the oil and the fuel levels. Check  
the oil level each time you refuel.  
CAUTION  
Do not allow the pressure washer to idle for more  
than 10 minutes. Doing so may cause the  
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 10  
minutes. If heated inlet water is used, reduce this  
time further. Do not operate the pressure washer  
with the inlet water screen removed. This screen  
helps keep abrasive sediment, which could clog  
the pump or damage the pump cylinders, out of the  
pump. Keep this screen clean. Do not pump  
caustic materials; such materials could corrode the  
pump components.  
2. Check the fuel level.  
WARNING  
FIRE HAZARD  
Do not refuel a hot engine. Refueling a  
hot engine could cause a fire. Use only  
fresh, clean, regular or unleaded gasoline. Close  
the fuel shutoff valve during refueling.  
308524  
5
 
Operation  
6. Pull the starter rope to start the engine. Brace one  
Spray Tip Number  
Spray Pattern Fan Angle  
0_ blaster (red)  
15_ (yellow)  
foot on the pressure washer cart, and pull the  
00XXX  
starter rope out quickly.  
15XXX  
25XXX  
25_ (green)  
CAUTION  
40XXX  
40_ (white)  
Do not allow the starter rope to snap back against  
the engine. Let the rope recoil gently to prevent  
damage to the recoil mechanism.  
NOTE: The chemical injector tip is brass and has a  
large opening and a black plastic cap.  
NOTE: For easier starting, have one person start  
the pressure washer while another person triggers  
the gun.  
Relieve the pressure.  
See page 5.  
1.  
If the engine is cold, start the engine with the  
choke completely closed. In cool weather, you  
might have to let the engine run with the choke  
closed for the first 10 to 30 seconds. In warm  
weather, open the choke completely as soon as  
the engine starts.  
2. Point the gun and wand away from yourself and  
anyone else.  
3. Without holding your hand over the spray tip (A),  
pull back the quick coupler ring (B). Remove the  
current tip and/or install a different one. Then push  
back the ring. See Fig. 2.  
If the engine is warm, start the engine with the  
choke completely open or partially closed. When  
the engine starts, open the choke completely.  
4. Pull on the tip to be sure it is secure before you  
spray again.  
Trigger Safety Latch  
CAUTION  
To avoid blowing the O-ring out of the quick coupler  
due to the high pressure in the system, never  
operate the pressure washer without a tip securely  
mounted in the quick coupler.  
WARNING  
To reduce the risk of serious bodily injury, including  
fluid injection or splashing in the eyes or on the  
skin, always engage the trigger safety latch when  
you stop spraying even for a moment. In the  
engaged position, the trigger safety latch prevents  
the gun from being triggered accidentally by hand  
or if it is dropped or bumped. Be sure the latch is  
pushed fully down, or it will not prevent the gun  
from being triggered. See Fig. 1.  
B
A
Trigger Safety Latch  
04929  
Fig. 2  
0412B  
engaged  
disengaged  
Fig. 1  
Installing and Changing Spray Tips  
Spray tips have 4- or 5-digit numbers on them. The  
first two digits are the spray angle. Select the spray tip  
appropriate for your application. Tip holding holes are  
provided on the chassis.  
6
308524  
 
Operation  
Water Sandblasting  
Maintenance  
Water Sandblasting Kit 244766 is available for  
abrasive cleaning of stubborn dirt and paint. The kit  
requires a sandblasting tip, sold separately as follows:  
Observing regular maintenance intervals helps ensure  
that you get maximum performance and life from the  
pressure washer.  
D 2545 pressure washer uses sandblasting  
There is a break-in period for the engine and pump.  
After you change the oil in these components following  
their respective break-in periods, the interval between  
required changes is longer.  
tip 805325.  
D 3040 pressure washer uses sandblasting  
tip 805317.  
D 3235 pressure washer uses sandblasting  
If the pressure washer is operated in dusty conditions,  
these maintenance checks should be made more  
often.  
tip 805313.  
Shutdown, Flushing, and Storage  
Maintenance Chart  
CAUTION  
If water freezes in the pressure washer, thaw it in a  
warm room before you try to start it. Do not pour  
hot water on or into the pump; it may crack the  
ceramic plungers!  
Relieve the pressure  
(see page 5) before you  
proceed with maintenance.  
Interval  
What to do  
Daily  
Clean water inlet screen and filter.  
Check engine and pump oil levels.  
Fill as necessary. Check gasoline  
level. Fill as necessary.  
D 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 it  
with a 50% antifreeze solution, and relieve the  
pressure. Flush the pressure washer before you  
use it again to remove the antifreeze.  
After first  
5 hours of  
operation  
Change engine break-in oil. Drain  
oil when warm. Use SAE 30 or  
10W–30 detergent oil.  
After every  
25 hours of  
operation  
Clean and remove air cleaner  
foam. Wash with water and  
detergent. Dry thoroughly. Rub  
with oil, and squeeze to distribute  
oil.  
D Before you store the pressure washer overnight or  
transport it, disconnect the water supply, and turn  
off the fuel supply valve.  
D After each use, wipe all surfaces of the pressure  
After first  
50 hours of  
operation  
Change pump break-in oil. Use  
SAE 20 or 30 non-detergent oil.  
washer with a clean, damp cloth.  
D Perform the appropriate maintenance. See  
Maintenance Chart at right.  
After every  
100 hours of  
operation, or  
Clean or replace paper air cleaner  
cartridge. Tap gently to remove  
dirt. Change engine oil. Use SAE  
every 3 months 30 or 10W–30 detergent oil.  
After every  
Change pump oil. Use SAE 20 or  
30 non-detergent oil.  
500 hours of  
operation, or  
every 6 months  
308524  
7
 
Pump Service  
Repair kits are available. See Pump Repair Kits on page 13. For the best results, use all parts in the kits.  
Pumping Section  
Relieve the pressure  
(see page 5) before you  
proceed with service.  
1. Remove the eight capscrews and lockwashers  
from the manifold using a 13 mm wrench.  
NOTES:  
2. Carefully separate the manifold from the  
crankcase.  
D The following metric wrenches are needed:  
10 mm, 13 mm, and 30 mm.  
NOTE: You might have to tap the manifold lightly with  
a soft mallet to loosen it.  
D There are two tool kits to aid in servicing the pump.  
Kit 800298 is used to ease installation of packings.  
Kit 800271 includes the items in 800298 and tools  
to aid in the removal of packing retainers.  
CAUTION  
To avoid damage to the plunger or seals, keep the  
manifold properly aligned with the ceramic plungers  
when you remove it.  
Valves  
NOTE: For a set of six valves, order 801472.  
3. Carefully examine each plunger for any scoring or  
cracking, and replace as necessary.  
1. Remove the hex plug from the manifold using a  
30 mm wrench.  
Servicing the Plungers  
2. Examine the o-ring under the hex plug and replace  
it if it is cut or distorted.  
NOTE: Plunger repair kit 801474 is available to  
replace retainers, o-rings, washers, and backup rings  
for three cylinders.  
3. Remove the valve assembly from the cavity; the  
assembly may come apart.  
1. Loosen the plunger retaining screw five to six turns  
using a 10 mm wrench. Push the plunger towards  
the crankcase to separate the plunger and  
retaining screw.  
4. Install the new valve. Install the o-ring and hex  
plug; torque to 75 ft-lb (103 NSm).  
NOTE: Retorque the plug after 5 hours of operation.  
2. Remove the screw from the plunger, and examine  
the o-ring, backup ring, and copper bearing/gasket  
washer. Replace these parts, if necessary.  
3. Remove the plunger and flinger from the plunger  
shaft. Clean, examine, and replace parts as  
necessary.  
4. Inspect the plunger shaft for oil leakage from the  
crankcase. If leaking is obvious, replace the oil  
seals. Otherwise, DO NOT remove these seals  
because they cannot be reused. Oil Seal Kit  
801473 is available for replacing the seals.  
5. Lightly grease the flinger (and the oil seal if it is  
being replaced), and replace on the plunger shaft.  
Then install the plunger.  
8
308524  
 
Pump Service  
6. Lightly grease the retaining screw and the outer  
Servicing the V-Packings  
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 NSm).  
NOTE: There are two types of packing kits:  
801486 contains packings only.  
801487 contains packings, rings, and retainers.  
NOTE: If you plan to replace the packings, See  
Servicing the V-Packings at right.  
1. Remove the manifold as outlined in Pumping  
Section on page 8.  
7. Lubricate the outside of each plunger. Slide the  
manifold onto the crankcase, being careful not to  
damage the seals.  
2. Carefully pull the packing retainer (43) from the  
manifold. Examine the o-ring (42), and replace if  
cut or damaged.  
8. Install the capscrews and washers finger tight.  
Torque the screws to 21.7 ft-lb (29 NSm) following  
the tightening pattern in Fig. 3. Uneven tightening  
can cause the manifold to bind or jam.  
3. Remove intermediate ring (46). Pull out restop  
v-packing (47). Remove the second V-packing (44)  
and ring head (45).  
4. Inspect all parts, and replace as necessary.  
5. Thoroughly clean the packing cavities, and  
examine for debris or damage.  
5
8
1
3
4
2
7
6
6. Lightly grease packing cavities, and replace packings  
in following order: ring head (45), V-packing (44),  
restop packing (47), intermediate ring (46). Install  
o-ring (42) in retainer groove and then install retainer  
ring (43) with low pressure seal (57).  
Fig. 3  
CAUTION  
Install the parts in the proper order and facing the  
proper direction. Improperly installed parts will  
cause a malfunction.  
7. Reassemble the manifold as instructed in  
Servicing the Plungers on page 8.  
308524  
9
 
Pressure Washer Parts  
Model 800629, Series B: 2545 Pressure Washer  
Model 800632, Series B: 3040 Pressure Washer  
Model 800634, Series B: 3235 Pressure Washer  
38  
37  
21  
87  
79  
96  
41  
74  
93  
36  
71  
55  
84  
73  
88  
48  
84  
83  
78  
70  
42  
34  
43  
67  
44  
39  
81  
67  
77  
80  
29  
30  
31  
32  
33  
76  
82  
89  
94  
95  
69  
45  
4
7
49  
55  
67  
84  
28  
25  
26  
46  
47  
9
51  
67  
6
84  
9
5
84  
85  
15  
55  
2
19  
84  
86  
22  
84  
13  
55  
2
18h  
14  
86  
15  
18a  
10  
11  
18c  
12  
23  
18e  
18g  
1
17  
18f  
18b  
18d  
18  
04604B  
10  
308524  
 
 
Pressure Washer Parts  
Ref.  
No.  
Ref.  
No.  
Part No. Description  
Qty.  
Part No. Description  
Qty.  
1
2
4
5
6
7
9
244450  
GUN & WAND ASSEMBLY  
WASHER, flat; 3/8  
BUMPER  
1
4
1
1
1
1
3
2
2
2
1
1
4
Model 800634  
100023  
801539  
803926  
803534  
800676  
100214  
29 805543  
30 805544  
31 805545  
32 805546  
33 805634  
34  
803297  
803737  
36 802127  
0004 (blasting)  
1504 (15_)  
1
1
1
1
1
1
1
1
4
BELT GUARD  
2504 (25_)  
LABEL, ID  
CHASSIS  
4004 (40_)  
TIP ASSY, (chemical injector)  
PUMP (page 18)  
Model 800629  
WASHER, lock; 5/16  
WHEEL, pneumatic  
WASHER, flat; 1/2  
NUT, lock; 1/2–13  
AXLE  
BRACKET, rail stiffener  
SCREW, cap, hex hd.  
3/8–16 x 1–1/4  
LABEL, ID  
10 801550  
11 801612  
12 801020  
13 801556  
14 800678  
15 801546  
Models 800632 and 800634  
SCREW, cap, hex hd.  
5/16–18 x 1–3/4  
37 802363  
38 290013  
39 803158  
41 804356  
42 804376  
LABEL, Caution  
1
1
1
1
1
LABEL, Warning  
ENGINE, 11 hp, Honda OHV  
BUMPER, rubber  
SCREW, cap, hex hd;  
5/16–18 x 3/8  
BELT, drive  
HUB, engine  
SHEAVE, engine  
Models 800629 and 800634  
Model 800632  
17  
1
1
1
1
1
803303  
803161  
803904  
18 800160  
Model 800629  
Model 800632  
Model 800634  
43 801285  
44 801898  
45  
801911  
803941  
46 801135  
47  
801004  
803890  
48 804495  
49 803531  
51 801522  
2
1
1
1
1
1
1
1
1
1
1
2
FRONT LEG ASSEMBLY  
(includes 18a to 18h)  
@ LEG, Front  
18a 801537  
18b 801506  
18c 801593  
18d 801505  
18e 801504  
18f 801531  
18g 100132  
18h 101566  
19 803925  
21 804498  
22 803298  
1
1
1
1
1
@ BOOT  
@ SPRING  
HUB, pump  
@ RETAINER, spring  
SHEAVE, pump  
@ BUMPER, rubber  
Model 800629  
@ SCREW, cap, hex hd; 3/8–16 x 7 1  
Models 800632 and 800634  
LABEL, Warning  
PLATE, back  
SCREW, cap, hex hd;  
5/16–18 x 6–1/2  
NUT, lock; 5/16–18  
SCREW, flange, hex hd;  
5/16–18 x 3/4  
BRACKET, pump  
NIPPLE  
UNLOADER ASSEMBLIES  
Model 800629 (2500 psi)  
Model 800632 (3000 psi)  
Model 800634 (3200 psi)  
NIPPLE  
@ WASHER, flat  
@ NUT, lock; 3/8–16  
HANDLE  
1
1
1
1
1
QUICK COUPLER, 3/8 male  
SCREW, cap, hex hd.  
5/16–18 x 3–1/2  
HOSE ASSEMBLY  
BRACKET, rail stiffener  
LABEL, Warning  
GROMMET, rubber  
TIP ASSEMBLIES  
Model 800629  
55 111040  
67 110963  
13  
5
23 244449  
25 802016  
26 804500  
28 801012  
29 to 32  
1
1
1
5
69 801526  
70 156849  
71  
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
20  
4
4
1
1
1
1
4
4
1
800323  
800324  
800325  
29 805555  
30 805556  
31 805557  
32 805558  
00055 (blasting)  
15055 (15_)  
1
1
1
1
73 803142  
74 803141  
76 801111  
77 801110  
78 804051  
79 402278  
80 801622  
81 801523  
82 116461  
83 804382  
84 100527  
85 100450  
86 100133  
87* 804388  
88 804275  
89 801683  
93 162024  
94 802304  
95 802305  
96 801137  
25055 (25_)  
BYPASS HOSE  
40055 (40_)  
NUT, garden hose  
ADAPTER, garden hose  
FILTER  
Model 800632  
29 805547  
30 805548  
31 805549  
32 805550  
00045 (blasting)  
15045 (15_)  
1
1
1
1
PLUG, plastic  
TEE  
NIPPLE  
VALVE, thermal relief  
BUSHING  
WASHER, flat; 5/16  
BOLT, hex hd; 5/16 x 18 x 1.0  
WASHER, lock; 3/8  
CHEMICAL INJECTOR  
TUBE, chemical injector  
STRAINER, chemical injector  
COUPLING  
WASHER, lock  
SCREW, cap, socket head  
KEY, square  
25045 (25_)  
40045 (40_)  
* Chemical Injector Repair Kit – 244351  
308524  
11  
 
Pump Parts  
Pump Model 803297 used on 2545 Pressure Washer  
Pump Model 803737 used on 3040 and 3235 Pressure Washers  
27  
28  
29  
26  
33  
32  
25  
12  
34  
30  
35  
23  
20  
31  
36  
37  
56  
38  
19  
18  
22  
24  
22  
21  
39  
31  
40  
14  
41  
15  
15  
14  
13  
12  
10  
9
8
7
6
5
4
53  
11  
54  
52  
51  
17  
16  
42  
3
43  
57  
2
47  
44  
46  
45  
10  
Kit 28  
04608b  
1
11  
9
12  
308524  
 
Pump Parts  
Ref.  
Ref.  
No. Part No.  
Description  
Qty  
No. Part No.  
Description  
Qty  
1
2
3
4
5
6
7
8
9
801467  
801468  
801469  
KIT 1  
KIT 1  
KIT 1  
KIT 1  
KIT 1  
KIT 4  
MANIFOLD  
SCREW, cap, hex hd  
WASHER, lock  
O-RING  
SEAT, valve  
PLATE, valve  
SPRING  
GUIDE, valve  
O-RING  
CAP  
1
8
8
29 802345  
30 802793  
31 KIT 6  
32 803294  
33 801652  
34 801660  
and KIT 6  
35 801490  
36 KIT 6  
37 KIT 6  
GAUGE, sight  
PLUG, oil drain  
O-RING  
SCREW, cap, socket hd  
WASHER, lock  
WASHER, flinger  
1
1
6
6
3
PLUNGER, ceramic  
RING, backup  
WASHER  
SCREW, piston  
COVER, crankcase  
SHIM  
SEAL, oil  
O-RING  
RETAINER, packing  
PACKING  
RING, head  
RING, intermediate  
RESTOP, packing  
BRACKET, pump  
SCREW, cap, socket hd  
WASHER, lock  
PLUG, hex  
WASHER, flat  
PLUG, hex  
WASHER, flat  
LABEL, prevent freezing  
SEAL, low pressure  
3
10 KIT 4  
11 KIT 1  
12 803283  
13 803284  
14 802500  
15 803285  
16 KIT 2  
17 803286  
18 802895  
19 801475  
20 803144  
21  
VALVE ASSEMBLY (includes 4 to 8)  
38 KIT 6  
SCREW, cap, socket hd  
COVER, crankcase  
O-RING, crankcase cover  
BEARING, tapered roller  
SEAL, oil  
BUSHING, piston  
CRANKCASE  
8
39 803295  
40 803296  
41 KIT 3  
1
2
1
2
2
42 KIT 28  
43 KIT 28  
44 KIT 8, 28  
45 KIT 28  
46 KIT 28  
47 KIT 28  
48 801526  
49 802305  
50 802304  
51 801482  
52 801483  
53 801484  
54 801485  
56 803083  
57 KIT 28  
1
1
1
1
DIPSTICK  
GASKET, cover  
CRANKSHAFT  
Pump 803297  
Pump 803737  
RING, retaining  
KEY  
PIN, wrist  
GUIDE, piston  
ROD, connecting  
SCREW, cap, socket hd  
COVER, crankcase  
2
2
2
1
1
1
1
1
1
803287  
803332  
1
1
6
1
3
3
1
5
1
22 803288  
23 802794  
24 803289  
25 803290  
26 803291  
27 803292  
28 803293  
Pump Repair Kits  
Kit Repair Kit Ref.  
Kit Repair Kit Ref.  
No. Part No. No. Description  
Part No.  
No. Description  
Qty  
No.  
Qty  
1
6
801472  
11  
VALVE ASSEMBLY  
6
801474  
Plunger  
Repair  
31  
34  
36  
37  
38  
O-RING  
3
3
3
3
3
Valve  
(includes 4 to 8)  
O-RING  
WASHER, flinger  
RING, backup  
WASHER  
4
5
6
7
8
6
6
6
6
6
SEAT, valve  
PLATE, valve  
SPRING  
SCREW, piston  
8
801486  
Packing  
44  
PACKING  
6
GUIDE, valve  
2
3
801473  
Oil Seal  
16  
SEAL, oil  
SEAL, oil  
3
28  
801487  
Packing  
and  
42  
43  
44  
45  
46  
47  
57  
O-RING  
1
1
1
1
1
1
1
RETAINER, ring  
PACKING  
802511  
Crankshaft  
Seal  
41  
2
Retainer  
RING, head  
RING, intermediate  
RESTOP, packing  
SEAL, low pressure  
4
802306  
Valve  
Cap  
9
10  
O-RING  
CAP  
6
6
308524  
13  
 
Troubleshooting  
Relieve the pressure (see page 5) before you proceed with troubleshooting.  
PROBLEM  
CAUSE  
SOLUTION  
Engine not starting or  
hard to start  
No gasoline in fuel tank or carburetor  
Fill the tank with gasoline, and open fuel shut off valve.  
Check fuel line and carburetor.  
Low oil  
Add oil to proper level.  
Start/Stop switch in STOP position  
Water in fuel, or old fuel  
Move switch to START position.  
Drain fuel tank and carburetor. Use new fuel, and make  
sure dry spark plug is dry.  
Engine flooded or improperly choked  
Open choke, and crank engine several times to clear  
out gas. Make sure spark plug is dry.  
Dirty air cleaner filter  
Remove and clean.  
Spark plug dirty, wrong gap, or wrong type Clean, adjust the gap, or replace.  
Gun not triggered  
Trigger gun while starting engine.  
Remove and clean.  
Engine missing or  
lacking power  
Partially plugged air cleaner filter  
Spark plug dirty, wrong gap, or wrong type Clean, adjust the gap, or replace.  
Pressure too low  
and/or pump running  
roughly  
Worn or wrong size tip  
Inlet filter clogged  
Replace with tip of proper size.  
Clean. Check more frequently.  
Worn packings, abrasives in water, or  
natural wear  
Check filter. Replace packings. See Pump Service on  
page 8.  
Inadequate water supply  
Belts slipping  
Check water flow rate to pump.  
Tighten or replace; use correct belts, and replace both  
at same time.  
Fouled or dirty inlet or discharge valves  
Restricted inlet  
Clean inlet and discharge valve assemblies. Check filter.  
Check if garden hose is collapsed or kinked.  
Replace worn valves. See Pump Service on page 8.  
Replace high-pressure hose.  
Worn inlet or discharge valves  
Leaking high-pressure hose  
Water leaking from  
Worn packings  
Install new packings. See Pump Service on page 8.  
under pump manifold  
Water in pump oil  
Humid air condensing inside crankcase  
Worn packings  
Change oil as specified in Maintenance on page 7.  
Install new packings. See Pump Service on page 8.  
Install new oil seals. See Pump Service on page 8.  
Oil seals leaking  
Packings failing  
frequently or  
prematurely.  
Scored, damaged, or worn plungers  
Install new plungers. See Pump Service on page 8.  
Abrasive material in the fluid being  
pumped  
Install proper filtration on pump inlet plumbing.  
Inlet water temperature too high  
Check water temperature. It should not exceed  
160_F (70_C).  
Overpressurizing pump  
Do not modify any factory-set adjustments. See  
EQUIPMENT MISUSE HAZARD on page 3.  
Excessive pressure due to partially  
plugged or damaged tip  
Clean or replace tip. See Installing and Changing  
Spray Tips on page 6.  
Pump running too long without spraying  
Running pump dry  
Never run pump more than 10 minutes without spraying.  
Do not run pump without water.  
Strong surging at inlet, Foreign particles in the inlet or discharge  
Clean or replace valves. See Pump Service on  
and low pressure on  
discharge side  
valve, or worn inlet and/or discharge  
valves  
page 8.  
14  
308524  
 
Technical Data  
2545  
3040  
3235  
Model 800629  
Model 800632  
Model 800634  
Engine  
(4 cycle, air cooled)  
11 HP Honda OHV  
11 HP Honda OHV  
11 HP Honda OHV  
Gasoline tank capacity  
6.9 quarts (6.5 liters)  
6.9 quarts (6.5 liters)  
6.9 quarts (6.5 liters)  
Water pump maximum operating pressure  
2500 psi  
(17.2 MPa, 172 bar)  
3000 psi  
(21 MPa, 207 bar)  
3200 psi  
(22.1 MPa, 221 bar)  
Water pump maximum flow  
Inlet hose connection  
Weight  
4.5 gpm (17 lpm)  
3/4” garden hose (f)  
219 lb (100 kg)  
4 gpm (15 lpm)  
3/4” garden hose (f)  
219 lb (100 kg)  
3.5 gpm (13 lpm)  
3/4” garden hose (f)  
219 lb (100 kg)  
Dimensions  
Length  
46” (1168mm)  
30” (762mm)  
26” (660mm)  
46” (1168mm)  
30” (762mm)  
26” (660mm)  
46” (1168mm)  
30” (762mm)  
26” (660mm)  
Width  
Height  
Maximum inlet water temperature  
160_ F (70_ C)  
160_ F (70_ C)  
160_ F (70_ C)  
Wetted parts  
High-pressure hose  
Bypass hose  
Acrylonitrile and Buna–N cover and tube  
Synthetic yarn and EPDM  
Pressure washer (including fittings)  
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 plate with or without yellow chromate  
308524  
15  
 
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 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  
International Offices: Belgium, Korea, Hong Kong, Japan  
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441  
PRINTED IN USA 308524 06/1997, Revised 04/2004  
16  
308524  
 

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