308–525
INSTRUCTIONS-PARTS LIST
Rev
A
This manual contains IMPORTANT
WARNINGS and INSTRUCTIONS READ
AND RETAIN FOR REFERENCE
HYDRA-CLEANR 3050, 3540, 4043
Pressure Washer
HYDRA-CLEANr 3050, 13 HP ENGINE
P/N 800–681, Series A
3000 psi (207 bar) OPERATING PRESSURE
3400 psi (234 bar) MAXIMUM WORKING PRESSURE
HYDRA-CLEANr 3540, 13 HP ENGINE
P/N 800–635, Series A
P/N 800–636, Series A
3500 psi (241 bar) OPERATING PRESSURE
3900 psi (269 bar) MAXIMUM WORKING PRESSURE
HYDRA-CLEANr 4043, 16 HP ENGINE
P/N 800–637, Series A
4000 psi (276 bar) OPERATING PRESSURE
4300 psi (296 bar) MAXIMUM WORKING PRESSURE
GRACO INC. P.O. Box 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1991, GRACO INC.
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FUEL AND EMISSION HAZARDS
NEVER fill the fuel tank while the unit is running or hot.
The fuel used in this unit is combustible and when spilled
on a hot surface can ignite and cause a fire. ALWAYS fill
tank slowly to avoid spilling.
odorless, invisible gas which can cause serious injury or
death if inhaled.
NEVER alter the maximum throttle setting, which is
factory set. Tampering with this adjustment can damage
NEVER operate the unit in a closed building. The
exhaust contains carbon monoxide, a poisonous,
the pressure washer and will void the warranty.
EQUIPMENT MISUSE HAZARD
recommendations on additional protective equipment,
such as a respirator
General Safety
.
Any misuse of the pressure washer or accessories,
such as overpressurizing, modifying parts, using
incompatible chemicals and fluids, or using worn or
damaged parts, can cause them to rupture and result in
fluid injection, splashing in the eyes or on the skin, or
other serious bodily injury, fire, explosion or property
damage.
System Pressure
This sprayer can develop high operating pressures. Be
sure that all spray equipment and accessories are rated
to withstand the maximum working pressure of this
sprayer. DO NOT exceed the maximum working
pressure of any component or accessory used in the
system.
NEVER alter or modify any part of this equipment; doing
so could cause it to malfunction.
Chemical Compatibility
CHECK all spray equipment regularly and repair or
BE SURE that all chemicals used in the chemical
injector are compatible with the wetted parts of the hose,
gun, wand and tip, as given in the Technical Data (inside
back cover). Always read the chemical manufacturer’s
literature before using any chemical in this pressure
washer.
replace worn or damaged parts immediately
.
ALWAYS wear protective eyewear and appropriate
clothing. If using a chemical injector, read and follow the
chemical
manufacturer’s
literature
for
HOSE SAFETY
High pressure fluid in the hoses can be very dangerous.
If the hose develops a leak, split or rupture due to any
kind of wear, damage or misuse, the high pressure
spray emitted from it can cause a fluid injection injury or
other serious bodily injury or property damage.
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.
ALL FLUID HOSES MUST HAVE STRAIN RELIEFS
ON BOTH ENDS. The strain reliefs help protect the
hose from kinks or bends at or close to the coupling,
which can result in hose rupture.
HANDLE AND 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
and cover of the hose. DO NOT expose Graco hose to
TIGHTEN all 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.
temperatures above 200_ F (93_ C) or below –40_
F
(–40_ C).
308-525
3
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MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers or other
body parts. KEEP CLEAR of moving parts when starting
Pressure Relief Procedure before checking or
servicing the pressure washer to prevent discharging
high pressure fluid from the gun.
or operating the pressure washer
.
NEVER operate the pressure washer without all guards
and interlocks installed and functioning. Follow the
TERMS
WARNING: Alerts user to avoid or correct conditions
CAUTION: Alerts user to avoid or correct conditions
that could cause bodily injury
.
that could cause damage to the equipment.
NOTE: Identifies helpful procedures and information.
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These
standards—particularly the General Standards, Part 1910, and the Construction Standards, Part 1926—should be
consulted.
4 308-525
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INSTALLATION
QUICK
COUPLER
TEE HANDLE
(4043 ONLY)
HIGH
PRESSURE
HOSE
CONNECTION
SPRAY
GUN
QUICK
COUPLER
WATER
SUPPL
CONNECTION
Y
SPRAY
HOSE
Figure
1
Check for Shipping Damage
Connect to Water Supply
CAUTION
Check the unit for any damage that may have occurred
in shipping. Notify the carrier immediately if there is
any damage.
Before attaching to the water supply, check your
local plumbing code regarding cross– connection
to the water supply. A backflow preventer, P/N
801–133, is available to prevent backflow of
contaminated water into the fresh water supply.
Install it upstream from the pump.
Set Up
Fill the battery cells with electrolyte and water. 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
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.
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.
,
Do not exceed 160_ F (70_ C) inlet water
Connect the high pressure hose between the pump
outlet and the gun inlet. Both of these connections are
made with quick couplers.
temperature.
Connect a hose with at least a 3/4 inch (19 mm) ID from
CAUTION
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.
Up to 100 ft (30 m) of high pressure hose may
be used. Longer hoses may affect sprayer
performance, and chemical injector performance,
if used.
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).
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.
308-525
5
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STARTUP
Always use this startup procedure to ensure that the unit
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.
is started safely and properly
.
1. Check oil levels.
Engine: Add SAE 30 or 10W–30 weight detergent
oil as necessary
.
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
Pump: Add SAE 20 or 30 weight non–detergent oil
as necessary
.
sure to open the choke completely
.
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.
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
eyes or on the skin if the gun is bumped or triggered
accidentally.
8. ALWAYS observe the following CAUTIONS to
2. Check fuel level.
avoid costly damage to the pressure washer
.
WARNING
CAUTION
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.
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.
3. Turn on the water supply
.
CAUTION
Never run the unit dry. Costly damage to the pump
will result. Always be sure the water supply is
completely turned on before operating.
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.
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
ignition cables are pushed firmly onto the spark
plugs. Put the ignition shutoff switch in the “on”
position and the throttle in the “run” position.
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
accessories are used.
6. Start the engine.
NOTE: For easier starting, have one person start the
pressure washer while another person
triggers the spray gun.
6 308-525
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Trigger Safety Latch
WARNING
Installing and Changing Spray Tips
WARNING
To reduce the risk of serious bodily injury, including
fluid injection or splashing in the eyes or onto the
skin, use extreme caution when changing spray
To reduce the risk of serious bodily injury,
including fluid injection, splashing in the eyes or
on the skin, ALWAYS engage the trigger safety
latch whenever spraying stops, even for a
moment.
tips. ALWAYS follow the procedure below
.
1. Follow the Pressure Relief Procedure
.
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 when
engaging it or it cannot prevent the gun from being
triggered. See Figure 2.
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 old tip
and/or 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 on the chassis.
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
.
TRIGGER SAFETY LATCH SHOWN ENGAGED
A
B
TRIGGER SAFETY LATCH SHOWN
DISENGAGED
Figure 3
Figure 2
308-525
7
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SHUTDOWN, FLUSHING
AND STORAGE
MAINTENANCE
Observing regular maintenance intervals helps ensure
that you get maximum performance and life from the
WARNING
pressure washer
.
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.
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. Engage the trigger safety latch.
2. Turn the sprayer off.
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.
3. Remove the ignition cable from the spark
plug.
4. Shut off the water supply
.
5. Disengage the trigger safety latch and trigger
the gun to relieve pressure, and then engage
the trigger safety latch again.
Interval
What to do
Daily
Clean water inlet screen and
filter. Check engine and pump oil
levels. Fill as necessary. Check
6. Before long–term (overnight) storage or
transporting of the unit, disconnect the water
gasoline level. Fill as necessary
.
supply, and disconnect the fuel supply
.
After first 5
hours of
operation
Change engine break–in oil.
Drain oil when warm. Use SAE
30 or 10W–30 detergent oil.
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.
Each 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.
NOTE: An anti–freeze flush kit, P/N 802–327, is
After first 50
hours of
operation
Change pump break–in oil. Use
SAE 20 or 30 non–detergent oil.
available to make flushing easier
.
CAUTION
Each 100 hours Clean or replace paper air
of operation
or 3 months
cleaner cartridge. Tap gently to
remove dirt. Change engine oil.
Use SAE 30 or 10W–30
detergent oil.
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
the ceramic plungers!
Each 500 hours Change pump oil. Use SAE 20
of operation
or 6 months
or 30 non–detergent oil.
2. After each use, wipe all surfaces of the pressure
washer with a clean, damp cloth.
3. Perform the appropriate maintenance. See
maintenance chart.
8 308-525
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TROUBLESHOOTING CHART
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.
Problem
Cause
Solution
Engine will not start or No gasoline in fuel tank or carburetor
is hard to start
.
Fill the tank with gasoline, open fuel shut off valve.
Check fuel line and carburetor.
Low oil level.
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.
Battery not properly charged.
Check and tighten battery connections.
Check electrolyte level of cells, recharge battery
.
Choked improperly. Flooded engine.
Open choke and crank engine several times to
clear out gas.
Dirty air cleaner filter
.
Remove and clean.
Spark plug dirty, wrong gap or wrong type.
Spray gun closed.
Clean, adjust the gap or replace.
Trigger spray gun.
Engine misses or
lacks power
Partially plugged air cleaner filter
.
Remove and clean.
Spark plug dirty, wrong gap or wrong type.
Incorrect ignition timing.
Clean, adjust the gap or replace.
T
ime engine.
Replace with tip of proper size.
Clean. Check more frequently
Low pressure and/or
pump runs rough
W
orn or wrong size tip.
Inlet filter clogged.
orn packings, abrasives in water or natural
wear.
.
W
Check filter. Replace packings. See PUMP
SERVICE.
Inadequate water supply
.
Check water flow rate to pump.
Belt slippage.
T
ighten or replace; use correct belts and replace
both at same time.
Fouled or dirty inlet or discharge valves. Even Clean inlet and discharge valve assemblies. Check
a small particle can cause the valve to stick.
filter.
Restricted inlet.
Check garden hose, may be collapsed or kinked.
Replace worn valves.
W
orn inlet or discharge valves.
Leaking high pressure hose.
Worn packings.
Replace high pressure hose.
Install new packings. See PUMP SERVICE.
Water leakage from
under pump manifold
W
ater in pump
Humid air condensing inside crankcase.
orn packings.
Change oil as specified in MAINTENANCE.
Install new packings. See PUMP SERVICE.
Install new oil seals. See PUMP SERVICE.
Install new plungers. See PUMP SERVICE.
Install proper filtration on pump inlet plumbing.
Check water temperature; may not exceed 160_F.
W
Oil seals leaking.
Frequent or
premature failure of
the packings
Scored, damaged or worn plungers.
Abrasive material in the fluid being pumped.
Inlet water temperature too high.
Overpressurizing pump.
Do not modify any factory–set adjustments. See
EQUIPMENT MISUSE HAZARD.
Excessive pressure due to partially plugged or
damaged tip.
Clean or replace tip. See Installing and Changing
Spray Tips.
Pump running too long without spraying.
Never run pump more than 10 minutes without
spraying.
Running pump dry
.
Do not run pump without water
.
Strong surging at the
Foreign particles in the inlet or discharge
Clean or replace valves. See PUMP SERVICE.
inlet and low pressure valve or worn inlet and/or discharge valves.
on the discharge side
308-525
9
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PARTS DRAWING
800–635 & 800–636 Hydra–Cleanr 3540 Pressure Washer
76
77
77
76
89
37
63
5
1
2
87
88
62
63
5
45
46
87
86
85
38
48
47
5
3
2
37
48
4
5
50
6
49
61
51
60
58
53
52
33
34
35
36
57
71
58
57
72
73
74
54
56
70
31
55
9
59
64
32
7
8
29
28
15
5
11
1
2
5
27
65
44
30
2
10
5
6
67
66
68
5
16
2
25
17
24
20
19
69
26
42
18
5
23
13
22
84
12
14
43
69
39
83
40
87
89
26
42
81
80
41
79
82
5
75
91
78
92
21
90
10 308-525
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PARTS LIST
800–635 & 800–636 Hydra–Cleanr 3540 Pressure Washer
REF PART
NO. NO.
REF PART
NO. NO.
DESCRIPTION
QTY
11
13
2
1
26
DESCRIPTION
QTY
1
2
3
4
5
6
100–188 NUT, Hex 5/16–18
100–214 ASHER, Lock 5/16
803–945 BELT, Drive
803–800 SHEAVE, Engine
100–023
801–941 SCREW, Cap, Hex hd
5/16–18 x 1
47
48
177–144 LABEL, Belt Guard
803–535 SCREW, Cap, Hex hd
(used on 800–635 only)
1
W
1
801–559 SCREW, Cap, Hex hd
(used on 800–636 only)
803–942 SHEAVE, Pump
801–898 HUB, Engine
801–135 HUB, Pump
801–959 TERMINAL PROTECTOR, Black
801–945 CABLE, Battery 12” Long
803–077 LABEL, BATTERY
801–954 BATTERY, 12 Volt, 30 Amp
100–527
100–016
100–015 NUT, Hex 1/4–20
801–964 BOLT, Carriage 1/4–20 x 1
801–946 CABLE, Battery 24” Long
801–958 TERMINAL PROTECTOR, Red
803–531 BASEPLATE, Belt Guard
801–022 SCREW, Cap, Hex hd
5/16–18 x 3/4
WASHER, Flat 5/16
1
1
1
1
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
9
1
1
2
1
1
2
2
2
1
1
1
7
8
9
803–534 LABEL, Belt Guard
803–926 BELT GUARD
803–525 BOLT, Battery
804–282 BRACKET, Battery
801–972
801–550 WHEEL & TIRE ASSEMBL
801–612 ASHER, Flat 1/2
801–020 NUT, Lock 1/2–13
800–676 CHASSIS
801–556 AXLE
1
1
1
1
2
4
4
2
1
1
1
10
11
12
13
14
15
16
17
18
PAD, Battery
Y
W
W
ASHER, Flat 1/4
ASHER, Lock 1/4
W
800–678 BRACKET, Rail Stiffener
801–546 SCREW, Cap, Hex hd
3/8–16 x 1–1/4
4
4
4
19
20
21
100–133
100–132
W
W
ASHER, Lock 3/8
ASHER, Flat 3/8
4
1
64
65
107–069 BRACKET, Battery
801–009 QUICK COUPLER, Female 1/4
(incl. 27)
800–160 FRONT LEG ASSEMBL
Y
(incl. 5, 78 through 84)
803–905 LABEL, Model 3540
111–040 NUT, Lock 5/16–18
803–925 HANDLE
803–298 SCREW, Cap, Hex hd
5/16–18 x 3–1/2
1
1
4
1
1
1
1
22
23
24
25
66
67
68
801–134
801–674 SLEEVE, 28”
803–350 GUN, Spray (see Instruction
Manual 308–511)
WAND, 32”
1
1
4
1
1
1
1
1
2
1
1
2
1
5
1
1
1
1
1
69
70
71
72
73
74
75
156–849 NIPPLE, Hex 3/8
801–090 QUICK COUPLER, Male 1/4
803–106 TIP, Spray 00045
803–107 TIP, Spray 15045
803–108 TIP, Spray 25045
803–109 TIP, Spray 40045
800–375 HOSE ASSEMBLY W/QUICK
COUPLERS (incl 41, 42, 43)
802–363 LABEL, Caution
181–867 LABEL, Warning
801–531 SCREW, Cap, Hex hd
3/8–16 x 7
26
27
28
29
30
31
32
33
34
35
36
37
156–082 O–RING, Quick Coupler 3/8
154–594 O–RING, Quick Coupler 1/4
802–016 BRACKET, Rail Stiffener
801–522 SCREW, Cap, Hex hd
176–250 LABEL, Chassis
801–548 GROMMET, Rubber
172–981 LABEL, Chassis
800–314 TIP ASS’Y, 00045 (incl. 70, 71)
800–315 TIP ASS’Y, 15045 (incl. 70, 72)
800–316 TIP ASS’Y, 25045 (incl. 70, 73)
800–317 TIP ASS’Y, 40045 (incl. 70, 74)
803–883 ENGINE, 12.5 HP, Briggs &
Stratton Vanguard OHV
1
1
1
76
77
78
1
1
1
1
1
1
1
79
80
81
82
83
84
85
801–504 BUMPER, Rubber
801–505 RETAINER, Spring
801–593 SPRING
801–506 BOOT
801–537 LEG, Front
801–499 NUT, Lock 3/8–16
802–907 CONNECTOR, Fuel
(used on 800–635 only)
(used on 800–635 only)
1
803–967 ENGINE, 13 HP, Honda OHV
(used on 800–636 only)
1
1
38
39
PUMP ASS’Y (see page 16)
800–652 FUEL TANK ASSEMBL
Y
(incl 40, 87, 89, 90, 91, 92)
(used on 800–635 only)
1
1
3
1
2
1
1
86
87
88
89
90
91
92
801–919 BRACKET, Fuel Connector
(used on 800–635 only)
801–971 CLAMP, Hose
(used on 800–635 only)
40
801–733 BARB, Hose 1/4
(used on 800–635 only)
801–571 HOSE, High Pressure 3/8 x 50’
801–569 QUICK COUPLER, Female 3/8
(incl. 26)
1
1
41
42
801–629 LINE, Fuel
2
2
(used on 800–635 only)
43
44
801–568 QUICK COUPLER, Male 3/8
800–392 GUN & WAND ASSEMBL
801–716 LABEL, Warning
(used on 800–635 only)
803–881 LINE, Fuel w/Squeeze Bulb
(used on 800–635 only)
Y
(incl. 42, 65, 66, 67, 68, 69)
WASHER, Flat 5/16
(used on 800–635 only)
1
1
45
100–023
802–025
T
ANK, Fuel
(used on 800–635 only)1
801–008 LABEL, Graco G
(used on 800–635 only)
803–526 SPACER (used on
800–636 only)
801–217 BUMPER, Rubber
1
1
46
1
308-525 11
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PARTS DRAWING
800–637 Hydra–Cleanr 4043 Pressure Washer
76
89
77
37
1
2
87
88
2
62
63
5
87
86
85
46
38
47
5
3
2
48
4
5
50
6
49
51
61
60
58
53
52
33
34
35
36
57
71
58
57
72
73
74
54
56
70
31
55
9
59
64
32
7
8
29
28
15
5
11
1
2
5
30
44
2
27
65
10
5
67
6
45
66
68
5
16
2
25
17
24
20
19
18
5
69
26
42
23
12
13
22
84
14
39
83
40
87
43
69
89
26
42
81
80
79
82
41
5
75
91
78
92
21
90
12 308-525
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PARTS LIST
800–637 Hydra–Cleanr 4043 Pressure Washer
REF PART
REF PART
NO. NO.
NO. NO.
DESCRIPTION
100–188 NUT, Hex 5/16–18
100–214 ASHER, Lock 5/16
803–889 BELT, Drive
803–943 SHEAVE, Engine
100–023
801–941 SCREW, Cap, Hex hd
5/16–18 x 1
QTY
11
13
2
1
26
DESCRIPTION
QTY
1
2
3
4
5
6
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
801–217 BUMPER, Rubber
177–144 LABEL, Belt Guard
803–535 SCREW, Cap, Hex hd
803–944 SHEAVE, Pump
801–898 HUB, Engine
801–135 HUB, Pump
801–959 TERMINAL PROTECTOR, Black1
801–945 CABLE, Battery 12” Long
803–077 LABEL, BATTERY
801–954 BATTERY, 12 Volt, 30 Amp
100–527
1
1
1
1
1
1
W
WASHER, Flat 5/16
9
1
1
2
1
1
2
2
2
1
1
1
7
8
9
803–534 LABEL, Belt Guard
803–926 BELT GUARD
803–525 BOLT, Battery
803–530 BRACKET, Battery
801–972
801–550 WHEEL & TIRE ASSEMBL
801–612 ASHER, Flat 1/2
801–020 NUT, Lock 1/2–13
800–676 CHASSIS
801–556 AXLE
1
1
1
2
4
4
2
1
1
1
10
11
12
13
14
15
16
17
18
WASHER, Flat 1/4
PAD, Battery
100–016
WASHER, Lock 1/4
Y
100–015 NUT, Hex 1/4–20
801–964 BOLT, Carriage 1/4–20 x 1
801–946 CABLE, Battery 24” Long
801–958 TERMINAL PROTECTOR, Red
803–531 BASEPLATE, Belt Guard
801–022 SCREW, Cap, Hex hd
5/16–18 x 3/4
W
800–678 BRACKET, Rail Stiffener
801–546 SCREW, Cap, Hex hd
3/8–16 x 1–1/4
4
1
4
4
4
64
65
107–069 BRACKET Battery
801–009 QUICK COUPLER, Female 1/4
(incl. 27)
19
20
21
100–133
100–132
WASHER, Lock 3/8
WASHER, Flat 3/8
1
1
1
800–160 FRONT LEG ASSEMBL
Y
66
67
68
801–134
801–674 SLEEVE, 28”
803–351 GUN, Spray (see Instruction
Manual 308–511)
WAND, 32”
(incl. 5, 78 thru 84)
803–906 LABEL, Model 4043
111–040 NUT, Lock 5/16–18
803–925 HANDLE
803–298 SCREW, Cap, Hex hd
5/16–18 x 3–1/2
1
1
4
1
22
23
24
25
1
1
4
1
1
1
1
69
70
71
72
73
74
75
156–849 NIPPLE, Hex 3/8
801–090 QUICK COUPLER, Male 1/4
803–106 TIP, Spray 00045
803–107 TIP, Spray 15045
803–108 TIP, Spray 25045
803–109 TIP, Spray 40045
800–450 HOSE ASSEMBLY W/QUICK
COUPLERS (incl. 41, 42, 43)
802–363 LABEL, Caution
181–867 LABEL, Warning
801–531 SCREW, Cap, Hex hd
3/8–16 x 7
1
2
1
1
2
1
5
1
1
1
1
1
26
27
28
29
30
31
32
33
34
35
36
37
156–082 O–RING, Quick Coupler 3/8
154–594 O–RING, Quick Coupler 1/4
802–016 BRACKET, Rail Stiffener
801–522 SCREW, Cap, Hex hd
176–250 LABEL, Chassis
1
1
1
801–548 GROMMET, Rubber
172–981 LABEL, Chassis
76
77
78
800–314 TIP ASS’Y, 00045 (incl. 70, 71)
800–315 TIP ASS’Y, 15045 (incl. 70, 72)
800–316 TIP ASS’Y, 25045 (incl. 70, 73)
800–317 TIP ASS’Y, 40045 (incl. 70, 74)
803–884 ENGINE, 16 HP, Briggs &
Stratton Vanguard OHV
1
1
1
1
1
1
1
1
1
3
1
2
1
1
1
79
80
81
82
83
84
85
86
87
88
89
90
91
92
801–504 BUMPER, Rubber
801–505 RETAINER, Spring
801–593 SPRING
801–506 BOOT
801–537 LEG, Front
801–499 NUT, Lock 3/8–16
802–907 CONNECTOR, Fuel
801–919 BRACKET, Fuel Connector
801–971 CLAMP, Hose
801–629 LINE, Fuel
801–716 LABEL, Warning
803–881 LINE, Fuel w/Squeeze Bulb
1
1
38
39
PUMP ASS’Y (see page 16)
800–652 FUEL TANK ASSEMBL
(incl. 40, 87, 89, 90, 91, 92)
801–733 BARB, Hose 1/4
803–519 HOSE, High Pressure 3/8 x 50’
803–157 QUICK COUPLER, Female 3/8
(incl. 26)
Y
1
1
1
40
41
42
2
2
43
44
801–568 QUICK COUPLER, Male 3/8
800–429 GUN & WAND ASSEMBL
(incl. 42, 45, 65 thru 69)
802–851 HANDLE, Tee
Y
802–025
801–008 LABEL, Graco G
TANK, Fuel
1
1
45
308-525 13
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PARTS DRAWING
800–681 Hydra–Cleanr 3050 Pressure Washer
77
76
37
63
5
1
2
62
45
38
46
47
5
3
2
48
4
5
50
6
49
61
51
60
58
53
52
33
57
34
35
36
71
72
73
74
58
57
54
56
70
31
55
9
59
64
32
7
8
29
28
15
5
11
1
2
5
27
65
44
30
2
10
5
6
67
66
68
5
16
2
25
17
24
20
19
69
26
18
5
23
13
42
22
84
12
14
43
69
83
26
42
81
80
79
82
41
5
75
78
21
14 308-525
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PARTS LIST
800–681 Hydra–Cleanr 3050 Pressure Washer
REF PART
REF PART
NO. NO.
NO. NO.
DESCRIPTION
100–188 NUT, Hex 5/16–18
100–214 ASHER, Lock 5/16
801–285 BELT, Drive
803–941 SHEAVE, Engine
100–023
801–941 SCREW, Cap, Hex hd
5/16–18 x 1
QTY
11
13
2
1
26
DESCRIPTION
QTY
1
2
3
4
5
6
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
803–526 SPACER
1
1
1
1
1
1
1
W
801–217 BUMPER, Rubber
177–144 LABEL, Belt Guard
801–559 SCREW, Cap, Hex hd
801–004 SHEAVE, Pump
801–898 HUB, Engine
801–135 HUB, Pump
801–959 TERMINAL PROTECTOR, Black1
801–945 CABLE, Battery 12” Long
803–077 LABEL, BATTERY
801–954 BATTERY, 12 Volt, 30 Amp
WASHER, Flat 5/16
9
1
1
2
1
1
2
2
2
1
1
1
7
8
9
803–534 LABEL, Belt Guard
803–926 BELT GUARD
803–525 BOLT, Battery
804–282 BRACKET, Battery
801–972
801–550 WHEEL & TIRE ASSEMBL
801–612 ASHER, Flat 1/2
801–020 NUT, Lock 1/2–13
800–676 CHASSIS
801–556 AXLE
1
1
1
2
4
4
2
1
1
1
10
11
12
13
14
15
16
17
18
PAD, Battery
100–527
100–016
WASHER, Flat 1/4
Y
WASHER, Lock 1/4
W
100–015 NUT, Hex 1/4–20
801–964 BOLT, Carriage 1/4–20 x 1
801–946 CABLE, Battery 24” Long
801–958 TERMINAL PROTECTOR, Red
803–531 BASEPLATE, Belt Guard
801–022 SCREW, Cap, Hex hd
5/16–18 x 3/4
800–678 BRACKET, Rail Stiffener
801–546 SCREW, Cap, Hex hd
3/8–16 x 1–1/4
4
4
4
4
1
19
20
21
100–133
100–132
WASHER, Lock 3/8
64
65
107–069 BRACKET, Battery
801–009 QUICK COUPLER, Female 1/4
(incl. 27)
WASHER, Flat 3/8
800–160 FRONT LEG ASSEMBL
Y
1
1
1
(incl. 5, 78 thru 84)
803–949 LABEL, Model 3050
111–040 NUT, Lock 5/16–18
803–925 HANDLE
803–298 SCREW, Cap, Hex hd
5/16–18 x 3–1/2
1
1
4
1
66
67
68
801–134
801–674 SLEEVE, 28”
803–350 GUN, Spray (see Instruction
WAND, 32”
22
23
24
25
Manual 308–511)
1
1
4
1
1
1
1
69
70
71
72
73
74
75
156–849 NIPPLE, Hex 3/8
801–090 QUICK COUPLER, Male 1/4
801–665 TIP, Spray 0006
801–666 TIP, Spray 1506
801–552 TIP, Spray 2506
801–553 TIP, Spray 4006
800–375 HOSE ASSEMBLY W/QUICK
COUPLERS (incl. 41, 42, 43)
802–363 LABEL, Caution
181–867 LABEL, Warning
801–531 SCREW, Cap, Hex hd
3/8–16 x 7
1
2
1
1
2
1
5
1
1
1
1
1
1
1
1
26
27
28
29
30
31
32
33
34
35
36
37
38
41
42
156–082 O–RING, Quick Coupler 3/8
154–594 O–RING, Quick Coupler 1/4
802–016 BRACKET, Rail Stiffener
801–522 SCREW, Cap, Hex hd
176–250 LABEL, Chassis
801–548 GROMMET, Rubber
172–981 LABEL, Chassis
1
1
1
76
77
78
800–135 TIP ASS’Y, 0006 (incl. 70, 71)
800–134 TIP ASS’Y, 1506 (incl. 70, 72)
800–060 TIP ASS’Y, 2506 (incl. 70, 73)
800–061 TIP ASS’Y, 4006 (incl. 70, 74)
803–967 ENGINE, 13 HP, Honda OHV
PUMP ASS’Y (see page 16)
801–571 HOSE, High Pressure 3/8 x 50’
801–569 QUICK COUPLER, Female 3/8
(incl. 26)
1
1
1
1
1
1
1
79
80
81
82
83
84
801–504 BUMPER, Rubber
801–505 RETAINER, Spring
801–593 SPRING
801–506 BOOT
801–537 LEG, Front
2
2
801–499 NUT, Lock 3/8–16
43
44
801–568 QUICK COUPLER, Male 3/8
800–392 GUN & WAND ASSEMBL
Y
(incl. 42, 65, 66, 67, 68, 69)
1
308-525 15
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PARTS DRAWING
Pump Assembly, 3000 psi (used on Model 3050), 3500 & 4000 psi (used on Models 3540 & 4043)
10
9
63
65
55
8
66
67
64
7
6
11
46
60
61
62
5
4
1
47
44
45
3
2
54
53
57
58
59
52
50
49
11
48
51
13
9
10
19
56
20
14
18
12
12
17
40
15
16
42
41
43
14
44
45
39
29
28
23
21
32
33
26
22
24
30
25
34
31
35
36
27
31
37
38
16 308-525
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PARTS LIST
Pump Assembly, 3000 psi (used on Model 3050), 3500 & 4000 psi (used on Models 3540 & 4043)
REF PART
REF PART
NO. NO.
DESCRIPTION
QTY
NO. NO.
DESCRIPTION
QTY
1
801–467
MANIFOLD, 3000 psi
MANIFOLD, 3500 & 4000 psi
SCREW, Cap, hex hd
WASHER, Lock
O–RING
1
55 801–624
803–508
56 803–083
PUMP, 3000 psi
1
803–504
801–468
801–469
Kit 1
1
8
8
PUMP, 3500 & 4000 psi
LABEL, Keep From Freezing,
3000 psi
LABEL, Keep From Freezing,
3500 & 4000 psi
NIPPLE 1/2
TEE 1/2
FILTER (see Instruction
Manual 801–744)
NUT, Garden hose
ADAPTER, Garden hose
STRAINER, Garden hose
HOSE, Bypass
NIPPLE, Hex 1/2 NPSM x
3/8 NPT 3000 psi
1
1
2
3
4
5
6
7
8
9
803–517
Kit 1
SEAT, Valve
1
1
1
Kit 1
PLATE, Valve
57 802–085
58 801–106
59 800–113
Kit 1
SPRING
Kit 1
GUIDE, Valve
Kit 4 or 106
O–RING
1
1
1
1
1
10 Kit 4 or 106
11 Kit 1
12 803–283
13 803–284
803–506
CAP
60 801–111
61 801–110
62 801–112
63 803–141
64 803–142
VALVE ASSEMBLY
SCREW, Cap, socket hd
COVER, Crankcase, 3000 psi
COVER, Crankcase,
3500 & 4000 psi
O–RING, Crankcase cover
BEARING, Tapered roller
SEAL, Oil
8
1
1
2
2
1
14 802–500
15 803–324
16 Kit 2
17 803–286
18 802–895
803–501
802–534
NIPPLE, Hex 1/2 NPSM x
1/2 NPT, 3500 & 4000 psi
UNLOADER, 3000 psi
UNLOADER, 3500 psi
UNLOADER, 4000 psi
NIPPLE, Hex 3/8, 3000 psi
NIPPLE, Hex 1/2x3/8,
3500 & 4000 psi
1
1
65 800–325
800–689
BUSHING, Piston
CRANKCASE, 3000 psi
CRANKCASE,
3
1
800–427
1
1
66 801–868
801–236
3500 & 4000 psi
DIPSTICK
1
1
1
1
6
1
3
3
19 801–475
20 803–144
21 803–287
22 803–288
23 802–794
24 803–289
25 803–325
803–503
2
1
GASKET, Cover
CRANKSHAFT
67 801–568
COUPLER, Male 3/8
RING, Retaining
KEY
Kit Repair Kit
No. Part No.
Ref
No.
Description
Qty.
PIN, Wrist
1
801–472
Valve
4
5
6
7
8
O–RING
6
6
6
6
6
6
GUIDE, Piston, 3000 psi
GUIDE, Piston,
SEAT, Valve
PLATE, Valve
SPRING
3500 & 4000 psi
ROD, Connecting
SCREW, Cap, socket hd
COVER, Crankcase, 3000 psi
COVER, Crankcase,
3500 & 4000 psi
GAUGE, Sight
3
3
5
1
GUIDE, Valve
26 803–291
27 803–292
28 803–293
803–507
11 VALVE ASSEMBL
Y
2
3
4
6
801–473
16 SEAL, Oil
41 SEAL, Oil
3
Oil Seal
1
1
1
802–511
Crankshaft Seal
2
29 802–345
30 802–793
31 Kit 6 or 107
32 803–294
33 803–652
34 Kit 6 or 107
35 801–490
803–502
36 Kit 6 or 107
37 Kit 6 or 107
38 Kit 6 or 107
39 803–295
803–505
PLUG, Oil drain
O–RING
802–306
9
O–RING
6
6
Valve Cap, 3000 psi
10 CAP
SCREW, Cap, socket hd
WASHER, Lock
6
6
801–474
31 O–RING
1
1
1
1
1
Plunger Repair
,
34
WASHER, Flinger
WASHER, Flinger
3000 psi
36 RING, Backup
37 WASHER
PLUNGER, Ceramic
PLUNGER, Ceramic
RING, Backup
3
3
38 SCREW, Piston
8
801–468
Packing, 3000 psi
44 PACKING
6
WASHER
SCREW, Piston
COVER, Crankcase, 3000 psi
COVER, Crankcase,
3500 & 4000 psi
SHIM
28 801–487
42 O–RING
43 RETAINER,
44 Packing
1
1
2
1
1
1
1
Packing & Retainer
,
3000 psi
1
2
45 PACKING
46 RING, Head
47 RETAINER,
Packing
40 803–296
41 Kit 3
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
48 801–526
49 802–305
50 802–304
51 801–482
52 801–483
53 801–484
54 801–485
SEAL, Oil
RING, Long Life
106 803–509
9
O–RING
6
6
Valve Cap,
10 CAP
3500 & 4000 psi
107 803–510
Plunger Repair
3500 & 4000 psi
31 O–RING
1
1
1
1
1
,
34
WASHER, Flinger
36 RING, Backup
37 WASHER
BRACKET, Pump
SCREW, Cap, socket hd
WASHER, Lock
PLUG, Hex
WASHER, Flat
PLUG, Hex
WASHER, Flat
2
4
2
1
1
1
1
38 SCREW, Piston
109 803–511
Packing & Retainer
3500 & 4000 psi
42 O–RING
43 RETAINER,
44 Packing
1
1
2
1
1
1
,
45 PACKING
46 RING, Head
47 RETAINER,
Packing
RING, Long Life
112 803–512
44 PACKING
6
Packing,
3500 & 4000 psi
308-525 17
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PUMP SERVICE
Servicing the Plungers
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: Plunger repair kit, P/N 801–474 or 803–510 is
available to replace retainers, o–rings,
washers and backup rings for three cylinders.
1. Loosen the plunger retaining screw five to six turns,
using an M10 wrench. Push the plunger towards the
crankcase to separate the plunger and retaining
screw.
NOTE: The following metric wrenches are needed:
M10, M13 and M30. Repair kits are available.
Refer to the individual repair sections and the
pump parts page for more details. For the best
results, use all parts in the kits.
2. Remove the screw from the plunger and examine
the o–ring, backup ring and copper bearing/gasket
washer. Replace these parts, if necessary, using kit
801–474 or 803–510.
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.
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 as
they cannot be reused. An oil seal kit is available to
replace the seals.
Valves
NOTE: For a set of six valves, order P/N 801–472.
1. Remove the hex plug from the manifold using an
M30 wrench.
5. Lightly grease the flinger and oil seal, if it is being
replaced and replace them on the plunger shaft.
2. Examine the o–ring under the hex plug and replace
it if it is cut or distorted.
Then install the plunger
.
6. 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).
3. Remove the valve assembly from the cavity; the
assembly may come apart.
4. Install the new valve. Install the o–ring and hex plug;
torque to 75 ft–lb (103 Nm).
NOTE: If you plan to replace the packings, refer to
Servicing the V–Packings.
NOTE: Retorque the plug after 5 hours of operation.
7. Lubricate the outside of each plunger. Slide the
manifold onto the crankcase, being careful not to
damage the seals.
Pumping Section
1. Remove the eight capscrews and lockwashers from
the manifold using an M13 wrench.
8. Install the capscrews and washers finger–tight.
Torque the screws to 21.7 ft–lb (29 Nm) following
the tightening pattern (Figure 4). Uneven tightening
may cause the manifold to bind or jam.
2. Carefully separate the manifold from the crankcase.
NOTE: It may be necessary to tap the manifold lightly
with a soft mallet to loosen.
CAUTION
Keep the manifold properly aligned with the
ceramic plungers when removing to avoid
damage to the plunger or seals.
5
8
1
3
4
2
7
6
3. Carefully examine each plunger for any scoring or
cracking and replace as necessary
.
Figure 4
18 308-525
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5. Thoroughly clean the packing cavities and examine
for debris and damage.
Servicing the V–Packings
NOTE: There are two types of packing kits: one is
packings only, the other includes the
packings, rings and retainers.
6. 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.
1. Remove the manifold as outlined in the Pumping
Section.
2. Carefully pull the packing retainer from the
manifold. Examine the o–ring and replace it if it is cut
or damaged.
CAUTION
Install the parts in the proper order and facing the
correct direction. Improperly installed parts will
cause a malfunction.
3. Remove the v–packing and head ring. Pull out the
intermediate retainer ring. Remove the second
v–packing and second head ring.
7. Reassemble the manifold as instructed in Servicing
the Plungers.
4. Inspect all parts and replace as necessary
.
ACCESSORIES
(Must be purchased separately)
DOWNSTREAM CHEMICAL INJECTOR KIT
800–117 (3540)
800–649 (3540 & 4043)
For injecting harsh cleaning chemicals downstream
from the pump. 800–649 is stainless steel construction.
WATER SANDBLASTING KIT 800–120
For abrasive cleaning of stubborn dirt and paint.
Requires a spray tip which is not included in kit (3245
uses 801–667, 4040 uses 801–600).
ANTI–FREEZE FLUSH KIT 802–327
For flushing system with 50% anti–freeze solution prior
to transporting or storing pressure washer in below
freezing temperatures.
UPSTREAM CHEMICAL INJECTOR KIT
800–257
For injecting mild cleaning chemicals upstream into the
pump.
INLET PRESSURE REGULATOR 800–258
Regulates inlet water pressure to 60 psi (4 bar)
maximum.
BACKFLOW PREVENTOR 801–133
Prevent back–up of contaminated water into fresh
supply. Install upstream of pump.
TECHNICAL DATA
Model 800–681
Model 800–635
Model 800–636
Model 800–637
Engine (4 cycle, air–cooled)
Battery
13 HP Honda OHV
12.5 HP Briggs &
Stratton OHV
13 HP Honda OHV
16 HP Briggs &
Stratton OHV
12 Volt, 30 AMP
250 CCA
12 Volt, 30 AMP
250 CCA
12 Volt, 30 AMP
250 CCA
12 Volt, 30 AMP
250 CCA
Gasoline Tank Capacity
2 Gallon (7.6 Liter)
3000 psi (207 bar)
6 Gallon (23 Liter)
3500 psi (241 bar)
2 Gallon (7.6 Liter)
3500 psi (241 bar)
6 Gallon (23 Liter)
4000 psi (276 bar)
Water Pump Maximum Working
Pressure
Water Pump Maximum Flow
5 gpm (19 lpm)
4 gpm (15 lpm)
4 gpm (15 lpm)
4.25 gpm (16 lpm)
Inlet Hose Connection
Weight
3/4” garden hose (f) 3/4” garden hose (f) 3/4” garden hose (f) 3/4” garden hose (f)
255 lbs (116 kg)
255 lbs (116 kg)
255 lbs (116 kg)
255 lbs (116 kg)
Dimensions
Length
49” (1245 mm)
30” (762 mm)
26.5” (673 mm)
49” (1245 mm)
30” (762 mm)
26.5” (673 mm)
49” (1245 mm)
30” (762 mm)
26.5” (673 mm)
49” (1245 mm)
30” (762 mm)
26.5” (673 mm)
Width
Height
Maximum Inlet Water
Temperature
160_F (70_C)
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
r
composite, Ceramic, Buna–N, Cotton phenolic, 303, 304, and 316 Stainless steel,
Polymide–12 thermoplastic, PTFEr, Carbon steel, Zinc with or without yellow chromate
plate
r
308-525 19
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THE GRACO WARRANTY
WARRANTY AND DISCLAIMERS
Graco warrants all equipment manufactured by it 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. As
purchaser’s sole remedy for breach of this warranty, Graco will, for a period of twenty four months from date
of sale, repair or replace any part of the equipment proven 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, 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 with Graco equipment of structures,
accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, 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 for
examination by Graco to verify 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.
DISCLAIMERS AND LIMITATIONS
THE TERMS OF THIS WARRANTY CONSTITUTE THE PURCHASER’S SOLE AND EXCLUSIVE
REMEDY AND ARE IN LIEU OF ANY OTHER WARRANTIES (EXPRESS OR IMPLIED), INCLUDING
WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR 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 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 THREE (3) YEARS OF THE DATE OF SALE.
EQUIPMENT NOT COVERED BY GRACO WARRANTY
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WITH RESPECT TO
ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED
BY GRACO. These items sold, but not manufactured by Graco (such as electric motor, 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.
IMPORTANT PHONE NUMBERS
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the
distributor closest to you: 1–800–328–0211 Toll Free
FOR TECHNICAL ASSISTANCE, service repair information or assistance regarding the
application of Graco equipment: 1–800–543–0339 Toll Free
Factory Branches: Atlanta, Chicago, Dallas, Detroit, Los Angeles, West Caldwell (N.J.)
Subsidiary and Affiliate Companies: Canada; England; Switzerland; France; Germany; Hong Kong; Japan; Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
PRINTED IN U.S.A. 308–525 1/91
20 308-525
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3X8–525
Rev. D
Parts Change Notice
Some parts in Rev. A of manual 308–525 have changed but have not yet been changed in the
instruction manual. Please note the changes below and mark them in your manual or keep
this sheet with your manual.
The following pressure washers have been obsoleted and are no longer covered by this manual:
800–681
800–635
800–637
The following changes apply to the page11 parts list for 800–636:
Series
Letter
Part That Ref
Assembly No.
Change Changed No.
Part Description
Label
Description of Change
Replaced by 804–500
Replaced by 801–012
Deleted
Model 800–636
B
176–250
801–548
172–981
801–571
30
31
32
41
Rubber grommet
Label
Hose, high pressure,
3/8” x 50’
Replaced by 804–427
801–568
177–144
181–867
800–314
800–315
800–316
800–317
803–106
803–107
803–108
803–109
NEW
43
47
77
33
34
35
36
71
72
73
74
–
Quick coupler, male, 3/8”
Replaced by 804–498
Replaced by 804–495
Replaced by 290–013
Replaced by 805–547
Replaced by 805–548
Replaced by 805–549
Replaced by 805–550
Deleted
Label
Label
T
ip assembly, 00045
ip assembly, 15045
ip assembly, 25045
ip assembly, 40045
T
T
T
Spray tip, 00045
Spray tip, 15045
Spray tip, 25045
Spray tip, 40045
Chemical injector
Deleted
Deleted
Deleted
Added 804–388
Added 804–275
Added 801–683
Added 805–634
Added 100–081
NEW
–
T
ube, chemical injector
Strainer, chemical injector
ip, chemical injector
Adapter
NEW
–
NEW
–
T
NEW
–
The following two pages replace page 17 of manual 308–525:
3X8–525 Rev. D 1/30/95
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Pump Assembly – Parts
USE ONLY GENUINE GRACO PARTS AND ACCESSORIES
Ref.
Ref.
No. Part No.
Description
Qty
No. Part No.
Description
Qty
1
801–467
803–504
801–468
801–469
KIT 1
KIT 1
KIT 1
MANIFOLD
MANIFOLD, 3500 & 4000 psi
SCREW, Cap, hex hd
1
1
8
8
37 KIT 6 or 107 WASHER
38 KIT 6 or 107 SCREW, Piston
2
3
4
5
6
7
8
9
39 803–295
803–505
COVER, Crankcase
COVER, Crankcase,
3500 & 4000 psi
SHIM
1
WASHER, lock
O-RING
1
2
SEAT, Valve
PLATE, Valve
SPRING
40 803–296
41 KIT 3
SEAL, Oil
KIT 1
KIT 1
42 KIT 28 or 112O-RING
GUIDE, Valve
43 KIT 28 or 112RETAINER, Packing
44 KIT 28 or 112PACKING
Kit 8 or 109
KIT 4 or 106 O-RING
10 KIT 4 or 106 CAP
11 KIT 1
VALVE ASSEMBL
Y
SCREW, Cap, socket hd
COVER, Crankcase.
COVER, Crankcase,
3500 & 4000 psi
O–RING, Crankcase Cover
BEARING, Tapered Roller
SEAL, Oil
45 KIT 28 or 112RING, Head
46 KIT 28 or 112RETAINER, Packing
47 KIT 28 or 112RING, Long Life
12 803–283
13 803–284
803–506
8
1
48 801–526
49 802–305
50 802–304
51 801–482
52 801–483
53 801–484
54 801–485
55 801–624
803–508
BRACKET, Pump
SCREW, Cap, socket hd
2
2
2
1
1
1
1
1
1
1
1
1
2
2
14 802–500
15 803–324
16 KIT 2
17 803–286
18 802–895
803–501
W
ASHER, Lock
PLUG, Hex
ASHER, Flat
PLUG, Hex
ASHER, Flat
W
BUSHING, Piston
CRANKCASE
CRANKCASE,
3500 & 4000 psi
DIPSTICK
GASKET, Cover
CRANKSHAFT
RING, Retaining
KEY
PIN, Wrist
GUIDE, Piston, 3000 psi
GUIDE, Piston,
1
1
W
PUMP, 3000 psi
1
1
1
1
6
1
3
3
PUMP, 3500 & 4000 psi
LABEL, Keep From Freezing
3000 psi
19 801–475
20 803–144
21 803–287
22 803–288
23 802–794
24 803–289
25 803–325
803–503
56 803–083
803–517
LABEL, Keep From Freezing
3500 & 4000 psi
1
1
1
57 802–085
58 801–106
59 800–113
NIPPLE 1/2
TEE 1/2
FILTER (see Instruction
Manual 801–744)
1
1
1
1
1
3500 & 4000 psi
ROD, Connecting
SCREW, Cap, socket hd
COVER, Crankcase
COVER, Crankcase,
3500 & 4000 psi
GAUGE, Sight
3
3
5
1
60 801–111
61 801–110
62 801–112
63 803–141
64 803–142
NUT, Garden Hose
ADAPTER, Garden Hose
STRAINER, Garden Hose
HOSE, Bypass
NIPPLE, Hex 1/2 NPSM x
3/8 NPT 3000 psi
NIPPLE, Hex 1/2 NPSM x
1/2 NPT, 3500 & 4000 psi
UNLOADER, 3000 psi
UNLOADER, 3500 psi
UNLOADER, 4000 psi
NIPPLE, Hex 3/8, 3000 psi
NIPPLE, Hex 1/2x3/8,
3500 & 4000 psi
26 803–291
27 803–292
28 803–293
803–507
1
1
1
1
29 802–345
30 802–793
802–534
PLUG, Oil Drain
1
1
31 KIT 6 or 107 O-RING
65 800–325
800–689
800–427
66 801–868
801–236
32 803–294
33 8033–652
34 KIT 6 or 107
35 801–490
803–502
SCREW, Cap, socket hd
6
6
3
3
3
W
ASHER, Lock
1
1
WASHER, Flinger
PLUNGER, Ceramic
PLUNGER, Ceramic
2
1
36 KIT 6 or 107 RING, Backup.
67 801–568
COUPLER, Male 3/8
3X8–525 Rev. D 1/30/95
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Kit Repair Kit
No. Part No.
Ref
No.
Description
Qty.
1
801–472
Valve
4
5
6
7
8
O–RING
6
6
6
6
6
6
SEAT, Valve
PLATE, Valve
SPRING
GUIDE, Valve
11 VALVE ASSEMBL
Y
2
3
4
6
801–473
16 SEAL, Oil
41 SEAL, Oil
3
Oil Seal
802–511
Crankshaft Seal
2
802–306
9
O–RING
6
6
Valve Cap, 3000 psi
10 CAP
801–474
31 O–RING
1
1
1
1
1
Plunger Repair
,
34
WASHER, Flinger
3000 psi
36 RING, Backup
37 WASHER
38 SCREW, Piston
8
801–486
Packing, 3000 psi
44 PACKING
6
28 801–487
42 O–RING
1
1
2
1
1
1
Packing & Retainer
,
43 RETAINER, Packing
44 PACKING
3000 psi
45 RING, Head
46 RETAINER, Packing
47 RING, Long Life
106 803–509
9
O–RING
6
6
V
alve Cap,
10 CAP
3500 & 4000 psi
107 803–510
Plunger Repair
3500 & 4000 psi
31 O–RING
1
1
1
1
1
,
34
WASHER, Flinger
36 RING, Backup
37 WASHER
38 SCREW, Piston
109 803–511
Packing, 4000 psi
44 PACKING
3
3
3
47 RING, Long life
–
PACKING
112 803–512
42 O-RING
1
1
1
2
1
1
1
Packing &
43 RETAINER, packing
44 PACKING
Retainer,4000 psi
45 RING, head
46 RETAINER, packing
47 RING, Long life
–
PACKING
The following changes apply to the page17 parts list for pump asssembly of Models 3540 and 4043 only:
Series
Letter
Part That Ref
Assembly No.
Change Changed No.
Part Description
Description of Change
Pump asssembly
for Models 3540
and 4043 only
–
804–497
Unloader outlet fitting
Added replacement part no.
804–497 for the unloader out
let fitting.This outlet fitting is
only used on Pressure Wash-
er Models 3540 and 4043
-
3X8–525 Rev. D 1/30/95
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