FLUID INJECTION HAZARD

General Safety

This pressure washer generates very high fluid pressure. Spray from the gun, leaks or ruptured components can inject fluid through your skin and into your body and cause extremely serious bodily injury including the need for amputation. Also, fluid injected or splashed into the eyes or on the skin can cause serious damage.

NEVER point the spray gun or wand at anyone or at any part of the body . NEVER put hand or fingers over the spray tip.

ALWAYS follow the Pressure Relief Procedure ,

before cleaning or servicing any part of the sprayer.

NEVER try to stop or deflect leaks with your hand or body.

Be sure equipment safety devices are operating properly before each use.

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: Injection in the skin is a traumatic injury. It is important to treat the injury surgically as soon as possible. Do not delay treatment to research toxicity. Toxicity is a concern with some exotic coatings injected directly into the bloodstream. Consultation with a plastic surgeon or reconstructive hand surgeon may be advisable.

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 gun to relieve pressure, and then engage the trigger safety latch again.

6.Before long???term (overnight) storage or transporting of 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 moment, always set the gun safety latch in the engaged or ???safe??? position, making the gun inoperative. Failure 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. If a spray tip clogs while spraying, engage the gun safety latch immediately .

ALWAYS follow the Pressure Relief Procedure and then remove the spray tip to clean it.

EQUIPMENT MISUSE HAZARD

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.

NEVER alter or modify any part of this equipment; doing so could cause it to malfunction.

CHECK all spray equipment regularly and repair or 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

recommendations on additional protective equipment, such as a respirator.

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.

Chemical Compatibility

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.

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.

ALL FLUID HOSES MUST HA VE 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.

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.

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.

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 temperatures above 200_???F (93_???C) or below ???40_ F (???40_??? C).

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.

NEVER operate the unit in a closed building. The exhaust contains carbon monoxide, a poisonous, odorless, invisible gas which can cause serious injury or death if inhaled.

NEVER alter the throttle setting, which is factory set. Tampering with this adjustment can damage the pressure washer and will void the warranty.

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers or other body parts. KEEP CLEAR of moving parts when starting or operating the pressure washer.

NEVER operate the pressure washer without all guards and interlocks installed and functioning. Follow the

Pressure Relief Procedure before checking or servicing the pressure washer to prevent discharging high pressure fluid from the gun.

WARNING: Alerts user to avoid or correct conditions that could cause bodily injury.

CAUTION: Alerts user to avoid or correct conditions that could cause damage to the equipment.

NOTE: Identifies helpful procedures and information.

INSTALLATION

HIGH 1026

PRESSURE

SPRAY

HOSE

CONNECTION

FOR THE 1026 & 1530

SPRAY

HOSE

2340

GUN

Check for Shipping Damage

Check the unit for any damage that may have occurred in shipping. Notify the carrier immediately if there is any damage.

Set Up (1026 & 1530)

Connect the high pressure hose between the pump

Set Up (2340)

If you are using a downstream chemical injector, install it between the pump unloader and the high pressure hose, using the quick couplers provided.

Connect the high pressure hose between the pump outlet and the gun inlet. Both of these connections are made with quick couplers.

CAUTION

Up to 100 ft (30 m) of high pressure hose may be used. Longer hoses may af fect sprayer performance, and chemical injector performance, if used.

Install the appropriate spray tip on the wand. See Installing and Changing Spray Tips. If you are using a sandblaster kit, see its separate manual for installation instructions.

Connect to Water Supply

CAUTION

Before attaching to the water supply, check your local plumbing code regarding cross???connection to the water supply . A backflow preventer , P/N 801???133, is available to prevent backflow of contaminated water into the fresh water supply . Install it upstream from the pump.

If inlet water pressure is over 60 psi (4.1 bar) a regulating water valve, 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 3/4 inch garden hose inlet. The supply hose should not be more than 50 ft (15 m) long.

minimum flow rate equal to that of the unit (see Technical Data, inside back cover).

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 10W???30 weight detergent oil as necessary.

Pump: Add SAE 20 or 30 weight non???detergent oil as necessary.

NOTE: Some units are equipped with a low???oil sensor that shuts the engine of f if the oil level falls below a certain level. If the unit stops unexpectedly, check both the oil and the fuel levels. Check the oil level each time the unit is refueled.

2. Check fuel level.

WARNING

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.

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.

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 cable is pushed firmly onto the spark plug.

On those units equipped with an ignition shutof f switch, put the switch in the ???on??? position and put the throttle in the ???run??? position.

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.

If the 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.

avoid costly damage to the pressure washer.

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 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 accessories are used (2340 only).

Chemical Injector

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.

WARNING

Observe chemical manufacturer ???s safety precautions regarding use of goggles, protective clothing or respirators.

1026 & 1530: A downstream chemical injector is provided with the pressure washer. Insert the chemical strainer (attached with clear tubing to the chemical injector) into the container of chemical. Push the nozzle holder on the end of the wand away from the gun. This causes a drop in pressure that actuates the chemical injector. Pull the nozzle holder to deactivate the chemical injector and produce high pressure for rinsing. The flowrate of the chemical is regulated by turning the chemical adjuctment knob on the injector . Maximum chemical flow is at a full two turns counterclockwise from the closed (clockwise) position. T wisting the nozzle holder will change the spray fan angle.

2340: The chemical injector is an accessory. See the chemical injector instruction manual.

WARNING

DO NOT attempt to open or close the adjustable nozzle when the spray gun is in use. Be sure that the trigger safety latch on the gun is in the ???ON??? position before adjusting to avoid serious bodily injury or fluid injection.

Check the distance that you will need to hold the spray nozzle from the surface by test spraying on a scrap of similar material. For soft surfaces, such as wook, hold nozzle 3 ft (1 m) from the surface and gradually bring it closer, checking to see if the high pressure spray is damaging the surface.

Trigger Safety Latch

WARNING

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.

TRIGGER SAFETY LATCH SHOWN ENGAGED

TRIGGER SAFETY LATCH SHOWN

Mist the wet surface with cleaning solution. Let it soak briefly, then use the high pressure rinse to ???chisel??? off the soil. Keep the nozzle at an angle to the surface and at a distance determined to be best for the surface. If some soil remains, repeat the procedure, letting the chemical soak a little longer . Stubborn soil can be cleaned of f better with a stronger, heated cleaning solution.

Protect surfaces that might be damaged by the cleaning solution or the high pressure spray. Rinse the solution before it dries.

Figure 2

DISENGAGED

Installing and Changing Spray Tips (2340)

including fluid injection or splashing in the eyes or onto the skin, use extreme caution when

1.Follow the Pressure Relief Procedure.

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.

A

B

Figure 3

SHUTDOWN, FLUSHING

AND STORAGE

WARNING

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 gun to relieve pressure, and then engage the trigger safety latch again.

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 the ceramic plungers!

2.After each use, wipe all surfaces of the pressure washer with a clean, damp cloth.

3.Perform the appropriate maintenance. See maintenance chart.

MAINTENANCE

Observing regular maintenance intervals helps ensure that you get maximum performance and life from the pressure washer.

There is a break???in period for the engine and pump. After changing the oil in these components following their respective break???in periods, the interval between required changes is longer.

If the unit is operating in dusty conditions, these maintenance checks should be made more often.

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.

23

20 21

25

14

13

35

1

2

3

8

1

36 37

25

4

10

2 3

27

13

1

11

36

37

38

39

40

41

12 5 10 9 8

4

67

7 6

42

43

44

45

46

47

48

49

50

51

47

52

53

54

55

47

56

57

58

68 69

91

70

80

76

75 74

50

49

PARTS LIST

803???931 Pump and Unloader Assembly

7KIT 96,97 PACKING

13

1

11

36

37

38

39

40

41

12 5 10 9 8

4

67

7 6

42

43

44

45

46

47

48

49

50

51

47

52

53

54

55

47

56

57

58

68 69

91

70

80

76

75 74

50

49

PARTS LIST (Continued)

803???931 Pump and Unloader Assembly

49KIT 102 RING, Backup

50KIT 102,94 O???RING

51KIT 102 PISTON, Control

52KIT 102 RING, Backup

53KIT 102 GUIDE, Valve

63KIT 1 PLATE, Valve

64KIT 1 SEAT, Valve

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: 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.

NOTE: There are two dif ferent 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 801???472.

1.Remove the hex plug from the manifold using an M30 wrench.

2.Examine the o???ring under the hex plug and replace it if it is cut or distorted.

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: 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.

CAUTION

Keep the manifold properly aligned with the ceramic plungers when removing to avoid damage to the plunger or seals.

3.Carefully examine each plunger for any scoring or cracking and replace as necessary.

Servicing the Plungers

NOTE: Plunger repair kit, P/N 801???474 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.

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.

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.

5.Lightly grease the flinger and oil seal, if it is being replaced and replace them on the plunger shaft. 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).

NOTE: If you plan to replace the packings, refer to Servicing the V???Packings.

Figure 4

Servicing the V???Packings

NOTE: There are two types of packing kits: one is just packings only, the other includes the packings, rings and retainers.

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.

3.Remove the v???packing and head ring. Pull out the intermediate retainer ring. Remove the second v???packing and second head ring.

4.Inspect all parts and replace as necessary.

5.Thoroughly clean the packing cavities and examine for debris and damage.

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.

CAUTION

Install the parts in the proper order and facing the correct direction. Improperly installed parts will cause a malfunction.

7.Reassemble the manifold as instructed in Servicing the Plungers.

ACCESSORIES

(Must be purchased separately)

DOWNSTREAM CHEMICAL INJECTOR KIT 800???117 & 800???649 (2340)

For injecting harsh cleaning chemicals downstream from the pump. 800???649 is all stainless steel wetted parts.

UPSTREAM CHEMICAL INJECTOR KIT 800???257

For injecting mild cleaning chemicals upstream into the pump.

CHASSIS & WHEELS ASSEMBLY 800???719 (1026 & 1530)

Complete chassis with semi???pneumatic wheels for portability.

BACKFLOW PREVENTOR 801???133

Prevent back???up of contaminated water into fresh supply. Install upstream of pump.

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.

INLET PRESSURE REGULATOR 800???258

Regulates inlet water pressure to 60 psi (4 bar) maximum.