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308–529

19

Servicing the V–Packings

NOTE:

  There are two types of packing kits: one is

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

For  injecting  harsh cleaning chemicals downstream

from the pump.

UPSTREAM CHEMICAL INJECTOR KIT

800–257

For injecting mild cleaning chemicals upstream into the

pump.

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.

TECHNICAL DATA

Model 800–638

Model 800–690

Model 800–639

Engine (air–cooled, 4 cycle)

9 hp Honda OHV

9 hp Briggs & Stratton OHV 11 hp Honda OHV

Gasoline Tank Capacity

6.2 quarts (6 liters)

5 quarts (4.8 liters)

6.9 quarts (6.5 liters)

Water Pump Maximum Working

Pressure

2500 psi (172 bar)

2500 psi (172 bar)

3000 psi (207 bar)

Water Pump Maximum Flow

4 gpm (15 lpm)

4 gpm (15 lpm)

4 gpm (15 lpm)

Inlet Hose Connection

3/4” garden hose (f)

3/4” garden hose (f)

3/4” garden hose (f)

Weight

158 lb (70 kg)

158 lb (70 kg)

172 lb (78 kg)

Dimensions

Length

Width

Height

36” (914 mm)

21” (533 mm)

23.5” (597 mm)

36” (914 mm)

21” (533 mm)

23” (584 mm)

36” (914 mm)

21” (533 mm)

24” (610 mm)

Maximum Inlet Water Temperature 160

_

F (70

_

C)

160

_

F (70

_

C)

160

_

F (70

_

C)

Wetted Parts

High Pressure Hose
Bypass Hose
Pressure Washer

(including fittings)

Acrylonitrile and Buna–N cover and tube
Synthetic yarn and EPDM
Anodized aluminum, Aluminum or bronze alloys, Brass Copper, Nylon–

r

composite, Ceramic, Buna–N, Cotton phenolic, 303, 304, and 316 Stainless steel,

Polymide–12 thermoplastic, 

r

, Carbon steel, Zinc with or without yellow

chromate plate

 is a registered trademark of the DuPont Company

.

PTFE

PTFE

PTFE

PTFE

PTFE

PTFE

PTFE

PTFE

PTFE

Summary of Contents for Hydra-Clean 2540

Page 1: ...asher HYDRA CLEAN 2540 9 HP ENGINE P N 800 638 Series A P N 800 690 Series A 2500 psi 172 bar OPERATING PRESSURE 3000 psi 207 bar MAXIMUM WORKING PRESSURE HYDRA CLEAN 3040 11 HP ENGINE P N 800 639 Ser...

Page 2: ...ings 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 in...

Page 3: ...re 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 HAVE STRAI...

Page 4: ...sure washer to prevent discharging high pressure fluid from the gun TERMS WARNING Alerts user to avoid or correct conditions that could cause bodily injury CAUTION Alerts user to avoid or correct cond...

Page 5: ...ppropriate 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...

Page 6: ...rmly 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 en...

Page 7: ...ing 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 tips ALWAYS follow the pr...

Page 8: ...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 i...

Page 9: ...l sensor Start Stop switch in Stop position Water in gasoline or old fuel Choked improperly Flooded engine Dirty air cleaner filter Spark plug dirty wrong gap or wrong type Spray gun closed Water leak...

Page 10: ...ssure Washer 8 7 4 29 12 11 10 10 18 23 33 20 24 35 36 42 44 26 25 3 3 0 32 26 32 26 28 22 26 27 34 11 10 61 60 20 6 21 43 65 64 38 17 19 5 2 14 1 63 9 15 16 13 15 16 47 10 10 11 52 62 56 57 58 37 49...

Page 11: ...EW Cap hex hd 3 8 16 x 3 1 28 801 858 BRACKET Front Leg 1 29 803 925 HANDLE 1 30 800 641 FRONT LEG ASSEMBLY incl 22 26 27 28 32 1 31 803 301 LABEL Model 2540 1 REF PART NO NO DESCRIPTION QTY 32 101 56...

Page 12: ...3040 Pressure Washer 29 12 22 10 10 18 23 33 20 24 26 25 30 32 26 32 26 28 19 26 27 20 6 21 10 22 62 35 36 42 44 34 52 46 56 57 58 37 50 47 51 13 51 53 54 48 8 7 3 22 10 49 55 43 61 60 38 11 17 5 2 14...

Page 13: ...hd 3 8 16 x 3 1 28 801 858 BRACKET Front Leg 1 29 803 925 HANDLE 1 30 800 641 FRONT LEG ASSEMBLY incl 19 26 27 28 32 1 31 801 090 COUPLER Male 1 4 4 32 101 566 NUT Lock 3 8 16 5 REF PART NO NO DESCRIP...

Page 14: ...ed Replacing the Oil Seal 14 NOTE The oil seal MUST be replaced with a new one if removed 1 Follow steps 1 and 3 under Replacing the Gasket 2 Remove the snap ring 6 from the gear case using a snap rin...

Page 15: ...CREW Set 1 4 802 335 GEAR Pump 1 5 802 336 GEAR Engine 1 6 802 337 RING Snap 1 7 802 338 BEARING 1 8 802 339 RING Snap 1 9 802 340 GASKET 1 10 801 475 DIPSTICK 1 11 802 341 CASE Mounting 1 12 100 527...

Page 16: ...PARTS DRAWING 803 737 Pump Assembly 46 47 44 45 10 9 8 7 6 5 4 1 3 2 10 9 11 52 51 54 53 40 15 41 14 39 12 21 23 22 24 26 33 32 28 29 30 31 27 25 34 35 36 31 37 38 11 43 42 16 17 44 45 13 14 18 19 20...

Page 17: ...3 294 SCREW Cap socket hd 6 33 801 652 WASHER Lock 6 34 801 660 WASHER Flinger 3 35 801 490 PLUNGER Ceramic 3 36 KIT 6 RING Backup 37 KIT 6 WASHER 38 KIT 6 SCREW Piston 39 803 295 COVER Crankcase 1 40...

Page 18: ...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 ri...

Page 19: ...ck 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 i...

Page 20: ...ade at a reasonable charge which charges may include the costs of parts labor and transportation DISCLAIMERS AND LIMITATIONS THE TERMS OF THIS W ARRANTY CONSTITUTE THE PURCHASER S SOLE AND EXCLUSIVE R...

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