308–532
INSTRUCTIONS-PARTS LIST
Rev
A
This manual contains IMPORTANT
WARNINGS and INSTRUCTIONS READ
AND RETAIN FOR REFERENCE
HYDRA-CLEANR 3540, 4043
Pressure Washers
HYDRA-CLEANr 3540, 12.5 HP ENGINE
P/N 800–706, Series A
3500 psi (241 bar) OPERATING PRESSURE
3900 psi (269 bar) MAXIMUM WORKING PRESSURE
HYDRA-CLEANr 4043, 16 HP ENGINE
P/N 800–707, 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.
NEVER alter the maximum throttle setting, which is
factory set. Tampering with this adjustment can
damage the pressure washer and will void the warranty
.
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.
EQUIPMENT MISUSE HAZARD
General Safety
System Pressure
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.
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
NEVER alter or modify any part of this equipment;
doing so could cause it to malfunction.
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
CHECK all spray equipment regularly and repair or
replace worn or damaged parts immediately
.
this pressure washer
.
ALWAYS wear protective eyewear and appropriate
clothing. If using a chemical injector , read and follow
the chemical manufacturer
recommendations on additional protective equipment,
such as a respirator
’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).
308–532
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MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers or other
body parts. KEEP CLEAR of moving parts when
Pressure Relief Procedure before checking or
servicing the pressure washer to prevent discharging
high pressure fluid from the gun.
starting 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.
308–532
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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 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.
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
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
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.
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.
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.
Installing and Changing Spray Tips. If you are using a
sandblaster kit, see its separate manual for installation
instructions.
See
308–532
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STARTUP
Always use this startup procedure to ensure that the
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.
unit 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
or genuine CATr pump 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 shutof f 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.
308–532
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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
308–532
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
,
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
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.
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
3. Remove the ignition cables from the spark
plugs.
on the skin or injury from moving parts, always
follow the Pressure Relief Procedure Warning
before proceeding.
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
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.
operation
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
Change pump break–in oil. Use
SAE 20 or 30 non–detergent oil
or genuine CATr pump oil.
available to make flushing easier
.
operation
CAUTION
Each 100 hours Clean or replace paper air
of operation
or 3 months
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!
cleaner cartridge. Tap gently to
remove dirt. Change engine oil.
Use SAE 30 or 10W–30
detergent oil.
Each 500 hours Change pump oil. Use SAE 20
2. After each use, wipe all surfaces of the pressure
washer with a clean, damp cloth.
of operation
or 6 months
or 30 non–detergent oil or
genuine CATr pump oil.
3. Perform the appropriate maintenance. See
maintenance chart.
308–532
8
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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
308–532
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PARTS DRAWING
800–706 Hydra–Cleanr 3540 Pressure Washer
76
89
77
37
1
2
87
88
62
63
5
5
5
2
87
86
85
46
38
48
47
3
4
5
50
6
49
51
61
60
58
53
52
57
71
72
73
74
33
34
35
36
58
57
54
56
70
31
55
9
59
64
7
32
8
29
2
11
28
15
5
1
2
5
27
65
44
10
5
67
6
30
66
68
5
16
2
25
17
24
20
19
69
18
5
26
42
23
13
12
84
14
22
43
69
39
40
87
89
26
42
41
83
82
81
80
79
5
75
91
78
92
21
90
308–532
10
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PARTS LIST
800–706 Hydra–Cleanr 3540 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
804–136 SHEAVE, Engine
100–023
801–941 SCREW, Cap, Hex hd
5/16–18 x 1
QTY
11
13
2
1
27
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
803–796 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
1
1
1
1
1
1
W
WASHER, Flat 5/16
1
9
1
1
2
1
1
2
2
2
1
1
1
1
1
1
2
4
4
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
W
W
ASHER, Flat 1/4
ASHER, Lock 1/4
10
11
12
13
14
15
16
17
18
PAD, Battery
Y
W
800–678 BRACKET, Rail Stiffener
801–546 SCREW, Cap, Hex hd
3/8–16 x 1–1/4
4
1
64
65
107–069 BRACKET, Battery
801–009 QUICK COUPLER, Female 1/4
(incl. 27)
4
4
4
19
20
21
100–133
100–132
W
W
ASHER, Lock 3/8
ASHER, Flat 3/8
1
1
1
66
67
68
801–134
801–674 SLEEVE, 28”
803–350 GUN, Spray (see Instruction
Manual 308–511)
WAND, 32”
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
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
800–375 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
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
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 14)
800–652 FUEL TANK ASSEMBL
(incl 40, 87, 89, 90, 91, 92)
802–026 BARB, Hose 1/4
801–571 HOSE, High Pressure 3/8 x 50’
801–569 QUICK COUPLER, Female 3/8
(incl. 26)
Y
40
41
42
1
1
2
2
43
44
801–568 QUICK COUPLER, Male 3/8
800–392 GUN & WAND ASSEMBL
802–025
801–008 LABEL, Graco G
TANK, Fuel
Y
(incl. 42, 65, 66, 67, 68, 69)
1
308–532
11
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PARTS DRAWING
800–707 Hydra–Cleanr 4043 Pressure Washer
76
89
77
37
1
2
87
88
62
63
5
5
5
2
87
86
85
46
38
48
47
3
4
5
50
6
49
51
61
60
58
53
52
57
71
72
73
74
33
34
35
36
58
57
54
56
70
31
55
9
59
64
7
32
8
29
11
2
28
15
5
1
2
5
44
27
65
10
67
5
45
6
30
66
68
5
16
2
25
17
24
20
19
69
26
42
18
5
23
13
12
84
14
22
43
69
39
40
87
89
26
42
41
81
83
79
5
82
80
75
91
78
92
21
90
308–532
12
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PARTS LIST
800–707 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
801–814 BELT, Drive
803–160 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
803–068 SHEAVE, Pump
801–898 HUB, Engine
804–141 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 14)
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
308–532
13
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PARTS DRAWING
Pump Assembly
12
9
53
51
8
20
7
5
13
19
53
51
4
3
16
14
11
6
10
14
15
20
22
16
17
2
21
18
23
24
25
27
1
52
34
26
55
28
49
2
51
53
48
19
47
30
33
46
45
40
39
50
44
38
29
37
31
43
42
37
32
57
36
58
67
71
70
69
68
42
43
44
45
65
64
63
46
47
48
2
59
49
62
61
60
56
73
54
66
72
74
66
72
59
308–532
14
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PARTS LIST
Pump Assembly
REF PART
REF PART
NO. NO.
.
DESCRIPTION
QTY
NO. NO.
DESCRIPTION
QTY
1
1
2
804–175 CRANKCASE
42
43
44
45
46
47
48
49
50
51
52
53
54
KIT C4
KIT C4
KIT C4
KIT C4
KIT C4
KIT C4
KIT C4
RING, Back Up
O–RING, Valve Seat
SEAT, Valve
804–132 RING, Backup, valve cap
804–196 COVER, Crankshaft
801–028 O–RING, Oil Fill Cap
801–027 CAP, Oil Fill
1
3
1
4
1
5
1
VALVE
6
804–190 O–RING, Crankcase Cover
804–158 COVER, Crankcase
804–171 GASKET, Sight Gauge
804–150 GAUGE, Sight, oil level
802–189 O–RING, Drain Plug
804–089 PLUG, Drain
804–238 SCREW, Cap, hex hd./cross
recess 6mm x 20mm
804–195 CRANKSHAFT
804–108 BEARING
804–109 SEAL, Oil, crankshaft
804–074 O–RING, Crankshaft Cover
804–114 SHIM
804–131 SEAL, Oil, crankshaft
804–237 SCREW, Cap, hex hd./cross
recess 6mm x 16mm
1
SPRING, Valve
RETAINER, Valve Spring
O–RING, Valve Cap
7
1
8
1
9
1
804–140 CAP, Valve
KIT C22 O–RING, Seal Case
804–075
KIT C22 RETAINER, Seal, front
804–077 ASHER, Lock, 6mm
804–233 SCREW, Cap, socket hd. ,
10mm x 25mm
6
10
11
12
1
1
WASHER, Flat, 6mm
12
12
4
1
2
1
2
1
1
W
13
14
15
16
17
18
19
4
3
4
1
1
2
1
1
55
56
57
58
59
60
61
62
804–214
802–178
W
W
ASHER, SST, 18mm
ASHER, Lock, 10mm
803–083 LABEL, Keep from freezing
804–247 PUMP
800–692 BRACKET, Pump
801–523 NIPPLE, 1/2 x 2
801–106 TEE, 1/2
800–113 FILTER (see instruction
manual 801–744)
8
3
3
3
3
3
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
804–110 ROD, Connecting
804–160 ROD, Plunger
804–111 PIN, Rod
801–030 WASHER, Flat
1
1
1
1
4
1
1
2
801–031 SEAL, Oil, connecting rod
KIT C22 RETAINER, Seal, rear
804–121 WASHER, Flinger
804–161 WICK, Oil
63
64
65
66
67
68
69
70
801–111 NUT, Garden Hose
801–110 ADAPTER, Garden Hose
801–112 STRAINER, Garden Hose
100–214
803–141 HOSE ASSEMBL
801–568 QUICK COUPLER, Male, 3/8
159–239 NIPPLE, Hex, 3/8 x 1/2
802–534 NIPPLE, Hex,
3
3
3
3
3
3
3
3
1
1
801–036 PLUNGER, Ceramic
804–133 WASHER, Copper
804–235 STUD, 6mm x 58mm
801–038 RING, Backup
801–039 O–RING, Retaining, plunger
801–040 RETAINER, Plunger
802–753 PAN, Oil
804–199 MANIFOLD, Forged
KIT C22 ADAPTER, Front
KIT C22
WASHER, Lock 5/16
Y, Bypass
1/2 NPT x 1/2 NPSM
1
1
1
71
72
800–689 UNLOADER, 3500 PSI
800–427 UNLOADER, 4000 PSI
108–842 SCREW, Cap,
Hex hd. 8mm x 16mm
PACKING, High Pressure
4
1
1
KIT C22 ADAPTER, Rear
804–211 CASE, Seal
KIT C22
3
73
74
101–754 PLUG, 3/8
100–361 PLUG, 1/2
PACKING, Low Pressure
Kit
Repair Kit Ref
No. Description
Kit
Repair Kit Ref
No. Part No.
Qty.
No. Part No.
No. Description
Qty.
C4
801–041
Valve
42
43
RING, Back Up
O–RING, Valve
Seat
SEAT, Valve
VALVE
SPRING, Valve
RETAINER, Valve
Spring
6
6
C22 804–099
Packing &
25
RETAINER, Seal,
rear
ADAPTER, Front
PACKING, High
Pressure
ADAPTER, Rear
3
Retainer
36
37
3
6
44
45
46
47
6
6
6
6
38
40
3
3
PACKING, Low
Pressure
48
O–RING, Valve
Cap
6
50
52
O–RING, Seal
Case
RETAINER, Seal,
front
3
3
308–532
15
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PUMP SERVICE
Reassembly:
Servicing the Valves
1. Carefully examine each ceramic plunger for
scoring or cracks, replace if worn and slip onto
plunger rod.
1. Remove the hex valve plug.
2. Examine the o–ring under the plug for cuts or
distortion and replace if worn. Lubricate new o–ring
before installing.
Note:
Ceramic plunger can only be installed one
direction (front to back). Do not force onto
rod.
3. Grasp valve retainer by tab at the top with pliers
and remove from valve chamber . V alve parts
usually separate during removal.
2. Examine plunger retainer and stud and replace if
worn.
Note:
A special tool will be needed to remove the
seat from the manifold. A reverse pliers or a
standard vise grip and a 1/4” x 3” bolt to fit I.D.
of seat inserted under the edge of the seat,
Note:
Thread stud into plunger retainer
.
3. Examine o–ring, back–up ring and gasket on
plunger retainer and replace if worn or cut.
Lubricate o–ring for ease of installation and to avoid
damaging o–rings.
will pry the valve seat out easily
.
4. Examine all valve parts for wear and replace with
preassembled valve assembly in service kit
containing retainer , spring, valve, valve seat,
o–ring, and back–up ring.
Note:
First install gasket, then back–up ring and
o–ring.
4. Thread plunger retainer and stud assembly into
plunger rod. Exercise caution not to over torque.
5. Grasp new valve assembly by tab at top with pliers,
immerse in oil and push into valve chamber . Be
certain valve assembly is square in valve chamber
.
5. Saturate new oil wick by soaking in oil, place in seal
retainer and slip retainer over ceramic plunger
.
6. Apply Loctite 242 to valve plug, thread into manifold
port and torque per chart.
6. Replace oil pan.
7. Turn shaft by hand to line up plungers so end
plungers are parallel.
Note:
Corrosion Resistant models require the coil
spring installed in the Valve Plug.
8. Carefully slip manifold onto plungers, keeping
manifold level, and tap with mallet to bring manifold
flush with crankcase.
Servicing the Pumping Section
Disassembly:
1. Remove the four (4) hex nuts or two (2) bolts from
the manifold (varies with model).
9. Replace washers and nuts or bolts and torque per
chart.
Servicing the Seals and V–Packings
2. Rotate crankshaft by hand to start separation of
manifold from crankcase. Support the underside of
the manifold and tap lightly with a mallet to remove
Disassembly:
1. Remove the manifold as described.
the manifold assembly
.
2. With crankcase side of manifold facing up, unscrew
the seal case from the manifold using a special key
wrench.
CAUTION
Keep manifold properly aligned with ceramic
plungers when removing to avoid damage to
either plungers or seals.
3. Remove o–ring from seal case.
4. Remove snap ring and low pressure seal from the
seal case. Seals are generally removed easily
without any tools.
3. Remove oil pan and slide out seal retainer with
wicks.
5. High Pressure Seal Models: The high pressure
seal is generally easily removed from the manifold
without any tools. If extremely worn a reverse pliers
may be used.
4. Using a wrench, loosen the plunger retainer. Grasp
ceramic plunger and push toward crankcase until
plunger retainer pops out.
5. Remove plunger retainer with copper gasket,
back–up Ring and o–ring.
6. V–Packing Models: The female adapter , two
v–packings and male adapter are easily removed
from manifold without tools. If extremely worn a
reverse pliers may be used.
6. Remove plunger from plunger rod.
308–532
16
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Reassembly:
Servicing Crankcase Section
V–Packing Models:
1. While manifold, plungers and seal retainers are
removed, examine crankcase seals for wear
.
1. Lubricate high pressure packing area in manifold.
2. Check oil level and for evidence of water in oil.
2. Insert male adapter with notches down and “v” side
up.
3. Rotate crankshaft by hand to feel for
bearing movement.
smooth
3. Lubricate v–packings and install one–at–a–time
with grooved side down.
4. Examine crankshaft oil seal externally for drying,
cracking or leaking.
4. Next install female adapter with grooved side
down.
5. Consult factory or your local distributor if crankcase
service is evidenced.
5. Examine seal case o–ring and replace if worn.
Lubricate new o–ring before installing.
T
orque Chart
Pump Part Thread ool Size Torque
1 mm hex 80 in. lbs.
6. Thread seal case into manifold and tighten with key
wrench.
T
Plunger
Retainer
M5
1
High Pressure Seal Models:
Manifold
M8 x 1.25 13 mm hex 125 in. lbs.
M10 x 1.25 17 mm hex 217 in. lbs.
1. Lubricate seal area in manifold.
2. Carefully square seal into position by hand with the
metal grooved side up.
M10
—
17 mm hex 217 in. lbs.
Valve
Covers
24 mm
75 ft. lbs.
3. Examine seal case o–ring and replace if worn.
Lubricate new o–ring before installing.
27 mm
75 ft. lbs.
4. Next secure high pressure seal into position by
threading seal case into manifold. T ighten seal
case with key wrench.
Low Pressure Seal–All Models:
1. Examine seal for wear or broken spring and lace if
necessary.
2. Install low pressure seal in seal case with garter
spring down.
3. Reinstall snap ring. Be certain snap ring is a tight fit.
Replace if it can be easily turned.
4. Replace manifold on pump as described and
torque per chart.
308–532
17
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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 (3540
uses 803–107, 4043 uses 803–107).
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.
308–532
18
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TECHNICAL DATA
Model 800–706
Model 800–707
Engine (4 cycle, air–cooled)
Battery
12.5 HP Briggs & Stratton OHV
16 HP Briggs & Stratton OHV
12 Volt, 30 AMP
250 CCA
12 Volt, 30 AMP
250 CCA
Gasoline Tank Capacity
6 Gallon (23 Liter)
3500 psi (241 bar)
6 Gallon (23 Liter)
4000 psi (276 bar)
Water Pump Maximum Working
Pressure
W
ater Pump Maximum Flow
4 gpm (15 lpm)
4.25 gpm (16 lpm)
3/4” garden hose (f)
255 lbs (116 kg)
Inlet Hose Connection
Weight
3/4” garden hose (f)
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)
Width
Height
Maximum Inlet Water
Temperature
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,
plate
r, Carbon steel, Zinc with or without yellow chromate
PTFE
is a registered trademark of the DuPont Company
.
PTFE
308–532
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 W ARRANTY 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 EXPRESSL Y 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 W ARRANTY, AND DISCLAIMS ALL IMPLIED W
ARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A P ARTICULAR PURPOSE, WITH RESPECT T
O
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 ASSIST ANCE, 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. 308–532 3/91
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3X8–532
Rev. D
Parts Change Notice
Some parts in Rev. A of manual 308–532 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.
Pressure washer 800–706 has been obsoleted and is no longer covered by this manual.
The following changes apply to the page 13 parts list for 800–707:
Series
Letter
Part That Ref
Assembly No.
Change Changed No.
Part Description
Description of Change
Model 800–707
B
801–814
803–160
803–530
176–250
801–548
172–981
803–519
801–568
3
Drive belt
Replaced by 803–889
4
Sheave, engine
Battery bracket
Label
Replaced by 803–943
Replaced by 804–282
Replaced by 804–500
Replaced by 801–012
Deleted
10
30
31
32
41
43
Rubber grommet
Label
Hose, high
pressure, 3/8” x 50’
Replaced by 804–427
Quick coupler, male, Replaced by 804–498
3/8”
177–144
803–068
804–141
800–450
47
49
51
75
Label
Replaced by 804–495
Replaced by 803–944
Replaced by 801–135
Sheave, pump
Hub, pump
Hose assembly with Replaced by 800–375
quick couplers
181–867
800–314
800–315
800–316
800–317
803–106
803–107
803–108
77
33
34
35
36
71
72
73
Label
ip assembly, 00045 Replaced by 805–547
ip assembly, 15045 Replaced by 805–548
ip assembly, 25045 Replaced by 805–549
ip assembly, 40045 Replaced by 805–550
Replaced by 290–013
T
T
T
T
Spray tip, 00045
Spray tip, 15045
Spray tip, 25045
Deleted
Deleted
Deleted
3X8–532 Rev. D 1/30/95
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The following changes apply to the page 13 parts list for 800–707:
Series
Letter
Part That Ref
Assembly No.
Change Changed No.
Part Description
Spray tip, 40045
Chemical injector
Description of Change
Deleted
Model 800–707
803–109
NEW
74
–
Added 804–388
NEW
NEW
NEW
NEW
–
–
–
–
T
ube, chemical
Added 804–275
Added 801–683
Added 805–634
Added 100–081
injector
Strainer, chemical
injector
Tip, chemical
injector
Adapter
The following three pages replace pages 14 and 15 of manual 308–532:
3X8–532 Rev. D 1/30/95
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Pump Assembly – Parts
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
3X8–532 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
3X8–532 Rev. D 1/30/95
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28 801–487
42 O–RING
1
1
2
1
1
1
Kit Repair Kit
No. Part No.
Ref
No.
Packing & Retainer
,
43 RETAINER, Packing
44 PACKING
Description
Qty.
3000 psi
1
801–472
Valve
4
5
6
7
8
O–RING
6
6
6
6
6
6
45 RING, Head
46 RETAINER, Packing
47 RING, Long Life
SEAT, Valve
PLATE, Valve
SPRING
106 803–509
9
O–RING
6
6
GUIDE, Valve
Valve Cap,
10 CAP
11 VALVE ASSEMBL
Y
3500 & 4000 psi
107 803–510
Plunger Repair
3500 & 4000 psi
2
3
4
6
801–473
16 SEAL, Oil
41 SEAL, Oil
3
31 O–RING
1
1
1
1
1
Oil Seal
,
34
WASHER, Flinger
802–511
Crankshaft Seal
2
36 RING, Backup
37 WASHER
38 SCREW, Piston
802–306
9
O–RING
6
6
Valve Cap, 3000 psi
10 CAP
109 803–511
Packing, 4000 psi
44 PACKING
3
3
3
47 RING, Long life
801–474
31 O–RING
1
1
1
1
1
–
PACKING
Plunger Repair
,
34
WASHER, Flinger
3000 psi
36 RING, Backup
37 WASHER
112 803–512
42 O-RING
1
1
1
2
1
1
1
Packing &
43 RETAINER, packing
44 PACKING
38 SCREW, Piston
Retainer,4000 psi
45 RING, head
8
801–486
Packing, 3000 psi
44 PACKING
6
46 RETAINER, packing
47 RING, Long life
–
PACKING
3X8–532 Rev. D 1/30/95
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