18
PUMP SERVICE: 4035 MODEL
PRESSURE WASHERS
Repair kits are available. See the Parts List, page 26.
For the best results, use all parts in kits.
Follow Shutdown Procedure, page 13 to relieve system
pressure.
Valves
For a set of six valves, order Valve Assembly Kit
801472.
1. Remove hex plug from the manifold using a 30mm
wrench.
2. Examine o-ring located under hex plug. Replace if cut
or distorted.
3. Remove valve assembly from cavity. The assembly
may come apart!
4. Install new valve, o-ring and hex plug. Torque to 73.7
ft-lb (100 Nm).
Note: Retorque the plug after 5 hours operation.
Pumping Section
1. Remove the eight capscrews and lockwashers from
manifold.
2. Carefully separate manifold from the crankcase. You
may have to lightly tap the manifold with a soft mallet
to loosen it.
NOTICE
To avoid damage to plunger or seals, keep manifold
properly aligned with the ceramic plungers when
you remove it.
3. Carefully examine each plunger for any scoring or
cracking. Replace as necessary.
Servicing Plungers
Note: Plunger repair kit 801474 is available to replace
retainers, o-rings, washers, and backup rings for three
cylinders.
1. Loosen plunger retaining screw five to six turns. Push
plunger toward the crankcase to separate 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.
3. Remove plunger and flinger from plunger shaft. Clean,
examine and replace parts as necessary.
4. Inspect plunger shaft for oil leakage from the crankcase.
If leaking is obvious, replace the oil seals. Otherwise,
DO NOT remove these seals because they cannot be
reused. Oil Seal Kit 801473 is available for replacing
the seals.
5. Lightly grease the flinger (and oil seal if it is being
replaced), and replace 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 screw and install the screw through plunger.
Torque to 14.7 ft-lb (20 Nm).
Note: If you plan to replace the packings, see Servicing
the V-Packings.
7. Lubricate outside of each plunger. Slide the manifold
onto the crankcase, being careful not to damage
seals.
8. Install capscrews and washers finger tight. Torque
screws to 22.1 ft-lb (30 Nm) following the tightening
pattern in the following figure.
NOTICE
Uneven tightening could cause the manifold to bind
or jam.
Servicing V-Packings
Note: There are two types of packing kits:
801486 contains packings only.
801487 contains packings rings, and retainers.
1. Remove manifold as described in Pumping Section.
2. Carefully pull packing retainer from manifold. Examine
o-ring. Replace o-ring if cut or damaged.
3. Remove V-packing and head ring. Pull out the
intermediate retainer ring. Remove second V-packing
and second head ring.
4. Inspect all parts and replace as necessary.
5. Thoroughly clean packing cavities and inspect for
damage or debris.
6. Lightly grease packing cavities. Replace packings in
the following order:
• head ring
• v-packing
• restop ring
• intermediate ring
• v-packing
• packing retainer
• o-ring in retainer groove
NOTICE
Install the parts in the proper order and facing the
proper direction. Improperly installed parts will
cause a malfunction.
7. Reassemble manifold following procedure described
in Servicing Plungers.
5
1
4
7
8
3
2
6
