PUMP SERVICE 4043 MODEL PRESSURE WASHERS, Valves

PUMP SERVICE: 4043 MODEL PRESSURE WASHERS

Repair kits are available. See the Parts List, page 22. 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 under hex plug and 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

1Remove the eight capscrews and lock washers 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 803510 is available to replace retainers, o-rings, washers, and backup rings for three cylinders.

1.Loosen plunger retaining screw five or six turns. Push plunger toward the crankcase to separate plunger and retaining screw.

2.Remove screw from plunger and examine 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 leaks from crankcase. If leaking is obvious, replace oil seals. Otherwise, DO NOT remove these seals because they cannot be reused. Oil Seal Kit 801473 is available for replacing seals.

5.Lightly grease the flinger (and oil seal if it is being replaced), and replace the plunger shaft. Then install

the plunger.

6.Lightly grease the retaining screw and outer end of the plunger. Place washer, o-ring and backup ring around screw and install nut through plunger. Torque to 14.7 ft-lb (20 Nm).

Note: If replacing packings, see Servicing V-Packings.

7.Lubricate outside of each plunger. Slide the manifold on the crankcase, being careful not to damage seals.

8.Install cap screws and washers finger tight. Torque screws 22.1 ft-lb (30 Nm) following the tightening pattern in the following figure.

5	1	4	7
8	3	2	6

NOTICE

Uneven tightening could cause the manifold to bind or jam.

Servicing V-Packings

Note: There are two types of packing kits: 803511 contains packings only.

803512 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

•intermediate ring

•head ring

•v-packing

•packing retainer

•o-ring in retainer groove

NOTICE

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

7.Reassemble manifold following procedure described in Servicing Plungers.