PUMP SERVICE 4035 MODEL PRESSURE WASHERS, Valves

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.

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:

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.