Valves, Pumping Section, Servicing Plungers

PUMP SERVICE: 2730 MODEL PRESSURE WASHERS

Repair kits are available. See the Parts List, page 28 (2730B). For the best results, use all parts in kits.

Follow Shutdown Procedure, page 13, to relieve system pressure.

•Drain and refill pump after 25 hours of operation.

Valves

For a set of six valves, order Valve Assembly Kit 804402.

1.Remove hex plug from the manifold using a 22mm 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 60 ft-lb (81 Nm)

Note: Retorque the plug after 5 hours operation.

Pumping Section

1.Remove 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

1.Loosen plunger retaining nut five or six turns using a 13mm wrench. Push plunger toward the crankcase to separate plunger and retaining screw.

2.Remove nut from plunger and examine and clean o-ring, backup ring, and copper bearing/gasket washer.

3.Remove plunger and flinger from plunger shaft. Clean 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 Kits are available for replacing seals.

5.Lightly grease the flinger (and oil seal if it is being replaced) on plunger shaft. Then install 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 11.0 ft-lb (15 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 capscrews and washers finger tight. Torque screws to 8.8 ft-lb (12 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

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 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.

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

Packings must be installed in the proper order and facing the correct direction. Improperly installed parts will cause the pump to malfunction.

7.Reassemble manifold following procedure described in Servicing Plungers.

PUMP SERVICE: 3030 AND 3540 MODEL PRESSURE WASHERS

Repair kits are available. See the Parts List, page 32, 34. For the best results, use all parts in kits.

Follow Shutdown Procedure, page 13, to relieve system pressure.

•Drain and refill pump-after 25 hours of operation.

Valves

For a set of six valves, order Valve Assembly Kit 804402.

1.Remove hex plug from the manifold using a 27mm 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 ft-lb (99 Nm).

Note: Retorque the plug after 5 hours operation.

Pumping Section

1.Remove 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

1.Loosen plunger retaining nut five or six turns using a 13mm wrench. Push plunger toward the crankcase to separate plunger and retaining screw.

2.Remove nut from plunger and examine and clean o-ring, backup ring, and copper bearing/gasket washer.

3.Remove plunger and flinger from plunger shaft. Clean parts as necessary.

5.Lightly grease the flinger (and oil seal if it is being replaced) on plunger shaft. Then install 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 11.0

ft-lb (15 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 14.7 ft-lb (20 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

Two packing kits are available: one kit contains pack- ings only. The other includes packings, rings and retain- ers.

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 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.

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

Packings must be installed in the proper order and facing the correct direction. Improperly installed parts will cause the pump to malfunction.

7.Reassemble manifold following procedure described in Servicing Plungers.