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PUMP SERVICE: 3540 GHW MODEL
PRESSURE WASHERS
Repair kits are available. See the Parts List, page 32.
For the best results, use all parts in kits.
Follow Shutdown Procedure page 14, to relieve system
pressure.
• Drain and refill pump after 25 hours of operation.
Valves
For a set of six valves, order Valve Assembly Kit
24E976.
1. Remove hex plug from the manifold using a 24mm
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 40
ft-lb (54.2 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.
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
16mm wrench. Push plunger toward the crankcase to
separate plunger and retaining screw.
2. Remove nut from plunger and examine and clean o-
ring.
3. Remove piston sleeve, backup ring, and copper
washer 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
20
NOTICE
replaced) on plunger shaft. Then install copper washer,
backup ring, piston and washer.
6. Lightly grease the retaining screw and outer end of the
plunger and install nut through plunger. Torque to 7.4
ft-lb (10.2 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 18 ft-lb (24.2 Nm) following the tightening
pattern in the following figure.
5
8
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 support ring. Remove low
pressure seal from retainer.
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:
• support ring
• v-packing
• packing retainer
• low pressure seal in retainer
• o-ring in retainer groove
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.
1
4
7
3
2
6
NOTICE
NOTICE
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