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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.
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
20
NOTICE
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
8
3
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
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.
4
7
2
6
NOTICE
NOTICE
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