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Pump Service: 3030, 3340, and 3540 Model Pressure Washers
16 309286K
Pump Service: 3030, 3340, and 3540 Model Pressure
Washers
Repair kits are available. See the Parts List, page 22. For the best results, use all parts in kits.
Follow Pressure Relief Procedure, page 6.
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 N◆m).
Pumping Section
1. Remove capscrews and lock washers from manifold
using a 6mm wrench.
2. Carefully separate manifold from the crankcase. You
may have to lightly tap the manifold with a soft mal-
let to loosen it.
3. Carefully examine each plunger for any scoring or
cracking. Replace as necessary.
Servicing Plungers
Plunger Repair Kit 243430 is available to replace retain-
ers, o-rings, washers, and backup rings for three cylin-
ders.
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. Replace these parts if necessary using
Plunger Repair Kit 243430.
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 14.4 ft-lb (19.5 N◆m).
7. Lubricate outside of each plunger. Slide the mani-
fold on the crankcase, being careful not to damage
seals.
• The following metric wrenches are needed:
6mm, 13mm, and 27mm.
• Drain and refill pump after 50 hours of opera-
tion.
Retorque the plug after 5 hours operation.
CAUTION
To avoid damage to plunger or seals, keep manifold
properly aligned with the ceramic plungers when you
remove it.
If replacing packings, see Servicing V-Packings,
page 17.