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Yamaha PW3028A, Service Manual

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Yamaha PW3028A Service Manual Download Page 19

19

Fig. 10

(A) 

SEAL

(B) 

SEAL RETAINER

(D) 

WASHER

(C) 

CERAMIC 

PLUNGER

(C) 

CERAMIC 

PLUNGER

CRANKCASE

(E) 

PLUNGER RETAINER 

BOLT

Fig. 11

1

4

3

2

6

5

TORQUE SEQUENCE

CAT PUMP TORQUE SETTINGS

Pump Item 

Torque (in lbs.)

Plunger Retainer 

55

Manifold Head Screws 

132

Valve Plugs 

750

Bearing Cover Screws 

50

Bubble Oil Gauge 

45

Fig. 12

Fig. 14

SERVICING

Fig. 13

CRANKCASE

MANIFOLD

(A) 

BEARING COVER

(D) 

SEAL

(C) 

O-RING

(B) 

BOLT

Summary of Contents for PW3028A

Page 1: ...PRESSURE WASHER SERVICE MANUAL PW3028A PW3028B LIT 19616 PW 30 7DH F819P 10 ...

Page 2: ...er System 14 Servicing 15 24 Manifold Removal 15 Valve Assembly Removal 15 Soap Injector Assembly Removal 15 Unloader Removal 15 Plunger Chamber Removal 15 Ceramic Plunger Removal 16 Valve Assembly Replacement 16 Soap Injector Assembly Replacement 16 Unloader Replacement 16 Ceramic Plunger Replacement 17 Plunger Chamber Replacement 17 Manifold Replacement 17 Crankcase Seal and O Ring Replacement 1...

Page 3: ...add engine oil until the fluid level rises to the upper portion of the hatched area on the dipstick Replace the oil cap dipstick and securely tighten PUMP LUBRICANT All pumps ship with oil already inside direct from the factory There is no need to add oil unless this is a pump maintenance issue Make a visual inspection of the pressure washer s pump NOTE Before commencing with service shut off driv...

Page 4: ...lect a spray tip size Quick Connect Nozzles Spray tips are available in various spray angles degrees 0 15 25 and 40 Turbo Nozzles These increase cleaning efficiency as much as 200 compared to a 25 degree flat fan nozzle The 0 degree rotation creates a cleaning and tearing action Soap Blaster The nozzle can be easily adjusted for long range or short range cleaning NOZZLE MAINTENANCE ALL PRESSURE WA...

Page 5: ...M METER HEX KEY 5 mm AND 10 mm PRESSURE GAUGE REVERSE PLIERS WRENCH 19 mm AND 24 mm 3 8 in NPT QUICK CONNECTS 0º NOZZLE PICKS SEAL INSTALLATION TOOL RUBBER MALLET SAFETY GOGGLES Silicone Grease Silicone Grease NEEDLE NOSE PLIERS FLAT HEAD SCREWDRIVER PHILLIPS HEAD SCREWDRIVER Fig 1 MENU LOCK 99 999 RPM MONARCH PT99 ...

Page 6: ... If The Engine Does Not Start Check for enough fuel May need to adjust choke position Try starting again 940873007 04 NOTICE DONOTUSEFUEL CONTAININGMORE THAN10 ETHANOL ITISAVIOLATION OFU S FEDERALLAW WILLDAMAGEYOUR PRODUCT ANDVOID THE WARRANTY ETHANO L FREE DO NOT USE E15 OR E85 FUEL IN THIS UNIT IT IS A VIOLATION OF FEDERAL LAW AND WILL DAMAGE THE UNIT AND VOID YOUR WARRANTY WARNING Never use ble...

Page 7: ...inside the pump D DETERGENT INJECTOR a Detergent not drawing Check that nozzle is in low chemical position Check that metering valve on pickup filter is open Check pickup filter for clog Check detergent tube for holes and kinks Remove tube from nipple Remove detergent non return check valve Inspect non return check valve for clogs NOTE Leaving detergent in pump will cause ball to stick Reinstall n...

Page 8: ...dequate water flow Check connections and or replace trigger handle or spray wand Clean nozzle Squeeze trigger on trigger handle to remove air from line Remove filter rinse clean and reinstall Clean adjust relief valve check for worn and dirty valve seats Kit available Machine doesn t reach high pressure Diameter of garden hose is too small Water supply is restricted Not enough inlet water pressure...

Page 9: ... Install new seal kit Pressure drop Worn nozzle Dirty or blocked valves Worn packing Low Water Pressure Replace the nozzle Replace check valves Install new seal kit Check for proper pressure should be 35 to 80 PSI Excessive noise Pump sucking air Blocked suction Water temperature is too hot Worn dirty blocked valves Worn bearing Valve stuck open or shut or not opening enough Check that there is no...

Page 10: ...es Replace with properly sized nozzle Tighten fittings and hoses Use PTFE liquid or tape Check with new gauge Replace worn or damaged gauge Clean adjust relief valve Replace worn seats and o rings Clean filter Use adequate size filter Check more frequently Install proper filter Replace discharge hose with proper rating for system Inadequate water supply minimum 35 PSI and hose size 3 4 5 8 Check i...

Page 11: ...l to red dot on the bubble gauge Pump runs extremely rough Inlet conditions Pump valves Pump seals Restricted inlet or air entering the inlet plumbing Stuck inlet discharge valves Leaking V Packing Hi Pressure or Lo Pressure seals Correct inlet sized plumbing Check for air tight seal Clean out foreign material or install new valve kit Install new seal it Increase frequency of service Premature sea...

Page 12: ... Plumbing Keep elbows to a minimum and less than 90 Excessive Liquid Temperature Use Thermo Valve in bypass line Do not exceed pump temperature 104 F Substitute closed loop with baffled holding tank Adequately sized tank for frequent or high volume bypass Pressure feed high temperature liquids Air Leaks in Plumbing Check all connections Use PTFE thread tape or pipe thread sealant Agitation in Supp...

Page 13: ...Protector Debris damage is caused when the user does not use a filter screen to filter the water that is connected to the pump Without a filter debris can flow freely into the pump Bleach damage is caused by using it as a cleaning agent with the pressure washer Do not use bleach as a cleaning agent Cavitation damage is caused by agitated liquid that contains air bubbles that enter the pump Fig 4 F...

Page 14: ...ader pressure must be done with the system turned on Start the system with the unloader backed off to the lowest pressure setting counterclockwise direction Squeeze the trigger and read the pressure on the gauge at the pump Do not read pressure at the wand or nozzle If more pressure is desired release the trigger turn adjusting cap one quarter turn in a clockwise direction Squeeze the trigger and ...

Page 15: ...tainer F may separate from the seat E Remove the spring D and valve from the valve chamber C and I 5 Separate valve assembly by inserting screwdriver into spring retainer and press the backside of valve until seat separates from the spring retainer 6 Remove o ring B and K from each seat and valve plug SOAP INJECTOR ASSEMBLY REMOVAL 1 Remove soap injector assembly U See figure 15 page 20 2 Remove s...

Page 16: ...embly onto the inlet valve assembly and press into valve chamber until completely seated 11 Lubricate with silicon grease and install new O ring B onto each valve plug A 12 Apply thin coat Loctite 242 to threads of each valve plug A and thread in hand tight Torque to specs per chart SOAP INJECTOR ASSEMBLY REPLACEMENT 1 Examine O rings check valves and spring for fatigue or breaks and replace as ne...

Page 17: ...fold chamber with grooved side down Depending on the model pump if the pump has a male adapter E install it with the notch side down Lubricate and install new V Packing Not Shown by hand into manifold chamber with grooved side down 6 Lubricate and install o ring C on each seal case B Press small end of seal case B into each manifold chamber 7 Press new low pressure seal A into each seal case with ...

Page 18: ...MBLY G O RING B O RING H SEAL C VALVE I VALVE D SPRING D SPRING E SEAT E SEAT F SPRING RETAINER J SPRING RETAINER K O RING Fig 9 A LOW PRESSURE SEAL B SEAL CASE C O RING D HIGH PRESSURE SEAL E MALE ADAPTER SEAL CHAMBER MANIFOLD L REVERSE PLIERS ...

Page 19: ...GER RETAINER BOLT Fig 11 1 4 3 2 6 5 TORQUE SEQUENCE CAT PUMP TORQUE SETTINGS Pump Item Torque in lbs Plunger Retainer 55 Manifold Head Screws 132 Valve Plugs 750 Bearing Cover Screws 50 Bubble Oil Gauge 45 Fig 12 Fig 14 SERVICING Fig 13 CRANKCASE MANIFOLD A BEARING COVER D SEAL C O RING B BOLT ...

Page 20: ...TON STEM I WASHER K VALVE RETAINER M VALVE N SEAT P O RING T O RING Q CHECK VALVE R CHECK VALVE WITH O RING S SPRING U SOAP INJECTOR ASSEMBLY V SOAP INJECTOR KIT Y QUICK DISCONECT SPECIFICATIONS U S Measure Metric Measure Flow 3 0 GPM 11 36 L M PSI Range 100 3000 PSI 7 206 8 BAR Inlet Port 3 4 in GHF 3 4 in GHF Discharge Port M18 x 1 0 M18 x 1 0 UNLOADER ASSEMBLY ...

Page 21: ...6 to 17 rings out See figure 16 2 Set the engine idle adjustment C idle setting to 2800 RPM See figure 17 NO LOAD 2200 2800 RPM OUTLET 2550 PSI Minimum LOADED 3350 3500 RPM BYPASS 4400 PSI Max GPM 2 7 GPM Minimum IDLE DOWN 2200 2800 RPM A OUTER CABLE C ENGINE IDLE ADJUSTMENT B CABLE ADJUSTMENT BOLT ...

Page 22: ... Number 7DH R4101 00 CHECK VALVE KIT Part Number 7DH R4104 00 O RING KIT Part Number 7DH R4102 00 CAT PUMP REPAIR KITS CAT PUMP REPAIR KITS FOR MODEL 4GXT31 Fig 21 Fig 20 SEAL KIT Part Number 7DH R4100 00 Fig 18 Fig 19 ...

Page 23: ...Number 7DH R4138 01 CHEMICAL INJECTOR KIT Part Number 7DH R4105 00 OIL DRAIN PLUG Part Number 7DH R413A 00 BUBBLE OIL GAUGE WITH GASKET Part Number 7DH R4137 00 CAT PUMP REPAIR KITS Continued Fig 22 Fig 24 Fig 25 Fig 23 ...

Page 24: ...the small rectangular shaft key to reuse on new pump Installation Before installing the pump it is best to apply a copper based antiseize compound to the engine shaft This allows easier removal of the pump from the engine in the future Hold rectangular shaft key in place on the engine shaft keyway Align keyway of pump shaft with engine shaft keyway Slide pump onto engine shaft Insert hex head bolt...

Page 25: ...nted into a plastic drum B or equivalent for safety and hold for 15 seconds Release Record the Bypass Pressure on the high pressure gage See Figure 28 If the bypass pressure is lower than the model listed in the spec charts below loosen locking nut on the unloader adjustment while holding the unloader nut in place see Fig 29 If the pressure is over the aoutn specified in the spec chart adjust the ...

Page 26: ...ith a 7 8 in wrench B turn the locking nut C down to the unloader and tighten the locking nut using torque setting as shown Mark the nut and cap with a paint dot to indicate if the customer has adjusted the unloader at a later time See Figure 29 If the pump has heat damage due to running pump with no water in it then this would not covered under warranty If the pump has no pressure after the above...

Page 27: ...pressure loss created by valves fittings and eleva tion of lines If a sufficient number of valves and fittings are incorporated in the system to materially affect the total line loss and to the total line length the equivalent length of line of each valve or fitting GENERAL SPECIFICATIONS HOSE FRICTION LOSS Water Flow Gal Min PRESSURE DROP IN PSI PER 100 FT OF HOSE WITH TYPICAL WATER FLOW RATES Ho...

Page 28: ...0 1 9 7 0 14 2 1 4 5 1 1 6 0 20 40 1 5 5 5 11 1 8 3 6 120 400 13 45 94 2 9 10 20 1 0 3 4 6 7 1 3 2 6 5 8 10 150 330 520 36 86 130 12 28 43 2 8 6 7 10 1 9 3 0 100 220 320 28 62 90 9 0 21 30 2 2 5 2 7 8 1 6 2 4 230 500 50 120 180 17 40 56 6 1 15 22 3 0 6 5 10 15 25 40 270 670 90 240 21 56 6 2 16 66 1 6 4 2 17 2 0 8 0 190 470 62 150 16 40 5 0 12 39 1 5 3 8 11 1 7 5 0 120 330 550 44 110 200 20 50 88 6...

Page 29: ......

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