INSTALL ALL KIT COMPONENTS TO INSURE OPTIMUM PERFORMANCE OF THE REPAIRED PUMP.

Repair Parts Sheet JL-4GBS Gas Power Units L1918 Rev. C 2/99 For Date Codes Beginning With "O" INSTALL ALL KIT COMPONENTS TO INSURE OPTIMUM PERFORMANCE OF THE REPAIRED PUMP. Repair parts that are included in Repair Parts Kits are marked throughout this sheet as follows: Seal Kits Used whenever pump unit is disassembled for service. Contains seals only. Overhaul Kits Used for complete rebuild of pump. The Overhaul Kit includes a complete Seal Kit. Seal and Overhaul Kits include repair parts for the control valve. Also available... Spark Plug - part number DA9771009 Spark Plug Wrench - part number DA10711816 Figure 1A - Basic Pump Assembly............. 2 Figure 1B - Basic Pump Assembly............. 3 Figure 2 - Pumping Assembly................. 4 Figure 3 - Piston Block Assembly.............. 6 CONTENTS Figure 4 - Bypass Valve Assembly............. 7 Figure 5 - Dump Valve...................... 9 Figure 6 - Selector Valve.................... 10

Read Owner's Manual Before Operating. Figure 1A - Basic Pump Assembly 84 38 45, 57, 87, 90 40, 42 Torque Items 40 and 41 to 14-16 ft-lbs (19-22 Nm). 54, 58, 88 54, 58, 88 39 Torque to 28-32 ft-lbs (37,9-43,4 Nm). Apply Loctite 242 to mounting bolts of motor and valve. 89, 57, 87 38 40,41 39 43, 44 31 39 13 32 30 32 31 9 2, 8 REPAIR PARTS LIST FOR FIGURE 1A Item Part Number Qty. Description Item Part Number Qty. Description 2 DA9760025 1 4 Liter Reservoir 39 Y649167 1 Gasket 8 C187018 1 Magnet 40 CCA0829028-1A 6 Screw (dump only) 9 A1008245 1 Hex Plug CCA833028-1A 3 Screw (selector only) 12 DA9898259 1 4 HP Gas Engine 41 CCA843028-1A 2 M8x80 Screw (selector only) 13 CCA831028-1A 2 Cap Screw 42 C846037 6 Gasket 14 DA9772186 1 Honda Engine Spacer 18 19 12 14 27 43 DC284101 1 Manifold (selector only) 18 CU892110 1 Spring 44 A1008245 1 Hex Plug 19 DA10096325 1 Woodruff Key 45 DA5973096 1 Elbow Fitting 27 B1331303 1 O-Ring 54 CH313096 1 Male Adaptor 30 DA7105096SR 1 Connector Tube 84 DA11534026 1 Decal (dump only) 30 DA10064096SR 1 Connector 57 DA10717647 1 Blue Cable Tie Tube(relief only) 87 F100271-1 1 Thread Protector 87 F100271-1 1 Thread Protector 88 F100094-12 1 Flare Fitting 1 58 DA10718647 Red Cable tie 89 CB548096 2 Male Connector 31 B1012303 O-Ring 118 DA11386186 4 Foot 32 B1012303 2 Back-Up Ring 119 DA11422008 4 Tube Nut 120 B1015066 4 Washer 38 DA9926900SR 1 Dump Valve Block 121 DA11387108 4 Washer DA9833900SR 1 Selector Valve Block 122 B1009046 4 Bolt 2

Figure 1B - Basic Pump Assembly 58 85 10, 33 JAWS OF LIFE RES Pressure Hose 57 86 JAWS OF LIFE RES Tank Hose Note: Pumps with dump valves use one (1) of each hose. Pumps with selector valves use two (2) of each hose. Torque to 3-4 ft-lbs (4-5 Nm). 7 22 17, 16, 15 28 29 Torque to 28-34 ft-lbs (38-43 Nm). 3, 4 23, 25 REPAIR PARTS LIST FOR FIGURE 1B Item Part Number Qty. Description Item Part Number Qty. Description 3 DA7867900SR 2 Filter Assembly 33 B1912303 1 O-Ring 4 DA10667431SR 2 0.25 NPT Pipe 57 DA10717647 1 Blue Cable Tie Nipple 7 CBE419046-18 18 Screw 58 DA10718647 1 Red Cable Tie 10 DA11644223 1 Level Gauge 85 DA10573950 1 Hose Ass y. - Pressure 15 CCA837028-5A 1 M8 Set Screw 86 DA10576950 1 Hose Ass y. - Tank 16 CBE1080120-1D 1 Hex Nut 95 DA12183026 1 Inhalation Hazard Decal 17 DA10241186 1 Spacer 96 DA12184026 1 Hot Surface Decal 22 DA10007500 1 Roll Cage Weldment 97 DA12185260 1 Flammable Mat. Decal (not shown) 23 CBE825046-1A 4 Hex Bolt 98 DA12186026 1 Power Warning Decal 25 CAE1080108-1A 4 Flat Washer 99 DA12187026 1 CE Label 3

Figure 2 - Pumping Assembly IMPORTANT: When servicing any of the pump components, a complete Seal Kit must be installed to eliminate the potential for failure resulting from the reuse of original seals. CAUTION Parts have machined surfaces. Be careful when handling to avoid damaging parts. NOTE: Set Item 34 to 5000-5400 psi 1 Use Loctite 545 for pipe fittings. Apply Loctite 242 to threads. Torque to 15-17 ft-lbs. Use Loctite 545 34 26 31 for pipe fittings. Apply Loctite 242 to threads. Torque to 15-17 ft-lbs. A 26 33 32 30 28 Apply Loctite 242 to threads. Use Loctite 545 for pipe fittings. A 32 29 27 Apply Loctite 242 to threads. 25 Use Loctite 545 for pipe fittings. 4

1 4 11 3 8,9 6 5 17 10 6 14 18,19 7 SECTION "A-A" 35 REPAIR PARTS LIST FOR FIGURE 2 Item Part Number Qty. Description Item Part Number Qty. Description 1 DA12047098SR 1 Top Plate 1 19 DA7065155 2 Thrust Race 3 DA6759537 1 Eccentric Shaft 25 Y530096 1 Male Branch Tee 4 DA7275155 1 Needle Roller Bearing 1 26 CCA0839028-1A 12 Mounting Bolt (M8 x 65) 5 DA11578950SR 2 Piston Block Assembly (See Fig. 3 for details.) 27 DA9790268 1 Tube Assembly 6 BSS4725D 2 Ring 2 28 DA9791268 1 Tube Assembly 7 1 Retaining Ring 2 29 F100095-7 1 0.25 Street Elbow CCA1035044-1A 8 DA7063155 1 Cam Bearing 2 30 C332291 1 Fitting 9 DA6819350SR 1 Hex Cam 2 31 B202291 1 Elbow 10 DA9713101SR 1 Bottom Plate 3 32 DC566950SR 1 Bypass Valve Assembly 4 (See Fig. 4 for details) 11 DA10420476 1 Lip Seal 1 33 DA7266095 1 Hose Fitting 14 DA6821155 1 Bottom Bearing 3 34 DA9764900SR 1 Relief Valve Assembly 17 B1013303 2 O-Ring 35 DA10723108 2 Washer 18 DA7064155 1 Thrust Bearing 5

Figure 3 - Current By-Pass Assembly 9 10 8 7 Figure 4 - Previous By-Pass Assembly 1 3 4 5 6 7 8 9 10 11 15 Torque to 28-34 ft-lbs. (38-46 Nm). 14 13 12 6

Figure 5 - Piston Block Assembly 2 3 8 13 15 Figure 6 - Relief Valve Assembly 1 2 3 11 4 5 6 7 8 9 10 12 7

REPAIR PARTS LIST FOR FIGURE 3 Item Part Number Quantity Description Item Part Number Quantity Description 7 B1006564 1 Back-up Washer 9 B1013303 1 EPR O-Ring 8 B1006303 1 O-ring 10 DC566950SR 1 Complete By-pass Valve Assembly REPAIR PARTS LIST FOR FIGURE 4 No longer serviced. Order DC566950SR complete bypass valve assembly. REPAIR PARTS LIST FOR FIGURE 5 Item Part Number Quantity Description Item Part Number Quantity Description 2 DA6771110 1 Conical Spring 8 B1013303 2 EPR O-Ring 3 See Fig. 3, Item 5 1 Piston Block Assembly 13 B1018303 1 EPR O-Ring REPAIR PARTS LIST FOR FIGURE 6 1 CCA1023028-5A 1 Set Screw 7 DA11791110 1 Compression Spring 2 DA7033123 1 Nut 8 DC1317013 1 Ball Guide 3 DA7322190 1 Threaded Body 9 B1004016 1 5/32" Ball 4 CCA0307028-5C 1 Set Screw 10 4See Fig. 3, Item 3 1 Relief Valve Assembly 5 DA7312040 1 Plunger 11 B1008303 1 EPR O-Ring 6 DA5772013 1 Spring Guide 12 B1025057 1 Spring Pin 8

Figure 7 - Dump Valve 6 5 1 Loctite 222 2 3 7 9 REPAIR PARTS LIST FOR FIGURE 7 Item Part Number Quantity Description Item Part Number Quantity Description DA9926900SR 1 Complete Valve 5 DC1401028 1 SS Screw Assembly 1 DC675108 1 SS Washer 6 DC180070 1 Valve Handle 2 B1111564 1 Back-Up Washer 7 B1111303 1 EPR O-Ring 3 DA12458010 1 Valve Stem 9 B1009016 1 Ball Items included in and available only as part of Repair Kit VM2K1E. Note: The pump seal kit, JL4GK, includes a VM2K1E valve repair kit. 9

Figure 8 - Selector Valve Assembly Torque Item 7 to 28-34 ft-lbs. (38-46 Nm). Loctite 222 10

Item No. Part Number Quantity Description REPAIR PARTS LIST FOR FIGURE 8 Item No. Part Number Quantity Description 1 DC667028 1 Screw 15 B1012303 1 EPR O-Ring 2 DC675108 1 Washer 16 CH542950SR 1 Disc Assembly 3 DC455070 1 Valve Handle 17 B1109057 1 Roll Pin 4 DC676071 1 Disc 18 DA9560041 3 Shear Seal 5 B1006016 1 7 32 " Ball 19 B1011564 6 Back-Up Washer 6 A8039110 1 Spring 20 B1011303 3 O-Ring 7 B1389028 4 Socket Hd. Cap 22 CB28110 3 Spring Screw 8 DC687057 1 Roll Pin 23 CH539190 1 Body 9 CB324001 1 Valve Cap 24 B1326028 2 Screw 10 B1134303 1 EPR O-Ring 25 B1111303 4 O-Ring 11 CB327101 1 Bearing Plate 27 DA11122038 1 Adaptor Block 12 CB328281 1 Bearing 28 A1006245 2 Pipe Plug 13 DC650104 1 Shaft 29 DA6192245 1 Pipe Plug 14 B1012564 1 Back-Up Washer 31 B1051057 1 Roll Pin Items included in and available only as part of Repair Kit DA9833900KE. Note: The pump seal kit, JL4GK, includes a DA9833900KE valve repair kit. 11