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Repairing triplex General Pump for Pressure Washer

AL`

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Joined
Sep 2, 2011
Messages
318
Location
Texas
I have a Dewalt pressure washer with a General Pump Model TX1510A series 63 triplex pump. It has a very slight leak from the manifold when operating, so I took it apart to check the packing seals and plungers. The leftmost ceramic plunger is clearly cracked, the center one shows a slight discoloration I need to inspect more closely when I get it pulled off. My problem is, they seem to be stuck in there really tight. I've checked scores of youtube videos on this and the plungers always come out with ease for the demonstrators, but not in my case. Does anyone have any suggestions? I don't want to damage good plungers pulling them off since they are rather expensive to replace at about $60 each. See attached pics. If there were a proper sized collet available for my slide hammer, that's one idea. Alas, no such collet exists in my puller set. Maybe I can make a wooden bushing and clamp it to the plunger. One thing I noticed that is different from the General Pumps I saw on youtube is that the plungers were secured with a cap bolt on the end whereas mine has a bolt with a nut on the end.
 

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AL`

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Joined
Sep 2, 2011
Messages
318
Location
Texas
Well, the clamped wooden bushing did the trick. I cleaned the plungers off with some contact cleaner to get grease off for a good grip. Then I put masking tape on the plunger for a tighter fit and grip to the bushing since the hole I bored was slightly oversize and clamped it tight. Worked like a charm but it still took considerable force pulling on them while wiggling/rotating the plungers back and forth to get them off.
 

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AL`

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Sep 2, 2011
Messages
318
Location
Texas
Thanks zoomzoom. Once in a while an idea actually works while I forget to mention those that don't ... grin. The C-clamp made for an easy handle too while bracing my other hand against the pump crank case to keep from pulling the entire pressure washer off the bench while yanking on it. Perhaps someone else may run across this thread while searching for an answer to the same problem. On a brighter note, I found a cheaper price for the plunger of $42.06 + S&H at Pressure-Washer-Parts.com The other plungers look OK.

It is a nice pump and pressure washer sberry. It's a DeWalt Model DP3750. See pic of it below amidst general garage clutter.
 

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