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  4.591-040.0 Spill Valve Complete

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Spill Valve Complete - 4.591-040.0:Karcher 360 View
Spill Valve Complete - 4.591-040.0:KarcherSpill Valve Complete - 4.591-040.0:KarcherSpill Valve Complete - 4.591-040.0:KarcherSpill Valve Complete - 4.591-040.0:Karcher 360 View

Spill Valve Complete 4.591-040.0

Part Number: 4.591-040.0
Karcher
Availability: In Stock
Price: $20.68
Ships within 1 business day

*This part replaces obsolete part #: 4.591-036.0.

Product Information
Description:
This is a genuine Karcher replacement part, it is sold individually.
When your pressure washer loses pressure, it probably means you have a bad spill valve.
Also known as an unloader valve.
This part allows water to recirculate in the pump when you're not spraying water and is responsible for most of the pressure-related problems with your pressure washer.

We do have an article and video on "How to Replace the Spill Valve on a Karcher Pressure Washer" on our site. Just go to the front page of our site and click on Repair Center.

Frequently Purchased With
Products Compatibility

This item works with the following types of products:

  • • Pressure Washer
Repair Guides
Watch the Repair Video for Spill Valve Complete

Questions & Answers for Spill Valve Complete


pulsates when trying to use soap cannon works fine with other spray tips have tried 3 different soap connons same results
Barry for model number G2650HH asked on 2023-05-16
Hi Barry, Thank you for writing. This could be an indication the Cannon is faulty or clogged and may need to be replaced or cleaned. We hope this helps!
eReplacementParts Team May 16, 2023
I need several O rings for the discharge hose where it connects to the power washer.
Charles for model number G 2000 QT asked on 2022-10-26
Hello Charles, Thank you for your inquiry. We show the o-rings that go from the hose to the gun/wand as part numbers 6.363-198.0 and 2.880-154.0. We hope this helps and if you need help placing an order for a part, customer service is open 7 days a week. Please feel free to give us a call. We look forward to hearing from you!
eReplacementParts Team October 26, 2022
Is your spill valve number 4.591-040 compatible with my model number G2600-VH (1.194.404.0)
Maurice for model number G2600VH (1.194.404.0) asked on 2022-07-01
Hi Maurice, Thank you for your question. Yes, this would be the correct unloader valve for your pressure washer. If you need help placing an order for it, customer service is open 7 days a week and anyone will be happy to assist you. Please feel free to give us a call. We look forward to hearing from you!
eReplacementParts Team July 01, 2022
is this the correct unloader valve for a Kracher 3050 OH
John for model number Karcher 3050 oh asked on 2022-06-23
Hi John, Thank you for your question. This would not be the correct unloader valve for your pressure washer. The part number listed under your model number for the unloader assembly is 9.175-007.0. If you need help placing an order for it, customer service is open 7 days a week and anyone will be happy to assist you. Please feel free to give us a call. We look forward to hearing from you!
eReplacementParts Team June 23, 2022
WATER IS SPRAYING FROM THE 2 HOLES ON THE PLASTIC HEAD ON TOP OF THE UNLODER VALVE IS THE VCALVE FAULTY?
Nick for model number k2400hh asked on 2022-05-13
Hello Nick, Thank you for the question. This is normally am indication the seal on the valve is faulty and the valve will need to be replaced. If you need help placing an order, customer service is open 7 days a week. Please feel free to give us a call. We look forward to hearing from you!
eReplacementParts Team May 13, 2022
Repair Instructions: Submitted by Customers Like You
80 of 81 people found this instruction helpful
Tool Type:
Pressure Washer
Parts Used:
Spill Valve Complete - 4.591-040.0
Repair Difficulty:
Easy
Time Spent Repairing:
30-60 minutes
Tools Used:
Screwdriver, Pliers, Allen wrench
High pressure intermittent on Karcher 2401 HH pressure washer.
After pulling the pump off, I first tried pulling the spill valve with needle nose pliers. It was in there to tight to pull out so I reinstalled the pump without the cover on the spill valve. Hook the hoses up to the pressure washer as you normally would and turn on the water. The spill valve did not push out, so I started the engine and "pop" - slick as a whistle the valve came out. Next time I'll just leave the pump in place and take the the cover off the valve and pop out the valve as I just described. Reassemble just as the eReplacement Parts video shows. A note: The spill valve part # 4.591-040 actually is a direct replacement for 4.591-036, so fear not. It looks like they improved the upper o-ring grove so the o-ring fits better without the need for a spacer. Otherwise the dimensions are identical.
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59 of 59 people found this instruction helpful
Tool Type:
Pressure Washer
Parts Used:
Spill Valve Complete - 4.591-040.0
Repair Difficulty:
Easy
Time Spent Repairing:
15-30 minutes
Tools Used:
Socket set, long nose vise grips
Karcher 2400 pressure washer wouldn't pressure-up when trigger was pulled - bad unloader valve
Had to remove the pump from the motor due to not enough clearance between the unloader valve and the frame above it to access the old unloader valve. This was just 4 bolts, very easy. The toughest part of this repair was extracting the old unloader valve from the pump. Long nose pliers were nowhere near enough, they would just slip off no matter how tightly they were gripped. The tool that solved this problem was a pair of long nose vise grips. They were able to firmly clamp on the top of the old valve and pull it out. Having this tool was *essential* for completing this repair. (Other brands of pressure washer may not present this difficulty in removing the old valve) Applied a little Teflon grease on the top O-ring of the new valve and reassembled the pump. Works like new now!
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12 of 16 people found this instruction helpful
Tool Type:
Pressure Washer
Parts Used:
Spill Valve Complete - 4.591-040.0
Repair Difficulty:
Easy
Time Spent Repairing:
Less than 15 minutes
Tools Used:
Pliers, Socket set, allen key
Pump goes into bypass and doesn't pressure up.
I followed the video on you tube. Thank you.

https://www.youtube.com/watch?v=SAhiUyk3TIk
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7 of 7 people found this instruction helpful
Tool Type:
Pressure Washer
Parts Used:
Spill Valve Complete - 4.591-040.0
Repair Difficulty:
Hard
Time Spent Repairing:
More than 2 hours
Tools Used:
Pliers, Socket set, Nutdriver
no pressure
I watched your video on pump repair several times before starting. Pulled pump, disassembled per video instruction. Found 3 stuck valves (pistons caught in the springs... unstuck them and put them back. Replaced unloader valve. Reassembled pump per video instruction. Remounted pump per video instruction. To my utter amazement, it worked like a charm!

I did all this with the instruction from the video. Could not have done it without the video, I am a scientist and not mechanically inclined

B.G. Huff
Philo, IL
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7 of 7 people found this instruction helpful
Tool Type:
Pressure Washer
Parts Used:
Spill Valve Complete - 4.591-040.0
Repair Difficulty:
Easy
Time Spent Repairing:
15-30 minutes
Tools Used:
Pliers, Socket set, Wrench Set, Torx #30 driver
Washer lost high pressure
1. Spent part of a day becoming an expert on karcher washer pumps (u-tube, karcher, et. al.)
2. Removed washer front cover.
3. Removed unloader cover with screwdriver.
4. Removed plastic unloader cap screws with torx driver.
5. Removed top spring & seals.
6. Removed broken unloader (spill) valve.
7. Reassembled top spring & seals & new spill valve after lubing seal surfaces with lithium grease.
8. Notes: Clean off any corrosion; no grease on spill valve lower seal surface.
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5 of 5 people found this instruction helpful
Tool Type:
Pressure Washer
Parts Used:
Spill Valve Complete - 4.591-040.0
Repair Difficulty:
Medium
Time Spent Repairing:
1-2 hours
Tools Used:
Screwdriver, Allen wrench, torx screwdriver & large needle-nose pliers.
Unloader valve failed
Placed Karcher pressure washer on truck tailgate.
Used allen wrench to loosen 4 bolts holding pump onto the pressure washer motor.
Removed button cap holding black cap on to the pump.
Used torx screwdriver to remove 2 screws on white plastic upper portion piece that houses the unloader valve.
Removed spring, then used large needle-nose pliers to remove unloader valve.
Put grease around green band on new unloader valve.
Reinserted the new unloader valve into the pump.
Put spring and white plastic piece back in place and screwed into place.
Put black cap and button cap back into place.
Reinstalled pump back onto the pressure washer and tightened all 4 bolts.
Hooked up water hose and turned on spigot.
Started the pressure washer and all worked fine.
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7 of 9 people found this instruction helpful
Tool Type:
Pressure Washer
Parts Used:
Spill Valve Complete - 4.591-040.0
Repair Difficulty:
Medium
Time Spent Repairing:
More than 2 hours
Tools Used:
Screwdriver, Pliers, Power Drill, Socket set, Wrench Set
No pressure
Tried every pair of pliers and vice grips available could not get the valve out.
I ended up having to drill and tap the valve with 10-32 threads. I put in a socket head screw and still couldn't get it out with the vice grips. I finally was able to pry it out by using two screwdrivers under the screw head. The valve cavity was very corroded so I wrapped fine sandpaper around a small drill bit and used my drill to clean it up a little. Installed the new valve and it works fine now.
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6 of 7 people found this instruction helpful
Tool Type:
Pressure Washer
Parts Used:
Spill Valve Complete - 4.591-040.0
Repair Difficulty:
Medium
Time Spent Repairing:
1-2 hours
Tools Used:
Screwdriver, Pliers, Socket set, Wrench Set
SPRAY WAS PULSING -
Had broken internal valve which was replaced. Your repair video was very helpful. As a precaution I replaced all 6 valves instead of just the one that broke. Spill valve was also replaced. Works fine now.
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6 of 7 people found this instruction helpful
Tool Type:
Pressure Washer
Parts Used:
Spill Valve Complete - 4.591-040.0
Repair Difficulty:
Easy
Time Spent Repairing:
30-60 minutes
Tools Used:
Screwdriver, Pliers, Nutdriver, Adjustable Wrench, Allen
No Pressure when handle pressed
Followed your tube tube video and fixed problem by replacing bent valve.
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4 of 4 people found this instruction helpful
Tool Type:
Pressure Washer
Parts Used:
Spill Valve Complete - 4.591-040.0
Repair Difficulty:
Medium
Time Spent Repairing:
30-60 minutes
Tools Used:
Screwdriver, Pliers, Socket set, Wrench Set, Nutdriver, Rubber mallet, needle nose vise grips
Spill valve was sticking so the pressure washer would surge or stop working.
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Reviews
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43 Reviews
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  • The new parts fit perfect and my machine now works great
    Unloader valve great replacement part
    Barry - August 29, 2023 Verified Purchase
    Easy fix
    Perfect
    John - April 17, 2023 Verified Purchase
    Spill value
    My Karcher Pressure Washer is working great now after replacing it with your recommended part. Great Customer Service.
    Guest - August 31, 2022 Verified Purchase
    right part
    ordering was easy. part was correct. fast service
    Guest - August 5, 2022 Verified Purchase
    Better part than original
    For my model, it was easier to remove the detergent bottle, then I could access the valve without removing the pump. When I removed original valve, found it had disassembled itself into 4 parts, so getting them all out was difficult. Part is designed to adjust spring tension by a threaded rod going through the center. This had unscrewed and come apart. New part was sealed with red plastic at correct tension. Used teflon based Super Lube on reassembly, immediately washed my house without problem. Thanks for the speed of delivery and the video.
    Guest - May 24, 2022 Verified Purchase
    Easy Repair
    part fit ,came came quick enough and in good condition. havent installed it yet.
    Guest - November 19, 2021 Verified Purchase
    Correct Part for my Karcher Power Washer
    Part arrived in a timely manner. Watched eReplacementParts videos to refill pump with new oil. Old oil was full of water. I was not able to remove the old unloader valve with a pair of needle nosed pliers as described in video. ACE Hardware personal were also unable to remove unloader valve with their tools. I finally took the pump assembly, hooked it up to my water hose, installed the wand, turned the pump, unloader valve side down, turn on the water and the valve popped out of its seat. Voila! Lubed new unloader valve up, seated it into position as described in the video and reinstalled the pump assembly to the frame and motor. Started the power washer up and it works like new!
    Guest - July 24, 2021 Verified Purchase
    Easy repair
    Fit porfectly
    SENAT - July 5, 2021 Verified Purchase
    Pump Pressure issues
    I called the replacements parts contact number and discussed the issues I was having. I had disassembled and cleaned the pump so I was familiar enough to have sufficient context with the tech. We got the unloader valve ordered. Once received, I installed the uploaded and my pump was functioning as designed. Good service, good, part, and good shipping/tracking.
    Guest - July 3, 2021 Verified Purchase
    Power washer repair.
    The part worked perfectly. My power washer is running again.
    Guest - May 25, 2021 Verified Purchase
    Verified Purchase
    eReplacementParts Team
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    Product Information
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    Watch the Repair Video for Spill Valve Complete
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