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Familiarization & Troubleshooting Guide

PRESSURE WASHER
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BRIGGS & STRATTON CORPORATION Milwaukee, WI 53201 Part No. B3277GS Rev. 0 11/98 Printed in U.S.A.

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Electronic Version #B3277 Rev. 1 4/03

Pressure Washer
Familiarization & Troubleshooting Guide

FORWARD
This guide has been written and published by Briggs & Stratton Corporation to aid our dealers' mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with the servicing procedures for these products, or like or similar products, manufactured by Briggs & Stratton Corporation. It is also assumed that they have been trained in the recommended servicing procedures for these products, which includes the use of mechanics hand tools and any special tools that might be required. Proper service and repair is important to the safe, economical and reliable operation of all engine driven systems. The troubleshooting, testing, service and repair procedures described in this guide are effective methods of performing such operations. We could not possibly know of and advise the service trade of all conceivable procedures or methods by which a service might be performed, nor of any possible hazards and/or results of each procedure or method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a procedure or method not described by the manufacturer must first satisfy himself that neither his safety, nor the safety of the product, will be endangered by the service or operating procedure selected. All information, illustrations, and specifications contained in this guide are based on the latest production information available at the time of publication. However, Briggs & Stratton Corporation reserves the right to change, alter, or otherwise improve the product at any time without prior notice. Some components or assemblies of the product described in this guide may not be considered repairable. Disassembly, repair and reassembly of such components may not be included in this guide.

Copyright 2003 Briggs & Stratton Corporation All rights reserved.

No part of this material may be reproduced or transmitted, in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage and retrieval system, without prior permission in writing from Briggs & Stratton Corporation.

Portable Pressure Washer Familiarization and Troubleshooting Guide Table of Contents

TABLE OF CONTENTS
1 Operation 2 Pressure Washer Components
Power Source Pressure washer pumps Inlet and Outlet Check Valves Unloader - Pressure Regulator Thermal Bypass System Chemical Injection Easy Start Valve High Pressure Hose Spray Guns Spray Wands and Nozzles 5

4 Small Frame Electric Pump


Part 1 - Specifications and Views Performance Specifications Cross-Sectional View Exploded View Part 2 - Disassembly General Information & Special Tools Pump Head Piston Housing Removal Piston Housing Disassembly Chemical Injection System Auto Start Switch Assembly Axial Cam Part 3 - Inspection Seals, O-Rings, and Gaskets Piston & Spring Assemblies Pump Head and Piston Housing Axial Cam Drive Components Part 4 - Reassembly Pump Head Assembly Auto Start Switch Assembly Chemical Inject Assembly Piston Housing Assembly Pilot Spacer Installation Pump Head Bolts Assemble Axial Cam Oil Fill Main Component Assembly Final Assembly and Test Part 5 - Troubleshooting

17
17 17 18 20 22 22 22 23 24 24 25 26 27 27 27 27 28 29 29 29 30 31 31 32 32 32 32 33 34

7
7 7 8 8 9 9 10 11 11 12

3 General Information
Part 1 - General Maintenance Chemical Injection System Inlet Water Supply Connector Inlet Supply Filter/Strainer Hose, Spray Gun and Wand Systems Spray Nozzle Servicing Part 2 - Lubrication Check Pump Oil Level Change Pump Oil Part 3 - Storage Pump Storage Protection Against Freezing Purging Air From the System

13
13 13 13 13 13 14 15 15 15 16 16 16 16

Portable Pressure Washer Familiarization and Troubleshooting Guide Table of Contents

TABLE OF CONTENTS
Small Frame Gas Pump
Part 1 - Specifications and Views Performance Specifications Cross-Sectional view Exploded View Part 2 - Disassembly General Information & Special Tools Pump Head Piston & Unloader Housing Removal Piston & Unloader Housing Disassembly Chemical Injection System Unloader Engine Adapter Part 3 - Inspection Seals, O-Rings, and Gaskets Piston & Spring Assemblies Engine Adapter, Pump Head and Piston/Unloader Housing Axial Cam Drive Components Part 4 - Reassembly Engine Adapter Unloader Assembly Chemical Injection Assembly Piston & Unloader Housing Assembly Pump Head Assembly Main Component Assembly Pilot Spacer Installation Pump Head Bolts Oil Fill Part 5 - Troubleshooting

35
35 35 36 38 40 40 40 40 41 42 42 43 43 43 43 44 44 45 45 45 45 46 46 47 48 49 49 50

Part 2 - Disassembly General Information & Special Tools Pump Head Axial Cam Drive Components Pistons and Piston Springs Pump Head Spacer Plate Inlet Check Valves Outlet Check Valves Unloader Spindle Assembly Chemical Injection System Thermal Bypass Actuator Removal Part 3 - Inspection Seals, O-Rings, and Gaskets Seals Check Valves Head Gasket Engine Adapter O-Rings Engine Adapter, Pump Crankcase and Spacer Plate/Head Axial Cam Drive Components Piston & Spring Assemblies High Pressure Outlet/Chemical Injection Assembly Part 4 - Reassembly Engine Adapter Piston Oil Seals and Pistons Spacer Plate High Pressure Seal Assembly Check Valve Assembly High Pressure Outlet and Chemical Injection Assembly Unloader Spindle Assembly Pump Head Installation Main Component Assembly Oil Fill Part 5 - Troubleshooting 2

56 56 56 57 57 58 58 59 59 59 60 60 61 61 61 61 61 62 62 62 62 63 64 64 65 67 67 68 69 69 70 71 72 73

5 Medium Frame Pump


Part 1 - Specifications and Views Performance Specifications Cross-Sectional View Exploded View

51
51 51 52 55

Portable Pressure Washer Familiarization and Troubleshooting Guide Table of Contents

TABLE OF CONTENTS
6 Large Frame Pump
Part 1 - Specifications and Views Performance Specifications Cross-Sectional View Exploded View Part 2 - Disassembly General Information & Special Tools Pump Head Axial Cam Drive Components (Tapered Engine Shaft) Axial Cam Drive Component (Straight Engine Shaft) Pistons and Piston Springs Regulator/Unloader Valve Cylinder Head Thermal Bypass Actuator Removal Spacer Plate Part 3 - Inspection Seals, O-Rings, and Gaskets Oil Seals Inlet Check Valve Seals Outlet Check Valve Seals Head Gasket Engine Adapter Gasket Engine Adapter, Pump Crankcase, Spacer Plate and Head Axial Cam Drive Components Piston & Spring Assemblies Unloader-Pressure Regulator Valve

75
75 75 76 78 80 80 80 81 82 82 82 84 85 86 87 87 87 87 87 88 88 88 88 89 90

Part 4 - Reassembly Engine Adapter Piston Oil Seals and Pistons Spacer Plate Pump Head Assembly Pump Head Installation Unloader-Pressure Regulator Valve Main Component Assembly Oil Fill Part 5 - Troubleshooting

91 91 94 96 96 98 99 99 101 102

Glossary

105

Portable Pressure Washer Familiarization and Troubleshooting Guide Table of Contents

Pressure Washer Familiarization and Troubleshooting Guide Section 1 Operation

PRESSURE WASHER OPERATION


Operation of a pressure washer system may be briefly described as follows. Please refer to Figure 1.1 for visual component identification: 1. An inlet hose delivers water to the motor-driven, pistontype pump. An inlet strainer (item 6) protects the pump (item 5) against damage from solid impurities. The motor driving the pump (item 9) may be gas or electric. 2. Rotary motion of the motor crankshaft is converted to reciprocating motion of the pumps pistons using an axial cam. On a pistons suction stroke, an inlet valve opens and water is drawn into the piston chamber. On the pistons pressure stroke, that pistons inlet check valve closes and its outlet check valve is forced open so pressurized water can leave the chamber. There is one inlet check valve and one outlet check valve for each piston.

Figure 1.1 Example Pressure Washer System

Item 1 2 3 4 5

Name Spray nozzle Hi-Lo nozzle collar Spray gun extension wand Spray gun with locking trigger Pump, including optional thermal relief and/or easy start valve 5

Item 6 7 8 9 10

Name Inlet strainer Unloader/pressure regulator valve Chemical inject fitting (optional) Engine on cart High pressure hose

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 1 Operation

3. The linear movement of the pistons pump a fixed volume of water through the pressure washer system. The volume of water flow depends on a. piston diameter b. length of piston stroke c. number of pistons d. number of piston strokes per minute. 4. The pressure that builds up in the system then depends on the size of the spray nozzle orifice (item 1). 5. The fixed volume of water flows past an unloader/pressure regulator valve (item 7), an optional chemical injection assembly (item 8), through a highpressure hose (item 10), and to a spray gun (item 4). 6. The spray gun permits the operator to turn the flow of water on or off. 7. If the water flow is turned off, water pressure within the pump will increase until the unloader/regulator valve (item 7) is moved off its seat. Flow is then bypassed back to the pump inlet through an internal bypass channel. Fluid bypass continues as long as the spray is turned off. 8. Recirculating bypass water can become hot enough to damage seals and other pump parts. Some pressure washer systems may be equipped with an internal thermal relief valve which automatically replaces hot water with cool water.

9. The optional chemical injection assembly (item 8) permits detergents or other chemicals to be drawn into the water stream and (along with the water) discharged from the nozzle. 10. The nozzle collar (item 2), a part of the spray gun nozzle, permits easy selection of high or low velocity spray or a fan or stream spray pattern. 11. An optional easy start valve relieves pump outlet pressure during cranking for quicker and easier starts. 12. As a nozzle is used, it often becomes clogged with various types of matter. A clogged nozzle obstructs the water flow causing a reduction in outlet pressure. It also may cause the water stream to pulsate while the gun is triggered. Therefore, the nozzle should be checked and cleaned before every use, using the cleaning kit provided with every Generac Portable Products pressure washer system. 13. The flow of water through the nozzle will gradually wear away the nozzle orifice, causing the orifice to become larger. This enlargement will eventually cause a reduction in system pressure. For this reason, the nozzle should be replaced periodically and always replaced with the correct nozzle.

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 2 Pressure Washer Components

PRESSURE WASHER COMPONENTS


Power Source
Generac Portable Products uses several engine manufacturers and different pump types on its pressure washers. Generac Portable Products also uses an electric motor on some models. Figure 2.1 Pressure Washer Pump

The motor horsepower rating is designed into the overall rating of the pressure washer. Pressure pumps require a specified amount of horsepower for the pressure rating of the pump. It is important to remember that engine performance may be miss-diagnosed as a failed pump, and a failed pump may also be miss-diagnosed as a faulty engine. This manual does not cover service and repair of the engine. Refer to the engine manufacturers service manual for engine repair specifications.

Pressure washer pumps


Generac Portable Products pressure washer pumps are positive displacement, piston type pumps. They use an axial cam to impart a reciprocating motion to its three (3) pistons. The volume of water moved by the pump depends on:

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Name Pressure adjust knob Thermal bypass actuator Inlet check valve Garden hose connector/strainer Thermal bypass outlet Axial cam Engine drive shaft Engine adapter bearing assembly Piston shoe bearing assembly Piston spring retainer Piston return spring Piston Outlet check valve High pressure discharge port

1. The axial distance each piston moves on its pressure stroke 2. The diameter of each piston bore 3. The rotating speed of the axial cam (RPM of the engine or electric motor) 4. The number of pistons Theoretically, a pump will always move the same volume of water, regardless of flow restrictions. The pumps axial cam is coupled to the engine crankshaft, so that it revolves at the same speed as the engine. Figure 2.1 depicts a simplified cross-sectional diagram of a typical pressure washer pump mechanism.

If the pump simply discharges water to atmosphere, no pressure will be created. A pressure buildup in the system occurs when flow is restricted downstream from the pump. By adding a nozzle to the system, pressure will increase to force the same volume of water through the nozzle orifice. The smaller the nozzle orifice, the greater the pressure needed to force the pumped volume through the nozzle.

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 2 Pressure Washer Components

Inlet and Outlet Check Valves


A set of six (6) inlet and outlet check valves work in conjunction with the pump pistons to create volume flow. As a piston is moved toward the axial cam by its return spring during its suction stroke, that pistons inlet check valve opens and allows water to enter the pumping chamber. During the suction stroke, that pistons outlet check valve is forced closed, as depicted in Figure 2.2.
Figure 2.2 Inlet Check Valve - Suction Stroke

Unloader - Pressure Regulator


Output water pressure can be adjusted using the pressure adjust knob on the Unloader-Pressure Regulator assembly. Turn the knob clockwise to increase pressure (up to the rated maximum pump pressure), counterclockwise to decrease pressure. The pressure washer is provided with an unloader pressure regulator valve to protect the pump and hose system whenever water flow is blocked upstream. Blockage is caused when the spray gun trigger is normally closed or by a kinked pressure hose or a clogged nozzle. Without an unloader system, water pressure could increase until the engine stalls or part of the system ruptures to relieve the pressure. As shown in Figure 2.4, the unloader valve will open at a preset maximum pressure to divert all or part of the flow back to the pump inlet. During such shutdown conditions, the water will circulate from the pumping chambers to the pump inlet and then back to the pumping chambers.
Figure 2.4 Typical Unloader - Pressure Regulator System

Item 1 2

Name Inlet check valve Outlet check valve

When the piston is pressed forward by the axial cam on its pressure stroke, its inlet check valve is forced closed and its outlet check valve is forced open, as seen in Figure 2.3.
Figure 2.3 Outlet Check Valve - Pressure Stroke

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 2 Pressure Washer Components

Thermal Bypass System


When the trigger on the gun is not squeezed, the water in the pump is recirculating and under pressure. This condition causes the water in the pump to become hot. Excessively hot water may cause damage to the pressure washer pump elements. To resolve this problem, some Generac Portable Products pressure washers are equipped with a thermal bypass system. Figure 2.5 depicts components of such a system.
Figure 2.5 Thermal Bypass System

Figure 2.6 Low Pressure Suctionof Chemical Injection System

Item Item 1 2 3 4 5 Name Thermal bypass actuator Thermal bypass actuator stem O-ring Thermal bypass piston Thermal bypass spring 1 2 3 4 5 6 7 8 9

Name Venturi o-ring Spring Check ball moved OFF valve seat Chemical injection fitting Chemical injection venturi Discharge port Chemical solution reservoir Siphon tube strainer Chemical siphon tube

At a water temperature of approximately 140F, the thermal actuator stem will push the thermal piston off its seat. Heated water will then bleed out of the pump to the ground. As cool water enters the pump, the thermal actuator stem retracts and the thermal piston closes against its seat, halting the water bleed-off.

Chemical Injection
Generac Portable Products pressure washers commonly incorporate a means of adding wax or cleaning/sanitizing chemicals into the low-pressure water stream. As depicted in Figure 2.6, the chemical injection assembly includes a venturi, a spring-loaded ball and seat, a chemical siphon tube, and a strainer.

As low-pressure water flows through the injector venturi throat, its velocity increases and its pressure decreases. The suction created by the low pressure at the venturi throat draws the liquid chemical through a strainer into the siphon tube, around and past the spring-loaded ball, through small orifices in the venturi, and into the water stream. Chemical injection only operates at the low pressure setting because detergents and chemicals require some soak or residence time on the surface to be cleaned. Low pressure also avoids splashing, over-spraying, and waste.

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 2 Pressure Washer Components

When the pump is in the high pressure mode, the chemical injector ball is forced against its seat, cutting off the siphon effect and preventing water from back-flowing into the chemical reservoir. Figure 2.7 depicts this high pressure condition.
Figure 2.7 High Pressure Cut-off of Chemical Injection System

Easy Start Valve


Certain larger Generac Portable Products pressure washers may be equipped with an easy start valve. This patented device relieves pump outlet pressure during engine cranking so that it is easier for an individual to pull the recoil starter rope. Figure 2.8 depicts a Generac Portable Products medium frame pump in its starting condition. Inlet water is connected to the pumps garden hose connector. Air has been purged from the pumps water passages. The check ball is attached to its restraint magnet (magnet not shown).
Figure 2.8 Starting Condition

Item Item 1 2 3 4 5 Name Ball shown seated, cutting off chemical flow Chemical injection fitting Siphon tube Check ball seat Venturi throat 1 2 3

Name Location of restraint magnet (not shown) Check ball shown attached to magnet Inlet water channel

In this condition, the pumps internal water pressure is at garden hose pressure. Water is free to circulate throughout the pump without restriction, thus permitting an easier pull on the starter rope. As soon as the engine starts, water flow forces the check ball against its seat, closing the garden hose pressure water passage. Pressure within the system becomes regulated by the unloader valve setting and the nozzle restriction.

The chemical injector must be carefully sized for the system. Too small of a venturi orifice will result in too low a pressure and too much chemical will flow into the stream. Too large an orifice will cause too much pressure at the venturi throat and the injector will not work.

10

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 2 Pressure Washer Components

Bypass refers to the direction of fluid flow as the water recirculates through the pump. Bypass occurs when the normal flow of water through a nozzle is shut off. Figure 2.9 depicts the pump in the bypass condition with the engine running and the spray gun trigger released.
Figure 2.9 Bypass Condition

High Pressure Hose


Generac Portable Products uses excellent quality high pressure hoses appropriate for each pressure washer model. Hose length, hose internal diameter, and hose pressure rating are all factored into the overall design of the pressure washer system.

Hose specification factors include: gallons per minute rating of the pump, pressure rating of the pump, and pressure drop over the length of the hose between the pump and the spray gun. Additional factors may also be used. Accessory hoses are available to lengthen the hose from its stock length. Generac Portable Products does not recommend exceeding a total length of 100 feet between pump and nozzle because excessive length may adversely affect chemical injection and adequate high pressure operation.

Item 1 2 3 4 5

Name Outlet pressure water stream Trapped line pressure piston shown in closed condition Easy start check ball OFF its seat Unloader piston assembly Inlet water channel

Spray Guns
Generac Portable Products uses several types of spray guns for different model pressure washers. A diagram of a typical spray gun with the trigger closed is seen in Figure 2.11. Figure 2.11 Typical Spray Gun Mechanism

Figure 2.10 depicts the pump in a normal operating condition with the engine running and the spray gun trigger depressed.
Figure 2.10 Normal Operating Condition

Item Item 1 2 3 4 5 Name Outlet pressure water stream Trapped line pressure piston shown in open condition Easy start check ball against its seat Unloader spindle assembly Inlet water channel 1 2 3 4 5 6 7 8 9

Name High pressure inlet connector Spray gun body Valve body Valve return spring Check ball Check ball valve seat Wand body Trigger Safety latch in lock position

11

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 2 Pressure Washer Components

Pulling back on the trigger moves the spray gun check ball off of its seat, as shown in Figure 2.12. The water then flows through the open valve and out of the wand to the nozzle.
Figure 2.12 Spray Gun - Trigger Open

Spray Wands and Nozzles


The spray nozzle is critical to proper operation of a pressure washer. The nozzle restricts the liquid flow and allows the required pressure to develop. The smaller the nozzle orifice, the higher the system pressure. Use of a nozzle having too large an orifice will result in a reduced system pressure. In addition to establishing system pressure, the nozzle breaks the liquid into droplets, forms the spray pattern, and propels the liquid in the proper direction. Several different types of spray nozzles may be used. The most popular type provides adjustable pressure and spray patterns. For Generac Portable Products nozzles, slide the nozzle backward for High Pressure spray; push the nozzle forward for Low Pressure spray; twist the nozzle clockwise for a Fan Spray Pattern; and twist the nozzle counterclockwise for a Narrow Stream. In addition, Generac Portable Products offers several accessory nozzles, such as a rotating brush, utility brush, and turbo nozzle.

DANGER: Do not attempt to adjust pressure or


spray pattern while spraying. Never place your hand in front of the spray nozzle to adjust pressure or spray pattern. Refer to the Owners Manual for the specific pressure washer model for correct operating instructions.

When the trigger is released, the valve shuts against its seat and the water flow is stopped. This condition causes the pump to enter the bypass mode.

CAUTION: Spray guns and wands are rated for maximum pressure and flow rate. Use of an incorrect spray gun and wand can be dangerous and will adversely affect pump performance. If replacement becomes necessary, you must replace the gun as an assembly. Use only the spray gun and wand listed in the Repair Parts section of the owners manual for the specific pressure washer model being serviced.

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 3 General Information

GENERAL INFORMATION Part 1 - General Maintenance


This section describes the general maintenance procedures recommended for pressure washer components that are common across product lines. Chemical Injection System Before each use, inspect the chemical injection suction hose strainer. Clean as necessary, or replace if damaged, torn or perforated. Examine the chemical suction hose and replace if damaged. Rinse the chemical injection system thoroughly after each use by siphoning several pints of clean water through the system. Inlet Water Supply Connector The pressure washer may be equipped with a Quick Disconnect type connector for convenient attachment of the inlet water supply. This type of connector, depicted in Figure 3.1, operates easily if the o-ring is periodically lubricated with a petroleum jelly.
Figure 3.1 Quick-Disconnect Hardware

the strainer or replace it if it is damaged, torn, or perforated. Reassemble the connectors, using petroleum jelly as necessary to ease the connections.
Figure 3.2 Inlet Supply Strainer

Hose, Spray Gun and Wand Systems With the pressure washer OFF, inspect the hose connection to the spray gun. Make sure it is tight. Test the trigger by squeezing it and making sure it springs back to the OFF position when released. Set the safety latch to ON and and test the trigger, making sure the trigger cannot be squeezed. With the pressure washer ON and the trigger latched OFF, verify the absence of leaks from the spray gun. With the pressure washer OFF, inspect the high pressure hose for cuts, leaks, abrasions, bulging, kinking, or abuse. With the pressure washer ON and the trigger latched OFF, verify the absence of leaks from the hose. The water supply quick-disconnect must be correctly installed on the supply hose and the pressure washer or its inlet supply filter will not be effective. Inlet Supply Filter/Strainer Remove the quick disconnect from the hose and inspect the inlet water strainer. It should be oriented so that the pointed part (the screen) points away from the pump (towards the garden hose). A typical inlet supply connection is seen in Figure 3.2. Clean 13

DANGER: Water spraying from a leaking hose can inject material into the skin or cause serious injury. Never attempt to repair high pressure hoses. Replace the hose with a high quality hose that meets the minimum pressure rating recommended by the manufacturer.
An o-ring maintenance kit for each model is available to refurbish all connection seals.

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 3 General Information

Spray Nozzle Servicing If the spray nozzle becomes clogged with dirt, excessive pump pressures may develop. A nozzle that has become partly clogged will demonstrate a pulsing sensation during use. If the nozzle becomes clogged or partially restricted, it can be cleaned as follows: 1. Shut down the engine and turn off the water supply to the pump. 2. Put on your safety glasses, as there could be trapped pressure behind a totally-clogged nozzle. 3. Disconnect the wand from the spray gun. 4. As seen in Figure 3.3, use a 5/64 inch (2mm) Allen wrench to remove the nozzle from the end of the wand. 5. Use a length of wire similar to that seen in Figure 3.3 to free any dirt from the nozzle.
Figure 3.3 Nozzle Removal and Cleaning

6. Remove any additional dirt from the wand by backflushing with water, as described below and shown in Figure 3.4.
Figure 3.4 Back-flushing the Wand

a. Hold the water supply against the wand and back-flush for about 30 seconds to 1 minute. b. While flushing, move the nozzle collar between stream and spray positions and between the low and high pressure positions. 7. Use the 5/64 inch (2mm) Allen wrench to reinstall the nozzle into the wand. DO NOT OVERTIGHTEN. 8. Reattach the wand to the spray gun. 9. Reconnect the inlet water supply to the pump and turn on the water. 10. Start the engine and test operation.

NOTE: If desired, a 5/64 inch (2mm) wrench can be ordered by specifying Generac nozzle kit part number 96961. A length of 17 gauge (0.039 inch) wire may be used to clean the nozzle. If desired, a nozzle cleaning rod may be ordered by specifying Generac nozzle kit part number 96869.

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 3 General Information

Part 2 - Lubrication
All pressure washers require oil lubrication of the piston mechanism in order to maintain long-term reliability and service. Certain early model Generac Portable Products pressure washers incorporate sight glasses or dipsticks to be used to monitor pump oil levels. Later Generac Portable Products models have improved designs that eliminate the need to routinely monitor oil levels or to change lubricating oil. This section describes how to check and change pump oil on early Generac Portable Products pressure washer systems. If servicing a non-Generac Portable Products-manufactured pump, please refer to the maintenance instructions provided with that specific system. Check Pump Oil Level Certain pressure washers may be equipped with a glass sight gauge, as depicted in Figure 3.5.
Figure 3.5 Sight Gauge on Side of Pump

Always check pump oil level with the unit resting on a level surface. Oil should be at the full mark on the sight gauge (near the center). On units equipped with an oil dipstick, oil level should be near the full mark. Add recommended pump oil as required, to the full mark only. Change Pump Oil

WARNING: DO NOT change pump oil unless the pressure washer Owners Manual requires this AND your pump is equipped with a pump drain plug.
Please refer to the maintenance instructions that were shipped with your non-Generac Portable Products-manufactured pump if it is necessary to change pump oil. Pay particular attention to the manufacturers recommended torque values when tightening drain plugs and breather/dipstick caps. To change oil in Generac Portable Productsmanufactured pumps, refer to Figure 3.5 and proceed as follows: 1. Place a suitable container under the pump drain plug. 2. Remove the oil fill cap (breather cap) from the top of the pump. 3. Remove the pump drain plug from the bottom of the pump. Drain oil completely into the container. 4. When all oil has drained, reinstall the pump drain plug and tighten to the torque value specified in the Torque Chart, found on the exploded view in the chapter for your pump. 5. Insert a funnel into the oil fill cap opening and add the recommended oil until the oil level reaches the full mark. Oil capacity and type is listed in Part 1, earlier in Section 3. 6. When oil is at the proper level, install and tighten the oil fill cap to the torque value specified in the Torque Chart, found on the exploded view in the chapter for your pump.

Item 1 2 3

Name Breather cap/oil fill location Drain plug Sight gauge location

15

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 3 General Information

Part 3 - Storage
Pump Storage Water should not be allowed to remain in the pump for long periods of time. Sediment can become deposited on pump parts, resulting in pump freeze-up. To protect the pump against water sediment buildup, proceed as follows after each use: 1. If the chemical injection siphon was used, flush the system as follows: a. While running the pressure washer with the nozzle set to low pressure mode, place the chemical siphon tube and its strainer into a pail of clear water. b. Permit siphon action to continue for two or three minutes to flush the system. c. Shut off the engine and let it cool. Squeeze the spray gun trigger to relieve trapped line pressure. Then remove all hoses.

Protection Against Freezing To protect the pump against freezing, proceed as follows: 1. Draw automotive windshield washer fluid into the pump: a. Connect a three (3) foot length of garden hose to the pump inlet. b. While holding the open hose end higher than the pump, pour the washer fluid into the length of hose. c. With the engine RUN/STOP switch in the STOP position, pull the engines recoil starter handle two or three times. This should replace most of the water in the pump with anti-freeze solution. Purging Air From the System Prior to use, the pressure washer pump, hose, and spray gun should be purged of air. To do this, proceed as follows: 1. Prepare the pressure washer for use as outlined in the Owners Manual. Make sure a proper water supply is connected and turned ON. 2. Put on your safety goggles and remove the wand from the spray gun. 3. Pull the trigger on the gun and hold open. 4. When the water flow is steady and constant, release the trigger to turn off the flow. 5. Reattach the wand to the gun. The system is now ready for use.

WARNING: Never start the engine or operate


the pump unless the proper water supply is connected. Any attempt to run the pump without the correct water supply will result in damage to the pump. 2. With the engine RUN/STOP switch in the STOP position, pull the engines recoil starter about six (6) times. This should remove most of the liquid from the pump. 3. Drain water from the high pressure hose, then coil the hose and stow it properly. 4. Store the unit in a clean, dry area.

16

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump

SMALL FRAME ELECTRIC PUMP


This section describes the small frame pump assemblies powered by electric motors. This small frame electric pump may also be referred to as EE or GPW-EE or Economy Electric pumps. The small frame electric pump has the following features: 1100 to 1300 PSI water pressure 1.5 to 1.8 Gallons per minute flow Axial Cam Design Stainless Steel Pistons Fixed Pressure Unloader Chemical Injection System or Foamer Bottle available Grip-Start - Automatically turns on the pump when spray trigger is pressed Safety Flow switch - Pump will not operate unless water supply is turned on. Oil bath, helical gear drive system 14 Amp Universal motor Designed to UL 1097 Double Insulation standards

Part 1 - Specifications and Views


Performance specifications for Generac Portable Products small frame electric pumps, sectional and exploded views, and a table showing recommended torque values are provided below.
Model Part No. 0762-0 0776-0 0766-1 0793-0 1007-0 9606-0 9737-0 Rated Pressure+ 1250 1300 1250 1250 1250 1100 1150 Pump Head Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Flow Rate* 1.5 1.5 1.5 1.5 1.5 1.8 1.8 Piston Material Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Oil Type/ Capacity 80W90/60ml 80W90/60ml 80W90/60ml 80W90/60ml 80W90/60ml 15W40/150ml 15W40/150ml

Performance Specifications + Pressure (in pounds per square inch) is adjustable up to the unit's rated pressure. * Flow rate is given in gallons per minute. Pump assemblies are listed by part number and were current at time of publication. Other pump assemblies will become available as our products evolve.

17

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump Cross-Sectional View
Figure 4.1 Small Frame Electric Pump (cross-sectional view)

A typical small frame electric pump is shown in Figure 4.1 in cross-section.

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump

Cross-Sectional View Parts List


Item
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Qty.
1 4 1 1 3 3 1 2 1 1 1 1 1 2 1 1 1 1 3 1 3 1 3 3 3

Description
O-ring O-ring Shuttle valve spring Shuttle valve O-ring Outlet port check valve cap Tie wrap O-ring Motor assembly, complete Motor cover housing Housing and switch assembly Foam air filter Axial cam idler shaft Bearing washer 35 x 55 x 3mm Needle thrust bearing 35 x 52mm Axial cam/gear assembly Bearing washer 40 x 60 x 1mm Needle thrust bearing 40 x 60mm SHCS M6-1.0 x 20mm Bearing washer 36 x 60 x 6mm Piston spring retainer Piston housing Piston return spring Oil seal Pilot spacer

Item
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51

Qty.
3 4 4 3 1 3 3 1 1 1 1 1 1 4 2 4 1 1 1 1 1 1 1 1 1 1

Description
High pressure water seal Lock washer, M6 ribbed SHCS M6- 1.0 x 35mm Piston Pump head Inlet check valve Outlet check valve Hex socket set screw w/ Locktite DO NOT REMOVE Taper plug DO NOT REMOVE Pop off valve spring Pop off valve ball seat Pop off valve check ball O-ring Rubber mount Taptite screw, M4-0.7x10mm Plastite screw, 6-19 x 0.75 Backup ring O-ring Auto switch piston return stop Auto switch piston return spring Auto switch piston assembly Backup ring Retainer cap Auto switch grommet Auto switch Auto switch housing

19

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump

Exploded View
Figure 4.2 Small Frame Electric Pump (exploded view)

A typical small frame electric pump is depicted in exploded view in Figure 4.2.

Item
6 19 28 33 40 41 48 54 57

Torque Value
15-17 ft-lbs 7-9 ft-lbs 9-12 ft-lbs 9-12 ft-lbs 2-4 ft-lbs 2-4 ft-lbs 10-12 ft-lbs Brass: 15-23 ft-lbs Nylon: 10-12 ft-lbs 20-30 in-lbs

20

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump

Exploded View Parts List


Item
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Qty
1 4 1 1 3 3 1 2 1 1 1 1 1 2 1 1 1 1 3 1 3 1 3 3 3 3 4 4 3

Description
O-ring O-ring Shuttle valve spring Shuttle valve O-ring Outlet port check valve cap Tie wrap O-ring Motor assembly, complete Motor cover housing Housing and switch assembly Foam air filter Axial cam idler shaft Bearing washer 35 x 55 x 3mm Needle thrust bearing 35 x 52mm Axial cam/gear assembly Bearing washer 40 x 60 x 1mm Needle thrust bearing 40 x 60mm SHCS M6-1.0 x 20mm Bearing washer 36 x 60 x 6mm Piston spring retainer Piston housing Piston return spring Oil seal Pilot spacer High pressure water seal Lock washer, M6 ribbed SHCS M6- 1.0 x 35mm Piston

Item
30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58

Qty.
1 3 3 1 1 1 1 1 1 4 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Description
Pump head Inlet check valve Outlet check valve Hex socket set screw w/ Locktite DO NOT REMOVE Taper plug DO NOT REMOVE Pop off valve spring Pop off valve ball seat Pop off valve check ball O-ring Rubber mount Taptite screw, M4-0.7x10mm Plastite screw, 6-19 x 0.75 Backup ring O-ring Auto switch piston return stop Auto switch piston return spring Auto switch piston assembly Backup ring Retainer cap Auto switch grommet Auto switch Auto switch housing Chemical suction hose Hose clamp Chemical inject fitting Chemical inject check ball Chemical inject check spring Chemical inject venturi Venturi o-ring

21

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump

Part 2 - Disassembly
General Information & Special Tools

Figure 4.3 Pump Head

NOTE: There are no special tools required to disassemble or reassemble this pump. CAUTION: The pump is full of oil. When removing pump from motor, drain by pouring oil out of crankcase.
Pump Head Refer to Figure 4.3 for this procedure. Using a 5mm Allen wrench, remove the four (4) M6-1.0 x 35 cap screws to separate pump head from piston housing. To disassemble pump head: 1. Remove the three (3) high pressure water seals (item 2). Seals should slide out easily. 2. Remove the three (3) inlet check valves (item 1). A 5/16-18 bottoming tap may be used to remove these valves. 3. Remove the o-ring (item 3) from the pop off valve boss. 4. Secure the head in a vice or with a clamp and use an 8mm wrench to remove the three (3) M8-1.5 outlet port caps (items 5 & 6). 5. Remove the three (3) outlet check valves and o-rings (items 4 & 7). 6. Do not attempt to remove the pipe plug (item 10) from the head (item 15). It is installed with a thread-locking compound to secure the pop off components and is not meant to be removed. Should these components be damaged or broken, the entire head assembly must be replaced. Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Name Inlet check valve assembly High pressure water seal Pop off o-ring Outlet check valve assembly Outlet port cap o-ring Outlet port cap Check valve o-ring Taper plug DO NOT REMOVE Pop off check ball Hex socket plug DO NOT REMOVE Pop off valve spring Pop off ball seat M6 ribbed lock washer SHCS, M6-1.0 x 35mm Pump head

22

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump

Piston Housing Removal Refer to Figure 4.4 for this procedure.


Figure 4.4 Piston Housing

WARNING: There may be up to 50 pounds of stored energy when separating the piston housing from the motor. Remove these bolts slowly and evenly.
4. Using a 5mm wrench, gradually loosen each of the three (3) M6-1.0 x 20 bolts that hold the motor to the piston housing, as seen in Figure 4.5.
Figure 4.5 Motor Removal

Item 1 2 3 4 5

Name Piston housing Piston Pilot spacer Check valve o-ring Shuttle valve o-ring Item 1 2 3 Name Electric motor SHCS, M6-1.0 x 20mm Piston housing

Before disassembling the piston assembly, do the following: 1. Remove the three (3) pilot spacers (item 3). These will just slide off. 2. Remove the three (3) check valve o-rings (item 4). 3. Remove the shuttle valve o-ring (item 5).

NOTE: Piston housing is full of gear oil. Take care


to handle the fluid safely.

23

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump

Piston Housing Disassembly Refer to Figure 4.6 for this disassembly, as follows:
Figure 4.6 Piston Housing Disassembly

Chemical Injection System Not all pumps are equipped with a chemical injection system. Refer to Figure 4.7 when following this disassembly procedure. Be careful not to lose check ball and spring.
Figure 4.7 Chemical Inject System

Item 1 2 3 Item 1 2 3 4 5 6 Name Housing o-ring Piston spring retainer Piston Piston spring Piston housing Oil seal 4 5 6

Name Chemical inject venturi (brass or plastic) Venturi o-ring Chemical inject fitting Check ball Check spring Piston housing

1. Remove the chemical injection fitting, check ball, and spring (items 3, 4, & 5). 2. Using a large straight tip screwdriver, unscrew and remove the chemical injection venturi and o-ring (items 1 & 2) from discharge port. It may be necessary to insert a sheet metal screw into the venturi hole, then pull on the screw with a pliers, to remove the venturi and o-ring.

1. Remove the large o-ring (item 1) from the housing. 2. Remove the three (3) pistons, springs, and retainers. To do this, grasp the piston springs and pull straight out. The retainers will stay attached to the pistons. 3. Remove the three (3) piston oil seals (item 6). 24

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump

Auto Start Switch Assembly Refer to Figure 4.8 when following this disassembly procedure.
Figure 4.8 Auto Start Switch Group

1. Remove the housing covering the auto switch (item 4) and disconnect two spade lugs from the switch. 2. Remove two (2) 5.5mm Taptite screws (item 3) using a 5.5mm socket. Remove the switch housing (item 4) from the piston housing. 3. Remove the retainer cap (item 11) with a 22mm socket or box wrench. Be careful to not round the hex head corners on this plastic part.

NOTE: The retainer cap, spring, and piston parts may show some slight differences depending on production date. Newer parts are completely interchangeable with older models.
4. Remove the piston spring and the piston components, as follows: a. To non-destructively remove the components, grasp the end of the piston shaft with a soft-jaw locking pliers and lever the assembly out of its port, prying against the port rim. b. If no soft-jaw pliers are available, a short length of brass tubing can be slipped over the piston shaft. A standard locking jaw plier can be used to grasp the tubing and squeeze it against the shaft, then remove as described in (a.). Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Name Piston housing Rubber diaphragm Taptite screw Auto switch housing Auto switch Auto switch piston spring Auto switch piston assembly O-ring Auto switch piston return stop Backup ring Retainer cap O-ring Backup ring Any other removal method will require replacement of all auto switch piston components.

25

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump

Axial Cam Refer to Figure 4.9 when following this disassembly procedure.
Figure 4.9 Axial Cam Components

1. Grasp the protruding end of the axial cam idler shaft (item 1) with your fingers and withdraw it from the motor housing (item 5). 2. Remove the two thrust washers and the needle bearing. 3. Remove the axial cam/gear assembly. Because the gear is pressed onto the cam with special factory tooling, the cam and gear must be replaced as an assembly. 5. Remove the remaining thrust washers and needle bearing.

Item 1 2 3 4 5 6 7 8

Name Axial cam idler shaft Bearing washer Axial cam/gear assembly Needle thrust bearing Motor Bearing washer Bearing washer Needle thrust bearing

26

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump

Part 3 - Inspection
Seals, O-Rings, and Gaskets Once the pump is disassembled, make a careful inspection of all seals and o-rings for any defects that may affect the proper operation of the pressure washer. Piston & Spring Assemblies Referring to Figure 4.10, inspect the three (3) pistons carefully. Reject any piston that is scratched, dented, or otherwise damaged.
Figure 4.10 Piston & Spring Assemblies

Each of the three (3) pump pistons pass through an oil seal in the piston and unloader housing. Note the oil seal and pilot spacer illustrated in Figure 4.11. The oil seal lip will face towards the piston spring and retainer to retain the pump oil.
Figure 4.11 Piston Seals

Item 1 2 3 4 5 Item 1 2 3 Name Piston spring retainer Piston Piston return spring

Name Piston, spring, and retainer Piston housing Oil seal Pilot spacer High pressure water seal

Inspect the three (3) piston springs. Replace any spring that is damaged or broken. Pump Head and Piston Housing Clean all parts. Inspect carefully for cracks, damage, wear, etc.. Check for corrosion. Replace any damaged, defective, or corroded part as necessary.

WARNING: Do not strike a piston with any object or use a piston to strike any object.Do not drop the piston. Dropping the piston will result in damage.

27

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump

Axial Cam Drive Components Referring to Figure 4.12, carefully inspect axial cam bearing assemblies for wear, damage, and freedom of rotation. Replace any damaged or defective bearing assembly.
Figure 4.12 Axial Cam Components

Inspect the axial cam idler shaft. Replace if worn, bent, or damaged. Inspect the thrust washers. Replace if damaged. Inspect the axial cam/gear assembly. Replace if worn excessively or damaged. Inspect the motor assembly, particularly the axial cam housing. Ensure that the axial cam idler shaft socket is true and not worn or cracked. Ensure that the fastening bosses are not cracked or chipped. Inspect the housing for the absence of cracks, chips, evidence of oil leaks, or other damage. Inspect the motor drive gear for evidence of wear or damage. Inspect the motor wires for evidence of corrosion, fraying or damaged connectors, wires, or other defects. Replace the motor assembly as a unit if any defects are found.

Item 1 2 3 4 5 6 7 8

Name Axial cam idler shaft Bearing washer Axial cam/gear assembly Needle thrust bearing Motor Bearing washer Bearing washer Needle thrust bearing

28

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump

Part 4 - Reassembly
Refer to the Torque Specifications provided on the pump sectional view found at the beginning of this section when reassembling this product. Pump Head Assembly The pop off valve is not serviceable. The entire head assembly must be replaced if a problem occurs in these components. To assemble the pump head, refer to Figure 4.13 for the following steps:
Figure 4.13 Pump Head

found on Figure 4.2 (Exploded View) at the beginning of this chapter. 4. Press three (3) inlet check valves (item 1) into place. Notice that the small end of the valve goes into the cavity first, and that the valve is pressed in until it is flush with the head surface. It may be necessary to pre-lubricate the check valve o-rings with silicone spray before installation. 5. Pre-lubricate three (3) high pressure water seals (item 2) with silicone spray. Insert a seal into each piston cylinder cavity with the flat side facing out. Review Figure 4.11, seen earlier, for a view of proper seal orientation. 6. Install the pop off valve o-ring (item 3). Petroleum jelly will help to hold it in place. Auto Start Switch Assembly Refer to Figure 4.14 for this assembly.
Figure 4.14 Auto Start Switch

Item 1 2 3 4 5 6 7 8

Name Inlet check valve assembly High pressure water seal Pop off valve o-ring Outlet check valve assembly Outlet port cap o-ring Outlet port cap Check valve o-ring Pump head Item 1 2 3 4 5 6 7 Name Piston housing Rubber diaphragm Taptite screw Auto switch housing Auto switch Auto switch piston spring Auto switch piston assembly 10 11 12 13 Item 8 9 Name O-ring Auto switch piston return stop Backup ring Retainer cap O-ring Backup ring

1. Install three (3) outlet check valve o-rings (item 7). Ensure they lie flat at the bottom of the cavity. 2. Install three (3) outlet check valves, with large end first (item 4). 3. Install and snug the three (3) M18-1.5 outlet caps with pre-installed o-rings (items 5 & 6). After the pump is assembled, tighten the three (3) outlet caps to the torque value specified in the Torque Chart, 29

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump

Before assembly, ensure the auto switch cavity is clean and free from scale, corrosion, dirt, etc. 1. If necessary, install new backup rings and o-rings (items 8, 10, 12, 13) to the auto start piston return stop (item 7). 2. Remove and do not replace the teflon rings on the auto switch piston assembly. These rings should be removed for optimum auto switch operation. 3. Install the auto switch piston return spring (item 6) in the auto switch cavity on the piston housing. 4. Install the auto switch piston assembly, ensuring that it engages the spring inserted in step (3.). 5. Install the auto switch piston return stop (item 9) on the piston shaft so that the small backup ring faces out. 6. Install the retainer cap (item 11) over the piston shaft and hand thread it into the piston housing. 7. Tighten the retainer cap to the torque value specified in the Torque Chart, found on Figure 4.2 (Exploded View) at the beginning of this chapter. 8. Ensure that the rubber diaphragm (item 2) is not damaged or perforated, and is installed in the hole in the side of the auto switch housing. 9. Using a 5.5mm socket, install two (2) Taptite screws to secure the auto switch housing to the piston housing. Make sure the auto switch housing is anchored at the midpoint of its lateral adjustment. After the pressure washer is assembled, it may be necessary to adjust the position of the auto switch housing to ensure proper auto switch operation.

Chemical Inject Assembly Refer to Figure 4.15 for this assembly.


Figure 4.15 Chemical Inject System

Item 1 2 3 4 5 6

Name Chemical inject venturi (brass or plastic) Venturi o-ring Chemical inject fitting Check ball Check spring Piston housing

1. Install the check ball into the chemical inject fitting, followed by the spring (with the small end of the spring towards the ball). 2. Install the chemical inject fitting into the piston housing. Be careful not to drop the ball and spring. 3. Tighten the chemical injection fitting to the torque value specified in the Torque Chart, found on Figure 4.2 (Exploded View) at the beginning of this chapter. 4. Carefully install the chemical inject venturi o-ring onto the venturi. 5. Hand thread the chemical inject venturi into the discharge port of the piston housing. 6. Tighten the venturi to the torque value specified in the Torque Chart, found on Figure 4.2 (Exploded View) at the beginning of this chapter. 30

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump

Piston Housing Assembly Refer to Figure 4.16 for this procedure.


Figure 4.16 Pistons and Springs

Pilot Spacer Installation Refer to Figure 4.17 for this procedure. 1. Install the three (3) check valve o-rings (item 4). Use a small amount of petroleum jelly to hold them in place.
Figure 4.17 Piston Housing

Item 1 2 3 4 5

Name Piston spring retainer Piston Piston spring Piston housing Oil seal Item 1 2 3 4 5 Name Piston housing Piston Pilot spacer Check valve o-ring Shuttle valve o-ring

1. Pre-lubricate the three (3) oil seals (item 5) with silicone spray. Press the seals into the piston housing with their flat side (the side with writing on it) facing the installer. If you see the seals internal spring, the seal has been installed upside down. 2. Apply a small amount of 80W90 oil to the three (3) pistons, then install the pistons, springs, and retainers into the piston housing. The pistons are merely pushed into place. 3. Invert the piston housing so that the pistons protrude vertically from the housing. Place the piston housing on a flat surface. 31

2. Install the three (3) pilot spacers (item 3) over the pistons, with large end inserted in piston housing. 3. Install the shuttle valve o-ring (item 5). Use a small amount of petroleum jelly to hold it in place. 4. Carefully lift the pump head assembly, invert it, and align the high pressure water seals with the pistons protruding from the piston housing. 5. Verify that the o-rings remain in their proper position and press the head down to the piston housing.

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump

Pump Head Bolts 1. Grasp the head/piston housing assembly and invert it onto a flat surface. 2. Install the four (4) M6-1.0 x 35 cap screws . Tighten the cap screws to the torque value specified in the Torque Chart, found on Figure 4.2 (Exploded View) at the beginning of this chapter. Assemble Axial Cam Refer to Figure 4.18 for this procedure:
Figure 4.18 Axial Cam Assembly

1. Invert the head/piston housing assembly and place it on a flat surface. Ensure that the pistons are fully inserted into the piston housing. 2. Install the axial cam idler shaft (item 7) into its socket in the piston housing (item 8). 3. Install a 36 x 60 x 6mm thrust washer (item 6) on the idler shaft, with chamfer towards the pistons. 4. Lay a 40 x 60mm needle bearing (item 5) on the thrust washer, either side up. 5. Lay a 40 x 60 x 1mm thrust washer (item 4) on the needle bearing, chamfer side up. 6. Install the axial cam/gear assembly (item 3) onto the idler shaft, gear end on top. Ensure that the axial cam engages the bearing and thrust washers previously installed. 7. Install a 35 x 55 x 3mm thrust washer (item 2) on the axial cam, with chamfer towards the cam. 8. Install a 35 x 52mm needle thrust bearing (item 1) on the thrust washer (either side up). 9. Install the large o-ring into the piston housing groove. 10. Ensure that the idler shaft protrudes from the axial cam/bearing assembly about 8mm. This will make motor alignment easier. Oil Fill Pour the specified amount of 80W90 oil into the piston housing. For specific recommendations for oil type and capacity, please refer to the table given in Part 1, at the beginning of this section. Main Component Assembly 1. Use a dab of petroleum jelly to adhere the remaining 35 x 55 x 3mm thrust washer in its recess in the motor housing, with chamfer towards the motor housing.

Item 1 2 3 4 5 6 7 8

Name Needle thrust bearing Bearing washer Axial cam/gear assembly Bearing washer Needle thrust bearing Bearing washer Axial cam idler shaft Pump head/piston housing assembly 32

2. Grasp the motor assembly with both hands and invert it over the piston housing so that the axial cam idler shaft aligns with the mating hole in the motor housing. Gently lower the motor and rotate the cam to ensure the gear teeth engage the motor drive gear teeth. 3. Align the mounting screw holes on the motor housing with the threaded holes on the piston housing.

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump

CAUTION: The motor adapter bolt holes line up with the holes on the piston housing in one position only. Rotate the motor housing until proper alignment is achieved.
4. Referring to Figure 4.19, install the three (3) M6-1.0 x 20 socket head cap screws into the mounting screw holes on the motor housing and thread them into the piston housing. Because of piston return spring tension, the motor housing will remain elevated.
Figure 4.19 Motor Assembly

Final Assembly and Test

NOTE: Torque the outlet caps at this time, if not done previously. Verify that all other fasteners have been torqued to proper values.
1. Position the motor cover housing over the pump assembly, feeding the two white wires up through the channel in the housing, as show on Figure 4.1. 2. Insert the bayonet plug into its mating connector in the housing and switch assembly. 3. Insert the spade connector into its mating spade lug in the housing and switch assembly. 4. Fasten the housing and switch assembly to the motor cover housing with four (4) Plastite 6-19 x 0.75 screws. 5. Reassemble the pump into the pressure washer housing, taking care to avoid pinching wires, etc. 6. Cthe pressure washer to a water supply and connect the high pressure hose, wand, and spray gun. Connect the pressure washer to line voltage through a GFCI receptacle. 7. The pressure washer should provide a spray when the spray gun trigger is depressed. If the unit does not produce a spray, the auto switch may need to be adjusted, as follows: a. Disconnect the pressure washer from line voltage and from the water supply. b. Disassemble the unit so that you can get to the two taptite screws. c. Loosen the screws enough to be able to laterally move the auto switch housing further away from the piston housing. d. Tighten the taptite screws to recommended torque value. e. Reassemble the unit, reconnect the water and line voltage and depress the spray gun trigger again. Normal unit operation should be obtained.

Item 1 2 3

Name Electric motor SHCS, M6-1.0 x 20mm Piston housing

5. Snug each M6-1.0 cap screw, alternating between screws until the housings meet. Tighten screws to the torque value specified in the Torque Chart, found on Figure 4.2 (Exploded View) at the beginning of this chapter.

33

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 Small Frame Electric Pump

Part 5 - Troubleshooting
Problem
1. Water leakage between pump head and piston housing.

Possible Cause
a. Head bolts improperly torqued. b. Damaged head. c. Missing or damaged o-rings

Corrective Action
a. Torque head bolts. b. Replace head. c. Install new o-rings.

2. Water leaks from pressure out connector.

a. Connector not properly sealed. b. Damaged connector.

a. Seal with teflon tape and tighten properly. b. Replace bad connector.

3. Oil leak between motor and motor adapter.

a. Defective or missing motor adapter o-ring. b. Motor adapter cap screws not tightened properly.

a. Install new o-ring. b. Tighten to correct torque.

4. Oil leak between motor adapter and piston/unloader housing.

a. Missing or bad o-ring seal. b. Cap screws not tightened properly.

a. Install new o-ring seal. b. Tighten to correct torque.

5. Pump does not produce pressure, exhibits erratic pressure, chatters, or has a low water volume.

a. Nozzle is set to low pressure mode. b. Incorrect spray nozzle is used. c. Spray nozzle is obstructed. d. Water Inlet blocked e. Inadequate water supply to pump. f. Water supply hose kinked or leaking. g. Clogged inlet hose strainer. h. Water supply too hot. i. Worn or defective pump.

a. Reset nozzle to high pressure. b. Replace with correct nozzle. c. Clear obstruction from nozzle. d. Clear inlet. e. Provide sufficient water supply. f. Relieve kinking or repair leak. g. Clean strainer. h. Reduce inlet water temperature to below 140oF. i. Disassemble and repair pump.

6. Detergent does not mix with spray.

a. Nozzle is in high pressure mode. b. Chemical suction line is not submerged. c. Chemical suction strainer or line is clogged.

a. Reset nozzle to low pressure. b. Insert line into fluid. c. Clean or replace strainer or line.

34

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 Small Frame Gas Pump

SMALL FRAME GAS PUMP


This section describes the small frame pump assemblies powered by gasoline engines intended for use in light duty applications. This small frame gas pump may also be referred to as GPW-EG or EG or Economy Gas pumps. Most of the information previously printed in publication A4453 will be found here. The small frame gas pump has the following features: 1500 to 1800 PSI water pressure 2.0 Gallons per minute flow Axial Cam Design Stainless Steel Pistons Fixed Pressure Unloader Chemical Injection System available Thermal Relief Valve available Oil Bath Drive System Vertical or Horizontal Engine Mount

Part 1 - Specifications and Views


This section presents the torque and performance specifications for Generac Portable Products small frame gas pumps. Also presented are sectional and exploded views of this type of pump assembly. Performance Specifications
Pump Assembly Part No. B1906A 20965 20965A B1262 B1262A Rated Pressure+ 1500 1650 1650 1750 1750 Engine Shaft Straight Straight Straight Straight Straight Pump Head Flow Rate* Piston Material Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Oil Type/ Capacity 80W90/120ml 80W90/120ml 80W90/120ml 80W90/120ml 80W90/120ml

Aluminum Aluminum Aluminum Aluminum Aluminum

2.0 2.0 2.0 2.0 2.0

+ Pressure (in pounds per square inch) is adjustable up to the unit's rated pressure. * Flow rate is given in gallons per minute. A suffix denotes pumps with thermal relief valve. Pump assemblies are listed by part number and were current at time of publication. Other pump assemblies will become available as our products evolve.

35

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 Small Frame Gas Pump

Cross-Sectional view

A typical small frame gas pump is shown in cross-section in Figure 5.1.

Figure 5.1 Small Frame Gas Pump (cross-sectional view)

36

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 Small Frame Gas Pump

Cross Sectional View Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 23 24 Qty. 3 1 1 1 3 3 3 1 1 1 3 3 3 1 1 6 1 1 6 3 1 3 1 Description Rubber grommet spacer sleeve Cage needle bearing assembly Bearing washer Bearing washer Oil piston seal Piston return spring U-cup seal Axial cam w/insert Engine adapter Piston and unloader housing Piston spring retainer Pilot spacer Piston Pump head Radial ball bearing Rubber bushing Piston and unloader housing O-Ring seal High pressure transfer O-Ring Check valve assembly Outlet check valve cap O-Ring Thermal relief valve (if equipped) w/sealant Outlet check valve cap Unloader seat 43 1 42 3 32 33 34 35 36 37 39 40 1 1 1 1 1 6 7 4 Item 25 26 27 28 29 30 31 Qty. 1 1 2 1 1 1 1 Description Unloader seat O-Ring Unloader piston Unloader split-ring seal Unloader spring Unloader cap O-Ring Unloader cap Pipe plug (if item 22 not equipped) w/sealant Chemical injection hose barb Plug, w/sealant Chemical injection ball Chemical injection spring Chemical injection venturi Low pressure transfer O-Ring Lock washer Socket head cap screw M6-1.0 x 35 Socket head cap screw M6-1.0 x 25 Venturi O-Ring

37

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 Small Frame Gas Pump

Exploded View
Figure 5.2 Small Frame Gas Pump (exploded view)

A typical small frame gas pump is shown in exploded view in FIgure 5.2.

Torque Chart Torque Item 23 30 31 32 33 36 40 42 43 15-17 ft-lbs Brass: 15-18 ft-lbs Plastic: 7-10 ft-lbs 15-18 ft-lbs 9-12 in-lbs 12-15 ft-lbs 20-30 in-lbs 9-12 ft-lbs 9-12 ft-lbs 15-18 ft-lbs

38

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 Small Frame Gas Pump

Exploded View Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 23 24 25 Qty. 3 1 1 1 3 3 3 1 1 1 3 3 3 1 1 6 1 1 6 3 3 1 1 Description Rubber grommet spacer sleeve Cage needle bearing assembly Bearing washer Bearing washer Oil piston seal Piston return spring U-cup seal Axial cam w/insert Engine adapter Piston and unloader housing Piston spring retainer Pilot spacer Piston Pump head Radial ball bearing Rubber bushing Piston and unloader housing O-Ring seal High pressure transfer O-Ring Check valve assembly Outlet check valve cap O-Ring Outlet check valve cap Unloader seat Unloader seat O-Ring 45 1 43 1 42 3 32 33 34 35 36 37 39 40 1 1 1 1 1 6 7 4 Item 26 27 28 29 30 31 Qty. 1 2 1 1 1 1 Description Unloader piston Unloader split-ring seal Unloader spring Unloader cap O-Ring Unloader cap Pipe plug (if item 43 not equipped) w/sealant Chemical injection hose barb Plug, w/sealant Chemical injection ball Chemical injection spring Chemical injection venturi Low pressure transfer O-Ring Lock washer Socket head cap screw M6-1.0 x 35 Socket head cap screw M6-1.0 x 25 Thermal relief valve (if equipped) w/sealant Venturi O-Ring

39

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 Small Frame Gas Pump

Part 2 - Disassembly
General Information & Special Tools

To disassemble pump head: 1. Remove the three (3) water seals. Seals should slide out by hand. 2. Remove the three (3) inlet check valves. A 5/16-18 bottoming tap may be used to remove these valves. DO NOT use a screwdriver as it will damage valve and head! 3. Remove the O-Ring from the high pressure transfer boss. 4. Remove the three (3) M8-1.5 outlet check valve caps and O-Rings. 5. Remove the three (3) outlet check valves and O-Rings. 6. Do not attempt to remove the pipe plug (item 7). It is installed with a thread-locking compound and is not meant to be removed. Piston & Unloader Housing Removal Refer to Figure 5.4 for this procedure.
Figure 5.4 - Pump-Adapter Assembly

NOTE: There are no special tools required to disassemble or reassemble this pump. CAUTION: The pump is full of oil. When removing pump from engine, drain by pouring oil out of port used by the crankshaft.
Pump Head Refer to Figure 5.3 for this procedure.
Figure 5.3 - Pump Head

Item 1 2 3 4 5 6 7 8 9

Name Water seal Check valve Low pressure transfer O-Ring High pressure transfer O-Ring Outlet check valve cap Outlet check valve cap O-Ring Pipe Plug - If present, DO NOT REMOVE M6 lock washer M6-1.0 x 35 cap screw

Item 1 2 3

Name Piston Pilot spacer Low pressure transfer O-Ring

Before disassembling the piston and unloader assembly, do the following: 1. Remove the three (3) pilot spacers. These will just slide off. 40

Using a 5mm Allen wrench, remove the four (4) M6-1.0 x 35 cap screws and lockwashers to separate pump head from piston housing.

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 Small Frame Gas Pump

2. Remove the three (3) low pressure transfer O-Rings.

WARNING: There may be up to 75 pounds of stored energy when separating the piston and unloader housing from the engine adapter housing. Remove these bolts slowly and evenly.
3. Apply a 6 C-clamp to hold the engine adapter and the pump head together. 4. Remove the three (3) M6-1.0 x 25 cap screws that hold the engine adapter to the piston and unloader housing, as seen in Figure 5.5.
Figure 5.5 - Engine Adapter

Piston & Unloader Housing Disassembly Refer to Figure 5.6 for this disassembly, as follows:
Figure 5.6 - Piston & Unloader Housing

Item 1 2 3 Item 1 2 Name M6-1.0 x 25 cap screw & M6 lock washer Engine adapter 4 5 6

Name O-Ring Piston and retainer Spring Thermal bypass valve or pipe plug Piston and unloader housing Piston oil seal

5. Slowly loosen the C-clamp until spring tension is released and the components separate.

1. Remove O-Ring from housing. 2. Remove the three (3) pistons, springs, and retainers. To do this, grasp the piston springs and pull straight out. The retainers will stay attached to the pistons. 3. Remove the three (3) piston oil seals. 4. Remove the thermal relief valve (if present). It is not necessary to remove the pipe plug, if installed in place of the thermal relief valve.

41

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 Small Frame Gas Pump

Chemical Injection System Refer to Figure 5.7 and follow this chemical injection system disassembly procedure.
Figure 5.7 - Chemical Injection System

Unloader Refer to Figure 5.8 when following this disassembly procedure.

CAUTION: Unloader cap is under strong spring


pressure. 1. Remove the M25-1.0 unloader cap with a 24mm wrench.

NOTE: Unloader cap, unloader spring, and unloader piston parts may show some slight differences depending on production date. If the entire unloader system is replaced, newer assemblies are completely interchangeable with older models.
Figure 5.8 - Unloader Parts

Item 1 2 3 4 5 6

Name Chemical injection venturi O-Ring Barbed nipple Check ball Spring Piston and unloader housing Item 1 2 3 4 5 6 7 Name Piston and unloader housing O-Ring Unloader seat Unloader piston Unloader cap Unloader spring Split-ring seal

CAUTION: Be careful not to lose check ball and


spring. 1. Remove the chemical injection fitting, check ball, and spring. 2. Using a large straight tip screwdriver, unscrew and remove the chemical injection venturi and O-Ring from discharge port.

2. Remove the unloader spring and the unloader piston. These pieces should just slide out. 3. Remove the unloader seat by inserting a 90 O-Ring pick into the orifice machined in the side of the seat, then gently pull the seat out of the housing.

42

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 Small Frame Gas Pump

Engine Adapter Refer to Figure 5.9 when following this disassembly procedure.
Figure 5.9 - Engine Adapter & Axial Cam

Part 3 - Inspection
Seals, O-Rings, and Gaskets Once the pump is disassembled, make a careful inspection of all seals and O-Rings for any defects that may affect the proper operation of the pressure washer. Piston & Spring Assemblies Referring to Figure 5.10, inspect the three (3) pistons carefully. Reject any piston that is scratched, dented, or otherwise damaged.
Figure 5.10 - Piston Assembly

Item Item 1 2 3 4 5 6 Name Thrust washer Cage needle bearing Retainer washer Axial cam Radial ball bearing Engine adapter 1 2 3

Name Retainer Piston Spring

CAUTION: Do not strike a piston with any object or use a piston to strike any object.Do not drop the piston. Dropping the piston will result in damage.

1. Remove the thrust washer. 2. Remove the cage needle bearing. 3. Remove the retainer washer. 4. Remove the axial cam/radial ball bearing assembly. Because the bearing is pressed onto the cam, the cam and bearing must be replaced as an assembly. 5. If present, the pipe plug was installed with a threadlocking compound and should not be removed.

43

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 Small Frame Gas Pump

Each of the three (3) pump pistons pass through an oil seal in the piston and unloader housing. Note the oil seal and pilot spacer illustrated in Figure 5.11. The oil seal lip will face towards the piston spring and retainer to retain the pump oil.
Figure 5.11 Piston Chamber

Axial Cam Drive Components Referring to Figure 5.12, carefully inspect the engine adapter bearing and the axial cam bearing assemblies for wear, damage, and freedom of rotation. Replace any damaged or defective bearing assembly.
Figure 5.12 - Axial Cam Drive Components

Item 1 2 3 4 5

Name Piston and unloader housing Piston Oil seal Pilot spacer Pump head

Inspect the three (3) piston springs. Replace any spring that is damaged or broken. Engine Adapter, Pump Head, and Piston & Unloader Housing Clean all parts. Inspect carefully for cracks, damage, and so forth. Check for corrosion. Replace any damaged, defective, or corroded part as necessary. Item 1 2 3 4 5 6 Name Thrust washer Cage needle bearing Retainer washer Axial cam Radial ball bearing Engine adapter

Inspect the retainer washer and the thrust washer. Replace if damaged. Inspect the axial cam. Replace if worn excessively or damaged.

44

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 Small Frame Gas Pump

Part 4 - Reassembly
NOTE: Refer to the Torque Specifications provided
on the pump exploded view found at the beginning of this section when reassembling this product. Engine Adapter 1. Install the retainer washer (thinner one) on the axial cam/radial ball bearing assembly. 2. Install the cage needle bearing (either side up). 3. Install the thrust washer (thicker one, either side up). Unloader Assembly Refer to Figure 5.13 for this assembly.
Figure 5.13 - Unloader Assembly

4. Install the unloader piston. It will seat itself inside of the unloader seat. 5. Install the unloader spring. 6. Install the M25-1.0 unloader cap and O-Ring. 7. Tighten the unloader cap to the torque value specified in the Torque Chart, found on Figure 5.2 (Exploded View) at the beginning of this chapter. Chemical Injection Assembly Refer to Figure 5.14 for this assembly.
Figure 5.14 - Chemical Injection System

Item 1 2 3 4 5 6 7

Name Piston and unloader housing O-Ring Unloader seat Unloader piston Unloader cap Unloader spring Split-ring seals

Item Name 1 2 3 4 5 6 Chemical injection venturi O-Ring Barbed nipple Check ball Spring Piston and unloader housing

1. Install the new O-Ring on the unloader seat (if replacing). 2. Install the unloader seat with O-Ring (use a small amount of petroleum jelly on O-Ring if necessary). Seat will press itself into place when unloader piston, spring, and cap are installed. 3. Install the new split-ring seal onto the unloader piston (if replacing). 45

1. Install the check ball into the chemical injection nipple, followed by the spring (with the small end of the spring towards the ball). 2. Install the M10-1.0 chemical injection nipple into the piston and unloader housing. Be careful to not drop the ball and spring. 3. Tighten the chemical injection nipple to the torque value specified in the Torque Chart, found on Figure 5.2 (Exploded View).

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 Small Frame Gas Pump

4. Install the chemical injection venturi O-Ring into the piston and unloader housing. 5. Hand thread the M14-1.25 chemical injection venturi into the housing. 6. Tighten the venturi to the torque value specified in the Torque Chart, found on Figure 5.2 (Exploded View). Piston & Unloader Housing Assembly Refer to Figure 5.15 for this assembly.
Figure 5.15 - Piston & Unloader Housing

2. Apply a small amount of 80W90 oil to the three (3) pistons, then install the pistons, springs, and retainers into the piston and unloader housing. The pistons are merely pushed into place. 3. Install the thermal relief valve (item 3). 4. Tighten the thermal relief valve (or substitute plug) to the torque value specified in the Torque Chart, found on Figure 5.2 (Exploded View) at the beginning of this chapter. Pump Head Assembly Refer to Figure 5.16 for this assembly.
Figure 5.16 - Pump Head

Item Item 1 2 3 4 5 6 Name O-Ring Piston and retainer Spring Thermal bypass valve or pipe plug Piston and unloader housing Piston oil seal 1 2 3 4 5 6 7 8 9

Name Water seal Check valve Low pressure transfer O-Ring High pressure transfer O-Ring Outlet check valve cap Outlet check valve cap O-Ring Pipe Plug - If present, DO NOT REMOVE M6 lock washer M6-1.0 x 35 cap screw

1. Refer to Figure 5.15 and install the three (3) oil seals. Press the seals into the piston and unloader housing using a small amount of petroleum jelly.

NOTE: Do not reuse springs color coded RED. All


piston return springs must be replaced in sets of three (3). 46

1. Install the three (3) low pressure transfer O-Rings. Use a small amount of petroleum jelly to hold them in place. 2. Install the high pressure transfer O-Ring. Petroleum jelly will help to hold it in place.

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 Small Frame Gas Pump

3. Press three (3) inlet check valves into place, as shown in Figure 5.16. 4. Install three (3) outlet check valves, observing their orientation, as shown in Figure 5.16. 5. Install the three (3) M18-1.5 outlet caps and O-Rings. 6. After the head is bolted to the pump, tighten the three (3) outlet caps to the torque value specified in the Torque Chart, found on Figure 5.2 (Exploded View) at the beginning of this chapter. Main Component Assembly Refer to Figure 5.17 for this assembly.
Figure 5.17 Main Component Assembly

3. Place the piston housing O-Ring into the groove on the housing. 4. Grasp the engine adapter with both hands and invert it while holding the axial cam, washers, and bearing in place. 5. Place the engine adapter over the piston housing so that the thrust bearing is touching all three (3) pistons, and the mounting screw holes on the adapter line up with the threaded holes on the housing. 6. Referring to Figure 5.18, install the three (3) M6-1.0 x 25 socket head cap screws into the mounting screw holes on the engine adapter and thread them into the piston housing.
Figure 5.18 Installing Engine Adapter Bolts

Item Name 1 2 3 M6-1.0 x 25 cap screws & M6 lock washers Engine adapter Widest opening between three (3) engine adapter legs aligns with the chemical injector-thermal relief side of piston and unloader housing Pump head

4 Item 1 2 3 Name Engine adapter assembly with axial cam, bearings, and washers held in place. Assembled piston and unloader housing with pistons, seals, and O-Ring Pump head assembly placed on flat surface

7. Tighten the M6-1.0 cap screws to the torque value specified in the Torque Chart, found on Figure 5.2 (Exploded View) at the beginning of this chapter.

1. Place the pump head assembly on a flat surface, with the inner side up. 2. Position the piston and unloader housing on the pump head so that the pistons line up with their respective cylinders in the pump head. 47

NOTE: The engine adapter bolt holes line up with the holes on the piston housing in one position only. Use the widest of the three openings between the engine adapter legs as a reference. This opening should line up roughly with the chemical injection/thermal relief valve side of the piston housing.

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 Small Frame Gas Pump

Pilot Spacer Installation 1. Grasp the complete pump assembly with both hands and turn it over onto the three (3) engine adapter legs, as shown in Figure 5.19.
Figure 5.19 Invert Pump Assembly

3. Install the three (3) low pressure transfer O-Rings around the inlet openings on the piston housing, as seen in Figure 5.20.
Figure 5.20 Install Pilot Spacers/O-Rings

2. Carefully lift the pump head from the pump and slide the three (3) pilot spacers over the pistons, which will be protruding from the piston housing.

Item 1 2 3 4

Name Pump head Pilot spacer Low pressure transfer O-Ring Piston

48

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 Small Frame Gas Pump

Pump Head Bolts Referring to Figure 5.21, reposition the pump head and install the four (4) M6-1.0 x 35 cap screws.
Figure 5.21 Head Bolt Installation

Oil Fill As shown in Figure 5.22, set the pump on its head. Pour in the specified amount of 80W90 oil through the port used by the engine crankshaft.
Figure 5.22 Oil Fill

Item 1 2 3

Name M6-1.0 x 35 cap screw M6 lock washer Piston & unloader housing attached to engine adapter

Verify that the oil level reaches the upper lip of the piston housing, as shown in Figure 5.23. The pump can now be installed onto the engine.
Figure 5.23 Oil Level

Tighten the M6-1.0 cap screws to the torque value specified in the Torque Chart, found on Figure 5.2 (Exploded View) at the beginning of this chapter.

NOTE: Torque the outlet check valve caps at this time, if not done previously.

For specific recommendations for oil type and capacity, please refer to the table given in Part 1, at the beginning of this section.

49

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 Small Frame Gas Pump

Part 5 - Troubleshooting
Problem
1. Water leakage between pump head and piston housing.

Possible Cause
a. Head bolts improperly torqued. b. Damaged head. c. Missing or damaged o-rings

Corrective Action
a. Torque head bolts. b. Replace head. c. Install new o-rings.

2. Water leaks from pressure out connector.

a. Connector not properly sealed. b. Damaged connector.

a. Seal with teflon tape and tighten properly. b. Replace bad connector.

3. Oil leak between motor and motor adapter.

a. Defective or missing motor adapter o-ring. b. Motor adapter cap screws not tightened properly.

a. Install new o-ring. b. Tighten to correct torque.

4. Oil leak between motor adapter and piston/unloader housing.

a. Missing or bad o-ring seal. b. Cap screws not tightened properly.

a. Install new o-ring seal. b. Tighten to correct torque.

5. Pump does not produce pressure, exhibits erratic pressure, chatters, or has a low water volume.

a. Nozzle is set to low pressure mode. b. Incorrect spray nozzle is used. c. Spray nozzle is obstructed. d. Water Inlet blocked e. Inadequate water supply to pump. f. Water supply hose kinked or leaking. g. Clogged inlet hose strainer. h. Water supply too hot. i. Worn or defective pump.

a. Reset nozzle to high pressure. b. Replace with correct nozzle. c. Clear obstruction from nozzle. d. Clear inlet. e. Provide sufficient water supply. f. Relieve kinking or repair leak. g. Clean strainer. h. Reduce inlet water temperature to below 140oF. i. Disassemble and repair pump.

6. Detergent does not mix with spray.

a. Nozzle is in high pressure mode. b. Chemical suction line is not submerged. c. Chemical suction strainer or line is clogged.

a. Reset nozzle to low pressure. b. Insert line into fluid. c. Clean or replace strainer or line.

50

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

MEDIUM FRAME PUMP


This section describes the medium frame pump assemblies powered by gasoline engines. This medium frame pump may also be referred to as GPW-FH or flat head pumps. The medium frame pump has the following features: 1800 to 2250 PSI water pressure 2.0 to 2.5 Gallons per minute flow Axial Cam Design Ceramic Pistons Easy Start Unloader Adjustable Output Water Pressure Chemical Injection System available Thermal Bypass Valve available Oil Bath Drive System Vertical and Horizontal Engine Mount

Part 1 - Specifications and Views


This section presents the performance specifications for Generac Portable Products medium frame pumps. Also presented are sectional and exploded views of this type of pump assembly. A table listing torque specifications may be found on the exploded view page.
Pump Assembly Part No. A1803 A1803A A1803C A1803C B3166 B3166A B3166C B3166C B3358 B3358 B3358A B3358C B3358D Rated Pressure+ 2250 2000 2200 2200 2250 2000 2000 2000 2250 2250 2000 2200 2000 Flow Rate* 2.222 2.0 2.2 2.2 2.222 2.0 2.2 2.2 2.222 2.5 2.0 2.2 2.2 Unit Style Horizontal Vertical Vertical Horizontal Horizontal Vertical Vertical Horizontal Vertical Horizontal Vertical Vertical Horizontal Engine Shaft Straight Straight Straight Straight Straight Straight Straight Straight Straight Straight Straight Straight Straight Pump Head Piston Material Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Oil Type/ Capacity 80w90 280ml 80w90 305ml 80w90 305ml 80w90 280ml 80w90 280ml 80w90 305ml 80w90 305ml 80w90 280ml 80w90 305ml 80w90 280ml 80w90 305ml 80w90 305ml 80w90 280ml

Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum

Performance Specifications Pump assemblies are listed by part number and were current at time of publication. Other pump assemblies will be added as our product line evolves. + Rated Pressure is given in pounds per square inch. * Flow Rate is given in gallons per minute.

51

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Cross-Sectional View
Figure 6.1 Medium Frame Pump (cross-sectional view)

A typical medium frame pump is shown in cross section in Figure 6.1.

52

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Sectional View Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Qty 3 3 6 3 1 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 Description Outlet port cap O-ring, outlet port Check valve O-ring, check valve Head sub-assembly Bearing ring High pressure seal O-ring, check valve Thermal bypass actuator and stem Trapped line pressure seat Chemical injection venturi Chemical injection spring Chemical injection ball Chemical injection fitting Unloader ball spring Trapped line pressure piston assembly Unloader ball Ball seat assembly Unloader spindle assembly Unloader handle Setscrew, M6-1.0 x 8mm Plastic cap Unloader spring Thermal actuator piston o-ring Thermal actuator spring Thermal actuator piston Piston 43 44 45 46 47 48 49 50 51 41 Item 28 29 30 31 32 33 34 35 36 37 38 39 40 Qty 1 1 1 1 1 1 1 1 1 1 1 4 or 4 4 or 4 3 6 3 1 1 3 1 6 6 Description Oil breather cap Loctite O-ring Axial cam bearing assembly Axial cam Engine adapter Engine adapter bearing Thrust washer O-ring Washer retainer Engine shaft adapter C-ring cam retainer Button head cap screw, 5/16-24 Socket head cap screw, 5/16-24 O-ring, if button head Flat washer, if socket head Piston pivot shoe Socket head cap screw, M6-1.0 Piston return spring Pump crankcase Spacer plate Pilot ring Head gasket Socket head cap screw, M8-1.25 Special steel washer

53

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Exploded View
Figure 6.2 Medium Frame Pump (exploded view)

A typical medium frame pump shown in exploded view in Figure 6.2.

Item 1 11 14 19 29 40 44 50

Torque Value 20-30 ft-lbs 10-12 ft-lbs 9-12 ft-lbs 20-23 ft-lbs 24-36 in-lbs w/Loctite 18-20 ft-lbs 10-12 ft-lbs 18-20 ft-lbs Certain components have been changed, added, or deleted since this Medium Frame pump became available. Always refer to the Owners Manual shipped with each model pressure washer for appropriate part number references.

54

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Exploded View Parts List Item 25 26 27 29 30 31 32 33 34 36 40 41 43 44 45 46 47 48 49 50 51 Qty 1 1 3 1 1 1 1 1 1 1 4 or 4 4 or 4 3 6 3 1 1 3 1 6 6 Description Thermal actuator spring Thermal actuator piston Piston Oil breather cap O-ring Axial cam bearing assembly Axial cam assembly Engine adapter Engine adapter bearing assembly O-ring Button head cap screw, 5/16-24 Socket head cap screw, 5/16-24 O-ring, if button head Flat washer, if socket head Piston pivot shoe Socket head cap screw, M6-1.0 Piston return spring Pump crankcase assembly Spacer plate assembly Pilot ring Head gasket Socket head cap screw, M8-1.25 Steel washer

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Qty 3 3 6 3 1 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Description Outlet port cap O-ring, outlet port Check valve O-ring, check valve Head sub-assembly Bearing ring High pressure seal Check valve Thermal bypass actuator and stem Trapped line pressure seat Chemical injection venturi assembly Chemical injection spring Chemical injection ball Chemical injection fitting Unloader ball spring Trapped line pressure piston assembly Unloader ball Ball seat assembly Unloader spindle assembly Unloader handle Setscrew, M6-1.0 x 8mm Plastic cap Unloader spring Thermal actuator piston o-ring

55

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Part 2 - Disassembly
General Information & Special Tools

1. Referring to Figure 6.3, replace the two (2) M6-1.0 x 20 cap screws (identified with arrows on the figure) with two (2) M6-1.0x 45 hex head bolts. 2. Ensure the two bolts described in (1.) above are tight, then remove the four (4) remaining M6-1.0 x 20 cap screws.

DANGER:The pump removal procedures described in this section must be followed carefully or personal injury could result. During removal of the pump, very powerful springs tend to separate the pump crankcase from the engine adapter. Failure to follow the described procedure may result in a forceful separation of the components. Differences may exist in pump head components. For example, the axial cam used on a pump rated 2.0 gallons per minute must necessarily be different than the axial cam used on a pump rated at 2.5 gallons per minute. Special tools needed: Dead blow hammer 5/16-18 bottoming tap Brass rod, 5mm diameter x 20cm long Pump Head Before removing the pump head, disconnect the inlet water hose from the pumps water inlet. Disconnect the spray gun high pressure hose from the pumps high pressure outlet connector. Disconnect the chemical injection siphon tube from the chemical injection hose barb. Place a shallow pan underneath the pump crankcase to catch pump oil. Remove the pump, as described below:
Figure 6.3 - Pump Head

CAUTION: Do Not attempt to disassemble the pump without installing two longer screws to relieve the spring tension.
3. As indicated in Figure 6.4, start backing out the two bolts installed in (1.). Alternate between the two bolts, using them as a jacking device to separate the pump crankcase from the engine adapter while relieving spring tension from between these two components.
Figure 6.4 - Head Screw Removal

4. As the pump crankcase is separated from the engine adapter, a piston pivot shoe (shown in Figure 6.5) Figure 6.5 - Pivot Shoe may fall out. Ensure that each shoe is identified with the same identification number as the piston it fell away from. Retain each shoe with its piston as a set for later inspection and installation.

56

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Axial Cam Drive Components To disassemble medium frame units, refer to Figure 6.6 and proceed as follows:
Figure 6.6 - Axial Cam Drive Components

Pistons and Piston Springs Refer to Figure 6.7 for this disassembly. The three (3) pistons along with their springs can be removed from the pump crankcase by grasping the springs and pulling straight out.
Figure 6.7 - Piston Assembly

Item 1 2 3 4 5 6 7

Name O-ring Engine adapter Engine adapter bearing assembly Axial cam assembly Roller thrust bearing assembly Button head cap screw O-ring

Item 1 2

Name Spring Piston

1. Remove the pump piston bearing assembly (item 5) as a unit. 2. Remove the axial cam with pressed-in engine shaft adapter, thrust washer and retainers (item 4). 3. Remove the engine adapter bearing assembly (item 3). You may need to use a 90 o-ring pick to pull the bearing race out of the engine adapter housing. 4. Remove the four (4) 5/16-24 screws that retain the engine adapter to the engine. The engine adapter can now be removed. 5. On units so equipped, completely remove the engine adapter gasket. If necessary, remove the pilot sleeve from these older-style engine adapters. This sleeve is secured into the housing with LockTite.

57

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Pump Head To remove the pump head assembly, refer to Figure 6.8 and proceed as follows:
Figure 6.8 Pump Head Removal

Spacer Plate Referring to Figure 6.9, remove the spacer plate from between the crankcase and pump head, as follows:
Figure 6.9 - Spacer Plate Removal

Item Item 1 2 3 4 5 6 7 8 9 Name Spacer plate assembly Head gasket Thermal bypass actuator and stem Chemical injection fitting Chemical injection check ball Chemical injection spring Pump head assembly Steel washer Socket head cap screw 1 2 3 4 5

Name Pump crankcase assembly Pilot spacer Spacer plate Thermal bypass piston Thermal bypass spring

1. Separate the spacer plate from the crankcase, being careful to not damage the thermal bypass spring and piston. 2. Remove the thermal bypass piston and the thermal bypass spring. 3. Remove the three (3) low-pressure water seals from the spacer plate. 4. Completely remove all traces of the head gasket from the mating surface. 5. Remove the three (3) white pilot spacers from the pump crankcase. 6. Using a small flat-blade screwdriver, gently remove the three (3) piston oil seals from the pump crankcase.

1. Remove six (6) M8-1.25 socket head cap screws and M8 washers. 2. Remove the pump head assembly. 3. Remove the thermal actuator stem. 4. Remove the three (3) check valve o-rings. 5. Gently remove the three (3) high pressure seals with a small flat-blade screwdriver. 6. Remove the three (3) plastic bearing rings. 7. Remove the head gasket and any remaining gasket material from mating surfaces. 58

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Inlet Check Valves The three (3) inlet check valves are removed from the pump head with a standard 5/16-18 bottoming tap. 1. As shown in Figure 6.10, gently turn the tap into the check valve with your fingers, approximately three full turns.
Figure 6.10 - Inlet Check Valve Removal

3. Use a 90 o-ring pick to remove the o-ring from the base of the cavity. 4. Repeat steps 2 and 3 for the remaining outlet check valves. Unloader Spindle Assembly Referring to Figure 6.11: 1. Unscrew and remove the unloader handle, turning it counterclockwise.
Figure 6.11 - Unloader/Regulator and Chemical Inject Removal

Item 1 2 Item 1 2 3 4 5 Name Outlet port cap Outlet port cap o-ring Outlet check valve O-ring Pump head with tap threaded into inlet check valve 3 4 5 6 7 8 9 10 11 12 13 14 15

Name Setscrew, M6-1.0 x 8mm Unloader handle Unloader spindle assembly Spring Chemical injection fitting Check ball Trapped line pressure seat Trapped line pressure spring Chemical injection venturi Trapped line pressure piston Unloader ball Ball seat assembly Pump head Unloader spring Plastic cap

2. When securely threaded, gently rock the check valve and withdraw it from its cavity.

CAUTION: Do not turn the tap in too far. An engagement of 2 or 3 threads is sufficient.
Outlet Check Valves Referring to Figure 6.10: 1. Remove the outlet port cap. 2. Grasp the end of an outlet check valve with a needle nose plier and pull it out. 59

3. Carefully loosen and unscrew the unloader spindle assembly with a 19mm deep socket or wrench.

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Chemical Injection System Refer again to Figure 6.11 and follow this procedure to disassemble the rest of the unloader mechanism and the chemical injection system:

Thermal Bypass Actuator Removal 1. Referring to Figure 6.12, secure the pump head to a rigid surface, taking care to not damage the milled surfaces.
Figure 6.12 Thermal Bypass Actuator Removal

CAUTION: Be careful not to lose check ball and


spring. 1. Remove the chemical injection fitting, check ball, and spring. 2. Using a large straight tip screwdriver, unscrew and remove the chemical injection venturi and o-ring from discharge port. Be careful not to strip the venturi slot. It may be necessary to use a sheet metal screw inserted in the center hole of the venturi. Grab the screw with pliers and pull to remove the venturi. 3. Insert a 0.25 diameter, 8 long brass rod through the unloader spindle opening. Push out the trapped line pressure seat, the 9/32 ball, and the rest of the unloader components. It may be necessary to gently tap the end of the rod with the dead blow hammer.

Item 1 2

Name Flat blade screw driver Thermal actuator

2. Insert a medium-sized flat-blade screwdriver in the pump head water passage so that its tip engages the lower lip of the thermal actuator. 3. Pry down on the screwdriver with a constant force, taking care to avoid severely gouging the head surface under the screwdriver. 4. The thermal bypass actuator will slide up and out of the pump head.

60

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Part 3 - Inspection
Seals, O-Rings, and Gaskets Replace seals and gaskets during the reassembly process. Seals Each of the three (3) pump pistons pass through seals in the pump crankcase, spacer plate, and head. Figure 6.13 shows the orientation of each of these seals.
Figure 6.13 Piston Seals

Check Valves The check valves used in the pump illustrated in this chapter are the same for the inlet and outlet, as shown in Figure 6.14.
Figure 6.14 Typical Check Valve

Earlier pump models used inlet check valves different from outlet check valves. Be sure to observe the type of valve as they are removed so that proper reassembly can be performed. Item 1 2 3 4 5 6 7 8 9 Name Pump head Bearing ring High pressure seal Spacer plate Low pressure seal Pilot spacer Oil seal Crankcase Piston Replacement check valves and o-rings are provided in the seal kit. Head Gasket The head gasket is installed between the pump head and the spacer plate. Different versions have been used (two are seen in Figure 6.15), but the current gasket will replace all previous gaskets. Replace the gasket each time the pump is reassembled.
Figure 6.15 Two Types of Head Gaskets

The oil seal in the pump crankcase is oriented with the groove towards the crankcase. If you see the internal spring when installed, the seal is installed backward. The high-pressure seal in the pump head is oriented with the flat surface and writing visible. If you see the grooved surface when installed, the seal is pressed in backwards. Remember that the bearing ring is installed in the head before the seal is pressed in.

61

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Engine Adapter O-Rings Examine the engine adapter o-ring and bolt head o-rings to ensure they are not damaged. Replace the engine adapter gasket each time the unit is reassembled. Newer gaskets can replace older gaskets. Engine Adapter, Pump Crankcase, Spacer Plate and Head Clean all parts. Inspect carefully for cracks, damage, or other defects. Check for corrosion. Replace any damaged, defective, or corroded part as necessary. Axial Cam Drive Components Referring to Figure 6.16, carefully inspect the engine adapter bearing and the axial cam bearing assemblies for wear, damage, freedom of rotation, or evidence of overheating. Replace any damaged or defective bearing assembly.
Figure 6.16 Axial Cam Drive Assembly

Piston & Spring Assemblies Referring to Figure 6.7 (seen earlier), inspect the three (3) pistons carefully. Reject all three pistons if any one piston is scratched, dented, chipped, or otherwise damaged.

WARNING: Do not strike a piston with any object or use a piston to strike any object. Do not drop the piston.
Measure the piston diameter and the piston length (as shown in Figure 6.17). If the values are not within the tolerances specified below, replace all three pistons as a set:
Figure 6.17 Piston Dimensions

Piston diameter: 14.977 mm to 14.985 mm Piston length: 86.65 mm to 90.05 mm Inspect the piston pivot shoes, depicted in Figure 6.18. If damaged, worn, scored, etc., you must replace all three (3) pistons and shoes as a set.
Figure 6.18 Piston Pivot Shoe

Item 1 2 3 4

Name Engine adapter Engine adapter bearing assembly Axial cam assembly Axial cam bearing assembly

Inspect the axial cam assembly and the integral engine shaft adapter, which mates with an engine shaft keyway. This item is factory assembled must be replaced as a unit if the keyway or cam unit is worn or damaged.

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Inspect the three (3) piston springs. Ends must be closed and ground square. Check spring free length and load length as follows, referring to Figure 6.19:
Figure 6.19 Piston Return Spring

High Pressure Outlet/Chemical Injection Assembly Referring to Figure 6.20, inspect the chemical injection and unloader components for signs of damage, obstructions, or wear. Replace any damaged or defective parts as necessary.
Figure 6.20 High Pressure Outlet/Chemical Inject Assembly

Item 1 2

Name Free length Load length

1. Free length should be 62.57 mm (2.463). 2. Apply a force of 51.0 to 56.4 pounds (227.2 to 251.1 Newtons). 3. At the stated load, spring length should be 39.8 mm (1.567). 4. Replace all three (3) springs as a set if any one spring is damaged or broken. Replace the springs as a set if the free length or load length of any one spring does not meet specifications. Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Name Setscrew, M6-1.0 x 8mm Unloader handle Unloader spindle assembly Chemical injection spring Chemical injection fitting Check ball Trapped line pressure seat Spring Venturi assembly Trapped line pressure piston assembly Unloader ball Ball seat assembly Head Unloader spring Plastic cap

63

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Part 4 - Reassembly
Refer to the Torque Specifications provided on the pump exploded view found at the beginning of this section when reassembling this pump. Engine Adapter 1. Early medium frame pumps may have an engine adapter pilot sleeve. Referring to Figure 6.21, apply LOCTITE Permabond No. HM160 to the outside of the larger diameter of the sleeve, then install the sleeve into the engine adapter as follows:
Figure 6.21 Engine Adapter Sleeve

Figure 6.22 Engine Adapter Components

Item 1 2 3 4 5 6 7 Item 1 Name Apply Loctite around the larger circumference of the ring in this area.

Name O-ring Engine adapter Engine adapter bearing assembly Axial cam assembly Axial cam bearing assembly Button head cap screw O-ring

3. Retain the engine adapter to the engine with four (4) 5/16-24x 3/4 screws and four (4) o-rings or washers.

a. From the inside of the engine adapter, press the smaller-diameter end of the adapter sleeve into the large bore of the engine adapter. b. Tap the adapter sleeve into the engine adapter bore until it seats flush against the inside machined surface of the engine adapter. 2. Referring to Figure 6.22, use a new o-ring around the housing pilot or a new engine adapter gasket. Install the engine adapter onto the engine. Note that newer engine adapter castings have the word TOP cast into it. The oil breather designates the top of the pump crankcase. Both top sides must be matched for proper pump operation.

CAUTION: When installing the engine adapter having the O-Ring seals, be sure to use the correct button head cap screws. DO NOT use any other type fastener.
4. Tighten the screws to the torque value specified in the Torque Chart, found on Figure 6.2 (Exploded View) at the beginning of this chapter. 5. Install the engine shaft adapter over the engine shaft, ensuring the key in the axial cam adapter engages the keyway on the engine shaft.

64

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Figure 6.23 Bearing Race Assemblies

and piston shoe bearing race. - The inside diameter of the outer cam bearing race is larger than the piston shoe bearing race. - The piston shoe bearing race may be thicker than the other races. The chamfered edge of the bearing races must face AWAY FROM THE BEARING ROLLERS, as shown in Figure 6.23. Piston Oil Seals and Pistons Refer to Figure 6.24 for this procedure. 1. Pre-lubricate three (3) piston oil seals with 80W90 oil.
Figure 6.24 Piston Oil Seals

Item 1 2 3 4 5 6 7 A B C

Name Engine adapter bearing race Engine adapter bearing Inner cam bearing race Axial cam assembly Outer cam bearing race Axial cam bearing Piston shoe bearing race Larger inside diameter Smaller inside diameter Chamfer faces this way Item 1 2 3 4 5 Name Pilot spacer tang engaged in crankcase locating notch Crankcase locating notch Pump crankcase High pressure oil seal Pilot spacer

Note: inset at lower left shows bearing race cross-section and locations of chamfers.

NOTE: Bearing race inside dimensions are different.


Follow this procedure or the parts wont go together. 6. Install the engine adapter bearing race, followed by the engine adapter bearing and the inner cam bearing race. - The inside diameter of the engine adapter bearing race is larger than the cam bearing race. - The chamfered edge of the bearing races must face AWAY FROM THE BEARING ROLLERS. That is, the flat (unchamfered) side of the race must ride against the rollers, as shown in Figure 6.23. 7. Install the outer cam bearing race, the axial cam bearing 65

2. Press a seal into one of the piston bores provided on the pump crankcase, with the writing on the face of seal toward the installer. Press the seal in until it bottoms. Repeat this step for the two (2) remaining seals. 3. Install the three (3) pilot spacers over the piston oil seals, as shown in Figure 6.24: a. The larger diameter flange of the pilot spacer mates with the crankcase bore. b. The pilot spacer locating tangs must engage the crankcase locating notch, as shown in Figure 6.24.

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

3. Piston assemblies have an integral spring retainer ring. Install the small end of the tapered spring so that it contacts the spring retainer, as seen in Figure 6.25.
Figure 6.25 Return Spring Orientation

6. Install the thermal bypass piston and spring into the socket cast into the upper portion of the pump crankcase, as shown in Figure 6.27. A small amount of petroleum jelly will hold these parts in the crankcase during subsequent assembly tasks.
Figure 6.27 Thermal Bypass Spring and Piston

Item 1 2

Name Return spring Piston Item 1 2 3 4 Name Crankcase Thermal bypass spring Thermal bypass piston Thermal bypass o-ring

4. Apply a small amount of SAE 80W90 oil to the lip of the oil seals and the piston surface. 5. Install each piston through the spring, crankcase, oil seal, and pilot spacer, as shown in Figure 6.26.
Figure 6.26 Piston Installation

Item 1 2 3 4 5

Name Return spring Pump crankcase Piston oil seal Pilot spacer Piston 66

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Spacer Plate 1. Install the three (3) low pressure seals into the bores provided in the spacer plate. Make sure the seals groove side is inserted into the spacer plate bore, as shown in Figure 6.28.
Figure 6.28 Low Pressure Seal Orientation

High Pressure Seal Assembly Refer to Figure 6.29 for this assembly.
Figure 6.29 High Pressure Seal Assembly

Item 1 2

Name Low pressure seal Spacer plate Item 1 2 3 Name High pressure seal Bearing ring Pump head

2. Align the mounting holes in the spacer plate with the threaded holes in the pump crankcase. Align the low pressure seal bores of the spacer plate with the pistons protruding from the crankcase. And align the thermal bypass piston with its seat on the spacer plate. With all components aligned, push down on the spacer plate. The pilot spacers should engage the low pressure seal bores of the spacer plate. 3. Ensure that the thermal bypass piston remains aligned with its mating seat on the spacer plate.

1. Insert a bearing ring into each of the heads piston cylinders, small end first. Ensure that the ring is fully seated on its boss. 2. Pre-lubricate the three (3) high pressure seals with silicone spray. 3. Insert a seal in each piston cylinder so that the groove side goes in first. A properly inserted seal has its flat side out and nearly flush with the machined head surface.

67

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Check Valve Assembly Refer to Figure 6.30 for this assembly.


Figure 6.30 Check Valve Assembly

a. Check that the actuator is fully seated. b. Make sure the small actuating stem is installed into the actuator. Petroleum jelly may be used to ensure that the actuating stem stays in place for the remainder of the assembly process. 3. Install the three (3) inlet check valves: a. Align a check valve with its bore in the pump head so that the o-ring end is up. b. Push the check valve down into the head until it seats. The valve will be just overflush with the surrounding machined surface. c. Install the two remaining inlet check valves in the same manner. 4. Install the three (3) outlet check valves: a. Position the pump head so that the outlet check valve ports are up. b. Install an o-ring seal into the bottom of each check valve port. c. Align a check valve with the port so that the o-ring end goes in first. d. Press the check valve into the bore. e. Ensure that an o-ring is installed on an outlet port cap. f. Hand thread the cap into the port containing an installed check valve. g. Tighten the outlet port cap to the torque value specified in the Torque Chart, found on Figure 6.2 (Exploded View) at the beginning of this chapter. Note that final tightening is best performed after the pump is completely reassembled. h. Repeat steps e to g to install the two remaining outlet check valves.

Item 1 2 3 4 5 6 7

Name Outlet check valve port cap Cap o-ring Check valve Check valve o-ring Pump head Thermal actuator stem Thermal actuator

1 Lay the pump head on a flat surface so that its machined surfaces are up. 2. Press the thermal bypass actuator into its recess in the pump head. 68

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

High Pressure Outlet and Chemical Injection Assembly Refer to Figure 6.31 for this assembly.
Figure 6.31 High Pressure Outlet and Chemical Injection

a. Ball seat assembly, o-ring end first. b. Stainless steel ball. c. Trapped line pressure seat, slotted end first. d. Trapped pressure piston assembly, o-ring end first. e. Trapped pressure return spring 6. Ensure that an o-ring is installed on the chemical injection venturi. 7. Insert and hand thread the chemical injection venturi into the head. 8. Carefully tighten the venturi to the torque value specified in the Torque Chart, found on Figure 6.2 (Exploded View) at the beginning of this chapter. Avoid stripping out the slot. Unloader Spindle Assembly Refer to Figure 6.32 for this assembly.
Figure 6.32 Unloader Spindle Assembly

Item 1 2 3 4 5 6 7 8 9 10

Name Chemical injection fitting Check ball Spring Ball seat assembly Unloader ball Trapped line pressure seat Trapped line pressure piston assembly Spring Venturi assembly Head assembly Item 1 2 3 4 5 6 Name Plastic cap Setscrew, M6-1.0 x 8mm Unloader handle Spring Unloader spindle assembly Head assembly

1. Install the check ball into the chemical injection fitting, followed by the spring (with the small end of the spring towards the ball). 2. Install the chemical injection fitting into the pump head. Be careful not to drop the ball and spring. 3. Tighten the chemical injection nipple to the torque value specified in the Torque Chart, found on Figure 6.2 (Exploded View) at the beginning of this chapter. 4. Lightly coat the high pressure port components with silicone spray. 5. Insert the following components into the pump head in the order listed (refer to Figure 6.31): 69

1. Lightly coat the unloader spindle threads and o-rings with silicone spray. 2. Insert the spindle into the bore provided on the pump head and hand start the threads. 3. Tighten the spindle assembly to the torque value specified in the Torque Chart, found on Figure 6.2 (Exploded View). The unloader spindle assembly is preset at the factory and does not need adjustment.

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Pump Head Installation Referring to Figure 6.33, install the pump head onto the pump spacer plate, as follows:
Figure 6.33 Pump Head Installation

4. Align the pump head with the pistons protruding from the spacer plate and gently press the head into place.

CAUTION: Make sure the small stem of the


thermal bypass actuator does not fall out during installation of the pump head. 5.Install six (6) M8-1.25 socket head cap screws with six (6) M8 washers. 6. Tighten the socket head screws in the order shown on Figure 6.34 to the torque value specified in the Torque Chart, found on Figure 6.2 (Exploded View) at the beginning of this chapter.
Figure 6.34 Head Bolt Tightening Sequence

Item 1 2 3 4 5 6 7

Name Crankcase assembly, including pistons and thermal bypass components Spacer plate Head gasket Check valve o-rings (3) Pump head assembly, including thermal bypass stem Steel washer (6) M8-1.25 socket head cap screw (6)

1. Install three (3) inlet check valve o-rings over the installed check valves using a dab of petroleum jelly. 2. Set the head gasket into place on the spacer plate with its holes properly aligned with mating spacer plate holes. 3. Ensure that the thermal bypass piston is properly aligned with its seat in the spacer plate.

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Main Component Assembly Before installing the pump onto the engine, place the engine with its shaft in a vertical position and facing the installer. Make sure the engine adapter has been properly installed to the engine. Also check that the axial cam drive components are installed properly. The pump may now be installed as follows: 1. Install a new o-ring seal around the mounting flange of the pump crankcase. 2. To aid reassembly, apply a dab of petroleum jelly to the piston pivot shoes, in the area indicated by item 1 in Figure 6.35.
Figure 6.35 Piston Pivot Shoes

Figure 6.36 Jacking Bolt Locations

5. Lower the pump toward the engine adapter. Align the crankcase and engine adapter mounting holes and also position the three piston pivot shoes so that they engage the axial cam bearing race properly. 6. When you are sure the pump crankcase and piston pivot shoes are properly aligned and positioned, thread the two long hex head bolts into the engine adapter mounting holes. 3. Place the piston pivot shoes onto the tips of the three pistons. The grease should hold the shoes in place. 4. Insert two (2) M6-1.0 x 45mm hex head bolts through mounting holes in the pump crankcase, 180 apart, and at the locations shown in Figure 6.36. These are the two long jacking screws. 7. Visually verify that the piston shoes remain properly seated on the bearing race as you tighten the two screws alternately. 8. When the two jacking bolts are tight, install four (4) M61.0 socket head cap screws through the mounting holes of the pump crankcase. Thread them into the mounting holes of the engine adapter until they are snug. 9.Remove the two (2) jacking hex head bolts and replace them with the two (2) remaining M6-1.0 socket head cap screws. 10. When all six (6) socket head cap screws are snugged down, tighten them to the torque value specified in the Torque Chart, found on Figure 6.2 (Exploded View) at the beginning of this chapter.

71

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Oil Fill Before filling the pump crankcase with oil, ensure that the head screws, outlet port caps, and crankcase screws are tightened to the torque value specified in the Torque Chart, found on Figure 6.2 (Exploded View) at the beginning of this chapter. Referring to Figure 6.37, insert a funnel into the Oil Fill/Breather cap threaded opening at top of the pump crankcase. Add the amount and type of oil recommended in the table in Part 2 of the Common Pump Components section, earlier in this manual.
Figure 6.37 Pump Oil Fill Location

Item 1 2 3

Name Funnel Breather cap Assembled pump/crankcase

72

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Part 5 - Troubleshooting
Problem 1. Water leakage at mating flanges. Possible Cause
a. Head bolts improperly torqued. b. Damaged head. c. Missing or damaged o-rings

Corrective Action
a. Torque head bolts. b. Replace head. c. Install new o-rings.

2. Water leakage from chemical

injector.

a. Chemical injection fitting improperly torqued. b.Check ball missing. c. Check ball stuck.

a. Torque fitting. b. Replace check ball and spring. c. Remove, clean and replace fitting, ball and spring. a. Torque head bolts. b. Install good head gasket. c. Replace head. d. Install new o-rings. a. Seal with teflon tape and tighten properly. b. Replace bad connector.

3. Water leakage between pump head

a. Head bolts improperly torqued. b. Defective head gasket. c. Damaged head. d. Missing or damaged o-rings.

and spacer plate.

4. Water leaks from high pressure out

a. Connector not properly seated. b. Damaged connector.

connector.

5. Water leaking out of head bolts.

a. Defective or missing head gasket. b. Head bolts improperly torqued. c. Porosity in spacer plate.

a. Install new head gasket. b.Torque head bolts properly. c. Replace spacer plate. a. Install thermal bypass piston. b. Install new spring. c. Install new o-ring. d. Install new low pressure seals.

6. Water leaking out behind spacer

plate.

a. Thermal bypass piston missing or defective. b. Bad or missing thermal bypass piston spring. c. Bad o-ring on thermal bypass piston. d. Low pressure water seals leaking.

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 Medium Frame Pump

Part 5 - Troubleshooting (Continued)

Problem
7. Oil leak between engine and engine adapter.

Possible Cause
a. Defective or missing engine adapter oring or gasket. b. Engine adapter cap screws not tightened properly.

Corrective Action
a. Install new o-ring or gasket. b. Tighten to correct torque.

8. Oil leak between engine adapter and pump crankcase.

a. Missing or bad o-ring seal. b. Cap screws not tightened properly. a. Missing or bad low pressure seals. b. Missing or bad piston oil seal. c. Cracks in casting.

a. Install new o-ring seal. b. Tighten to correct torque. a. Install new seals. b. Install new oil seals. c. Replace cracked casting. a. Reset nozzle to high pressure. b. Replace with correct nozzle. c. Clear obstruction from nozzle. d. Clear inlet. e. Provide sufficient water supply. f. Relieve kinking or repair leak. g. Clean strainer. h. Reduce inlet water temperature to below 140oF. i. Disassemble and repair pump. j. Set valve to high pressure. k. Remove, clean and replace chemical injection components. a. Reset nozzle to low pressure. b. Insert line into fluid. c. Clean or replace strainer or line.

9. Oil leak between pump crankcase and spacer plate.

a. Nozzle is set to low pressure mode. 10. Pump does not produce pressure, exhibits erratic pressure, chatters or has b. Incorrect spray nozzle is used. a low water volume. c. Spray nozzle is obstructed. d. Water Inlet blocked e. Inadequate water supply to pump. f. Water supply hose kinked or leaking. g. Clogged inlet hose strainer. h. Water supply too hot. i. Worn or defective pump. j. Unloader-regulator valve set wrong. k. Obstructed nozzle oe chemical venturi.

11. Detergent does not mix with spray.

a. Nozzle is in high pressure mode. b. Chemical suction line is not submerged. c. Chemical suction strainer or line is clogged.

74

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

LARGE FRAME PUMP


This section describes the large frame pump assemblies powered by gasoline or diesel engines intended for use in heavy duty applications. This large frame pump may also be referred to as a GPW pump. Most of the information previously printed in publication 97492 will be found here. The large frame pump has the following features: 1500 to 3000 PSI water pressure 2.0 to 3.0 Gallons per minute flow Axial Cam Design QPQ, Stainless Steel, or Ceramic Pistons Easy Start Unloader Adjustable Output Water Pressure Chemical Injection System available Brass heads (above 2200psi) Aluminum heads (2200psi and below) Thermal Relief Valve Oil Bath Drive System

Part 1 - Specifications and Views


This section presents the torque and performance specifications for Generac Portable Products large frame pumps. Also presented are sectional and exploded views of this type of pump assembly.
Pump Assembly Part No. 21300A 21300B 21300D 21300E 95523A 95523B 95523C 95523D 95523E 95523F 95523G 97239A 97239B 97239C 99750A 99750G Rated Pressure+ 2250 2700 2600 2900 1500 1800 1500 1500 2000 2200 2500 1600 1900 2600 2500 3000 Engine Shaft Straight Straight Tapered Tapered Straight Straight Straight Straight Tapered Tapered Tapered Straight Straight Straight Tapered Tapered Pump Head Flow Rate* Piston Material Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Oil Type/ Capacity 80W90/300ml 80W90/285ml 80W90/285ml 80W90/285ml 80W90/285ml 80W90/285ml 80W90/285ml 80W90/285ml 80W90/285ml 80W90/285ml 80W90/285ml 80W90/285ml 80W90/285ml 80W90/285ml 80W90/285ml 80W90/285ml

Aluminum Brass Brass Brass Aluminum Aluminum Aluminum Aluminum Brass Brass Brass Aluminum Aluminum Brass Brass Brass

2.2 2.5 2.6 2.9 2.0 2.3 3.0 2.0 3.0 3.0 3.0 2.0 2.5 3.0 3.0 2.5

Performance Specifications + Pressure (in pounds per square inch) is adjustable up to the unit's rated pressure. * Flow rate is given in gallons per minute. Pump assemblies are listed by part number and were current at time of publication. Other pump assemblies will become available as our product evolves. 75

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Cross-Sectional View

A typical large frame pump is shown in cross-sectional view in Figure 7.1.

Figure 7.1 Large Frame Pump (cross-sectional view)

76

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Sectional View Parts List

Item 1 2 3 4 5 6 7 8 9 10 11 12 13

Qty 1 3 3 1 1 3 1 1 1 1 1 1 1

Description Unloader-pressure regulator assembly Socket head cap screw, M6-1.0 x 45mm M6 ribbed lock washer Pump head assembly O-ring Piston pivot shoe Axial cam bearing Axial cam Engine adapter Engine adapter bearing Thrust washer Engine pilot sleeve Retainer washer

Item 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Qty 1 1 1 4 6 6 6 6 1 1 4 4 1 1

Description Straight engine shaft adapter C-ring cam retainer Engine adapter gasket Socket head cap screw, 5/16-24 M6 ribbed lock washer Socket head cap screw, M6-1 x 20mm Socket head cap screw, M8-1.25 x 0.75 M8 ribbed lock washer Engine adapter o-ring Tapered engine shaft adapter O-ring Button head cap screw, 5/16 - 24 Belleville washer Jam nut

77

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Exploded View
Figure 7.21 Large Frame Pump (exploded view)

A typical large frame pump is shown in exploded view in Figure 7.2.

Torque Chart
Item Torque Value 5-8 ft-lbs 12-18 ft-lbs 5-8 ft-lbs 18-20 ft-lbs 8-10 ft-lbs 10-15 in-lbs w/Loctite in Aluminum head:12-15 ft-lbs in Brass head: 15-17 ft-lbs 5-8 ft-lbs 180 in-lbs max. (if equipped)

The larger view above is a typical tapered engine shaft parts group. The inset is a typical straight engine shaft adapteraxial cam parts group. Certain components have been changed, added, or deleted since this large frame pump began production. Always refer to the Owners Manual shipped with each model pressure washer for appropriate part number references.

2 17 19 20 25 30 41 41 49 Drain plug

78

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Exploded View Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Qty 1 3 3 1 1 3 1 1 1 1 1 1 1 1 1 1 4 6 6 6 6 1 1 4 4 Description Unloader-pressure regulator assembly Socket head cap screw, M6-1.0 x 45mm M6 ribbed lock washer Pump head assembly O-ring Piston pivot shoe Axial cam bearing Axial cam Engine adapter Engine adapter bearing Thrust washer Engine pilot sleeve Retainer washer Straight engine shaft adapter C-ring cam retainer Engine adapter gasket Socket head cap screw, 5/16-24 x 0.75 M6 ribbed lock washer Socket head cap screw, M6-1 x 20mm Socket head cap screw, M8-1.25 x 0.75 M8 ribbed lock washer Engine adapter o-ring Tapered engine shaft adapter O-ring Button head cap screw, 5/16-24 x 0.75 Item 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 Qty 1 1 3 3 1 1 3 3 3 3 3 3 3 3 3 1 1 1 3 3 3 3 3 1 1 1 1 1 1 1 Description Belleville washer Jam nut Piston Piston return spring Breather cap Pump crankcase Oil piston seal Pilot spacer Low pressure water seal High pressure seal Bearing seal ring Backup ring O-ring High pressure port tower Check valve guide Pipe plug, 1/8 NPT Cylinder head Handle Check valve guide Check valve poppet O-ring Backup ring Check valve support Garden hose connector Thermal bypass actuator Head gasket Spacer plate O-ring Thermal bypass piston Thermal bypass spring

79

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Part 2 - Disassembly
General Information & Special Tools

Figure 7.3 - Pump Head

DANGER: The pump removal procedures described in this section must be followed carefully or personal injury could result. During removal of the pump, extremely powerful springs tend to separate the pump head from the engine adapter. Failure to follow the described procedure may result in a forceful separation of the head from the adapter.
Because different pressure washer models may use different engines, some differences may exist between pressure washer pumps. Such differences will be found primarily in the engine adapter section of the pump. For example, some engines feature a tapered crankshaft while others may be equipped with a straight shaft. And, of course, the engine adapter itself must be designed for attachment to a specific engine. In addition, some pumps may be equipped with ball cam bearings while others have roller cam bearings. Differences may also exist in pump head components. The axial cam used on a pump rated 2.5 gallons per minute, for example, must necessarily be different than the axial cam used on a pump rated at 3 gallons per minute. Special tools needed: Special engine shaft adapter puller tool, Generac Portable Products part number SRV95523 Dead blow mallet 0.25 dia. 7 long brass rod Pump Head Before removing the pump head, disconnect the inlet water hose from the pumps water inlet. Also disconnect the spray gun high pressure hose from the pumps water outlet connector. With the hoses disconnected, remove the pump: 1. Referring to Figure 7.3, replace the two (2) M6-1.0 cap screws with two (2) M6-1.0 x 45mm hex head bolts. 2. Ensure the two bolts described in (1.) above are tight, then remove the four (4) remaining M6-1.0 cap screws. 3. As depicted in Figure 7.4, start backing out the two bolts installed in (1.). Alternate between the two bolts, using them as a jacking device to separate the pump crankcase from the engine adapter while relieving spring tension from between these two components.
Figure 7.4 - Head Screw Removal

CAUTION: Do Not attempt to disassemble the pump without installing two longer screws, as described, to relieve the spring tension.
80

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

4. As the pump crankcase is separated from the engine adapter, three (3) piston pivot shoes (shown in Figure 7.5) will fall out. Retain the shoes for later inspection and installation.

Figure 7.5 - Pivot Shoe

3. Remove the engine adapter bearing assembly. 4. Remove the M16-1.50 Jam Nut and the Belleville washer. 5. Remove the axial cam. 6. Referring to Figure 7.7, use a special engine shaft adapter puller tool to remove the engine shaft adapter:
Figure 7.7 - Puller Tool on Tapered Shaft

Axial Cam Drive Components - (Tapered Engine Shaft) On units with tapered engine shafts, the engine shaft adapter is retained to the engine shaft by means of an M16-1.50 Jam Nut and a Belleville washer. To remove the axial cam drive components from the engine shaft, proceed as follows, referring to Figure 7.6:
Figure 7.6 - Axial Cam Drive Components (Units with Tapered Engine Shaft)

a. Attach the tool to the threaded portion of the engine shaft adapter. b. Turn the bolt on the tool firmly against the engine tapered shaft, putting tension on the engine adapter. Then strike the bolt head with a dead blow mallet. c. Continue tightening the tool bolt against the engine shaft and striking with the mallet until the engine shaft adapter is completely free of the engine shaft. Remove the engine shaft adapter. 7. Remove four (4) 5/16-24 socket head or button head cap screws that retain the engine adapter to the engine. Remove the engine adapter. The large o-ring seal or gasket found between the engine adapter flange and pump crankcase flange can also be removed. 8. If necessary, remove the engine adapter sleeve from an older-model engine adapter. New models have an integral engine adapter pilot.

Item 1 2 3 4 5 6 7 8

Name O-ring Engine Adapter Roller Thrust Bearing Engine Shaft Adapter Axial Cam Bearing Assembly Belleville washer Jam nut

1. Remove the pump head, as described previously. 2. Remove the axial cam bearing assembly. Some models will have a ball bearing, some a roller bearing. KEEP BEARING RACES AND BEARINGS TOGETHER AS A SET. 81

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

9. Remove all traces of the engine adapter gasket or o-ring. Use a new gasket or o-ring each time the engine adapter is installed. Axial Cam Drive Components - (Straight Engine Shaft) On units with straight engine shafts, proceed as follows, referring to Figure 7.8.
Figure 7.8 - Axial Cam Drive Components (Units with Straight Engine Shaft)

Pistons and Piston Springs Refer to Figure 7.9 for this disassembly. The three (3) pistons along with their springs can be removed from the pump crankcase by grasping the springs and pulling straight out.
Figure 7.9 - Piston Assembly

Item 1 2 3 4 Item 1 2 3 4 5 6 7 8 Name Engine adapter Roller thrust bearing assembly C-ring cam retainer Washer retainer Thrust washer Engine shaft adapter Axial cam Piston pivot bearing assembly

Name Return spring Piston Retainer Lock ring

Newer model pumps have the retaining ring attached permanently to the piston (upper illustration). On older models, the springs are retained by spring retainers and a lock ring. It is not necessary to remove the spring retainer and lock ring unless they are obviously damaged and require replacement. Regulator/Unloader Valve Referring to Figure 7.10, remove the three (3) M6-1.00 unloader cap socket screws and M6 ribbed lock washers.
Figure 7.10 Unloader Valve Removal

1. Remove the axial cam bearing, the axial cam, and the engine adapter bearing assembly as a unit. Bearings may be either ball or roller bearing type, depending on the pump model. 2. Remove the engine shaft adapter, thrust washer and retainer washer 3. Remove the four (4) 5/16-24 socket head or button head cap screws that retain the engine adapter to the engine. The engine adapter can now be removed. 4. Remove the engine adapter gasket completely. 82

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Figure 7.11 depicts the Unloader/Pressure Regulator Valve assembly in cross sectional view.
Figure 7.11 - Pressure Regulator/Unloader Valve Assembly

Item 1 2 3 4 5 6 7 8 9 10

Name Adapter housing O-ring Bushing 11/32 ball Magnet Magnet stop ring Guide Guide plug Support ring Elastic pin

Item 11 12 13 14 15 16 17 18 19 20

Name Guide stem Support ring Piston Zinc plated nut Regulator spring Spring guide stop Knob insert Pressure knob Self locking nut Piston seal

Item 21 22 23 24 25 26 27 28 29 30

Name Stainless steel spring Chemical injector body Stop ring Washer Hose barb coupling Adjusting screw Chemical injection knob Hose barb connection 7/32 ball Taper spring

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Cylinder Head

NOTE: Some pump models feature a BRASS


cylinder head, some an ALUMINUM cylinder head. To remove the pump cylinder head, refer to Figure 7.12 and proceed as follows: 1. Remove six (6) M8-1.25 socket head cap screws and M8 ribbed lock washers.
Figure 7.12 Pump Head Removal

To remove the three (3) inlet (low pressure) check valves, refer to Figure 7.14 and proceed as follows:
Figure 7.13 Check Valve Puller

1. Insert the T handle through the puller tool thimble (item 1). 2. Turn the puller upper tee handle clockwise until the
Figure 7.14 Inlet Check Valve Removal

Item 1 2 3 4 5 6 7 8

Name Spacer plate Head gasket Thermal bypass Plug Cylinder head Lock washer Socket head cap screw Inlet water connector/filter Item 1 2 3 4 Name Puller tool O-ring Check valve Backup ring

2. Remove the cylinder head and head gasket. To disassemble the head and remove the check valves, refer to Figures 7.13 to 7.15 and proceed as follows: A special puller tool (included in Generac Portable Products kit number SRV95523) is used to remove the inlet and outlet check valves. As shown in Figure 7.13, the tool consists of a threaded (7/16-20) tee handle arrangement. Three (3) inlet and three (3) outlet check valves are threaded (7/16-20) to accept the threaded tee handle. 84

puller threads have engaged the check valve threads.

NOTE: Do not turn the tool in too far. An


engagement of 2 or 3 threads is sufficient. 3. With the puller threads engaged in the check valve threads, hold the upper T handle and keep it from turning while you turn the tool lower T handle clockwise. 4. Repeat steps 2 and 3 for the other inlet check valves.

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

To remove the three (3) outlet (high pressure) check valves, refer to Figure 7.15 and proceed as follows:
Figure 7.15 Outlet Check Valve Removal

Thermal Bypass Actuator Removal Refer to Figure 7.16 and:


Figure 7.16 Thermal Bypass Actuator Removal

Item 1 2 3 4

Name Puller tool Backup rings Check valve O-rings

Item 1 2 3 4 5 6 7 8

Name Pump crankcase Spring O-ring Spacer plate Head gasket Pump head Insert brass rod here Thermal bypass actuator

1. Insert the T handle through the puller tool thimble (item 1). 2. Turn the puller lower tee handle fully counterclockwise. 3. Insert the puller down through the high pressure port tower. 4. Turn the puller upper tee handle clockwise until the puller threads have engaged the check valve threads.

1. Remove the small bypass piston. 2. Obtain a brass rod approximately 1/4 (5.35 mm) in diameter and 7 long. 3. Insert rod from the unloader/pressure regulator valve side of the head. 4. Tap the rod gently with the dead blow hammer to free the actuator.

NOTE: Do not turn the tool in too far. An engagement of 2 or 3 threads is sufficient.
5. With the puller threads engaged with the check valve threads, turn the tool lower handle clockwise to remove the check valve. Both the high pressure port tower and the outlet check valve will be removed. 6. Repeat steps 2 to 5 for the other outlet check valves.

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Spacer Plate Referring to Figure 7.17, remove the spacer plate from between the crankcase and pump head, as follows:
Figure 7.17 - Spacer Plate Removal

1. If present, remove two (2) M5-0.80 x 20mm truss head bolts along with the o-ring seal on each bolt. 2. Separate the spacer plate from the crankcase. 3. Remove the three (3) white pilot spacers. 4. Remove the three (3) piston oil seals from the pump crankcase. 5. Remove the thermal bypass piston and the thermal bypass spring. 6. Completely remove all traces of the head gasket from the mating surface.

Item 1 2 3 4 5 6

Name Thermal bypass spring Thermal bypass piston & o-ring Spacer plate Low pressure seal Pilot spacer Piston oil seal (in crankcase)

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Part 3 - Inspection
Seals, O-Rings, and Gaskets Replace seals and gaskets during the reassembly process. Oil Seals Each of the three (3) pump pistons pass through an oil seal in the pump crankcase. The inset in Figure 7.18 shows that the lip of the the spacer plate low-pressure oil seal points into the opening.
Figure 7.18 Oil Seals

Figure 7.19 Inlet Check Valve

Outlet Check Valve Seals The three (3) outlet check valves are assembled into the head with the components shown in Figure 7.20.
Figure 7.20 Outlet Check Valve Parts

Item 1 2

Name Spacer plate Oil seal

Inlet Check Valve Seals An inlet check valve is shown in Figure 7.19. The three (3) inlet check valves are pressed into cylindrical openings machined in the pump head, followed by an o-ring seal, backup ring, and check valve seat support.

Item 1 2 3 4 5 6 7

Name High pressure seal Bearing seal ring Backup ring O-ring High pressure port tower Check valve Cylinder head

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Head Gasket A head gasket, depicted in Figure 7.21, is installed between the pump head and the spacer plate. Replace the gasket each time the pump is reassembled.
Figure 7.21 Two Types of Head Gaskets

Engine Adapter, Pump Crankcase, Spacer Plate and Head Clean all parts. Inspect carefully for cracks, damage, and so forth. Check for corrosion. Replace any damaged, defective, or corroded part as necessary. Axial Cam Drive Components Units with Tapered Engine Shaft: If so equipped, carefully inspect the engine adapter sleeve (seen later in Figure 7.28). Replace if worn or damaged. The engine adapter sleeve is retained to the engine adapter with Permabond No. HM160 LOCTITE. Referring to Figure 7.23, inspect the engine adapter bearing and the axial cam bearing assemblies for wear, damage, freedom of rotation, and evidence of overheating. Replace any damaged or defective bearing assembly.
Figure 7.23 - Axial Cam Drive Components (Units with Tapered Engine Shaft)

Engine Adapter Gasket On models so equipped, replace the engine adapter gasket, seen in Figure 7.22, whenever the engine adapter has been removed.
Figure 7.22 Engine Adapter Gasket

Item 1 2 3 4 5 6

Name O-ring Engine Adapter Roller Thrust Bearing Engine Shaft Adapter Axial Cam Bearing Assembly

Later model pumps use a flange o-ring and bolt head o-ring seals instead of the engine adapter gasket. 88

Check the axial cam for wear, damage, scoring, overheating, grooving, etc. Replace if worn excessively or damaged. Inspect the engine shaft adapter. Check for evidence of scoring, wear, damage, overheating. Replace if necessary.

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Inspect the jam nut and the Belleville washer for wear or damage. Replace if necessary. Units with Straight Engine Shaft: Referring to Figure 7.24, carefully inspect the engine adapter bearing and the axial cam bearing assemblies for wear, damage, freedom of rotation, or evidence of overheating. Replace any damaged or defective bearing assembly.
Figure 7.24 - Axial Cam Drive Components (Units with Straight Engine Shaft)

Piston & Spring Assemblies Referring to Figure 7.9 (seen earlier), inspect the three (3) pistons carefully. Replace all three pistons and piston shoes as a set if any one piston is scratched, dented, chipped, or otherwise damaged.

CAUTION: Do not strike a piston with any object or use a piston to strike any object. Do not drop the piston. Dropping the piston will result in damage.
Measure the piston diameter and the piston length (as shown in Figure 7.25). If the values are not within the tolerances specified below, replace all three pistons as a set:
Figure 7.25 Piston Dimensions

Piston diameter: 14.977 mm to 14.985 mm Item 1 2 3 4 5 6 7 8 Name Engine adapter Roller thrust bearing assembly C-ring cam retainer Washer retainer Thrust washer Engine shaft adapter Axial cam Piston pivot bearing assembly Piston length: 86.65 mm to 90.05 mm Inspect the piston pivot shoes, depicted in Figure 7.26. Replace pistons and shoes as a set, if damaged.
Figure 7.26 Piston Pivot Shoe

Check the engine shaft adapter assembly (items 3, 4, 5, and 6), which is a part of the axial cam. Since these parts require factory assembly, they must be replaced as a set. The adapter has a built-in key which mates with an engine shaft keyway. Replace if worn or damaged.

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

On units so equipped, inspect the three (3) lock rings and the three (3) spring retainers; replace if damaged. Inspect the three (3) piston springs. Ends must be closed and ground square. Check spring free length and load length as follows, referring to Figure 7.27:
Figure 7.27 Piston Return Spring

Item 1 2

Name Free length Load length

1. Free length should be 62.57 mm (2.463). 2. Apply a force of 51.0 to 56.4 pounds (227.2 to 251.1 Newtons). At the stated load, spring length should be 39.8 mm (1.567). Replace any spring that is damaged or broken. replace spring if free length or load length is not as stated. Unloader-Pressure Regulator Valve Refer to Figure 7.11, seen earlier. Replace any damaged or defective parts as necessary.

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Part 4 - Reassembly
Refer to the Torque Specifications provided on the pump sectional view found at the beginning of this section when reassembling this product. Engine Adapter Units with Tapered Engine Shaft: 1. Units with a tapered engine shaft may have an engine adapter sleeve. Referring to Figure 7.28, apply LOCTITE Permabond No. HM160 to the outside of the larger diameter of the sleeve, then install the sleeve into the engine adapter as follows:
Figure 7.28 Engine Adapter Sleeve

Figure 7.29 Engine Adapter Attachment (Units with Tapered Engine Shaft)

Item 1 2 3 4 5 6 7 8 9 Item 1 Name Apply Loctite around the larger circumference of the ring in this area. 10

Name Engine adapter gasket Engine adapter Engine adapter bearing assembly Engine shaft adapter Axial cam Axial cam bearing assembly Belleville washer Jam nut Socket head cap screw Lock washer

a. From the inside of the engine adapter, press the smaller-diameter end of the adapter sleeve into the large bore of the engine adapter. b. Tap the adapter sleeve into the engine adapter bore until it seats flush against the inside machined surface of the engine adapter. 2. Position the engine with engine shaft facing up. Referring to Figure 7.29: a. Use a new adapter gasket and install the engine adapter onto the engine.

b. Orient the TOP mark in engine adapter with top of engine and fasten the engine adapter to the engine with four (4) 5/16-24 socket head cap screws and four (4) M8 ribbed lock washers. c. Tighten the cap screws to the torque value specified in the Torque Chart, found on Figure 7.2 (Exploded View) at the beginning of this chapter.

NOTE: When installing the engine adapter having the glued-in sleeve, be sure to use the correct socket head cap screws. Pump assemblies used on engines with straight (non-tapered) shafts use 5/16-24 x 3/4 long cap screws. Pumps on engines with tapered shafts use 5/16-24 x 1 long cap screws.
3. Install the engine shaft adapter over the tapered engine shaft, as shown in Figure 7.29. 91

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

4. Install the engine adapter bearing race, followed by the engine adapter bearing and the inner cam bearing race. Refer to Figure 7.30.
Figure 7.30 Bearing Race Assembly

5. Install the axial cam (with cam surface facing you) over the engine shaft adapter. Push the cam toward the engine until it seats against the engine adapter bearing race. 6. Again referring to Figure 7.30. install the outer cam bearing race, axial cam bearing and piston shoe bearing race. a. For ROLLER BEARINGS, the chamfered edge of the bearing races must face AWAY FROM THE BEARING ROLLERS. That is, the flat (unchamfered) side of the race must ride against the rollers. The inside diameter of the outer cam bearing race is larger than the piston shoe bearing race. b. For BALL BEARINGS, the bearing races are grooved to accept the bearing balls. MAKE SURE THE BEARING BALLS ARE RIDING IN THE BEARING RACE GROOVES. 7. Install the Belleville washer and the M16-1.50 jam nut over the engine tapered shaft. Tighten the M16-1.50 jam nut to the torque value specified in the Torque Chart, found on Figure 7.2 (Exploded View) at the beginning of this chapter.

Item 1 2 3 4 5 6 7 A B C

Name Engine adapter bearing race Engine adapter bearing Inner cam bearing race Axial cam assembly Outer cam bearing race Axial cam bearing Piston shoe bearing race Larger inside diameter Smaller inside diameter Chamfer faces this way

Note: Inset at lower left shows bearing race cross-section and locations of chamfers a. For ROLLER BEARINGS, the chamfered edge of the bearing races must face AWAY FROM THE BEARING ROLLERS. That is, the flat (unchamfered) side of the race must ride against the rollers. b. For BALL BEARINGS, the bearing races are grooved to accept the bearing balls. MAKE SURE THE BEARING BALLS ARE RIDING IN THE BEARING RACE GROOVES. 92

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Units with Straight Engine Shaft:


Two types of engine adapters have been produced - one that uses an engine adapter gasket and socket head cap screws, and one that uses an o-ring and button head fasteners. 1. To assemble units having an engine adapter gasket, refer to Figure 7.31:
Figure 7.31 Axial Cam Drive Components (Units with Straight Engine Shaft)

When installing the engine adapter having the gluedin sleeve, be sure to use the correct socket head cap screws. Pump assemblies used on engines with straight (non-tapered) shafts use 5/16-24 x 3/4 long cap screws. Pumps on engines with tapered shafts use 5/16-24 x 1 long cap screws. 2. To assemble units having an O-ring seal and button head cap screws with o-ring seals, refer to Figure 7.32:
Figure 7.32 Axial Cam Drive Components (Units with Straight Engine Shaft and O-Ring Seal)

Item 1 2 3 4 5 6 7 8 9 10 11

Name Engine adapter gasket Engine adapter Engine adapter bearing assembly C-ring cam retainer Washer retainer Thrust washer Engine shaft adapter Axial cam Axial cam bearing assembly Lock washer Socket head cap screw
Item 1 2 3 4 5 6 7 8 9 10 11 Name O-ring Engine adapter Engine adapter bearing assembly C-ring cam retainer Washer retainer Thrust washer Engine shaft adapter Axial cam Axial cam bearing assembly Button head cap screw O-ring

a. Use a new adapter gasket and install the engine adapter onto the engine. b. Retain the engine adapter to the engine with four (4) 5/16-24x 3/4 socket head cap screws and for (4) M8 ribbed lock washers. c. Tighten the cap screws to the torque value specified in the Torque Chart, found on Figure 7.2 (Exploded View) at the beginning of this chapter. 93

a. Use a new O-ring around the housing pilot and install the engine adapter onto the engine. b. Retain the engine adapter to the engine with four (4) 5/16-24x 3/4 button head cap screws and four (4) o-rings. c. Tighten the cap screws to the torque value specified in the Torque Chart, found on Figure 7.2 (Exploded View) at the beginning of this chapter.

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

NOTE: When installing the engine adapter having the o-ring seals, be sure to use the correct button head cap screws. DO NOT use any other type fastener.
3. Install the engine shaft adapter over the engine shaft, as shown in Figure 7.31 or 7.32. 4. Install the engine adapter bearing race, followed by the engine adapter bearing and the inner cam bearing race. Refer to Figure 7.30. a. For ROLLER BEARINGS, the chamfered edge of the bearing races must face AWAY FROM THE BEARING ROLLERS. That is, the flat (unchamfered) side of the race must ride against the rollers. b. For BALL BEARINGS, the bearing races are grooved to accept the bearing balls. MAKE SURE THE BEARING BALLS ARE RIDING IN THE BEARING RACE GROOVES. 5. Install the axial cam assembly. The factory-installed adapter has a built-in key which must engage with a keyway on the straight (non-tapered) engine shaft. Push the cam toward the engine until it seats against the engine adapter bearing race. 6. Again referring to Figure 7.30, install the outer cam bearing race, axial cam bearing and piston shoe bearing race. a. For ROLLER BEARINGS, the chamfered edge of the bearing races must face AWAY FROM THE BEARING ROLLERS. That is, the flat (unchamfered) side of the race must ride against the rollers. The inside diameter of the outer cam bearing race is larger than the piston shoe bearing race. b. For BALL BEARINGS, the bearing races are grooved to accept the bearing balls. MAKE SURE THE BEARING BALLS ARE RIDING IN THE BEARING RACE GROOVES.

Piston Oil Seals and Pistons Refer to Figure 7.33 for this procedure.
Figure 7.33 Oil Seals & Pilot Spacers

Item 1 2 3 4 5

Name Pilot spacer tang engaged in crankcase locating notch Crankcase locating notch Pump crankcase High pressure oil seal Pilot spacer

1. Pre-lubricate three (3) piston oil seals with 80W90 oil. 2. Press a seal into one of the piston bores provided on the pump crankcase, with the writing on the face of seal toward the installer. Press the seal in it bottoms. Repeat this step for the two (2) remaining seals. 3. Install the three (3) pilot spacers over the piston oil seals, as shown in Figure 7.33: a. Larger diameter flange of the pilot spacers must face downward (away from installer). b. Two small locating tangs on the pilot spacers must fit inside locating notch of the pump crankcase, as depicted in Figure 7.33.

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

4. If the piston assemblies use a lock ring and have been disassembled, assemble them as follows: a. Install a retainer ring into the groove at one end of each piston. b. Slide the piston spring retainer up the piston until it contacts the retainer ring. Retainer must be installed exactly as shown in Figure 7.34. c. Springs are tapered. Install small end of tapered spring so that it contacts the spring retainer. 3. If the piston assemblies have an integral spring retainer ring, install the small end of the tapered spring so that it contacts the spring retainer.
Figure 7.34 Return Spring Orientation

Figure 7.35 Piston Installation

Item 1 2 3 4 5

Name Return spring Pump crankcase Piston oil seal Pilot spacer Piston

Item 1 2 3 4

Name Lock ring Spring retainer Return spring Piston

6. Install the thermal bypass piston and spring into the bore provided in the center of the pump crankcase, as shown in Figure 7.36.
Figure 7.36 Thermal Bypass Components

4. Apply a small amount of SAE 80W90 oil to the lip of the oil seals and the piston surface. 5. With spring in place around piston as shown in Figure 7.34, install the piston through the crankcase, oil seal, and pilot spacer, as shown in Figure 7.35.

Item 1 2 3 4 95

Name Pump crankcase Thermal bypass spring Thermal bypass piston O-ring

Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Spacer Plate 1. Referring to Figure 7.37, install the three (3) low pressure seals into the bores provided in the spacer plate.
Figure 7.37 Inlet Check Valve Seat Supports

Pump Head Assembly 1. Install an o-ring and backup ring on all check valves, as shown in Figure 7.38.
Figure 7.38 Check Valve O-Ring Assembly

Item 1 2 Item 1 2 3 Name Low pressure seal Spacer plate Check valve support

Name O-ring Backup ring

2. To install the three (3) inlet check valves, along with their o-ring seals, use a 7/16-20 bolt of sufficient length along with a nut, washer, and one of the high pressure port towers, similar to that depicted earlier in Figure 7.15. a. Thread a jam nut onto the bolt, then the washer. b. Install the high pressure port tower over the bolt until it contacts the washer and leaves 4 or 5 bolt threads exposed. c. Thread the 7/16-20 bolt into the female threads of the inlet check valve. Then use the jam nut to fingertighten the high pressure port tower against the valve backup ring. Make sure the high pressure port tower is snugged firmly against the backup ring. Again, refer to Figure 7.15 for a depiction of this assemblys appearance. d. Lubricate an inlet check valve, seal, and backup ring with silicone spray.

2. Align the low pressure seal bores of the spacer plate with the pistons protruding from the pump crankcase. With mating holes aligned, push down on the spacer plate. The low pressure seal bores of the spacer plate should engage the pilot spacers. 3. If present in older-model units, install an o-ring over the two M5-0.80 x 20mm truss head screws. Install and tighten the two truss head screws into holes provided in the spacer plate and threaded holes in the pump crankcase. 4. The inlet check valve seat supports are installed over the spacer place, as shown in Figure 7.37, with the large diameter end toward the crankcase.

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

e. Align the inlet check valve with its bore in the pump head, as shown in Figure 7.39. Push the check valve, along with its seal and backup ring, down into the check valve bore.
Figure 7.39 - Inlet Check Valve Installation

d. Insert the 7/16-20 bolt/jam nut/washer down through the bore of the high pressure port tower and engage the bolt threads with the internal threads of the outlet check valve. e. Snug the jam nut down against the washer to force the end of the tower firmly against the backup ring of the outlet check valve. f. Lubricate an outlet check valve and tower with silicone spray. g. As shown in Figure 7.40, carefully align the check valve and tower with the high pressure bore provided in the pump head. Press the check valve and tower into the bore. h. Unscrew and withdraw the bolt, jam nut, and washer. i. Install the two remaining outlet check valves and towers in the same manner.
Figure 7.40 - Outlet Check Valve Installation

f. Unscrew and withdraw the bolt, jam nut, and washer. g. Install the two remaining inlet check valves in the same manner. 3. Install the three (3) outlet check valves and three (3) high pressure port towers as follows: a. Install an o-ring seal and backup ring onto the high pressure port tower, similar to that seen earlier in Figure 7.38. b. Install a bearing seal ring into the high pressure port tower (seen in Figure 7.38). c. Install a high pressure seal into the high pressure port tower, over the bearing seal ring previously installed (Figure 7.38). 4. Press the thermal bypass actuator into its recess at the center of the pump head. Check that the actuator is fully seated. Make sure the small actuating stem is installed into the actuator. A small dab of petroleum jelly will help hold it in place.

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Pump Head Installation Referring to Figure 7.41, install the pump head onto the pump spacer plate, as follows:
Figure 7.41 Pump Head Installation

4. Install six (6) M8-1.25 socket head cap screws with six (6) M8 ribbed lock washers to retain the head. 5. Tighten the socket head screws in the order shown on Figure 7.42 to the torque value specified in the Torque Chart, found on Figure 7.2 (Exploded View) at the beginning of this chapter.
Figure 7.42 Head Bolt Tightening Sequence

Item 1 2 3 4 5 6 7* 8* 9

Name Spacer plate Head gasket Thermal bypass actuator Pump head Lock washer Socket head cap screw O-ring Unloader valve spindle seat Inlet water connector/filter 6. Install the garden hose connector with filter screen onto the pump head.

* May not be present, depending on age of pump 1. If equipped, check that three (3) inlet check valve seat supports are properly installed into the bores provided on the spacer plate. 2. Set the head gasket into place on the spacer plate with its holes properly aligned with mating spacer plate holes. 3. Align the pump head with high and low pressure bores of the spacer plate and set the head into place.

CAUTION: Make sure the small stem of the thermal bypass actuator does not fall out during installation of the pump head.
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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Unloader-Pressure Regulator Valve 1. Install the valve spindle with o-ring seal into the bore provided on the pump head (illustrated in Figure 7.41). 2. Install the assembled unloader-pressure regulator valve. Retain with three (3) M6-1.00 socket head cap screws, as shown in Figure 7.43.
Figure 7.43 Unloader-Pressure Regulator

Main Component Assembly Before installing the pump onto the engine, place the engine with its shaft in a vertical position and facing the installer. Make sure the engine adapter has been properly installed. Check that the axial cam drive components are installed properly. The pump may now be installed as follows: 1. Install a new o-ring seal around the mounting flange of he pump crankcase. 2. To aid reassembly, apply a dab of axle grease or petroleum jelly to the piston pivot shoes, as indicated by item 1 in Figure 7.44. This will allow the shoes to stick to the tips of the three pistons.
Figure 7.44 Piston Pivot Shoes

Item 1 2 3

Name Unloader/pressure regulator assembly Washer Socket head cap screw 3. Place the piston pivot shoes onto the tips of the three pistons. The grease should hold the shoes in place.

3. Tighten the socket head cap screws to the torque value specified in the Torque Chart, found on Figure 7.2 (Exploded View) at the beginning of this chapter.

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

4. Insert two (2) M6-1.0 x 45mm hex head bolts through mounting holes in the pump crankcase, 180 apart and at the locations shown in Figure 7.45. These are the two long jacking screws.
Figure 7.45 Jacking Bolt Locations

5. Lower the pump toward the engine adapter. Align the crankcase and engine adapter mounting holes and also position the three piston pivot shoes so that they engage the axial cam bearing race properly. 6. When you are sure the pump crankcase and piston pivot shoes are properly aligned and positioned, thread the two long hex head bolts (shown in Figure 7.45) into the engine adapter mounting holes. Turn the two screws alternately to compress the piston springs and pull the pump crankcase against the engine adapter. 7. Install four (4) M6-1.0 socket head cap screws through the mounting holes of the pump crankcase and thread them into the mounting holes of the engine adapter. Snug the four cap screws. 8. Remove the two (2) jacking hex head bolts and replace them with the two (2) remaining M6-1.0 socket head cap screws. 9. When all six (6) socket head cap screws are snugged down, tighten them to the torque value specified in the Torque Chart, found on Figure 7.2 (Exploded View) at the beginning of this chapter.

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Oil Fill Figure 7.46 depicts an early model pump and shows the drain plug (item 2) and the sight gauge (item 3).
Figure 7.46 Pump Oil Fill Location

1. On units so equipped, install the glass sight gauge in its proper position on the side of the pump. Tighten the sight gauge to the torque value specified in the Torque Chart, found on Figure 7.2 (Exploded View) at the beginning of this chapter. 2. On units so equipped, install the 3/8 NPT oil drain plug in its proper location. Tighten the oil drain plug to the torque value specified in the Torque Chart, found on Figure 7.2 (Exploded View) at the beginning of this chapter. 3. Insert a funnel into the Oil Fill/Breather cap threaded opening at top of the pump crankcase. Add the amount and type of oil recommended in the table in Part 2 of the Common Pump Components section, earlier in this manual. On units so equipped, the oil level should reach the center of the sight gauge. 4. When pump has been properly serviced with the recommended oil, install and tighten the Oil Fill/Breather cap to the torque value specified in the Torque Chart, found on Figure 7.2 (Exploded View) at the beginning of this chapter. 5. If so equipped, install the 1/8 NPT pipe plug into its threaded opening on the pump head. Tighten the plug to the torque value specified in the Torque Chart, found on Figure 7.2 (Exploded View) at the beginning of this chapter.

Item 1 2* 3*

Name Oil fill - breather cap Drain plug Sight gauge

* Items not used in current models

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Part 5 - Troubleshooting
Problem 1. Water leakage at mating flanges. Possible Cause
a. Head bolts improperly torqued. b. Damaged head. c. Missing or damaged o-rings

Corrective Action
a. Torque head bolts. b. Replace head. c. Install new o-rings.

2. Water leakage from chemical

injector.

a. Chemical injection fitting improperly torqued. b.Check ball missing. c. Check ball stuck.

a. Torque fitting. b. Replace check ball and spring. c. Remove, clean and replace fitting, ball and spring. a. Torque head bolts. b. Install good head gasket. c. Replace head. d. Install new o-rings and backup rings.

3. Water leakage between pump head

a. Head bolts improperly torqued. b. Defective head gasket. c. Damaged head. d. Missing or damaged o-rings and backup rings.

and spacer plate.

4. Water leaks from high pressure out

a. Connector not properly seated. b. Damaged connector.

a. Seal with teflon tape and tighten properly. b. Replace bad connector.

connector.

5. Water leaking out of head bolts.

a. Defective or missing head gasket. b. Head bolts improperly torqued. c. Porosity in spacer plate.

a. Install new head gasket. b. Torque head bolts properly. c. Replace spacer plate. a. Install thermal bypass piston. b. Install new spring. c. Install new o-ring. d. Install new low pressure seals. e. Install new o-rings on screws. f.Tighten to correct torque. a. Install new o-ring or gasket. b. Tighten to correct torque.

6. Water leaking out behind spacer

plate.

a. Thermal bypass piston missing or defective. b. Bad or missing thermal bypass piston spring. c. Bad o-ring on thermal bypass piston. d. Low pressure water seals leaking. e. Defective or missing o-rings on spacer plate truss head screws. f. Spacer plate screws not tight.

7. Oil leak between engine and engine adapter.

a. Defective or missing engine adapter o-ring or gasket. b. Engine adapter cap screws not tightened properly.

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

Part 5 - Troubleshooting
Problem
8. Oil leak between engine adapter and pump crankcase.

Possible Cause
a. Missing or bad o-ring seal. b. Cap screws not tightened properly. a. Missing or bad low pressure seals. b. Missing or bad piston oil seal. c. Cracks in casting.

Corrective Action
a. Install new o-ring seal. b. Tighten to correct torque. a. Install new seals. b. Install new oil seals. c. Replace cracked casting. a. Reset nozzle to high pressure. b. Replace with correct nozzle. c. Clear obstruction from nozzle. d. Clear inlet. e. Provide sufficient water supply. f. Relieve kinking or repair leak. g. Clean strainer. h. Reduce inlet water temperature to below 140oF. i. Disassemble and repair pump. j. Set valve to high pressure. k. Clear nozzle of obstructions. l. Remove, clean and replace chemical injection components. a. Reset nozzle to low pressure. b. Insert line into fluid. c. Clean or replace strainer or line.

9. Oil leak between pump crankcase and spacer plate.

a. Nozzle is set to low pressure mode. 10. Pump does not produce pressure, exhibits erratic pressure, chatters or has b. Incorrect spray nozzle is used. a low water volume. c. Spray nozzle is obstructed. d. Water Inlet blocked e. Inadequate water supply to pump. f. Water supply hose kinked or leaking. g. Clogged inlet hose strainer. h. Water supply too hot. i. Worn or defective pump. j. Unloader-regulator valve set wrong. k. Obstructed nozzle. l. Obstructed chemical injection system.

11. Detergent does not mix with spray.

a. Nozzle is in high pressure mode. b. Chemical suction line is not submerged. c. Chemical suction strainer or line is clogged.

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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 Large Frame Pump

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Portable Pressure Washer Familiarization and Troubleshooting Guide Glossary

GLOSSARY
The following are definitions for terms commonly used in the pressure washer industry. Ampere a unit of measure for current draw Annovi Reverberi a pressure washer pump manufacturer Arrestor see spark arrestorAssy same as assembly or group of parts Awg a unit of measure, relating a wire diameter in terms of American Wire Gauge Axial cam - a device (cam) used to transform the rotary motion of the motor crankshaft into the reciprocating motion of a pumps pistons; also known as a wobble plate Backflushing a method of reversing water flow through a system in order to flush out any blockages or impurities Backwashing same as backflushing Belleville a trade name for a certain type of domed steel washer BHCS same as button head cap screw, a type of fastener BSP - same as British Straight Pipe, a type of pipe thread Centura a trade name for a certain type of Tecumseh internal combustion engine Connector a device used to make an electrical connection between two or more circuit wires; a device used to attach water hoses, high pressure hoses, and so forth Contaminants chemicals or particles of inappropriate matter mixed with known good materials Couplings devices used to make a mechanical connection between two rotating shafts or threaded pipes, etc. CSA - characters which signify that the labeled device complies with applicable regulations promoted by the Canadian Standards Association CST signifies Central Standard Time Degreaser a chemical used to remove grease or similar petroleum-based products from a surface or object Dia same as diameter Dipstick a device used to indicate the level (amount) of oil in a pump/engine crankcase EE same as economy electric pump, now known as a small frame pump powered by an electric motor EG same as economy gas pump, now known as a small frame pump powered by a gasoline engine Eng stands for engine or engineering FAIP a pressure washer pump manufacturer FH same as flathead pump, now known as a medium frame pump Foamer a device used to inject soap, wax, or other additives into a stream of low pressure water General a pressure washer pump manufacturer GFCI same as ground fault circuit interrupter, a device used to almost instantly cut off circuit power when an improper grounding condition is sensed GN a trade name for a certain type of Generac-Nagano internal combustion engine, such as GN-220, etc. GPM a unit of measure for water flow; same as gallons per minute GPW same as Generac pressure washer pump, now known as a large frame pump Helpline special telephone answering service that can assist Generac owners having operational questions HHCS - same as hex head cap screw; a type of fastener HM same as hour meter, a device used to record the elapsed time a device is operated HP same as horsepower, a unit of measure for work Intek - a trade name for a certain type of Briggs & Stratton internal combustion engine Keyway a special slot cut into an engine shaft that is intended to mate with a matching key in a pump; permits maximum transfer of power from engine to pump Lavor Wash a pressure washer pump manufacturer Lbs same as pounds Loctite trade name for a brand of assembly adhesive Ml same as milliliter, a unit of measure for volume Newton a unit of measure for force NFPA same as National Fire Prevention Association NPT same as national pipe taper, a designator applied to a specific type of pipe threads NSP same as non-service part; the entire assembly must be replaced as a unit OHV same as overhead valve, an improved way to control exhaust and intake valves on internal combustion engines OHVI an industrial, more durable version of the ohv engine 105

Portable Pressure Washer Familiarization and Troubleshooting Guide Glossary

Overchoking a condition where the engine is being deprived of intake air while being flooded with fuel Overflush a mechanical condition where one surface is slightly higher than its surrounding surface Overspraying a condition where a substance (paint, high pressure atomized water, etc.) is broadcast outside of its intended region Overtighten a condition where a fastener or other securing device is more than fully engaged, causing possible damage to its associated components or difficulty in removal Parback a trade name for a type of fluid seal device Permabond a trade name for a type of industrial adhesive Poppet a type of valve used to relieve pressure PSI - a unit of pressure; same as pounds per square inch Purge - a method of eliminating air from a pressure washer so that starting the engine is easier PW same as pressure washer QPQ same as quench purge quench, a heat treating process designed to case-harden pressure washer pistons Quantum - a trade name for a certain type of Briggs & Stratton internal combustion engine Quattro - a trade name for a certain type of Briggs & Stratton internal combustion engine RPM same as revolutions per minute SAE same as Society of Automotive Engineers SF designates a specific grade of automotive oil SG same as sf SH same as sf Side valve - a type of internal combustion engine that uses a conventional L type cylinder head with intake and exhaust valves on the side SHCS same as socket head cap screw; a type of fastener Spark Arrestor a device or screen that prevents the emission of sparks from an engines exhaust Sprint - a trade name for a certain type of Briggs & Stratton internal combustion engine SRV same as service, used to designate a service part Thermal relief - a technique used to reduce the build-up of high temperature water with a pressure washer pump caused when the spray gun trigger is closed.

Turbo wand/nozzle a device used to increase the effectiveness of high pressure water when directed against a surface UL same as Underwriters Laboratory, a safety and performance testing service Unchamfered indicates that sharp edges are not machined with a chamfer Unloader - a device used to reduce the water pressure within a pressure washer pump whenever the spray flow is blocked. Vanguard - a trade name for a certain type of Briggs & Stratton internal combustion engine Vaseline a trade name for a type of petroleum jelly Wireform a type of hose or accessory hanger formed from heavy wire and attached to pressure washers

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