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PRESSURE WASHER Visit us at: www.briggsandstratton.com www.generac-portables.com www.briggspowerproducts.com
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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
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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
5
7
4 • Small Frame Electric Pump
17
Part 1 - Specifications and Views Performance Specifications
17 17
Cross-Sectional View
18
Exploded View
20
Power Source
7
Pressure washer pumps
7
Inlet and Outlet Check Valves
8
Unloader - Pressure Regulator
8
Thermal Bypass System
9
Pump Head
22
Chemical Injection
9
Piston Housing Removal
23
Easy Start Valve
10
Piston Housing Disassembly
24
High Pressure Hose
11
Chemical Injection System
24
Spray Guns
11
Auto Start Switch Assembly
25
Spray Wands and Nozzles
12
Axial Cam
26
3 • General Information Part 1 - General Maintenance Chemical Injection System
Part 2 - Disassembly General Information & Special Tools
13 13 13
Inlet Water Supply Connector
13
Inlet Supply Filter/Strainer
13
Hose, Spray Gun and Wand Systems
13
Spray Nozzle Servicing
14
Part 2 - Lubrication Check Pump Oil Level
15 15
Change Pump Oil
15
Part 3 - Storage Pump Storage
16 16
Protection Against Freezing
16
Purging Air From the System
16
Part 3 - Inspection Seals, O-Rings, and Gaskets
27 27
Piston & Spring Assemblies
27
Pump Head and Piston Housing
27
Axial Cam Drive Components
28
Part 4 - Reassembly Pump Head Assembly
29 29
Auto Start Switch Assembly
29
Chemical Inject Assembly
30
Piston Housing Assembly
31
Pilot Spacer Installation
31
Pump Head Bolts
32
Assemble Axial Cam
32
Oil Fill
32
Main Component Assembly
32
Final Assembly and Test
33
Part 5 - Troubleshooting
1
22 22
34
Portable Pressure Washer Familiarization and Troubleshooting Guide Table of Contents
TABLE OF CONTENTS Small Frame Gas Pump Part 1 - Specifications and Views Performance Specifications
35
Part 2 - Disassembly General Information & Special Tools
35 35
56 56
Pump Head
56
Axial Cam Drive Components
57 57
Cross-Sectional view
36
Exploded View
38
Pistons and Piston Springs
40 40
Pump Head
58
Spacer Plate
58
Inlet Check Valves
59
Outlet Check Valves
59
Unloader Spindle Assembly
59
Chemical Injection System
60
Thermal Bypass Actuator Removal
60
Part 2 - Disassembly General Information & Special Tools Pump Head
40
Piston & Unloader Housing Removal
40
Piston & Unloader Housing Disassembly
41
Chemical Injection System
42
Unloader
42
Engine Adapter
43
Part 3 - Inspection Seals, O-Rings, and Gaskets
43 43
Piston & Spring Assemblies
43
Engine Adapter, Pump Head and Piston/Unloader Housing Axial Cam Drive Components
61
Check Valves
61
Head Gasket
61
44
Engine Adapter O-Rings
62
44
Engine Adapter, Pump Crankcase and Spacer Plate/Head
62
Axial Cam Drive Components
62
Piston & Spring Assemblies
62
High Pressure Outlet/Chemical Injection Assembly
63
45 45
Unloader Assembly
45
Chemical Injection Assembly
45
Piston & Unloader Housing Assembly
46
Pump Head Assembly
46
Main Component Assembly
47
Pilot Spacer Installation
48
Pump Head Bolts
49
Oil Fill
49
5 • Medium Frame Pump Part 1 - Specifications and Views Performance Specifications
61 61
Seals
Part 4 - Reassembly Engine Adapter
Part 5 - Troubleshooting
Part 3 - Inspection Seals, O-Rings, and Gaskets
Part 4 - Reassembly Engine Adapter
50
51 51 51
Cross-Sectional View
52
Exploded View
55
Piston Oil Seals and Pistons
65
Spacer Plate
67
High Pressure Seal Assembly
67
Check Valve Assembly
68
High Pressure Outlet and Chemical Injection Assembly
69
Unloader Spindle Assembly
69
Pump Head Installation
70
Main Component Assembly
71
Oil Fill
72
Part 5 - Troubleshooting 2
64 64
73
Portable Pressure Washer Familiarization and Troubleshooting Guide Table of Contents
TABLE OF CONTENTS 6 • Large Frame Pump Part 1 - Specifications and Views Performance Specifications
75 75
Cross-Sectional View
76
Exploded View
78
Part 2 - Disassembly General Information & Special Tools
80 80
Pump Head
80
Axial Cam Drive Components (Tapered Engine Shaft)
81
Axial Cam Drive Component (Straight Engine Shaft)
82
Pistons and Piston Springs
82
Regulator/Unloader Valve
82
Cylinder Head
84
Thermal Bypass Actuator Removal
85
Spacer Plate
86
Part 3 - Inspection Seals, O-Rings, and Gaskets
Part 4 - Reassembly Engine Adapter
75
Oil Seals
87
Inlet Check Valve Seals
87
Outlet Check Valve Seals
87
Head Gasket
88
Engine Adapter Gasket
88
Engine Adapter, Pump Crankcase, Spacer Plate and Head
88
Axial Cam Drive Components
88
Piston & Spring Assemblies
89
Unloader-Pressure Regulator Valve
90
Piston Oil Seals and Pistons
94
Spacer Plate
96
Pump Head Assembly
96
Pump Head Installation
98
Unloader-Pressure Regulator Valve
99
Main Component Assembly
99
Oil Fill
101
Part 5 - Troubleshooting
102
Glossary
87 87
3
91 91
105
Portable Pressure Washer Familiarization and Troubleshooting Guide Table of Contents
4
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:
2. Rotary motion of the motor crankshaft is converted to reciprocating motion of the pump’s pistons using an axial cam.
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.
On a piston’s ‘suction’ stroke, an inlet valve opens and water is drawn into the piston chamber. On the piston’s ‘pressure’ stroke, that piston’s 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
Item 6 7 8 9 10
5
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
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.
a. piston diameter
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.
b. length of piston stroke c. number of pistons d. number of piston strokes per minute.
11. An optional easy start valve relieves pump outlet pressure during cranking for quicker and easier starts.
4. The pressure that builds up in the system then depends on the size of the spray nozzle orifice (item 1).
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.
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.
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.
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.
6
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 2 • Pressure Washer Components
PRESSURE WASHER COMPONENTS Power Source
Figure 2.1 — Pressure Washer Pump
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.
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
Name
1
Pressure adjust knob
2
Thermal bypass actuator
3
Inlet check valve
4
Garden hose connector/strainer
5
Thermal bypass outlet
6
Axial cam
7
Engine drive shaft
4. The number of pistons
8
Engine adapter bearing assembly
Theoretically, a pump will always move the same volume of water, regardless of flow restrictions.
9
Piston shoe bearing assembly
10
Piston spring retainer
The pump’s 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.
11
Piston return spring
12
Piston
13
Outlet check valve
14
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)
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.
7
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 2 • Pressure Washer Components
Inlet and Outlet Check Valves
Unloader - Pressure Regulator
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 piston’s inlet check valve opens and allows water to enter the pumping chamber. During the suction stroke, that piston’s outlet check valve is forced closed, as depicted in Figure 2.2.
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.
Figure 2.2 — Inlet Check Valve - Suction Stroke
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
Name
1
Inlet check valve
2
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
8
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 2 • Pressure Washer Components
Thermal Bypass System
Figure 2.6 — Low Pressure Suctionof Chemical Injection 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
Item
Name
1
Thermal bypass actuator
2
Thermal bypass actuator stem
3
O-ring
4
Thermal bypass piston
5
Thermal bypass spring
At a water temperature of approximately 140°F, 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.
Item
Name
1
Venturi o-ring
2
Spring
3
Check ball moved OFF valve seat
4
Chemical injection fitting
5
Chemical injection venturi
6
Discharge port
7
Chemical solution reservoir
8
Siphon tube strainer
9
Chemical siphon tube
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 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.
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.
9
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 2 • Pressure Washer Components
Easy Start Valve
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.
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 2.7 — High Pressure Cut-off of Chemical Injection System
Figure 2.8 depicts a Generac Portable Products® medium frame pump in its starting condition. Inlet water is connected to the pump’s garden hose connector. Air has been purged from the pump’s water passages. The check ball is attached to its restraint magnet (magnet not shown). Figure 2.8 — Starting Condition
Item
Name
Item
Name
1
Location of restraint magnet (not shown)
1
Ball shown seated, cutting off chemical flow
2
Check ball shown attached to magnet
2
Chemical injection fitting
3
Inlet water channel
3
Siphon tube
4
Check ball seat
5
Venturi throat
In this condition, the pump’s 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.
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.
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.
10
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 2 • Pressure Washer Components
High Pressure Hose
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.
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.
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
Item
Name
1
Outlet pressure water stream
2
Trapped line pressure piston shown in closed condition
3
Easy start check ball OFF its seat
4
Unloader piston assembly
5
Inlet water channel
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.
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
Name
1
Outlet pressure water stream
2
Trapped line pressure piston shown in open condition
3
Easy start check ball against its seat
4
Unloader spindle assembly
5
Inlet water channel
11
Item
Name
1
High pressure inlet connector
2
Spray gun body
3
Valve body
4
Valve return spring
5
Check ball
6
Check ball valve seat
7
Wand body
8
Trigger
9
Safety latch in lock position
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 2 • Pressure Washer Components
Spray Wands and Nozzles
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.
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.
Figure 2.12 — Spray Gun - Trigger Open
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 Owner’s 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 owner’s manual for the specific pressure washer model being serviced.
12
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 3 • General Information
GENERAL INFORMATION Part 1 - General Maintenance
the strainer or replace it if it is damaged, torn, or perforated. Reassemble the connectors, using petroleum jelly as necessary to ease the connections.
This section describes the general maintenance procedures recommended for pressure washer components that are common across product lines.
Figure 3.2 — Inlet Supply Strainer
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
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.
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.
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).
An o-ring maintenance kit for each model is available to refurbish all connection seals.
A typical inlet supply connection is seen in Figure 3.2. Clean 13
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:
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
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
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.
14
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 3 • General Information
Part 2 - Lubrication
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.
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.
Change Pump Oil
WARNING: DO NOT change pump oil unless the pressure washer Owner’s Manual requires this AND your pump is equipped with a pump drain plug.
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.
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 manufacturer’s recommended torque values when tightening drain plugs and breather/dipstick caps.
Check Pump Oil Level Certain pressure washers may be equipped with a glass sight gauge, as depicted in Figure 3.5.
To change oil in Generac Portable Products®manufactured pumps, refer to Figure 3.5 and proceed as follows:
Figure 3.5 — Sight Gauge on Side of Pump
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
Name
1
Breather cap/oil fill location
2
Drain plug
3
Sight gauge location
15
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 3 • General Information
Part 3 - Storage
Protection Against Freezing To protect the pump against freezing, proceed as follows:
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’.
1. Draw automotive windshield washer fluid into the pump: a. Connect a three (3) foot length of garden hose to the pump inlet.
To protect the pump against water sediment buildup, proceed as follows after each use:
b. While holding the open hose end higher than the pump, pour the washer fluid into the length of hose.
1. If the chemical injection siphon was used, flush the system as follows:
c. With the engine RUN/STOP switch in the STOP position, pull the engine’s recoil starter handle two or three times. This should replace most of the water in the pump with anti-freeze solution.
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.
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:
c. Shut off the engine and let it cool. Squeeze the spray gun trigger to relieve trapped line pressure. Then remove all hoses.
1. Prepare the pressure washer for use as outlined in the Owner’s 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.
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.
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.
2. With the engine RUN/STOP switch in the STOP position, pull the engine’s recoil starter about six (6) times. This should remove most of the liquid from the pump.
The system is now ready for use.
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.
Rated Pressure+
Pump Head
Flow Rate*
Piston Material
Oil Type/ Capacity
0762-0 0776-0 0766-1 0793-0 1007-0 9606-0 9737-0
1250 1300 1250 1250 1250 1100 1150
Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum
1.5 1.5 1.5 1.5 1.5 1.8 1.8
Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel
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
A typical small frame electric pump is shown in Figure 4.1 in cross-section.
Figure 4.1 — Small Frame Electric Pump (cross-sectional view)
18
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump
Cross-Sectional View Parts List Item
Qty.
Description
Item
Qty.
Description
1
1
O-ring
26
3
High pressure water seal
2
4
O-ring
27
4
Lock washer, M6 ribbed
3
1
Shuttle valve spring
28
4
SHCS M6- 1.0 x 35mm
4
1
Shuttle valve
29
3
Piston
5
3
O-ring
30
1
Pump head
6
3
Outlet port check valve cap
31
3
Inlet check valve
7
1
Tie wrap
32
3
Outlet check valve
8
2
O-ring
33
1
9
1
Motor assembly, complete
Hex socket set screw w/ Locktite DO NOT REMOVE
10
1
Motor cover housing
34
1
Taper plug DO NOT REMOVE
11
1
Housing and switch assembly
35
1
Pop off valve spring
12
1
Foam air filter
36
1
Pop off valve ball seat
13
1
Axial cam idler shaft
37
1
Pop off valve check ball
14
2
Bearing washer 35 x 55 x 3mm
38
1
O-ring
15
1
Needle thrust bearing 35 x 52mm
39
4
Rubber mount
16
1
Axial cam/gear assembly
40
2
Taptite screw, M4-0.7x10mm
17
1
Bearing washer 40 x 60 x 1mm
41
4
Plastite screw, 6-19 x 0.75”
18
1
Needle thrust bearing 40 x 60mm
42
1
Backup ring
19
3
SHCS M6-1.0 x 20mm
43
1
O-ring
20
1
Bearing washer 36 x 60 x 6mm
44
1
Auto switch piston return stop
21
3
Piston spring retainer
45
1
Auto switch piston return spring
22
1
Piston housing
46
1
Auto switch piston assembly
23
3
Piston return spring
47
1
Backup ring
24
3
Oil seal
48
1
Retainer cap
25
3
Pilot spacer
49
1
Auto switch grommet
50
1
Auto switch
51
1
Auto switch housing
19
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump
Exploded View
A typical small frame electric pump is depicted in exploded view in Figure 4.2.
Figure 4.2 — Small Frame Electric Pump (exploded view)
Item
Torque Value
6
15-17 ft-lbs
19
7-9 ft-lbs
28
9-12 ft-lbs
33
9-12 ft-lbs
40
2-4 ft-lbs
41
2-4 ft-lbs
48
10-12 ft-lbs
54
Brass: 15-23 ft-lbs Nylon: 10-12 ft-lbs
57
20-30 in-lbs
20
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump
Exploded View Parts List Item
Qty
Description
1
1
O-ring
2
4
O-ring
3
1
Shuttle valve spring
4
1
Shuttle valve
5
3
O-ring
6
3
Outlet port check valve cap
7
1
Tie wrap
8
2
O-ring
9
1
Motor assembly, complete
10
1
Motor cover housing
11
1
Housing and switch assembly
12
1
Foam air filter
13
1
Axial cam idler shaft
14
2
Bearing washer 35 x 55 x 3mm
15
1
Needle thrust bearing 35 x 52mm
16
1
Axial cam/gear assembly
17
1
Bearing washer 40 x 60 x 1mm
18
1
Needle thrust bearing 40 x 60mm
19
3
SHCS M6-1.0 x 20mm
20
1
Bearing washer 36 x 60 x 6mm
21
3
Piston spring retainer
22
1
Piston housing
23
3
Piston return spring
24
3
Oil seal
25
3
Pilot spacer
26
3
High pressure water seal
27
4
Lock washer, M6 ribbed
28
4
SHCS M6- 1.0 x 35mm
29
3
Piston
Item
21
Qty.
Description
30
1
Pump head
31
3
Inlet check valve
32
3
Outlet check valve
33
1
Hex socket set screw w/ Locktite DO NOT REMOVE
34
1
Taper plug DO NOT REMOVE
35
1
Pop off valve spring
36
1
Pop off valve ball seat
37
1
Pop off valve check ball
38
1
O-ring
39
4
Rubber mount
40
2
Taptite screw, M4-0.7x10mm
41
4
Plastite screw, 6-19 x 0.75”
42
1
Backup ring
43
1
O-ring
44
1
Auto switch piston return stop
45
1
Auto switch piston return spring
46
1
Auto switch piston assembly
47
1
Backup ring
48
1
Retainer cap
49
1
Auto switch grommet
50
1
Auto switch
51
1
Auto switch housing
52
1
Chemical suction hose
53
1
Hose clamp
54
1
Chemical inject fitting
55
1
Chemical inject check ball
56
1
Chemical inject check spring
57
1
Chemical inject venturi
58
1
Venturi o-ring
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump
Part 2 - Disassembly
Figure 4.3 — Pump Head
General Information & Special Tools
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.
Item
Name
1
Inlet check valve assembly
2
High pressure water seal
3. Remove the o-ring (item 3) from the pop off valve boss.
3
Pop off o-ring
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).
4
Outlet check valve assembly
5
Outlet port cap o-ring
6
Outlet port cap
7
Check valve o-ring
8
Taper plug DO NOT REMOVE
9
Pop off check ball
10
Hex socket plug DO NOT REMOVE
11
Pop off valve spring
12
Pop off ball seat
13
M6 ribbed lock washer
14
SHCS, M6-1.0 x 35mm
15
Pump head
2. Remove the three (3) inlet check valves (item 1). A 5/16”-18 bottoming tap may be used to remove these valves.
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.
22
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump
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.
Piston Housing Removal Refer to Figure 4.4 for this procedure. Figure 4.4 — Piston Housing
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
Name
1
Piston housing
2
Piston
3
Pilot spacer
4
Check valve o-ring
Item
Name
5
Shuttle valve o-ring
1
Electric motor
2
SHCS, M6-1.0 x 20mm
3
Piston housing
Before disassembling the piston assembly, do the following: 1. Remove the three (3) pilot spacers (item 3). These will just slide off.
NOTE: Piston housing is full of gear oil. Take care
2. Remove the three (3) check valve o-rings (item 4).
to handle the fluid safely.
3. Remove the shuttle valve o-ring (item 5).
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:
Chemical Injection System Not all pumps are equipped with a chemical injection system. Refer to Figure 4.7 when following this disassembly procedure.
Figure 4.6 — Piston Housing Disassembly
Be careful not to lose check ball and spring. Figure 4.7 — Chemical Inject System
Item
Name
1
Chemical inject venturi (brass or plastic)
2
Venturi o-ring
3
Chemical inject fitting
Item
Name
4
Check ball
1
Housing o-ring
5
Check spring
2
Piston spring retainer
6
Piston housing
3
Piston
4
Piston spring
5
Piston housing
6
Oil seal
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.
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.
Figure 4.8 — Auto Start Switch Group
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
Name
1
Piston housing
2
Rubber diaphragm
3
Taptite screw
4
Auto switch housing
5
Auto switch
6
Auto switch piston spring
7
Auto switch piston assembly
8
O-ring
9
Auto switch piston return stop
10
Backup ring
11
Retainer cap
12
O-ring
13
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.
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.
Figure 4.9 — Axial Cam Components
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
Name
1
Axial cam idler shaft
2
Bearing washer
3
Axial cam/gear assembly
4
Needle thrust bearing
5
Motor
6
Bearing washer
7
Bearing washer
8
Needle thrust bearing
26
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump
Part 3 - Inspection
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.
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.
Figure 4.11 — Piston Seals
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
Item
Name
1
Piston spring retainer
2
Piston
3
Piston return spring
Item
Name
1
Piston, spring, and retainer
2
Piston housing
3
Oil seal
4
Pilot spacer
5
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.
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.
Figure 4.12 — Axial Cam Components
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
Name
1
Axial cam idler shaft
2
Bearing washer
3
Axial cam/gear assembly
4
Needle thrust bearing
5
Motor
6
Bearing washer
7
Bearing washer
8
Needle thrust bearing
28
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump
Part 4 - Reassembly
found on Figure 4.2 (Exploded View) at the beginning of this chapter.
Refer to the Torque Specifications provided on the pump sectional view found at the beginning of this section when reassembling this product.
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.
Pump Head Assembly The pop off valve is not serviceable. The entire head assembly must be replaced if a problem occurs in these components.
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.
To assemble the pump head, refer to Figure 4.13 for the following steps:
6. Install the pop off valve o-ring (item 3). Petroleum jelly will help to hold it in place.
Figure 4.13 — Pump Head
Auto Start Switch Assembly Refer to Figure 4.14 for this assembly. Figure 4.14 — Auto Start Switch
Item
Name
1
Inlet check valve assembly
2
High pressure water seal
3
Pop off valve o-ring
4
Outlet check valve assembly
5
Outlet port cap o-ring
6
Outlet port cap
7
Check valve o-ring
8
Pump head
Item
Name
Item
Name
1
Piston housing
8
O-ring
2
Rubber diaphragm
9
Auto switch piston return stop
3
Taptite screw
1. Install three (3) outlet check valve o-rings (item 7). Ensure they lie flat at the bottom of the cavity.
4
Auto switch housing
10
Backup ring
11
Retainer cap
2. Install three (3) outlet check valves, with large end first (item 4).
5
Auto switch
12
O-ring
6
Auto switch piston spring
13
Backup ring
7
Auto switch piston assembly
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.
Chemical Inject Assembly Refer to Figure 4.15 for this assembly.
1. If necessary, install new backup rings and o-rings (items 8, 10, 12, 13) to the auto start piston return stop (item 7).
Figure 4.15 — Chemical Inject System
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.
Item
Name
1
Chemical inject venturi (brass or plastic)
2
Venturi o-ring
3
Chemical inject fitting
4
Check ball
5
Check spring
6
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.
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 4.16 — Pistons and Springs
Figure 4.17 — Piston Housing
Item
Name
1
Piston spring retainer
2
Piston
Item
Name
3
Piston spring
1
Piston housing
4
Piston housing
2
Piston
5
Oil seal
3
Pilot spacer
4
Check valve o-ring
5
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 seal’s internal spring, the seal has been installed upside down.
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.
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.
4. Carefully lift the pump head assembly, invert it, and align the high pressure water seals with the pistons protruding from the piston housing.
3. Invert the piston housing so that the pistons protrude vertically from the housing. Place the piston housing on a flat surface.
5. Verify that the o-rings remain in their proper position and press the head down to the piston housing. 31
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.
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 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.
2. Install the axial cam idler shaft (item 7) into its socket in the piston housing (item 8).
Assemble Axial Cam Refer to Figure 4.18 for this procedure:
4. Lay a 40 x 60mm needle bearing (item 5) on the thrust washer, either side up.
3. Install a 36 x 60 x 6mm thrust washer (item 6) on the idler shaft, with chamfer towards the pistons.
5. Lay a 40 x 60 x 1mm thrust washer (item 4) on the needle bearing, chamfer side up.
Figure 4.18 — Axial Cam Assembly
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
Name
1
Needle thrust bearing
2
Bearing washer
3
Axial cam/gear assembly
4
Bearing washer
5
Needle thrust bearing
6
Bearing washer
7
Axial cam idler shaft
8
Pump head/piston housing assembly
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.
32
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.
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.
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.
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.
Figure 4.19 — Motor 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.
Item
Name
1
Electric motor
2
SHCS, M6-1.0 x 20mm
3
Piston housing
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.
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
Possible Cause
Corrective Action
1. Water leakage between pump head and piston housing.
a. Head bolts improperly torqued.
a. Torque head bolts.
b. Damaged head.
b. Replace head.
c. Missing or damaged o-rings
c. Install new o-rings.
a. Connector not properly sealed.
a. Seal with teflon tape and tighten properly.
b. Damaged connector.
b. Replace bad connector.
a. Defective or missing motor adapter o-ring.
a. Install new o-ring.
b. Motor adapter cap screws not tightened properly.
b. Tighten to correct torque.
4. Oil leak between motor adapter and piston/unloader housing.
a. Missing or bad o-ring seal.
a. Install new o-ring seal.
b. Cap screws not tightened properly.
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.
a. Reset nozzle to high pressure.
b. Incorrect spray nozzle is used.
b. Replace with correct nozzle.
c. Spray nozzle is obstructed.
c. Clear obstruction from nozzle.
d. Water Inlet blocked
d. Clear inlet.
e. Inadequate water supply to pump.
e. Provide sufficient water supply.
f. Water supply hose kinked or leaking.
f. Relieve kinking or repair leak.
g. Clogged inlet hose strainer.
g. Clean strainer.
h. Water supply too hot.
h. Reduce inlet water temperature to below 140oF.
i. Worn or defective pump.
i.
a. Nozzle is in “high pressure” mode.
a. Reset nozzle to “low pressure”.
b. Chemical suction line is not submerged.
b. Insert line into fluid.
c. Chemical suction strainer or line is clogged.
c. Clean or replace strainer or line.
2. Water leaks from pressure out connector.
3. Oil leak between motor and motor adapter.
6. Detergent does not mix with spray.
34
Disassemble and repair pump.
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.‡
Rated Pressure+
Engine Shaft
Pump Head
Flow Rate*
Piston Material
Oil Type/ Capacity
B1906A 20965 20965A B1262 B1262A
1500 1650 1650 1750 1750
Straight Straight Straight Straight Straight
Aluminum Aluminum Aluminum Aluminum Aluminum
2.0 2.0 2.0 2.0 2.0
Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel
80W90/120ml 80W90/120ml 80W90/120ml 80W90/120ml 80W90/120ml
+ 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
Qty.
Description
1
3
Rubber grommet spacer sleeve
2
1
3
Item
Qty.
Description
25
1
Unloader seat O-Ring
Cage needle bearing assembly
26
1
Unloader piston
1
Bearing washer
27
2
Unloader split-ring seal
4
1
Bearing washer
28
1
Unloader spring
5
3
Oil piston seal
29
1
Unloader cap O-Ring
6
3
Piston return spring
30
1
Unloader cap
7
3
U-cup seal
31
1
8
1
Axial cam w/insert
Pipe plug (if item 22 not equipped) w/sealant
9
1
Engine adapter
32
1
Chemical injection hose barb
1
Plug, w/sealant
10
1
Piston and unloader housing
33
11
3
Piston spring retainer
34
1
Chemical injection ball
12
3
Pilot spacer
35
1
Chemical injection spring
13
3
Piston
36
1
Chemical injection venturi
14
1
Pump head
37
6
Low pressure transfer O-Ring
15
1
Radial ball bearing
39
7
Lock washer
16
6
Rubber bushing
40
4
Socket head cap screw
17
1
Piston and unloader housing
M6-1.0 x 35
O-Ring seal 18
1
42
3
43
1
M6-1.0 x 25
High pressure transfer O-Ring
20
6
Check valve assembly
21
3
Outlet check valve cap O-Ring
22
1
Thermal relief valve (if equipped) w/sealant
23
3
Outlet check valve cap
24
1
Unloader seat
Socket head cap screw
37
Venturi O-Ring
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 • Small Frame Gas Pump
Exploded View
A typical small frame gas pump is shown in exploded view in FIgure 5.2.
Figure 5.2 — Small Frame Gas Pump (exploded view)
Torque Chart Torque Item 23
15-17 ft-lbs
30
Brass: 15-18 ft-lbs Plastic: 7-10 ft-lbs
38
31
15-18 ft-lbs
32
9-12 in-lbs
33
12-15 ft-lbs
36
20-30 in-lbs
40
9-12 ft-lbs
42
9-12 ft-lbs
43
15-18 ft-lbs
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 • Small Frame Gas Pump
Exploded View Parts List Item
Qty.
Description
1
3
Rubber grommet spacer sleeve
2
1
3
Qty.
Description
26
1
Unloader piston
Cage needle bearing assembly
27
2
Unloader split-ring seal
1
Bearing washer
28
1
Unloader spring
4
1
Bearing washer
29
1
Unloader cap O-Ring
5
3
Oil piston seal
30
1
Unloader cap
6
3
Piston return spring
31
1
7
3
U-cup seal
Pipe plug (if item 43 not equipped) w/sealant
8
1
Axial cam w/insert
32
1
Chemical injection hose barb
9
1
Engine adapter
33
1
Plug, w/sealant
10
1
Piston and unloader housing
34
1
Chemical injection ball
11
3
Piston spring retainer
35
1
Chemical injection spring
12
3
Pilot spacer
36
1
Chemical injection venturi
13
3
Piston
37
6
Low pressure transfer O-Ring
14
1
Pump head
39
7
Lock washer
15
1
Radial ball bearing
40
4
Socket head cap screw
16
6
Rubber bushing 42
3
17
1
Item
M6-1.0 x 35
Piston and unloader housing
M6-1.0 x 25
O-Ring seal 18
1
High pressure transfer O-Ring
20
6
Check valve assembly
21
3
Outlet check valve cap O-Ring
23
3
Outlet check valve cap
24
1
Unloader seat
25
1
Unloader seat O-Ring
Socket head cap screw
43
1
Thermal relief valve (if equipped) w/sealant
45
39
1
Venturi O-Ring
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 • Small Frame Gas Pump
Part 2 - Disassembly
To disassemble pump head:
General Information & Special Tools
1. Remove the three (3) water seals. Seals should slide out by hand.
NOTE: There are no special tools required to disassemble or reassemble this pump.
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!
CAUTION: The pump is full of oil. When removing pump from engine, drain by pouring oil out of port used by the crankshaft.
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.
Pump Head Refer to Figure 5.3 for this procedure.
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.
Figure 5.3 - Pump Head
Piston & Unloader Housing Removal Refer to Figure 5.4 for this procedure. Figure 5.4 - Pump-Adapter Assembly
Item
Name
1
Water seal
2
Check valve
3
Low pressure transfer O-Ring
4
High pressure transfer O-Ring
5
Outlet check valve cap
6
Outlet check valve cap O-Ring
7
Item
Name
1
Piston
Pipe Plug - If present, DO NOT REMOVE
2
Pilot spacer
8
M6 lock washer
3
Low pressure transfer O-Ring
9
M6-1.0 x 35 cap screw
Before disassembling the piston and unloader assembly, do the following:
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.
1. Remove the three (3) pilot spacers. These will just slide off. 40
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 • Small Frame Gas Pump
Piston & Unloader Housing Disassembly Refer to Figure 5.6 for this disassembly, as follows:
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.
Figure 5.6 - Piston & Unloader Housing
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
Item
Name
1
M6-1.0 x 25 cap screw & M6 lock washer
2
Engine adapter
Item
Name
1
O-Ring
2
Piston and retainer
3
Spring
4
Thermal bypass valve or pipe plug
5
Piston and unloader housing
6
Piston oil seal
1. Remove O-Ring from housing.
5. Slowly loosen the C-clamp until spring tension is released and the components separate.
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.
Unloader Refer to Figure 5.8 when following this disassembly procedure.
CAUTION: Unloader cap is under strong spring
Figure 5.7 - Chemical Injection System
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
Name
1
Chemical injection venturi
2
O-Ring
3
Barbed nipple
4
Check ball
5
Spring
6
Piston and unloader housing
Item
Name
1
Piston and unloader housing
2
O-Ring
3
Unloader seat
CAUTION: Be careful not to lose check ball and
4
Unloader piston
spring.
5
Unloader cap
6
Unloader spring
7
Split-ring seal
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
Part 3 - Inspection
Engine Adapter Refer to Figure 5.9 when following this disassembly procedure.
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.
Figure 5.9 - Engine Adapter & Axial Cam
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
Name
Name
1
Retainer
1
Thrust washer
2
Piston
2
Cage needle bearing
3
Spring
3
Retainer washer
4
Axial cam
5
Radial ball bearing
6
Engine adapter
Item
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
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.
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 5.12 - Axial Cam Drive Components
Figure 5.11 — Piston Chamber
Item
Name
1
Piston and unloader housing
2
Piston
3
Oil seal
4
Pilot spacer
5
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
Name
1
Thrust washer
2
Cage needle bearing
3
Retainer washer
4
Axial cam
5
Radial ball bearing
6
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
4. Install the unloader piston. It will seat itself inside of the unloader seat.
NOTE: Refer to the Torque Specifications provided
5. Install the unloader spring.
on the pump exploded view found at the beginning of this section when reassembling this product.
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.
Engine Adapter 1. Install the retainer washer (thinner one) on the axial cam/radial ball bearing assembly.
Chemical Injection Assembly Refer to Figure 5.14 for this assembly.
2. Install the cage needle bearing (either side up). 3. Install the thrust washer (thicker one, either side up).
Figure 5.14 - Chemical Injection System
Unloader Assembly Refer to Figure 5.13 for this assembly. Figure 5.13 - Unloader Assembly
Item
Name
1
Piston and unloader housing
2
O-Ring
3
Unloader seat
4
Unloader piston
5
Unloader cap
6
Unloader spring
7
Split-ring seals
Item Name 1
Chemical injection venturi
2
O-Ring
3
Barbed nipple
4
Check ball
5
Spring
6
Piston and unloader housing
1. Install the check ball into the chemical injection nipple, followed by the spring (with the small end of the spring towards the ball).
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.
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. Install the new split-ring seal onto the unloader piston (if replacing).
3. Tighten the chemical injection nipple to the torque value specified in the Torque Chart, found on Figure 5.2 (Exploded View). 45
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 • Small Frame Gas Pump
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.
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.
3. Install the thermal relief valve (item 3).
6. Tighten the venturi to the torque value specified in the Torque Chart, found on Figure 5.2 (Exploded View).
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.
Piston & Unloader Housing Assembly Refer to Figure 5.15 for this assembly.
Pump Head Assembly Refer to Figure 5.16 for this assembly.
Figure 5.15 - Piston & Unloader Housing
Figure 5.16 - Pump Head
Item
Name
1
O-Ring
2
Piston and retainer
3
Spring
4
Thermal bypass valve or pipe plug
5
Piston and unloader housing
6
Piston oil seal
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.
Item
Name
1
Water seal
2
Check valve
3
Low pressure transfer O-Ring
4
High pressure transfer O-Ring
5
Outlet check valve cap
6
Outlet check valve cap O-Ring
7
Pipe Plug - If present, DO NOT REMOVE
8
M6 lock washer
9
M6-1.0 x 35 cap screw
1. Install the three (3) low pressure transfer O-Rings. Use a small amount of petroleum jelly to hold them in place.
NOTE: Do not reuse springs color coded RED. All piston return springs must be replaced in sets of three (3).
2. Install the high pressure transfer O-Ring. Petroleum jelly will help to hold it in place. 46
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.
3. Place the piston housing O-Ring into the groove on the housing.
4. Install three (3) outlet check valves, observing their orientation, as shown in Figure 5.16.
4. Grasp the engine adapter with both hands and invert it while holding the axial cam, washers, and bearing in place.
5. Install the three (3) M18-1.5 outlet caps and O-Rings.
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. 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.
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.
Main Component Assembly Refer to Figure 5.17 for this assembly.
Figure 5.18 — Installing Engine Adapter Bolts
Figure 5.17 — Main Component Assembly
Item Name
Item
Name
1
Engine adapter assembly with axial cam, bearings, and washers held in place.
2
Assembled piston and unloader housing with pistons, seals, and O-Ring
3
Pump head assembly placed on flat surface
1
M6-1.0 x 25 cap screws & M6 lock washers
2
Engine adapter
3
Widest opening between three (3) engine adapter ‘legs’ aligns with the chemical injector-thermal relief side of piston and unloader housing
4
Pump head
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.
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.
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
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.
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
Figure 5.19 — Invert Pump Assembly
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.
48
Item
Name
1
Pump head
2
Pilot spacer
3
Low pressure transfer O-Ring
4
Piston
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.
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 5.21 — Head Bolt Installation
Item
Name
1
M6-1.0 x 35 cap screw
2
M6 lock washer
3
Piston & unloader housing attached to engine adapter
Figure 5.22 — Oil Fill
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
Possible Cause
Corrective Action
1. Water leakage between pump head and piston housing.
a. Head bolts improperly torqued.
a. Torque head bolts.
b. Damaged head.
b. Replace head.
c. Missing or damaged o-rings
c. Install new o-rings.
a. Connector not properly sealed.
a. Seal with teflon tape and tighten properly.
b. Damaged connector.
b. Replace bad connector.
a. Defective or missing motor adapter o-ring.
a. Install new o-ring.
b. Motor adapter cap screws not tightened properly.
b. Tighten to correct torque.
4. Oil leak between motor adapter and piston/unloader housing.
a. Missing or bad o-ring seal.
a. Install new o-ring seal.
b. Cap screws not tightened properly.
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.
a. Reset nozzle to high pressure.
b. Incorrect spray nozzle is used.
b. Replace with correct nozzle.
c. Spray nozzle is obstructed.
c. Clear obstruction from nozzle.
d. Water Inlet blocked
d. Clear inlet.
e. Inadequate water supply to pump.
e. Provide sufficient water supply.
f. Water supply hose kinked or leaking.
f. Relieve kinking or repair leak.
g. Clogged inlet hose strainer.
g. Clean strainer.
h. Water supply too hot.
h. Reduce inlet water temperature to below 140oF.
i. Worn or defective pump.
i.
a. Nozzle is in “high pressure” mode.
a. Reset nozzle to “low pressure”.
b. Chemical suction line is not submerged.
b. Insert line into fluid.
c. Chemical suction strainer or line is clogged.
c. Clean or replace strainer or line.
2. Water leaks from pressure out connector.
3. Oil leak between motor and motor adapter.
6. Detergent does not mix with spray.
50
Disassemble and repair pump.
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.‡
Rated Pressure+
Flow Rate*
Unit Style
Engine Shaft
Pump Head
Piston Material
Oil Type/ Capacity
A1803 A1803A A1803C A1803C B3166 B3166A B3166C B3166C B3358 B3358 B3358A B3358C B3358D
2250 2000 2200 2200 2250 2000 2000 2000 2250 2250 2000 2200 2000
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
Horizontal Vertical Vertical Horizontal Horizontal Vertical Vertical Horizontal Vertical Horizontal Vertical Vertical Horizontal
Straight Straight Straight Straight Straight Straight Straight Straight Straight Straight Straight Straight Straight
Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum
Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic
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
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
A typical medium frame pump is shown in cross section in Figure 6.1.
Figure 6.1 — Medium Frame Pump (cross-sectional view)
52
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump
Sectional View Parts List Item
Qty
Description
1
3
Outlet port cap
2
3
3
Item 28
Qty 1
Description Oil breather cap
29
-
Loctite
O-ring, outlet port
30
1
O-ring
6
Check valve
31
1
Axial cam bearing assembly
4
3
O-ring, check valve
32
1
Axial cam
5
1
Head sub-assembly
33
1
Engine adapter
6
3
Bearing ring
34
1
Engine adapter bearing
7
3
High pressure seal
35
1
Thrust washer
8
3
O-ring, check valve
36
1
O-ring
9
1
Thermal bypass actuator and stem
37
1
Washer retainer
10
1
Trapped line pressure seat
38
1
Engine shaft adapter
11
1
Chemical injection venturi
39
1
C-ring cam retainer
12
1
Chemical injection spring
40
4
Button head cap screw, 5/16”-24
13
1
Chemical injection ball
or 4
Socket head cap screw, 5/16”-24
14
1
Chemical injection fitting
4
O-ring, if button head
15
1
Unloader ball spring
or 4
Flat washer, if socket head
16
1
Trapped line pressure piston assembly
43
3
Piston pivot shoe
17
1
Unloader ball
44
6
Socket head cap screw, M6-1.0
18
1
Ball seat assembly
45
3
Piston return spring
19
1
Unloader spindle assembly
46
1
Pump crankcase
20
1
Unloader handle
47
1
Spacer plate
21
1
Setscrew, M6-1.0 x 8mm
48
3
Pilot ring
22
1
Plastic cap
49
1
Head gasket
23
1
Unloader spring
50
6
Socket head cap screw, M8-1.25
24
1
Thermal actuator piston o-ring
51
6
Special steel washer
25
1
Thermal actuator spring
26
1
Thermal actuator piston
27
3
Piston
41
53
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump
Exploded View
A typical medium frame pump shown in exploded view in Figure 6.2.
Figure 6.2 — Medium Frame Pump (exploded view)
Item
Torque Value
1
20-30 ft-lbs
11
10-12 ft-lbs
14
9-12 ft-lbs
19
20-23 ft-lbs
29
24-36 in-lbs w/Loctite
40
18-20 ft-lbs
44
10-12 ft-lbs
50
18-20 ft-lbs
Certain components have been changed, added, or deleted since this Medium Frame pump became available. Always refer to the Owner’s 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 Qty
Description
25
1
Thermal actuator spring
O-ring, outlet port
26
1
Thermal actuator piston
6
Check valve
27
3
Piston
4
3
O-ring, check valve
29
1
Oil breather cap
5
1
Head sub-assembly
30
1
O-ring
6
3
Bearing ring
31
1
Axial cam bearing assembly
7
3
High pressure seal
32
1
Axial cam assembly
8
3
Check valve
33
1
Engine adapter
9
1
Thermal bypass actuator and stem
34
1
Engine adapter bearing assembly
10
1
Trapped line pressure seat
36
1
O-ring
11
1
Chemical injection venturi assembly
40
4
Button head cap screw, 5/16”-24
12
1
Chemical injection spring
or 4
Socket head cap screw, 5/16”-24
13
1
Chemical injection ball
41
4
O-ring, if button head
14
1
Chemical injection fitting
or 4
Flat washer, if socket head
15
1
Unloader ball spring
43
3
Piston pivot shoe
16
1
Trapped line pressure piston assembly
44
6
Socket head cap screw, M6-1.0
45
3
Piston return spring
17
1
Unloader ball
46
1
Pump crankcase assembly
18
1
Ball seat assembly
47
1
Spacer plate assembly
19
1
Unloader spindle assembly
48
3
Pilot ring
20
1
Unloader handle
49
1
Head gasket
21
1
Setscrew, M6-1.0 x 8mm
50
6
Socket head cap screw, M8-1.25
22
1
Plastic cap
51
6
Steel washer
23
1
Unloader spring
24
1
Thermal actuator piston o-ring
Item
Qty
Description
1
3
Outlet port cap
2
3
3
Item
55
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump
Part 2 - Disassembly
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.
General Information & Special Tools
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.
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.
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
Figure 6.4 - Head Screw Removal
• 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 pump’s water inlet. Disconnect the spray gun high pressure hose from the pump’s 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
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:
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 6.6 - Axial Cam Drive Components
Figure 6.7 - Piston Assembly
Item
Name
1
O-ring
2
Engine adapter
3
Engine adapter bearing assembly
4
Axial cam assembly
5
Roller thrust bearing assembly
6
Button head cap screw
7
O-ring
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
Item
Name
1
Spring
2
Piston
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:
Spacer Plate Referring to Figure 6.9, remove the spacer plate from between the crankcase and pump head, as follows:
Figure 6.8 — Pump Head Removal
Figure 6.9 - Spacer Plate Removal
Item
Name
Item
Name
1
Pump crankcase assembly
1
Spacer plate assembly
2
Pilot spacer
2
Head gasket
3
Spacer plate
3
Thermal bypass actuator and stem
4
Thermal bypass piston
4
Chemical injection fitting
5
Thermal bypass spring
5
Chemical injection check ball
6
Chemical injection spring
7
Pump head assembly
8
Steel washer
9
Socket head cap screw
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.
1. Remove six (6) M8-1.25 socket head cap screws and M8 washers.
4. Completely remove all traces of the head gasket from the mating surface.
2. Remove the pump head assembly.
5. Remove the three (3) white pilot spacers from the pump crankcase.
3. Remove the thermal actuator stem. 4. Remove the three (3) check valve o-rings.
6. Using a small flat-blade screwdriver, gently remove the three (3) piston oil seals from the pump crankcase.
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.
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.
1. As shown in Figure 6.10, gently turn the tap into the check valve with your fingers, approximately three full turns.
Unloader Spindle Assembly Referring to Figure 6.11: 1. Unscrew and remove the unloader handle, turning it counterclockwise.
Figure 6.10 - Inlet Check Valve Removal
Figure 6.11 - Unloader/Regulator and Chemical Inject Removal
Item
Name
1
Setscrew, M6-1.0 x 8mm
2
Unloader handle
Item
Name
3
Unloader spindle assembly
1
Outlet port cap
4
Spring
2
Outlet port cap o-ring
5
Chemical injection fitting
3
Outlet check valve
6
Check ball
4
O-ring
7
Trapped line pressure seat
5
Pump head with tap threaded into inlet check valve
8
Trapped line pressure spring
9
Chemical injection venturi
10
Trapped line pressure piston
11
Unloader ball
12
Ball seat assembly
13
Pump head
14
Unloader spring
15
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.
3. Carefully loosen and unscrew the unloader spindle assembly with a 19mm deep socket or wrench.
2. Grasp the end of an outlet check valve with a needle nose plier and pull it out. 59
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
Name
1
Flat blade screw driver
2
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
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.
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 6.14 — Typical Check Valve
Figure 6.13 — Piston Seals
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
Name
1
Pump head
2
Bearing ring
3
High pressure seal
4
Spacer plate
5
Low pressure seal
6
Pilot spacer
7
Oil seal
8
Crankcase
9
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.
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.
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.
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:
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 6.17 — Piston Dimensions
Figure 6.16 — Axial Cam Drive Assembly
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
Name
1
Engine adapter
2
Engine adapter bearing assembly
3
Axial cam assembly
4
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.
62
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump
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.
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
Figure 6.20 — High Pressure Outlet/Chemical Inject Assembly
Item
Name
1
Free length
2
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.
63
Item
Name
1
Setscrew, M6-1.0 x 8mm
2
Unloader handle
3
Unloader spindle assembly
4
Chemical injection spring
5
Chemical injection fitting
6
Check ball
7
Trapped line pressure seat
8
Spring
9
Venturi assembly
10
Trapped line pressure piston assembly
11
Unloader ball
12
Ball seat assembly
13
Head
14
Unloader spring
15
Plastic cap
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump
Part 4 - Reassembly
Figure 6.22 — Engine Adapter Components
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
Item
Name
1
Apply Loctite around the larger circumference of the ring in this area.
Item
Name
1
O-ring
2
Engine adapter
3
Engine adapter bearing assembly
4
Axial cam assembly
5
Axial cam bearing assembly
6
Button head cap screw
7
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.
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.
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.
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.
b. Tap the adapter sleeve into the engine adapter bore until it seats flush against the inside machined surface of the engine adapter.
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.
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.
64
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump
and piston shoe bearing race.
Figure 6.23 — Bearing Race Assemblies
- 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
Name
1
Engine adapter bearing race
2
Engine adapter bearing
3
Inner cam bearing race
4
Axial cam assembly
5
Outer cam bearing race
6
Axial cam bearing
7
Piston shoe bearing race
A
Larger inside diameter
Item
Name
B
Smaller inside diameter
1
C
Chamfer faces this way
Pilot spacer tang engaged in crankcase locating notch
2
Crankcase locating notch
3
Pump crankcase
4
High pressure oil seal
5
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 won’t go together.
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.
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.
3. Install the three (3) pilot spacers over the piston oil seals, as shown in Figure 6.24:
- 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.
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.
7. Install the outer cam bearing race, the axial cam bearing 65
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.
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 6.25 — Return Spring Orientation
Figure 6.27 — Thermal Bypass Spring and Piston
Item
Name
1
Return spring
2
Piston
Item
Name
4. Apply a small amount of SAE 80W90 oil to the lip of the oil seals and the piston surface.
1
Crankcase
5. Install each piston through the spring, crankcase, oil seal, and pilot spacer, as shown in Figure 6.26.
2
Thermal bypass spring
3
Thermal bypass piston
4
Thermal bypass o-ring
Figure 6.26 — Piston Installation
Item
Name
1
Return spring
2
Pump crankcase
3
Piston oil seal
4
Pilot spacer
5
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 seal’s groove side is inserted into the spacer plate bore, as shown in Figure 6.28.
High Pressure Seal Assembly Refer to Figure 6.29 for this assembly. Figure 6.29 — High Pressure Seal Assembly
Figure 6.28 — Low Pressure Seal Orientation
Item
Name
1
Low pressure seal
Item
Name
2
Spacer plate
1
High pressure seal
2
Bearing ring
3
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.
1. Insert a bearing ring into each of the head’s 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.
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. 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.
3. Ensure that the thermal bypass piston remains aligned with its mating seat on the spacer plate.
67
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump
Check Valve Assembly Refer to Figure 6.30 for this 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.
Figure 6.30 — Check Valve Assembly
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.
Item
Name
1
Outlet check valve port cap
2
Cap o-ring
3
Check valve
4
Check valve o-ring
5
Pump head
6
Thermal actuator stem
7
Thermal actuator
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.
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.
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.
Figure 6.31 — High Pressure Outlet and Chemical Injection
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
Name
1
Chemical injection fitting
2
Check ball
3
Spring
4
Ball seat assembly
5
Unloader ball
6
Trapped line pressure seat
7
Trapped line pressure piston assembly
8
Spring
Item
Name
9
Venturi assembly
1
Plastic cap
10
Head assembly
2
Setscrew, M6-1.0 x 8mm
3
Unloader handle
4
Spring
5
Unloader spindle assembly
6
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.
1. Lightly coat the unloader spindle threads and o-rings with silicone spray.
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.
2. Insert the spindle into the bore provided on the pump head and hand start the threads.
4. Lightly coat the high pressure port components with silicone spray.
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.
5. Insert the following components into the pump head in the order listed (refer to Figure 6.31): 69
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:
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.
Figure 6.33 — Pump Head Installation
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
Name
1
Crankcase assembly, including pistons and thermal bypass components
2
Spacer plate
3
Head gasket
4
Check valve o-rings (3)
5
Pump head assembly, including thermal bypass stem
6
Steel washer (6)
7
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.
70
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:
Figure 6.36 — “Jacking” Bolt Locations
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
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. 7. Visually verify that the piston shoes remain properly seated on the bearing race as you tighten the two screws alternately.
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.
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
Name
1
Funnel
2
Breather cap
3
Assembled pump/crankcase
72
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump
Part 5 - Troubleshooting Problem
Possible Cause
Corrective Action
1. Water leakage at mating flanges.
a. Head bolts improperly torqued.
a. Torque head bolts.
b. Damaged head.
b. Replace head.
c. Missing or damaged o-rings
c. Install new o-rings.
a. Chemical injection fitting improperly torqued.
a. Torque fitting.
b.Check ball missing.
b. Replace check ball and spring.
c. Check ball stuck.
c. Remove, clean and replace fitting, ball and spring.
a. Head bolts improperly torqued.
a. Torque head bolts.
b. Defective head gasket.
b. Install good head gasket.
c. Damaged head.
c. Replace head.
d. Missing or damaged o-rings.
d. Install new o-rings.
a. Connector not properly seated.
a. Seal with teflon tape and tighten properly.
b. Damaged connector.
b. Replace bad connector.
a. Defective or missing head gasket.
a. Install new head gasket.
b. Head bolts improperly torqued.
b.Torque head bolts properly.
c. Porosity in spacer plate.
c. Replace spacer plate.
a. Thermal bypass piston missing or defective.
a. Install thermal bypass piston.
b. Bad or missing thermal bypass piston spring.
b. Install new spring.
2. Water leakage from chemical
injector.
3. Water leakage between pump head
and spacer plate.
4. Water leaks from high pressure out
connector.
5. Water leaking out of head bolts.
6. Water leaking out behind spacer
plate.
c. Bad o-ring on thermal bypass piston. d. Low pressure water seals leaking.
73
c. Install new o-ring. d. Install new low pressure seals.
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump
Part 5 - Troubleshooting (Continued)
Problem
Possible Cause
Corrective Action
7. Oil leak between engine and engine adapter.
a. Defective or missing engine adapter oring or gasket.
a. Install new o-ring or gasket.
b. Engine adapter cap screws not tightened properly.
b. Tighten to correct torque.
8. Oil leak between engine adapter and pump crankcase.
a. Missing or bad o-ring seal.
a. Install new o-ring seal.
b. Cap screws not tightened properly.
b. Tighten to correct torque.
9. Oil leak between pump crankcase and spacer plate.
a. Missing or bad low pressure seals.
a. Install new seals.
b. Missing or bad piston oil seal.
b. Install new oil seals.
c. Cracks in casting.
c. Replace cracked casting.
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.
11. Detergent does not mix with spray.
a. Reset nozzle to high pressure. b. Replace with correct nozzle. c. Clear obstruction from nozzle.
d. Water Inlet blocked
d. Clear inlet.
e. Inadequate water supply to pump.
e. Provide sufficient water supply.
f. Water supply hose kinked or leaking.
f. Relieve kinking or repair leak.
g. Clogged inlet hose strainer.
g. Clean strainer.
h. Water supply too hot.
h. Reduce inlet water temperature to below 140oF.
i. Worn or defective pump.
i.
j. Unloader-regulator valve set wrong.
j. Set valve to high pressure.
k. Obstructed nozzle oe chemical venturi.
k. Remove, clean and replace chemical injection components.
a. Nozzle is in “high pressure” mode.
a. Reset nozzle to “low pressure”.
b. Chemical suction line is not submerged.
b. Insert line into fluid.
c. Chemical suction strainer or line is clogged.
c. Clean or replace strainer or line.
74
Disassemble and repair pump.
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.
Rated Pressure+
Engine Shaft
Pump Head
Flow Rate*
Piston Material
Oil Type/ Capacity
21300A 21300B 21300D 21300E 95523A 95523B 95523C 95523D 95523E 95523F 95523G 97239A 97239B 97239C 99750A 99750G
2250 2700 2600 2900 1500 1800 1500 1500 2000 2200 2500 1600 1900 2600 2500 3000
Straight Straight Tapered Tapered Straight Straight Straight Straight Tapered Tapered Tapered Straight Straight Straight Tapered Tapered
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
Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic Ceramic
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
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
Qty
Description
1
1
Unloader-pressure regulator assembly
2
3
Socket head cap screw, M6-1.0 x 45mm
3
3
M6 ribbed lock washer
4
1
Pump head assembly
5
1
O-ring
6
3
Piston pivot shoe
7
1
Axial cam bearing
8
1
9
Item
Qty
Description
14
1
Straight engine shaft adapter
15
1
C-ring cam retainer
16
1
Engine adapter gasket
17
4
Socket head cap screw, 5/16”-24
18
6
M6 ribbed lock washer
19
6
Socket head cap screw, M6-1 x 20mm
20
6
Socket head cap screw, M8-1.25 x 0.75
Axial cam
21
6
M8 ribbed lock washer
1
Engine adapter
22
1
Engine adapter o-ring
10
1
Engine adapter bearing
23
1
Tapered engine shaft adapter
11
1
Thrust washer
24
4
O-ring
12
1
Engine pilot sleeve
25
4
Button head cap screw, 5/16” - 24
13
1
Retainer washer
26
1
Belleville washer
27
1
Jam nut
77
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump
Exploded View
A typical large frame pump is shown in exploded view in Figure 7.2.
Figure 7.21 — Large Frame Pump (exploded view)
Torque Chart 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 Owner’s Manual shipped with each model pressure washer for appropriate part number references.
78
Item
Torque Value
2
5-8 ft-lbs
17
12-18 ft-lbs
19
5-8 ft-lbs
20
18-20 ft-lbs
25
8-10 ft-lbs
30
10-15 in-lbs w/Loctite
41
in Aluminum head:12-15 ft-lbs
41
in Brass head: 15-17 ft-lbs
49
5-8 ft-lbs
Drain plug
180 in-lbs max. (if equipped)
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump
Exploded View Parts List Item
Qty
Description
Item
Qty
Description
1
1
Unloader-pressure regulator assembly
26
1
Belleville washer
27
1
Jam nut
2
3
Socket head cap screw, M6-1.0 x 45mm
28
3
Piston
29
3
Piston return spring
30
1
Breather cap
31
1
Pump crankcase
32
3
Oil piston seal
33
3
Pilot spacer
34
3
Low pressure water seal
35
3
High pressure seal
36
3
Bearing seal ring
37
3
Backup ring
38
3
O-ring
39
3
High pressure port tower
40
3
Check valve guide
41
1
Pipe plug, 1/8 NPT
42
1
Cylinder head
43
1
Handle
44
3
Check valve guide
45
3
Check valve poppet
46
3
O-ring
47
3
Backup ring
3
3
M6 ribbed lock washer
4
1
Pump head assembly
5
1
O-ring
6
3
Piston pivot shoe
7
1
Axial cam bearing
8
1
Axial cam
9
1
Engine adapter
10
1
Engine adapter bearing
11
1
Thrust washer
12
1
Engine pilot sleeve
13
1
Retainer washer
14
1
Straight engine shaft adapter
15
1
C-ring cam retainer
16
1
Engine adapter gasket
17
4
Socket head cap screw, 5/16”-24 x 0.75
18
6
M6 ribbed lock washer
19
6
Socket head cap screw, M6-1 x 20mm
20
6
Socket head cap screw, M8-1.25 x 0.75
48
3
Check valve support
49
1
Garden hose connector
21
6
M8 ribbed lock washer
50
1
Thermal bypass actuator
22
1
Engine adapter o-ring
51
1
Head gasket
23
1
Tapered engine shaft adapter
52
1
Spacer plate
24
4
O-ring
53
1
O-ring
25
4
Button head cap screw, 5/16”-24 x 0.75
54
1
Thermal bypass piston
55
1
Thermal bypass spring
79
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump
Part 2 - Disassembly
Figure 7.3 - Pump Head
General Information & Special Tools
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.
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.
Special tools needed: • Special engine shaft adapter puller tool, Generac Portable Products® part number SRV95523
Figure 7.4 - Head Screw Removal
• Dead blow mallet • 0.25” dia. 7” long brass rod Pump Head Before removing the pump head, disconnect the inlet water hose from the pump’s water inlet. Also disconnect the spray gun high pressure hose from the pump’s 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.
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.
3. Remove the engine adapter bearing assembly.
Figure 7.5 - Pivot Shoe
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.
Item
Name
1
O-ring
2
Engine Adapter
3
Roller Thrust Bearing
4
Engine Shaft Adapter
5
Axial Cam
6
Bearing Assembly
7
Belleville washer
8
Jam nut
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.
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
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.
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 7.9 - Piston Assembly
Figure 7.8 - Axial Cam Drive Components (Units with Straight Engine Shaft)
Item
Name
1
Engine adapter
2
Roller thrust bearing assembly
3
C-ring cam retainer
4
Washer retainer
5
Thrust washer
6
Engine shaft adapter
7
Axial cam
8
Piston pivot bearing assembly
Item
Name
1
Return spring
2
Piston
3
Retainer
4
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
Name
Item
Name
Item
Name
1
Adapter housing
11
Guide stem
21
Stainless steel spring
2
O-ring
12
Support ring
22
Chemical injector body
3
Bushing
13
Piston
23
Stop ring
4
11/32” ball
14
Zinc plated nut
24
Washer
5
Magnet
15
Regulator spring
25
Hose barb coupling
6
Magnet stop ring
16
Spring guide stop
26
Adjusting screw
7
Guide
17
Knob insert
27
Chemical injection knob
8
Guide plug
18
Pressure knob
28
Hose barb connection
9
Support ring
19
Self locking nut
29
7/32” ball
10
Elastic pin
20
Piston seal
30
Taper spring
83
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump
Cylinder Head
To remove the three (3) inlet (low pressure) check valves, refer to Figure 7.14 and proceed as follows:
NOTE: Some pump models feature a BRASS cylinder head, some an ALUMINUM cylinder head.
Figure 7.13 — Check Valve Puller
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
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
Name
1
Spacer plate
2
Head gasket
3
Thermal bypass
4
Plug
5
Cylinder head
6
Lock washer
7
Socket head cap screw
8
Inlet water connector/filter
Item
Name
1
Puller tool
2
O-ring
3
Check valve
4
Backup ring
puller threads have engaged the check valve threads.
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:
NOTE: Do not turn the tool in too far. An engagement of 2 or 3 threads is sufficient.
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.
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.
Three (3) inlet and three (3) outlet check valves are threaded (7/16”-20) to accept the threaded tee handle. 84
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump
Thermal Bypass Actuator Removal Refer to Figure 7.16 and:
To remove the three (3) outlet (high pressure) check valves, refer to Figure 7.15 and proceed as follows:
Figure 7.16 — Thermal Bypass Actuator Removal
Figure 7.15 — Outlet Check Valve Removal
Item 1 2 3 4
Name Puller tool Backup rings Check valve O-rings
Item
Name
1
Pump crankcase
2
Spring
3
O-ring
1. Insert the ‘T’ handle through the puller tool thimble (item 1).
4
Spacer plate
5
Head gasket
2. Turn the puller lower tee handle fully counterclockwise.
6
Pump head
3. Insert the puller down through the high pressure port tower.
7
Insert brass rod here
8
Thermal bypass actuator
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.
NOTE: Do not turn the tool in too far. An engagement of 2 or 3 threads is sufficient.
3. Insert rod from the unloader/pressure regulator valve side of the head.
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.
4. Tap the rod gently with the dead blow hammer to free the actuator.
6. Repeat steps 2 to 5 for the other outlet check valves.
85
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:
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.
Figure 7.17 - Spacer Plate Removal
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
Name
1
Thermal bypass spring
2
Thermal bypass piston & o-ring
3
Spacer plate
4
Low pressure seal
5
Pilot spacer
6
Piston oil seal (in crankcase)
86
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump
Part 3 - Inspection
Figure 7.19 — Inlet Check Valve
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
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
Name
1
Spacer plate
2
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.
87
Item
Name
1
High pressure seal
2
Bearing seal ring
3
Backup ring
4
O-ring
5
High pressure port tower
6
Check valve
7
Cylinder head
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.
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.
Figure 7.21 — Two Types of Head Gaskets
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
Name
1
O-ring
2
Engine Adapter
3
Roller Thrust Bearing
4
Engine Shaft Adapter
5
Axial Cam
6
Bearing Assembly
Check the axial cam for wear, damage, scoring, overheating, grooving, etc. Replace if worn excessively or damaged.
Later model pumps use a flange o-ring and bolt head o-ring seals instead of the engine adapter gasket.
Inspect the engine shaft adapter. Check for evidence of scoring, wear, damage, overheating. Replace if necessary. 88
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump
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.
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.
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.
Figure 7.24 - Axial Cam Drive Components (Units with Straight Engine Shaft)
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
Name
1
Engine adapter
2
Roller thrust bearing assembly
3
C-ring cam retainer
4
Washer retainer
5
Thrust washer
6
Engine shaft adapter
7
Axial cam
8
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
Name
1
Free length
2
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
Figure 7.29 — Engine Adapter Attachment (Units with Tapered Engine Shaft)
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
Item
Name
1
Apply Loctite around the larger circumference of the ring in this area.
Item
Name
1
Engine adapter gasket
2
Engine adapter
3
Engine adapter bearing assembly
4
Engine shaft adapter
5
Axial cam
6
Axial cam bearing assembly
7
Belleville washer
8
Jam nut
9
Socket head cap screw
10
Lock washer
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.
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.
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.
b. Tap the adapter sleeve into the engine adapter bore until it seats flush against the inside machined surface of the engine adapter.
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.
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.
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.
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.
Figure 7.30 — Bearing Race Assembly
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.
Item
Name
1
Engine adapter bearing race
2
Engine adapter bearing
3
Inner cam bearing race
4
Axial cam assembly
5
Outer cam bearing race
6
Axial cam bearing
7
Piston shoe bearing race
A
Larger inside diameter
B
Smaller inside diameter
C
Chamfer faces this way
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.
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:
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.
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:
2. To assemble units having an O-ring seal and button head cap screws with o-ring seals, refer to Figure 7.32:
Figure 7.31 — Axial Cam Drive Components (Units with Straight Engine Shaft)
Item
Name
1
Engine adapter gasket
2
Engine adapter
3
Engine adapter bearing assembly
4
C-ring cam retainer
5 6
Figure 7.32 — Axial Cam Drive Components (Units with Straight Engine Shaft and O-Ring Seal)
Item
Name
1
O-ring
2
Engine adapter
Washer retainer
3
Engine adapter bearing assembly
Thrust washer
4
C-ring cam retainer
7
Engine shaft adapter
5
Washer retainer
8
Axial cam
6
Thrust washer
9
Axial cam bearing assembly
7
Engine shaft adapter
10
Lock washer
8
Axial cam
11
Socket head cap screw
9
Axial cam bearing assembly
10
Button head cap screw
11
O-ring
a. Use a new adapter gasket and install the engine adapter onto the engine.
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” socket head cap screws and for (4) M8 ribbed lock washers.
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.
c.
93
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.
Piston Oil Seals and Pistons Refer to Figure 7.33 for this procedure. Figure 7.33 — Oil Seals & Pilot Spacers
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.
Item
Name
1
Pilot spacer tang engaged in crankcase locating notch
2
Crankcase locating notch
3
Pump crankcase
4
High pressure oil seal
5
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.
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.
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:
Figure 7.35 — Piston Installation
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
Item
Name
1
Lock ring
2
Spring retainer
3
Return spring
4
Piston
Item
Name
1
Return spring
2
Pump crankcase
3
Piston oil seal
4
Pilot spacer
5
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.
95
Item
Name
1
Pump crankcase
2
Thermal bypass spring
3
Thermal bypass piston
4
O-ring
Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump
Pump Head Assembly 1. Install an o-ring and backup ring on all check valves, as shown in Figure 7.38.
Spacer Plate 1. Referring to Figure 7.37, install the three (3) low pressure seals into the bores provided in the spacer plate.
Figure 7.38 — Check Valve O-Ring Assembly
Figure 7.37 — Inlet Check Valve Seat Supports
Item
Name
1
Low pressure seal
2
Spacer plate
3
Check valve support
Item
Name
1
O-ring
2
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.
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.
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.
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.
Again, refer to Figure 7.15 for a depiction of this assembly’s appearance. d. Lubricate an inlet check valve, seal, and backup ring with silicone spray.
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.
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.
Figure 7.39 - Inlet Check Valve Installation
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:
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 7.41 — Pump Head Installation
Figure 7.42 — Head Bolt Tightening Sequence
Item
Name
1
Spacer plate
2
Head gasket
3
Thermal bypass actuator
4
Pump head
5
Lock washer
6
Socket head cap screw
7*
O-ring
8*
Unloader valve spindle seat
9
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. 98
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).
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:
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.
1. Install a new o-ring seal around the mounting flange of he pump crankcase.
Figure 7.43 — Unloader-Pressure Regulator
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
Name
1
Unloader/pressure regulator assembly
2
Washer
3
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
Name
1
Oil fill - breather cap
2*
Drain plug
3*
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
Possible Cause
Corrective Action
1. Water leakage at mating flanges.
a. Head bolts improperly torqued.
a. Torque head bolts.
b. Damaged head.
b. Replace head.
c. Missing or damaged o-rings
c. Install new o-rings.
a. Chemical injection fitting improperly torqued.
a. Torque fitting.
b.Check ball missing.
b. Replace check ball and spring.
c. Check ball stuck.
c. Remove, clean and replace fitting, ball and spring.
a. Head bolts improperly torqued.
a. Torque head bolts.
b. Defective head gasket.
b. Install good head gasket.
c. Damaged head.
c. Replace head.
d. Missing or damaged o-rings and backup rings.
d. Install new o-rings and backup rings.
a. Connector not properly seated.
a. Seal with teflon tape and tighten properly.
b. Damaged connector.
b. Replace bad connector.
a. Defective or missing head gasket.
a. Install new head gasket.
b. Head bolts improperly torqued.
b. Torque head bolts properly.
c. Porosity in spacer plate.
c. Replace spacer plate.
a. Thermal bypass piston missing or defective.
a. Install thermal bypass piston.
b. Bad or missing thermal bypass piston spring.
b. Install new spring.
c. Bad o-ring on thermal bypass piston.
c. Install new o-ring.
d. Low pressure water seals leaking.
d. Install new low pressure seals.
e. Defective or missing o-rings on spacer plate truss head screws.
e. Install new o-rings on screws.
f. Spacer plate screws not tight.
f.Tighten to correct torque.
a. Defective or missing engine adapter o-ring or gasket.
a. Install new o-ring or gasket.
b. Engine adapter cap screws not tightened properly.
b. Tighten to correct torque.
2. Water leakage from chemical
injector.
3. Water leakage between pump head
and spacer plate.
4. Water leaks from high pressure out
connector.
5. Water leaking out of head bolts.
6. Water leaking out behind spacer
plate.
7. Oil leak between engine and engine adapter.
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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump
Part 5 - Troubleshooting Problem
Possible Cause
Corrective Action
8. Oil leak between engine adapter and pump crankcase.
a. Missing or bad o-ring seal.
a. Install new o-ring seal.
b. Cap screws not tightened properly.
b. Tighten to correct torque.
9. Oil leak between pump crankcase and spacer plate.
a. Missing or bad low pressure seals.
a. Install new seals.
b. Missing or bad piston oil seal.
b. Install new oil seals.
c. Cracks in casting.
c. Replace cracked casting.
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.
11. Detergent does not mix with spray.
a. Reset nozzle to high pressure. b. Replace with correct nozzle. c. Clear obstruction from nozzle.
d. Water Inlet blocked
d. Clear inlet.
e. Inadequate water supply to pump.
e. Provide sufficient water supply.
f. Water supply hose kinked or leaking.
f. Relieve kinking or repair leak.
g. Clogged inlet hose strainer.
g. Clean strainer.
h. Water supply too hot.
h. Reduce inlet water temperature to below 140oF.
i. Worn or defective pump.
i. Disassemble and repair pump.
j. Unloader-regulator valve set wrong.
j. Set valve to high pressure.
k. Obstructed nozzle.
k. Clear nozzle of obstructions.
l. Obstructed chemical injection system.
l. Remove, clean and replace chemical injection components.
a. Nozzle is in “high pressure” mode.
a. Reset nozzle to “low pressure”.
b. Chemical suction line is not submerged.
b. Insert line into fluid.
c. Chemical suction strainer or line is clogged.
c. Clean or replace strainer or line.
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Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump
104
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
FAIP – a pressure washer pump manufacturer
Annovi Reverberi – a pressure washer pump manufacturer
FH – same as ‘flathead’ pump, now known as a medium frame pump
Arrestor – see ‘spark arrestor’Assy – same as ‘assembly’ or group of parts
Foamer – a device used to inject soap, wax, or other additives into a stream of low pressure water
Awg – a unit of measure, relating a wire diameter in terms of American Wire Gauge
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
Axial cam - a device (cam) used to transform the rotary motion of the motor crankshaft into the reciprocating motion of a pump’s pistons; also known as a ‘wobble plate’
GN – a trade name for a certain type of Generac-Nagano internal combustion engine, such as GN-220, etc.
Backflushing – a method of reversing water flow through a system in order to flush out any blockages or impurities
GPM – a unit of measure for water flow; same as ‘gallons per minute’
Backwashing – same as backflushing
GPW – same as ‘Generac pressure washer’ pump, now known as a large frame pump
Belleville – a trade name for a certain type of domed steel washer BHCS – same as ‘button head cap screw’, a type of fastener
Helpline – special telephone answering service that can assist Generac owners having operational questions
BSP - same as “British Straight Pipe”, a type of pipe thread
HHCS - same as ‘hex head cap screw’; a type of fastener
Centura – a trade name for a certain type of Tecumseh internal combustion engine
HM – same as ‘hour meter’, a device used to record the elapsed time a device is operated
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
HP – same as ‘horsepower’, a unit of measure for work Intek - a trade name for a certain type of Briggs & Stratton internal combustion engine
Contaminants – chemicals or particles of inappropriate matter mixed with known good materials
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
Couplings – devices used to make a mechanical connection between two rotating shafts or threaded pipes, etc.
Lavor Wash – a pressure washer pump manufacturer
CSA - characters which signify that the labeled device complies with applicable regulations promoted by the Canadian Standards Association
Loctite – trade name for a brand of assembly adhesive
Lbs – same as ‘pounds’ Ml – same as ‘milliliter’, a unit of measure for volume
CST – signifies Central Standard Time
Newton – a unit of measure for force
Degreaser – a chemical used to remove grease or similar petroleum-based products from a surface or object
NFPA – same as ‘National Fire Prevention Association’
Dia – same as ‘diameter’
NPT – same as ‘national pipe taper’, a designator applied to a specific type of pipe threads
Dipstick – a device used to indicate the level (amount) of oil in a pump/engine crankcase
NSP – same as ‘non-service part’; the entire assembly must be replaced as a unit
EE – same as ‘economy electric’ pump, now known as a small frame pump powered by an electric motor
OHV – same as ‘overhead valve’, an improved way to control exhaust and intake valves on internal combustion engines
EG – same as ‘economy gas’ pump, now known as a small frame pump powered by a gasoline engine Eng – stands for ‘engine’ or ‘engineering’
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
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
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 engine’s 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. 106