Briggs And Stratton Pressure Washer Repair Manual Pdf Download

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Electronic Version #B3277 Rev. 1 4/03

®

Pressure Washer Familiarization & Troubleshooting Guide

FORWARD This guide has been written and published by Briggs & Stratton Corporation to aid our dealers' mechanics and company service personnel when servicing the products described herein.

It is assumed that these personnel are familiar with the servicing procedures for these products, or like or similar products, manufactured by Briggs & Stratton Corporation. It is also assumed that they have been trained in the recommended servicing procedures for these products, which includes the use of mechanics hand tools and any special tools that might be required.

Proper service and repair is important to the safe, economical and reliable operation of all engine driven systems.

The troubleshooting, testing, service and repair procedures described in this guide are effective methods of performing such operations.

We could not possibly know of and advise the service trade of all conceivable procedures or methods by which a service might be performed, nor of any possible hazards and/or results of each procedure or method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a procedure or method not described by the manufacturer must first satisfy himself that neither his safety, nor the safety of the product, will be endangered by the service or operating procedure selected.

All information, illustrations, and specifications contained in this guide are based on the latest production information available at the time of publication. However, Briggs & Stratton Corporation reserves the right to change, alter, or otherwise improve the product at any time without prior notice.

Some components or assemblies of the product described in this guide may not be considered repairable.

Disassembly, repair and reassembly of such components may not be included in this guide.

Copyright Š 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

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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 35 35

Cross-Sectional view

36

Exploded View

38

Part 2 - Disassembly General Information & Special Tools

40 40

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

56

Axial Cam Drive Components

57

Pistons and Piston Springs

57

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 3 - Inspection Seals, O-Rings, and Gaskets

61 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

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

Part 1 - Specifications and Views Performance Specifications

Pump Head

61

45 45

5 • Medium Frame Pump

56 56

Seals

Part 4 - Reassembly Engine Adapter

Part 5 - Troubleshooting

Part 2 - Disassembly General Information & Special Tools

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

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

Item 6 7 8 9 10

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

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 ProductsÂŽ 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

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

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: 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

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