Part 5 - Troubleshooting

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

Problem Possible Cause

1. Water leakage at mating flanges. a. Head bolts improperly torqued.

b. Damaged head. c. Missing or damaged o-rings a. Torque head bolts. b. Replace head. c. Install new o-rings.

Corrective Action

2. Water leakage from chemical injector.

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

b. Replace check ball and spring. c. Remove, clean and replace fitting, ball and spring.

3. Water leakage between pump head and spacer plate.

4. Water leaks from high pressure out connector.

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

a. Connector not properly seated. b. Damaged connector. a. Seal with teflon tape and tighten properly. b. Replace bad connector.

5. Water leaking out of head bolts. a. Defective or missing head gasket. b. Head bolts improperly torqued. c. Porosity in spacer plate.

6. Water leaking out behind spacer plate.

7. Oil leak between engine and engine adapter. a. Defective or missing engine adapter o-ring or gasket. b. Engine adapter cap screws not tightened properly. a. Install new o-ring or gasket.

b. Tighten to correct torque.

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

b. Install new spring.

c. Install new o-ring. d. Install new low pressure seals. e. Install new o-rings on screws.

f.Tighten to correct torque.

a. Install new head gasket. b. Torque head bolts properly. c. Replace spacer plate.

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

Part 5 - Troubleshooting

Problem

8. Oil leak between engine adapter and pump crankcase. a. Missing or bad o-ring seal. b. Cap screws not tightened properly. a. Install new o-ring seal. b. Tighten to correct torque.

Possible Cause

9. Oil leak between pump crankcase and spacer plate. a. Missing or bad low pressure seals. b. Missing or bad piston oil seal. c. Cracks in casting.

10. Pump does not produce pressure, exhibits erratic pressure, chatters or has a low water volume. a. Nozzle is set to low pressure mode. b. Incorrect spray nozzle is used. c. Spray nozzle is obstructed. d. Water Inlet blocked e. Inadequate water supply to pump. f. Water supply hose kinked or leaking. g. Clogged inlet hose strainer. h. Water supply too hot.

i. Worn or defective pump. j. Unloader-regulator valve set wrong. k. Obstructed nozzle. l. Obstructed chemical injection system.

11. Detergent does not mix with spray. a. Nozzle is in “high pressure” mode. b. Chemical suction line is not submerged. c. Chemical suction strainer or line is clogged. Corrective Action

a. Install new seals. b. Install new oil seals. c. Replace cracked casting.

a. Reset nozzle to high pressure. b. Replace with correct nozzle. c. Clear obstruction from nozzle. d. Clear inlet. e. Provide sufficient water supply. f. Relieve kinking or repair leak. g. Clean strainer. h. Reduce inlet water temperature to below 140oF. i. Disassemble and repair pump. j. Set valve to high pressure. k. Clear nozzle of obstructions. l. Remove, clean and replace chemical injection components.

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

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

Portable Pressure Washer Familiarization and Troubleshooting Guide Glossary

GLOSSARY

The following are definitions for terms commonly used in the pressure washer industry. Ampere – a unit of measure for current draw Annovi Reverberi – a pressure washer pump manufacturer Arrestor – see ‘spark arrestor’Assy – same as ‘assembly’ or group of parts Awg – a unit of measure, relating a wire diameter in terms of American Wire Gauge Axial cam - a device (cam) used to transform the rotary motion of the motor crankshaft into the reciprocating motion of a pump’s pistons; also known as a ‘wobble plate’ Backflushing – a method of reversing water flow through a system in order to flush out any blockages or impurities Backwashing – same as backflushing Belleville – a trade name for a certain type of domed steel washer BHCS – same as ‘button head cap screw’, a type of fastener BSP - same as “British Straight Pipe”, a type of pipe thread Centura – a trade name for a certain type of Tecumseh internal combustion engine Connector – a device used to make an electrical connection between two or more circuit wires; a device used to attach water hoses, high pressure hoses, and so forth Contaminants – chemicals or particles of inappropriate matter mixed with known good materials Couplings – devices used to make a mechanical connection between two rotating shafts or threaded pipes, etc. CSA - characters which signify that the labeled device complies with applicable regulations promoted by the

Canadian Standards Association CST – signifies Central Standard Time Degreaser – a chemical used to remove grease or similar petroleum-based products from a surface or object Dia – same as ‘diameter’ Dipstick – a device used to indicate the level (amount) of oil in a pump/engine crankcase EE – same as ‘economy electric’ pump, now known as a small frame pump powered by an electric motor EG – same as ‘economy gas’ pump, now known as a small frame pump powered by a gasoline engine Eng – stands for ‘engine’ or ‘engineering’ FAIP – a pressure washer pump manufacturer FH – same as ‘flathead’ pump, now known as a medium frame pump Foamer – a device used to inject soap, wax, or other additives into a stream of low pressure water General – a pressure washer pump manufacturer GFCI – same as ‘ground fault circuit interrupter’, a device used to almost instantly cut off circuit power when an improper grounding condition is sensed GN – a trade name for a certain type of Generac-Nagano internal combustion engine, such as GN-220, etc. GPM – a unit of measure for water flow; same as ‘gallons per minute’ GPW – same as ‘Generac pressure washer’ pump, now known as a large frame pump Helpline – special telephone answering service that can assist Generac owners having operational questions HHCS - same as ‘hex head cap screw’; a type of fastener HM – same as ‘hour meter’, a device used to record the elapsed time a device is operated HP – same as ‘horsepower’, a unit of measure for work Intek - a trade name for a certain type of Briggs & Stratton internal combustion engine Keyway – a special slot cut into an engine shaft that is intended to mate with a matching key in a pump; permits maximum transfer of power from engine to pump Lavor Wash – a pressure washer pump manufacturer Lbs – same as ‘pounds’ Loctite – trade name for a brand of assembly adhesive Ml – same as ‘milliliter’, a unit of measure for volume Newton – a unit of measure for force NFPA – same as ‘National Fire Prevention Association’ NPT – same as ‘national pipe taper’, a designator applied to a specific type of pipe threads NSP – same as ‘non-service part’; the entire assembly must be replaced as a unit OHV – same as ‘overhead valve’, an improved way to control exhaust and intake valves on internal combustion engines OHVI – an industrial, more durable version of the ohv engine

Portable Pressure Washer Familiarization and Troubleshooting Guide Glossary

Overchoking – a condition where the engine is being deprived of intake air while being flooded with fuel Overflush – a mechanical condition where one surface is slightly higher than its surrounding surface Overspraying – a condition where a substance (paint, high pressure atomized water, etc.) is broadcast outside of its intended region Overtighten – a condition where a fastener or other securing device is more than fully engaged, causing possible damage to its associated components or difficulty in removal Parback – a trade name for a type of fluid seal device Permabond – a trade name for a type of industrial adhesive Poppet – a type of valve used to relieve pressure PSI - a unit of pressure; same as ‘pounds per square inch’ Purge - a method of eliminating air from a pressure washer so that starting the engine is easier PW – same as ‘pressure washer’ QPQ – same as ‘quench purge quench’, a heat treating process designed to case-harden pressure washer pistons Quantum - a trade name for a certain type of Briggs &

Stratton internal combustion engine Quattro - a trade name for a certain type of Briggs &

Stratton internal combustion engine RPM – same as ‘revolutions per minute’ SAE – same as ‘Society of Automotive Engineers’ SF – designates a specific grade of automotive oil SG – same as ‘sf’ SH – same as ‘sf’ Side valve - a type of internal combustion engine that uses a conventional “L” type cylinder head with intake and exhaust valves on the side 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

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.