Briggs & Stratton CE8070 Troubleshooting Manual
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Briggs & Stratton CE8070 Troubleshooting Manual

Briggs & Stratton CE8070 Troubleshooting Manual

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Part No. B3277GS Rev. 0 11/98
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Familiarization & Troubleshooting Guide

PRESSURE WASHER

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Summary of Contents for Briggs & Stratton CE8070

  • Page 1: Pressure Washer

    For Briggs & Stratton Discount Parts Call 606-678-9623 or 606-561-4983 Look for these other repair manuals from the Briggs & Stratton Power Products line: 86262GS Portable Generators Familiarization & Troubleshooting Guide 190275 Hand-Held Generator Familiarization & Troubleshooting Guide Familiarization & Troubleshooting Guide 275110 Outboard Motor Repair Manual PRESSURE WASHER...
  • Page 2 Please click the “Bookmarks” tab at left to enable the search and navigational features of this document. ® Pressure Washer Familiarization & Troubleshooting Guide...

  • Page 3: Operation 5

    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 &...

  • Page 4: Table Of Contents

    Portable Pressure Washer Familiarization and Troubleshooting Guide Table of Contents TABLE OF CONTENTS 1 • 4 • Operation Small Frame Electric Pump Part 1 - Specifications and Views Performance Specifications 2 • Pressure Washer Components Cross-Sectional View Power Source Exploded View Pressure washer pumps Part 2 - Disassembly Inlet and Outlet Check Valves...
  • Page 5 Portable Pressure Washer Familiarization and Troubleshooting Guide Table of Contents TABLE OF CONTENTS Small Frame Gas Pump Part 2 - Disassembly General Information & Special Tools Part 1 - Specifications and Views Pump Head Performance Specifications Axial Cam Drive Components Cross-Sectional view Pistons and Piston Springs Exploded View...
  • Page 6 Portable Pressure Washer Familiarization and Troubleshooting Guide Table of Contents TABLE OF CONTENTS 6 • Large Frame Pump Part 4 - Reassembly Engine Adapter Part 1 - Specifications and Views Piston Oil Seals and Pistons Performance Specifications Spacer Plate Cross-Sectional View Pump Head Assembly Exploded View Pump Head Installation...
  • Page 7 Portable Pressure Washer Familiarization and Troubleshooting Guide Table of Contents...

  • Page 8: Operation

    Pressure Washer Familiarization and Troubleshooting Guide Section 1 • Operation PRESSURE WASHER OPERATION Operation of a pressure washer system may be briefly 2. Rotary motion of the motor crankshaft is converted to described as follows. Please refer to Figure 1.1 for visual reciprocating motion of the pump’s pistons using an axial component identification: cam.
  • Page 9 Portable Pressure Washer Familiarization and Troubleshooting Guide Section 1 • Operation 3. The linear movement of the pistons pump a fixed volume 9. The optional chemical injection assembly (item 8) permits of water through the pressure washer system. The detergents or other chemicals to be drawn into the water volume of water flow depends on stream and (along with the water) discharged from the nozzle.

  • Page 10: Pressure Washer Components

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 2 • Pressure Washer Components PRESSURE WASHER COMPONENTS Power Source Figure 2.1 — Pressure Washer Pump uses several Generac Portable Products® engine manufacturers and different pump types on its pressure washers. Generac Portable Products® also uses an electric motor on some models.

  • Page 11: Inlet And Outlet Check Valves

    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 Output water pressure can be adjusted using the pressure conjunction with the pump pistons to create volume flow.

  • Page 12: Thermal Bypass System

    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.

  • Page 13: Easy Start Valve

    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 Certain larger Generac Portable Products®...

  • Page 14: High Pressure Hose

    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 uses excellent Generac Portable Products® normal flow of water through a nozzle is shut off.

  • Page 15: Spray Wands And Nozzles

    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 The spray nozzle is critical to proper operation of a through the open valve and out of the wand to the nozzle.

  • Page 16: General Information

    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 This section describes the general maintenance procedures jelly as necessary to ease the connections.

  • Page 17: Spray Nozzle Servicing

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 3 • General Information Spray Nozzle Servicing 6. Remove any additional dirt from the wand by back- flushing with water, as described below and shown in If the spray nozzle becomes clogged with dirt, excessive Figure 3.4.

  • Page 18: Part 2 - Lubrication

    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 All pressure washers require oil lubrication of the piston (near the center).

  • Page 19: Part 3 - Storage

    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 1. Draw automotive windshield washer fluid into the pump: Water should not be allowed to remain in the pump for a.

  • Page 20: Small Frame Electric Pump

    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: •...

  • Page 21: Cross-Sectional View

    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)
  • Page 22 Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump Cross-Sectional View Parts List Item Qty. Description Item Qty. Description High pressure water seal O-ring Lock washer, M6 ribbed O-ring SHCS M6- 1.0 x 35mm Shuttle valve spring Piston Shuttle valve Pump head...

  • Page 23: Exploded View

    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 15-17 ft-lbs 7-9 ft-lbs...
  • Page 24 Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump Exploded View Parts List Item Qty. Description Item Description Pump head O-ring Inlet check valve O-ring Outlet check valve Shuttle valve spring Hex socket set screw w/ Locktite Shuttle valve DO NOT REMOVE O-ring...

  • Page 25: Part 2 - Disassembly

    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.

  • Page 26: Piston Housing Removal

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump WARNING: Piston Housing Removal There may be up to 50 pounds of stored energy when separating the piston housing Refer to Figure 4.4 for this procedure. from the motor.

  • Page 27: Piston Housing Disassembly

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump Piston Housing Disassembly Chemical Injection System Refer to Figure 4.6 for this disassembly, as follows: Not all pumps are equipped with a chemical injection system. Refer to Figure 4.7 when following this disassembly Figure 4.6 —...

  • Page 28: Auto Start Switch Assembly

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump Auto Start Switch Assembly 1. Remove the housing covering the auto switch (item 4) and disconnect two spade lugs from the switch. Refer to Figure 4.8 when following this disassembly procedure.

  • Page 29: Axial Cam

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump Axial Cam 1. Grasp the protruding end of the axial cam idler shaft (item 1) with your fingers and withdraw it from the Refer to Figure 4.9 when following this disassembly motor housing (item 5).

  • Page 30: Part 3 - Inspection

    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 Seals, O-Rings, and Gaskets pilot spacer illustrated in Figure 4.11.

  • Page 31: Axial Cam Drive Components

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump Axial Cam Drive Components Inspect the axial cam idler shaft. Replace if worn, bent, or damaged. Referring to Figure 4.12, carefully inspect axial cam bearing assemblies for wear, damage, and freedom of rotation. Inspect the thrust washers.

  • Page 32: Part 4 - Reassembly

    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 4. Press three (3) inlet check valves (item 1) into place. pump sectional view found at the beginning of this Notice that the small end of the valve goes into the cavity section when reassembling this product.

  • Page 33: Chemical Inject Assembly

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump Before assembly, ensure the auto switch cavity is clean and Chemical Inject Assembly free from scale, corrosion, dirt, etc. Refer to Figure 4.15 for this assembly. 1.

  • Page 34: Piston Housing Assembly

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump Piston Housing Assembly Pilot Spacer Installation Refer to Figure 4.16 for this procedure. Refer to Figure 4.17 for this procedure. 1. Install the three (3) check valve o-rings (item 4). Use a Figure 4.16 —...

  • Page 35: Pump Head Bolts

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump Pump Head Bolts 1. Invert the head/piston housing assembly and place it on a flat surface. Ensure that the pistons are fully inserted into 1. Grasp the head/piston housing assembly and invert it the piston housing.

  • Page 36: Final Assembly And Test

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 4 • Small Frame Electric Pump CAUTION: Final Assembly and Test The motor adapter bolt holes line up with the holes on the piston housing in one position NOTE: Torque the outlet caps at this time, if not only.

  • Page 37: Part 5 - Troubleshooting

    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 a. Head bolts improperly torqued. a. Torque head bolts. piston housing. b.

  • Page 38: Small Frame Gas 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.

  • Page 39: Cross-Sectional View

    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)
  • Page 40 Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 • Small Frame Gas Pump Cross Sectional View Parts List Item Qty. Description Item Qty. Description Rubber grommet spacer sleeve Unloader seat O-Ring Cage needle bearing assembly Unloader piston Bearing washer Unloader split-ring seal Bearing washer Unloader spring...

  • Page 41: Exploded View

    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 Item Torque 15-17 ft-lbs...
  • Page 42 Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 • Small Frame Gas Pump Exploded View Parts List Item Qty. Description Item Qty. Description Rubber grommet spacer sleeve Unloader piston Cage needle bearing assembly Unloader split-ring seal Bearing washer Unloader spring Bearing washer Unloader cap O-Ring Oil piston seal...

  • Page 43: Part 2 - Disassembly

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 • Small Frame Gas Pump Part 2 - Disassembly To disassemble pump head: 1. Remove the three (3) water seals. Seals should slide out General Information & Special Tools by hand. NOTE: There are no special tools required to 2.

  • Page 44: Piston & Unloader Housing Disassembly

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 • Small Frame Gas Pump 2. Remove the three (3) low pressure transfer O-Rings. Piston & Unloader Housing Disassembly Refer to Figure 5.6 for this disassembly, as follows: WARNING: There may be up to 75 pounds of stored energy when separating the piston and Figure 5.6 - Piston &...

  • Page 45: Chemical Injection System

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 • Small Frame Gas Pump Chemical Injection System Unloader Refer to Figure 5.7 and follow this chemical injection system Refer to Figure 5.8 when following this disassembly disassembly procedure. procedure. CAUTION: Figure 5.7 - Chemical Injection System Unloader cap is under strong spring pressure.

  • Page 46: Engine Adapter

    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 Seals, O-Rings, and Gaskets procedure. Once the pump is disassembled, make a careful inspection of Figure 5.9 - Engine Adapter &...

  • Page 47: Engine Adapter, Pump Head And Piston/Unloader Housing

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 • Small Frame Gas Pump Each of the three (3) pump pistons pass through an oil seal Axial Cam Drive Components in the piston and unloader housing. Note the oil seal and Referring to Figure 5.12, carefully inspect the engine adapter pilot spacer illustrated in Figure 5.11.

  • Page 48: Part 4 - Reassembly

    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 6.

  • Page 49: Piston & Unloader Housing Assembly

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 • Small Frame Gas Pump 4. Install the chemical injection venturi O-Ring into the 2. Apply a small amount of 80W90 oil to the three (3) piston and unloader housing. pistons, then install the pistons, springs, and retainers into the piston and unloader housing.

  • Page 50: Main Component Assembly

    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 3. Place the piston housing O-Ring into the groove on the Figure 5.16. housing. 4.

  • Page 51: Pilot Spacer Installation

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 • Small Frame Gas Pump Pilot Spacer Installation 3. Install the three (3) low pressure transfer O-Rings around the inlet openings on the piston housing, as seen in Figure 1. Grasp the complete pump assembly with both hands and 5.20.

  • Page 52: Pump Head Bolts

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 5 • Small Frame Gas Pump Pump Head Bolts Oil Fill Referring to Figure 5.21, reposition the pump head and As shown in Figure 5.22, set the pump on its head. Pour in install the four (4) M6-1.0 x 35 cap screws.

  • Page 53: Part 5 - Troubleshooting

    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 a. Head bolts improperly torqued. a. Torque head bolts. piston housing. b.

  • Page 54: Medium Frame 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: •...

  • Page 55: Cross-Sectional View

    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)

  • Page 56: Socket Head Cap Screw M6-1.0 X

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump Sectional View Parts List Item Description Item Description Oil breather cap Outlet port cap Loctite O-ring, outlet port O-ring Check valve Axial cam bearing assembly O-ring, check valve Axial cam Head sub-assembly Engine adapter...
  • Page 57 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 20-30 ft-lbs 10-12 ft-lbs 9-12 ft-lbs 20-23 ft-lbs...

  • Page 58: Exploded View

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump Exploded View Parts List Item Description Item Description Outlet port cap Thermal actuator spring O-ring, outlet port Thermal actuator piston Check valve Piston O-ring, check valve Oil breather cap Head sub-assembly O-ring Bearing ring...

  • Page 59: Part 2 - Disassembly

    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 General Information & Special Tools (2) M6-1.0x 45 hex head bolts.

  • Page 60: Axial Cam Drive Components

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump Axial Cam Drive Components Pistons and Piston Springs To disassemble medium frame units, refer to Figure 6.6 and Refer to Figure 6.7 for this disassembly. The three (3) proceed as follows: pistons along with their springs can be removed from the pump crankcase by grasping the springs and pulling straight...

  • Page 61: Pump Head

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump Pump Head Spacer Plate To remove the pump head assembly, refer to Figure 6.8 and Referring to Figure 6.9, remove the spacer plate from proceed as follows: between the crankcase and pump head, as follows: Figure 6.8 —...

  • Page 62: Inlet Check Valves

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump Inlet Check Valves 3. Use a 90° o-ring pick to remove the o-ring from the base of the cavity. The three (3) inlet check valves are removed from the pump head with a standard 5/16”-18 bottoming tap.

  • Page 63: Chemical Injection System

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump Chemical Injection System Thermal Bypass Actuator Removal Refer again to Figure 6.11 and follow this procedure to 1. Referring to Figure 6.12, secure the pump head to a rigid disassemble the rest of the unloader mechanism and the surface, taking care to not damage the milled surfaces.

  • Page 64: Part 3 - Inspection

    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 Seals, O-Rings, and Gaskets are the same for the inlet and outlet, as shown in Figure Replace seals and gaskets during the reassembly process.

  • Page 65: Engine Adapter O-Rings

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump Engine Adapter O-Rings Piston & Spring Assemblies Examine the engine adapter o-ring and bolt head o-rings to Referring to Figure 6.7 (seen earlier), inspect the three (3) ensure they are not damaged.

  • Page 66: High Pressure Outlet/Chemical Injection Assembly

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump Inspect the three (3) piston springs. Ends must be closed High Pressure Outlet/Chemical Injection Assembly and ground square. Check spring free length and load length Referring to Figure 6.20, inspect the chemical injection and as follows, referring to Figure 6.19: unloader components for signs of damage, obstructions, or wear.

  • Page 67: Part 4 - Reassembly

    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.

  • Page 68: Piston Oil Seals And Pistons

    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.
  • Page 69 Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump 3. Piston assemblies have an integral spring retainer ring. 6. Install the thermal bypass piston and spring into the Install the small end of the tapered spring so that it socket cast into the upper portion of the pump crankcase, contacts the spring retainer, as seen in Figure 6.25.

  • Page 70: Spacer Plate

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump Spacer Plate High Pressure Seal Assembly 1. Install the three (3) low pressure seals into the bores Refer to Figure 6.29 for this assembly. provided in the spacer plate. Make sure the seal’s groove Figure 6.29 —...

  • Page 71: Check Valve Assembly

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump Check Valve Assembly a. Check that the actuator is fully seated. Refer to Figure 6.30 for this assembly. b. Make sure the small actuating stem is installed into the actuator.

  • Page 72: High Pressure Outlet And Chemical Injection Assembly

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump High Pressure Outlet and Chemical Injection a. Ball seat assembly, o-ring end first. Assembly b. Stainless steel ball. Refer to Figure 6.31 for this assembly. c. Trapped line pressure seat, slotted end first. d.

  • Page 73: Pump Head Installation

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump Pump Head Installation 4. Align the pump head with the pistons protruding from the spacer plate and gently press the head into place. Referring to Figure 6.33, install the pump head onto the pump spacer plate, as follows: CAUTION: Make sure the small stem of the...

  • Page 74: Main Component Assembly

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump Main Component Assembly Figure 6.36 — “Jacking” Bolt Locations 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.

  • Page 75: Oil Fill

    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.

  • Page 76: Part 5 - Troubleshooting

    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.
  • Page 77 Portable Pressure Washer Familiarization and Troubleshooting Guide Section 6 • Medium Frame Pump Part 5 - Troubleshooting (Continued) Problem Possible Cause Corrective Action a. Defective or missing engine adapter o- a. Install new o-ring or gasket. 7. Oil leak between engine and engine adapter.

  • Page 78: Large Frame 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.

  • Page 79: Cross-Sectional View

    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)
  • Page 80 Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump Sectional View Parts List Item Description Item Description Unloader-pressure regulator Straight engine shaft adapter assembly C-ring cam retainer Socket head cap screw, M6-1.0 x Engine adapter gasket 45mm Socket head cap screw, 5/16”-24 M6 ribbed lock washer...

  • Page 81: Exploded View

    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 Item Torque Value 5-8 ft-lbs The larger view above is a typical tapered engine shaft parts 12-18 ft-lbs...
  • Page 82 Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump Exploded View Parts List Item Description Item Description Belleville washer Unloader-pressure regulator assembly Jam nut Socket head cap screw, M6-1.0 x Piston 45mm Piston return spring M6 ribbed lock washer Breather cap Pump head assembly Pump crankcase...

  • Page 83: Part 2 - Disassembly

    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.

  • Page 84: Axial Cam Drive Components (Tapered Engine Shaft)

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump 4. As the pump crankcase is 3. Remove the engine adapter bearing assembly. Figure 7.5 - Pivot Shoe separated from the engine 4. Remove the M16-1.50 Jam Nut and the Belleville washer. adapter, three (3) piston pivot 5.

  • Page 85: Axial Cam Drive Component (Straight Engine Shaft)

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump 9. Remove all traces of the engine adapter gasket or o-ring. Pistons and Piston Springs Use a new gasket or o-ring each time the engine adapter Refer to Figure 7.9 for this disassembly. The three (3) is installed.
  • Page 86 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 Adapter housing Guide stem Stainless steel spring O-ring...

  • Page 87: Cylinder Head

    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.

  • Page 88: Thermal Bypass Actuator Removal

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump To remove the three (3) outlet (high pressure) check valves, Thermal Bypass Actuator Removal refer to Figure 7.15 and proceed as follows: Refer to Figure 7.16 and: Figure 7.16 —...

  • Page 89: Spacer Plate

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump Spacer Plate 1. If present, remove two (2) M5-0.80 x 20mm truss head bolts along with the o-ring seal on each bolt. Referring to Figure 7.17, remove the spacer plate from between the crankcase and pump head, as follows: 2.

  • Page 90: Part 3 - Inspection

    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.

  • Page 91: Head Gasket

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump Head Gasket Engine Adapter, Pump Crankcase, Spacer Plate and Head A head gasket, depicted in Figure 7.21, is installed between the pump head and the spacer plate. Replace the gasket each Clean all parts.

  • Page 92: Piston & Spring Assemblies

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump Inspect the jam nut and the Belleville washer for wear or Piston & Spring Assemblies damage. Replace if necessary. Referring to Figure 7.9 (seen earlier), inspect the three (3) pistons carefully.

  • Page 93: Unloader-Pressure Regulator Valve

    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.

  • Page 94: Part 4 - Reassembly

    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.
  • Page 95 Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump 4. Install the engine adapter bearing race, followed by the 5. Install the axial cam (with cam surface facing you) over engine adapter bearing and the inner cam bearing race. the engine shaft adapter.
  • Page 96 Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump Units with Straight Engine Shaft: When installing the engine adapter having the glued- in sleeve, be sure to use the correct socket head cap Two types of engine adapters have been produced - one screws.

  • Page 97: Piston Oil Seals And Pistons

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump NOTE: Piston Oil Seals and Pistons When installing the engine adapter having the o-ring seals, be sure to use the correct button Refer to Figure 7.33 for this procedure. head cap screws.
  • Page 98 Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump 4. If the piston assemblies use a lock ring and have been Figure 7.35 — Piston Installation disassembled, assemble them as follows: a. Install a retainer ring into the groove at one end of each piston.

  • Page 99: Spacer Plate

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump Spacer Plate Pump Head Assembly 1. Referring to Figure 7.37, install the three (3) low pressure 1. Install an o-ring and backup ring on all check valves, as seals into the bores provided in the spacer plate.
  • Page 100 Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump e. Align the inlet check valve with its bore in the pump d. Insert the 7/16”-20 bolt/jam nut/washer down through head, as shown in Figure 7.39. Push the check valve, the bore of the high pressure port tower and engage along with its seal and backup ring, down into the the bolt threads with the internal threads of the outlet...

  • Page 101: Pump Head Installation

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump Pump Head Installation 4. Install six (6) M8-1.25 socket head cap screws with six (6) M8 ribbed lock washers to retain the head. Referring to Figure 7.41, install the pump head onto the pump spacer plate, as follows: 5.

  • Page 102: Unloader-Pressure Regulator Valve

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump Unloader-Pressure Regulator Valve Main Component Assembly 1. Install the valve spindle with o-ring seal into the bore Before installing the pump onto the engine, place the engine provided on the pump head (illustrated in Figure 7.41).
  • Page 103 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 5. Lower the pump toward the engine adapter. Align the mounting holes in the pump crankcase, 180° apart and at crankcase and engine adapter mounting holes and also the locations shown in Figure 7.45.

  • Page 104: Oil Fill

    Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump Oil Fill 1. On units so equipped, install the glass sight gauge in its proper position on the side of the pump. Tighten the sight Figure 7.46 depicts an early model pump and shows the gauge to the torque value specified in the Torque Chart, drain plug (item 2) and the sight gauge (item 3).

  • Page 105: Part 5 - Troubleshooting

    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.
  • Page 106 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 a. Missing or bad o-ring seal. a. Install new o-ring seal. pump crankcase.
  • Page 107 Portable Pressure Washer Familiarization and Troubleshooting Guide Section 7 • Large Frame Pump...

  • Page 108: Glossary

    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 FH –...
  • Page 109 Portable Pressure Washer Familiarization and Troubleshooting Guide Glossary Overchoking – a condition where the engine is being Turbo wand/nozzle – a device used to increase the deprived of intake air while being flooded with fuel effectiveness of high pressure water when directed against a surface Overflush –...

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