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DIAGNOSTIC
REPAIR
MANUAL
Residential and Commercial Power Washers
RESIDENTIAL MODELS:
2500
5921
6921
6922
2700
5922
6882
7132
3100
5923
6597
6694
OneWASH™
6412
6414
COMMERCIAL MODELS:
3100
6924
6565
9488
3500
6590
6228
6229
4000
6607
6855
6564
Important Note: Always use the unit specific Schematics and
P O W E R W A S H E R S
6923
7019
6602
8543
7143
7130
7131
6595
6549
6598
6599
6692
6436
6321
6413
6809
6712
6230
6607
Wiring Diagrams for troubleshooting.
7122
6596
6603
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Summary of Contents for Generac Power Systems 2500
- Page 1 DIAGNOSTIC REPAIR MANUAL Residential and Commercial Power Washers RESIDENTIAL MODELS: 2500 5921 6921 6922 6923 7019 6602 8543 7122 2700 5922 6882 7132 7143 7130 7131 6595 6596 3100 5923 6597 6694 6549 6598 6599 6692 6603 OneWASH™ 6412 6414...
- Page 2 Safety Read This Manual Thoroughly Throughout this publication and on tags and decals This diagnostic manual has been written and published affixed to the generator, DANGER, WARNING, and by Generac to aid dealer technicians and company CAUTION blocks are used to alert personnel to special service personnel when servicing the products described instructions about a particular operation that may be herein.
- Page 3 Table of Contents Safety ................ ii Test 27 – Check Spark Plugs .........17 Read This Manual Thoroughly ........ii Test 29 – Check Carburetion ........18 Replacement Parts ........... ii Test 30 – Choke Test ..........18 Test 33 – Check Valve Adjustment ......19 Section 1Pump Troubleshooting Test 36 –...
- Page 4 Table of Contents This page intentionally left blank. Diagnostic Repair Manual...
- Page 5 Section 1 Pump Troubleshooting Section 1 Pump Troubleshooting Troubleshooting Flow Charts Problem 1 – No Flow While Pump is Running TEST 1 – VERIFY TEST 2 – TEST 3 – TEST TEST 4 – CHECK SUPPLY WATER CHECK PUMP HIGH PRESSURE SPRAY GUN GOOD GOOD...
- Page 6 Section 1 Pump Troubleshooting Problem 3 – Line Vibration WATER SUPPLY HIGH PRESSURE WATER SUPPLY INLET AND INLET LINE OUTPUT LINE HIGH PRESSURE LINE VIBRATION VIBRATION VIBRATION TEST 6 – TEST 6 – TEST 6 – CHECK FOR CHECK FOR CHECK FOR AIR LEAKS AIR LEAKS...
- Page 7 Section 1 Pump Troubleshooting Diagnostic Tests Results 1. If water does flow discontinue testing. Test 1 – Verify Supply Water Source 2. If water does not flow, the high pressure hose is clogged. It will need to be replaced. Procedure 3.
- Page 8 Section 1 Pump Troubleshooting Results Check Valve Removal- Current Valve (Type A) with hole in Center 1. If pressurized water flows correctly discontinue testing. 1. Screw a 1/8” diameter machine screw approxi- mately 3 inches long into the hole in the top of the 2.
- Page 9 Section 1 Pump Troubleshooting Axial Pump Discharge Valve Replacement 3. Point the lance in a safe direction and pull the trigger until water ceases to flow from the lance. Assembly Engage trigger lock when not in use. 1. Before installing the valve verify the threads of the 4.
- Page 10 Section 1 Pump Troubleshooting 5. Once removed, check the valve for any damage. Also inspect the O-ring. Remove any debris within WARNING the valve. Replace any damaged valves or O-rings. Personal injury. Risk of fluid injection. 6. To test a valve use a paper-clip to press down on Do not aim spray gun at people, animals, electrical devices, or fragile items.
- Page 11 Section 1 Pump Troubleshooting damaged or worn, or if debris can not be removed, the valve should be replaced. 002931 002931 Figure 1-12. Check Valve Installation 002932 002932 Figure 1-14. Pump Removal Triplex Pump Inlet Valve Replacement Disassembly Triplex Pump Inlet Valve Replacement Assembly 1.
- Page 12 Section 1 Pump Troubleshooting 3. Place the piston guide back into the pump and push firmly down until the piston guide is seated. Figure 1-17 shows the piston guide not seated and Figure 1-18shows the piston guide seated. 002936 002936 Figure 1-17.
- Page 13 Section 2 Engine Troubleshooting Section 2 Engine Troubleshooting Troubleshooting Flow Charts Problem 10 – Recoil Cord Will Not Pull TEST 49 – TEST TEST 50 – VISUALLY INSPECT FOR OBSTRUCTIONS RECOIL GOOD TEST ENGINE GOOD THAT WOULD CAUSE BINDING OF THE FUNCTION FUNCTION RECOIL ONCE INSTALLED...
- Page 14 Section 2 Engine Troubleshooting Problem 12 – Engine Turns Over But Will Not Start CHECK TEST 26 – CHECK FUEL TEST 39 – FUEL GOOD CHECK REMOVE SHUTOFF GOOD SUPPLY SPARK SHUTDOWN LEAD VALVE SPARK SPARK REPLENISH TEST 38 – GOOD FUEL TURN...
- Page 15 Section 2 Engine Troubleshooting Problem 13 – Engine “Hunts” / Erratic Idle RPM limits for the engine are between 3700-3800 RPM. This can be checked with a suitable vibration style tachometer. TEST 26 – TEST 33 – TEST 30 – STILL CHECK CHECK VALVE...
- Page 16 Section 2 Engine Troubleshooting Diagnostic Tests Test 14 – Check Battery and Cables already available allowing the engine to crank. Once the ground is removed by putting the switch in the RUN Procedure position it disengages the starter allowing the engine to operate normally.
- Page 17 Section 2 Engine Troubleshooting Test 18 – Check Starter Motor DANGER following conditions affect starter motor Explosion and Fire. Fuel and vapors are extremely performance: flammable and explosive. Store fuel in a well 1. Binding or seizing in starter motor bearings. ventilated area.
- Page 18 Section 2 Engine Troubleshooting 2. Connect one meter lead to the female side of the 4. See Figure 2-6. Using a pliers, hold the cable connector. between the knob and panel. Remove the knob by unscrewing counterclockwise. a. On OneWASH units, disconnect the black wire and connect one meter lead to the switch spade connector.
- Page 19 Test 26 – Check Ignition Spark Procedure A commercially available spark tester may be used to test the engine ignition system. One can also be purchased from Generac Power Systems (Part No. 0C5969). 1. See Figure 2-10. Disconnect the spark plug lead (A) from a spark plug.
- Page 20 Section 2 Engine Troubleshooting Results Results 1. Clean and regap or replace sparks plug as neces- If carburetor is varnished, clean or replace. Refer to back sary. to Flow Chart. 2. Refer back to the Flow Chart. Test 30 – Choke Test Test 29 –...
- Page 21 Section 2 Engine Troubleshooting Test 33 – Check Valve Adjustment 4. Use a torque wrench to final tighten jam nut to torque shown in the chart below. After torquing the Adjusting Valve Clearance jam nut, recheck valve clearance to make sure adjustment did not change.
- Page 22 Section 2 Engine Troubleshooting Test 38 – Check Flywheel 7. Connect an air source of at least 90 psi to the leak down tester. Discussion 8. Adjust the regulated pressure on the gauge to 80 psi. Test 26 – Check Ignition Spark, a spark tester was 9.
- Page 23 Section 2 Engine Troubleshooting 3. Remove the four bolts that secure the tank to the 9. See Figure 2-21. Place a brass 0.015" feeler mounting brackets on the engine. gauge between the left side of the magneto and the face of the flywheel. Press the magneto firmly 4.
- Page 24 Section 2 Engine Troubleshooting Results 1. If spark now occurs, shutdown lead has a short to ground. Trace shutdown lead back to the ON/OFF switch and Oil Pressure Module (If so equipped). 2. If spark still does not occur, refer back to flow chart. 002952 002952 Figure 2-23.
- Page 25 Section 2 Engine Troubleshooting 3. Set DMM to measure resistance. 6. There is a coiled spring under the recoil assembly. Turn the recoil assembly clockwise seven or eight 4. Connect one meter test lead to the previously times. Stop when it feels tight, then back off to line disconnect wire coming from the oil level switch.
- Page 26 Section 2 Engine Troubleshooting Test 52 – Verify Water Pressure Switch Is Functioning (For OneWash™ Power Washer Only) Procedure 1. See Figure 2-27. With engine off, unplug the red and white wires connected to the pressure switch located on water pump. 2.
- Page 27 Section 3 Disassembly Section 3 Disassembly Residential Pump – Removal From Engine 6. Using a Allen wrench, remove the four (4) socket head fasteners attaching the pump to the engine. 1. Turn Engine OFF and make sure the switch is in the OFF position.
- Page 28 Section 3 Disassembly 3. Slide the pump onto the crankshaft, a rubber mallet may be used help slide pump on. 4. Tighten the bolts that attach the pump to the engine to 15 foot-pounds. 5. Tighten the set screw (grub screw) firmly. 3300/3500/4000 PSI 1.
- Page 29 Electrical Data Section 4 Introduction Go to www.generac.com (http://www.generac.com/service-support/product-support-lookup) for the most current wiring diagrams and electrical schematics. Use model or serial number. Electrical Schematic, Electric Start Models 007132 and 007143, Drawing No. 10000026492-A 21( 386+ 67$57 %87721 *5((1 /(' <(/ 5(' /(' <(/...
- Page 30 Section 4 Electrical Data This page intentionally left blank. Diagnostic Repair Manual...
- Page 31 Electrical Formulas To Find Known Values 1-phase 3-phase E X I E x I x 1.73 x PF Kilowatts (kW) Volts, Current, Power Factor 1000 1000 E x I E x I x 1.73 Volts, Current 1000 1000 kW x 1000 kW x 1000 Amperes kW, Volts, Power Factor...
- Page 32 ©2018 Generac Power Systems, Inc. S45 W29290 Hwy. 59 All rights reserved Waukesha, WI 53189 Specifications are subject to change without notice. 1-888-GENERAC (1-888-436-3722) No reproduction allowed in any form without prior written www.generac.com consent from Generac Power Systems, Inc.
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