Troubleshooting

Problem	Cause	Solution

Engine will not start.	Various engine problems.	Refer to the engine manual accom-
		panying your unit.

	Unit components are frozen.	Allow to thaw. If any part of the unit
		becomes frozen; excessive pres-
		sure may build up in the unit which
		could cause the unit to burst result-
		ing in possible serious injury to the
		operator or bystanders.

No discharge at nozzle when trig-	Inadequate water supply.	Ensure hose is 3/4” (19.05mm) di-
ger mechanism is squeezed.		ameter and incoming water supply
		is turned on.

Low or fluctuating pressure.	Kink in water inlet hose.	Remove kink.

	Kink in high pressure discharge	Replace hose.
	hose.

	Water inlet screen obstructed.	Remove screen, clean or replace.
	Pump sucking air. (Prime eliminated)	Tighten all water intake connec-
		tions. Eliminate leaks in intake line.

	Not in high pressure mode.	Insert a high pressure nozzle.

	Obstructed or worn spray nozzle.	Remove, clean or replace.

	Damaged or obstructed valve as-	Remove, inspect, clean or replace.
	sembly on pump.

	Pump packing worn.	Replace packings.

	Bypass valve not operating correctly.	Repair or replace.

Water is leaking from the “Heat	Water temperature is too high.	Do not allow the unit to operate in
Dump Valve”.		the bypass mode (with trigger gun
		closed) for more than 3 minutes.

	Defective valve.	Replace.

Oil appears milky or foamy.	Water in oil.	Change pump oil. Fill to proper
		level.

Oil leaking from unit.	Do Not Use.	Contact Customer Service.

Detergent will not siphon into Low	Detergent strainer is not completely	Check, submerge if necessary.
Pressure Detergent mode.	submerged in detergent solution.
	Detergent strainer is obstructed.	Inspect, clean or replace.

	Detergent hose cut, obstructed.	Inspect, clean or replace.

	Detergent adjusting knob on pump	Open adjusting knob. Refer to
	turned to closed position. (If appli-	“Cleaning with Detergents” pg.13.
	cable.)

	Not in low pressure mode.	Insert 6540° (BLACK) nozzle.

	Nozzle assembly is plugged.	Clean or replace.
	Too many high pressure hose exten-	Use one extension maximum.
	sions attached to the water outlet.

	Ball and Spring in Venturi stuck.	Remove, clean or replace.

Water flows back into detergent	Ball and Spring in Venturi reversed,	Remove, clean or replace.
container.	missing or corroded.

Water flows from the nozzle when	Gun is malfunctioning.	Repair or replace.
the trigger gun is locked in the
“OFF” position.

PUMP SERVICE: 2525 MODEL PRESSURE WASHERS

Repair kits are available. See the Parts List, page 24. For the best results, use all parts in kits.

Follow Shutdown Procedure, page 13, to relieve system pressure.

•Drain and refill pump after 25 hours of operation.

For Outlet Valves

1.Remove hex plug from the manifold using a 14mm wrench.

2.Examine o-ring located under hex plug. Replace if cut or distorted.

3.Remove valve assembly from cavity. The assembly may come apart!

4.Install new valve, o-ring and hex plug. Torque to 14.75 ft-lb (20 Nm)

Note: Re-torque the plug after 5 hours operation.

For Inlet Valves

1.Remove 4 hex bolts from the manifold using a 6mm hex bit.

2.Carefully separate manifold from crankcase. You may have to lightly tap the manifold with a soft mallet to loosen it.

3.Using a screwdriver, press valves out of the manifold through the 3 holes located on the backside of the manifold (look for the stainless valve seats through the holes).

4.Remove the valve.

5.Install new o-ring. Then install new valve assembly.

Reinsert brass plugs.

6.Reinstall manifold to pump. Torque hex bolts to 14.75 ft-lb (20 Nm).

Servicing Plungers or Internal Bearings

1.Damage to the plungers or any internal parts in the pump housing is considered a catastrophic failure and is not recommended for service. Replace pump if necessary.

Servicing V-Packings

1.Remove manifold as described in Valve Replacement

Section.

2.Remove white retaining ring, this may be stuck on the piston.

3.Remove packing from manifold.

4.Inspect all parts and replace as necessary.

5.Thoroughly clean packing cavities and inspect for damage.

6.Lightly grease packing cavities. Replace packings in the following order:

•packing

•retainer ring

NOTICE

Packings must be installed in the proper order and facing the correct direction. Improperly installed parts will cause the pump to malfunction.

7.Remove brass retainer located around the piston.

8.Remove the outer and inner o-rings on the brass retainer.

9.Replace o-rings, reinstall brass retainer around piston.

10.Reassemble manifold. Torque hex bolt to 14.75 ft-lb

(20 Nm).