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Troubleshooting
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-
ger mechanism is squeezed.
Inadequate water supply. Ensure hose is 3/4” (19.05mm) di-
ameter and incoming water supply
is turned on.
Low or uctuating pressure. Kink in water inlet hose. Remove kink.
Kink in high pressure discharge
hose.
Replace 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-
sembly on pump.
Remove, inspect, clean or replace.
Pump packing worn. Replace packings.
Bypass valve not operating correctly. Repair or replace.
Water is leaking from the “Heat
Dump Valve”.
Water temperature is too high. Do not allow the unit to operate in
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
Pressure Detergent mode.
Detergent strainer is not completely
submerged in detergent solution.
Check, submerge if necessary.
Detergent strainer is obstructed. Inspect, clean or replace.
Detergent hose cut, obstructed. Inspect, clean or replace.
Detergent adjusting knob on pump
turned to closed position. (If appli-
cable.)
Open adjusting knob. Refer to
“Cleaning with Detergents” pg.13.
Not in low pressure mode. Insert 6540° (BLACK) nozzle.
Nozzle assembly is plugged. Clean or replace.
Too many high pressure hose exten-
sions attached to the water outlet.
Use one extension maximum.
Ball and Spring in Venturi stuck. Remove, clean or replace.
Water ows back into detergent
container.
Ball and Spring in Venturi reversed,
missing or corroded.
Remove, clean or replace.
Water ows from the nozzle when
the trigger gun is locked in the
“OFF” position.
Gun is malfunctioning. Repair or replace.
Problem Cause Solution
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 rell 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).