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11

309016

Troubleshooting

Problem

Cause

Solution

Water on oil side of
pump

Humid air condensing inside crankcase

Change oil as specified in 

Maintenance on page 9.

Worn packings

Install new packings.  See 

Pump Service on page

12 or 14.

Oil seals leaking

Install new oil seals.  See 

Pump Service on page

12 or 14.

Frequent or
premature failure of
packings

Scored, damaged, or worn plungers

Install new plungers.  See 

Pump Service on page

12 or 14.

Abrasive material in the fluid being
pumped

Install proper filtration on pump inlet plumbing.

Inlet water temperature too high

Check water temperature; may not exceed 70

_

 C

(160

_

 F).

Over pressurizing pump

Do not modify any factory-set adjustments.  See
Equipment Misuse Hazard on page 3.

Excessive pressure due to partially
plugged or damaged tip

Clean or replace tip.  See 

Installing and Changing

Spray Tips on page 7.

Pump running too long without spraying

Never run pump more than 10 minutes without
spraying.

Running pump dry

Do not run pump without water.

Strong surging at
inlet, and low
pressure on
discharge side

Foreign particles in the inlet or discharge
valve or worn inlet and/or discharge
valves

Clean or replace valves.  See 

Pump Service on page

12 or 14.

Summary of Contents for AquaMax 804594 A Series

Page 1: ...del 804597 Series A AquaMax DD9021 pressure washer with 11 hp engine and 900 liters hr 4 gpm pump on Hi Boy cart with hose gun and tips 210 bar 21 MPa 3000 psi Maximum Working Pressure Model 804596 Se...

Page 2: ...ents can inject fluid into your body and cause serious injury Fluid splashed in the eyes or on the skin can also cause serious injury D Fluid injected into the skin might look like just a cut but it i...

Page 3: ...ed by the fluid manufac turer FUEL HAZARD The fuel used in this unit is combustible and when spilled on a hot surface can ignite and cause a fire Do not fill the fuel tank while the engine is running...

Page 4: ...ge 7 If you are using a sandblaster kit see its separate manual for installation instructions Connect to Water Supply CAUTION Before you connect to the water supply check your local plumbing code rega...

Page 5: ...riggered Pressure at the gun may be significantly higher than the bypass pressure indicated on the pressure gauge Therefore always follow the Pressure Relief Procedure above regardless of the pressure...

Page 6: ...ap back against the engine Return it gently to prevent damage to the recoil mechanism NOTE For easier starting have one person start the engine while another person triggers the spray gun If the engin...

Page 7: ...ou spray again CAUTION To avoid blowing the O ring out of the quick coupler due to the high pressure in the system never operate the pressure washer without a tip securely mounted in the quick coupler...

Page 8: ...8 309016 Notes...

Page 9: ...ine level Fill as necessary After first 5 hours of operation Change engine break in oil Drain oil when warm Use SAE 30 or 10W 30 detergent oil After first 25 hours of operation Retorque exhaust manifo...

Page 10: ...type Clean adjust spark plug gap or replace Spray gun closed Trigger spray gun while starting Engine misses or lacks power Partially plugged air cleaner filter Remove and clean Spark plug dirty wrong...

Page 11: ...iltration on pump inlet plumbing Inlet water temperature too high Check water temperature may not exceed 70_ C 160_ F Over pressurizing pump Do not modify any factory set adjustments See Equipment Mis...

Page 12: ...TE You might have to tap the manifold lightly with a soft mallet to loosen it CAUTION Keep the manifold properly aligned with the ce ramic plungers when removing to avoid damage to the plunger or seal...

Page 13: ...ings only the other includes the packings rings and retainers See Pump Repair Kits on page 20 1 Remove the manifold as outlined in Pumping Section on page 12 2 Carefully pull the packing retainer from...

Page 14: ...You might have to tap the manifold lightly with a soft mallet to loosen CAUTION Keep the manifold properly aligned with the ce ramic plungers when removing to avoid damage to the plunger or seals 3 Ca...

Page 15: ...e is packings only the other includes the packings rings and retainers See Pump Repair Kits on page 20 1 Remove the manifold as outlined in Pumping Section on page 14 2 Carefully pull the packing reta...

Page 16: ...1 30 2 25 24 23 3 Ref 18 19 17 1 Apply sealant to threads 3 All parts supplied with unloader 10 28 29 43 39 47 See Detail 1 48 1 1 2 Supplied with pump 2 39 3 49 1 51 50 4 Shaft key supplied with engi...

Page 17: ...15_ yellow 1 805545 TIP spray Q type 2504 25_ green 1 805546 TIP spray Q type 4004 40_ white 1 19 805634 TIP spray chemical injector black 1 23 114801 HOOK pail 1 24 112380 SCREW mach fil hd 1 2 in 2...

Page 18: ...31 30 2 1 25 24 23 3 Ref 18 19 17 1 Apply sealant to threads 2 50 48 1 2 All parts supplied with unloader 3 Supplied with pump 3 27 10 28 29 40 39 9261A 49 1 47 See Detail 1 52 51 43 41 54 18 309016 P...

Page 19: ...TIP spray Q type 25_ green 805545 Model 804596 2504 1 805549 Model 804597 25045 1 TIP spray Q type 40_ white 805546 Model 804596 4004 1 805550 Model 804597 40045 1 19 805634 TIP spray chemical inject...

Page 20: ...472 Valve assembly 804402 Valve assembly 804402 Valve assembly O ring Valve seat Valve Spring Valve cage 6 6 6 6 6 804034 Valve cap 804403 Valve cap 804403 Valve cap O ring Cap 6 6 804036 Packing asse...

Page 21: ...kg 151 lb 69 kg 151 lb Dimensions Length Width Height 927 mm 36 5 in 533 mm 22 in 788 mm 31 5 in 927 mm 36 5 in 533 mm 22 in 813 mm 32 5 in 927 mm 36 5 in 533 mm 22 in 813 mm 32 5 in Maximum inlet wat...

Page 22: ...but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach...

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