When you turn on at the mains the pumps starts then stops, press the trigger and only mains pressure flows through. after stripping down the spill valve is jammed in down position and pull this out and replace it repeats process again. any solutions please????
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My experience is that the pump pressures prevent the engine from starting, so we hold the trigger while starting.
My brother has cut a wedge of wood that he uses to jam the trigger open to bypass the problem. It can get a bit wild if the wand is not secured when the unit is started..
What you are describing is an unloader valve failure. The unloader valve (also called a spill valve or safety pressure relief valve) is sticking in what is known as bypass. Your pump is able to build pressure but when the trigger is squeezed, rather than directing the flow up to the nozzle it is looping the pressure back through the pump as it does when you release the trigger. Depending on the specific brand and model you will need to either replace the unloader or lubricate it if it is a Karcher with a spill valve. If it is a Karcher there is a known issue with the following models:
K2300G1 K2400HB K2400HH K2401HH K5800G K5800G
All of these have an issue where the spill valve sticks and will need to be lubricated with Vaseline or lithium grease. You can view a guide for this process at http://www.landanorthwest.com/dms. Select Maintenance/Karcher/Pressure Washers/All/Spill valve lubrication.
The issue you are having is with the unloader valve in the pump. Now with the 520m it is a little bit harder to repair than with more gasoline powered pressure washers but it can still be done. It would be easier if I could just send you a email of the breakdown on the machine. Send me a email to firstname.lastname@example.org with the discription of the problem you are having.
When the trigger is released, pressure builds up and this acts on a valve (spill valve or pressure control valve). When this pressure is big enough it will push the spill valve out and closes a micro switch. Now this Spill Valve gets stuck sometimes, mainly due to soap and chemicals...so the micro switch is not closed...so the machine contiues running. If this is left likee this it will cause damage to the valves. So all one has to do is service the spill valve or as I usually do I replace it. There are cases were the micro switch is damaged also..and needs to be replaced. To see the spill valve and micro switch you must open the cover. The spill valve is located where you see a cover with an electric wire coming out of it. If the micro switch is good...you must tackle the Spill valve.
When trigger is shut, pressure builds up in machine and this activates a control-valve or often called a Spill Valve. This Spill Valve compresses with the built up pressure and switches off a micro-switch...which in turn stops the machine. Now when this Spill Valve gets faulty, it starts compressing and de-compressing undr pressure. Thus the micro switch is activated on and off. That is why your machine is starting and stopping. Now this Spill Valve also controls pressure. So to fix the fault you must change the Spill Valve with a new one. Myself I rarely service Spill Valves. You can locate the spill valve after you open the cover. The spill valve is usually covered with a plastic cap that contains the electrical micro switch. I do not know what model you have....but sometimes to improve the pressure you must also change the suction and delivery valves. But in most cases like yours...it is only the Spill Valve that is causing the starting and stopping and the low pressure.
This problem is most probably due to a faulty Spill Valve( also called Control Valve). When the gun is released the spill valve is compressed and it either closes a micro switch or just opens from the bottom and keeps the water circulating. All spill valves keep the water circulating from the bottom part. Now when the gun is pulled (opened)...the spill valve extends and closes the bottom part, and thus water goes out of the nozzel. When you work with no nozzel, there is enough water flow to close the bottom part of the spill valve. So when the nozzel is placed back there is no chance that the bottom part leaks water. When the gun is started with the nozzel....the bottom part of a FAULTY spill valve,..will colapse and pressure drops. So to fix the fault you must change the Spill Valve. In some occasions, I also found that suction valves give this problem. A faulty sucktion valve will colapse under high pressure, and lets water pass the other way round.
But in my opinion and experience, your problem is in the Spill Valve.
Most pressure washers when their gun is released, the machine stops automaticaly. This is done ny means of a control valve. When the gun is closed...pressure is built and the control valve moves and switches a micro switch off. In your case the micro switch is still closed in off position. Now this happens if a machine is left and stored with pressure in it., This control valve could get jammed and leaving the micro switch in off position. It could also stay in off position by sticking, due to incorrect chemical.
So the control valve or even called spill valve, must be renewed.
Sometimes a little lubrication with the right type of silicon grease will get the control valve working again. This job is sometimes delicate and better done by a qualified technician.
The solution is very simple. All you have to do is change the spill valve.
This because the spill valve is not worth servicing. The actual problem is that the spill valve is leaking from its bottom-part seating. When you close the gun, the spill valve goes down, opens from the underside, and switches the electricity off. When you press the gun, the spill valve returns to normal, and if the underside does not close, you have low presure, because the water keeps circulating.
MG. (Karcher service engineer).
I had the same problem - good water inlet pressure, no output pressure, even though the lance and handle seemed to be clear and working find.
I found that the electrical switch wasn't being operated correctly by the spill valve and wasn't turning the motor on/off correctly.
Inside the plastic electrical box there is a small white device that presses against the micro switch assembly. Carefully adjust the allen screw perhaps 1/4 turn out or 1/4 turn in to obtain correct operation of the microswitch - you will hear the micro switch clicking in and out when re-assembled. I'm sure they must have a rig to check correct positioning of this screw in the factory!
Hope it helps - mine is working find now and saved me buying another!