This step-by-step guide shows how you take service your AVA Master P60-P80.
Servicing your unit improve long-term performance, can help resolve frost damage and comes with the added benefit of extending your warranty by another 5 years*
The service itself doesn’t involve many steps, but each one is described in detail to make the process as easy as possible for you – and to ensure the best possible result. We recommend reading through all the steps before you begin, so you understand the procedure and have the necessary tools to complete the task.
Always unplug the pressure washer from both the mains power and the water outlet before starting the service.
Click here to read our article regarding safety
Even though power and water is disconnected there may be pressurized water in the hose. Discharge this pressure by pulling the trigger on the gun in a safe direction.
Make sure your work area is clean and appropriate for the work you are about to do. There will usually be a small amount of water inside the pump and hose.
When you are doing a 10-year service, be prepared to collect the used oil from the oil chamber. Please dispose of the oil in accordance with local law and regulations.
ISO 46 hydraulic oil can be substituted with similar non detergent oil of the same viscosity.
00. Parts and tools
An overview of what is needed to do this service
01. Remove water filter
Unscrew the water filter.
02. Remove screws from the back cabinet
Unscrew 6 T25 screws from the back cabinet.
03. Remove the front cover
Push the front brace release button and pull the front cover off.
04. Remove screws from the motor/pump
Unscrew 4 T25 screws securing the motor/pump.
05. Release cable strain relief
Release the cable strain release form the back cabinet.
06. Lift the motor/pump unit
Carefully lift the motor/pump so that it is on an angle.
07. Release the internal hose
Carefully use a flat screwdriver or a small knife to release the u-pin securing the internal hose to the pump outlet.
Pull the hose from the pump head.
08. Lift the motor/pump
Carefully lift out the motor/pump out of the rear cabinet.
09. Remove parts
Remove the pump head cover and the on/off knob.
10. Remove screw holding the switch box
Rotate the motor/pump so that you gain access and can unscrew the T25 screw securing the switch box.
11. Remove the ground cable
Unscrew the crosshead Phillips screw that secure the grounding cable to the motor.
12. Disconnect the power cables
Release the motor power cables. The cables are connected with spade contacts. Push down the small locking tab (blue arrow) and gently pull the spade contacts apart.
13. Remove switch box
Remove the switch box by pulling it in the direction indicated. It is press fitted onto the start/stop valve on the pump and will release with a pop.
14. Remove screws from piston housing
Use a 6 mm hex/Allen key to remove the four screws on the pump. Be ready to catch the oil from the oil chamber.
15. Rotate the pump assembly
Remove 4 screws. Rotate the whole pump assembly 15-20° counterclockwise to release it from the motor oil chamber.
16. Remove the pump assembly
Remove the complete pump assembly.
During a 10-year service, all included parts should be replaced, as shown in the image. If you've chosen this kit for other reasons, you may assess whether the oil-bath parts need replacement. If the oil looks clean and everything appears fine, both oil and components may be reused.
Disassembly:
Older machines have a center bolt on the motor shaft that must be loosened. Newer models do not have this bolt. If needed, hold the motor with a 15 mm spanner between fan and shaft. If the bolt breaks, the remains can stay in place – the bolt has no function for the pump and does not need to be reinstalled.
Bearing installation:
- Lower bearing (the larger one): consists of glide washer – bearing – glide washer. Important: the washer with a number must face downward. Incorrect orientation creates a gap and reduces function.
- Upper bearing (smaller): also has a correct orientation, but it matters less. For ideal assembly, let the number face upwards toward the pistons.
17. Refill oil
Fill oil to the maximum level, the top of the ball bearing. The minimum level is to the center of the bearing.
Which oil should I use for the pump?
Use a simple hydraulic or compressor oil without additives (non-detergent).
Recommended viscosity:
ISO VG 46 or ISO VG 68
- 46 is slightly thinner – better for lower temperatures.
- 68 is slightly thicker – offers more protection under heat or heavy load.
Both types work well. Use whichever is easiest to find locally – for example, ISO VG 46 hydraulic oil from a hardware or machinery store.
Do not use engine oil like 5W-30 – it contains additives that may damage the pump.
18. Preparing for reassembly
Place the new O-ring in the groove on the oil chamber. Lubricate it using some oil from the oil chamber or acid-free silicone.
Fitting the pump assembly back onto the motor requires a bit of force since you have to compress the piston springs. To avoid damage to the screw attachments you should support the cowling with two blocks of wood or something similar before proceeding.
19. Attaching the pump assembly
Before fitting the pump to the motor, make sure that the start/stop valve on the pump head is on the same side as the cutout for the screw (red arrow).
As soon as everything is aligned correctly press the pump assembly down on to the motor. A fair amount of force is needed as you are compressing the piston springs onto the wobble plate.
When the two mating surfaces are in contact, twist the pump assembly 15-20° clockwise so that the two locks engages.
20. Secure the pump
Use 4 short Allen bolts to fasten the pump to the motor.
21. Attach the new switch box
Attach the switch box to the pump. It requires a fair amount of pressure to get the box firmly seated on the start/stop valve. It should pop into place.
Secure the switch box with a T25 screw.
22. Reattach the power cables
Reattach the power cable by pushing the male spade connector into the female spade connector. Give them a light tug to check that they are securely connected. Make sure that the rubber cover is protecting the spade contacts to prevent short circuits and water ingress.
23. Reattach the grounding cable
Place the green and yellow grounding cable as indicated in the picture and then secure it with a Phillips/cross head screw.
24. Fit on/off button and pump head cover
Reattach the pump head cover and the on/off knob.
25. Put the motor/pump back into the rear cabinet
Carefully lower the motor/pump back into the rear cabinet. The water inlet should be pointing upwards.
26. Attach the internal pressure hose
With the motor/pump at an angle, reattach the internal high-pressure hose to the pump head.
Secure the hose using a U-pin. Some force may be needed to properly secure the U-pin to the pump head.
27. Align the internal pressure hose
Make sure that the internal high-pressure hose runs through these two depressions in the back cabinet (red arrows). If you are unable to fit the motor/pump properly then lift it up and check that the internal hose runs as indicated in this picture
28. Align the motor/pump
If the previous step was successful the motor/pump unit should now fit correctly in the back cabinet.
29. Fix the cable strain relief
Reattach the cable strain relief into the slot in back cabinet.
30. Secure the motor/pump
Secure the motor/pump unit using 4 T25 screws. 2 screws on top of the motor cowling and 2 screws on the pump head cover.
31. Attach the front cover
Put the front cover back onto the pressure washer. This is easiest with the pressure washer lying flat. A bit of work may be needed to get it to align perfectly with the back cabinet, take your time. Push the front brace release button to allow for a correct alignment of the brace. When you are happy with your alignment, raise the pressure washer to the upright position.
32. Fasten the front cover
Secure the front cover with 6 T25 screws from the backside of the pressure washer.
33. Reattach the water filter
Check that the filter cassette is clean and without damage. (The cassette can be taken out and cleaned)
Reattach the water filter to the water inlet.
34. First start after service
Congratulations with finishing the service of your AVA product.
It is now time to do the first start after service.
- Start by connecting the pressure gun to the hose.
- Connect water.Make sure no water is leaking from the inside or anywhere else on the pressure washer.
- Pull the trigger and let the water flow until there is no more air coming out.
- Connect the power cord.
- Turn on the pressure washer.
- Pull the trigger and let water run for a minute before connecting a nozzle.
- Connect the nozzle.
- Use the pressure washer and make sure it is operating as normal.
Troubleshooting
Water is leaking from the inside
- Disconnect the power and open the pressure washer to locate the leak.
- Take necessary action to remedy any leaks.
Motor runs and won't stop when you release the trigger
- This is most likely due to an improper seating of the switch box on the start/stop valve.
- Open the machine and check that the switch box is correctly seated.
The pressure washer won't turn on
- Check that the power cable is connected
- Check that the circuit breaker has not been tripped.
- Check that the fuse in the power plug is intact (UK models only).
- Open the machine and check that all the internal cabling is connected.
Poor performance/pressure
- Improper assembly or dirt/debris in the pump.
- Check that the pump and especially the main valve for foreign objects/debris.
- Make sure that the spring in the main valve is correctly seated and working as intended.
Motor is making a humming noise and is not able to start
- Check that the capacitor is connected to the motor.
- It should be connected with one white and one black cable.
