SERVICE MANUAL HD 2.5/27 PB AL HD 3.7/35 PB AL PGA PGA BXA BXA BGA BGA

Transcription

1 SERVICE MANUAL MODEL # ORDER # HD 2.5/27 PB AL HD 3.7/35 PB AL PGA PGA BXA BXA BGA BGA

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3 CONTENTS Exploded View... 4 Exploded View Parts List M4035R.3 Pump Assembly Exploded and View... 8 M4035R.3 Series Pump Exploded and Parts List D3030R.1 Pump Assembly Exploded and View D3030R.1 Series Pump Exploded and Parts List Unloader Exploded and Parts List Troubleshooting Preventive Manteinance Oil Change Record

4 PRESSURE WASHER SERVICE MANUAL 33 EXPLODED VIEW For Detail See Pump Assy (389cc) 11 (196cc) (389cc) 85 (196cc) 64 (389cc) 11 (196cc) (389cc) 14 (196cc) 64 (389cc) 86 (196cc)

5 46 EXPLODED VIEW PRESSURE WASHER SERVICE MANUAL (389cc) 11 (196cc) 17 (389cc) 84 (196cc)

6 PRESSURE WASHER SERVICE MANUAL 6 EXPLODED VIEW PARTS LIST (CONT) Engine, Honda, GX390UT2QA2 (389 cc) Engine, Honda, GX200UTQX2 (196 cc) Handle Support Assy Al Direct Drive Rotary Tube-Joint Handle Assy Al Direct Drive Handle Stiffener Al Bushing, H X 24MM Pulley, 2BK 90 H (389 cc) Pulley, BK 80 H (196 cc) Bushing, H X 1 (389 cc) Bushing, H X 3/4 (196 cc) Pulley, 2BK 32 H (389 cc) Pulley, BK 36 H (196 cc) Bolt, 1/2 X 3-1/2", NC HH(615595) Washer, 5/16" (389 cc) 41 (196 cc) Retainer Bracket, Handle, Black Washer, 7/16", Lock Split Ring (389 cc) Washer, 5/16", Lock Split Ring (196 cc) Nylon Insert Nut 5/16" (389 cc) 27 (196 cc) Bolt, 5/16" X 2" /8-16 Nylon Insert (389 cc) 6 (196 cc) Hex Head Bolt 3/8-16 X 1-3/4 (389 cc) 7 (196 cc) Holder Wand Left Silver Knob Nut, Cage, 1/4" X 16 GA Wheel & Tire, 6.5" Steel Rim, 12.5 Tire (389 cc) Wheel & Tire Assy, 10" Steel Rim (196 cc) Screw 5/16" x 1" NC Screw, 3/8" X 3/4" Nut, 3/8" NC, Whiz Loc Flange Washer, 3/8" X 1-1/2" (389 cc) Pad Soft Rubber Bolt, 3/8" X 5" Screw, 1/4" x 1/2" NC Aluminium Bumper Al Base Long (389 cc) Al Base Short (196 cc) Under-Frame Slider Slider Stiffener Long 1 33 Pump Assy 2700 PSI (See M4035R Specs Pages) 1 Pump Assy 3500 PSI (See D3030R Specs Pages) Axle Spacer RH 2.0" (389 cc) Axle Spacer Silver (196 cc) Axle Spacer Left 5.00" Collar, 5/8" Bore Shaft /4-20 x 1-1/2 GR 2 Hex Bolt Zinc /4-20 Nylon Insert Lock Nut Sleeve rubber 4 40 Quick Connect Nozzle Kit (389 cc) Nozzle, SAQCMEG 0004, RED Nozzle, SAQCMEG 1504, YELLOW Nozzle, SAQCMEG 2504, GREEN Nozzle, SAQCMEG 4004, WHITE Quick Connect Nozzle Kit (196 cc) Nozzle, SAQCMEG 0003, Red Nozzle, SAQCMEG 1503, Yellow Nozzle, SAQCMEG 2503, Green Nozzle, SAQCMEG 4003, White Bolt, 5/16"-18X3/4", NC Crrge Bolt, 5/16"-18 X 1-3/4", NC Carriage Trigger Gun Model M Al Foot Belt Drive (389 cc) Al Foot Belt Drive Short(196 cc) Axle, 5/8" x 26.80" (389 cc) Axle Short Base Al 24" (196 cc) Wand 44" Zinc Plated, Handle & Coupler (389 cc) Wand 30" Zinc Plated, Handle & Coupler (196 cc) 1

7 EXPLODED VIEW PARTS LIST (CONT) Hose, 3/8" x 50', 1 Wire Tuff-Skin (BGA Models) Hose, 3/8" x 50', 1 Wire Tuff-Skin (BXA Models) Hose, 3/8" x 50', 1 Wire Tuff-Skin (HD Models) Hose, 3/8" x 50', 1 Wire Tuff-Skin (PGA Models) Belt, BX38 (389 cc) Belt, BX34 (196 cc) Bolt M10 X 25MM (389 cc) Bolt, 8mm x 20mm (196 cc) Axle Holder Al Frame Washer Flat 5/8" Al Back Beltguard Long (389 cc) Al Back Beltguard Short(196 cc) Front Beltguard Long (389 cc) Front Beltguard Short (196 cc) Al Trim, 750 B2 X 1/ ft Hose Hanger Al Frames Washer, 1/2" Flat Screw, 5/16" x 3/4" Nut, Whiz Loc 5/16 Flange Cushion, Pump Washer, 7/16" x 2 1/2" Key, SQR X 1.75" (196 cc) Key, SQR X 2.125" (389 cc) Scew, 4mm X 6 mm (196 cc) Suspension Bracket Washer, 3/8" x 1" (389 cc) Bushing, Fuel Line, Rubber Rubber Washer Spring, Foot, Compression Bellows, Leg (BOOT) Tube, PC Foot Bolt Coupler, 3/8" Socket, Female, Brass Label, Hot/Caliente W/Arrows Label, Regulation Label, Warning-Exposed Pulleys Label, Intended For Outdoor Use-Mexico Label, Quick Start Guide Label, Warning Pictogram Label Operation Warn Trilingual Small Label, Universal DB Rating, Ear Protection Label, Danger Cool Engine Label, Long (HD Models) (389 cc) Label, Short (HD Models) (196 cc) Label, Guard (PGA Models) Label, Logo Red (BXA Models) Label, Logo Die-Cut (BGA Models) Label, ETL, Mty, UL Label, Clear Lexan 4.3" X 5.5" Label Name Plate (HD Models) Label NamePlate (PGA Models) Label Name Plate (BXA Models) Label Name Plate (BGA Models) Socket Head Screw, 5/16''-24 x1.25'' (196 cc) Bolt, 5/16" X 1-1/2" (196 cc) Washer 21/64 X 1" (196 cc) Al Muffl er Defl ector (196 cc) 1 Not Shown PRESSURE WASHER SERVICE MANUAL 7

8 PRESSURE WASHER SERVICE MANUAL M4035R.3 PUMP ASSEMBLY EXPLODED VIEW Pump, KM4035R.3, 4.8@ RP Pump, LM4035R.3, 4.8@ RPM Pump, HM4035R.3, 4.8@ RPM Tee, 1/4" Branch Male Pump Protector, 1/4" 145 Deg Swivel, 1/2" MP x 3/4" GHF W/Strainer Hose Barb, 1/4" Barb x 1/4" MPT, 90 Dgr Elbow, 3/8", Street 90 Deg, Steel Valve, EZ Start, 3/8 MPT X 1/8 FPT UU1 3500PSI, Universal Unloader (SPARE) Hose Barb 1/4" Barb X 1/8" MPT, 90 Deg Hose, 1/4" Push-On, /FT Clamp, Hose,.46-,.54 ST Coupler, 3/8" Plug, Male 1 8

9 KM4035R LM4035R HM4035R.3 M4035R.3 SERIES PUMP EXPLODED VIEW TORQUE SPECS Item # Ft.-lbs PRESSURE WASHER SERVICE MANUAL M4035R.3 SERIES PUMP EXPLODED VIEW PARTS LIST Crankcase 1 2* See Kits Below Plunger Oil seal 3 3* See Kits Below O-Ring Ø1.78 x * See Kits Below Pressure Ring 3 5* See Kits Below U-Seal 3 6* See Kits Below Intermediate Ring 3 7* See Kits Below U-Seal Washer, Copper Plug, Brass 1/ Manifold Head 1 11* See Kits Below O-Ring Ø2.62 x * See Kits Below Valve Assembly 6 13* See Kits Below O-Ring Ø2.62 x Valve Plug Manifold Stud Bolt Washer Copper Washer 3/ Brass Plug 3/ Hexagonal Screw Closed Bearing Housing O-Ring Ø1.78 x Tapered Roller Bearing Crankshaft (3540) Crankshaft (4035) Crankshaft Key Oil Dip Stick Crankshaft Seal Shim Bearing Housing 1 33* See Kits Below Plunger Nut, M8 3 34* See Kits Below Copper Spacer 3 35* See Kits Below Plunger (4035) 3 Plunger (3540) 3 36* See Kits Below Copper Spacer 3 37* See Kits Below O-Ring Ring 3 38* See Kits Below Tefl on Ring Plunger Rod 3 9

10 PRESSURE WASHER SERVICE MANUAL M4035R.3 SERIES PUMP EXPLODED VIEW PARTS LIST Connecting Rod Connecting Rod Pin Spring Washer Connecting Rod Screw O-Ring, Ø2.62 x Crankcase Cover O-Ring, Ø1.78 x Sight Glass 3/ Cover Screw 5 * Available in kit (See below) REPAIR KIT NO KIT DESCRIPTION Plunger Seal mm Plunger Seal mm Complete Seal Packing mm Complete Seal Packing mm Plunger mm Plunger mm Complete Valve Plunger Oil Seals ITEM NUMBERS INCLUDED 3, 5, 7 3, 5, 7 3, 4, 5, 6, 7 3, 4, 5, 6, 7 33, 34, 35, 36, 37, 38 33, 34, 35, 36, 37, 38 11, 12, 13 2 NO. OF CYLIN- DERS KIT WILL SERVICE

11 D3030R.1 PUMP ASSEMBLY EXPLODED VIEW 1 PRESSURE WASHER SERVICE MANUAL Pump, KD3030R.1, 3@3000,1650 RPM Pump, LD3030R.1, 3@3000, 1650 RPM Pump, HD3030R.1, 3@3000, 1650 RPM UU1 3500PSI, Universal Unloader (SPARE) Pump Protector, 1/4" 145 Deg Swivel, 1/2" MP x 3/4" GHF W/Strainer Coupler, 3/8" Plug, Male 1 11

12 PRESSURE WASHER SERVICE MANUAL LD 3025R LD 3030R LD 4020R.1 D.1 PUMP EXPLODED VIEW TORQUE SPECS Item # Ft.-lbs LD.1 PUMP EXPLODED VIEW PARTS LIST Crankcase 1 2* See Kits Below Plunger Oil Seal 3 3* See Kits Below O-Ring Ø1.78 x * See Kits Below Pressure Ring 15mm (3030) 3 See Kits Below Pressure Ring 18mm (4020, 3025) 3 5* See Kits Below U-Seal, 15mm (3030) 3 See Kits Below U-Seal, 18mm (4020, 3025) 3 6* See Kits Below Intermediate Ring 15mm (3030) 3 See Kits Below Intermediate 18mm (4020, 3025) 3 7* See Kits Below Intermed. Ring 15mm (3030) 3 See Kits Below Intermed. Ring 18mm (4020, 3025) Brass Plug 1/2" Copper Washer 1/2" Manifold Housing 1 11* O-Ring Ø1.78 x * See Kits Below Valve Assembly 6 13* O-Ring Ø2.62 x Valve Plug Copper Washer 1/ Brass Plug G1/ Manifold Stud Bolt Washer Copper Washer 3/ Brass Plug 3/ Screw Bearing Cover Bearing Seal Snap Ring Ball Bearing Crankshaft Crankshaft Key Oil Dipstick 1 12

13 LD.1 PUMP EXPLODED VIEW PARTS LIST Crankshaft Seal 1 34* See Kits Below Plunger Nut 3 35* See Kit Below Copper Spacer 3 36* See Kits Below Plunger, 15mm (3030) 3 See Kits Below Plunger, 18mm 3 (4020, 3025) 37* See Kits Below Copper Spacer 3 38* See Kits Below O-Ring Ø1.78 x * See Kits Below Tefl on Ring 3 40* See Kits Below Plunger Rod Connecting Rod Pin Connecting Rod Spring Washer Connecting Rod Screw Sight Glass Gasket Crankcase Cover O-Ring Ø2.62 x * Available in kit (See below) PRESSURE WASHER SERVICE MANUAL REPAIR KIT NUM- BER Kit Description ITEM NUMBERS INCLUDED NUMBER OF CYL- INDERS KIT WILL SERVICE Plunger Seal 15mm D-3030 Plunger Seal 18mm D-3025 D , 5, 7 3, 5, 7 Complete Seal Packing, 15mm D , 4, 5, 6, 7 Complete Seal Packing, 18mm D-3025 D , 4, 5, 6, 7, Plunger 15mm D , 35, 36, 37, 38 Plunger 18mm D-3025 D , 35, 36, 37, 38 Complete Valve Plunger Oil Seals 11, 12,

14 PRESSURE WASHER SERVICE MANUAL UU1 3500PSI, UNIVERSAL UNLOADER (SPARE) UU1 UNLOADER EXPLODED VIEW UU1 UNLOADER EXPLODED VIEW PARTS LIST 14 ITEM PART # DESCRIPTION KIT QTY Piston Housing D 1 2 Piston C, D 1 3 Piston O-Ring Back Up A, D Main Block Piston Ring D 1 6 Ball Seat C, D 1 7 O-Ring 10.5 ID x 1.5 CS A,C,D 1 8 Plunger B Plunger Housing 1 10 Bypass Spring C, D Low Pressure Port Sliding Connector, 30mm Sliding Connector, 40mm, Long Sliding Connector H 1/2" Sliding Connector H 3/8" Plug 5/8-18 UNF D 1 15 O-Ring 12 ID x 2 CS A, D 2 16 O-Ring 6 ID X 2 CS A, D 1 ITEM PART # DESCRIPTION KIT QTY Sliding Connector Guide 1 18 O-Ring Backup A, D 1 6 x 1.45 x Ball Housing Assy C, D 1 20 O-Ring 6.75 x 1.78 BN80 A, D 1 21 Spring Seat C, D 2 22 Plunger Spring B Banjo Bolt 1/2" Short Banjo Bolt 1/2"-1/4" NPT Short Banjo Bolt 3/8" Short Seal Washer 3/8" Seal Washer 1/2" Seal Washer 3/8" 2 27 O-Ring 15 ID x 2CS A,B,D Plug, 1/4" Countersunk 1 Kit A O-Ring Repair Kit Kit B Outlet Kit Kit C Stem Basic Kit Kit D UU1 Complete Stem Kit

15 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION LOW OPERATING PRESSURE Faulty pressure gauge Insuffi cient water supply Old, worn or incorrect spray nozzle Belt slippage Plumbing or hose leak Faulty or mis-adjusted unloader valve Worn packing in pump Fouled or dirty inlet or discharge valves in pump Worn inlet or discharge valves Obstruction in spray nozzle Install new gauge. Use larger supply hose; clean fi lter at water inlet. Match nozzle number to machine and/or replace with new nozzle. Tighten or replace; use correct belt. Check plumbing system for leaks. Re-tape leaks with tefl on tape. Adjust unloader for proper pressure. Install repair kit when needed. Install new packing kit. Clean inlet and discharge valves. Replace with valve kit. Remove obstruction. PRESSURE WASHER Troubleshooting Guide FLUCTUATING PRESSURE PRESSURE LOW AFTER PERIOD OF NORMAL USE Leaking pressure control valve Slow engine RPM Pump sucking air Valves sticking Unloader valve seat faulty Worn or dirty pump valves Nozzle is obstructed Pump sucking air, inlet hose leaking Insuffi cient water supply Nozzle worn Unloader valve worn Rebuild or replace as needed. Set engine speed at proper specifi cations. Check water supply and possibility of air seepage. Check and clean or replace if necessary. Check and replace if necessary. Call local distributor. Blow out or remove debris with fi ne needle. Check that all hoses and fi ttings are airtight. Turn off machine and trigger spray gun until a steady fl ow of water emerges through the nozzle. Turn water on full force. Check garden hose for kinks, leaks or blockage. Replace nozzle. Replace unloader valve. ENGINE WILL NOT START OR STOPS WHILE OPERATING ENGINE IS OVERLOADED Low oil shutdown Out of gas Water in gasoline Nozzle partially blocked Excessive pressure from high engine RPM Fill engine with oil. Fill fuel tank. Drain gas tank; fi ll with clean fuel. Clean nozzle. Adjust engine throttle to lower RPM. 15

16 PRESSURE WASHER Troubleshooting Guide TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION WATER OR OIL LEAKING FROM BOTTOM OF PUMP PRESENCE OF WATER IN PUMP OIL ENGINE OPERATES FOR 15 MINUTES THEN STOPS A small amount of leaking is normal Water sprayed at machine High humidity in air Piston packing worn. Oil seal worn. Not enough gas or engine oil Vapor lock developed by heat of day Obstruction in fuel fi lter If excessive leaking occurs, call local distributor. Change oil. Direct spray away from machine. Check and change oil twice as often. Call local distributor. Fill tank with gas. Check oil level. Keep gas tank full to avoid vapor locking. Clean or replace fuel filter. ENGINE LACKS Dirty air filter Replace air filter. POWER ENGINE FALTERS Choke is opened too soon Move choke to halfway position until engine runs smoothly. WATER DRIPPING Piston packing worn Call local distributor. FROM UNDER PUMP O-Ring plunger retainer worn Call local distributor. Cracked piston Call local distributor. OIL DRIPPING FROM UNDER PUMP WATER LEAKING FROM PUMP PROTECTOR NO DETERGENT Oil seal worn or damaged Call local distributor. Spray gun closed with machine Open spray gun or turn off machine. running 5 minutes or longer Excess water supply pressure Place a pressure regulator at end of 50' garden hose. Detergent suction tube not properly connected to machine Detergent is too thick Detergent filter valve is at lowest setting Filter on detergent suction tube is clogged Damaged or clogged detergent suction tube A high pressure nozzle is attached. Check connection. Dilute detergent. For best results, use manufacturers detergent. Set detergent fi lter valve to a higher setting. Run warm water through fi lter to remove debris. Remove obstruction or replace detergent suction tube. Replace with black detergent nozzle. GARDEN HOSE CONNECTION LEAKS Discharge nozzle is obstructed Loose fittings Missing/worn rubber washer Blow out or remove debris with fi ne needle. Tighten fi ttings. Insert new washer. 16

17 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION SPRAY WAND LEAKS Spray wand not properly attached Broken o-ring PREVENTATIVE MAINTENANCE Slide the spray wand into the gun. Turn the wand collar clockwise onto the spray gun threads until tight. Call local distributor and order an o-ring. PUMP IS NOISY Pump is sucking air Check that hoses and fi ttings are air tight. Turn off machine and purge pump by squeezing trigger gun until a steady fl ow of water emerges through nozzle. This pressure washer was produced with the best available materials and quality craftsmanship. However, you as the owner have certain responsibilities for the correct care of the equipment. Attention to regular preventative maintenance procedures will assist in preserving the performance of your equipment. Contact your dealer for maintenance. Regular preventative maintenance will add many hours to the life of your pressure washer. Perform maintenance more often under severe conditions. Check pump oil and engine oil level before fi rst use of your new pressure washer. PRESSURE WASHER Troubleshooting Guide Engine Oil Air Cleaner/Filter Engine Fuel Filter Spark Plug Maintenance Clean Fuel Tank(s) Inspect Change Filter Inspect Clean Inspect Change Inspect Pump Oil Change Replace High Pressure Nozzle Replace Quick Connects Clean Water Screen/Filter Replace HP Hose Belts* Tighten Inspect/Replace MAINTENANCE SCHEDULE Daily First month or 20 hours. Every 100 hours or every 6 months after fi rst month Every 50 hours Daily Every 3 months or 50 hours 500 hours or 6 months Every 6 months or 100 hours Every year or 300 hours Annually Oil level daily After fi rst 50 hours, then every 500 hours or annually (or 3 months) Every 6 months Annually Weekly Annually (if there are any signs of wear) Every 6 months Every 6 months *Note: When servicing belts, don't exceed 14 lb-ft on pump mounting screws.failure to do so will cause pump thread damage. 17

18 PRESSURE WASHER SERVICE MANUAL Date Oil Changed Month/Day/Year OIL CHANGE RECORD Check pump oil and engine oil level before fi rst use of your new pressure washer. Estimated Operating Hours Since Last Oil Change Date Oil Changed Month/Day/Year Estimated Operating Hours Since Last Oil Change 18

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20 Form # Printed in U.S.A. or Mexico