Workshop manual PW 235 PW 235R English
Workshop Manual PW 235, PW 235R Contents 1 Introduction and safety regulations... 3 1.1 General...3 1.2 Revisions...3 1.3 Target group...3 1.4 Safety instructions...3 1.4.1 General safety instructions...3 1.4.2 Special safety instructions...3 2 Repair instructions... 4 2.1 Product overview, Cabinet torque...4 2.2 Product overview, Pump unit torque...5 2.3 To disasseme/asseme the front cabinet and accessory storage...6 2.4 To disasseme/asseme the control unit and/or wireless unit*...7 2.5 To pair the product and the handle*...7 2.6 To exchange the battery in the handle*...7 2.7 To disasseme/asseme the motor cover...8 2.8 To disasseme/asseme the start/stop valve...8 2.9 To disasseme/asseme the water/oil seal and valves...9 3 Specifications... 11 3.1 Technical data...11 4 Appendices and schemas... 12 4.1 Operating supplies...12 4.1.1 Recommended oil types...12 4.1.2 Recommended luication...12 4.1.3 Recommended glue...12 4.2 Start stop System guide...13 4.2.1 No pressure in system...13 4.2.2 Start up-pressure build up...13 4.2.3 Pressure build up-opening pressure/close gun...14 4.2.4 Motor stop - standby pressure...14 4.2.5 Gun is activated...15 4.2.6 Machine run...15 4.3 Wiring diagram PW 235...16 4.4 Wiring diagram PW 235R...17 2 English
1 Introduction and safety regulations 1.1 General This workshop manual gives a full description of how to do troueshooting, repair and test of the high pressure washer. It also gives safety instructions that the personnel must obey during repair work. Introduction and safety regulations 1.4.2 Special safety instructions WARNING: Do not use accessories and/or do changes that are not approved by the manufacturer. This can cause injury or death to the operator or other persons. 1.2 Revisions If there are changes to the product, these are gradually introduced into ongoing production. These changes can have an effect on servicing and/or spare parts. This can cause sections of the workshop manual to become out of date. Servicing information is sent out for each change. To make sure that the repair and servicing instructions are complete and up to date, always read the workshop manual together with all servicing information applicae for the high pressure washer. 1.3 Target group This workshop manual is written for personnel with a general knowledge of how to repair and do servicing on high pressure washers. All personnel that repair or do servicing on the high pressure washer must read and understand the workshop manual. 1.4 Safety instructions WARNING: All personnel that repair or do servicing on the high pressure washer must read and understand the safety instructions. 1.4.1 General safety instructions The service center that repairs the high pressure washer must have safety devices that comply with local regulations. Warnings and cautions are used to point out specially important parts of the workshop manual. WARNING: Used if there is a risk of injury or death if the instructions are not followed. CAUTION: Used if there is a risk of material damage if the instructions are not followed. Note: This information makes the product easier to use. WARNING: Always use original spare parts and accessories. WARNING: Disconnect from electrical power supply before carrying out user maintenance. WARNING: Use approved hearing protection. Noise from the product can result in permanent hearing loss. WARNING: High pressure jets can be dangerous. Never direct the water jet at persons pets, live electrical equipment or the machine. WARNING: The operator and anyone in the immediate vicinity of the site of cleaning should take action to protect themselves from being struck by deis dislodged during operation. Wear goggles during operation. WARNING: Never try to clean clothes or footwear on yourself or other persons. WARNING: Never use the machine in an environment where there could be a danger of explosion. If any doubt arises, contact the local authorities.. WARNING: It is not allowed to clean asbestos- containing surfaces with high pressure. WARNING: This high pressure washer must not be used at temperatures below 0 C. WARNING: Never let any persons stay under the product when stored on the wall. English 3
Repair instructions 2.1 Product overview, Cabinet torque 2 Repair instructions 1,5 Nm 1,2 Nm 1,5 Nm 1,2 Nm 1,5 Nm 4 English
Repair instructions 2.2 Product overview, Pump unit torque 8 Nm 18 Nm 10 Nm 16 Nm 8 Nm 8 Nm English 5
Repair instructions 2.3 To disasseme/asseme the front cabinet and accessory storage 1. Tools: Torx 20 screwdriver and flat screwdriver. 4. Loosen the front cabinet from the accessories storage. Use a screwdriver on both sides, see figure below. Remove the accessories storage. 2. Remove the handle by pressing the 2 * 2 snap locks. Loosen one side first and then the other side. 5. Lift up the front cabinet to remove it. 3. Remove the 2 torx TX20 screws (A) from the rear side. Assemy: Place the accessories storage on the front cabinet and push it in place until you hear a click. Install the 2 screws. A A 6 English
Repair instructions 2.4 To disasseme/asseme the control unit and/or wireless unit* Tools: Torx 9 screwdriver. 1. Control unit: - Disconnect the cae (A) to the wireless unit. - Remove the 3 torx TX9 screws (B) screws. - Exchange the control unit. - Disconnect the 3 wires (C). - Install and tighten the 3 torx TX9 (B) screws, torque max 0.8 Nm. - Connect the cae (A) to the wireless unit. - Check the circuit diagram and install the 3 wires (C) accordingly on the control unit. B C A B 2. Wireless unit*: - Disconnect the cae (A) to the wireless unit. - Slide the wireless unit out (B). - Exchange the wireless unit. - Slide the wireless unit back (B). - Connect the cae (A) to the wireless unit. 3. Reconfigure the pairing of the product and the handle, see section 2.5 To pair the product and the handle*. B 2.5 To pair the product and the handle* * PW 235R version only Pairing of the wireless devices is needed if: The handle has been exchanged. The wireless unit of the handle has been exchanged. The control unit in the product has been exchanged. The wireless unit in the product has been exchanged. If the user has not paired the product and the handle. Pairing of the product and the handle: 1. Make sure that the product is not switched on. 2. Remove the battery and attach the battery again. 3. The orange indicator on the handle is now flashing for approx. 2 minutes. This indicates that the handle is in pairing mode. 4. Switch on the product within the 2 minute of pairing mode. When the orange indicator stops inking, the handle and the product has been paired and can now be operated. 2.6 To exchange the battery in the handle* * PW 235R version only 1. Remove the screw (Philips) and the battery cover. 2. Remove the old battery. 3. Make sure that the new battery (type CR 2032) is placed with the correct polarity in the battery holder. 4. Install the battery cover and the screw. A B * PW 235R version only English 7
Repair instructions 2.7 To disasseme/asseme the motor cover 1. Put the product on the side and remove the 4 torx 20 screws. 2. Remove the wheel to remove the 5th screw. The micro switch box can be removed by hand. 4. Install the motor/pump unit: - Install the micro switch box by hand (alternatively use a plastic hammer). Make sure you install it in the correct position. - Install the motor/pump unit inside the cabinet. 2.8 To disasseme/asseme the start/stop valve 1. Asseme the start/stop valve, see figure below. 3. Remove the cabinet. Take out the motor/pump unit. 2. Use a special tool to remove the seat of the start/stop valve. Use Puller for valve seat M4 part number 592 94 50-01. NOTE: The seat of the start/stop valve is no longer usae after using the puller. 8 English
Repair instructions 2.9 To disasseme/asseme the water/oil seal and valves 1. To change the oil seals, water seals and pressure valve, use a screw driver to disasseme the parts. Alternatively use a puller, part number 592 94 49-01, to pull out the valves seats (pressure and suction valves). NOTE: The seat is no longer usae after using the puller. 2. The figure below shows the pump after opening the cylinder head from the cylinder ock. CAUTION: Clean and luicate the parts before assemy! English 9
Repair instructions CAUTION: Make sure to position the valve bodies correctly according to the water canals inside the cylinder head. This is to optimize the self suction mode. The leg of the valve body must not be placed in front of a canal. WRONG position: CORRECT position: 3. Asseme all parts into the cylinder head, see figure below. 10 English
Specifications 3.1 Technical data 3 Specifications Value PW 235/PW 235R Specification Max 130 bar Voltage 230 V Frequency 50 Hz Power consumtion 7.8 A Power absorbed 1.8 kw Number of revolutions 17,000-18,000 rpm./min. Water volume, HP 5.3-6.3 l/min Pump pressure 90-105 bar Nozzle pressure 84-99 bar Opening pressure 115-140 bar Type of battery CR 2032 Retaining time 5 min Oil contents 80 ml Oil type LMH 32 Max water inlet temperature 40 C Max water inlet pressure 10 bar High pressure hose length, m 8m, textile/soft Suction height 0.5 m Electric cae 5 m Insulation class B Tightness IPX5 English 11
Appendices and schedules 4.1 Operating supplies 4.1.1 Recommended oil types The pump is filled with 80 ml LHM 32 from the production. In case of service where the oil must be changed, Husqvarna recommends to use 80 ml Bartran HV 46. Alternative oil types that are allowed: BP, Bartram HV 46 Shell, Tellus T 46 Exxon, Statoil Univis N 46 Mobil Oil Mobil DTE 25. 4.1.2 Recommended luication White grease for o-rings, sealings etc.: Silicone grease, DOW CORNING(R) 55 O-RING LUBRICANT 4.1.3 Recommended glue Loctite 680, alternatively Loctite 270 or 271 4 Appendices and schemas 2 1 3 4 5 Item Description Used for Article number 1 T-handle Torx T20 For screws with torx head 588 59 85-01 2 Puller M4 For valve seat 592 94 50-01 2 Puller M8 For valve seat 592 94 49-01 3 Screw driver PH2 For screws N/A 4 Screw driver Torx T9 For screws with torx head N/A 5 Screw driver, flat For screws N/A 12 English
Appendices and schedules 4.2 Start stop System guide 4.2.1 No pressure in system No pressure in system - except inlet pressure 3 bar. Machine switch off. Pump 3 BAR Non return valve Outlet 3 Bar Inlet 3 BAR 4.2.2 Start up-pressure build up Machine switch on / Start up - Pressure build up Pump >5 BAR Non return valve Outlet >5 Bar Inlet 3 BAR English 13
Appendices and schedules 4.2.3 Pressure build up-opening pressure/close gun Gun close. Pressure build up. Opening pressure. Micro switch is activated Pump 130 BAR Non return valve Outlet 130 BAR Inlet 3 BAR 4.2.4 Motor stop - standby pressure Gun close. Motor stops. Pressure in hose decreases to standby pressure Pump pressure is also standby pressure. Pump 25 BAR Non return valve Outlet 25 BAR Inlet 3 BAR 14 English
Appendices and schedules 4.2.5 Gun is activated Gun is open - Control piston is closed. Micro switch is deactivated. Motor starts. Pump 3 BAR Non return valve Outlet 3 BAR Inlet 3 BAR 4.2.6 Machine run Machine runs (normal working pressure). Gun is open. Pump 100 BAR Non return valve Outlet 98 BAR Inlet 3 BAR English 15
Appendices and schedules 4.3 Wiring diagram PW 235 Wiring diagram Circuit diagram L N [ro] [hv] 2 1 2 1 s1 2a c1 1a s1 N S1 2a 1c S2M Switch so o b Thermo 140 M M so gu hv C1 S1 S2 CU M Brown Blue Black Yellow White Capacitor Switch Single-pole switch/ micro switch Control unit Motor 16 English
Appendices and schedules 4.4 Wiring diagram PW 235R Wiring diagram Circuit diagram L N [so] [hv] S1 2 1 2 1 WU 2a C1 CU S2 1a S1 2a 1a N L S2M Switch Thermo 140 CU M N L WU so M so gu hv C1 S1 S2 CU M Brown Blue Black Yellow White Capacitor Switch Single-pole switch/ micro switch Control unit Motor English 17
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