SERVICE MANUAL - Martin Pressure Washers.com
Contents
1. 8 2 5 See Kit Below U Seal 15mm 3 27 9 802 939 0 Hexagonal Screw 9 6 See Kit Below Intermediate Ring 15mm 3 28 9 803 953 0 Bearing Cover 1 7 See Kit Below Backup Ring 15mm 3 29 9 803 954 0 Seal Bearing 1 8 See Kit Below U Seal 15mm 3 30 9 802 914 0 Snap Ring 1 9 See Kit Below Support Ring 15mm 3 31 9 803 955 0 Ball Bearing 1 10 9 802 926 0 Brass Plug 1 2 1 32 8 717 069 0 Crankshaft 2530G 1 11 9 803 199 0 Copper Washer 1 2 1 33 9 803 957 0 Oil Dip Stick 1 12 9 803 946 0 Manifold Housing 1 34 9 804 581 0 O Ring 3 53 x 55 56 1 13 9 803 947 0 O Ring 01 78 x 15 54 6 35 9 804 582 0 Needle Roller Bearing 1 14 See Kit Below Valve Assembly 6 36 8 717 212 0 Engine Flange 1 15 9 803 948 0 O Ring 02 62 x 18 77 6 37 9 803 210 0 Spring Washer 4 16 9 803 949 0 Valve Plug 6 38 9 804 584 0 Flange Screw 4 17 9 803 950 0 Washer Copper 1 18 9 803 951 0 Brass Plug G1 4 1 Xpert HD DD PD DA e 8 780 000 0 e Rev 03 12 G 1 SERIES PUMP EXPLODED VIEW PARTS LIST CONT ITEM PART NO DESCRIPTION QTY 39 9 804 585 0 Crankshaft Seal 1 40 See Kit Below Plunger Nut 3 41 See Kit Below Copper Spacer 3 42 See Kit Below Plunger 15mm 3 43 See Kit Below Copper Spacer 3 44 See Kit Below O Ring 1 78x5 28 3 45 See Kit Below Teflon Ring 3 46 9 803 964 0 Plunger Rod 3 47 9 803 965 0 Connecting Rod Pin 3 45 9 803 966 0 Connecting Rod 3 49 9 803 218 0 Spring Washer 6 50 8 933 020 0 Connecting Rod Screw 6 54 9 8032. before first use of your new pressure washer Estimated Operating Estimated Operating Date Oil Changed Hours Since Last Date Oil Changed Hours Since Last Month Day Year Oil Change Month Day Year Oil Change E Lu 9 gt fc Lu Y cr m I lt T cc D 0 m cr Q Xpert HD DD PD DA 8 780 000 0 e Rev 03 12 Form 8 780 000 0 Xpert HD DD PD DA Revised 03 12 Printed in U S A or Mexico
3. coupling OJO AJOJN xk me ui mi er cb co 8 725 561 0 Ki 12 8 725 567 0 Knob easy start Xpert HD DD PD DA 8 780 000 0 e Rev 03 12 aja 1 sch ar oa Dd D m 0 0 m N 5 E m D o m X S O m gt D rm PUMP EXPLODED VIEW AND PARTS LIST 8 920 004 0 lt Lu 9 gt fc Lu YN cr m I lt T cc D 0 m cr Q ITEM PART DESCRIPTION QTY ITEM PART DESCRIPTION QTY 1 8 762 010 0 Cylinder Head 15 5 332 290 0 Helical Spring 2 9 175 004 0 Valve Assy Horizontal 16 9 175 005 0 Unloader Assembly 3 2 884 916 0 Valve Complete Kit 3 17 4 132 007 0 Drain Plug Replacement 4 5 443 448 0 Nipple Chemestry 18 5 003 062 0 Plate 5 6 362 451 0 O Ring Seal 8 0 x 1 0 19 9 177 301 0 Hich Pressure Seal 6 7 8 1 3 1 1 1 6 362 175 0 O Ring Seal 5 28 x 1 78 1 20 9 177 310 0 Back Ring 7 401 909 0 Sphere 7 G40 1 4401 1 21 6 362 833 0 O Ring Seal 12 5 x 1 73 1 1 1 1 1 1 1 5 110 714 0 Sleeve 9 5 332 258 0 Helical Spring 10 9 139 372 0 Nozzle INS 020 021 Pump 11 9 184 018 0 Outlet Thermal Valve 12 6 362 480 0 O Ring Seal 12 42 x 1 78 13 7 362 507 0 O Ring Seal 8 x 2 NBR 90 14 6 413 403 0 Thermo Valve Tin Coated 22 9 155 011 0 Housing Low Pressure Seal 23 6 363 058 0 Grooved Ring 24 9 134 016 0 Spacer 25 6 365 393 0 Oil Sealing 12 20x4 6 26 9 133 007 0 Piston Guide 27 6 362 390 0 O Ring Seal 15 6 x 1 8 28 9 13
4. 4 019 0 Male Adapter 29 9 181 005 0 Filter Seal 30 9 155 013 0 Female House Conn 31 9 178 005 0 Adapter Garden 32 9 139 370 0 Spare Part List Piston 33 6 362 471 0 O Ring Seal 80 0x3 0 NBR70 L L L l i ic clico c cici c ani 2 Xpert HD DD PD DA e 8 780 000 0 e Rev 03 12 PUMP EXPLODED VIEW PARTS LIST CONT 8 920 004 0 Housing View D D m 0 0 m N 5 E m D o m X S O m gt D rm ITEM PART DESCRIPTION QTY 1 9 166 016 0 Grooved Ball Bearing 9 135 018 0 Swash Plate Hor 9 165 356 0 Ball Bearing No 6207 9 177 314 0 Radial Seal 35 x 52x 7 9 135 016 0 Oil Housing O1 BI wy Pp adi adha sahi sad ou Xpert HD DD PD DA 8 780 000 0 e Rev 03 12 lt Lu 9 gt fr Lu Y cr m I lt T cc D 0 m cr Q G 1 SERIES PUMP w 3 4 HOLLOW SHAFT EXPLODED VIEW 9 804 033 0 KG2530G 1 8 904 893 0 LG2530G 1 8 904 748 0 HG2530G 1 TORQUE SPECS G 1 SERIES PUMP EXPLODED VIEW PARTS LIST ITEM PART NO DESCRIPTION QTY ITEM PART NO DESCRIPTION QTY 1 9 803 938 0 Crankcase 1 19 9 803 952 0 Manifold Stud Bolt 8 2 See Kit Below Plunger Oil Seal 3 20 9 802 884 0 Washer 8 3 See Kit Below O Ring 01 78 x 28 30 3 21 9 803 198 0 Copper Washer 3 8 1 4 See Kit Below Pressure Ring 15mm 3 22 9 802 925 0 Brass Plug 3
5. 969 0 O Ring 2 62 x 107 62 1 53 9 803 968 0 Crankcase Cover 1 52 9 803 197 0 Gasket G3 4 1 51 9 803 202 0 Sightglass G3 4 1 Part available in kit See below REPAIR KIT NUMBER G 1 SERIES PUMP REPAIR KITS 8 725 354 0 8 725 355 0 9 803 934 0 9 803 936 0 9 803 937 0 KIT DE SCRIPTION ITEM NUM BERS INCLUDED Plunger Oil Seals Complete Seal Packing 15mm Plunger Seal 15mm Plunger 15mm Complete Valve 40 41 42 43 44 45 3 5 7 8 9 13 14 15 Xpert HD DD PD DA 8 780 000 0 e Rev 03 12 Dd D m 0 0 m N 5 E m D o m X S O m gt D rm l x UU1 UNLOADER EXPLODED VIEW 9 175 018 0 GI UU1 3500PSI UNIVERSAL UNLOADER SPARE ds 2 F Y m U u tc DI I Qn Lu tc LD Wu Lu tc D ITEM PART DESCRIPTION KIT QTY ITEM PART DESCRIPTION KIT QTY 1 8 751 394 0 Piston Housing D 1 17 9 149 006 0 Sliding Connector Guide 1 2 Piston C D 1 18 O Ring Backup AD 1 3 Piston O Ring Back Up A D 1 6 x 1 45 x 1 68 4 8 749 796 0 Main Block 1 19 Ball Housing Assy C D 1 5 9 152 372 0 Piston Ring D 4 20 O Ring 6 75 x 1 78 BN80 A D 1 6 Ball Seat CD 1 21 Spring Seat GD 2 7 O Ring 10 5 ID x 1 5 C8 A C D 1 22 Plunger Spring B 1 8 Plunger B 1 23 8 917 699 0 Banjo Bolt 1 2 Short 1 9 9 152 016 0 Plunger Housing 1 8 917 700 0 Banjo Bolt 1 2 1 4 NPT Short 1 10 Bypass Spring G
6. D 1 24 8 917 698 0 Banjo Bolt 3 8 Short 1 11 9 149 001 0 Low Pressure Port 1 E Seal Washer 3 8 2 12 9 152 017 0 Sliding Connector 30mm 1 29 GE pee no S 8 762 005 0 Sliding Connector 40mm Long 1 13 9 149 002 0 Sliding Connector H 1 2 1 EE ABD 3 9 149 005 0 Sliding Connector H 3 8 1 28 8 706 865 0 Plug 1 4 Countersunk 1 14 9 196 011 0 Plug 5 8 18 UNF D 1 Kit A 9 104 038 0 O Ring Repair Kit E Kit B 9 104 039 0 Outlet Kit 2 Ang Deets ADE g Kit C 9 104 040 0 Stem Basic Kit B 16 O Ring 6 ID X 2 CS AD 1 Kit D 8 920 045 0 UU1 Complete Stem Kit Xpert HD DD PD DA e 8 780 000 0 e Rev 03 12 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION LOW OPERATING Insufficient water supply Closed Use larger garden hose clean inlet water PRESSURE faucet Inlet hose kinked screen Open faucet Clogged inlet hose strainer Check plumbing system for leaks Retape leaks with teflon tape Faulty or mis adjusted unloader Adjust unloader for proper pressure Install valve repair kit when needed Call local distributor Worn packing in pump Call Dealer Customer Support Machine has been stored in freez Thaw out machine completely including ing temperatures hose spray gun and wand Slow engine RPM Call local distributor FLUCTUATING Worn or dirty pump valves Call local distributor PRESSURE Nozzle is obstructed Blow out or remove debris with fine needle Pump sucking air inlet hose Check that all hoses and fittings are airtight leaki
7. EM PART NO DESCRIPTION QTY 31 8 930 124 0 Label Intended for Outdoor Use Serial Specs 1 32 9 800 008 0 Label Danger Cool Engine 1 33 9 800 006 0 Label Hot Caliente w Arrows 1 34 8 917 015 0 Label Regulation 4442 6 1 35 8 783 034 0 Label Quick Start Guide 1 196 cc Models 208 cc Models 1 8 783 037 0 Label Quick Start Guide 2 163 cc Legacy amp Comet Pump Models 1 36 8 783 035 0 Label Operator Warnings Trilingual 1 37 8 783 036 0 Label Warning Pictogram 1 38 8 783 038 0 Label Universal DB Rating Ear Protection Trilingual 1 39 9 802 215 0 Injector Chem Non Adj 2 3 GPM 0 070 G Series Pump Models 1 40 6 388 216 0 A Hose DN 5 1 41 5 731 609 0 A Filter with weigh 1 42 9 802 958 0 4 Shaft Key 0 185 SQR X 1 75 All Models Except Comet Pump Models 1 A Not Shown Xpert HD DD PD DA e 8 780 000 0 e Rev 03 12 COMET PUMP BXD 5 8 SHAFT EXPLODED VIEW 8 920 017 0 COMET PUMP BXD Gas Engine G VERSION 3 4 E vERSION 5 8 Electric Motor Nu A qe db COMET PUMP BXD REPAIR KITS ITEM PART NO DESCRIPTION QTY ITEM PART NO DESCRIPTION 1 8 725 556 0 Kit valve 7 8 725 562 0 Kit complete valve kit QTY 8 725 557 0 Ki 8 8 725 563 0 Kit piston seal suction valve 8 725 558 0 Kit check valve 8 725 564 0 Oil site glass 8 725 559 0 Kit 10 8 725 565 0 Oring injector body 8 725 560 0 Ki 11 8 725 566 0 Oil cap chemical
8. MODEL ORDER XPERT HD 2 3 23 P 1 107 103 0 XPERT HD 2 3 23 P 1 107 104 0 XPERT HD 2 5 27 P 1 107 106 0 PD3 23326 1 107 091 0 PD3 23327 1 107 092 0 PD3 27324 1 107 094 0 DA 232336 1 107 097 0 DA 232337 1 107 098 0 DA 252739 1 107 100 0 DD 232336 1 107 134 0 DD 232337 1 107 135 0 DD 252737 1 107 136 0 DD 252797 1 107 198 0 DD 263097 1 107 197 0 SERVICE MANUAL 8 780 000 0 CONTENTS Exploded VIEW se cnr ute nenne tene EH e Exploded View Parts ist BXD Comet Pump and Pepairkits asarana aaae aana anan anna anana anana Legacy Axial PUM EE G 1 Pump w 3 4 Hollow Shaft Exploded and Parts List UU1 Universal Unloader Exploded and Parts List Troubleshooltlhg une Preventive Manteinance ss asas sasanga TAn aaa SENA TIGA KENGING ESA EN KAEN ANAN AN ENE Oil Change Record scion cenit eae de da Xpert HD DD PD DA 8 780 000 0 e Rev 03 12 EXPLODED VIEW Legacy Honda 196cc Kohler 208cc G series 23 E Lu 9 gt oO Lu 0 tr D I lt w x n Y D D a Xpert HD DD PD DA 8 780 000 0 e Rev 03 12 EXPLODED VIEW PARTS LIST ITEM PART NO DESCRIPTION QTY 1 9 194 015 0 Engine Honda GC160 QHA 163cc Legacy amp Comet Pump Models 9 802 317 0 Engine Honda GX200UTQX2 196cc Models 8 751 876 0 Engine Kohler CH270 Recoil 208 cc All Models Except Comet Pump 2 see page 7 Comet Pump BXD Assy see page 8 Pump Legacy Ax
9. all local distributor and order an o ring Pump is sucking air Check that hoses and fittings are air tight Turn off machine and purge pump by squeezing trigger gun until a steady flow of water emerges through nozzle Xpert HD DD PD DA 8 780 000 0 e Rev 03 12 PREVENTATIVE MAINTENANCE 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 preventa tive 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 first use of your new pressure washer MAINTENANCE SCHEDULE Inspect Daily Engine Oil First month or 20 hours Every 100 hours or every 6 months after first month Every 50 hours Air Cleaner Filter Se EA Monthly 500 hours or 6 months 300 hours or annually Annually Annually Pump Oil Oil level daily Comet and G Series After first 50 hours then every 500 hours or annually pumps only Every 6 months Xpert HD DD PD DA 8 780 000 0 e Rev 03 12 U V m Y 0 c V m S gt V I m XJ j 9 c 7 gt O O 3 Q 9 e 15 OIL CHANGE RECORD Check pump oil and engine oil level
10. ial 2 6 GPM 3000PSI see page 10 G 1 Series Pump 2 5 3000 3400 RPM 196cc Models 3 8 707 256 0 Pump protector 1 2 PTP 140DEG P N 1005 All Models Except Legacy A Comet Pumps 8 707 254 0 Pump protector 3 8 145 DEG Comet Pump Models 4 9 802 146 0 Swivel 1 2 MP X 3 4 GHF w strainer All Models Except Legacy Pump Models 5 9 802 170 0 Nipple 3 8 X 3 8 NPT ST Female Comet Pump Models 9 802 171 0 Nipple 3 8 X 3 8 NPT ST Male 196cc Models 6 6 965 007 0 5 16 24X1 GR 5 SHCS THRU Hardener ZC 9 802 813 0 Washer 5 16 Lock Split Ring 9 138 437 0 Karcher branding label Xpert HD 9 138 439 0 Landa branding label PD Models 9 138 440 0 Hotsy branding label DA Models 8 750 881 0 Shark branding label DD Models 9 8 739 133 0 Hose 3 8 X 25 1 Wire Tuff Skin 163cc PD Models 8 739 026 0 Hose 3 8 X 50 1 Wire Tuff Skin 196cc PD Models 8 739 106 0 Hose 3 8 X 25 1 Wire Tuff Skin 163cc DA Models 8 739 011 0 Hose 3 8 X 50 1 Wire Tuff Skin 196cc DA Models 8 739 124 0 Hose 3 8 X 25 1 Wire Tuff Skin 163cc Xpert amp DD Models 8 739 021 0 Hose 3 8 X 50 1 Wire Tuff Skin 196cc 208 cc Xpert and DD Models 10 8 750 247 0 Gun M407 11 8 783 039 0 Wand 30 12 9 104 024 0 Quick connect nozzle Kit 030 9 802 287 0 ANozzle 0003 Red 9 802 288 0 ANozzle 0015 Yellow 9 802 289 0 ANozzle 0025 Green 8 932 998 0 ANozzle 0040 White 9 802 311 0 ANozzle Black Soaper 13 8 917 794 0 Fra
11. me O4 BLK Wrinkle Professional 14 9 140 131 0 Handle BLK Wrinkle 15 9 142 014 0 Hanger RT side 16 9 802 778 0 Nut 5 16 Whiz Loc Flange 17 see page 12 UU1 3500PSI Universal Unloader 196cc Models 18 9 134 022 0 Name plate 19 9 196 049 0 Nylon Rivet 20 9 196 307 0 1 4 20 x 1 1 2 GR 2 Hex Bolt Zinc 21 8 767 003 0 1 4 20 Star Knob 22 9 802 713 0 Bolt 5 16 X 1 1 2 NC HH 612975 23 9 802 776 0 Nut 5 16 ESNA NC 24 8 718 980 0 Washer 5 16 Flat SAE 780452 25 9 189 007 0 Wheel 10 X 3 50 Pneu 26 9 182 506 0 Cap Black Plastic 5 8 Fastener 27 9 183 405 0 Rubber dampener 28 9 196 308 0 5 16 18 X 1 2 Carriage Bolt A307 BLK 29 9 802 166 0 Coupler 3 8 Female Brass 8 702 088 0 AO Ring Viton 3 8 8 707 182 0 Coupler Twist Connect M22 Fx3 8 FNP Legacy Pump Models 8 704 036 0 AO Ring Viton Twist Connect 30 9 138 438 0 Shark branding label DD Models A Not Shown Dd D m 0 00 5 m 5 5 I m D o m X O m gt D rm 2 a A Pl sch AH Aa sch Af sch 2 2 po p P P oO BR BP PO Pl UM 1 e sch 1 sch ae sch ae sch df sch 1 sch ch ch sch ch sch Xpert HD DD PD DA 8 780 000 0 e Rev 03 12 lt Lu 9 gt fc Lu Y cr m I lt W Es D 0 m cr Q EXPLODED VIEW PARTS LIST CONT IT
12. ng Turn off machine and trigger spray gun until a steady flow of water emerges through the nozzle Insufficient water supply Turn water on full force Check garden hose for kinks leaks or blockage PRESSURE LOW Replace nozzle AFTER PERIOD OF NORMAL USE Unloader valve worn Replace unloader valve ENGINE WILL NOT Low oil shutdown Fill engine with oil START OR STOPS WHILE OPERATING Ale Drain gas tank fill with clean fuel LOADED SERIES Excessive pressure from high Adjust engine throttle to lower RPM engine RPM WATER OR OIL A small amount of leaking is If excessive leaking occurs Call local LEAKING FROM normal distributor BOTTOM OF PUMP PRESENCE OF Water sprayed at machine Change oil Direct spray away from machine WATER IN PUMP OIL SEHE BXD Comet amp G High humidity in air Check and change oil twice as often Pump Series Only Piston packing worn Oil seal worn Call local distributor U V m Y 0 c V m S gt V I m y j 9 c 7 gt O O 3 Q 9 e 13 Xpert HD DD PD DA 8 780 000 0 e Rev 03 12 PRESSURE WASHER Troubleshooting Guide TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION ENGINE OPERATES Not enough gas or engine oil Fill tank with gas Check oil level FOR 15 MINUTE g p oe Geck 5 Vapor lock developed by heat of day Keep gas tank full to avoid vapor locking Obstruction in fuel filter Clean or replace fuel filter ENGINE LACKS Dirty air filte
13. r 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 OIL DRIPPING WATER LEAKING FROM PUMP PROTECTOR NO DETERGENT GARDEN HOSE CONNECTION LEAKS SPRAY WAND LEAKS PUMP IS NOISY Cracked piston Call local distributor 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 Check connection connected to machine Detergent is too thick Dilute detergent For best results use manufacturers detergent Detergent filter valve is at lowest Set detergent filter valve to a higher setting setting Filter on detergent suction tube is Run warm water through filter to remove clogged debris Damaged or clogged detergent suc Remove obstruction or replace detergent tion tube suction tube A high pressure nozzle is attached Replace with black detergent nozzle Discharge nozzle is obstructed Blow out or remove debris with fine needle Loose fittings Tighten fittings Spray wand not properly attached Slide the spray wand into the gun Turn the wand collar clockwise onto the spray gun threads until tight C
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