Service mANUAl - R.J. Bowers Distributors, Inc.
Contents
1. 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 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 9 134 019 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 1 8 762 010 0 Cylinder Head 1 15 5 332 290 0 Helical Spring 2 9 175 004 0 Valve Assy Horizontal 3 16 9 175 005 0 Unloader Assembly 3 9 139 371 0 Spare Part List Set 3 1 17 4 132 007 0 Drain Plug Replacement 4 5 443 448 0 Nipple Chemestry 1 18 5 003 062 0 Plate 5 6 362 451 0 O Ring Seal 8 0 x 1 0 1 19 9 177 301 0 Hich Pressure Seal 6 6 362 175 0 O Ring Seal 5 28 x 1 78 1 20 9 177 310 0 Back Ring 7 7 401 909 0 Sphere 7 G40 1 4401 1 21 6 362 833 0 O Ring Seal 12 5 x 1 73 8 5 110 714 0 Sleeve 1 22 9 155 011 0 Housing Low Pressure Seal 9 5 332 258 0 Helical Spring 1 23 6 363 058 0 Grooved Ring 1 1 1 1 1 sl eo eo oe oo CO E coe v sch 8 780 000 0 e Xpert HD DD PD DA Rev 11 09 PUMP EXPLODED VIEW PARTS LIST CONT 8 920 004 0 Housing View c m n e E m N 5 m D v 3 lt m S R rm ITEM PART DESCRIPTION QTY 1 9 1662. 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 k i sch or BR P 8 780 000 0 e Xpert HD DD PD DA Rev 11 09 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 SERVICE MANUAL r Mm I lt S t D x a 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 19 9 803 952 0 Manifold Stud Bolt 2 See Kit Below Plunger Oil Seal 20 9 802 884 0 Washer 3 See Kit Below O Ring 01 78 x 28 30 21 9 803 198 0 Copper Washer 3 8 4 See Kit Below Pressure Ring 15mm 22 9 802 925 0 Brass Plug 3 8 5 See Kit Below U Seal 15mm 27 9 802 939 0 Hexagonal Screw 6 See Kit Below Intermediate Ring 15mm 28 9 803 953 0 Bearing Cover 7 See Kit Below Backup Ring 15mm 29 9 803 954 0 Seal Bearing 8 See Kit Below U Seal 15mm 30 9 802 914 0 Snap Ring 9 See Kit Below Support Ring 15mm 31 9 803 955 0 Ball Bearing 10 9 802 926 0 Brass Plug 1 2 32 8 717 069 0 Crankshaft 2530G 11 9 808 199 0 Copper Washer 1 2 33 9 803 957 0 Oil Dip Stick 12 9 803 946 0 Manifold Housing 34 9 804 581 0 O Ring 3 53 x 55 56 13 9 803 947 0 O Ring 01 78 x 15 54 14 See Kit Below Valve Assembly 35 9 804 582 0 Needle Rol
3. 09 V m n e E m N 5 m D v 3 lt m S R rm 3 UU1 UNLOADER EXPLODED VIEW 9 175 018 0 S UU1 3500PSI UNIVERSAL UNLOADER SPARE amp 21 2 Y d e r Mm I lt S t D x a UU UNLOADER EXPLODED VIEW PARTS LIST ITEM PART DESCRIPTION KIT QTY ITEM PART DESCRIPTION KIT QTY 1 8 749 792 0 Piston housing 1 17 9 149 006 0 Sliding connector guide 1 2 Piston C 1 18 O ring backup A 1 3 Piston O ring back up A 1 6X 1 45X 1 68 4 8749 796 0 Main block 1 19 Conical seal C 1 5 9 152 372 0 Piston ring 1 20 O ring 6 75 X 1 78 BNBO A 1 6 Ball seat C 1 21 Spring seat C i 7 O ring 10 5 ID X 1 5 CS__ AC 1 22 Plunger spring B 1 8 Plunger B 1 23 8 762 001 0 Banjo bolt 1 2 1 9 9 152 016 0 Plunger housing 1 redde Gei E Geer ZK Bypass spring S 24 8 762 000 0 Banjo bolt 3 8 1 s EC So pressure mum 25 9 802 893 0 Seal washer 3 8 2 laing connector mm 8 762 005 0 Siding connector 40mm long 1 o a SE ie Ge 5 0146 0000 Sling connector H 38 er _O RINGISIDx2C8 AB 3 14 9 196 011 0 Plug 5 8 18 UNF 1 28 8 706 865 0 Plug 1 4 Countersunk 1 15 O ring 12 ID x 2 CS A Kit A 9 104 038 0 O ring Repair Kit Kit B 9 104 039 0 Outlet Kit E O ring 6 ID X 2 CS A 1 Kit C 9 104 040 0 Stem Repair Kit 8 780 000 0 e Xpert HD DD PD DA e Rev 11 09 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION LOW OPERATING Insufficie
4. MODEL ORDER XPERT HD 2 3 23 P DD 232336 1 107 103 0 XPERT HD 2 3 23 P DD 232337 1 107 104 0 XPERT HD 2 5 27 P DD 252737 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 SERVICE MANUAL 8 780 000 0 CONTENTS Exploded VIEW Exploded View Parts iert BXD Comet Pump and Pepairkits ii Legacy Axial PU 2 2 2t aaa G 1 Pump w 3 4 Hollow Shaft Exploded and Parts List UU1 Universal Unloader Exploded and Parts List Troubleshoolhg E Preventive Manteinance eeeeesssseeeeseeeeeeeeee nennen enne Oil Change Record ion nectar a 8 780 000 0 e Xpert HD DD PD DA e Rev 11 09 EXPLODED VIEW Legacy SERVICE MANUAL Honda 6 5hp 196cc oc uj T lt t R m Cc Q Honda 5 0hp 163cc 8 780 000 0 e Xpert HD DD PD DA e Rev 11 09 EXPLODED VIEW PARTS LIST ITEM PART NO DESCRIPTION QTY 1 9 194 015 0 Engine Honda GC 160 QHA 5 0 HP 163cc 5 0HP Legacy amp Comet Pump Models 9 802 317 0 Engine Honda GX200UTQX2 6 5 HP 196cc 6 5HP Models 2 seepage 7 Comet Pump BXD Assy see page 8 see page 10 Pump Legacy Axial 2 6 GPM 3000PSI G 1 Series Pump 2 5 3000 3400 RPM 196cc 6 5HP Models 1 1 1 1 1 3 8 707 256 0 Pump prot
5. bel 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 196cc 6 5HP 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 A Shaft Key 0 185 SQR X 1 75 All Models Except Comet Pump Models 1 A Not Shown 8 780 000 0 e Xpert HD DD PD DA e Rev 11 09 COMET PUMP BXD 5 8 SHAFT EXPLODED VIEW 8 920 017 0 COMET PUMP BXD Gas Engine G vERSION 3 4 V m n e E m N 5 m D v 3 lt m gt R rm gt E 2 61 1 e St 5 8 S Electric Motor of Ex o q9 g 7 COMET PUMP BXD REPAIR KITS ITEM PART NO DESCRIPTION QTY ITEM PART NO DESCRIPTION QTY 1 8 725 556 0 Kit valve 8 725 557 0 Ki 8 725 558 0 Kit check valve 8 725 559 0 Kit 8 725 560 0 Kit chemical coupling 8 725 561 0 Kit 7 8 725 562 0 Kit complete valve kit 8 8 725 563 0 Kit piston seal 9 8 725 564 0 Oil site glass 10 8 725 565 0 Or ring 11 8 725 566 0 Oil cap 12 8 725 567 0 Knob suction valve injector body EH OQ oa Ww Pp xk eee ee a mi r Sekt m m let n m easy start 8 780 000 0 e Xpert HD DD PD DA e Rev 11 09 PUMP EXPLODED VIEW AND PARTS LIST 8 920 004 0 SERVICE MANUAL r Mm I lt t R D x a ITEM PART DESCRIPTION QTY ITEM PART DESCRIPTION QTY
6. chine Change oil Direct spray away from machine WATER IN PUMP OIL Ee 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 D m 5 X m S T m D 3 D Ka gt Q 9 zi Q Q S 13 8 780 000 0 Xpert HD DD PD DA e Rev 11 09 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION ENGINE OPERATES Not enough gas or engine oil Fill tank with gas Check oil level FOR 15 MINUTE oe Lo 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 PRESSURE WASHER Troubleshooting Guide 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 FROM UNDER PUMP OIL DRIPPING WATER LEAKING FROM PUMP PROTECTOR NO DETERGENT GARDEN HOSE CONNECTION LEAKS SPRAY WAND LEAKS PUMP IS NOISY Piston packing worn Call local distributor Call local distributor Call local distributor O Ring plunger retainer worn Cracked piston Call local distributor Open spray gun or turn off machine Place a pressure regulator at end of 50 garden hose Oil seal worn or damaged Spray gun closed with machine running 5 minutes or longer Excess water supply pressure Check connect
7. ector 1 2 PTP 140DEG P N 1005 All Models Except Legacy Pump Models 1 4 9 802 146 0 Swivel 1 2 MP X 3 4 GHF w strainer All Models Except Legacy Pump Models 1 5 9 802 170 0 Nipple 3 8 X 3 8 NPT ST Female Comet Pump Models 1 9 802 171 0 Nipple 3 8 X 3 8 NPT ST Male 196cc 6 5HP Models 1 6 6 965 007 0 5 16 24X1 GR 5 SHCS THRU Hardener ZC 4 7 9 802 813 0 Washer 5 16 Lock Split Ring 4 8 9 138 437 0 Karcher branding label Xpert HD amp DD Models 1 9 138 439 0 Landa branding label PD Models 1 9 138 440 0 Hotsy branding label DA Models 1 9 8 739 133 0 Hose 3 8 X 25 1 Wire Tuff Skin 5 HP PD Models 1 8 739 026 0 Hose 3 8 X 50 1 Wire Tuff Skin 6 5 HP PD Models 1 8 739 106 0 Hose 3 8 X 25 1 Wire Tuff Skin 5 HP DA Models 1 8 739 011 0 Hose 3 8 X 50 1 Wire Tuff Skin 6 5 HP DA Models 1 8 739 124 0 Hose 3 8 X 25 1 Wire Tuff Skin 5 HP Xpert amp DD Models 1 8 739 021 0 Hose 3 8 X 50 1 Wire Tuff Skin 6 5 HP Xpert and DD Models 1 10 8 750 247 0 Gun M407 1 11 _ 8 783 039 0 Wand 30 1 12 9 104 024 0 Quick connect nozzle Kit 030 1 A9 802 287 0 Nozzle 0003 Red 1 A9 802 288 0 Nozzle 0015 Yellow 1 A9 802 289 0 Nozzle 0025 Green 1 A8 932 998 0 Nozzle 0040 White 1 A9 802 311 0 Nozzle Black Soaper 1 13 9 115 095 0 Frame O4 BLK Wrinkle 1 14 9 140 131 0 Handle BLK Wrinkle 1 15 9 142 014 0 Hanger RT side 1 16 9 802 778 0 Nut 5 16 Whiz Loc Flange 2 17 see page 12 UU1 3500PSI Unive
8. ion 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 Call 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 Detergent suction tube not properly connected to machine Detergent is too thick 8 780 000 0 e Xpert HD DD PD DA e Rev 11 09 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
9. ler Bearing 36 8 717 212 0 Engine Flange 15 9 803 948 0 O Ring 22 62 x 18 77 37 9 803 210 0 Spring Washer BRR as sp ss as ae ss as Ss Oo DD CO CO 16 9 803 949 0 Valve Plug 38 9 804 584 0 Flange Screw 17 9 803 950 0 Washer Copper 18 9 803 951 0 Brass Plug G1 4 A B OOoo swWwowWwwWwwwww w 8 780 000 0 e Xpert HD DD PD DA e Rev 11 09 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 9 803 969 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 8 780 000 0 e Xpert HD DD PD DA e Rev 11
10. nt 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 leaking 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 dla 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 ma
11. rsal Unloader 196cc 6 5HP Models 1 18 9 134 022 0 Name plate 1 19 9 196 049 0 Nylon Rivet 4 20 9 196 307 0 1 4 20 x 1 1 2 GR 2 Hex Bolt Zinc 2 21 8 767 003 0 1 4 20 Star Knob 2 22 9 802 713 0 Bolt 5 16 X 1 1 2 NC HH 612975 4 23 9 802 776 0 Nut 5 16 ESNA NC 4 24 8 718 980 0 Washer 5 16 Flat SAE 780452 8 25 9 189 007 0 Wheel 10 X 3 50 Pneu 2 26 9 182 506 0 Cap Black Plastic 5 8 Fastener 2 27 9 183 405 0 Rubber dampener 2 28 9 196 308 0 5 16 18 X 1 2 Carriage Bolt A307 BLK 2 29 9 802 166 0 Coupler 3 8 Female Brass 1 A8 702 088 0 O Ring Viton 3 8 1 8 707 182 0 Coupler Twist Connect M22 Fx3 8 FNP Legacy Pump Models 1 A8 704 036 0 O Ring Viton Twist Connect 1 30 9 138 438 0 Shark branding label Xpert HD amp DD Models 1 8 780 000 0 Xpert HD DD PD DA e Rev 11 09 V m n e E m N 5 m D v 3 M S R rm SERVICE MANUAL E D I K t R D x a EXPLODED VIEW PARTS LIST CONT ITEM PART NO DESCRIPTION QTY 31 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 196cc 6 5HP Models 1 8 783 037 0 Label Quick Start Guide 2 163cc 5 0HP Legacy amp Comet Pump Models 1 36 8 783 035 0 Label Operator Warnings Trilingual 1 37 8 783 036 0 La
12. 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 Engine Oil Change First month or 20 hours ngine Every 100 hours or every 6 months after first month Every 50 hours Air Cleaner Filter Monthly Engine Fuel Filter 500 hours or 6 months Spark Plug Maintenance 300 hours or annually Clean Fuel Tank s Annually Replace Fuel Lines Annually Pump Oil Oil level daily pumps only 8 780 000 0 Xpert HD DD PD DA e Rev 11 09 D m 5 D m S E m Y 3 D Ka gt Q 9 Q Q S 15 OIL CHANGE RECORD Check pump oil and engine oil level 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 SERVICE MANUAL rc D T 2 t R D x a 8 780 000 0 e Xpert HD DD PD DA e Rev 11 09 Form 8 780 000 0 e Xpert HD DD PD DA e Revised 11 09 Printed in U S A or Mexico
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