SERVICE MANUAL - R.J. Bowers Distributors, Inc.
Contents
1. gt Sy ITEM PART NO DESCRIPTION QTY ITEM PART NO DESCRIPTION QTY ite 1 __8 750 580 0 Engine Honda 30 8 919 349 0 Al Base Long 389 cc 1 2 GX390UT20A2 389 cc 1 8 919 401 0 Al Base Short 196 cc 1 x 9 802 317 0 Engine Honda e z m GX200UTAX2 196 cc 1 31 8 919 352 0 A ame Slider 1 2 8 917 978 0 Handle Support Assy 32 8 919 354 0 Slider Stiffener Long 1 E Al Direct Drive 1 33 Pump Assy 2700 PSI 3 9 135 007 0 Rotary Tube Joint 4 ee PSI n 4 8 917 976 0 Handle Assy Al Direct Drive 1 See D3030R Specs Pages 1 J D _8 750 3030 Handle Stiffener Al 2 34 8 919 356 0 Axle Spacer RH 2 0 389 cc 1 Lu 6 9 802 402 0 Bushing H X 24MM 1 8 918 079 0 Axle Spacer Silver 196 cc 1 7 _8 715 593 0 Pulley 2BK 90 H 389 cc 1 35 8 919 358 0 Axle Spacer Left 5 00 1 Di 9 802 380 0 Pulley BK 80 H 196 cc 1 36 9 802 782 0 Collar 5 8 Bore Shaft 2 D 8 9 802 399 0 Bushing H X 1 389 cc 1 37 9 196 307 0 1 4 20 x 1 1 2 GR 2 Hex CC 9 803 897 0 Bushing H X 3 4 196 cc 1 Bolt Zinc 4 vil o 8 715 576 0 Pulley 2BK 32 H 389 cc 1 38 9 197 010 0 1 4 20 Nylon Insert Lock Nut 4 9 802 379 0 Pulley BK 36 H 196 cc 1 30 Anr Sane A TE rae Nee i 40 Quick Connect Nozzle Kit 389 cc 1 11 8 718 980 0 Washer 5 16 389 cc 41 8 712 345 0 A Nozzle 196 cc 47 SAQCMEG 0004 RED 12 9 803 114 0 Retainer Bracket 8 712 346 0 A Nozzle Handle Black 2 SAQCMEG 1504 YELLOW 13 9 802 816 0 Washer 7 16 W n2. C 5 M N n m I m J 9 m gt D m M4035R 3 PUMP ASSEMBLY EXPLODED VIEW x N W 9 gt an DI Vu cc TI T lt gt W ES gt D o Di cc a 3 ITEM PARTNO DESCRIPTION QTY ITEM PARTNO DESCRIPTION QTY 1 8 751 189 0 Pump KM4035R 3 8 9175 0180 HU 3500PSI 4 8 3500 1500RP 1 Universal Unloader SPARE 1 8 751 169 0 Pump LM4035R 3 9 8 706 955 0 Hose Barb Wwe ebe Y n sek 1 1 4 Barb X 1 8 MPT 90 Deg 1 751 180 ump 3 TA MERS BEREA Wees AMBERR JEF gt a 4 8 3500 1500 RPM 4 10 9 802 254 0 Hose 1 4 Push On ET 1 8 706 854 0 Tee 1 4 Branch Male 1 11 6 390 126 0 Clamp Hose 46 54 ST 2 12 9 802 171 0 Coupler 3 8 Plug Male 1 9 804 025 0 Pump Protector 1 4 145 Deg 1 9 802 146 0 Swivel 1 2 MP x 3 4 GHF W Sirainer 1 5 8 706 958 0 Hose Barb 1 4 Barb x 1 4 MPT 90 Dgr 1 6 8 706 207 0 Elbow 3 8 Street 90 Deg Steel 1 7 9 802 190 0 Valve EZ Start 3 8 MPT X 1 8 FPT 1 8 917 991 0 e HD PGA BXA BGA e Rev 01 12 8 751 169 0 LM4035R 3 8 751 180 0 HM4035R 3 M4035R 3 SERIES PUMP EXPLODED VIEW 8 751 189 0 KM4035R 3 M4035R 3 SERIES PUMP EXPLODED VIEW PARTS LIST TORQUE SPECS ITEM PART NO DESCRIPTION QTY ITEM PART NO DESCRIPTION QTY 1 8 751 216 0 Crankcase 1 23 9 802 944 0 Hexagonal S
3. SERVICE MANUAL ORDER 1 107 132 0 1 107 133 0 1 107 127 0 1 107 128 0 MODEL HD 2 5 27 PB AL HD 3 7 35 PB AL PGA3 27324 PGA4 35324 BXA 120 0 1 107 121 0 1 107 252739 BXA 373539 1 106 057 0 1 106 058 0 BGA 252737 BGA 373537 8 917 991 0 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION LOW OPERATING Faulty pressure gauge Install new gauge PRESSURE Insufficient water supply ES larger supply hose clean filter at water Match nozzle number to machine and or Old worn or incorrect spray nozzle e replace with new nozzle Belt slippage Tighten or replace use correct belt Plumbing or hose leak Check plumbing system for leaks Re tape leaks with teflon tape Faulty or mis adjusted unloader Adjust unloader for proper pressure Install valve repair kit when needed Worn packing in pump Install new packing kit Fouled or dirty inlet or discharge Clean inlet and discharge valves valves in eer Worn inlet or Worn inlet or discharge valves valves Replace with valve kit Obstruction in spray nozzle Remove obstruction Leaking pressure control valve Rebuild or replace as needed Slow engine RPM Set engine speed at proper specifications Pump sucking air Check water supply and possibility of air seepage Valves sticking Check and clean or replace if necessary Unloader valve seat faulty Check and replace if necessary FLUCTUATING Worn or dirty pump valves Call local distributor
4. 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 CONNECTION 8 917 991 0 HD PGA BXA BGA e Rev 01 12 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION SPRAY WAND Spray wand not properly attached Slide the spray wand into the gun Turn the LEAKS wand collar clockwise onto the spray gun threads until tight Broken o ring Call local distributor and order an o ring PUMP IS NOISY 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 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 V 20 m del Cc J m 5 del I m Ke j Si lt 2 a gt Q el E
5. 9 802 066 0 Pad Soft Rubber Handle amp Coupler 196 ce 3 27 8 718 684 0 Bolt 3 8 X 5 28 9 802 754 0 Screw 1 4 x 1 2 NC 29 8 919 712 0 Aluminium Bumper _ QI N N 8 917 991 0 e HD PGA BXA BGA e Rev 01 12 EXPLODED VIEW PARTS LIST CONT ITEM PART NO DESCRIPTION QTY ITEM PART NO DESCRIPTION QTY 47 8 916 740 0 Hose 3 8 x 50 76 8 783 036 0 Label Warning Pictogram 1 1 Wire Tuff Skin BGA Models 1 77 8 750 809 0 Label Operation 8 739 011 0 er Se Sen BXA Modele a Warn Trilingual Small 1 ire Tuff Skin odels 8 739 021 0 Hose 3 8 x 50 78 _8 783 038 0 E ee DB Rating 1 Wire Tuff Skin HD Models 1 zech 8 739 026 0 Hose 3 8 x 50 79 9 800 008 0 Label Danger Cool Engine 1 1 Wire Tuff Skin PGA Models 1 80 8 751 861 0 Label Long 48 9 802 417 0 Belt BX38 389 cc 2 HD Models 389 cc 1 8 715 695 0 Belt BX34 196 cc 1 8 751 862 0 Label Short HD Models 196 cc 1 49 8 751 212 0 Bolt M10 X 25MM 389 cc 4 8 750 465 0 s n Geer Gen Sa A DEU Ball smi n ESD A 8 704 654 0 Label Logo Red BXA Models 1 50 8 919 423 0 Axle Holder Al Frame 2 8 900 870 0 Label Logo Die Cut 51 9 802 810 0 Washer Flat 5 8 2 BGA Models 1 52 8 919 350 0 Al Back Beltguard 81 8 901 219 0 Label ETL Mty UL 1776 1 DEE SC Gen J 1 82 9 800 034 0 Label Clear Lexan 4 3 X 5 5 1 91974020 Shani ae i 83 8 750 284 0 L
6. k d ech Lock Split Ring 389 cc 4 SAQCMEG 2504 GREEN n 8 712 348 0 A Nozzle 9 802 813 0 Washer 5 16 SAQCMEL OENE Lock Split Ring 1 4 i Oo SEU ME LRE GE Quick Connect 14 9 802 776 0 Nylon Insert Nut 5 16 389 cc 27 Nozzle Kit 196 cc 1 196 cc 31 8 712 331 0 A Nozzle 15 9 802 716 0 Bolt 5 16 X 2 10 SAQCMEG 0003 Red 16 9 197 003 0 3 8 16 Nylon Insert 389 cc 6 8 712 333 0 A Nozzle 196 cc 2 SAQCMEG 1503 Yellow 8 712 334 0 A Nozzle 17 9 196 041 0 Hex Head Bolt SAQCMEG 2503 Green 3 8 16 X 1 3 4 Gen cc 8 712 335 0 A Nozzle 9E ea SAQCMEG 4003 White 18 8 918 437 0 Holder Wand Left Silver 1 41 8 718 625 0 Bolt 5 16 18X3 4 NC Crrge 1 19 9136 5020 _ Knob 2 42 9 802 712 0 Bolt 5 16 18 X 1 3 4 20 9 802 793 0 Nut Cage 1 4 X 16 GA 5 NC Carriage 1 21 8 711 907 0 Wheel amp Tire 6 5 Steel Rim 43 8 750 247 0 Trigger Gun Model M407 1 12 5 Tire 389 cc 2 44 8 919 348 0 Al Foot Belt Drive 389 cc 1 9 802 270 0 Wheel amp Tire Assy 8 919 421 0 Al Foot Belt Drive Short 196 cc 1 vera e ee gt 45 8 908 395 0 Axle 5 8 x 26 80 a ET 908 395 xle x 26 cc 22 9 802 710 0 Screw 5 16 x 1 NC 10 8 919 422 0 Axle Short Base Al 24 196 cc 1 eo EEN See KA S 46 8 783 040 0 Wand 44 Zinc Plated 24 9 802 781 0 Nut 3 8 NC Whiz Loc Flange 2 Handle amp Coupler 389 cc 1 25 9 802 811 0 Washer 3 8 X 1 1 2 389 cc 4 8 783 039 0 Wand 30 Zinc Plated 26
7. 5 ta Q MAINTENANCE SCHEDULE nspect Every 100 hours or every 6 months after first month Filter nspect Engine Fuel Filter Engine Oil Air Cleaner Filter oO Di 5 Maintenance Change Clean Fuel Tank s Ee nspect Change Replace High Pressure Nozzle Replace Quick Connects Clean Water Screen Filter Replace HP Hose Tighten Inspect Replace Note When servicing belts don t exceed 14 lb ft on pump mounting screws Failure to do so will cause pump thread damage Wa oO Oo 17 8 917 991 0 e HD PGA BXA BGA e Rev 01 12 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 l S E N W 9 gt X W ve lan D Es S gt TI G go ge D D a 8 917 991 0 e HD PGA BXA BGA e Rev 01 12 389cc 196cc 64 389cc 11 196cc 87 i 64 389cc 11 196cc 64 389cc 86 196cc EXPLODED VIEW LL ALL LE SEE EER E AIE LESELE 8 917 991 0 HD PGA BXA BGA e Rev 01 12 EXPLODED VIEW TVANVW F9IANAS YAHSVM E l EEE Lele 64 389cc 11 196cc 17 389cc 86 KA 84 196cc ff 8 917 991 0 e HD PGA BXA BGA e Rev 01 12 EXPLODED VIEW PARTS LIST CONT
8. 52 372 0 Piston Ring D 1 20 O Ring 6 75 x 1 78 BN80 A D 1 6 Ball Seat CD 1 21 Spring Seat CD 2 7 O Ring 10 5 ID x 1 5 CS A C D 1 22 Plunger Spring B 1 8 Plunger B 4 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 CD 1 24 8 917 698 0 Banjo Bolt 3 8 Short 1 11 9 149 001 0 Low Pressure Port 1 a SBE EDO Boal Washer aer 12 9 152 017 0 Sliding Connector 30mm 1 DEV Ha Wee e S 8 762 005 0 Sliding Connector 40mm Long 1 13 9 149 002 0 Sliding Connector H 1 2 1 Singles BDS 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 s web ea h xela Kit A E uiet Al 1 O Ring 12 1Dx2C5 AD 2 e 9 104 040 0 Stem Basic Kit 16 O Ring 6 ID X 2 CS AD 1 Kit D 8 920 045 0 UU1 Complete Stem Kit 8 917 991 0 e HD PGA BXA BGA e Rev 01 12
9. 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 EE Drain gas tank fill with clean fuel LOADED ovens Excessive pressure from high Adjust engine throttle to lower RPM engine RPM 8 917 991 0 e HD PGA BXA BGA e Rev 01 12 v J m Wel Wal s JJ m D Wal I m a ha E 5 ID 2 gt 3 Q Q S Q p 15 CONTENTS Exploded VIEW naren geernnnneeree deet eenmmatdegenneteen kla dik nala kay yek reed Exploded View Parts List M4035R 3 Pump Assembly Exploded and View esseer M4035R 3 Series Pump Exploded and Parts List D3030R 1 Pump Assembly Exploded and View UEUEU U UEUU D3030R 1 Series Pump Exploded and Parts List Unloader Exploded and Parts Let Troubleshooting YY E HEEE Preventive Manteinanc ka xal cu llw l dak kan daka ba la lal dk Oil Change Record ne kaks k l n kai nln xeba ka
10. abel Name Plate HD Models 1 8 750 285 0 Label NamePlate 53 8 919 351 0 Front Beltguard Long 389 cc 1 PGA Models 1 8 919 403 0 Front Beltguard Short 196 cc 1 8 750 286 0 Label Name Plate 54 9 802 071 0 Al Trim 750 B2 X 1 16 4 5 ft BXA Models 1 55 8 919 796 0 Hose Hanger Al Frames 1 8 750 714 0 Bes w odels 56 9 802 809 0 Washer 1 2 Flat 3 84 9 196 021 0 Socket Head Screw 57 9 803 551 0 Screw 5 16 x 3 4 3 5 16 24 x1 25 196 cc 1 58 9 802 778 0 Nut Whiz Loc 5 16 Flange 3 85 9 802 713 0 Bolt 5 16 X 1 1 2 196 cc 1 59 8932 9930 Cushion Pump 2 86 9 198 014 0 Washer 21 64 X 1 196 cc 1 60 98028190 Washer 7 16 x 2 1 2 2 87 8 919 425 0 Al Muffler Deflector 196 cc 1 61 9 802 958 0 Key 0 185 NotShown SQR X 1 75 196 cc 1 9 802 959 0 Key 0 247 SQR X 2 125 389 cc 1 62 8 718 779 0 Scew 4mmX6mm 196cc 2 63 8 919 592 0 Suspension Bracket 2 64 9 802 817 0 Washer 3 8 x 1 389 cc 13 65 9 802 053 0 Bushing Fuel Line Rubber 1 66 8 736 004 0 Rubber Washer 1 67 8 719 091 0 Spring Foot Compression 2 68 8 706 557 0 Bellows Leg BOOT 2 69 8 719 954 0 Tube PC Foot Bolt 2 70 9 802 166 0 Coupler 3 8 Socket Female Brass 1 71 9 800 006 0 Label Hot Caliente W Arrows 1 72 8 917 015 0 Label Regulation 4442 6 1 73 8 901 137 0 Label Beltguard Warning 1 74 8 930 124 0 Label Intended For Outdoor Use Mexico 1 75 8 783 034 0 Label Quick Start Guide 1 8 917 991 0 e HD PGA BXA BGA e Rev 01 12 D gt m Ie
11. crew 8 2 See Kits Below Plunger Oil seal 3 24 8 717 210 0 Closed Bearing 3 See Kits Below O Ring 01 78 x 31 47 3 Housing 1 4 See Kits Below Pressure Ring 3 25 9 803 192 0 O Ring 01 78 x 60 05 2 5 See Kits Below U Seal 3 26 8 933 011 0 Tapered Roller Bearing 2 6 See Kits Below Intermediate Ring 3 27 9 803 146 0 Crankshaft 3540 1 7 See Kits Below U Seal 3 9 803 147 0 Crankshaft 4035 1 8 9 803 199 0 Washer Copper 1 28 9 803 167 0 Crankshaft Key 1 9 9 802 926 0 Plug Brass 1 2 1 ZOI BUZE T O DIP Stek 1 10 8751 2180 Manifold Head 1 30 9 803 140 0 Crankshaft Seal 1 11 See Kits Below O Ring 02 62 x 17 13 6 31 _9 803 178 0 _Shim 2 12 See Kits Below Valve Assembly 6 32 8 717 209 0 Bearing Housing 1 13 See Kits Below O Ring 2 62 x 20 29 6 33 See Kits Below Plunger Nut M8 3 14 9 802 928 0 Valve Plug 6 34 See Kits Below Copper Spacer 3 15 9 802 938 0 Manifold Stud Bolt 8 35 See Kits Below Plunger 4035 2 16 9 802 884 0 Washer 16 Punuar AU S 17 9 803 198 0 Copper Washer 3 8 1 SP MIS BAW COPPET pachi 18 9 802 925 0 Brass Plug 3 8 2 oo Sen gt 38 See Kits Below Teflon Ring 3 39 9 803 144 0 Plunger Rod 3 8 917 991 0 HD PGA BXA BGA e Rev 01 12 D gt m O C 5 M N n m I m JU 9 m gt D r x N Lu Q gt an W U cc TI T lt gt W Es D o Lj cc a 10 M4035R 3 SERIES PUMP EXPLODED VIEW PARTS LIST ITEMPART NO DESCRIPTION QTY 40 9 803 158 0 Con
12. da eda kar naba wa bada ka kan 8 917 991 0 HD PGA BXA BGA e Rev 01 12 PRESSURE WASHER Troubleshooting Guide TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION WATER OR OIL A small amount of leaking is If excessive leaking occurs call local LEAKING FROM normal distributor BOTTOM OF PUMP WATER IN PUMP chine eo See 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 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 Se UNDER O Ring plunger retainer worn Call local distributor Cracked piston Call local distributor OIL DRIPPING Oil seal worn or damaged Call local distributor FROM UNDER PUMP WATER LEAKING Spray gun closed with machine Open spray gun or turn off machine FROM PUMP running 5 minutes or longer PROTECTOR Excess water supply pressure Place a pressure regulator at end of 50 garden hose NO DETERGENT Detergent suction tube not properly J 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
13. necting Rod 41 8 751 228 0 Connecting Rod Pin 42 9 803 218 0 Spring Washer 43 9 803 238 0 Connecting Rod Screw 44 70 060009 O Ring 02 62 x 126 67 45 8 751 229 0 Crankcase Cover 46 9 803 197 0 O Ring 01 78 x 14 47 9 803 202 0 Sight Glass 3 4 Ory sf Ss st gt gt O Oo 48 9 802 939 0 Cover Screw Available in kit See below REPAIR KIT NO 8 725 360 0 8 725 358 0 8 725 361 0 8 725 359 0 8 725 237 0 8 933 023 0 9 802 603 0 9 802 609 0 Complete Seal Complete Seal Plunger Seal Plunger Seal Packing Packing Plunger Plunger KIT 4035 3540 4035 3540 4030 3540 Plunger Oil DESCRIPTION 15mm 18mm 15mm Complete Valve Seals ITEM NUMBERS INCLUDED Wa 5 4 5 6 4 5 6 11 12 13 NO OF CYLIN DERS KIT WILL 3 3 1 1 1 3 SERVICE 8 917 991 0 e HD PGA BXA BGA e Rev 01 12 x N Lu 9 gt an DI Vu cc TI T lt gt W ES gt D o TI cc Q 14 UU1 UNLOADER EXPLODED VIEW 9 175 018 0 UU1 3500PSI UNIVERSAL UNLOADER SPARE 14 21 10 UU1 UNLOADER EXPLODED VIEW PARTS LIST ITEM PART DESCRIPTION KIT QTY ITEM PART 8 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 A D 1 3 Piston O Ring Back Up A D 1 6 x 1 45 x 1 68 A 8 749 796 0 Main Block 1 19 Ball Housing Assy GD 5 9 1
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