Shark PCA3-27324, HD 3.8/35 P AL, HD 3.0/30 P AL, PCA3-30324, PCA4-35324 Service Manual
...Page 1
SERVICE MANUAL
MODEL # ORDER #
HD 2.5/27 P AL
HD 3.0/30 P AL
HD 3.8/35 P AL
PCA3-27324
PCA3-30324
PCA4-35324
DBA-252739
DBA-303039
DBA-383539
DGA-252737
DGA-303037
DGA-383537
1.107-129.0
1.107-130.0
1.107-131.0
1.107-124.0
1.107-125.0
1.107-126.0
1.107-117.0
1.107-118.0
1.107-119.0
1.106-054.0
1.106-055.0
1.106-056.0
8.917-990.0
Page 2
Page 3
Exploded View ......................................................................................... 4
Exploded View Parts List ......................................................................5-6
S4040G Pump Exploded and Parts List .............................................7-9
G3035G Pump Exploded and Parts List ........................................... 10-12
G2530G Pump Exploded and Parts List ........................................... 13-15
Unloader Exploded and Parts List ......................................................... 16
Troubleshooting ................................................................................17-18
Preventive Manteinance ........................................................................ 19
Oil Change Record ................................................................................ 20
CONTENTS
3
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
Page 4
EXPLODED VIEW
389 cc
270 cc
SERVICE MANUAL
41
6
PRESSURE WASHER
For
Detail See
Pump
Assy
12
3
55
61
46
10
38
56
47
52
5
48
20
50
15
13
54
55
14
11
25
42
35
23
43
18
18
57
44
53
36
2
45
9
32
51
16
30
41
6
For
Detail
See Pump
Assy
29
22
40
1
46
52
5
47
50
48
16
13
19
17
4
33
8
26
37
34
39
40
49
24
62
31
9
8
9
8
8
7
21
22
8
7
28
27
38
12
60
8
22
59
58
25
11
14
8
8
44
56
9
57
9
45
8
8
9
9
22
19
8
3
4
10
12
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
Page 5
PRESSURE WASHER
EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.135-007.0 Rotary Tube-Joint 4
2 9.136-502.0 Knob 2
3 9.802-066.0 Pad Soft Rubber (270 cc, 389 cc) 3
Pad Soft Rubber (196 cc) 2
4 8.917-980.0 Hose Hanger Camaro Silver 1
5 8.750-580.0 Engine, Honda GX390UT2QA2 (389 cc) 1
9.802-315.0 Engine, Honda GX270UTQAG2 (270 cc) 1
9.802-317.0 Engine, Honda GX200UTQX2 (196 cc) 1
6 Pump Assy 3500 PSI (See S4040G.2 Specifi cations Pages) 1
Pump Assy 3000 PSI (See G3035G Specifi cations Pages) 1
Pump Assy 2700 PSI (See G2530G Specifi cations Pages) 1
7 9.802-716.0 Bolt, 5/16" x 2", NC HH 10
8 8.718-980.0 Washer, 5/16", FLAT, SAE(780452) (389 cc, 270 cc) 49
(196 cc) 53
9 9.802-776.0 Nylon Insert Nut 5/16" 29
10 9.802-720.0 Bolt, 3/8" x 1", NC HH(612984) (389 cc, 270 cc) 3
(196 cc) 2
11 9.197-003.0 3/8-16 NE Nylon Insert L/N ZC 5UM White (389 cc, 270 cc) 3
(196 cc) 2
12 9.802-817.0 Flat Washer (389 cc, 270 cc) 7
(196 cc) 6
13 9.196-041.0 Hex Head Bolt 3/8-16 x 1-3/4" (389 cc, 270 cc) 6
(196 cc) 2
14 9.198-004.0 3/8 USS F/W Zinc (389 cc, 270 cc) 7
(196 cc) 2
15 8.750-247.0 Trigger Gun Model M407 1
16 9.196-307.0 1/4-20 x 1-1/2" GR 2 Hex Bolt Zinc 4
17 9.197-010.0 1/4-20" Nylon Insert Lock Nut with Flange 4
18 9.177-204.0 Sleeve, Rubber 4
19 9.802-710.0 Screw 5/16" x 1" NC 3
20 8.739-011.0 Hose, 3/8"x50', 1W, TS, SO x SW (DBA Models) 1
8.739-026.0 Hose, 3/8"x50', 1W, TS, SO x SW (PCA Models) 1
8.739-021.0 Hose, 3/8"x50', 1W, TS, SO x SW (HD and DGA Models) 1
21 8.750-303.0 Handle Stiffener AL 2
22 8.718-618.0 Bolt, 5/16" x 3/4" NC GR 5 CS ZN(61294) 14
23 8.918-437.0 Holder Wand Left Silver 1
24 8.918-079.0 Axle Spacer Silver Aluminum Direct Frame 2
25 8.750-265.0 Aluminum Base Direct Drive 1
26 9.803-097.0 Axle, 5/8" x 20.125" Long 1
27 9.802-782.0 Collar, 5/8" Bore Shaft 3010 2
28 9.802-270.0 Wheel & Tire Assy, 4" Steel Rim W/Tube 2
29 8.750-287.0 Foot AL Direct Frame 1
30 8.919-712.0 Aluminum Front Bumper Direct Drive 1
31 8.917-978.0 Handle Support Assy AL Direct Drive 1
32 8.917-976.0 Handle Assy AL Direct Drive 1
33 9.803-114.0 Retainer Bracket, Handle, Black 2
34 9.802-103.0 Bush 5/8" ID, 7/8 OD SB-875-10 2
35 8.718-625.0 Bolt, 5/16"-18 x 3/4", Nc Carriage znc 6159 1
36 9.802-712.0 Bolt, 5/16"-18 x 1-3/4", Nc Carriage z 1
37 9.803-308.0 Mount, Rubber Vibration 5/16", 70 Duro (196 cc) 4
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
SERVICE MANUAL
5
Page 6
EXPLODED VIEW PARTS LIST (CONT)
ITEM PART NO. DESCRIPTION QTY
38 9.802-959.0 Key, 0.247 SQR x 2.125" (270 cc, 389 cc) 1
9.802-958.0 Key, 0.185 SQR x 1.750" (196 cc) 1
39 9.802-713.0 Bolt, 5/16" x 1-1/2", NC HH(612975) 4
40 9.802-813.0 Washer, 5/16 Lock Split Ring (51156560) (196 cc) 8
SERVICE MANUAL
41 8.733-007.0 Socket Head 5/16-24 X 3/4 Zinc Plated (196 cc) 4
9.802-722.0 Bolt, 3/8 x 1 1/4", NC HH (270 cc, 389 cc ) 4
42 8.783-040.0 Wand 44" Zinc Plated, Handle & Coupler (270 cc, 389 cc) 1
8.783-039.0 Wand 30" Zinc Plated, Handle & Coupler (196 cc) 1
43 Quick Connect Nozzle Kit (389 cc) 1
8.708-531.0 Nozzle, QC, 1/4", #4.0 x 0, Red, Legacy
8.708-532.0 Nozzle, QC, 1/4", #4.0 x 15, Yellow, Legacy
8.708-533.0 Nozzle, QC, 1/4", #4.0 x 24, Green, Legacy
8.708-534.0 Nozzle, QC, 1/4", #4.0 x 40, White, Legacy
Quick Connect Nozzle Kit (270 cc) 1
8.723-577.0 Nozzle, QC, 1/4", #3.5 x 0, Red, Legacy
PRESSURE WASHER
8.726-104.0 Nozzle, QC, 1/4", #3.5 x 15, Yellow, Legacy
8.708-526.0 Nozzle, QC, 1/4", #3.5 x 25, Green, Legacy
8.902-487.0 Nozzle, QC, 1/4", #3.5 x 40, White, Legacy
Quick Connect Nozzle Kit (196 cc) 1
8.723-576.0 Nozzle, QC, 1/4", #3.0 x 0, Red, Legacy
8.902-482.0 Nozzle, QC, 1/4", #3.0 x 15, Yellow, Legacy
8.902-484.0 Nozzle, QC, 1/4", #3.0 x 25, Green, Legacy
8.902-485.0 Nozzle, QC, 1/4", #3.0 x 40, White, Legacy
44 8.930-124.0 Label, Intended For Outdoor Use - Mexico 1
45 8.783-038.0 Label, Universal DB Rating, Ear Protection 1
46 9.800-008.0 Label, Danger Cool Engine 1
47 9.800-006.0 Label, Hot/Caliente w/arrows 1
48 8.783-034.0 Label, Quick Start Guide 1
49 8.783-036.0 Label, Warning Pictogram 1
50 8.917-015.0 Label, Regulation 4442.6 1
51 8.750-284.0 Label, Name Plate (HD Models) 1
8.750-285.0 Label, Name Plate (PCA Models) 1
8.750-286.0 Label, Name Plate (DBA Models) 1
8.750-714.0 Label, Name Plate (DGA Models) 1
52 9.138-438.0 Label, Die - Cut (DGA models) 1
53 8.932-992.0 Mount, Rubber Vibration 3/8" (270 cc, 389 cc) 4
54 9.802-166.0 Coupler, 3/8"Socket, Female, Brass 1
55 9.802-814.0 Washer, 3/8" Split Ring Lock, Zinc (270 cc, 389 cc) 8
56 9.802-744.0 Bolt, 10mm x 20mm, HH Zinc (389 cc) 2
9.802-741.0 Bolt, 8mm x 16 mm Hex Head (270 cc, 196 cc) 2
57 9.802-816.0 Washer, 7/16", Split Ring Lock, 780481 (389 cc ) 2
9.802-813.0 Washer, 5/16 Lock Split Ring (51156560) (270 cc, 196 cc) 2
58 9.183-409-0 Rubber Dampener 5/16"-18 Female 2001 (196 cc) 1
59 8.917-977.0 Pump Support LG Fab Black Wrinkle (196 cc) 1
60 9.196-308.0 5/16-18 x 1/2 Carriage Bolt A307 BLK (196 cc) 1
61 8.933-024.0 Rail, Pump Support (389 cc) 1
9.804-533.0 Rail, Pump Support (270 cc) 1
62 8.750-809.0 Label Operation Warn Trilingual Small 1
Not Shown
6
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
Page 7
S4040G.2 PUMP ASSEMBLY EXPLODED VIEW
9
3
4
PRESSURE WASHER
SERVICE MANUAL
2
8
S4040G.2 PUMP ASSY EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 8.707-256.0 Pump Protector, 1/2 PTP
140 DEG, P/N 1005 1
2 8.706-958.0 Hose Barb, 1/4" Barb x 1/4"
Pipe, 90D 1
3 8.706-207.0 Elbow, 3/8", Street 90 Deg
p/n-TF349X6 1
4 9.802-190.0 Valve, EZ Start,
3/8 MPT x 1/8 FPT 1
5 8.706-940.0 Hose Barb, 1/4" Barb x 1/8"
ML Pipe 1
6 9.802-254.0 Hose 1/4" 1.5 ft
7 6.390-126.0 Hose Clamp 2
8 9.175-013.0 Unloader, UU1 3500PSI
Banjo 1/2"-1/4" NPT 1
9 9.802-350.0 Pump KS4040G,
4@4000, 3400 RPM 1
8.904-905.0 Pump LS4040G,
4 @4000, 3400 RPM 1
8.904-755.0 Pump HS4040G,
4 @ 4000, 3400 RPM 1
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
1
5
7
10
11
6
ITEM PART NO. DESCRIPTION QTY
10 9.802-171.0 Nipple, 3/8" x 3/8" NPT
ST Male 1
11 9.802-146.0 Swivel, 1/2" MP x 3/4"
GHF W/Strainer 1
7
Page 8
9.802-350.0 KS4040G.2
8.904-905.0 LS4040G.2
8.904-755.0 HS4040G.2
SERVICE MANUAL
S4040G.2 PUMP EXPLODED VIEW
PRESSURE WASHER
S4040G.2 PUMP EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 8.717-129.0 Crankcase 1
2 9.803-196.0 Plunger Guide 3
3*
4*
5*
6*
7*
8*
9*
10*
11 9.802-926.0 Brass Plug, 1/2" 1
12 9.803-199.0 Copper Washer 1/2" 1
13 9.802-932.0 Manifold Housing 1
14* 9.803-191.0 O-Ring Ø2.62 x 17.13 6
15*
16* 9.803-193.0 O-Ring Ø2.62 x 20.29 6
17 9.802-928.0 Valve Plug 6
18 9.802-938.0 Manifold Stud Bolt 8
19 9.802-884.0 Washer 8
20 9.803-198.0 Copper Washer 3/8" 1
21 9.802-925.0 Brass Plug 3/8" 2
See Kit Below
See Kit Below
See Kit Below
See Kit Below
See Kit Below
See Kit Below
See Kit Below
See Kit Below
See Kit Below
Plunger Oil Seal 3
O-Ring Ø1.78 x 31.47 3
Pressure Ring 3
U-Seal, 15mm 3
Intermed. Ring 15mm 3
Back-up Ring 3
U-Seal, 15mm 3
Support Ring 15mm 3
Valve Assembly 6
TORQUE
SPECS
Item # Ft.-lbs
17 75
18 30
26 7.6
39 10
47 7
58 13
ITEM PART NO. DESCRIPTION QTY
26 9.802-939.0 Hexagonal Screw 9
27 9.803-210.0 Washer 4
28 9.803-184.0 Closed Bearing Housing 1
29 8.717-225.0 O-Ring Ø 2.62 x61.6 1
30 9.802-914.0 Snap Ring 1
31 9.803-168.0 Double Row Ball Bearing 1
32 9.803-152.0 Crankshaft (S4040G) 1
33 9.802-945.0 Set Screw 1
34 9.802-921.0 Oil Dip Stick 1
35 9.804-581.0 O-Ring Ø 3.53 x 55.56 1
36 9.803-161.0 Needle Roller Bearing 1
37 9.803-183.0 Engine Flange 1
38 9.803-221.0 Spring Washer 4
39 9.803-240.0 Flange Screw 4
40 9.803-243.0 Engine Screw, 5/16" 4
41 9.803-215.0 Washer 4
42 9.802-889.0 Spring Washer 4
43 9.803-244.0 Engine Screw 3/8" 4
8
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
Page 9
S4040G.2 PUMP EXPLODED VIEW PARTS LIST (CONT.)
ITEM PART NO. DESCRIPTION QTY
44 9.803-216.0 Washer 4
45 9.803-217.0 Spring Washer 4
46 9.803-142.0 Crankshaft Seal 1
47*
48*
9.2 x 13.5 3
49*
50*
51*
52*
53 9.803-145.0 Plunger Rod 3
54 9.802-913.0 Snap Ring 6
55 9.802-916.0 Connecting Rod Pin 3
56 9.803-158.0 Connecting Rod 3
57 9.803-218.0 Spring Washer 6
58 9.803-238.0 Connecting Rod Screw 6
59 8.933-016.0 O-Ring 2.62 x 126.67 1
60 8.717-145.0 Crankcase Cover 1
61 9.803-197.0 O-Ring, Ø 1.78 x 14 1
62 9.803-202.0 Sight Glass, G3/4 1
* Part available in kit (See below)
See Kit Below
See Kit Below
See Kit Below
See Kit Below
See Kit Below
See Kit Below
Plunger Nut 3
Washer, Copper,
Plunger, 15mm 3
Copper Spacer 3
O-Ring Ø1.78x5.28 3
Tefl on Ring 3
PRESSURE WASHER
SERVICE MANUAL
S4040G.2 PUMP REPAIR KITS
REPAIR KIT NUMBER 9.802-622.0 9.802-623.0 8.933-023.0 9.802-603.0 9.802-609.0
Complete
Seal Packing
15mm Plunger 15mm Complete Valve Plunger Oil Seals
4, 5, 6, 7, 8, 9, 1047, 48, 49, 50,
51, 52
14, 15, 16 3
KIT DESCRIPTION
ITEM NUMBERS
INCLUDED
NUMBER OF CYLINDERS
KIT WILL SERVICE
Plunger Seal
15mm
4, 6, 8, 9, 10
31 163
9
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
Page 10
SERVICE MANUAL
PRESSURE WASHER
G3035G PUMP ASSEMBLY EXPLODED VIEW
1
7
5
8
9
6
2
11
G3035G PUMP ASSY EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.803-819.0 Pump KG3035G1
3@3500,3400 RPM 1
8.904-897.0 Pump LG3035G1
3@3500, 3400 RPM 1
8.904-752.0 Pump HG3035G1
3@3500, 3400 RPM 1
2 9.175-013.0 Unloader, UU1 3500PSI
Banjo 1/2"-1/4" NPT 1
3 9.802-171.0 Nipple, 3/8" x 3/8" NPT
ST Male 1
4 9.802-146.0 Swivel, 1/2" MP x 3/4"
GHF W/Strainer 1
5 8.707-256.0 Pump Protector, 1/2" PTP
140 DEG-p/n 1005 1
6 8.706-958.0 Hose Barb, 1/4" Barb x 1/4"
Pipe 90 D. 1
7 8.706-207.0 Elbow, 3/8" Street 90 Deg
p/n TF3409X6 1
3
10
4
ITEM PART NO. DESCRIPTION QTY
8 9.802-190.0 Valve, EZ Start, 3/8"
MPT x 1/8 FPT 1
9 8.706-940.0 Hose Barb, 1/4"
Barb x 1/8" ML Pipe 1
10 9.802-254.0 Hose 1/4" 1.5 ft
11 6.390-126.0 Hose Clamp 2
10
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
Page 11
9.803-819.0 KG3035G2
8.904-897.0 LG3035G2
8.904-752.0 HG3035G2
G3035G PUMP EXPLODED VIEW
TORQUE
SPECS
Item # Ft.-lbs
16 65
19 18
27 7.6
39 8
47 7
57 13
PRESSURE WASHER
SERVICE MANUAL
G3035G PUMP EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.803-938.0 Crankcase 1
2*
3*
4*
5*
6*
7* See Kit Below Backup Ring, 15mm 3
8* See Kit Below U-Seal Assy, 15mm 3
9*
10 9.802-926.0 Brass Plug, 1/2" 1
11 9.803-199.0 Copper Washer 1/2" 1
12 9.803-946.0 Manifold Housing 1
13*
14*
15*
16 9.803-949.0 Valve Plug 6
17 9.803-950.0 Washer, Copper 1
18 9.803-951.0 Brass Plug G1/4 1
See Kit Below
See Kit Below
See Kit Below
See Kit Below
See Kit Below
See Kit Below
9.803-947.0
See Kit Below
9.803-948.0
O-Ring Ø1.78 x 15.54 6
O-Ring Ø2.62 x 18.77 6
Plunger Oil Seal 3
O-Ring Ø1.78 x 31.47 3
Pressure Ring, 15mm 3
U Seal Assy, 15mm 3
Intermediate Ring 15mm 3
Support Ring 15mm 3
Valve Assembly 6
ITEM PART NO. DESCRIPTION QTY
19 9.803-952.0 Manifold Stud Bolt 8
20 9.802-884.0 Washer 8
21 9.803-198.0 Copper Washer 3/8" 1
22 9.802-925.0 Brass Plug 3/8" 2
27 9.802-939.0 Hexagonal Screw 9
28 9.803-953.0 Bearing Cover 1
29 9.803-954.0 Seal Bearing 1
30 9.802-914.0 Snap Ring 1
31 9.803-955.0 Ball Bearing 1
32 8.730-825.0 Crankshaft (3035G1) 1
8.730-826.0 Crankshaft (3535G1) 1
8.730-827.0 Crankshaft (4030G1) 1
33 9.802-945.0 Set Screw 1
34 9.803-957.0 Oil Dip Stick 1
35 9.804-581.0 O-Ring 3.53 x 55.56 1
36 9.803-161.0 Needle Roller Bearing 1
37 9.803-183.0 Engine Flange 1
38 9.803-210.0 Spring Washer 4
11
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
Page 12
G3035G PUMP EXPLODED VIEW PARTS LIST (CONT)
ITEM PART NO. DESCRIPTION QTY
39 8.933-020.0 Flange Screw 4
46 9.803-142.0 Crankshaft Seal 1
47*
SERVICE MANUAL
48* See Kit Below Copper Washer 3
49*
50*
51*
52*
53 9.803-964.0 Plunger Rod 3
54 9.803-965.0 Connecting Rod Pin 3
55 9.803-966.0 Connecting Rod 3
56 9.803-218.0 Spring Washer 10
57 8.933-020.0 Connecting Rod Screw 6
PRESSURE WASHER
58 9.803-202.0 Sight Glass, G3/4 1
59 9.803-197.0 Gasket, G3/4 1
60 9.803-968.0 Crankcase Cover 1
61 9.803-969.0 O-Ring 2.62 x 107.62 1
* Part available in kit (See below)
See Kit Below
See Kit Below
See Kit Below
See Kit Below
See Kit Below
Plunger Nut 3
Plunger, 15mm 3
Copper Spacer 3
O-Ring Ø1.78x5.28 3
Tefl on Ring 3
G3035G PUMP REPAIR KITS
REPAIR KIT
NUMBER 9.802-622.0 9.802-623.0 8.933-023.0 9.802-603.0 9.802-609.0
KIT
DESCRIPTION
ITEM NUMBERS
INCLUDED
Plunger Seal
15mm
4, 6, 8, 9, 10 4, 5, 6, 7, 8, 9, 10
Complete
Seal Packing 15mm Plunger 15mm Complete Valve Plunger Oil Seals
47, 48, 49, 50,
51, 52
14, 15, 16 3
12
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
Page 13
G2530G PUMP ASSEMBLY EXPLODED VIEW
2
PRESSURE WASHER
1
SERVICE MANUAL
5
G2530G PUMP ASSY EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 8.707-256.0 Pump Protector, 1/2 PTP
140 DEG, P/N 1005 1
2 9.804-033.0 Pump, KG2530G
2.5@3000, 3400 RPM 1
8.904-893.0 Pump, LG2530G
2.5@3000, 3400 RPM 1
9.802-748.0 Pump, HG2530G
2.5@3000, 3400 RPM 1
3 9.802-171.0 Nipple, 3/8" x 3/8" NPT
ST Male 1
4 9.802-146.0 Swivel, 1/2" MP x 3/4"
GHF W/Strainer 1
5 9.175-012.0 Unloader, UU1 3500 PSI
Banjo 1/2" Closed 2
3
4
13
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
Page 14
9.804-033.0 KG2530G.2
8.904-893.0 LG2530G.2
8.904-748.0 HG2530G.2
SERVICE MANUAL
PRESSURE WASHER
G2530G PUMP EXPLODED VIEW
TORQUE
SPECS
Item # Ft.-lbs
16 65
19 18
27 7.6
38 8
40 7
50 13
G2530G PUMP EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.803-938.0 Crankcase 1
2*
See Kit Below
3*
See Kit Below
4*
See Kit Below
5*
See Kit Below
6*
See Kit Below
7*
See Kit Below
8*
See Kit Below
9*
See Kit Below
10 9.802-926.0 Brass Plug, 1/2" 1
11 9.803-199.0 Copper Washer 1/2" 1
12 9.803-946.0 Manifold Housing 1
13*
9.803-947.0
14*
See Kit Below
15*
9.803-948.0
16 9.803-949.0 Valve Plug 6
17 9.803-950.0 Washer, Copper 1
18 9.803-951.0 Brass Plug G1/4 1
Plunger Oil Seal 3
O-Ring Ø1.78 x 28.30 3
Pressure Ring, 15mm 3
U-Seal, 15mm 3
Intermediate Ring 15mm 3
Backup Ring 15mm 3
U-Seal, 15mm 3
Support Ring, 15mm 3
O-Ring Ø1.78 x 15.54 6
Valve Assembly 6
O-Ring Ø2.62 x 18.77 6
ITEM PART NO. DESCRIPTION QTY
19 9.803-952.0 Manifold Stud Bolt 8
20 9.802-884.0 Washer 8
21 9.803-198.0 Copper Washer 3/8" 1
22 9.802-925.0 Brass Plug 3/8" 2
27 9.802-939.0 Hexagonal Screw 9
28 9.803-953.0 Bearing Cover 1
29 9.803-954.0 Seal Bearing 1
30 9.802-914.0 Snap Ring 1
31 9.803-955.0 Ball Bearing 1
32 8.717-069.0 Crankshaft (2530G) 1
33 9.803-957.0 Oil Dip Stick 1
34 9.804-581.0 O-Ring 3.53 x 55.56 1
35 9.804-582.0 Needle Roller Bearing 1
36 8.717-212.0 Engine Flange 1
37 9.803-210.0 Spring Washer 4
38 9.804-584.0 Flange Screw 4
14
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
Page 15
G2530G PUMP EXPLODED VIEW PARTS LIST (CONT)
ITEM PART NO. DESCRIPTION QTY
39 9.804-585.0 Crankshaft Seal 1
40*
See Kit Below
41*
See Kit Below Copper Spacer 3
42*
See Kit Below
43*
See Kit Below
44*
See Kit Below
45*
See Kit Below
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)
Plunger Nut 3
Plunger, 15mm 3
Copper Spacer 3
O-Ring Ø1.78x5.28 3
Tefl on Ring 3
PRESSURE WASHER
SERVICE MANUAL
G2530G PUMP REPAIR KITS
REPAIR KIT
NUMBER 8.725-354.0 8.725-355.0 9.803-934.0 9.803-936.0 9.803-937.0
KIT
DESCRIPTION
ITEM NUMBERS
INCLUDED
Plunger Seal
15mm
3, 5, 7, 8, 9
Complete
Seal Packing 15mm Plunger 15mm Complete Valve Plunger Oil Seals
3, 4, 5,
6, 7, 8, 9
40, 41, 42, 43,
44, 45
13, 14, 15 2
15
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
Page 16
UU1 UNLOADER EXPLODED VIEW
9.175-018.0
UU1 3500PSI, UNIVERSAL UNLOADER (SPARE)
21
2
SERVICE MANUAL
PRESSURE WASHER
23
28
26
14
27
10
1
13
24
25
26
12
3
20
16
18
5
15
19
6
7
25
4
8
22
27
15
9
23
UU1 UNLOADER EXPLODED VIEW PARTS LIST
ITEM PART # DESCRIPTION KIT QTY
1 8.749-792.0 Piston Housing 1
2 Piston C 1
3 Piston O-Ring Back Up A 1
4 8.749-796.0 Main Block 1
5 9.152-372.0 Piston Ring 1
6 Ball Seat C 1
7 O-Ring 10.5 ID x 1.5 CS A,C 1
8 Plunger B 1
9 9.152-016.0 Plunger Housing 1
10 Bypass Spring C 1
11 9.149-001.0 Low Pressure Port 1
12 9.152-017.0 Sliding Connector, 30mm 1
8.762-005.0 Sliding Connector, 40mm, Long 1
13 9.149-002.0 Sliding Connector H 1/2" 1
9.149-005.0 Sliding Connector H 3/8" 1
14 9.196-011.0 Plug 5/8 -18 UNF 1
15 O-Ring 12 ID x 2 CS A 2
16 O-Ring 6 ID X 2 CS A 1
16
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
27
17
11
ITEM PART # DESCRIPTION KIT QTY
17 9.149-006.0 Sliding Connector Guide 1
18 O-Ring Backup A 1
6 x 1.45 x 1.68
19 Conical Seal C 1
20 O-Ring 6.75 x 1.78 BN80 A 1
21 Spring Seat C 1
22 Plunger Spring B 1
23 8.917-699.0 Banjo Bolt 1/2" Short 1
8.917-700.0 Banjo Bolt 1/2"-1/4" NPT Short 1
8.917-698.0 Banjo Bolt 3/8" Short 1
24 8.917-698.0 Banjo Bolt 3/8" Short 1
25 9.802-893.0 Seal Washer 3/8" 2
26 9.803-921.0 Seal Washer 1/2" 2
9.802-893.0 Seal Washer 3/8" 2
27 O-Ring 15 ID x 2CS A,B 3
28 8.706-865.0 Plug, 1/4" Countersunk 1
Kit A 9.104-038.0 O-Ring Repair Kit
Kit B 9.104-039.0 Outlet Kit
Kit C 9.104-040.0 Stem Repair Kit
Page 17
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
PRESSURE WASHER Troubleshooting Guide
LOW OPERATING
PRESSURE
FLUCTUATING
PRESSURE
PRESSURE LOW
AFTER PERIOD OF
NORMAL USE
Insuffi cient water supply. Closed
faucet. Inlet hose kinked
Clogged inlet hose strainer Check plumbing system for leaks. Retape
Faulty or mis-adjusted unloader
valve
Worn packing in pump Call Dealer Customer Support.
Machine has been stored in freezing temperatures
Slow engine RPM Call local distributor.
Worn or dirty pump valves Call local distributor.
Nozzle is obstructed Blow out or remove debris with fi ne needle.
Pump sucking air, inlet hose
leaking
Insuffi cient water supply Turn water on full force. Check garden hose
Nozzle worn Replace nozzle.
Unloader valve worn Replace unloader valve.
Use larger garden hose; clean inlet water
screen. Open faucet.
leaks with tefl on tape.
Adjust unloader for proper pressure. Install
repair kit when needed. Call local distributor.
Thaw out machine completely, including
hose, spray gun and wand.
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.
for kinks, leaks or blockage.
ENGINE WILL NOT
START OR STOPS
WHILE OPERATING
ENGINE IS
OVERLOADED
WATER OR OIL
LEAKING FROM
BOTTOM OF PUMP
PRESENCE OF
WATER IN PUMP OIL
Low oil shutdown Fill engine with oil.
Out of gas Fill fuel tank.
Water in gasoline Drain gas tank; fi ll with clean fuel.
Nozzle partially blocked Clean nozzle.
Excessive pressure from high
engine RPM
A small amount of leaking is
normal
Water sprayed at machine Change oil. Direct spray away from machine.
High humidity in air Check and change oil twice as often.
Piston packing worn. Oil seal worn. Call local distributor.
Adjust engine throttle to lower RPM.
If excessive leaking occurs, Call local
distributor.
17
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
Page 18
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
ENGINE OPERATES
FOR 15 MINUTES
THEN STOPS
ENGINE LACKS
POWER
ENGINE FALTERS
WATER DRIPPING
FROM UNDER PUMP
OIL DRIPPING
FROM UNDER PUMP
WATER LEAKING
FROM PUMP
PRESSURE WASHER Troubleshooting Guide
PROTECTOR
NO DETERGENT
Not enough gas or engine oil Fill tank with gas. Check oil level.
Vapor lock developed by heat of day Keep gas tank full to avoid vapor locking.
Obstruction in fuel fi lter Clean or replace fuel fi lter.
Dirty air fi lter Replace air fi lter.
Choke is opened too soon Move choke to halfway position until engine
runs smoothly.
Piston packing worn Call local distributor.
O-Ring plunger retainer worn Call local distributor.
Cracked piston Call local distributor.
Oil seal worn or damaged Call local distributor.
Spray gun closed with machine
running 5 minutes or longer
Excess water supply pressure Place a pressure regulator at end of 50'
Detergent suction tube not properly
connected to machine
Detergent is too thick Dilute detergent. For best results, use
Detergent fi lter valve is at lowest
setting
Open spray gun or turn off machine.
garden hose.
Check connection.
manufacturers detergent.
Set detergent fi lter valve to a higher setting.
GARDEN HOSE
CONNECTION
LEAKS
SPRAY WAND
LEAKS
PUMP IS NOISY
Filter on detergent suction tube is
clogged
Damaged or clogged detergent suction tube
A high pressure nozzle is attached. Replace with black detergent nozzle.
Discharge nozzle is obstructed Blow out or remove debris with fi ne needle.
Loose fi ttings Tighten fi ttings.
Missing/worn rubber washer Insert new washer.
Spray wand not properly attached Slide the spray wand into the gun. Turn the
Broken o-ring Call local distributor and order an o-ring.
Pump is sucking air Check that hoses and fi ttings are air tight.
Run warm water through fi lter to remove
debris.
Remove obstruction or replace detergent
suction tube.
wand collar clockwise onto the spray gun
threads until tight.
Turn off machine and purge pump by
squeezing trigger gun until a steady fl ow of
water emerges through nozzle.
18
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
Page 19
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 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.
MAINTENANCE SCHEDULE
Inspect Daily
Engine Oil
Air Cleaner/Filter
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
Replace High Pressure Nozzle Every 6 months
Replace Quick Connects/O-Rings Annually/As needed
Clean Water Screen/Filter Weekly
Replace HP Hose Annually (if there are any signs of wear)
Change First month or 20 hours.
Every 100 hours or every 6 months after fi rst month
Filter Every 50 hours
Inspect Every 50 hours
Clean Monthly
Inspect Oil level daily
Change After fi rst 50 hours, then every 500 hours or annually
PRESSURE WASHER Troubleshooting Guide
19
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
Page 20
OIL CHANGE RECORD
Check pump oil and engine oil level before fi rst use of your new pressure washer.
Date Oil Changed
SERVICE MANUAL
Month/Day/Year
PRESSURE WASHER
Estimated Operating
Hours Since Last
Oil Change
Date Oil Changed
Month/Day/Year
Estimated Operating
Hours Since Last
Oil Change
20
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
Page 21
Form #8.917-990.0 • HD, PCA, DBA, DGA • Rev. 05/11
Printed in U.S.A. or Mexico
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