Husqvarna PW 235 Instruction manual

Workshop manual
English
PW 235
PW 235R

2 – 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 disassemble/assemble the front cabinet
and accessory storage...................................................6
2.4 To disassemble/assemble 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 disassemble/assemble the motor cover ....................8
2.8 To disassemble/assemble the start/stop valve...............8
2.9 To disassemble/assemble the water/oil seal
and valves......................................................................9
3 Specications ................................................. 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 lubrication ..................................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

English – 3
1 Introduction and safety regulations
1.1 General
This workshop manual gives a full description of how to
do troubleshooting, repair and test of the high pressure
washer. It also gives safety instructions that the
personnel must obey during repair work.
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 applicable
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.
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.
WARNING: Always use original spare parts
and accessories.
WARNING: Disconnect from electrical
power supply before carrying out user
maintenance.
WARNING: Use approved hearing protec-
tion. 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 debris 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 asbes-
tos- containing surfaces with high pres-
sure.
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.
Introduction and safety regulations

4 – English
2 Repair instructions
Repair instructions
2.1 Product overview, Cabinet torque
1,2 Nm
1,2 Nm
1,5 Nm
1,5 Nm
1,5 Nm

English – 5
Repair instructions
8 Nm
18 Nm
10 Nm
8 Nm
16 Nm
8 Nm
2.2 Product overview, Pump unit torque

6 – English
2.3 To disassemble/assemble the
front cabinet and accessory storage
1. Tools: Torx 20 screwdriver and at screwdriver.
2. Remove the handle by pressing the 2 * 2 snap locks.
Loosen one side rst and then the other side.
3. Remove the 2 torx TX20 screws (A) from the rear side.
A
A
4. Loosen the front cabinet from the accessories
storage. Use a screwdriver on both sides, see gure
below. Remove the accessories storage.
5. Lift up the front cabinet to remove it.
Assembly: Place the accessories storage on the front
cabinet and push it in place until you hear a “click”. Install
the 2 screws.
Repair instructions

English – 7
2.4 To disassemble/assemble the
control unit and/or wireless unit*
Tools: Torx 9 screwdriver.
1. Control unit:
- Disconnect the cable (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 cable (A) to the wireless unit.
- Check the circuit diagram and install the 3 wires (C)
accordingly on the control unit.
B
B
B
A
C
2. Wireless unit*:
- Disconnect the cable (A) to the wireless unit.
- Slide the wireless unit out (B).
- Exchange the wireless unit.
- Slide the wireless unit back (B).
- Connect the cable (A) to the wireless unit.
3. Recongure the pairing of the product and the handle,
see section “2.5 To pair the product and the handle*”.
B
A
* PW 235R version only
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 ashing 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 blinking, 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.
Repair instructions

8 – English
2.7 To disassemble/assemble 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.
3. Remove the cabinet. Take out the motor/pump unit.
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 disassemble/assemble the
start/stop valve
1. Assemble the start/stop valve, see gure below.
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
usable after using the puller.
Repair instructions

English – 9
2. The gure below shows the pump after opening the
cylinder head from the cylinder block.
CAUTION: Clean and lubricate the parts
before assembly!
2.9 To disassemble/assemble the
water/oil seal and valves
1. To change the oil seals, water seals and pressure
valve, use a screw driver to disassemble 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 usable after using the
puller.
Repair instructions

10 – English
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. Assemble all parts into the cylinder head, see gure
below.
Repair instructions

English – 11
3 Specications
3.1 Technical data
Value PW 235/PW 235R
Specication 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 cable 5 m
Insulation class B
Tightness IPX5
Specications

12 – English
4.1 Operating supplies
4.1.1 Recommended oil types
The pump is lled 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 lubrication
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
Appendices and schedules
2
134 5
Item Description Used for Article number
1T-handle Torx T20 For screws with torx head 588 59 85-01
2Puller M4 For valve seat 592 94 50-01
2Puller M8 For valve seat 592 94 49-01
3Screw driver PH2 For screws N/A
4Screw driver Torx T9 For screws with torx head N/A
5Screw driver, at For screws N/A

English – 13
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
Inlet
Non return valve
Outlet 3 Bar
3 BAR
4.2.2 Start up-pressure build up
Machine switch on / Start up - Pressure build up
Pump
>5 BAR
Inlet
Non return valve
Outlet >5 Bar
3 BAR
Appendices and schedules

14 – English
4.2.3 Pressure build up-opening pressure/close gun
4.2.4
Gun close. Pressure build up. Opening pressure. Micro switch is activated
Pump
130 BAR
Inlet
Non return valve
Outlet 130 BAR
3 BAR
Motor stop - standby pressure
Gun close. Motor stops. Pressure in hose decreases to standby pressure
Pump pressure is also standby pressure.
Pump
25 BAR
Inlet
Non return valve
Outlet 25 BAR
3 BAR
Appendices and schedules

English – 15
4.2.5 Gun is activated
Gun is open - Control piston is closed. Micro switch is deactivated.
Motor starts.
Pump
3 BAR
Inlet
Non return valve
Outlet 3 BAR
3 BAR
4.2.6 Machine run
Machine runs (normal working pressure). Gun is open.
Pump
100 BAR
Inlet
Non return valve
Outlet 98 BAR
3 BAR
Appendices and schedules

16 – English
4.3 Wiring diagram PW 235
Wiring diagramCircuit diagram
bl
21
bl
s1
2a c1
s1
1a
br
br
br
N
M
Lbr[ro]
bl[hv]
bl
2
S1
2a 1c S2M Switch b
M
Thermo 140°
so br
bl
o
1
br
N
br
bl
so
gu
hv
C1
S1
S2
CU
M
Brown
Blue
Black
Yellow
White
Capacitor
Switch
Single-pole switch/
micro switch
Control unit
Motor
Appendices and schedules

English – 17
4.4 Wiring diagram PW 235R
br
Wiring diagram
2
S1
S2
C1
2a 1a
br bl
bl
br
N
M
L
CU
WU
1
bl
br
bl
so
gu
hv
C1
S1
S2
CU
M
Brown
Blue
Black
Yellow
White
Capacitor
Switch
Single-pole switch/
micro switch
Control unit
Motor
Circuit diagram
L br[so]
bl[hv]
br
2
S1
2a 1a S2M Switch
M
Thermo 140°
bl bl
br
CU
WU so
NL
br
bl
1
bl
N
Appendices and schedules

115 97 59-26
2017–11–23