SERVICE MANUAL MODEL # ORDER # XPERT-HD 3.8/35 P XPERT-HD 3.5/40 P PD PD DA DA DD DD

Transcription

1 SERVICE MANUAL MODEL # ORDER # XPERT-HD 3.8/35 P XPERT-HD 3.5/40 P PD PD DA DA DD DD RG

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3 CONTENTS Exploded View... 4 Exploded View Parts List... 5 S.3 Pump and Parts List K4000 Pump and Parts List... 9 UU1 Universal Unloader Exploded and Parts List VBA Unloader Exploded and Parts List Troubleshooting Preventive Manteinance Oil Change Record

4 PRESSURE WASHER SERVICE MANUAL K4000 Pump EXPLODED VIEW

5 ITEM PART NO. DESCRIPTION QTY Engine, Honda, GX390 1 UT2QA2, 389cc 2 See Page 7 S.3 Series Pump 1 See Page 9 K4000 Pump (RG Model) 1 3 See Page 10 UU1 Unloader 1 (3500psi Models except RG) See Page 11 VBA Unloader 1 (4000psi Models except RG) Pump protector, 1/2" Hose barb, 1/4" Barb X 1/4" 1 Pipe, 90 Drg Elbow, 3/8" Street 90 Deg. 1 Steel Valve, Ez start, 1 3/8 Mpt X 1/8 Fpt Hose barb,1/4" Barb X 1 1/8" ML Pipe Hose 1/4" Hose clamp Swivel, 1/2" Mp X 3/4", 1 Ghf W/Strainer Nipple, 3/8" X 3/8", Mpt St 1 (All Models except RG) Bolt, 3/8" X 1-1/4", Nc HH Washer, 3/8", Lock Split Ring Karcher branding label 1 (Xpert HD) Landa branding label 1 (PD Models) Hotsy branding label 1 (DA Models) Shark branding label 1 (DD & RG Models) Hose, 3/8 X 50 1 Wire 1 Tuff-Skin (PD Models) Hose, 3/8 X 50 1 Wire 1 Tuff-Skin (DA Models) Hose, 3/8 X 50 1 Wire 1 Tuff-Skin (Xpert HD and DD Models) HP Hose DN8/50'/ (RG Model) EXPLODED VIEW PARTS LIST ITEM PART NO. DESCRIPTION QTY Trigger Gun Model M AL5 Gun 4000 PSI (RG Model) Wand, 44 With Side Grip Lance-Al Quick Connect - Male 4000 PSI (RG Model) Quick Connect Nozzle Kit 1 (040) (3500psi & RG Models) Nozzle, 0003, Red Nozzle, 0015, Yellow Nozzle, 0025, Green Nozzle, 0040, White Nozzle, Black, Soaper Quick Connect Nozzle Kit 1 (035) (4000psi Models) Nozzle, , Red Nozzle, , Red Nozzle, , Red Nozzle, , White Nozzle, Black, Soaper Frame O-Blk Wrinkle Assy Holder, Handle Black /16" SAE F/W zinc Thk Washer, 5/16" Flat (RG Model) Nut, 5/16, ESNA, Nc Hose hanger Blk Wrinkle Bolt 5/16" X 2" NC, HH Name plate Nylon Rivet /4"-20 Star knob /4"-20 x 1-1/2" GR 2, 2 Hex bolt zinc Bolt, 3/8" X 1-3/4", TAP /8-16 X 2 GR 5 HHCS Zinc (RG Model) Nut 3/8" /8-16 NE Nylon Insert (RG Model) Washer, Flat 3/8" /8 USS F/W Zinc (RG Model) Wheel & Tire Assy, 10" 2 Steel Rim W/Tube PRESSURE WASHER SERVICE MANUAL 5

6 PRESSURE WASHER SERVICE MANUAL ITEM PART NO. DESCRIPTION QTY Cap black plastic, 2 5/8'' Fastener Rubber buffer Bolt, 5/16" X 1-3/4" Washer, 5/16"", Flat Coupler, 3/8" Female, Brass O-Ring, Viton, 3/ Shark branding label 1 (DD & RG Models) Label, Intended for Outdoor 1 Use Rating Plate, RG Label, Danger Cool Engine Label, Hot/Caliente Label Regulation Label, Quick Start Guide ww Quick Instruction Guide (RG Model) Label, Operator Warnings Label, Operation Warnings (RG Model) 1 EXPLODED VIEW PARTS LIST ITEM PART NO. DESCRIPTION QTY Label, Warning Pictogram Label, Universal DB Rating, 1 Ear Protection, Trilingual Injector, Chem, Non Adj, GPM, Hose DN Filter with weigh Filter chemistry regulation 1 (RG Model) Key, Sqr x " Label, Rate Specs, High 1 (RG Model) Washer, 5/16" Split Ring Lock, Zinc (RG Model) /16-24X1 GR 5 SHCS THRU Hardener (RG Model) O-Ring seal 24,77x5,33- NBR 70 (RG Model) 1 Not Shown 6

7 KS4040GR LS4040GR HS4040GR.3 S.3 PUMP EXPLODED VIEW KS3540GR LS3540GR HS3540GR SS3540GR.3 TORQUE SPECS Item # Ft.-lbs PRESSURE WASHER SERVICE MANUAL S.3 PUMP EXPLODED VIEW PARTS LIST ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY Crankcase O-Ring Ø 2.62 x * See Kit Below Plunger Oil Seal Snap Ring 1 3* See Kit Below O-Ring Ø1.78 x Double Row Ball Bearing 1 4* See Kit Below Pressure Ring Crankshaft (3540G.3) 1 5* See Kit Below U-Seal, 15mm Crankshaft (4040G.3) 1 6* See Kit Below Intermed. Ring 15mm Set Screw 1 7* See Kit Below U-Seal, 15mm Oil Dip Stick Copper Washer 1/2" O-Ring Ø 3.53 x Brass Plug, 1/2" Needle Roller Bearing Manifold Housing Gasket 1 11* O-Ring Ø2.62 x Screw, Set 1 12* See Kit Below Valve Assembly Engine Flange 1 13* O-Ring Ø2.62 x Flange Screw Valve Plug Crankshaft Seal Manifold Stud Bolt Spring Washer Washer 8 46* See Kit Below Plunger Nut, M Copper Washer 3/8" 1 47* See Kit Below Washer, Copper, 9.2 x Brass Plug 3/8" 2 48* See Kit Below Plunger, 15mm Washer, M6 x * See Kit Below Copper Spacer Hexagonal Screw Closed Bearing Housing 1 7

8 PRESSURE WASHER SERVICE MANUAL S.3 PUMP EXPLODED VIEW PARTS LIST ITEM PART NO. DESCRIPTION QTY 50* See Kit Below O-Ring Ø1.78x * See Kit Below Tefl on Ring Plunger Rod Connecting Rod Pin Connecting Rod Spring Washer Connecting Rod Screw O-Ring 2.62 x Crankcase Cover O-Ring, Ø 1.78 x Sight Glass, G3/4 1 * Part available in kit (See below) REPAIR KIT NUMBER KIT DESCRIPTION ITEM NUMBERS INCLUDED Plunger U-Seal 15mm Complete U-Seal Packing 15mm Plunger 15mm Complete Valve 3, 5, 7 3, 4, 5, 6, 7 46, 47, 48, 49, 50, 51 Plunger Oil Seals 11, 12, 13 2 NUMBER OF CYLINDERS KIT WILL SERVICE

9 K4000 PUMP EXPLODED VIEW PRESSURE WASHER SERVICE MANUAL ITEM PART NO. DESCRIPTION QTY Unloader Assy ( ) Pump Spare parts set seat excess-current Plug M22x O-Ring seal 14,0 x 2,0 NBR Valve (Set With 3 pc.) Nipple chemistry O-Ring seal 5,28x 1, Sphere 7 G DIN Helical spring Plug M10x Rupture Disk, 5000 PSI, Blue Spare Part List 019 (Set With 3 pc.) Cylinder Head-Machined Cylinder head screw M10X A3E IS Thermal Relief Valve O-Ring seal 4 x 2 NBR Valve Pin-Back Pressure Spring-Valve Pin O-Ring seal 9x1,5 - NBR Nozzle insert O-Ring seal 8,0 x 1, O-Ring seal 92X2 NBR 70 1 ITEM PART NO. DESCRIPTION QTY Spare Part of Piston (Set With 3 pc.) O-Ring seal 15,6 X 1, Male Adapter Filter Seal-Hose Connector Female Hose Connector Piston Guide-4000 psi Grooved ring 14X22X5/ Spacer Back Ring-Low Pressure Seal Compact seal Housing-Low Pressure Seal O-Ring seal 24,0 X 1, Back Ring-High Pressure Seal Seal high pressure Deep groove ball thrust bearing only for Swash Plate-Machined Taper roller bearing Radial shaft seal ring A40x52x7-NBR DIN Oil Housing-Machined Valve disc Helical spring Moulded part 1 9

10 PRESSURE WASHER SERVICE MANUAL UU1 3500PSI, UNIVERSAL UNLOADER (SPARE) UU1 UNLOADER EXPLODED VIEW UU1 UNLOADER EXPLODED VIEW PARTS LIST 10 ITEM PART # DESCRIPTION KIT QTY Piston Housing D 1 2 Piston C, D 1 3 Piston O-Ring Back Up A, D Main Block Piston Ring D 1 6 Ball Seat C, D 1 7 O-Ring 10.5 ID x 1.5 CS A,C,D 1 8 Plunger B Plunger Housing 1 10 Bypass Spring C, D Low Pressure Port Sliding Connector, 30mm Sliding Connector, 40mm, Long Sliding Connector H 1/2" Sliding Connector H 3/8" Plug 5/8-18 UNF D 1 15 O-Ring 12 ID x 2 CS A, D 2 16 O-Ring 6 ID X 2 CS A, D 1 ITEM PART # DESCRIPTION KIT QTY Sliding Connector Guide 1 18 O-Ring Backup A, D 1 6 x 1.45 x Ball Housing Assy C, D 1 20 O-Ring 6.75 x 1.78 BN80 A, D 1 21 Spring Seat C, D 2 22 Plunger Spring B Banjo Bolt 1/2" Short Banjo Bolt 1/2"-1/4" NPT Short Banjo Bolt 3/8" Short Seal Washer 3/8" Seal Washer 1/2" Seal Washer 3/8" 2 27 O-Ring 15 ID x 2CS A,B,D Plug, 1/4" Countersunk 1 Kit A O-Ring Repair Kit Kit B Outlet Kit Kit C Stem Basic Kit Kit D UU1 Complete Stem Kit

11 UNLOADER (VBA), VBA UNLOADER EXPLODED VIEW PRESSURE WASHER SERVICE MANUAL VBA UNLOADER EXPLODED VIEW PARTS LIST ITEM PART # DESCRIPTION KIT QTY 1 Body Valve (KG) 1 Body Valve (KS) 1 2 O-Ring A, C 1 3 Seat C 1 4 Ball, Sub Assy C 1 5 O-Ring A Guide Bushing 1 7 Tefl on Ring 1 8 O-Ring A 1 9 O-Ring A Connector 1 11 Tefl on Ring A 1 12 Stem C Connector Female 1 14 O-Ring A, B 1 15 Spring B 1 16 Poppet B 1 ITEM PART # DESCRIPTION KIT QTY Seal Washer 3/8" Banjo Bolt 3/8" Solid Cap Banjo Bolt 1/2", w 1/4" Pilot Seal Washer 1/2" 2 21 Plate C 1 22 Spring C Set Screw Nut Brass Handle Plug, 1/4" Countersunk 1 Kit A O-Ring Repair Kit Kit B Outlet Kit Kit C Stem Basic Kit 11

12 PRESSURE WASHER Troubleshooting Guide TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION 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 Faulty or mis-adjusted unloader valve Worn packing in pump Machine has been stored in freezing temperatures Slow engine RPM Worn or dirty pump valves Nozzle is obstructed Pump sucking air, inlet hose leaking Insuffi cient water supply Nozzle worn Unloader valve worn Use larger garden hose; clean inlet water screen. Open faucet. Check plumbing system for leaks. Retape leaks with tefl on tape. Adjust unloader for proper pressure. Install repair kit when needed. Call local distributor. Call Dealer Customer Support. Thaw out machine completely, including hose, spray gun and wand. Call local distributor. Call local distributor. Blow out or remove debris with fi ne needle. 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. Turn water on full force. Check garden hose for kinks, leaks or blockage. Replace nozzle. Replace unloader valve. 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 Out of gas Water in gasoline Nozzle partially blocked Excessive pressure from high engine RPM A small amount of leaking is normal Water sprayed at machine High humidity in air Piston packing worn. Oil seal worn. Fill engine with oil. Fill fuel tank. Drain gas tank; fi ll with clean fuel. Clean nozzle. Adjust engine throttle to lower RPM. If excessive leaking occurs, Call local distributor. Change oil. Direct spray away from machine. Check and change oil twice as often. Call local distributor. 12

13 PROBLEM POSSIBLE CAUSE SOLUTION ENGINE OPERATES FOR 15 MINUTES THEN STOPS Not enough gas or engine oil Vapor lock developed by heat of day Obstruction in fuel fi lter Fill tank with gas. Check oil level. Keep gas tank full to avoid vapor locking. 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. FROM UNDER PUMP O-Ring plunger retainer worn Call local distributor. Cracked piston Call local distributor. OIL DRIPPING Oil seal worn or damaged Call local distributor. WATER LEAKING FROM PUMP PROTECTOR NO DETERGENT TROUBLESHOOTING 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 connected to machine Detergent is too thick Detergent filter valve is at lowest setting Filter on detergent suction tube is clogged Damaged or clogged detergent suction tube A high pressure nozzle is attached. Check connection. Dilute detergent. For best results, use manufacturers detergent. Set detergent fi lter valve to a higher setting. Run warm water through fi lter to remove debris. Remove obstruction or replace detergent suction tube. Replace with black detergent nozzle. PRESSURE WASHER Troubleshooting Guide GARDEN HOSE CONNECTION LEAKS SPRAY WAND LEAKS Discharge nozzle is obstructed Loose fittings Missing/worn rubber washer Spray wand not properly attached Blow out or remove debris with fi ne needle. Tighten fi ttings. Insert new washer. Slide the spray wand into the gun. Turn the 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 fi ttings are air tight. Turn off machine and purge pump by squeezing trigger gun until a steady fl ow of water emerges through nozzle. 13

14 PRESSURE WASHER Troubleshooting Guide Engine Oil Inspect Change Filter Inspect Air Cleaner/Filter Clean Engine Fuel Filter Spark Plug Maintenance Clean Fuel Tank(s) Replace Fuel Lines Pump Oil Inspect (All Models except RG) Change Replace High Pressure Nozzle Replace Quick Connects/O-Rings Clean Water Screen/Filter Replace HP Hose 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 (All Models except RG) and engine oil level before fi rst use of your new pressure washer. MAINTENANCE SCHEDULE Daily First month or 20 hours. Every 100 hours or every 6 months after fi rst month Every 50 hours Every 50 hours Monthly 500 hours or 6 months 300 hours or annually Annually Annually Oil level daily After fi rst 50 hours, then every 500 hours or annually Every 6 months Annually/As needed Weekly Annually (if there are any signs of wear) 14

15 Date Oil Changed Month/Day/Year OIL CHANGE RECORD Check pump oil (All Models except RG) and engine oil level before fi rst use of your new pressure washer. Estimated Operating Hours Since Last Oil Change Date Oil Changed Month/Day/Year Estimated Operating Hours Since Last Oil Change PRESSURE WASHER SERVICE MANUAL 15

16 Form # Xpert HD-DD-PD-DA-RG Revised 12/13 Printed in U.S.A. or Mexico