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

Transcription

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

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3 CONTENTS Exploded View... 4 Exploded View Parts List... 5 S.2 Pump and Parts List UU1 Universal Unloader Exploded and Parts List... 8 Troubleshooting Preventive Manteinance Oil Change Record

4 PRESSURE WASHER SERVICE MANUAL 50 EXPLODED VIEW

5 ITEM PART NO. DESCRIPTION QTY Engine, Honda, GX390 1 UT2QA2, 389cc 2 S.3 Series Pump, 4000, RPM (see pages 6 and 7) 3 Unloader, UU1 3500PSI 1 (see page 8) Pump protector, 1 1/2""PTP,140DEG,P/N 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", 1 NPT ST male 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 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) Trigger Gun Model M Wand, 44 With Side Grip Quick connect nozzle Kit 1 (040) Nozzle, 0003, Red Nozzle, 0015, Yellow Nozzle, 0025, Green Nozzle, 0040, White Nozzle, Black, Soaper Frame O-BLK Wrinkle Handle O-BLK Wrinkle Holder, Wand, Right, Black /16"-18 X 1"-3/4", Bolt SQ 2 Neck EXPLODED VIEW PARTS LIST ITEM PART NO. DESCRIPTION QTY /16" SAE F/W zinc THK Nut, 5/16, ESNA, NC Hose hanger BLK Wrinkle Hex screw 5/16" X 2" UNC, 1 F zinc plated 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 Nut 3/8" Washer, Flat 3/8" Wheel & Tire Assy, 10" 2 Steel Rim W/Tube 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 Models) Label, Intended for Outdoor 1 Use Label, Danger Cool Engine Label, Hot/Caliente 1 w/arrows Label Regulation Label, Quick Start Guide Label, Operator Warnings 1 Trilingual Label, Warning Pictogram Label, Universal DB Rating, 1 Ear Protection, Trilingual Injector, Chem, Non Adj, GPM, Hose DN Filter with weigh KEY, SQR X " Not Shown PRESSURE WASHER SERVICE MANUAL 5

6 PRESSURE WASHER SERVICE MANUAL KS4040GR LS4040GR HS4040GR.3 S.3 PUMP EXPLODED VIEW TORQUE SPECS Item # Ft.-lbs 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 (3040G.3) 1 5* See Kit Below U-Seal, 15mm Crankshaft (3540G.3) 1 6* See Kit Below Intermed. Ring 15mm Crankshaft (4040G.3) 1 7* See Kit Below U-Seal, 15mm Crankshaft (5030G.3) Copper Washer 1/2" Set Screw Brass Plug, 1/2" Oil Dip Stick Manifold Housing O-Ring Ø 3.53 x * O-Ring Ø2.62 x Needle Roller Bearing 1 12* See Kit Below Valve Assembly Gasket 1 13* O-Ring Ø2.62 x Screw, Set Valve Plug Engine Flange Manifold Stud Bolt Flange Screw Washer Crankshaft Seal Copper Washer 3/8" Spring Washer Brass Plug 3/8" 2 46* See Kit Below Plunger Nut, M Washer, M6 x * See Kit Below Washer, Copper, 9.2 x Hexagonal Screw 9 48* See Kit Below Plunger, 15mm Closed Bearing Housing 1 49* See Kit Below Copper Spacer 3 6

7 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) PRESSURE WASHER SERVICE MANUAL 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

8 PRESSURE WASHER SERVICE MANUAL UU1 3500PSI, UNIVERSAL UNLOADER (SPARE) UU1 UNLOADER EXPLODED VIEW UU1 UNLOADER EXPLODED VIEW PARTS LIST 8 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

9 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. PRESSURE WASHER Troubleshooting Guide 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. 9

10 PRESSURE WASHER Troubleshooting Guide 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. 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. 10

11 Engine Oil 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. Inspect Change Filter MAINTENANCE SCHEDULE Daily First month or 20 hours. Every 100 hours or every 6 months after fi rst month Every 50 hours Air Cleaner/Filter Inspect Every 50 hours Clean 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 Inspect Oil level daily Change After fi rst 50 hours, then every 500 hours or annually 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) PRESSURE WASHER Troubleshooting Guide 11

12 PRESSURE WASHER SERVICE MANUAL Date Oil Changed Month/Day/Year OIL CHANGE RECORD Check pump oil 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 12

13 Form # Xpert HD-DD-PD-DA Revised 01/13 Printed in U.S.A. or Mexico