Service MANUAL
model #
Xpert-HD 3.8/35 P / DD-383537
PD4-35324
DA-383539
Order #
1.107-108.0
1.107-096.0
1.107-102.0
8.780-001.0
CONTENTS
Exploded View.......................................................................................... 4
Exploded View Parts List.......................................................................... 5
S.2 Pump and Parts List........................................................................7-8
UU1 Universal Unloader Exploded and Parts List.................................... 9
Troubleshooting.................................................................................10-11
Preventive Manteinance......................................................................... 12
Oil Change Record................................................................................. 13
3
8.780-001.0 • Xpert HD/DD-PD-DA • Rev. 11/09
SERVICE MANUAL
exploded View
18
17
PRESSURE WASHER
19
16
40
50
12
3
11
6
5
7
10
8
44
4
10
45
13
9
14
46
26
19
15
29
27
2
24
43
1
25
28
25
21
24
41
22
32
23
34
36
31
30
49
47
42
38
39
48
20
37
34
4
33
8.780-001.0 • Xpert HD/DD-PD-DA • Rev. 11/09
35
description
1
9.802-322.0
Engine, Honda, GX390UTQAA2, 389cc(13 HP)
1
2
(see page 7) S.2 Series Pump, 4 @ 4000, 3400 RPM
1
3
(see page 9) Unloader, UU1 3500PSI
1
4
8.707-256.0
Pump protector, 1/2""PTP,140DEG,P/N 1005
1
5
8.706-958.0
Hose barb, 1/4" Barb X 1/4" PIPE, 90 Drg
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
8.706-940.0 Hose barb,1/4" Barb X 1/8" ML PIPE
1
9
9.802-254.0
1
10 6.390-126.0 Hose clamp
2
Hose 1/4"
qty
11 9.802-146.0
Swivel, 1/2" MP X 3/4", GHF W/Strainer
12 9.802-171.0
Nipple, 3/8" X 3/8", NPT ST male
1
13 9.802-722.0
Bolt, 3/8" X 1-1/4", NC HH
4
14 9.802-814.0
Washer, 3/8", lock split ring
4
(Xpert HD & DD Models)
(PD Models)
(DA Models)
1
1
1
16 8.739-026.0
8.739-011.0
8.739-021.0
Hose, 3/8” X 50’ 1 Wire Tuff-Skin(PD Models) Hose, 3/8” X 50’ 1 Wire Tuff-Skin (DA Models)
Hose, 3/8” X 50’ 1 Wire Tuff-Skin(Xpert HD and DD Models)
1
1
1
17 8.750-247.0
Trigger Gun Model M407 1
18 8.783-040.0
Wand, 44” With Side Grip
1
9.104-030.0 Quick connect nozzle Kit(040)
s9.802-295.0 Nozzle, 0003, Red
s9.802-296.0 Nozzle, 0015, Yellow
s9.802-297.0 Nozzle, 0025, Green
s8.932-298.0 Nozzle, 0040, White
s9.802-311.0 Nozzle, Black, Soaper
1
1
1
1
1
1
15 9.138-437.0 Karcher branding label
9.138-439.0 Landa branding label
9.138-440.0 Hotsy branding label
19
SERVICE MANUAL
item part no.
PRESSURE WASHER
EXPLODED VIEW PARTS LIST
1
20 9.115-109.0
Frame O-BLK Wrinkle
1
21 9.140-151.0
Handle O-BLK Wrinkle
1
22 8.918-001.0
Holder, Wand, Right, Black
1
23 9.196-306.0
5/16"-18 X 1"-3/4", Bolt SQ Neck
2
24 9.198-002.0
5/16" SAE F/W zinc .062 THK
3
25 9.197-002.0
5/16"-18 NE nylon insert, L/N ZC 5UM
3
26 9.142-315.0
Hose hanger BLK Wrinkle
1
27 9.558-072.0
Hex screw 5/16" X 2" UNC, F zinc plated 1
28 9.134-022.0
Name plate
1
29 9.196-049.0
Nylon Rivet 4
30 7.767-003.0
1/4"-20 Star knob
2
31 9.196-307.0
1/4"-20 x 1-1/2" GR 2, Hex bolt zinc
2
32 9.802-727.0 Bolt, 3/8" X 1-3/4", TAP
4
33 9.802-779.0
Nut 3/8"
4
34 9.802-807.0
Washer, Flat 3/8"
8
35 9.189-011.0
Wheel 12" X 3.50", Pneu-BLK Rims
2
36 9.182-506.0
Cap black plastic, 5/8'' Fastener
2
37 9.183-405.0
Rubber dampener, 5/16''-18 female
2
38 9.802-713.0
5/16"-18 X 1-1/2", GR 5 HHCS zinc
2
5
8.780-001.0 • Xpert HD/DD-PD-DA • Rev. 11/09
SERVICE MANUAL
PRESSURE WASHER
EXPLODED VIEW PARTS LIST (cont)
item part no.
description
39 8.718-980.0
Washer, 5/16"", Flat
40 9.802-166.0 Coupler, 3/8" Female, Brass
s8.702-088.0 O-Ring, Viton, 3/8”
qty
2
1
1
41 9.138-438.0
Shark branding label
(Xpert HD & DD Models)
1
42
Label, Intended for Outdoor Use - Serial - Specs
1
43 9.800-008.0
Label, Danger Cool Engine
1
44 9.800-006.0
Label, Hot/Caliente w/Arrows
1
45 8.917-015.0 Label Regulation 4442.6
1
46 8.783-034.0
Label, Quick Start Guide 1
1
47 8.783-035.0
Label, Operator Warnings Trilingual
1
48 8.783-036.0
Label, Warning Pictogram
1
49 8.783-038.0
Label, Universal DB Rating, Ear Protection, Trilingual
1
50 9.802-215.0
Injector, Chem, Non Adj, 2-3 GPM, 0.070
1
51 6.388-216.0
s Hose DN 5 1
52 5.731-609.0
s Filter with weigh
1
53 9.802-959.0
s KEY, 0.247 SQR X 2.125"
1
s Not Shown
6
8.780-001.0 • Xpert HD/DD-PD-DA • Rev. 11/09
PRESSURE WASHER
S.2 SERIES PUMP
9.802-350.0 KS4040G.2
8.904-905.0 LS4040G.2
8.904-755.0 HS4040G.2
SERVICE MANUAL
TORQUE
SPECS
Item #
Ft.-lbs
17
75
18
30
26
7.6
39
10
47
7
58
13
S.2 SERIES PUMP PARTS LIST
itemPart no. Description QTY
itemPart no. Description QTY
1
1
26 9.802-939.0
Hexagonal Screw
9
4
8.717-129.0
Crankcase 2
9.803-196.0
Plunger Guide
3
27 9.803-210.0
Washer
3*
See Kit Below Plunger Oil Seal
3
28 9.803-184.0
Closed Bearing Housing 1
4*
See Kit Below O-Ring Ø1.78 x 31.47
3
29 8.717-225.0
O-Ring Ø 2.62 x61.6
1
5*
See Kit Below Pressure Ring
3
30 9.802-914.0
Snap Ring
1
6*
See Kit Below U-Seal, 15mm
3
31 9.803-168.0
Double Row Ball Bearing 1
7*
See Kit Below Intermed. Ring 15mm
3
32 9.803-152.0
Crankshaft (S4040G)
1
8*
See Kit Below Back-up Ring
3
33 9.802-945.0
Set Screw
1
9*
See Kit Below U-Seal, 15mm
3
34 9.802-921.0
Oil Dip Stick
1
10* See Kit Below Support Ring 15mm
3
35 9.804-581.0
O-Ring Ø 3.53 x 55.56
1
11 9.802-926.0
Brass Plug, 1/2"
1
36 9.803-161.0
Needle Roller Bearing
1
12 9.803-199.0
Copper Washer 1/2"
1
37 9.803-183.0
Engine Flange
1
13 9.802-932.0
Manifold Housing
1
38 9.803-221.0
Spring Washer
4
14* 9.803-191.0
O-Ring Ø2.62 x 17.13
6
39 9.803-240.0
Flange Screw
4
15* See Kit Below Valve Assembly
6
40 9.803-243.0
Engine Screw, 5/16"
4
16* 9.803-193.0
O-Ring Ø2.62 x 20.29
6
41 9.803-215.0
Washer
4
17 9.802-928.0
Valve Plug
6
42 9.802-889.0
Spring Washer
4
18 9.802-938.0
Manifold Stud Bolt
8
43 9.803-244.0
Engine Screw 3/8"
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
8.780-001.0 • Xpert HD/DD-PD-DA • Rev. 11/09
4
7
SERVICE MANUAL
PRESSURE WASHER
S.2 SERIES PUMP PARTS LIST (Cont)
itemPart 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* See Kit Below Plunger Nut
3
48* See Kit Below Washer, Copper,
9.2 x 13.5
3
49* See Kit Below Plunger, 15mm
3
50* See Kit Below Copper Spacer
3
51* See Kit Below O-Ring Ø1.78x5.28
3
52* See Kit Below Teflon Ring
3
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)
Repair kit
number
Kit description
item numbers
included
9.802-622.0
9.802-623.0
8.933-023.0
9.802-603.0
9.802-609.0
Plunger Seal
15mm
Complete
Seal Packing 15mm
Plunger 15mm
Complete Valve
Plunger Oil Seals
4, 6, 8, 9, 10
4, 5, 6, 7, 8, 9, 10
47, 48, 49, 50,
51, 52
14, 15, 16
3
8
8.780-001.0 • Xpert HD/DD-PD-DA • Rev. 11/09
PRESSURE WASHER
uu1 Unloader exploded view
9.175-018.0
UU1 3500PSI, UNIVERSAL UNLOADER (SPARE)
21
2
3
14
20
10
16
18
SERVICE MANUAL
5
1
15
19
6
27
7
25
23
25
4
24
8
22
27
28
26
13
15
26
12
23
9
17
27
11
UU1 Unloader exploded view parts list
ITEM Part # description Kit qty
ITEM Part # description 1 8.749-792.0 Piston housing
2
Piston
C
1
17
1
3
1
18 O-ring backup
6X 1.45X 1.68
Piston O-ring back up
A
Kit qty
9.149-006.0 Sliding connector guide
1
A
1 C
1
4
8.749-796.0 Main block
1
19
Conical seal
5
9.152-372.0 Piston ring
1
20
O-ring 6.75 X 1.78 BN80
A
1
C
1
21
Spring seat
C
1
A,C
1
22
Plunger spring
B
1
1
23
8.762-001.0 Banjo bolt 1/2" 8.762-011.0 Banjo bolt 1/2"-1/4"NPT 8.762-000.0 Banjo bolt 3/8" 1 1 1
24
8.762-000.0 Banjo bolt 3/8"
1
25
9.802-893.0 Seal washer 3/8"
2
26
9.803-921.0 Seal washer 1/2" 9.802-893.0 Seal washer 3/8" 2
2
27
3
28
Kit A
Kit B
Kit C
8.706-865.0 Plug, 1/4" countersunk
9.104-038.0 O-ring Repair Kit
9.104-039.0 Outlet Kit
9.104-040.0 Stem Repair Kit
6
Ball seat
7
O-ring 10.5 ID X 1.5 CS
8
Plunger
B
9
9.152-016.0 Plunger housing
1
10
1
11
9.149-001.0 Low pressure port
1
12
9.152-017.0 Sliding connector, 30mm
8.762-005.0 Sliding connector, 40mm, long
1
1
13
9.149-002.0 Sliding connector H 1/2"
9.149-005.0 Sliding connector H 3/8" 1 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
Bypass spring
C
8.780-001.0 • Xpert HD/DD-PD-DA • Rev. 11/09
O-RING 15 ID x 2CS
A,B
1
9
PRESSURE WASHER Troubleshooting Guide
troubleshooting
problem
possible cause
solution
low operating
pressure
Insufficient water supply. Closed
faucet. Inlet hose kinked
Use larger garden hose; clean inlet water
screen. Open faucet.
Clogged inlet hose strainer
Check plumbing system for leaks. Retape
leaks with teflon tape.
Faulty or mis-adjusted unloader
valve
Adjust unloader for proper pressure. Install
repair kit when needed. Call local distributor.
Worn packing in pump
Call Dealer Customer Support.
Machine has been stored in freezing temperatures
Thaw out machine completely, including
hose, spray gun and wand.
Slow engine RPM
Call local distributor.
Worn or dirty pump valves
Call local distributor.
Nozzle is obstructed
Blow out or remove debris with fine needle.
Pump sucking air, inlet hose
leaking
Check that all hoses and fittings are airtight.
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.
Nozzle worn
Replace nozzle.
Unloader valve worn
Replace unloader valve.
Low oil shutdown
Fill engine with oil.
Out of gas
Fill fuel tank.
Water in gasoline
Drain gas tank; fill with clean fuel.
engine is
overloaded
Nozzle partially blocked
Clean nozzle.
Excessive pressure from high
engine RPM
Adjust engine throttle to lower RPM.
water or oil
leaking from
bottom of Pump
A small amount of leaking is
normal
If excessive leaking occurs, Call local
distributor.
presence of
water in pump oil
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.
fluctuating
pressure
pressure low
after period of
normal use
engine will not
start or stops
while operating
10
8.780-001.0 • Xpert HD/DD-PD-DA • Rev. 11/09
PROBLEM
POSSIBLE CAUSE
SOLUTION
ENGINE OPERATES
FOR 15 MINUTES
THEN STOPS
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 filter
Clean or replace fuel filter.
ENGINE LACKS
POWER
Dirty air filter
Replace air filter.
ENGINE FALTERS
Choke is opened too soon
Move choke to halfway position until engine
runs smoothly.
WATER DRIPPING
Piston packing worn
FROM UNDER PUMP O-Ring plunger retainer worn
Call local distributor.
Call local distributor.
Cracked piston
Call local distributor.
OIL DRIPPING
Oil seal worn or damaged
Call local distributor.
WATER LEAKING
FROM PUMP
PROTECTOR
Spray gun closed with machine
running 5 minutes or longer
Open spray gun or turn off machine.
Excess water supply pressure
Place a pressure regulator at end of 50'
garden hose.
NO DETERGENT
Detergent suction tube not properly
connected to machine
Check connection.
Detergent is too thick
Dilute detergent. For best results, use
manufacturers detergent.
Detergent filter valve is at lowest
setting
Set detergent filter valve to a higher setting.
Filter on detergent suction tube is
clogged
Run warm water through filter to remove
debris.
Damaged or clogged detergent suction tube
Remove obstruction or replace detergent
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.
GARDEN HOSE
CONNECTION
LEAKS
Loose fittings
Tighten fittings.
Missing/worn rubber washer
Insert new washer.
SPRAY WAND
LEAKS
Spray wand not properly attached
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 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.
PUMP IS NOISY
PRESSURE WASHER Troubleshooting Guide
troubleshooting
11
8.780-001.0 • Xpert HD/DD-PD-DA • Rev. 11/09
PRESSURE WASHER Troubleshooting Guide
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 first use
of your new pressure washer.
MAINTENANCE SCHEDULE
Engine Oil
Air Cleaner/Filter
Inspect
Daily
Change
First month or 20 hours.
Every 100 hours or every 6 months after first month
Filter
Every 50 hours
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 first 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)
12
8.780-001.0 • Xpert HD/DD-PD-DA • Rev. 11/09
Check pump oil and engine oil level before first use of your new pressure washer.
Date Oil Changed
Month/Day/Year
Estimated Operating
Hours Since Last
Oil Change
Date Oil Changed
Month/Day/Year
Estimated Operating
Hours Since Last
Oil Change
PRESSURE WASHER
oil change record
SERVICE MANUAL
13
8.780-001.0 • Xpert HD/DD-PD-DA • Rev. 11/09
Form #8.780-001.0 • Xpert HD/DD-PD-DA • Revised 11/09 • Printed in U.S.A. or Mexico
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