Kärcher DA-232337, XPERT-HD 2.5/27 P Service Manual

SERVICE MANUAL
MODEL #
XPERT-HD 2.3/23 P
XPERT-HD 2.3/23 P
XPERT-HD 2.5/27 P
PD3-23326
PD3-23327
PD3-27324
DA-232336
DA-232337
DA-252739
DD-232336
DD-232337
DD-252737
ORDER #
1.107-103.0
1.107-104.0
1.107-106.0
1.107-091.0
1.107-092.0
1.107-094.0
1.107-097.0
1.107-098.0
1.107-100.0
1.107-134.0
1.107-135.0
1.107-136.0
8.780-000.0
CONTENTS
Exploded View ......................................................................................... 4
Exploded View Parts List ......................................................................5-6
BXD Comet Pump and Repair Kits .......................................................... 7
Legacy Axial Pump ...............................................................................8-9
G.1 Pump w/3/4" Hollow Shaft Exploded and Parts List...................10-11
UU1 Universal Unloader Exploded and Parts List ................................. 12
Troubleshooting ................................................................................13-14
Preventive Manteinance ........................................................................ 15
Oil Change Record ................................................................................ 16
3
8.780-000.0 • Xpert HD-DD-PD-DA • Rev. 12/10
PRESSURE WASHER
SERVICE MANUAL
EXPLODED VIEW
11
Legacy
Pump
10
2
12
Honda 6.5hp
(196cc)
29
9
33
34
6
7
1
32
G series
Pump
5
39
17
5
4
29
4
Comet
Pump
32
34
2
2
3
3
33
6
15
7
12
6
7
19
8
1
22
14
16
18
30
Honda 5.0hp
(163cc)
24
21
26
38
20
35
37
31
36
13
28
27
24
25
23
4
8.780-000.0 • Xpert HD-DD-PD-DA • Rev. 12/10
ITEM PART NO.
DESCRIPTION
QTY
Engine -Honda GC 160 QHA , 5.0 HP (163cc/5.0HP)-(Legacy & Comet Pump Models)
Engine, Honda, GX200UTQX2, 6.5 HP (196cc/6.5HP Models)
1
1
9.194-015.0
9.802-317.0
2
(see page 7) Comet Pump BXD Assy
(see page 8) Pump, Legacy Axial 2.6 GPM 3000PSI
(see page 10) G.1 Series Pump, 2.5 @3000, 3400 RPM (196cc/6.5HP Models)
3
8.707-256.0
8.707-254.0
Pump protector,1/2" PTP, 140DEG,P/N 1005 (All Models Except Legacy & Comet Pumps) 1
Pump protector , 3/8" 145 DEG (Comet Pump Models)
1
4
9.802-146.0
Swivel, 1/2" MP X 3/4", GHF w/strainer
5
9.802-170.0
9.802-171.0
Nipple, 3/8" X 3/8", NPT ST Female
Nipple, 3/8" X 3/8", NPT ST Male
6
6.965-007.0
5/16"-24X1" GR 5 SHCS THRU Hardener ZC
7
9.802-813.0
Washer, 5/16", Lock, Split Ring
4
8
9.138-437.0
9.138-439.0
9.138-440.0
8.750-881.0
Karcher branding label (Xpert HD)
Landa branding label (PD Models)
Hotsy branding label (DA Models)
Shark branding label (DD Models)
1
1
1
9
8.739-133.0
8.739-026.0
8.739-106.0
8.739-011.0
8.739-124.0
8.739-021.0
Hose, 3/8” X 25’ 1 Wire Tuff-Skin (5 HP PD Models)
Hose, 3/8” X 50’ 1 Wire Tuff-Skin (6.5 HP PD Models)
Hose, 3/8” X 25’ 1 Wire Tuff-Skin (5 HP DA Models)
Hose, 3/8” X 50’ 1 Wire Tuff-Skin (6.5 HP DA Models)
Hose, 3/8” X 25’ 1 Wire Tuff-Skin (5 HP Xpert & DD Models)
Hose, 3/8” X 50’ 1 Wire Tuff-Skin (6.5 HP Xpert and DD Models)
1
1
1
1
1
1
10
8.750-247.0
Gun, M407
1
11
8.783-039.0
Wand, 30"
1
12
9.104-024.0
▲9.802-287.0
▲9.802-288.0
▲9.802-289.0
▲8.932-998.0
▲9.802-311.0
Quick connect nozzle Kit(030)
Nozzle, 0003, Red
Nozzle, 0015, Yellow
Nozzle, 0025, Green
Nozzle, 0040, White
Nozzle, Black, Soaper
1
1
1
1
1
1
13
8.917-794.0
Frame O4-BLK Wrinkle Professional
1
14
9.140-131.0
Handle BLK Wrinkle
1
15
9.142-014.0
Hanger RT side
1
16
9.802-778.0
Nut, 5/16" Whiz Loc Flange
17
(see page 12) UU1, 3500PSI, Universal Unloader
18
9.134-022.0
Name plate
1
19
9.196-049.0
Nylon Rivet
4
20
9.196-307.0
1/4"-20 x 1-1/2" GR 2, Hex Bolt Zinc
2
21
8.767-003.0
1/4"-20 Star Knob
2
22
9.802-713.0
Bolt, 5/16" X 1-1/2", NC HH(612975)
4
23
9.802-776.0
Nut, 5/16", ESNA, NC
4
24
8.718-980.0
Washer, 5/16"", Flat, SAE(780452)
8
25
9.189-007.0
Wheel 10'' X 3.50'' Pneu
2
26
9.182-506.0
Cap Black Plastic, 5/8''Fastener
2
27
9.183-405.0
Rubber dampener
2
28
9.196-308.0
5/16"-18 X 1/2" Carriage Bolt, A307 BLK
2
29
9.802-166.0
▲8.702-088.0
8.707-182.0
▲8.704-036.0
Coupler, 3/8" Female, Brass
O-Ring, Viton, 3/8”
Coupler, Twist Connect, M22-Fx3/8"" FNP
O-Ring, Viton, Twist Connect
1
1
1
1
9.138-438.0
Shark branding label
30
(All Models Except Legacy Pump Models)
(Comet Pump Models)
(196cc/6.5HP Models)
1
1
1
1
1
1
4
SERVICE MANUAL
1
PRESSURE WASHER
EXPLODED VIEW PARTS LIST
2
(196cc/6.5HP Models)
(Legacy Pump Models)
(DD Models)
1
1
5
8.780-000.0 • Xpert HD-DD-PD-DA • Rev. 12/10
SERVICE MANUAL
PRESSURE WASHER
EXPLODED VIEW PARTS LIST (CONT)
ITEM PART NO.
31
DESCRIPTION
QTY
Label, Intended for Outdoor Use - Serial - Specs
1
32
9.800-008.0
Label, Danger Cool Engine
1
33
9.800-006.0
Label, Hot/Caliente w/Arrows
1
34
8.917-015.0
Label Regulation 4442.6
1
35
8.783-034.0
8.783-037.0
Label, Quick Start Guide 1
Label, Quick Start Guide 2
36
8.783-035.0
Label, Operator Warnings Trilingual
1
37
8.783-036.0
Label, Warning Pictogram
1
38
8.783-038.0
Label, Universal DB Rating, Ear Protection, Trilingual
1
1
(196cc/6.5HP Models)
(163cc/5.0HP)-(Legacy & Comet Pump Models)
(196cc/6.5HP Models)
1
1
39
9.802-215.0
Injector, Chem, Non Adj, 2-3 GPM, 0.070
40
6.388-216.0
▲ Hose DN 5
1
41
5.731-609.0
▲ Filter with weigh
1
42
9.802-958.0
▲ Shaft Key, 0.185 SQR X 1.75"
(All Models Except Comet Pump Models)
▲ Not Shown
6
8.780-000.0 • Xpert HD-DD-PD-DA • Rev. 12/10
1
PRESSURE WASHER
COMET PUMP BXD, 5/8" SHAFT EXPLODED VIEW
8.920-017.0 COMET PUMP BXD
SERVICE MANUAL
COMET PUMP BXD REPAIR KITS
ITEM
PART NO.
DESCRIPTION
QTY
ITEM
PART NO.
DESCRIPTION
QTY
1
8.725-556.0
Kit, valve
1
7
8.725-562.0
Kit, complete valve kit
1
2
8.725-557.0
Kit, suction valve
1
8
8.725-563.0
Kit, piston seal
1
3
8.725-558.0
Kit, check valve
1
9
8.725-564.0
Oil site glass
1
4
8.725-559.0
Kit, injector body
1
10
8.725-565.0
O´ring
1
5
8.725-560.0
Kit, chemical coupling
1
11
8.725-566.0
Oil cap
1
6
8.725-561.0
Kit, easy start
1
12
8.725-567.0
Knob
1
7
8.780-000.0 • Xpert HD-DD-PD-DA • Rev. 12/10
8.920-004.0
PRESSURE WASHER
SERVICE MANUAL
PUMP EXPLODED VIEW AND PARTS LIST
ITEM PART #
DESCRIPTION
1
8.762-010.0
Cylinder Head
1
15
5.332-290.0
Helical Spring
1
2
9.175-004.0
Valve Assy Horizontal
3
16
9.175-005.0
Unloader Assembly
1
3
9.139-371.0
Spare Part List, Set 3
1
17
4.132-007.0
Drain Plug Replacement
1
4
5.443-448.0
Nipple Chemestry
1
18
5.003-062.0
Plate
1
5
6.362-451.0
O-Ring Seal 8.0 x 1.0
1
19
9.177-301.0
Hich Pressure Seal
3
6
6-362-175.0
O-Ring Seal, 5.28 x 1.78
1
20
9.177-310.0
Back Ring
3
7
7.401-909.0
Sphere 7 G40 - 1.4401
1
21
6.362-833.0
O-Ring Seal 12.5 x 1.73
3
8
5.110-714.0
Sleeve
1
22
9.155-011.0
Housing Low Pressure Seal
3
9
5.332-258.0
Helical Spring
1
23
6.363-058.0
10
9.139-372.0
Nozzle, INS 020/021 Pump
1
24
9.134-016.0
11
9.184-018.0
Outlet-Thermal Valve
1
25
6.365-393.0
Oil Sealing 12.20x4/6
3
12
6.362-480.0
O-Ring Seal, 12.42 x 1.78
1
26
9.133-007.0
Piston Guide
1
27 6.362-390.0
28 9.134-019.0
O-Ring Seal 15.6 x 1.8
Male Adapter
1
1
29
Filter Seal
1
ITEM PART #
DESCRIPTION
QTY
13
7.362-507.0
O-Ring Seal 8 x 2 NBR 90
1
14
6.413-403.0
Thermo Valve Tin Coated
1
9.181-005.0
Grooved Ring
Spacer
QTY
3
3
30
9.155-013.0
Female House Conn
1
31
9.178-005.0
Adapter Garden
1
32
9.139-370.0
Spare Part List, Piston
1
33
6.362-471.0
O-Ring Seal 80.0x3.0 NBR70 1
8
8.780-000.0 • Xpert HD-DD-PD-DA • Rev. 12/10
8.920-004.0 Housing View
PRESSURE WASHER
PUMP EXPLODED VIEW PARTS LIST (CONT)
SERVICE MANUAL
ITEM PART #
DESCRIPTION
QTY
1
9.166-016.0
Grooved Ball Bearing
1
2
9.135-018.0
Swash Plate Hor.
1
3
9.165-356.0
Ball Bearing No 6207
1
4
9.177-314.0
Radial Seal 35 x 52 x 7
1
5
9.135-016.0
Oil Housing
9
8.780-000.0 • Xpert HD-DD-PD-DA • Rev. 12/10
9.804-033.0 KG2530G.1
8.904-893.0 LG2530G.1
8.904-748.0 HG2530G.1
PRESSURE WASHER
SERVICE MANUAL
G.1 SERIES PUMP w/3/4" HOLLOW SHAFT EXPLODED VIEW
TORQUE
SPECS
Item #
Ft.-lbs
16
65
19
18
27
7.6
38
8
40
7
50
13
G.1 SERIES PUMP EXPLODED VIEW PARTS LIST
ITEM
PART NO.
DESCRIPTION
QTY
ITEM
PART NO.
DESCRIPTION
QTY
1
9.803-938.0
Crankcase
1
19
9.803-952.0
Manifold Stud Bolt
8
2*
See Kit Below
Plunger Oil Seal
3
20
9.802-884.0
Washer
8
3*
See Kit Below
O-Ring Ø1.78 x 28.30
3
21
9.803-198.0
Copper Washer 3/8"
1
4*
See Kit Below
Pressure Ring, 15mm
3
22
9.802-925.0
Brass Plug 3/8"
2
5*
See Kit Below
U-Seal, 15mm
3
27
9.802-939.0
Hexagonal Screw
9
6*
See Kit Below
Intermediate Ring 15mm
3
28
9.803-953.0
Bearing Cover
1
7*
See Kit Below
Backup Ring 15mm
3
29
9.803-954.0
Seal Bearing
1
8*
See Kit Below
U-Seal, 15mm
3
30
9.802-914.0
Snap Ring
1
9*
See Kit Below
Support Ring, 15mm
3
31
9.803-955.0
Ball Bearing
1
10
9.802-926.0
Brass Plug, 1/2"
1
32
8.717-069.0
Crankshaft (2530G)
1
11
9.803-199.0
Copper Washer 1/2"
1
33
9.803-957.0
Oil Dip Stick
1
12
9.803-946.0
Manifold Housing
1
34
9.804-581.0
O-Ring 3.53 x 55.56
1
13* 9.803-947.0
O-Ring Ø1.78 x 15.54
14* See Kit Below Valve Assembly
6
35
9.804-582.0
Needle Roller Bearing
1
6
36
8.717-212.0
Engine Flange
1
15* 9.803-948.0
O-Ring Ø2.62 x 18.77
6
37
9.803-210.0
Spring Washer
4
16
9.803-949.0
Valve Plug
6
38
9.804-584.0
Flange Screw
4
17
9.803-950.0
Washer, Copper
1
18
9.803-951.0
Brass Plug G1/4
1
10
8.780-000.0 • Xpert HD-DD-PD-DA • Rev. 12/10
ITEM
39
PART NO.
DESCRIPTION
QTY
9.804-585.0
Crankshaft Seal
1
Plunger Nut
3
40* See Kit Below
41* See Kit Below
Copper Spacer
3
42* See Kit Below
Plunger, 15mm
3
43* See Kit Below
Copper Spacer
3
44* See Kit Below
O-Ring Ø1.78x5.28
3
45* See Kit Below
3
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
SERVICE MANUAL
Teflon Ring
46
PRESSURE WASHER
G.1 SERIES PUMP EXPLODED VIEW PARTS LIST (CONT)
* Part available in kit (See below)
G.1 SERIES 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
Plunger Seal
15mm
Complete
Seal Packing 15mm
Plunger 15mm
Complete Valve
Plunger Oil
Seals
ITEM NUMBERS
INCLUDED
3, 5, 7, 8, 9
3, 4, 5,
6, 7, 8, 9
40, 41, 42, 43,
44, 45
13, 14, 15
2
11
8.780-000.0 • Xpert HD-DD-PD-DA • Rev. 12/10
SERVICE MANUAL
UU1 UNLOADER EXPLODED VIEW
9.175-018.0
UU1 3500PSI, UNIVERSAL UNLOADER (SPARE)
21
2
3
14
PRESSURE WASHER
20
10
16
18
5
1
15
19
6
27
7
25
23
25
4
24
8
22
27
28
26
13
15
26
9
12
23
17
27
11
UU1 UNLOADER EXPLODED VIEW PARTS LIST
ITEM PART #
1
KIT QTY
ITEM PART #
DESCRIPTION
KIT QTY
1
17
18
O-ring backup
6X 1.45X 1.68
A
1
2
Piston
C
1
3
Piston O-ring back up
A
1
9.149-006.0 Sliding connector guide
1
4
8.749-796.0 Main block
1
19
Conical seal
C
1
5
9.152-372.0 Piston ring
1
20
O-ring 6.75 X 1.78 BN80
A
1
1
21
Spring seat
C
1
A,C
1
22
Plunger spring
B
1
B
1
23
8.917-699.0 Banjo bolt 1/2" short
8.917-700.0 Banjo bolt 1/2"-1/4"NPT short
8.917-698.0 Banjo bolt 3/8" short
1
1
1
C
1
24
8.917-698.0 Banjo bolt 3/8" short
1
25
9.802-893.0 Seal washer 3/8"
2
9.803-921.0 Seal washer 1/2"
9.802-893.0 Seal washer 3/8"
2
2
6
Ball seat
C
7
O-ring 10.5 ID X 1.5 CS
8
Plunger
9
10
12
DESCRIPTION
8.749-792.0 Piston housing
9.152-016.0 Plunger housing
1
Bypass spring
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
26
13
9.149-002.0 Sliding connector H 1/2"
9.149-005.0 Sliding connector H 3/8"
1
1
27
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
28
Kit A
Kit B
Kit C
O-RING 15 ID x 2CS
8.706-865.0
9.104-038.0
9.104-039.0
9.104-040.0
8.780-000.0 • Xpert HD-DD-PD-DA • Rev. 12/10
Plug, 1/4" countersunk
O-ring Repair Kit
Outlet Kit
Stem Repair Kit
A,B
3
1
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.
PRESSURE LOW
AFTER PERIOD OF
NORMAL USE
Nozzle worn
Replace nozzle.
Unloader valve worn
Replace unloader valve.
ENGINE WILL NOT
START OR STOPS
WHILE OPERATING
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
(BXD Comet & G
Pump Series Only)
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 WASHER Troubleshooting Guide
TROUBLESHOOTING
13
8.780-000.0 • Xpert HD-DD-PD-DA • Rev. 12/10
PRESSURE WASHER Troubleshooting Guide
TROUBLESHOOTING
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.
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.
NO DETERGENT
PUMP IS NOISY
14
8.780-000.0 • Xpert HD-DD-PD-DA • Rev. 12/10
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
(Comet and G Series
pumps only)
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)
PRESSURE WASHER Troubleshooting Guide
PREVENTATIVE MAINTENANCE
15
8.780-000.0 • Xpert HD-DD-PD-DA • Rev. 12/10
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
PRESSURE WASHER
SERVICE MANUAL
OIL CHANGE RECORD
16
8.780-000.0 • Xpert HD-DD-PD-DA • Rev. 12/10
Estimated Operating
Hours Since Last
Oil Change
Form #8.780-000.0 • Xpert HD-DD-PD-DA • Revised 12/10
Printed in U.S.A. or Mexico
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