Shark XPERT-HD 2.3/23 P, XPERT-HD 2.5/27 P, PD3-23326, PD3-23327, PD3-27324 Service Manual
...Page 1
SERVICE MANUAL
MODEL # ORDER #
XPERT-HD 2.3/23 P 1.107-103.0
XPERT-HD 2.3/23 P 1.107-104.0
XPERT-HD 2.5/27 P 1.107-106.0
PD3-23326 1.107-091.0
PD3-23327 1.107-092.0
PD3-27324 1.107-094.0
DA-232336 1.107-097.0
DA-232337 1.107-098.0
DA-252739 1.107-100.0
DD-232336 1.107-134.0
DD-232337 1.107-135.0
DD-252737 1.107-136.0
8.780-000.0
Page 2
Page 3
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
CONTENTS
3
Xpert HD-DD-PD-DA • 8.780-000.0 • Rev. 04/11
Page 4
EXPLODED VIEW
SERVICE MANUAL
Honda
196cc
34
PRESSURE WASHER
32
34
33
12
33
1
32
Comet
Pump
11
5
Legacy
Pump
10
2
7
17
7
29
6
G series
Pump
2
6
9
5
39
29
4
2
3
15
6
7
12
4
3
1
Honda
163cc
26
36
13
24
38
37
24
22
19
18
28
30
21
8
16
20
35
31
27
14
4
23
25
Xpert HD-DD-PD-DA • 8.780-000.0 • Rev. 04/11
Page 5
PRESSURE WASHER
EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.194-015.0 Engine -Honda GC160 QHA (163cc)-(Legacy & Comet Pump Models) 1
9.802-317.0 Engine, Honda, GX200UTQX2 (196cc Models) 1
2 (see page 7) Comet Pump BXD Assy 1
(see page 8) Pump, Legacy Axial 2.6 GPM 3000PSI 1
(see page 10) G.1 Series Pump, 2.5 @3000, 3400 RPM (196cc Models) 1
3 8.707-256.0 Pump protector,1/2" PTP, 140DEG,P/N 1005 (All Models Except Legacy & Comet Pumps) 1
8.707-254.0 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 (All Models Except Legacy Pump Models) 1
5 9.802-170.0 Nipple, 3/8" X 3/8", NPT ST Female (Comet Pump Models) 1
9.802-171.0 Nipple, 3/8" X 3/8", NPT ST Male (196cc Models) 1
6 6.965-007.0 5/16"-24X1" GR 5 SHCS THRU Hardener ZC 4
7 9.802-813.0 Washer, 5/16", Lock, Split Ring 4
8 9.138-437.0 Karcher branding label (Xpert HD) 1
9.138-439.0 Landa branding label (PD Models) 1
9.138-440.0 Hotsy branding label (DA Models) 1
8.750-881.0 Shark branding label (DD Models)
9 8.739-133.0 Hose, 3/8” X 25’ 1 Wire Tuff-Skin (163cc PD Models) 1
8.739-026.0 Hose, 3/8” X 50’ 1 Wire Tuff-Skin (196cc PD Models) 1
8.739-106.0 Hose, 3/8” X 25’ 1 Wire Tuff-Skin (163cc DA Models) 1
8.739-011.0 Hose, 3/8” X 50’ 1 Wire Tuff-Skin (196cc DA Models) 1
8.739-124.0 Hose, 3/8” X 25’ 1 Wire Tuff-Skin (163cc Xpert & DD Models) 1
8.739-021.0 Hose, 3/8” X 50’ 1 Wire Tuff-Skin (196cc Xpert and DD Models) 1
10 8.750-247.0 Gun, M407 1
11 8.783-039.0 Wand, 30" 1
12 9.104-024.0 Quick connect nozzle Kit (030) 1
9.802-287.0 ▲Nozzle, 0003, Red 1
9.802-288.0 ▲Nozzle, 0015, Yellow 1
9.802-289.0 ▲Nozzle, 0025, Green 1
8.932-998.0 ▲Nozzle, 0040, White 1
9.802-311.0 ▲Nozzle, Black, Soaper 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 2
17 (see page 12) UU1, 3500PSI, Universal Unloader (196cc Models) 1
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 Coupler, 3/8" Female, Brass 1
8.702-088.0 ▲O-Ring, Viton, 3/8” 1
8.707-182.0 Coupler, Twist Connect, M22-Fx3/8"" FNP (Legacy Pump Models) 1
8.704-036.0 ▲O-Ring, Viton, Twist Connect 1
30 9.138-438.0 Shark branding label (DD Models) 1
▲ Not Shown
Xpert HD-DD-PD-DA • 8.780-000.0 • Rev. 04/11
SERVICE MANUAL
5
Page 6
EXPLODED VIEW PARTS LIST (CONT)
ITEM PART NO. DESCRIPTION QTY
31 8.930-124.0 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
SERVICE MANUAL
35 8.783-034.0 Label, Quick Start Guide 1 (196cc Models) 1
8.783-037.0 Label, Quick Start Guide 2 (163cc)-(Legacy & Comet Pump Models) 1
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
39 9.802-215.0 Injector, Chem, Non Adj, 2-3 GPM, 0.070 (196cc Models) 1
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) 1
▲ Not Shown
PRESSURE WASHER
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Xpert HD-DD-PD-DA • 8.780-000.0 • Rev. 04/11
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COMET PUMP BXD, 5/8" SHAFT EXPLODED VIEW
8.920-017.0 COMET PUMP BXD
PRESSURE WASHER
SERVICE MANUAL
COMET PUMP BXD REPAIR KITS
ITEM PART NO. DESCRIPTION QTY
1 8.725-556.0 Kit, valve 1
2
8.725-557.0
3
8.725-558.0
4
8.725-559.0
5
8.725-560.0
6
8.725-561.0
Kit, suction valve 1
Kit, check valve 1
Kit, injector body 1
Kit, chemical coupling 1
Kit, easy start 1
ITEM PART NO. DESCRIPTION QTY
7
8.725-562.0
8
8.725-563.0
9
8.725-564.0
10
8.725-565.0
11
8.725-566.0
12
8.725-567.0
Xpert HD-DD-PD-DA • 8.780-000.0 • Rev. 04/11
Kit, complete valve kit 1
Kit, piston seal 1
Oil site glass 1
O´ring 1
Oil cap 1
Knob 1
7
Page 8
8.920-004.0
SERVICE MANUAL
PRESSURE WASHER
PUMP EXPLODED VIEW AND PARTS LIST
ITEM PART # DESCRIPTION QTY
1 8.762-010.0 Cylinder Head 1
2 9.175-004.0 Valve Assy Horizontal 3
3 2.884-916.0 Valve Complete (Kit 3) 1
4 5.443-448.0 Nipple Chemestry 1
5 6.362-451.0 O-Ring Seal 8.0 x 1.0 1
6 6.362-175.0 O-Ring Seal, 5.28 x 1.78 1
7 7.401-909.0 Sphere 7 G40 - 1.4401 1
8 5.110-714.0 Sleeve 1
9 5.332-258.0 Helical Spring 1
10 9.139-372.0 Nozzle, INS 020/021 Pump 1
11 9.184-018.0 Outlet-Thermal Valve 1
12 6.362-480.0 O-Ring Seal, 12.42 x 1.78 1
13 7.362-507.0 O-Ring Seal 8 x 2 NBR 90 1
14 6.413-403.0 Thermo Valve Tin Coated 1
ITEM PART # DESCRIPTION QTY
15 5.332-290.0 Helical Spring 1
16 9.175-005.0 Unloader Assembly 1
17 4.132-007.0 Drain Plug Replacement 1
18 5.003-062.0 Plate 1
19 9.177-301.0 Hich Pressure Seal 3
20 9.177-310.0 Back Ring 3
21 6.362-833.0 O-Ring Seal 12.5 x 1.73 3
22 9.155-011.0 Housing Low Pressure Seal 3
23 6.363-058.0 Grooved Ring 3
24 9.134-016.0 Spacer 3
25 6.365-393.0 Oil Sealing 12.20x4/6 3
26 9.133-007.0 Piston Guide 1
27 6.362-390.0 O-Ring Seal 15.6 x 1.8 1
28 9.134-019.0 Male Adapter 1
29 9.181-005.0 Filter Seal 1
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
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Xpert HD-DD-PD-DA • 8.780-000.0 • Rev. 04/11
Page 9
PUMP EXPLODED VIEW PARTS LIST (CONT)
8.920-004.0 Housing View
PRESSURE WASHER
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 1
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Xpert HD-DD-PD-DA • 8.780-000.0 • Rev. 04/11
Page 10
G.1 SERIES PUMP w/3/4" HOLLOW SHAFT EXPLODED VIEW
9.804-033.0 KG2530G.1
8.904-893.0 LG2530G.1
8.904-748.0 HG2530G.1
SERVICE MANUAL
PRESSURE WASHER
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
1 9.803-938.0 Crankcase 1
2*
See Kit Below
3*
See Kit Below
4*
See Kit Below
5*
See Kit Below
6*
See Kit Below
7*
See Kit Below
8*
See Kit Below
9*
See Kit Below
10 9.802-926.0 Brass Plug, 1/2" 1
11 9.803-199.0 Copper Washer 1/2" 1
12 9.803-946.0 Manifold Housing 1
13*
9.803-947.0
14*
See Kit Below
15*
9.803-948.0
16 9.803-949.0 Valve Plug 6
17 9.803-950.0 Washer, Copper 1
18 9.803-951.0 Brass Plug G1/4 1
Plunger Oil Seal 3
O-Ring Ø1.78 x 28.30 3
Pressure Ring, 15mm 3
U-Seal, 15mm 3
Intermediate Ring 15mm 3
Backup Ring 15mm 3
U-Seal, 15mm 3
Support Ring, 15mm 3
O-Ring Ø1.78 x 15.54 6
Valve Assembly 6
O-Ring Ø2.62 x 18.77 6
ITEM PART NO. DESCRIPTION QTY
19 9.803-952.0 Manifold Stud Bolt 8
20 9.802-884.0 Washer 8
21 9.803-198.0 Copper Washer 3/8" 1
22 9.802-925.0 Brass Plug 3/8" 2
27 9.802-939.0 Hexagonal Screw 9
28 9.803-953.0 Bearing Cover 1
29 9.803-954.0 Seal Bearing 1
30 9.802-914.0 Snap Ring 1
31 9.803-955.0 Ball Bearing 1
32 8.717-069.0 Crankshaft (2530G) 1
33 9.803-957.0 Oil Dip Stick 1
34 9.804-581.0 O-Ring 3.53 x 55.56 1
35 9.804-582.0 Needle Roller Bearing 1
36 8.717-212.0 Engine Flange 1
37 9.803-210.0 Spring Washer 4
38 9.804-584.0 Flange Screw 4
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Xpert HD-DD-PD-DA • 8.780-000.0 • Rev. 04/11
Page 11
G.1 SERIES PUMP EXPLODED VIEW PARTS LIST (CONT)
ITEM PART NO. DESCRIPTION QTY
39 9.804-585.0 Crankshaft Seal 1
40*
See Kit Below
41*
See Kit Below Copper Spacer 3
42*
See Kit Below
43*
See Kit Below
44*
See Kit Below
45*
See Kit Below
46 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
* Part available in kit (See below)
Plunger Nut 3
Plunger, 15mm 3
Copper Spacer 3
O-Ring Ø1.78x5.28 3
Tefl on Ring 3
PRESSURE WASHER
SERVICE MANUAL
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
ITEM NUMBERS
INCLUDED
Plunger Seal
15mm
3, 5, 7, 8, 9
Complete
Seal Packing 15mm Plunger 15mm Complete Valve
3, 4, 5,
6, 7, 8, 9
40, 41, 42, 43,
44, 45
13, 14, 15 2
Plunger Oil
Seals
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Xpert HD-DD-PD-DA • 8.780-000.0 • Rev. 04/11
Page 12
UU1 UNLOADER EXPLODED VIEW
9.175-018.0
UU1 3500PSI, UNIVERSAL UNLOADER (SPARE)
21
2
SERVICE MANUAL
PRESSURE WASHER
23
28
26
14
27
10
3
20
16
18
12
5
15
19
6
7
25
4
8
22
27
15
9
1
25
24
13
26
23
UU1 UNLOADER EXPLODED VIEW PARTS LIST
ITEM PART # DESCRIPTION KIT QTY
1 8.749-792.0 Piston housing 1
2 Piston C 1
3 Piston O-ring back up A 1
4 8.749-796.0 Main block 1
5 9.152-372.0 Piston ring 1
6 Ball seat C 1
7 O-ring 10.5 ID X 1.5 CS A,C 1
8 Plunger B 1
9 9.152-016.0 Plunger housing 1
10 Bypass spring C 1
11 9.149-001.0 Low pressure port 1
12 9.152-017.0 Sliding connector, 30mm 1
8.762-005.0 Sliding connector, 40mm, long 1
13 9.149-002.0 Sliding connector H 1/2" 1
9.149-005.0 Sliding connector H 3/8" 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
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Xpert HD-DD-PD-DA • 8.780-000.0 • Rev. 04/11
27
17
11
ITEM PART # DESCRIPTION KIT QTY
17 9.149-006.0 Sliding connector guide 1
18 O-ring backup A 1
6X 1.45X 1.68
19 Conical seal C 1
20 O-ring 6.75 X 1.78 BN80 A 1
21 Spring seat C 1
22 Plunger spring B 1
23 8.917-699.0 Banjo bolt 1/2" short 1
8.917-700.0 Banjo bolt 1/2"-1/4"NPT short 1
8.917-698.0 Banjo bolt 3/8" short 1
24 8.917-698.0 Banjo bolt 3/8" short 1
25 9.802-893.0 Seal washer 3/8" 2
26 9.803-921.0 Seal washer 1/2" 2
9.802-893.0 Seal washer 3/8" 2
27 O-RING 15 ID x 2CS A,B 3
28 8.706-865.0 Plug, 1/4" countersunk 1
Kit A 9.104-038.0 O-ring Repair Kit
Kit B 9.104-039.0 Outlet Kit
Kit C 9.104-040.0 Stem Repair Kit
Page 13
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
PRESSURE WASHER Troubleshooting Guide
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 Check plumbing system for leaks. Retape
Faulty or mis-adjusted unloader
valve
Worn packing in pump Call Dealer Customer Support.
Machine has been stored in freezing temperatures
Slow engine RPM Call local distributor.
Worn or dirty pump valves Call local distributor.
Nozzle is obstructed Blow out or remove debris with fi ne needle.
Pump sucking air, inlet hose
leaking
Insuffi cient water supply Turn water on full force. Check garden hose
Nozzle worn Replace nozzle.
Unloader valve worn Replace unloader valve.
Use larger garden hose; clean inlet water
screen. Open faucet.
leaks with tefl on tape.
Adjust unloader for proper pressure. Install
repair kit when needed. Call local distributor.
Thaw out machine completely, including
hose, spray gun and wand.
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.
for kinks, leaks or blockage.
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
(BXD Comet & G
Pump Series Only)
Low oil shutdown Fill engine with oil.
Out of gas Fill fuel tank.
Water in gasoline Drain gas tank; fi ll with clean fuel.
Nozzle partially blocked Clean nozzle.
Excessive pressure from high
engine RPM
A small amount of leaking is
normal
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.
Adjust engine throttle to lower RPM.
If excessive leaking occurs, Call local
distributor.
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Xpert HD-DD-PD-DA • 8.780-000.0 • Rev. 04/11
Page 14
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
ENGINE OPERATES
FOR 15 MINUTES
THEN STOPS
ENGINE LACKS
POWER
ENGINE FALTERS
WATER DRIPPING
FROM UNDER PUMP
OIL DRIPPING
WATER LEAKING
FROM PUMP
PRESSURE WASHER Troubleshooting Guide
PROTECTOR
NO DETERGENT
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 fi lter Clean or replace fuel fi lter.
Dirty air fi lter Replace air fi lter.
Choke is opened too soon Move choke to halfway position until engine
runs smoothly.
Piston packing worn Call local distributor.
O-Ring plunger retainer worn Call local distributor.
Cracked piston Call local distributor.
Oil seal worn or damaged Call local distributor.
Spray gun closed with machine
running 5 minutes or longer
Excess water supply pressure Place a pressure regulator at end of 50'
Detergent suction tube not properly
connected to machine
Detergent is too thick Dilute detergent. For best results, use
Detergent fi lter valve is at lowest
setting
Open spray gun or turn off machine.
garden hose.
Check connection.
manufacturers detergent.
Set detergent fi lter valve to a higher setting.
GARDEN HOSE
CONNECTION
LEAKS
SPRAY WAND
LEAKS
PUMP IS NOISY
Filter on detergent suction tube is
clogged
Damaged or clogged detergent suction tube
A high pressure nozzle is attached. Replace with black detergent nozzle.
Discharge nozzle is obstructed Blow out or remove debris with fi ne needle.
Loose fi ttings Tighten fi ttings.
Missing/worn rubber washer Insert new washer.
Spray wand not properly attached Slide the spray wand into the gun. Turn the
Broken o-ring Call local distributor and order an o-ring.
Pump is sucking air Check that hoses and fi ttings are air tight.
Run warm water through fi lter to remove
debris.
Remove obstruction or replace detergent
suction tube.
wand collar clockwise onto the spray gun
threads until tight.
Turn off machine and purge pump by
squeezing trigger gun until a steady fl ow of
water emerges through nozzle.
14
Xpert HD-DD-PD-DA • 8.780-000.0 • Rev. 04/11
Page 15
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.
MAINTENANCE SCHEDULE
Inspect Daily
Engine Oil
Air Cleaner/Filter
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)
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)
Change First month or 20 hours.
Every 100 hours or every 6 months after fi rst month
Filter Every 50 hours
Inspect Every 50 hours
Clean Monthly
Inspect Oil level daily
Change After fi rst 50 hours, then every 500 hours or annually
PRESSURE WASHER Troubleshooting Guide
15
Xpert HD-DD-PD-DA • 8.780-000.0 • Rev. 04/11
Page 16
OIL CHANGE RECORD
Check pump oil and engine oil level before fi rst use of your new pressure washer.
Date Oil Changed
SERVICE MANUAL
Month/Day/Year
PRESSURE WASHER
Estimated Operating
Hours Since Last
Oil Change
Date Oil Changed
Month/Day/Year
Estimated Operating
Hours Since Last
Oil Change
16
Xpert HD-DD-PD-DA • 8.780-000.0 • Rev. 04/11
Page 17
Page 18
Form #8.780-000.0 • Xpert HD-DD-PD-DA • Revised 04/11
Printed in U.S.A. or Mexico
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