SERVICE MANUAL - Shark Pressure Washers
Contents
1. KG 9 801 598 0 Rev 01 14 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 preventa tive 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 Inspect Daily Engine Oil First month or 20 hours Every 100 hours or every 6 months after first month Every 50 hours Air Cleaner Filter Se EA Monthly 500 hours or 6 months 300 hours or annually Annually Annually Pump Oil Oil level daily Comet and G Series After first 50 hours then every 500 hours or annually pumps only Every 6 months KG 9 801 598 0 Rev 01 14 U y m Y WO J m gt V I m y j S z a gt O O 3 ta 9 o 11 OIL CHANGE RECORD Check pump oil and engine oil level before first use of your new pressure washer Estimated Operating Estimated Operating Date Oil Changed Hours Since Last Date Oil Changed Hours Since Last Month Day Year Oil Change Month Day Year Oil Change x W Q gt Ac W Y cr2. YN cr m T lt W cc 5 D 0 cr a K4000 PUMP EXPLODED VIEW AND PARTS LIST 9 120 019 0 ITEM PART NO DESCRIPTION QTY ITEM PARTNO DESCRIPTION QTY 1 9 175 011 0 Unloader Assy 23 9 139 358 0 Spare Part of Piston 9 120 019 0 Pump 1 Set With 3 pc 1 2 9 139 359 0 pan parts set i 24 6 362 390 0 O Ring seal 15 6 X 1 78 1 SE a 3 25 9 134 019 0 Male Adapter 1 eee ei illest 26 9 181 005 0 Filter Seal Hose Connector 1 4 6 362 481 0 O Ring seal 14 0 x 2 0 NBR 80 3 27 9 155 013 0 Female Hose Connector 1 7 6 362 175 0 O Ring seal 5 28x 1 78 1 30 2 182936 Space 7 8 7 401 908 0 Sphere 7 G300 31 9 177 311 0 Back Ring Low 1 4301 DIN 5401 1 Pressure Seal 3 9 5 332 258 0 Helical spring 1 ne Gompa seal 3 10 9 154 049 0 Plug M10x1 1 33 9 155 014 0 Housing Low Pressure Seal 3 11 9151 0140 Rupture Disk 34 6 362 376 0 O Ring seal 24 0 X 1 5 3 5000 PSI Blue 1 35 9 177 312 0 Back Ring High 12 9 139 364 0 Spare Part List 019 Pressure Seal 3 Set With 3 pc 1 36 9 177 313 0 Seal high pressure 3 13 9 135 012 0 Cylinder Head Machined 1 37 4 401 096 0 Deep groove ball 14 7 306 072 0 Cylinder head screw thrust bearing only for 1 M10X 80 8 8 A3E IS 5 38 9 165 256 0 Swash Plate Machined 1 15 9 184 013 0 Thermal Relief Valve 1 39 6 401 225 0 Taper roller bearing 41 1 16 6 362 851 0 O Ring seal 4 x 2 NBR 90 1 40 7 367
3. 011 0 Radial shaft seal ring 17 9 184 012 0 Valve Pin Back Pressure 1 A40x52x7 NBR DIN 1 18 9 157 006 0 Spring Valve Pin 1 41 9 135 014 0 Oil Housing Machined 19 6 362 384 0 O Ring seal 9x1 5 NBR 702 42 3382 080 1 20 5 769 141 0 Nozzle insert 1 43 _5 332 209 0 Helical spring 1 21 6 362 451 0 O Ring seal 8 0 x 1 0 1 49 5030 5990 Moulded part 1 22 6 363 067 0 O Ring seal 92X2 NBR 70 1 KG 9 801 598 0 Rev 01 14 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION LOW OPERATING Insufficient water supply Closed Use larger garden hose clean inlet water PRESSURE faucet Inlet hose kinked screen Open faucet Clogged inlet hose strainer Check plumbing system for leaks Retape leaks with teflon tape Faulty or mis adjusted unloader Adjust unloader for proper pressure Install valve repair kit when needed Call local distributor Worn packing in pump Call Dealer Customer Support Machine has been stored in freez Thaw out machine completely including ing temperatures hose spray gun and wand Slow engine RPM Call local distributor FLUCTUATING Worn or dirty pump valves Call local distributor PRESSURE Nozzle is obstructed Blow out or remove debris with fine needle Pump sucking air inlet hose Check that all hoses and fittings are airtight leaking 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 bloc
4. 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 Grooved Ring 3 10 9 139 372 0 Nozzle INS 020 021 Pump 1 24 9 134 016 0 Spacer 3 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 13 7 362 507 0 O Ring Seal 8 x 2 NBR 90 1 27 6 362 390 0 O Ring Seal 15 6 x 1 8 1 14 6 413 403 0 Thermo Valve Tin Coated 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 8 751 121 0 Gooseneck Hose Adapter 1 For pump guard or Filters 32 9 139 370 0 Spare Part List Piston 1 33 6 362 471 0 O Ring Seal 80 0x3 0 NBR70 1 NotIncuded ss sts lt is 6 KG 9 801 598 0 Rev 01 14 LEGACY AXIAL PUMP EXPLODED VIEW AND PARTS LIST 8 920 004 0 Housing View D y m 0 7 m 5 0 m D 2 ul O m gt D rm ITEM PART DESCRIPTION QTY 1 9 166 016 0 Grooved Ball Bearing 9 135 018 0 Swash Plate Hor 9 165 356 0 Ball Bearing No 6207 9 177 314 0 Radial Seal 35 x 52 x 7 9 135 016 0 Oil Housing oa P2P Im 2 1 KG 9 801 598 0 Rev 01 14 x W 9 gt ec W
5. plunger retainer worn Call local distributor OIL DRIPPING WATER LEAKING FROM PUMP PROTECTOR NO DETERGENT GARDEN HOSE CONNECTION LEAKS SPRAY WAND LEAKS PUMP IS NOISY Cracked piston Call local distributor Oil seal worn or damaged Call local distributor 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 Check connection connected to machine Detergent is too thick Dilute detergent For best results use manufacturers detergent Detergent filter valve is at lowest Set detergent filter valve to a higher setting setting Filter on detergent suction tube is Run warm water through filter to remove clogged debris Damaged or clogged detergent suc Remove obstruction or replace detergent tion tube 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 Loose fittings Tighten fittings Spray wand not properly attached Slide the spray wand into the gun Turn the wand collar clockwise onto the spray gun threads until tight 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
6. 09 0 Rubber Dampener 5 16 typ A 1 270cc amp 389cc Models 160cc amp 187cc Models m 9 183 405 0 Rubber Dampener 5 16 typ B 1 39 9 802 767 0 Screw 3 8 x 3 4 NC 270cc amp 389cc Models Whiz Loc Flange 4 270cc amp 389cc Models 14 9 196 308 0 5 16 18 X 1 2 Carriage Bolt 1 i 40 8 707 185 0 Nipple 3 8 MPT X M22 15 8 751 142 0 SCR 1 4 20 X 1 75 Carriage 4 Twist Couple 1 270cc amp 389cc Models 270cc amp 389cc Models 16 5 389 000 0 Warning Label 1 A Not Shown 17 8 751 096 0 Label Regulation4442 6 1 18 8 918 645 0 HD Hose Reel Bracket Painted 1 270cc amp 389cc Models 19 9 802 041 0 Elbow 3 8 Street 45 1 270cc amp 389cc Models 20 8 753 547 0 Label KG Series GC 1 160cc amp 187cc Models 8 753 557 0 Label KG Series GX 1 270cc amp 389cc Models KG 9 801 598 0 Rev 01 14 y m 0 7 y m 5 0 T m D 2 m S O m gt D rm LEGACY AXIAL PUMP EXPLODED VIEW AND PARTS LIST 8 920 004 0 x W 9 gt ec W YN cr m T lt W cc D 0 W cr a ITEM PART DESCRIPTION QTY ITEM PART DESCRIPTION QTY 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 2 884 916 0 Valve Complete Kit 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
7. 25 8 767 003 0 1 4 20 Star Knob without logo 2 3 9 197 010 0 1 4 20 Nylon Insert Lock 26 9 196 307 0 1 4 20 x 1 1 2 GR 2 Hex Bolt 2 Nut with Flang 27 4 862 032 0 4 Filter chemistry regulation 1 alte A seed Models _ 28 6 388 216 0 A Hose DN 5 1 4 6 965 007 0 5 16 24X1 GR 5 SHCS 4 29 9 140 131 0 Powder Coated Handle 1 5 9 802 813 0 Washer 5 16 Split Ring Lock 4 30 9 112 017 0 Al5 Gun 4000 PSI 1 6 9 802 776 0 Nut 5 16 18 ESNA 4 31 9 802 220 0 Wand 18 M22 x 1 4 QC 1 160cc amp 187cc Models 9 197 003 0 3 8 16 NE Nylon Insert 4 32 9 162 320 0 HP Hose 50 Rubber DN6 210 1 270cc 8 389cc Models 1 60cc 187cc Models 9 162 323 0 HP Hose DN8 50 4000 1 7 8 718 980 0 Washer 5 16 Flat 8 270cc amp 389cc Models 160cc amp 187cc Models 9 198 004 0 3 8 USS F W Zinc 8 33 9 802 064 0 Grommet Rubber Nozzle 5 270cc amp 389cc Models Holder 8 9 186 010 0 5 16 18 X 1 1 2 GR 5 4 34 6 362 612 0 O Ring seal 24 77x5 33 NBR70 160cc amp 187cc Models 270cc 8 389cc Models 1 9 186 021 0 3 8 16X2GR5 4 35 9 142 009 0 Hanger Weld Assy 45 270cc amp 389cc Models 270cc amp 389cc Models 1 9 9 115 090 0 Powder Coated Frame 1 36 9 162 154 0 H P Hose 3FT 250BAR 1 10 9 802 270 0 Wheel amp Tire Aassy 27000 amp 329er Models 10 Steel Rim W Tube 2 37 9 804 067 0 Hose Reel EZEE 11 9 182 506 0 Cap Black Plastic 5 8 2 pe a 1 12 9 183 001 0 Black Plug Plastic 2 ee Ce Models 7 38 9 802 781 0 Nut 3 8 NC Whiz Loc Flange 4 13 9 183 4
8. SERVICE MANUAL MODEL KG 252437 KG 262637 KG 313137 KG 403637 ORDER 1 107 238 0 1 107 239 0 1 107 240 0 1 107 241 0 9 801 598 0 Exploded View een 4 Exploded View Parts List ps 5 Legacy Axial Pump Exploded View and Parts List pp 6 7 K4000 Pump Exploded View and parts iSt 8 Troubleshooting an 9 10 Preventive Manteinance pp 11 Ol Change Record ceci alias 12 KG 9 801 598 0 Rev 01 14 CONTENTS EXPLODED VIEW O y a 160cc amp 187cc Models CGY t 4 lt fy gt TVANVW 32M83S YAHSVM JYNSSAdd KG 9 801 598 0 Rev 01 14 EXPLODED VIEW PARTS LIST ITEMPART NO DESCRIPTION QTY ITEM PART NO DESCRIPTION QTY 1 SeePage6 Pump Legacy Axial 2 6 GPM 1 21 9 104 016 0 Q C Nozzle Kit 0325 1 160cc amp 187cc Models 160cc amp 187cc Models See Page 8 Pump K4000 1 9 104 030 0 Q C Nozzle Kit 040 1 270cc amp 389cc Models 389cc Model 2 9 194 015 0 Engine Honda GC 160QHA 1 8 751 357 0 Q C Nozzle Kit 045 1 160cc Model 270cc Model 9 194 081 0 Honda Engine GC190 1 22 9 142 010 0 Hanger Weld Assy 45DEG Left 1 187cc Model 160cc amp 187cc Models 8 750 680 0 En isa GX270QAG2 1 23 9 802 786 0 Nut 5 16 Hex NC 2 270cc Model 8 750 580 0 Engine Honda GX390QA2 4 24 9 198 003 0 5 16 Int L W 332 ID X 620 2 389cc Model
9. kage PRESSURE LOW Replace nozzle AFTER PERIOD OF NORMAL USE Unloader valve worn Replace unloader valve ENGINE WILL NOT Low oil shutdown Fill engine with oil START OR STOPS WHILE OPERATING Ale Drain gas tank fill with clean fuel LOADED ENERO Excessive pressure from high Adjust engine throttle to lower RPM engine RPM WATER OR OIL A small amount of leaking is If excessive leaking occurs Call local LEAKING FROM normal distributor BOTTOM OF PUMP PRESENCE OF Water sprayed at machine Change oil Direct spray away from machine WATER IN PUMP OIL EEE SEHE BXD Comet amp G High humidity in air Check and change oil twice as often Pump Series Only Piston packing worn Oil seal worn Call local distributor U y m Y Y J m D V I m y j S z a gt O O 3 ta 9 o KG 9 801 598 0 Rev 01 14 PRESSURE WASHER Troubleshooting Guide TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION ENGINE OPERATES Not enough gas or engine oil Fill tank with gas Check oil level FOR 15 MINUTE THEN a a 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 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
10. m W cc 5 D 0 cr a KG 9 801 598 0 Rev 01 14 Form 9 801 598 0 KG Revised 01 14 Printed in U S A or Mexico
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