Karcher Shark HDS 4.0/20 E Ec User manual

9.800-966.0-R06/07/17
SERVICE MANUAL
To locate your local Kärcher Shark Commercial Pressure Washer Dealer nearest you,
visit www.karchercommercial.com
HEATER
ON
TIMER — 7 DAY
CONTROLADORDETIEMPO DE SIETEDIEAS
MINUTERIEDE7JOURS
POWER
CORRIENTE
COURANT
HEATER
CALENTADOR
CHAUFFE-EAU
PULLOUT PINSTO S ETDESIRED“ON”TIMES
EXTRAIGALASCLAVI JASPARA ESTABL ECERELTIEMPODESEADO.
TIRERLESPOINTEURSVERSL
’EXTERIEURPOUR E’TABLIR
LESHORAIRESD’OPERATION
10-0726
ON
PRENDER
O
I
OFF
APAGAR
ETTEINT
.
INSTRUCTIONS
40°40°
25°
INSTRUCTIONS
INSTRUCCIONES
15°
ON
PRENDER
OFF
I
O
98009660-1
EXPOSEDPULLEYSAND
BELTSCANCAUSEINJURY
PRECAUCION/AVERTISSEMENT
WARNING
MODEL # ORDER #
HDS 4.0/20 E Ec 1.109-075.0
HDS 4.0/30 E Ec
HDS 4.0/20 E Ef
HDS 4.0/30 E Ef
1.109-076.0
1.109-956.0
1.109-957.0

CONTENTS
2
9.800-966.0-R • KÄRCHER HDS Service Manual
Model Number ______________________________
Serial Number ______________________________
Date of Purchase ___________________________
The model and serial numbers will be found on a decal attached
to the pressure washer.You should record both serial number and
date of purchase and keep in a safe place for future reference.
Exploded View 4-5
Exploded View Parts List 6-7
Cabinet Exploded View 8-9
Cabinet Parts List 10
Hose and Spray Gun Assembly 11
Specifications 12-13
Unloader Adjustment Procedure 13
VRT3 & VB8 Unloader Valves Exploded Views & Parts Lists 14-15
KM Series Pump Exploded View & Parts List 16-17
Troubleshooting 18-20
Wiring Diagrams 21-22

9.800-966.0-R • KÄRCHER HDS Service Manual
SERVICE MANUAL PRESSURE WASHER
4
98009660-2
EXPLODED VIEW - LEFT SIDE
Time Delay
Option
17
95
100
101
84
4
886 84
89
10 87
93
5
7
6
57
84
92
3
20
2
21
9
19
59, 94
56
16
82
22 18
15
23
65
96
24
82
82
26
75
64
49
25
24
Reversed View of
Electrical Panel
Components
92
62
Time
Delay
Option
1
98
26
1
49
97

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5
PRESSURE WASHER SERVICE MANUAL
98009660-3
EXPLODED VIEW - RIGHT SIDE
11
12
14
13
59 60
56
83
28
54
88
46
70
73 74
44
48
47
45
50
80
43
58
68
77
61
29
63
79
80
91
85
90
31
51
20
53
80
40 41
42
81
90
72
50
71
55
78
35
34
37
50
33
39
32
38
30
67
52 69
27
36
99
66

9.800-966.0-R • KÄRCHER HDS Service Manual
SERVICE MANUAL PRESSURE WASHER
6
EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.802-362.0 Unloader,
PA 8GPM@3650 PSI,
VB8 W/Switch 1
8.750-299.0 Unloader,VRT3, 8 GPM @
4500 PSI, (Time Delay Option) 1
2 Pump, See Specification Pages
3 Motor, See Specification Pages
4 Overload, See Specification Pages
5 Transformer, See Specification Pages
6 Fuse, See Specification Pages
7 Fuse, See Specification Page 28-29
8 Contactor, See Specification Pages
9 9.802-259.0 Hose, 1/2" Push On 18"
10 9.802-457.0 Din Rail, 35mm 4"
(Time Delay Option) 6"
11 9.802-476.0 Box, Plastic, 10" x 8" x 6" w/Lid 1
12 9.803-038.0 Bracket, Support for Elec Box 1
13 9.802-518.0 Strain Relief, 3/4" LQ Tite 1
9.802-526.0 ▲Locknut, 3/4" 1
14 9.802-515.0 Strain Relief, Strt, LQ Tite, Med 1
9.802-524.0 ▲Locknut, 1/2" Conduit 1
15 8.918-424.0 Hose, 3/8" X 25", 2 Wire,
Pressure Lo 1
16 9.803-670.0 Pump Protector, 1/2, 190° 1
17 8.751-306.0 Timer, Multi-Function
(Time Delay Option) 1
18 9.802-039.0 Elbow, 1/2" JIC, 3/8", 90°, Steel 1
19 9.802-779.0 Nut, 3/8" ESNA 4
20 9.802-807.0 Washer, 3/8", SAE, Flat 8
21 8.706-797.0 Nipple, 1/2" Hex, Brass 1
22 8.706-844.0 Tee, 1/2" Female, Pipe 1
23 9.802-128.0 Nipple, 1/2" JIC x 1/2"
MPT Pipe 1
24 9.802-131.0 Elbow, 1/2" JIC x 1/2", 90° 2
25 9.802-039.0 Elbow, 1/2" JIC x 3/8" Steel 1
26 9.802-129.0 Elbow, 1/2" x JIC x 3/8", Brass 1
27 9.802-807.0 Washer, 3/8 Flat 4
28 9.802-879.0 Cover, Kärcher 1
29 9.802-875.0 Base, Kärcher 1
30 9.802-451.0 Switch, Rocker, Carling
w/Green Lens 1
9.802-452.0 Switch, Rocker, Red Face
(Time Delay Only) 1
31 9.802-066.0 Pad, Soft Rubber, 50 Duro 4
32 9.802-064.0 Grommet, Rubber,
Nozzle Holder 4
33 9.802-146.0 Swivel, 1/2" MP x 3/4"
GHF w/Strainer 1
ITEM PART NO. DESCRIPTION QTY
34 8.707-000.0 Connector, 1/2" Anchor 1
35 8.755-033.0 Bulkhead, 3/8" FXF NPT, Steel 1
36 9.804-058.0 Bolt, Pump Mounting 4
37 9.802-039.0 Elbow, 1/2" JIC x 3/8" 90° MPT 1
38 8.712-353.0 Nozzle, SAQCMEG 0005, Red
(HDS 4.2/20) 1
8.712-345.0 Nozzle, SAQCMEG 0004 Red
(HDS 4.0/30) 1
39 8.712-354.0 Nozzle, SAQCMEG 1505, Yellow
(HDS 4.2/20) 1
8.712-346.0 Nozzle, SAQCMEG 1504 Yellow
(HDS 4.0/30) 1
40 8.712-355.0 Nozzle, SAQCMEG 2505, Green
(HDS 4.2/20) 1
8.712-347.0 Nozzle, SAQCMEG 2504 Green
(HDS 4.0/30) 1
41 8.712-356.0 Nozzle, SAQCMEG 4005, White
(HDS 4.2/20) 1
8.712-348.0 Nozzle, SAQCMEG 4004, White
(HDS 4.0/30) 1
42 9.800-064.0 Label Karcher Control Panel CT 1
43 8.932-985.0 Label Karcher Stripe 17" 2
44 Bushing, See Specification Pages
45 Bushing, See Specification Pages
46 Pulley, See Specification Pages
47 Pulley, See Specification Pages
48 Belt, See Specification Pages
49 9.802-048.0 Swivel, 1/2" JIC Fem, 3/8" Male 1
50 9.802-765.0 Screw, 1/4"x1/2" BH SOC ES 14
51 9.802-817.0 Washer, 3/8" x 1" Steel 4
52 9.802-283.0 Hour Meter 1
53 9.802-720.0 Bolt, 3/8" x 1", NC HH 4
54 8.932-965.0 Label, Warning, Exposed
Pulley 1
55 8.932-970.0 Label, Cold Water Outlet 1
56 9.802-429.0 Service Cord 12/4 10 ft.
57 8.932-969.0 Label, GFCI 1
58 9.802-522.0 Strain Relief 1" 1
59 9.802-429.0 Service Cord 12/4 40"
60 9.802-518.0 Strain Relief, Strt, LQ Tite 3234
Large 1
9.802-526.0 ▲Locknut, 3/4" 1
61 9.800-013.0 Label, Intended For Indoor Use 1
62 9.802-259.0 Hose, 1/2" Push-on 12"
63 9.802-779.0 Nut, 3/8" ESNA NC 4
64 8.706-207.0 Elbow, 3/8" Street, 90°, Steel 1
65 8.716-125.0 Switch, Pressure
(Time Delay Option) 1

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PRESSURE WASHER SERVICE MANUAL
ITEM PART NO. DESCRIPTION QTY
66 9.802-514.0 Strain Relief, 1/2" 1
9.802-524.0 ▲Locknut, 1/2" 1
67 9.803-081.0 Cover, Access Hole 1
68 9.800-016.0 Label, Disconnect power supply 1
69 9.800-020.0 Label, Cold Water Inlet 1
70 8.718-980.0 Washer, 5/16" Flat 4
71 9.802-738.0 Bolt, 1/2" x 8" NC HH 1
72 9.802-800.0 Washer, 1/2" Flat 1
73 9.803-100.0 Slider, Pump 1
74 9.802-776.0 Nut, 5/16" ESNA 4
75 9.802-042.0 Elbow, 1/2" JIC x 3/8"
Female, 90°, Steel 1
76 8.706-294.0 Bushing, 1/2" x 3/8" Steel 1
77 9.800-034.0 Clear Lexan 1
78 9.800-049.0 Detergent label 1
79 9.802-067.0 Bumper Pad 4
80 9.802-073.0 Weather Stripping 7 ft.
81 9.802-074.0 Nut, 1/4" Square 4
82 9.802-151.0 Swivel, 1/2" JIC Fem.
Push-On 4
83 9.802-424.0 Cord, 16-4 Service 30"
84 9.802-695.0 Nut, 10/32" Keps 7
85 9.802-723.0 Bolt, 3/8" x 1-1/2" NC HH 4
86 9.802-759.0 Screw, 10/32" x 1/2" Black 10
87 9.802-762.0 Screw, 10/32" x 1-1/4" 1
88 9.802-773.0 Nut, 1/4" ESNA NC 2
89 9.802-791.0 Cage Nut, 10/32" x 16 Gauge 6
90 9.802-794.0 Cage Nut, 1/4" x 12 Gauge 8
91 9.802-811.0 Washer, 3/8" x 1-1/2" Fender 4
92 9.800-040.0 Label, Ground 2
93 9.803-032.0 Standoff, Electrical Box 1
94 9.802-520.0 Strain Relief, 3/4" (075.0) 1
9.802-522.0 Strain Relief, 1" (076.0) 1
95 9.802-472.0 Timer, Solid State,
120V 5-60 Min. Adjust. 1
96 8.707-264.0 Plug, 3/8" Gas Tap
(Time Delay Option) 1
97 9.802-039.0 Elbow, 1/2" JIC x 3/8" MPT
Steel (Time Delay) 1
98 9.802-042.0 Elbow, 1/2" JIC x 3/8" Fem, 90°
Steel (Time Delay) 1
99 8.918-422.0 Hose, 3/8" x 20" 1
100 9.802-467.0 Base, Relay
(Time Delay Option) 1
101 9.802-468.0 Relay, 120V
(Time Delay Option) 1
▲Not Shown
EXPLODED VIEW PARTS LIST

9.800-966.0-R • KÄRCHER HDS Service Manual
SERVICE MANUAL PRESSURE WASHER
8
.
WARNING:
TANKFILL
ELBOW
DONOTPLUG
VENTHOLE
PartNo
98009660-4
CABINET EXPLODED VIEW - LEFT SIDE
1
2
6
5
4
7
9
8
3
10
11
13
12
17
16
64
15
14
42
43
44
45
46
47
24
To
Pressure
Washer
43
43
79
65
66
80
77
78
75
76
58
72
14

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9
PRESSURE WASHER SERVICE MANUAL
L1
L2
L3
98009660-5
32
31
30
CABINET EXPLODED VIEW - RIGHT SIDE
18
26
27
25
24
29
28
19
20
21
22
23
56
33
34
35
38
36
37
41
40
39
48
49, 81
50
51
53
52
54
55
43
59
47
53
56
64
57
48
23
61
60
62
63
53
61
52
43
25
71
68
67
70
69
Coil Assembly
8.918-685.0
59
42
73, 81

9.800-966.0-R • KÄRCHER HDS Service Manual
SERVICE MANUAL PRESSURE WASHER
10
ITEM PART NO. DESCRIPTION QTY
1 9.802-039.0 Elbow, 1/2" JIC x 3/8" MPT 1
2 8.913-216.0 Lid, Top Cover 1
3 8.913-218.0 Outer Wrap, Fill Side 1
4 8.913-219.0 Outer Wrap, Power Side 1
5 8.940-048.0 Label, Heating Unit Power 1
6 9.802-455.0 Light, Green 125V 1
7 9.802-451.0 Switch, Rocker Carling
w/Green Lens 1
8 8.716-254.0 Timer, 7 Day Pin, 120V, 20A
PB873MKZ 1
9 8.706-161.0 Elbow, 1/4" Street, 90° Galv 1
10 8.716-633.0 Switch, Limit w/Clamp 1
11 8.913-211.0 Tank Assembly 1
12 8.716-650.0 Gasket, 6000W Heater,
2500 Series 9
13 8.716-645.0 Heater, 4500W 480V
#055994-091 9
- 8.751-252.0 Heater, 1" Screw Plug 575/600V
4500W (575 Volt Models) 9
14 8.913-222.0 Plug, 1.5" Pipe, Black 2
15 8.913-221.0 Elbow, 1-1/2" Female,
Black 90° 1
16 9.802-518.0 Strain Relief, Large 1
17 9.802-526.0 Locknut, 3/4" 8465 1
18 8.913-212.0 Tank Assembly Lid 1
19 8.913-213.0 Bracket, Coil 2
20 8.706-542.0 Pad, 1/4" Rubber, Coil 4
21 8.711-785.0 Hose, 3/8" x 1/2" Push-on 10
22 8.913-214.0 Bracket, Coil Spacer 1
23 8.706-322.0 Tube Fitting, Parker
8MSC6N-316
1/2" SS A-Lok 2
24 8.706-207.0 Elbow, 3/8" Street 2
25 8.755-033.0 Bulkhead, 3/8" FXF NPT,
Steel 2
26 8.716-461.0 Terminal, Grounding Lug,
1/0-6 Copper Wire 1
27 8.716-122.0 Block, Power Distr, 3 Pol,
GO63133 1
28 9.802-491.0 Block, Terminal, 4 Pole 1
29 8.724-284.0 Contactor, 120V 1
30 8.913-210.0 Tank Base Assembly 1
31 8.718-696.0 Bolt, 1/2" x 3" NC, SS 4
32 8.716-225.0 Holder, Fuse Block, Buss
R60060-3CR 1
33 8.730-762.0 Fuse, Buss FRS-R-50,
600V 50 Amp
CABINET PARTS LIST
ITEM PART NO. DESCRIPTION QTY
34 8.716-883.0 Transformer, 208/230/460V-
24/115V, .050KVA 1
- 9.803-668.0 Transformer, 550V/575/600V-115V,
.050KVA (575 Volt Models) 1
35 8.712-179.0 Switch TH HI 84°C NC
1/2 x 1/2 SP 1
36 9.813-220.0 Electrical Panel 1
37 9.800-016.0 Label, Disconnect Power
Supply 1
38 8.913-215.0 Plate, Back Cover 1
39 8.913-217.0 Plate, Electrical Access 1
40 8.940-047.0 Label, Warning 1
41 8.912.251.0 Coil, 1/2" O.D. SS Tubing 1
42 9.802-793.0 Nut, Cage 1/4" x 16 Ga 30
43 9.802-754.0 Screw, 1/4" x 1/2" HH NC
Whiz Lock 32
44 8.717-480.0 Insulation, 1" x 24" x 48"
Fiberglass, Foil One Side 4
45 8.706-569.0 Gasket, Neop 8 ft
46 8.718-755.0 Screw, 8/32" x 1-1/2",
SS Phil PH 2
47 9.806-551.0 Screw, 5/16" x 3/4" Whiz 10
48 8.718-887.0 Nut, Whiz Loc, 5/16
Flange, SS 12
49 8.718-639.0 Bolt, 5/16' x 2-1/2', NC,
HH, SS 10
50 8.716-533.0 Clamp, Tie Wrap Adhesive 9
51 9.802-765.0 Screw, 1/4" x 1/2" BH
SOC CS 9
52 8.718-937.0 Screw, #8 x 3/4" Phillips, Zinc,
HEK 7
53 8.718-936.0 Screw, #8 x 1/2" Phillips, Zinc,
TEK 10
54 8.940-007.0 Label, Incoming Line 1
55 9.802-259.0 Hose, 1/2" Push-on 1 ft.
56 9.800-040.0 Label, Ground Symbol 3
57 9.802-103.0 Bushing, Snap 5/8 1
58 9.802-171.0 Nipple, 1/2" Hex Steel 1
59 9.802-073.0 Weatherstrip, 1/8" x 1/2" 10 ft.
60 8.718-803.0 Screw, 10/32" x 3/4" BHSOC 1
61 9.802-695.0 Nut, 10/32" Keps 3
62 9.802-464.0 Fuse, Paper Bass 8/10 250V 1
63 8.713-081.0 Fuse, Class R1/2 Amp 2
64 9.802-759.0 Screw, 10/32" x 1/2" BH SOC 19
65 8.724-513.0 Label, Fill Elbow 1
66 9.800-021.0 Label, Hot Water Outlet 1

9.800-966.0-R • KÄRCHER HDS Service Manual
11
PRESSURE WASHER SERVICE MANUAL
CABINET PARTS LIST
ITEM PART NO. DESCRIPTION QTY
67 8.915-607.0 Label, Class RD5, 50 Amp 1
68 8.915-610.0 Label, XFMR Primary/
Secondary Fuses 1
69 9.802-770.0 Screw, 1/4" x 1", BH SOC CS 1
70 9.802-773.0 Nut, 1/4" ESNA, NC 1
71 9.802-065.0 Grommet, 1-5/16" Rubber 1
72 9.802-225.0 Detergent Injector Assy,
Non-Adj. #3 1
73 8.718-621.0 Bolt 5/16" x 1", SS 2
74 8.716-707.0 ▲3/8" Shrink Tubing 30"
75 8.902-433.0 Pressure Relieve Valve 1
76 8.711-785.0 3/8" Push-on Hose 3 ft 1
77 9.802-048.0 1/2" Swivel JIC 1
78 9.802-036.0 Nipple, 1/2" JIC x 3/8" 1
79 8.706-214.0 Tee, 3/8" Female Pipe 1
80 9.800-013.0 Label, Indoor Use Only 1
81 9.802-805.0 Washer , 5/16" Flat, SS
▲Not Shown

9.800-966.0-R • KÄRCHER HDS Service Manual
SERVICE MANUAL PRESSURE WASHER
12
98009660-6
HOSE & SPRAY GUN ASSEMBLY AND PARTS LIST
6
5
3
2
14
8
High Pressure
Nozzle
7
10
9
10

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13
PRESSURE WASHER SERVICE MANUAL
HOSE & SPRAY GUN ASSEMBLY AND PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.802-165.0 Coupler, 1/4" Male 1
9.802-096.0 ▲Quick Coupler O-Ring,
Small 1
2 9.802-286.0 Nozzle Only, 1/8", Soap 1
3 8.711-293.0 Wand, SS, VP, AL344
w/Coupler & Soap Nozzle 1
4 See Nozzles, Page 18
5 8.917-057.0 Hose, 3/8" x 50', 1 Wire, 1
6 4.775-054.0 EASY! Force Advanced KNA 1
7 9.802-216.0 Detergent Injector, Non-Adjust
3-5 GPM 1
8 8.707-057.0 Strainer, 1/4" Hose Barb 1
9 9.802-251.0 Tube, 1/4" x 1/2" Clear Vinyl 6 ft.
10 9.802-210.0 Clamp, Hose, UNI .46 - .54 2
11 8.707-139.0 ▲ Coupler, 1/4"Plug, Male,
Steel/Zinc 1
12 9.802-164.0 ▲ Coupler, 1/4"Socket,
Female, Brass 1
▲Not Shown

9.800-966.0-R • KÄRCHER HDS Service Manual
PRESSURE WASHER Specifications
14
SPECIFICATIONS
Model# HP Motor Pump Pump Pulley
Pump Pulley
Description Motor Pulley
Motor Pulley
Description
Pump Bushing
Description
1.109-075.0 6 hp 8.751-004.0 8.751-189.0 9.802-374.0 2AK74H 9.802-373.0 2AK56H 24 mm
1.109-076.0 7.5 hp 8.755-604.0 8.751-189.0 8.715-592.0 2BK80H 8.715-583.0 2BK50H 24 mm
1.109-956.0 5 hp 8.751-009.0 8.751-189.0 9.802-374.0 2AK74H 9.802-373.0 2AK56H 24 mm
1.109-957.0 7.5 hp 8.751-010.0 8.751-189.0 8.715-592.0 2BK80H 8.715-583.0 2BK50H 24 mm

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15
PRESSURE WASHER Specifications
SPECIFICATIONS
Model#
Pump
Bushings
Motor
Bushing
Motor
Bushing# Belt Belt# Contactor Overload Primary Fuse Secondary Transformer
075.0 9.802-402.0 H x 1-1/8" 9.802-400.0 AX42 9.802-411.0 8.724-268.0 8.724-303.0
9.802-462.0(2) 9.802-463.0(1) 9.802-551.0
076.0 9.802-402.0 H x 1-3/8" 9.802-401.0 BX43 9.802-420.0 8.724-268.0 8.724-312.0 9.802-462.0(2) 9.802-463.0(1) 9.802-551.0
956.0 9.802-402.0 H x 1-1/8" 9.802-400.0 AX42 9.802-411.0 8.724-268.0 8.724-302.0 9.802-462.0(2) 9.802-463.0(1) 9.803-668.0
957.0 9.802-402.0 H x 1-3/8" 9.802-401.0 BX43 9.802-420.0 8.724-268.0 8.724-312.0
9.802-462.0(2) 9.802-463.0(1) 9.803-668.0

9.800-966.0-R • KÄRCHER HDS Service Manual
SERVICE MANUAL PRESSURE WASHER
16
VRT3 UNLOADER EXPLODED VIEW AND PARTS LIST
Unloader Adjustment Procedures
1. Remove lock nut (Item 19).
2. Remove adjustment knob (Item 18).
3. Loosen the two (2) nuts (Item 15), move them upward on stem (Item 8) until you see 4 or more threads below the nut.
4. Re-attach adjusting knob (Item 18).
5. Start machine. Open the trigger of the spray gun. Increase pressure by turning adjustment knob (Item 18) clockwise until
pressure is at the desired operating pressure.
6. Remove the adjustment knob (Item 18), tighten the lower nut (Item 15) tightly against the upper nut (Item 15). Re-
attach adjustment knob (Item 18) and screw down until contact is made with the nuts (Items 15). Screw down lock nut
(Item 19) onto the stem (Item 8) until the threads cut into the nylon insert of the lock nut (Item 19).
*If adjustment knob (Item 18) DOES NOT make contact with upper nut (Items 15), remove adjusting knob (Item 18), re-adjust
(raise) nuts (Items 15) on stem (Item 8) and re-attach adjustment knob (Item 18), then repeat step #6.
**If adjustment knob (Item 18) DOES make contact with upper nut; release the trigger of the spray gun and watch the pres-
sure gauge for the pressure increase (“spike”). This “spike” SHOULD NOT exceed 500 psi above the operating pressure. If
“spike” pressure exceeds the 500 psi limit, remove the adjusting knob (Item 18) and re-adjust (lower) the nuts (Items 15) on
the stem (Item 8). Re-attach the adjusting knob (Item 18), then repeat step #6.
9
8
23
26
3
16
1
10
24
11
6
4
13
14
20
25
12
22
19
15
2
15
21
17
18
7
9
5
ITEM PART NO. DESCRIPTION QTY
25 8.750-712.0 Outlet Fitting 1
18 8.750-713.0 Knob, Unloader 1
8.750-709.0 Repair Kit, VRT3, 2320/3630 PSI
8.750-710.0 Repair Kit, VRT3, 4500 PSI
(Kit Items: 1, 4, 8-12, 16, 21-22)
8.750-297.0, 8 GPM, 2320 PSI
8.750-298.0, 8 GPM, 3630 PSI
8.750-299.0, 8 GPM, 4500 PSI
6

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17
PRESSURE WASHER SERVICE MANUAL
VB8 UNLOADER VALVE EXPLODED VIEW & PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 8.705-749.0 3/8 Bsp F Outlet Fitting 1
2 8.704-218.0* O-ring 1.78 x 18.77 mm 2
3 Spring 1
4 Check Valve 1
5 8.704-230.0* O-ring 3 x 6 mm 1
6 VB8 Brass Body 1
7 O-Ring 2,.62 x 7.6 mm 1
8 Piston 1
9 O-ring 1 x 4 mm 1
10 9.804-550.0* O-ring 1.78 x 15.6 mm 1
11 M 6 Nut 1
12 VB8/9 Seat+Shutter 1
13 Back Ring 11.4 x 15.9 mm 2
14 O-ring 2.62 x 10.77 mm 1
15 Spring Guide 1
16 O-ring 2.62 x 5.23 mm 1
17 Piston Housing 1
18 M 4 x 4 mm Dowel 1
19 M 22 Nut 1
20 Washer 9 x 15 mm 1
21 8.932-987.0 3.2 x 33 mm Spring 1
ITEM PART NO. DESCRIPTION QTY
22 Upper Frame 1
23 1/4" Ball 1
24 Brass Cap 1
25 Sst Clip 1
26 Plastic Housing 1
27 El.Cable + Micro Switch 1
28 O-ring 2.62 x 28.25 mm 1
29 2.5 x 12 mm Screw 2
30 Cover 1
31 O-ring 2.62 x 6.02 mm 1
32 Black Nut-40 Bar 1
33 O-ring 1.78 x 3.68 mm 1
34 Sst Washer 4 x 8 mm 1
35 Spring 1
36 PR 5 Pin 1
37 Plastic Handle
(60.1290.00) 1
38 Washer D. 30 mm
(
60.1290.00) 1
39 M 30 Nut (60.1290.00) 1
40 8.705-930.0 PR 5 Pl.Housing Kit 1
1
2
3
4
6
7
8
9
10
11
12
13
14
15
16
17
18 19
20
21
22
23
24
25
26
27 28
29
30
31
32
33
34
35
36
37
39
40
5
38
27
13
2
9.802-362.0
8GPM@3650 PSI

9.800-966.0-R • KÄRCHER HDS Service Manual
SERVICE MANUAL PRESSURE WASHER
18
ITEM PART NO. DESCRIPTION QTY
1 8.751-216.0 Crankcase 1
2*
See Kits Below Plunger Oil Seal 3
3*
See Kits Below O-Ring Ø1.78 x 31.47 3
4*
See Kits Below Pressure Ring 3
5*
See Kits Below U-Seal 3
6*
See Kits Below Intermediate Ring 3
7*
See Kits Below U-Seal 3
8 9.803-199.0 Washer, Copper 1
9 9.802-926.0 Plug, Brass 1/2 1
10 8.751-218.0 Manifold Head 1
11*
See Kits Below O-Ring Ø2.62 x 17.13 6
12*
See Kits Below Valve Assembly 6
13*
See Kits Below O-Ring Ø2.62 x 20.29 6
14 9.802-928.0 Valve Plug 6
15 9.802-938.0 Manifold Stud Bolt 8
16 9.802-884.0 Washer 16
17 9.803-198.0 Copper Washer 3/8 1
18 9.802-925.0 Brass Plug 3/8 1
ITEM PART NO. DESCRIPTION QTY
23 9.802-944.0 Screw, Hex, 8mm x18mm 8
24 8.717-210.0 Closed Bearing Housing 1
25 9.803-192.0 O-Ring Ø1.78 x 60.05 2
26 8.933-011.0 Tapered Roller Bearing 2
27 8.751-222.0 Crankshaft (5030,3540) 1
8.751-223.0 Crankshaft
( 4030, 4035) 1
28 9.803-167.0 Crankshaft Key 1
29 9.802-921.0 Oil Dip Stick 1
30 9.803-140.0 Crankshaft Seal 1
31 9.803-178.0 Shim 2
32 8.717-209.0 Bearing Housing 1
33*
See Kits Below Plunger Nut, M8 3
34*
See Kits Below Copper Spacer 3
35*
See Kits Below Plunger (4035) 3
See Kits Below Plunger (4030, 5030) 3
See Kits Below Plunger (3540) 3
TORQUE
SPECS
Item # Ft.-lbs
14 75
15 30
23 8
33 9
43 13
48 7.6
8.751-186.0 KM3540R.3
8.751-187.0 KM4030R.3
8.751-188.0 KM4030L.3
8.751-189.0 KM4035R.3
8.751-190.0 KM4035L.3
8.751-191.0 KM5030R.3
8.751-192.0 KM5030L.3
KM.3 SERIES PUMP EXPLODED VIEW
KM.3 SERIES PUMP EXPLODED VIEW PARTS LIST

9.800-966.0-R • KÄRCHER HDS Service Manual
19
PRESSURE WASHER SERVICE MANUAL
ITEM PART NO. DESCRIPTION QTY
36* See Kits Below Copper Spacer 3
37*
See Kits Below O-Ring Ø1.78 x 7.66 3
38*
See Kits Below Teflon Ring 3
39 8.751-224.0 Plunger Rod 3
40 9.803-158.0 Connecting Rod 3
41 8.751-228.0 Connecting Rod Pin 3
42 9.803-218.0 Spring Washer 6
43 9.803-238.0 Connecting Rod Screw 6
44 8.933-016.0 O-Ring, Ø2.62 x 126.67 1
45 8.751-229.0 Crankcase Cover 1
46 9.803-197.0 O-Ring, Ø1.78 x 14 1
47 9.803-202.0 Sight Glass 3/4 1
48 9.802-939.0 Cover Screw 5
* Available in kit (See below)
KM.3 SERIES PUMP EXPLODED VIEW PARTS LIST
REPAIR KIT NO. 8.751-237.0 8.751-238.0 8.933-023.0 9.802-603.0 9.802-609.0
KIT
DESCRIPTION
Plunger
4035
18mm
Plunger
4030
5030
20mm
Plunger
3540
15mm Complete Valve
Plunger Oil
Seals
ITEM NUMBERS
INCLUDED
33, 34, 35, 36,
37, 38
33, 34, 35, 36,
37, 38
33, 34, 35, 36,
37, 38 11, 12, 13 2
NO. OF CYLINDERS
KIT WILL SERVICE 11163
REPAIR KIT NO. 8.725-360.0 8.725-362.0 8.725-358.0 8.725-361.0 8.725-363.0 8.725-359.0
KIT
DESCRIPTION
Plunger Seal
4035
18mm
Plunger Seal
4030
5030
20mm
Plunger Seal
3540
15mm
Complete Seal
Packing
4035
18mm
Complete Seal
Packing
4030
5030
20mm
Complete Seal
Packing
3540
15mm
ITEM NUMBERS
INCLUDED 3, 5, 7 3, 5, 7 3, 5, 7 3, 4, 5, 6, 7 3, 4, 5, 6, 7 3, 4, 5, 6, 7
NO. OF CYLINDERS
KIT WILL SERVICE 33311 1

9.800-966.0-R • KÄRCHER HDS Service Manual
PRESSURE WASHER Troubleshooting Guide
20
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
LOW
OPERATING
PRESSURE
Faulty pressure gauge Install new gauge.
Insufficient water supply Use larger garden hose; clean filter
washer at water inlet.
Old, worn or incorrect spray nozzle Match nozzle number to machine
and/or replace with new nozzle.
Plumbing or hose leak Check plumbing system for leaks.
Retape leaks with teflon tape.
Faulty or mis-adjusted unloader valve
(where applicable)
Adjust unloader for proper pressure.
Install repair kit when needed.
Worn packing in pump Install new packing kit.
Fouled or dirty inlet or discharge
valves in pump Clean inlet and discharge valves.
Worn inlet or discharge valves Replace with valve kit.
Leaking pressure control valve
(where applicable) Rebuild or replace as needed.
FLUCTUATING
PRESSURE
Valves worn Check and replace if necessary.
Blockage in valve Check and clean out if necessary.
Pump sucking air Check water supply and suction
line for air seepage at joints.
Worn piston packing Check and replace if necessary.
PRESSURE
LOW AFTER
PERIOD OF
NORMAL USE
Nozzle worn Check and replace if necessary.
Inlet or discharge valves blocked or
worn Check and clean or replace if necessary.
Unloader valve seat worn Check and replace if necessary.
PUMP NOISY Air in suction line Check water supply connections on
suction line.
Broken or weak inlet or discharge
valve springs Check and replace if necessary.
Foreign matter in valves Check and clean if necessary.
Worn bearings Check and replace if necessary.
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 Check and replace if necessary.