Kärcher HD 3.0/27 G User manual

9.801-760.0
SERVICE MANUAL
MODEL # ORDER #
HD 3.0/27 G 1.107-270.0
HD3.0/27 GB 1.107-271.0
HD 3.4/35 G 1.107-272.0
HD 3.3/35 GB
HD 4.0/40 G
HD 4.0/40 GB
HD 4.0/40 Ge
HD 4.0/40 GeB
1.107-273.0
1.107-274.0
1.107-275.0
1.107-276.0
1.107-277.0

9.801-760.0 • Rev. 03/16
PRESSURE WASHER
SERVICE MANUAL
4
EXPLODED VIEW
HD 3.0/27 G, HD 3.4/35 G, HD 4.0/40 G, HD 4.0/40 Ge
For
Detail
See Pump
Assy
13
12
9
11
10
26
25
28
29
37
31
30
32
27
27
2
33
35
36
34
20
21
9
8
3
17
22
19
18
15 7
6
14
23
23
24
4
40
542
40
41
38
39
16
1

9.801-760.0 • Rev. 03/16
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PRESSURE WASHER
SERVICE MANUAL
EXPLODED VIEW PARTS LIST
HD 3.0/27 G, HD 3.4/35 G, HD 4.0/40 G, HD 4.0/40 Ge
ITEM PART NO. DESCRIPTION QTY
1 8.924-115.0 Al Base Direct Drive CW 1
2 8.924-394.0 Al Handle CW 1
3 8.924-393.0 Al Bumper CW 1
4 8.924-233.0 Axle, 5/8" x 21.750" Long CW (HD 3.4/35 G, HD 4.0/40 G, HD 4.0/40 Ge) 1
9.803-097.0 Axle, 5/8 X 20.125 Long (HD 3.0/27 G) 1
5 8.924-072.0 AL Spacer Tube DD Frame CW (HD 3.4/35 G, HD 4.0/40 G, HD 4.0/40 Ge) 2
8.924-179.0 AL Spacer Tube DD Frame (HD 3.0/27 G) 2
6 8.711-898.0 Wheel & Tire Assy, 4" Steel Rim, Flat Pro 1
7 9.802-782.0 Collar, 5/8" Bore Shaft 3010 2
8 9.197-003.0 3/8-16 Nylon Insert l/n zc 5um White 2
9 9.802-817.0 Washer, 3/8" x 1" 4
10 8.924-116.0 Foot AL DD Frame CW (All Models) 1
11 9.802-064.0 Grommet, Rubber, Nozzle Holder 2
12 9.802-066.0 Pad Soft Rubber 2
13 9.196-041.0 Hex Head Bolt 3/8-16 x 1-3/4'' 2
14 8.924-074.0 Camaro Silver Axle Holder 2
15 9.802-706.0 Bolt, 1/4"-20 x 1-3/4" Carriage Zinc (HD 3.0/27 G) 8
9.802-706.0 Bolt, 1/4"-20 x 1-3/4" Carriage Zinc (HD 4.0/40 G, HD 4.0/40 Ge) 7
16 9.197-010.0 1/4-20'' Nylon Insert Lock Nut With Flange 10
17 9.802-317.0 Engine, Honda, GX200, 6.5 hp (HD 3.0/27 G) 1
8.750-680.0 Engine, Honda GX270, 9hp (HD 3.5/35 G) 1
8.750-580.0 Engine, Honda, GX390, 13hp ( HD 4.0/40 G) 1
8.750-581.0 Engine, Honda GX390, 13HP E/S (HD 4.0/40 Ge) 1
18 9.802-958.0 Key, 0.185 SQR X 1.75' ( HD 3.0/27 G) 1
9.802-959.0 Key, 0.247 SQR X 2.125" (HD 3.4/35 G, HD 4.0/40 G, HD 4.0/40 Ge) 1
19 8.754-756.0 Pump, Leuco LP3035G, 3.0@3500, 3400 RPM (HD 3.0/27 G) 1
8.754-758.0 Pump, Leuco LP3535G1, 3.0@3500, 3400 RPM (HD 3.4/35 G) 1
8.750-753.0 Pump, Leuco LS4040G.3, 4@4000, 3400 RPM (HD 4.0/40 G, HD 4.0/40 Ge) 1
20 9.802-813.0 Washer, 5/16" Split Ring Lock, Zinc (HD 3.0/27 G) 4
9.802-814.0 Washer, 3/8" Split Ring Lock, Zinc (HD 3.4/35 G, HD 4.0/40 G, HD 4.0/40 Ge) 4
21 8.718-618.0 Bolt, 5/16-18 x 3/4", hh gr 5 Cr Zinc (HD 3.0/27 G) 4
9.802-722.0 Bolt, 3/8 X 1-1/4", NC HH (HD 3.4/35 G, HD 4.0/40 G, HD 4.0/40 Ge) 4
22 9.802-713.0 Bolt, 5/16" X 1-1/2", NC HH (HD 3.0/27 G) 4
9.196-041.0 Hex Head Bolt 3/8-16 x 1-3/4 (HD 3.4/35 G, HD 4.0/40 G, HD 4.0/40 Ge) 4
23 8.718-980.0 Washer, 5/16" Flat, SAE (HD 3.0/27 G) 8
9.802-817.0 Washer, 3/8" x 1" (HD 3.4/35 G, HD 4.0/40 G, HD 4.0/40 Ge) 8
24 9.802-776.0 Nut, 5/16-18, ESNA (HD 3.0/27 G) 4
9.197-003.0 3/8-16 NE Nylon Insert L/N ZC 5UM White (HD 3.4/35 G, HD 4.0/40 G, HD 4.0/40 Ge) 4
25 8.750-247.0 Trigger Gun Model m407 (All Models) 1
26 8.783-039.0 Wand 30" Zinc Plated, Handle & Coupler (HD 3.0/27 G) 1
8.783-040.0 Wand 44" Zinc Plated, Handle & Coupler (HD 3.4/35 G, HD 4.0/40 G, HD 4.0/40 Ge) 1
27 9.802-166.0 Coupler, 3/8" Socket, Female, Brass 2
28 8.916-740.0 Hose, 3/8" x 50', 1w, TS, SOXSW 1
29 9.802-170.0 Coupler, 3/8" Plug, Female, Steel Zinc 1
30 9.802-216.0 Injector, Chem, Non Adj, 0.083 1
31 6.388-216.0 Hose DN 5 3.2 ft.
32 5.731-652.0 Filter with weight 1
33 8.924-120.0 Al Battery Support CW (HD 4.0/40 Ge) 1
34 8.706-652.0 Battery Box, Small (HD 4.0/40 Ge) 1
35 8.755-219.0 Battery, Sealed, D18S 1

9.801-760.0 • Rev. 03/16
PRESSURE WASHER
SERVICE MANUAL
6
EXPLODED VIEW PARTS LIST
HD 3.0/27 G, HD 3.4/35 G, HD 4.0/40 G, HD 4.0/40 Ge
ITEM PART NO. DESCRIPTION QTY
38 8.755-187.0 Grommet, Rubber, Nozzle Holder Base 3/16 5
39 8.712-337.0 Nozzle, SACQMEG, 0003.5, Red (HD 3.0/27 G, HD 3.4/35 G) 1
8.712-345.0 Nozzle, SAQCMEG 0004, Red (HD 4.0/40 G, HD 4.0/40 Ge) 1
8.712-338.0 Nozzle, SAQCMEG 1503.5, Yellow (HD 3.0/27 G, HD 3.4/35 G) 1
8.712-346.0 Nozzle, SAQCMEG 1504, Yellow (HD 4.0/40 G, HD 4.0/40 Ge) 1
8.712-339.0 Nozzle, SAQCMEG, 2503.5, Green (HD 3.0/27 G, HD 3.4/35 G) 1
8.712-347.0 Nozzle, SAQCMEG 2504, Green (HD 4.0/40 G, HD 4.0/40 Ge) 1
8.712-340.0 Nozzle, SAQCMEG 4003.5, White (HD 3.0/27 G, HD 3.4/35 G) 1
8.712-348.0 Nozzle, SAQCMEG 4004, White (HD 4.0/40 G, HD 4.0/40 Ge) 1
8.712-398.0 Nozzle kpl., QCEM-6540 Mess. (CHEM) (All Models) 1
40 8.755-187.0 Grommet, Rubber, Nozzle Holder Base 3/16 5
41 8.755-187.0 Grommet, Rubber, Nozzle Holder Base 3/16 5
42 9.802-073.0 Weatherstrip, 1/8" x 1/2" 12''

9.801-760.0 • Rev. 03/16
PRESSURE WASHER
SERVICE MANUAL
10
PUMP ASSEMBLY EXPLODED VIEW
PUMP ASSY EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 8.754-751.0 Pump, Leuco LB3030R,
3.0@3000, 1650 RPM
(HD 3.0/27 GB) 1
8.750-755.0 Pump, Leuco LM3540R.3
3.5@ 4000 1850RPM
(HD 3.3/35 GB) 1
8.755-216.0 Pump, Leuco LM3840R.3,
3.8@4000 1740 RPM
(HD 4.0/40 GB) 1
8.754-756.0 Pump, Leuco LP3035G,
3.0@3500, 3400 RPM
(HD 3.0/27 G) 1
8.754-758.0 Pump, Leuco LP3535G1,
3.5@3500, 3400RPM
(HD 3.4/35 G) 1
8.750-753.0 Pump, Leuco LS4040G.
3, 4@4000, 3400 RPM
(HD 4.0/40 G, HD 4.0/40 GE) 1
2 8.707-256.0 Pump protector,1/2" 1
(
HD 3.0/27G, HD3.4/35G, HD4.040G, HD4.0/40Ge)
8.707-254.0 Pump protector,3/8" 1
(
HD3.0/27 GB, HD3.3/35 GB, HD4.0/40GB, HD4.0/40GBe)
3 8.706-168.0 Elbow, 3/8" NPT-p/n-
tf3529x6 Steel
(All Models) 1
9
11
6
8
8
7
5
6
13
4
12
Position of Pump protector
on GB and GeB models
For G and Ge models
3
10
2
2
1
ITEM PART NO. DESCRIPTION QTY
4 8.750-299.0 Unloader, Vrt3, 8 GPM
@4500 psi
(All Models) 1
5 9.802-171.0 Coupler, 3/8" Clug, Male,
Steel/zinc
(All Models) 1
6 8.706-944.0 Hose Barb, 3/8' barb x 3/8'
ml pipe
(All Models) 2
7 8.706-860.0 Tee, 1/2" Street, Brass
(All Models) 1
8 9.802-146.0 Swivel, 1/2" mp x 3/4" ghf
w/Strainer (All Models) 1
9 8.706-917.0 Bushing, 1/2" x 3/8", Brass
p/n-5406 (All Models) 1
10 8.711-785.0 Hose, 3/8" Push on, per ft
(All Models) 18''
11 8.706-984.0 Adapter, 1/2" fptx 1/2" mpt,
Brass (HD 3.0/27 G,
HD 3.0/27GB,
HD, HD 3.4/35 G) 1
12 8.706-207.0 Elbow, 3/8", Street 90 deg,Steel
(
HD 3.0/27 G,HD 3.4/35 G, HD 4.0/40 G,
HD 4.0/40 Ge) 1
13 8.706-829.0 Elbow, 1/2" Street, Brass
(HD3.0/27G,HD 3.4/35G,
HD4.0/40G, HD4.0/40Ge) 1

9.801-760.0 • Rev. 03/16
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PRESSURE WASHER
SERVICE MANUAL
LP 3035G1 PUMP EXPLODED VIEW
8.754-758.0 LP3535G1
LP3535G1 PUMP PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 8.751-216.0 Crankcase 1
2 8.754-846.0 O-ring Ø1.78 X 72.75 3
3* See Kits Below Plunger Oil Seal 3
4* See Kits Below O-ring Ø1.78 X 26.7 3
5* See Kits Below Washer, Pressure Ring 3
6* See Kits Below U-Seal, 14mm 3
7* See Kits Below Pressure Ring, 14 mm 3
8 See Kits Below U-Seal, 14mm 1
9 9.803-199.0 Washer, Copper G1/2 1
10 9.802-926.0 Plug, Brass G1/2 1
11 8.754-853.0 Manifold 1
12* 8.717-233.0 O-ring Ø1.78 X 15.6 6
13* See Kits Below Valvel Assembly 6
14* 9.803-948.0 O-ring Ø1.78 X 18.77 6
15 9.803-949.0 Valve Plug 6
16 8.754-854.0 Bolt, Manifold M14 x 40 2
17 8.754-850.0 Washer, Lock 2
18 9.803-198.0 Washer, Copper G3/8 1
19 8.707-262.0 Plug, Brass G3/8 1
20* See Kits Below Valve Seat 6
21* See Kits Below Valve Plate 6
22* See Kits Below Valve Spring 6
23* See Kits Below Valve cage 6
24 9.802-939.0 Screw, M6 X 16 12
25 8.717-137.0 Bearing Cover 2
26 9.803-954.0 Bearing Seal 1
27 8.754-843.0 Seal Spacer, Crankshaft 1
ITEM PART NO. DESCRIPTION QTY
28 9.802-914.0 Snap Ring, 25 mm 1
29 9.803-955.0 Bearing, Ball 1
30 8.754-828.0 Shaft, 1" Hollow 1
31 8.754-219.0 Oil Dipstick 1
32 8.754-840.0 Bearing Needle 1
33 8.754-826.0 Seal, Crankshaft 1
34 9.802-889.0 Washer 4
35 9.803-243.0 Screw 4
36 9.803-215.0 Washer 6 mm 4
37 9.803-244.0 Screw 4
38 9.803-217.0 Washer 4
39 9.803-216.0 Washer 4
40 8.752-824.0 Screw, M6 x 20 4
41 9.803-218.0 Washer, 6 mm 10
42 8.754-864.0 Flange, Engine 1
43* 8.754-855.0 Bolt, Plunger 3
44* 8.754-092.0 Spacer, Copper 3
45* 8.754-849.0 Plunger, 14 mm 3
46* 9.803-962.0 Spacer, Copper 3
47 8.754-827.0 Plunger Rod 3
48 9.803-965.0 Connecting Rod Pin 3
49 9.803-966.0 Connecting Rod 6
50 8.933-020.0 Screw, Connecting Rod 6
51 8.754-847.0 O-ring Ø2.62 X 111.62 1
52 8.754-842.0 Cover, Crankcase 1
53 9.803-906.0 O-ring Ø1.78 X 14 1
54 9.803-202.0 Sight Glass, G3/4 1
TORQUE
SPECS
Item # Ft.-lbs
15 65
16 55
24 8
37 10
38 10
45 10

9.801-760.0 • Rev. 03/16
PRESSURE WASHER
SERVICE MANUAL
18
REPAIR KIT NUMBER 8.754-860.0 8.754-861.0 8.754-862.0 8.754-859.0 9.803-937.0
KIT DESCRIPTION
Plunger Seals 14
mm Seal Packing 14 mm Plunger 14 mm Complete Valve
Plunger Oil
Seals
ITEM NUMBERS
INCLUDED 4, 6, 8 4, 5, 6, 7, 8 36, 37, 38, 39 12, 13, 14 3
NUMBER OF CYLINDERS
KIT WILL SERVICE 31163

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PRESSURE WASHER
SERVICE MANUAL
VRT3 UNLOADER EXPLODED VIEW AND PART S LIST
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
6
8.750-297.0, 8 GPM, 2320 PSI
8.750-298.0, 8 GPM, 3630 PSI
8.750-299.0, 8 GPM, 4500 PSI
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)
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). Reattach
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 pressure
gauge for the pressure increase (“spike”). This “spike” SHOULD NOT exceed 500 psi above the operating pressure. If “spike” pres-
sure 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.
Unloader Adjustment Procedures

9.801-760.0 • Rev. 03/16
PRESSURE WASHER
SERVICE MANUAL
22
TROUBLESHOOTING
For Models: HD 3.0/27 G, HD 3.4/35 G, HD 4.0/40 G, HD 4.0/40Ge
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 freez-
ing temperatures
Thaw out machine completely, including
hose, spray gun and wand.
Slow engine RPM Call local distributor.
FLUCTUATING
PRESSURE
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
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.

9.801-760.0 • Rev. 03/16
23
PRESSURE WASHER Troubleshooting Guide
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
FROM UNDER PUMP
Piston packing worn Call local distributor.
O-Ring plunger retainer worn Call local distributor.
Cracked piston Call local distributor.
OIL DRIPPING
FROM UNDER PUMP
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 suc-
tion 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 NOISY 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.
TROUBLESHOOTING
For Models: HD 3.0/27 G, HD 3.4/35 G, HD 4.0/40 G, HD 4.0/40Ge

9.801-760.0 • Rev. 03/16
PRESSURE WASHER Troubleshooting Guide
24
MAINTENANCE SCHEDULE
Engine Oil
Inspect Daily
Change First month or 20 hours.
Every 100 hours or every 6 months after first month
Filter Every 50 hours
Air Cleaner/Filter 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)
PREVENTATIVE MAINTENANCE
For Models: HD 3.0/27 G, HD 3.4/35 G, HD 4.0/40 G, HD 4.0/40Ge
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.

KNA, Inc.4555 Airport Way Denver, CO 80239
Form #9.801-760.0 • Rev. 03/16 Printed in U.S.A. or Mexico