Shark HD 2.5/27 P AL User manual

8.917-990.0
MODEL # ORDER #
SERVICE MANUAL
HD 2.5/27 P AL
HD 3.0/30 P AL
HD 3.8/35 P AL
PCA3-27324
PCA3-30324
PCA4-35324
DBA-252739
DBA-303039
DBA-383539
DGA-252737
DGA-303037
DGA-383537
1.107-129.0
1.107-130.0
1.107-131.0
1.107-124.0
1.107-125.0
1.107-126.0
1.107-117.0
1.107-118.0
1.107-119.0
1.106-054.0
1.106-055.0
1.106-056.0

3
CONTENTS
HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
Exploded View ......................................................................................... 4
Exploded View Parts List ......................................................................5-6
S4040G Pump Exploded and Parts List .............................................7-9
G3035G Pump Exploded and Parts List...........................................10-12
G2530G Pump Exploded and Parts List...........................................13-15
Unloader Exploded and Parts List ......................................................... 16
Troubleshooting ................................................................................17-18
Preventive Manteinance ........................................................................ 19
Oil Change Record ................................................................................ 20

HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
PRESSURE WASHER
SERVICE MANUAL
4
EXPLODED VIEW
389 cc
270 cc
43
9
32
52
1
4
21
28
7
8
22
27
24
34
26
33
9
8
8
99
9
22
19
8
22
8
29
14
11
37
57
56
30 25
59
60
58
44
45
44
45
25
53
6
41 40
For
Detail
See Pump
Assy
For
Detail See
Pump
Assy
46
47
48
50
49
38
38
39
16
36
51
42
54
15
20
17
13
35
23
2
40
8
5
12
22
8
8
3
10
56
3
12
10
18
57
11
61
6
5
52
46
41
13
55
55
14
47
50
48
12
8
7
98
98
31
62
16
19
18

HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
5
PRESSURE WASHER
SERVICE MANUAL
EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.135-007.0 Rotary Tube-Joint 4
2 9.136-502.0 Knob 2
3 9.802-066.0 Pad Soft Rubber (270 cc, 389 cc) 3
Pad Soft Rubber (196 cc) 2
4 8.917-980.0 Hose Hanger Camaro Silver 1
5 8.750-580.0 Engine, Honda GX390UT2QA2 (389 cc) 1
9.802-315.0 Engine, Honda GX270UTQAG2 (270 cc) 1
9.802-317.0 Engine, Honda GX200UTQX2 (196 cc) 1
6 Pump Assy 3500 PSI (See S4040G.2 Specifications Pages) 1
Pump Assy 3000 PSI (See G3035G Specifications Pages) 1
Pump Assy 2700 PSI (See G2530G Specifications Pages) 1
7 9.802-716.0 Bolt, 5/16" x 2", NC HH 10
8 8.718-980.0 Washer, 5/16", FLAT, SAE(780452) (389 cc, 270 cc) 49
(196 cc) 53
9 9.802-776.0 Nylon Insert Nut 5/16" 29
10 9.802-720.0 Bolt, 3/8" x 1", NC HH(612984) (389 cc, 270 cc) 3
(196 cc) 2
11 9.197-003.0 3/8-16 NE Nylon Insert L/N ZC 5UM White (389 cc, 270 cc) 3
(196 cc) 2
12 9.802-817.0 Flat Washer (389 cc, 270 cc) 7
(196 cc) 6
13 9.196-041.0 Hex Head Bolt 3/8-16 x 1-3/4" (389 cc, 270 cc) 6
(196 cc) 2
14 9.198-004.0 3/8 USS F/W Zinc (389 cc, 270 cc) 7
(196 cc) 2
15 8.750-247.0 Trigger Gun Model M407 1
16 9.196-307.0 1/4-20 x 1-1/2" GR 2 Hex Bolt Zinc 4
17 9.197-010.0 1/4-20" Nylon Insert Lock Nut with Flange 4
18 9.177-204.0 Sleeve, Rubber 4
19 9.802-710.0 Screw 5/16" x 1" NC 3
20 8.739-011.0  Hose, 3/8"x50', 1W, TS, SO x SW (DBA Models) 1
8.739-026.0  Hose, 3/8"x50', 1W, TS, SO x SW (PCA Models) 1
8.739-021.0  Hose, 3/8"x50', 1W, TS, SO x SW (HD and DGA Models) 1
21 8.750-303.0 Handle Stiffener AL 2
22 8.718-618.0 Bolt, 5/16" x 3/4" NC GR 5 CS ZN(61294) 14
23 8.918-437.0 Holder Wand Left Silver 1
24 8.918-079.0 Axle Spacer Silver Aluminum Direct Frame 2
25 8.750-265.0 Aluminum Base Direct Drive 1
26 9.803-097.0 Axle, 5/8" x 20.125" Long 1
27 9.802-782.0 Collar, 5/8" Bore Shaft 3010 2
28 9.802-270.0 Wheel & Tire Assy, 4" Steel Rim W/Tube 2
29 8.750-287.0 Foot AL Direct Frame 1
30 8.919-712.0 Aluminum Front Bumper Direct Drive 1
31 8.917-978.0 Handle Support Assy AL Direct Drive 1
32 8.917-976.0 Handle Assy AL Direct Drive 1
33 9.803-114.0 Retainer Bracket, Handle, Black 2
34 9.802-103.0 Bush 5/8" ID, 7/8 OD SB-875-10 2
35 8.718-625.0 Bolt, 5/16"-18 x 3/4", Nc Carriage znc 6159 1
36 9.802-712.0 Bolt, 5/16"-18 x 1-3/4", Nc Carriage z 1
37 9.803-308.0 Mount, Rubber Vibration 5/16", 70 Duro (196 cc) 4

HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
PRESSURE WASHER
SERVICE MANUAL
6
EXPLODED VIEW PARTS LIST (CONT)
ITEM PART NO. DESCRIPTION QTY
38 9.802-959.0 Key, 0.247 SQR x 2.125" (270 cc, 389 cc) 1
9.802-958.0 Key, 0.185 SQR x 1.750" (196 cc) 1
39 9.802-713.0 Bolt, 5/16" x 1-1/2", NC HH(612975) 4
40 9.802-813.0 Washer, 5/16 Lock Split Ring (51156560) (196 cc) 8
41 8.733-007.0 Socket Head 5/16-24 X 3/4 Zinc Plated (196 cc) 4
9.802-722.0 Bolt, 3/8 x 1 1/4", NC HH (270 cc, 389 cc ) 4
42 8.783-040.0 Wand 44" Zinc Plated, Handle & Coupler (270 cc, 389 cc) 1
8.783-039.0 Wand 30" Zinc Plated, Handle & Coupler (196 cc) 1
43 Quick Connect Nozzle Kit (389 cc) 1
8.708-531.0  Nozzle, QC, 1/4", #4.0 x 0, Red, Legacy
8.708-532.0  Nozzle, QC, 1/4", #4.0 x 15, Yellow, Legacy
8.708-533.0  Nozzle, QC, 1/4", #4.0 x 24, Green, Legacy
8.708-534.0  Nozzle, QC, 1/4", #4.0 x 40, White, Legacy
Quick Connect Nozzle Kit (270 cc) 1
8.723-577.0  Nozzle, QC, 1/4", #3.5 x 0, Red, Legacy
8.726-104.0  Nozzle, QC, 1/4", #3.5 x 15, Yellow, Legacy
8.708-526.0  Nozzle, QC, 1/4", #3.5 x 25, Green, Legacy
8.902-487.0  Nozzle, QC, 1/4", #3.5 x 40, White, Legacy
Quick Connect Nozzle Kit (196 cc) 1
8.723-576.0  Nozzle, QC, 1/4", #3.0 x 0, Red, Legacy
8.902-482.0  Nozzle, QC, 1/4", #3.0 x 15, Yellow, Legacy
8.902-484.0  Nozzle, QC, 1/4", #3.0 x 25, Green, Legacy
8.902-485.0  Nozzle, QC, 1/4", #3.0 x 40, White, Legacy
44 8.930-124.0 Label, Intended For Outdoor Use - Mexico 1
45 8.783-038.0 Label, Universal DB Rating, Ear Protection 1
46 9.800-008.0 Label, Danger Cool Engine 1
47 9.800-006.0 Label, Hot/Caliente w/arrows 1
48 8.783-034.0 Label, Quick Start Guide 1
49 8.783-036.0 Label, Warning Pictogram 1
50 8.917-015.0 Label, Regulation 4442.6 1
51 8.750-284.0 Label, Name Plate (HD Models) 1
8.750-285.0 Label, Name Plate (PCA Models) 1
8.750-286.0 Label, Name Plate (DBA Models) 1
8.750-714.0 Label, Name Plate (DGA Models) 1
52 9.138-438.0 Label, Die - Cut (DGA models) 1
53 8.932-992.0 Mount, Rubber Vibration 3/8" (270 cc, 389 cc) 4
54 9.802-166.0 Coupler, 3/8"Socket, Female, Brass 1
55 9.802-814.0 Washer, 3/8" Split Ring Lock, Zinc (270 cc, 389 cc) 8
56 9.802-744.0 Bolt, 10mm x 20mm, HH Zinc (389 cc) 2
9.802-741.0 Bolt, 8mm x 16 mm Hex Head (270 cc, 196 cc) 2
57 9.802-816.0 Washer, 7/16", Split Ring Lock, 780481 (389 cc ) 2
9.802-813.0 Washer, 5/16 Lock Split Ring (51156560) (270 cc, 196 cc) 2
58 9.183-409-0 Rubber Dampener 5/16"-18 Female 2001 (196 cc) 1
59 8.917-977.0 Pump Support LG Fab Black Wrinkle (196 cc) 1
60 9.196-308.0 5/16-18 x 1/2 Carriage Bolt A307 BLK (196 cc) 1
61 8.933-024.0 Rail, Pump Support (389 cc) 1
9.804-533.0 Rail, Pump Support (270 cc) 1
62 8.750-809.0 Label Operation Warn Trilingual Small 1
 Not Shown

HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
7
PRESSURE WASHER
SERVICE MANUAL
S4040G.2 PUMP ASSEMBLY EXPLODED VIEW
S4040G.2 PUMP ASSY EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 8.707-256.0 Pump Protector, 1/2 PTP
140 DEG, P/N 1005 1
2 8.706-958.0 Hose Barb, 1/4" Barb x 1/4"
Pipe, 90D 1
3 8.706-207.0 Elbow, 3/8", Street 90 Deg
p/n-TF349X6 1
4 9.802-190.0 Valve, EZ Start,
3/8 MPT x 1/8 FPT 1
5 8.706-940.0 Hose Barb, 1/4" Barb x 1/8"
ML Pipe 1
6 9.802-254.0 Hose 1/4" 1.5 ft
7 6.390-126.0 Hose Clamp 2
8 9.175-013.0 Unloader, UU1 3500PSI
Banjo 1/2"-1/4" NPT 1
9 9.802-350.0 Pump KS4040G,
4@4000, 3400 RPM 1
8.904-905.0 Pump LS4040G,
4 @4000, 3400 RPM 1
8.904-755.0 Pump HS4040G,
4 @ 4000, 3400 RPM 1
ITEM PART NO. DESCRIPTION QTY
10 9.802-171.0 Nipple, 3/8" x 3/8" NPT
ST Male 1
11 9.802-146.0 Swivel, 1/2" MP x 3/4"
GHF W/Strainer 1
2
9
8
7
5
4
3
1
11
6
10

HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
PRESSURE WASHER
SERVICE MANUAL
8
S4040G.2 PUMP EXPLODED VIEW
S4040G.2 PUMP EXPLODED VIEW PARTS LIST
TORQUE
SPECS
Item # Ft.-lbs
17 75
18 30
26 7.6
39 10
47 7
58 13
9.802-350.0 KS4040G.2
8.904-905.0 LS4040G.2
8.904-755.0 HS4040G.2
ITEM PART NO. DESCRIPTION QTY
1 8.717-129.0 Crankcase 1
2 9.803-196.0 Plunger Guide 3
3*
See Kit Below Plunger Oil Seal 3
4*
See Kit Below O-Ring Ø1.78 x 31.47 3
5*
See Kit Below Pressure Ring 3
6*
See Kit Below U-Seal, 15mm 3
7*
See Kit Below Intermed. Ring 15mm 3
8*
See Kit Below Back-up Ring 3
9*
See Kit Below U-Seal, 15mm 3
10*
See Kit Below Support Ring 15mm 3
11 9.802-926.0 Brass Plug, 1/2" 1
12 9.803-199.0 Copper Washer 1/2" 1
13 9.802-932.0 Manifold Housing 1
14* 9.803-191.0 O-Ring Ø2.62 x 17.13 6
15*
See Kit Below Valve Assembly 6
16* 9.803-193.0 O-Ring Ø2.62 x 20.29 6
17 9.802-928.0 Valve Plug 6
18 9.802-938.0 Manifold Stud Bolt 8
19 9.802-884.0 Washer 8
20 9.803-198.0 Copper Washer 3/8" 1
21 9.802-925.0 Brass Plug 3/8" 2
ITEM PART NO. DESCRIPTION QTY
26 9.802-939.0 Hexagonal Screw 9
27 9.803-210.0 Washer 4
28 9.803-184.0 Closed Bearing Housing 1
29 8.717-225.0 O-Ring Ø 2.62 x61.6 1
30 9.802-914.0 Snap Ring 1
31 9.803-168.0 Double Row Ball Bearing 1
32 9.803-152.0 Crankshaft (S4040G) 1
33 9.802-945.0 Set Screw 1
34 9.802-921.0 Oil Dip Stick 1
35 9.804-581.0 O-Ring Ø 3.53 x 55.56 1
36 9.803-161.0 Needle Roller Bearing 1
37 9.803-183.0 Engine Flange 1
38 9.803-221.0 Spring Washer 4
39 9.803-240.0 Flange Screw 4
40 9.803-243.0 Engine Screw, 5/16" 4
41 9.803-215.0 Washer 4
42 9.802-889.0 Spring Washer 4
43 9.803-244.0 Engine Screw 3/8" 4

HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
9
PRESSURE WASHER
SERVICE MANUAL
S4040G.2 PUMP EXPLODED VIEW PARTS LIST (CONT.)
REPAIR KIT NUMBER 9.802-622.0 9.802-623.0 8.933-023.0 9.802-603.0 9.802-609.0
KIT DESCRIPTION
Plunger Seal
15mm
Complete
Seal Packing
15mm Plunger 15mm Complete Valve Plunger Oil Seals
ITEM NUMBERS
INCLUDED 4, 6, 8, 9, 10 4, 5, 6, 7, 8, 9,
10
47, 48, 49, 50,
51, 52 14, 15, 16 3
NUMBER OF CYLINDERS
KIT WILL SERVICE 31 163
ITEM PART NO. DESCRIPTION QTY
44 9.803-216.0 Washer 4
45 9.803-217.0 Spring Washer 4
46 9.803-142.0 Crankshaft Seal 1
47*
See Kit Below Plunger Nut 3
48*
See Kit Below Washer, Copper,
9.2 x 13.5 3
49*
See Kit Below Plunger, 15mm 3
50*
See Kit Below Copper Spacer 3
51*
See Kit Below O-Ring Ø1.78x5.28 3
52*
See Kit Below Teflon Ring 3
53 9.803-145.0 Plunger Rod 3
54 9.802-913.0 Snap Ring 6
55 9.802-916.0 Connecting Rod Pin 3
56 9.803-158.0 Connecting Rod 3
57 9.803-218.0 Spring Washer 6
58 9.803-238.0 Connecting Rod Screw 6
59 8.933-016.0 O-Ring 2.62 x 126.67 1
60 8.717-145.0 Crankcase Cover 1
61 9.803-197.0 O-Ring, Ø 1.78 x 14 1
62 9.803-202.0 Sight Glass, G3/4 1
* Part available in kit (See below)
S4040G.2 PUMP REPAIR KITS

HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
PRESSURE WASHER
SERVICE MANUAL
10
G3035G PUMP ASSEMBLY EXPLODED VIEW
G3035G PUMP ASSY EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.803-819.0 Pump KG3035G1
3@3500,3400 RPM 1
8.904-897.0 Pump LG3035G1
3@3500, 3400 RPM 1
8.904-752.0 Pump HG3035G1
3@3500, 3400 RPM 1
2 9.175-013.0 Unloader, UU1 3500PSI
Banjo 1/2"-1/4" NPT 1
3 9.802-171.0 Nipple, 3/8" x 3/8" NPT
ST Male 1
4 9.802-146.0 Swivel, 1/2" MP x 3/4"
GHF W/Strainer 1
5 8.707-256.0 Pump Protector, 1/2" PTP
140 DEG-p/n 1005 1
6 8.706-958.0 Hose Barb, 1/4" Barb x 1/4"
Pipe 90 D. 1
7 8.706-207.0 Elbow, 3/8" Street 90 Deg
p/n TF3409X6 1
6
1
2
9
8
5
7
4
3
10
ITEM PART NO. DESCRIPTION QTY
8 9.802-190.0 Valve, EZ Start, 3/8"
MPT x 1/8 FPT 1
9 8.706-940.0 Hose Barb, 1/4"
Barb x 1/8" ML Pipe 1
10 9.802-254.0 Hose 1/4" 1.5 ft
11 6.390-126.0 Hose Clamp 2
11

HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
11
PRESSURE WASHER
SERVICE MANUAL
9.803-819.0 KG3035G2
8.904-897.0 LG3035G2
8.904-752.0 HG3035G2
G3035G PUMP EXPLODED VIEW
G3035G PUMP EXPLODED VIEW PARTS LIST
TORQUE
SPECS
Item # Ft.-lbs
16 65
19 18
27 7.6
39 8
47 7
57 13
ITEM PART NO. DESCRIPTION QTY
1 9.803-938.0 Crankcase 1
2* See Kit Below Plunger Oil Seal 3
3*
See Kit Below O-Ring Ø1.78 x 31.47 3
4* See Kit Below Pressure Ring, 15mm 3
5* See Kit Below U Seal Assy, 15mm 3
6* See Kit Below Intermediate Ring 15mm 3
7* See Kit Below Backup Ring, 15mm 3
8* See Kit Below U-Seal Assy, 15mm 3
9*
See Kit Below Support Ring 15mm 3
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 O-Ring Ø1.78 x 15.54 6
14* See Kit Below Valve Assembly 6
15* 9.803-948.0 O-Ring Ø2.62 x 18.77 6
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
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 8.730-825.0 Crankshaft (3035G1) 1
8.730-826.0 Crankshaft (3535G1) 1
8.730-827.0 Crankshaft (4030G1) 1
33 9.802-945.0 Set Screw 1
34 9.803-957.0 Oil Dip Stick 1
35 9.804-581.0 O-Ring 3.53 x 55.56 1
36 9.803-161.0 Needle Roller Bearing 1
37 9.803-183.0 Engine Flange 1
38 9.803-210.0 Spring Washer 4

HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
PRESSURE WASHER
SERVICE MANUAL
12
G3035G PUMP EXPLODED VIEW PARTS LIST (CONT)
ITEM PART NO. DESCRIPTION QTY
39 8.933-020.0 Flange Screw 4
46 9.803-142.0 Crankshaft Seal 1
47*
See Kit Below Plunger Nut 3
48* See Kit Below Copper Washer 3
49*
See Kit Below Plunger, 15mm 3
50*
See Kit Below Copper Spacer 3
51*
See Kit Below O-Ring Ø1.78x5.28 3
52* See Kit Below Teflon Ring 3
53 9.803-964.0 Plunger Rod 3
54 9.803-965.0 Connecting Rod Pin 3
55 9.803-966.0 Connecting Rod 3
56 9.803-218.0 Spring Washer 10
57 8.933-020.0 Connecting Rod Screw 6
58 9.803-202.0 Sight Glass, G3/4 1
59 9.803-197.0 Gasket, G3/4 1
60 9.803-968.0 Crankcase Cover 1
61 9.803-969.0 O-Ring 2.62 x 107.62 1
* Part available in kit (See below)
REPAIR KIT
NUMBER 9.802-622.0 9.802-623.0 8.933-023.0 9.802-603.0 9.802-609.0
KIT
DESCRIPTION
Plunger Seal
15mm
Complete
Seal Packing 15mm Plunger 15mm Complete Valve Plunger Oil Seals
ITEM NUMBERS
INCLUDED 4, 6, 8, 9, 10 4, 5, 6, 7, 8, 9, 10 47, 48, 49, 50,
51, 52 14, 15, 16 3
G3035G PUMP REPAIR KITS

HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
13
PRESSURE WASHER
SERVICE MANUAL
G2530G PUMP ASSEMBLY EXPLODED VIEW
G2530G PUMP ASSY EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 8.707-256.0 Pump Protector, 1/2 PTP
140 DEG, P/N 1005 1
2 9.804-033.0 Pump, KG2530G
2.5@3000, 3400 RPM 1
8.904-893.0 Pump, LG2530G
2.5@3000, 3400 RPM 1
9.802-748.0 Pump, HG2530G
2.5@3000, 3400 RPM 1
3 9.802-171.0 Nipple, 3/8" x 3/8" NPT
ST Male 1
4 9.802-146.0 Swivel, 1/2" MP x 3/4"
GHF W/Strainer 1
5 9.175-012.0 Unloader, UU1 3500 PSI
Banjo 1/2" Closed 2
2
5
1
4
3

HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
PRESSURE WASHER
SERVICE MANUAL
14
G2530G PUMP EXPLODED VIEW
G2530G PUMP EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.803-938.0 Crankcase 1
2*
See Kit Below Plunger Oil Seal 3
3*
See Kit Below O-Ring Ø1.78 x 28.30 3
4*
See Kit Below Pressure Ring, 15mm 3
5*
See Kit Below U-Seal, 15mm 3
6*
See Kit Below Intermediate Ring 15mm 3
7*
See Kit Below Backup Ring 15mm 3
8*
See Kit Below U-Seal, 15mm 3
9*
See Kit Below Support Ring, 15mm 3
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 O-Ring Ø1.78 x 15.54 6
14*
See Kit Below Valve Assembly 6
15*
9.803-948.0 O-Ring Ø2.62 x 18.77 6
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
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
9.804-033.0 KG2530G.2
8.904-893.0 LG2530G.2
8.904-748.0 HG2530G.2
TORQUE
SPECS
Item # Ft.-lbs
16 65
19 18
27 7.6
38 8
40 7
50 13

HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
15
PRESSURE WASHER
SERVICE MANUAL
G2530G PUMP EXPLODED VIEW PARTS LIST (CONT)
ITEM PART NO. DESCRIPTION QTY
39 9.804-585.0 Crankshaft Seal 1
40*
See Kit Below Plunger Nut 3
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 Teflon Ring 3
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)
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
G2530G PUMP REPAIR KITS

HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
PRESSURE WASHER
SERVICE MANUAL
16
UU1 UNLOADER EXPLODED VIEW
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
ITEM PART # DESCRIPTION KIT QTY
17 9.149-006.0 Sliding Connector Guide 1
18 O-Ring Backup A 1
6 x 1.45 x 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
1
2
3
4
5
19
7
8
9
10
11
12
26
14
15
27
18
17
16
6
20
21
22
26
24
25
25
23
13
27
15
27
9.175-018.0
UU1 3500PSI, UNIVERSAL UNLOADER (SPARE)
23
28

HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
17
PRESSURE WASHER Troubleshooting Guide
TROUBLESHOOTING
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.

HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
PRESSURE WASHER Troubleshooting Guide
18
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

HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
19
PRESSURE WASHER Troubleshooting Guide
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
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.

HD, PCA, DBA, DGA • 8.917-990.0 • Rev. 05/11
PRESSURE WASHER
SERVICE MANUAL
20
Date Oil Changed
Month/Day/Year
Estimated Operating
Hours Since Last
Oil Change
Date Oil Changed
Month/Day/Year
Estimated Operating
Hours Since Last
Oil Change
OIL CHANGE RECORD
Check pump oil and engine oil level before first use of your new pressure washer.