Kärcher DB-232439 Service Manual Download

Page: 6 / 17

CART SERIES • 9.801-629.0 • Rev. 07/17

OPERATOR’S MANUAL

PRESSURE WASHER

SPECIFICATIONS

Machine

Pressure Nozzle

Hose

Pump

Unloader

Engine

Model

GPM

(PSI)

Size

Part #

Model

Part #

Engine

Part #

HD 2.3/24 P

2.3

2400

3.0

8.711-722.0

KP2535G

8.923-785.0 8.754-696.0 GC160 (163cc) 9.802-316.0

HD 2.5/27 P

2.5

2700

3.0

8.711-722.0

KP2535G

8.923-785.0 8.754-696.0 GX200 (196cc) 9.802-317.0

HD 3.0/30 P

3.0

3000

3.5

8.711-722.0 KP3035G1

8.923-787.0 9.754-696.0 GX270 (270cc) 8.750-680.0

HD 3.8/35 P

3.8

3500

4.0

8.711-722.0 KS4040GR.3 8.751-195.0 9.175-018.0 GX390 (390cc) 8.750-580.0

HD 3.5/40 P

3.5

4000

3.5

8.711-722.0 KS3540GR.3 8.751-194.0 9.803-900.0 GX390 (390cc) 8.750-580.0

Machine

Pressure Nozzle

Hose

Pump

Unloader

Engine

Model

GPM

(PSI)

Size

Part #

Model

Part #

Engine

Part #

DB-232439

2.3

2400

3.0

8.739-107.0

HP2535G

8.923-771.0 8.754-696.0 GC160 (163cc) 9.802-316.0

DB-252739

2.5

2700

3.0

8.739-107.0

HP2535G

8.923-771.0 8.754-696.0 GX200 (196cc) 9.802-317.0

DB-303039

3.0

3000

3.5

8.739-107.0 HP3035G1

8.923-773.0 8.754-696.0 GX270 (270cc) 8.750-680.0

DB-383539

3.8

3500

4.0

8.739-183.0 HS4040GR.3 8.751-184.0 9.175-018.0 GX390 (390cc) 8.750-580.0

DB-354039

3.5

4000

3.5

8.739-183.0 HS3540GR.3 8.751-183.0 9.803-900.0 GX390 (390cc) 8.750-580.0

ITEM PART NO.

DESCRIPTION

QTY

8.718-980.0 Washer, 5/16" Flat

(2400, 2700 PSI Models)

9.802-807.0 Washer, 3/8" Flat

(3000, 3500, 4000 PSI Models)

8.751-096.0 Label, Regulation 4442.6

8.706-207.0 Elbow, 3/8", Str 90 Deg, Steel 1

(4000 PSI Models)

8.706-940.0 Hose Barb 1/4" x 1/8" Npt Male 1

(4000 PSI Models)

9.802-170.0 Coupler, 3/8" Plug, Female

Steel/Zinc

Machine

Pressure Nozzle

Hose

Pump

Unloader

Engine

Model

GPM

(PSI)

Size

Part#

Model

Part #

Engine

Part #

PC3-24324

2.3

2400

3.0

8.739-380.0

LP2535G

8.923-757.0 8.754-696.0 GX160 (163cc)

9.802-316.0

PC3-27324

2.5

2700

3.0

8.739-380.0

LP2535G

8.923-757.0 8.754-696.0 GX200 (196cc)

9.802-317.0

PC3-30124

3.0

3000

3.5

8.739-380.0

LP3035G1

8.923-759.0 8.754-696.0 EX27 (265cc)

8.713-483.0

PC4-35324

3.8

3500

4.0

8.739-213.0 LS4040GR.3 8.751-177.0 9.175-018.0 GX390 (390cc)

8.750-580.0

PC4-40324

3.5

4000

3.5

8.739-213.0 LS3540GR.3 8.751-176.0 9.803-900.0 GX390 (390cc)

8.750-580.0

Machine

Pressure Nozzle

Hose

Pump

Unloader

Engine

Model

GPM

(PSI)

Size

Part #

Model

Part #

Engine

Part #

DG-232437

2.3

2400

3.0

8.711-722.0

SP2535G

8.923-799.0 8.754-696.0 GC160 (163)

9.802-316.0

DG-252737

2.5

2700

3.0

8.711-722.0

SP2535G

8.923-799.0 8.754-696.0 GX200 (196)

9.802-317.0

DG-303037

3.0

3000

3.5

8.711-722.0 SP3035G1

8.923-801.0 8.754-696.0 GX270 (270)

8.750-680.0

DG-383537

3.8

3500

4.0

8.711-722.0 KS4040GR.3 8.751-195.0 9.175-018.0 GX390 (390)

8.750-580.0

DG-354037

3.5

4000

3.5

8.711-722.0 SS3540GR.3 8.921-766.0 9.803-900.0 GX390 (390)

8.750-580.0

EXPLODED VIEW PARTS LIST (CONT.)

Summary of Contents for DB-232439

Page 1: ...039 1 107 033 0 DB 383539 1 107 034 0 DB 354039 1 107 222 0 DG 232437 1 107 138 0 1 107 244 0 DG 252737 1 107 139 0 1 107 245 0 DG 303037 1 107 140 0 DG 383537 1 107 141 0 DG 354037 1 107 225 0 1 107 246 0 OIL AL ER T WH EN OIL LEV EL LOW ENG INE STO PS IMM EDI ATE LY REA D OW NER S MA NUA L BEF OR E OPE RAT ION LIR E LE MA NUE L D U TIL ISA TEU R AVA NT USA GE VOR INB ETR IEB NAH ME UNB EDI NG T ...

Page 2: ......

Page 3: ...er You should record both serial number and date of purchase and keep in a safe place for future reference Exploded View 4 Exploded View Parts List 5 6 Specifications 6 Gun and Wand Exploded View and Parts List 7 LP3035G1 Pump Exploded View and Parts Lisst 8 9 S 3 Pump Exploded View and Parts List 10 11 UU1 Unloader Exploded View and Parts List 12 VBT Unloader Exploded View and Parts List 13 Troub...

Page 4: ...IZA R SIN ANT ES NO HAB ER LEI DO EL MA NUA L T S C O T E M C S T C S F A D V A S A M R T O S C L F A L R R F P R WARNIN G EXPLODED VIEW 37 44 34 35 36 23 26 14 33 25 26 28 30 31 32 33 6 5 5 2 2 3 3 8 8 11 15 13 7 7 18 17 16 21 1 20 45 8 11 11 11 52 53 4 9 9 44 43 42 10 23 22 24 50 41 40 39 50 49 19 38 22 12 Pump Assy w E Z Start Valve for 3000 3500 PSI Models 27 27 29 27 48 47 18 46 46 42 54 3 5 ...

Page 5: ...e 3 5 40 White 1 8 904 156 0 Nozzle Kit 4 0 3500 PSI 1 8 712 345 0 Nozzle 4 0 0 Red 1 8 712 346 0 Nozzle 4 0 15 Yellow 1 8 712 347 0 Nozzle 4 0 25 Green 1 8 712 348 0 Nozzle 4 0 40 White 1 8 712 398 0 Nozzle Compl QCEM 6540 Brass All Models 1 19 9 803 097 0 Axle 5 8 x 20 125 Long 1 ITEM PART NO DESCRIPTION QTY 20 9 800 006 0 Label HOT 1 21 9 802 713 0 Bolt 5 16 x 1 1 2 NC HH 4 2400 2700 PSI Models...

Page 6: ...80 0 Washer 5 16 Flat 8 2400 2700 PSI Models 9 802 807 0 Washer 3 8 Flat 12 3000 3500 4000 PSI Models 51 8 751 096 0 Label Regulation 4442 6 1 52 8 706 207 0 Elbow 3 8 Str 90 Deg Steel 1 4000 PSI Models 53 8 706 940 0 Hose Barb 1 4 x 1 8 Npt Male 1 4000 PSI Models 54 9 802 170 0 Coupler 3 8 Plug Female 1 Steel Zinc Machine Pressure Nozzle Hose Pump Pump Unloader Engine Model GPM PSI Size Part Mode...

Page 7: ...t 4000 PSI Models 1 9 802 223 0 Gun Sk2 3 8 Inlet Lance 22mm Coupler PC Models Except 4000 PSI Models 1 8 751 269 0 AL12 Eagle3 Trigger Gun DB Except 4000 PSI Models 1 8 750 247 0 Gun M407 All 4000 PSI Models Only 1 3 9 802 219 0 Wand Assy Side Grip w 1 4 Coupler All HD DG Models Except 4000 PSI modesls 1 9 802 220 0 Wand 18 M22 x 1 4 QC PC3 PC4 DB Models Except 4000 PSI Models 1 8 783 040 0 Wand ...

Page 8: ...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 Cooper G3 8 1 ITEM PART NO DESCRIPTION QTY 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 8 25 8 717 137 0 Bearing Cover 2 26 9 803 954 0 Bearing Se...

Page 9: ...opper 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 3 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 Available in kit See below REPAIR KIT NUMBER 8 754 860 0 8 754 861 0 8 754 862 0 8 754 859 0 9 803 937 0 KIT DESCRIP...

Page 10: ...e Assembly 6 13 9 803 193 0 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 8 17 9 803 198 0 Copper Washer 3 8 1 18 9 802 925 0 Brass Plug 3 8 2 23 9 803 201 0 Washer M6 x 16 4 24 9 802 939 0 Hexagonal Screw 9 25 9 803 184 0 Closed Bearing Housing 1 ITEM PART NO DESCRIPTION QTY 26 8 717 225 0 O Ring Ø 2 62 x61 6 1 27 9 802 914 0 Snap Rin...

Page 11: ...ng Washer 6 56 9 803 238 0 Connecting Rod Screw 6 57 8 933 016 0 O Ring 2 62 x 126 67 1 58 8 751 229 0 Crankcase Cover 1 59 9 803 197 0 O Ring Ø 1 78 x 14 1 60 9 803 202 0 Sight Glass G3 4 1 Part available in kit See below REPAIR KIT NUMBER 8 725 358 0 8 725 359 0 8 933 023 0 9 802 603 0 9 802 609 0 KIT DESCRIPTION Plunger U Seal 15mm Complete U Seal Packing 15mm Plunger 15mm Complete Valve Plunge...

Page 12: ...8 UNF D 1 15 O Ring 12 ID x 2 CS A D 2 16 O Ring 6 ID X 2 CS A D 1 ITEM PART DESCRIPTION KIT QTY 17 9 149 006 0 Sliding Connector Guide 1 18 O Ring Backup A D 1 6 x 1 45 x 1 68 19 Ball Housing Assy C D 1 20 O Ring 6 75 x 1 78 BN80 A D 1 21 Spring Seat C D 2 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 24 8 917 698 0 Banjo Bolt 3 8 Short 1 2...

Page 13: ... 1 15 8 754 936 0 O ring Ø2 62 x 10 78 A 1 16 9 803 920 0 Banjo Bolt 1 2 w 1 4 Port 1 VBT UNLOADER EXPLODED VIEW VBT UNLOADER EXPLODED VIEW PARTS LIST ITEM PART DESCRIPTION KIT QTY 17 9 803 914 0 Seal Washer 1 2 1 18 8 754 937 0 Bypass Manifold 1 19 9 802 892 0 Outlet Connector 3 8 MPT 1 20 9 803 191 0 O ring Ø2 62 X 17 13 A B 1 21 8 933 017 0 Poppet Spring B 1 22 8 754 939 0 Poppet B 1 23 8 754 9...

Page 14: ...ump valves Contact local dealer Nozzle is obstructed Blow out or remove debris with fine needle Pump sucking air inlet hose leaking Check all pump lines and connections PRESSURE LOW AFTER PERIOD OF NORMAL USE Nozzle worn Replace nozzle Unloader valve worn Replace unloader valve ENGINE WILL NOT START OR STOPS WHILE OPERAT ING Low oil shutdown Fill engine with oil Out of gas Fill fuel tank Water in ...

Page 15: ... 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 manufac turers detergent Detergent filter valve is at low est 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 deterg...

Page 16: ...vel before first use of your new pressure washer 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 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 hour...

Page 17: ...Form 9 801 629 0 Revised 07 17 Printed in U S A or Mexico ...

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