OPERATION MANUAL
OPERATION & MAINTENANCE
MANUAL
IMPORTANT:READBEFOREOPERATING
HIGH PRESSURE WASHERS
NATURAL GAS & PROPANE
HN SERIES
NATURAL GAS HEAT LINK SERIES
HYDRO TEK SYSTEMS, INC.
10418 Enterprise Drive
Redlands, CA USA 92374
PH(909)799-9222 FAX(909)799-9888
Website: www.hydroteksystems.com
© 2003 Hydro Tek Systems, Inc. 8/2004
$15.00
TABLE OF CONTENTS
3
INTRODUCTION ............................................................................................................................... 4
Statement of Warranty
SAFETY WARNINGS ......................................................................................................................... 5-6
Electrical Precautions
Fire Precautions
Ventilation Precautions
Spray Injection Precautions
Personal Hazard Precautions
OPERATING INSTRUCTIONS ......................................................................................................... 6-7
Before Start Up
Operation
Shut Down & Antifreeze Protection
SYSTEM INFORMATION ................................................................................................................. 8-11
Power System ........................................................................................................................... 8
Electric Motor
Power Transmission System - direct, & belt drive
Pumping System ...................................................................................................................... 8
Pump
Unloader and Pressure Relief Valve
Chemical Injection System - inlet & downstream injection
Water Supply - direct
Heating System ........................................................................................................................ 9
Coil/Heat Exchanger System - temperature & flow switch controls, lights
Natural Gas Burner
Pressure Delivery System ...................................................................................................... 10-11
Discharge Hose
Gun/Wand Assembly - trigger gun, wand, & quick coupler
Nozzles - spray nozzles and steam nozzle
Accessories - wet sandblaster, turbo nozzle, hoses and reels, wands, injectors............12
TROUBLE SHOOTING GUIDE ........................................................................................................13-14
SERVICE RECORD ........................................................................................................................... 15
SERVICE/MAINTENANCE INFORMATION ..................................................................................... 16
WIRING DIAGRAMS BY SERIES................................................................................................Enclosed
EXPLODED VIEW BY SERIES ...................................................................................................Enclosed
TEST SPECIFICATIONS ...........................................................................................................Enclosed
WARRANTY CARD .... ................................................................................................................Enclosed
INSTALLATION INSTRUCTIONS...................................................................................................Enclosed
4
INTROD
INTRODUCTION:
The employees and management of HYDRO TEK SYSTEMS, INC. thank you for selecting our products. The production and quality
assurance personnel have taken the greatest care in the assembly process to ensure that your new High Pressure Cleaner is of a quality
and standard acceptable to both you the customer and us the manufacturer.
This operators manual was compiled for your benefit. By studying and following the safety, installation, operation, maintenance,
and troubleshooting information contained within, you can look forward to many years of trouble free service from your equipment.
Upon receipt of the equipment, please inspect for any concealed freight damage. Should you find damage has occurred during
shipping, do not return the damaged merchandise to Hydro Tek, but file a claim immediately with the freight carrier involved.
Please locate the enclosed warranty registration card. Determine Series of your machine (Ultimate Line models include blue labeling and
extra operational features. Pro Line models include red labeling and the model numbers end in "H" or "C".) Fill out and return it to activate
the warranty on your machine. Also enclosed are installation instructions.
Please note that the owner/user has certain obligations under the terms of the warranty for this equipment, and as such you are
encouraged to always have every person who will operate the equipment, read and become familiar with the contents of this owners
manual, prior to their using this equipment.
Contact your AUTHORIZED HYDRO TEK DEALER or a trained HYDRO TEK SYSTEMS service engineer if problems occur, or if
installation is required.
THERE ARE NO USER SERVICEABLE COMPONENTS ON THIS EQUIPMENT.
ULTIMATE LINE LIMITED WARRANTY
FIVE YEARS PARTS + ONE YEAR LABOR: Cat Pump
crankcase, heater coil (wet end/freezing excluded)
THREE YEARS PARTS + ONE YEAR LABOR: Fuel, water
tanks, stainless steel panels, frames (finish excluded)
ONE YEAR PARTS + ONE YEAR LABOR: Electrical
componants and electric motors
90 DAY PARTS, NO LABOR: Accessories, balance of
components, and wear items but not limited to unloaders,
hoses, wands, guns, nozzles, quick couplers, filters, belts,
seals, o-rings and pump packings
PRO LINE PARTS WARRANTY
ONE YEAR LIMITED PARTS WARRANTY- Provided by Hydro
Tek on Pro Line machines excluding normal wear items
listed below.
THREE YEAR COIL WARRANTY - Three year parts warranty.
Labor, freezing & descaling excluded.
FIVE YEAR PUMP WARRANTY- Up to five year limited
warranty on crankcase of the pump provided by the
respective pump manufacturer.
90 DAY WARRANTY ON OPTIONAL ACCESSORIES
STATEMENT OF WARRANTY:
Hydro Tek Systems, Inc. (Hydro Tek) warranties the Ultimate and Pro Line pressure washers to be free from defects
in material and workmanship for the time periods stated above calculated from the date of the original retail purchase.
Hydro Tek will make the required repairs, or at Hydro Tek's option, provide replacement components if found to be
defective in material or workmanship in the reasonable judgment of Hydro Tek. This warranty only extends to the original
retail purchaser, and is subject to the exclusions shown below. Any parts replaced under this warranty will resume the
remainder of the parts warranty period.
This Warranty does not apply to and Hydro Tek is not responsible for:
1. Normal wear items such as Unloader Valves, Discharge Hoses, Guns, Wands, Nozzles, Quick Couplers, Brushes,
Filters, Belts, Seals, O-rings, and Packings.
2. Labor charges or costs related to the removal of the defective part, field labor charges, transportation to service
center and costs to return it to Hydro Tek, or service charges for scheduled maintenance or any adjustments.
3. Damage due to freezing, abrasive fluids, chemical deterioration, and scale build up (finish on frames and metal
excluded).
4. Damage from fluctuation in electrical or water supply.
5. Damage resulting from failure to follow manufacturer's maintenance instructions.
6. Damage resulting from misuse, neglect, accidents, modifications, alterations, abuse, or incorrect installation.
7. Products operated outside of specified limits or intended use as specified in the operation manual.
8. Repairs made necessary by the use of parts which are either not obtained from or approved by Hydro Tek.
9. Actions or inactions by any Hydro Tek distributor giving rise to or causing a warranty exclusion or promise of additional
warranty.
10. Warranty on engines, motors, and pumps, which are warranted by their respective manufacturers and are serviced
through the manufacturer's service centers.
IMPORTANT SAFETY WARNINGS: SAVE THESE INSTRUCTIONS 5
Do not spray high pressure water on to the machine.
LIMITATION OF LIABILITY
Hydro Tek's responsibility with respect to claims is limited in making
the required repairs or replacements. Hydro Tek reserves the right to
change or improve the design of any of its products or illustrations
without assuming any obligation to modify any product previously
manufactured.
THERE IS NO OTHER EXPRESSED WARRANTY.
This supersedes any and all previous warranty statements for
products purchased after June 1, 2001. Hydro Tek is not liable for
indirect, incidental or consequential damages including but not limited
to: The cost of substitute equipment, loss of revenue, pecuniary expense
or loss, or any damages whatsoever arising out of the use or inability to
use a Hydro Tek product. Hydro Tek disclaims all implied warranties,
including those of merchantability and fitness for use or a particular
purpose. It is the buyer's responsibility to ensure installation and use
of Hydro Tek products conforms to local codes.
Proof of purchase date required to obtain warranty.
ELECTRICAL PRECAUTIONS:
1. Observe all State, Local, and National codes for the installation
of your electrically powered washer.
2. For a grounded product rated 250 volts, single phase, or less: This
Product Is Provided With A Ground Fault Circuit Interrupter Built
Into The Power Cord Plug. If Replacement Of The Plug Or Cord Is
Needed, Use Only Identical Replacement Parts.
3. GROUNDING INSTRUCTIONS:
Cord Connected, Grounded Products:
This product must be grounded. If it should malfunction or breakdown,
grounding provides a path of least resistance for electric current to reduce
the risk of electric shock. This product is equipped with a cord having
an equipment-grounding conductor. The plug must be plugged into an
appropriate outlet that is properly installed and grounded in accordance
with all local codes and ordinances.
Danger - Improper connection of the equipment-grounding conductor can result in a risk of electrocution. Check with a qualified
electrician or service personnel if you are in doubt as to whether the
outlet is properly grounded. Do not modify the plug provided with
the product, do not cut off the ground pin - if it will not fit the outlet,
have a proper outlet installed by a qualified electrician. Do not use
any type of adaptor with this product.
4. To comply with the national electric code, this pressure washer
should only be connected to a receptacle that is protected by a ground
fault circuit interrupter (GFCI).
5. EXTENSION CORDS:
Use of extension cords is not recommended.
6. NEVER operate an electrically powered washer after it has tripped
a breaker or a ground fault device without having the reason
for the trip determined by an authorized service engineer or
competent electrician.
7. Use only in a dry area. Do not handle electrical cords and plugs when
they are wet, when your hands are wet, or when standing in water.
8. Disconnect power supply before making any repairs or adjustments.
9. Unit must be grounded. A grounding lug is provided on the machine.
FIRE PRECAUTIONS:
1. Propane bottle equipped units must have the bottle removed from the
unit and placed 10 feet away before start-up.
2. NEVER operate this equipment in the presence of flammable vapors,
dust, gases, or other potentially combustible materials.
3. AVOID contact with the exterior of the coil/heat exchanger assembly and
exhaust stack to prevent burns.
4. DO NOT store fuel or other flammable materials near the burner or any
other open flame.
5. To avoid burns NEVER stand over burner exhaust outlet . Burner may
start at any time once power is turned on.
6. Do not touch burner exhaust port, mufflers, or wands/hoses as
contact may cause burns. Use designated gripping areas.
7. Burner on/off switch must be placed in the OFF position when
the pressure washer is not being used.
VENTILATION PRECAUTIONS:
1. DO NOT run burner in an enclosed area. Exhaust gases contain carbon
monoxide, an odorless deadly poison.
2. Observe all State, Local, and National codes providing for indoor
use or installation of this unit.
3. If natural gas or propane odor is present, and/or unit does not light,
turn of all controls, close gas cock and call your gas company for
service.
4. Know the detergents you are using. Read and follow the
directions on the detergent labels.
PERSONAL HAZARD:
1. DO NOT remove belt guards or electrical covers while motor is
operating or when the power is connected.
2. DO NOT move engine powered machinery while the engine is
operating.
2. DO NOT lock the trigger on the gun valve in the on position.
3. DO NOT exceed recommended operating pressure or temperature.
4. KEEP HANDS CLEAR OF BELTS AND MOVING PARTS.
5. Do not operate the product when fatigued or under the influence of
alcohol or drugs.
6
SAFETY WARNINGS/OPERATING
SPRAY INJECTION PRECAUTION:
3. CONNECT HOSE AND GUN ASSEMBLY
INSTRUCTIONS
1. Fluid from high pressure spray or leaks can penetrate the skin
4. CONNECT THE WATER SUPPLY & TURN WATER ON:
2.
3.
2.
3.
4.
5.
and cause serious injury. If any fluid appears to penetrate the
skin get emergency medical help at once. DO NOT treat as a
simple cut. Tell the physician exactly what fluid was injected. For
treatment instructions have the physician call your local poison
center. Without proper treatment, complications can develop.
WARNING - Risk of injection or severe injury to persons - Keep
clear of nozzle. DO NOT direct discharge stream at persons. This
machine is to be used by trained operators. Keep operating area
clear of all persons.
CAUTION: Hot discharge fluid - DO NOT touch or direct
discharge stream at persons. Gun kicks back - Hold with both
hands. Stay alert - Watch what you are doing.
Always wear protective eye goggles when operating the
equipment. Additional protective items such as a rubber suit
and boots, gloves, and respirators are advisable, particularly
NEVER point the spray gun at yourself or other persons. Do
not lock the trigger in the "ON" position. Use only 48" long
wands on machines producing over 3000 psi. Also, only use
straight wands or wands with a bend of 10° or less.
NEVER put your hands or fingers over the spray tip or over
leaks which may occur on the discharge hose or other
components.
Always wear protective eye goggles when operating the
equipment. Additional protective items such as a rubber
suit, gloves, and respirators are advisable, particularly
when using cleaning detergents with a corrosive content.
Know the detergents you are using. Read and follow the
directions on the detergent labels.
PERSONAL HAZARD:
1. DO NOT remove belt guards or electrical covers while engine
is operating or when the power is connected.
2. DO NOT lock the trigger on the gun valve in the on position.
3. DO NOT exceed recommended operating pressure or temperature.
4. KEEP HANDS CLEAR of Belts: Some units equipped with
auto on may start at any time when power is connected.
BEFORE START UP:
HN SERIES
1. CHECK OIL AND FLUID LEVELS: Check pump oil by
locating the oil view window and fill to the red dot.
2. INSTALL LEGS TO BASE. Legs are required for safe pilot
operation and reduce riskof fire. The HN Legs include
forklift fork clearance slots to allow leg installation after
the HN is removed from the pallet. To reduce risk of
serious injury, always block load mechanism in place
before working:
Maintain an adequate supply of water using a ¾" I.D.
steel pipe with a pressure between 25 and 60 PSI. Burner
power switches should be off before starting. Do not run
dry for longer than one minute.
5. NATURAL GAS/PROPANE GAS: Connect gas supply
using appropriate shut off cock and recommended gas
plumbing procedures, including the use of a soap or leak
detection solutionon all fittings.(Contact your gas
supplier). Note that a Draft Diverter is not included as a
standard feature with the machine. Draft diverters are
required on HN models for better heating efficiency and
improved pilot ignition when cycling gun.Gas regulator,
gas and water supply lines are not included with the
machine.
OPERATION:
1. STARTING:
Connect power supply and ensure that all wiring connections and voltages are of sufficient rating to comply with the
equipments requirements. Turn pump power switch on.
Press "Reset" button to start motor if equipped with a Wash
Station Remote.
2. CONNECT SPRAY NOZZLE: Connect Nozzle securely to
spray wand and/or close pressure adjusting knob on dual
wand, hold gun firmly, squeeze trigger for high pressure spray.
3. START BURNER: Turn burner switch on. Unit is equipped
with an automatic lighting pilot with a 90 second lockout.
If burner does not light within 90 seconds turn burner
switch off then on again to start ignition sequence over.
Turn the thermostat to the desired temperature. Squeeze
the trigger on the spray gun and the burner will begin
heatingthe water. It will stop firing whenever the water
spray is off or if the temperature setting is exceeded.
4. STEAM: Insert steam nozzle and turn thermostat to 250º
steam setting. The steam nozzle is sized for approximately
25% less water volume than the hot water mode.
5. WASH STATION REMOTE: Install station on the wall at
a convenient wash site. ("R" models only) Control
switches in the Wash Station Remote will over-ride and
operate the HN Pump, Burner, and Soap Valve functions.
Soap (Chemical) Valve at machine must be preset before
soap switch at remote is activated. WARNING: Do not
leave soap switch in the "ON" position when soap is
depleted. Pressure drop will occur due to air intake and
harm system components. Remote systems have an Auto
off feature with an adjustable timer that can be set to your
preference.
OPERATING INSTRUCTIONS
HN SERIES OPERATING
CONDITIONS
Heat rise will vary depending on inlet water temperature and
environmental conditions. Natural gas burners are preset from
the factory for an inlet water temperature of 60-70 degree F and
approximately 4" of water column natural gas pressure on the
outlet of the gas valve for a 140 degree F heat rise. If the water
inlet temperature is 20 degree F colder than the factory setting
the heat rise will be approximately 6% less. Adjustments can
be made to the gas valve outlet pressure by a qualified gas
technician to increase the outlet gas pressure to 5" water
column with the use of a manometer to gain higher heat rise
and compensate for colder water inlet conditions if they
persist year round.
Inlet gas pressure when measured while the burner is on with
a manometer placed right before the gas valve, needs to be
between 6 and 7" of water column natural gas pressure and
properly sized gas supply piping is required to achieve full
factory rated heat rise. (See "INSTALLATION GUIDELINES"
include with this manual)
HL SERIES OPERATION
1. Connect power cord/GFCI to power supply.
2. Select spray nozzle, connect to spray wand and lock back
collar on quick connect.
3. Connect water supply garden hose (Minimum 35 PSI
required) turn water on.
4. Move L.P. tank off unit and away 10 feet. Open valve.
5. Turn pump switch on and pull trigger: Turn switch to burner
position and adjust thermostat for hot water cleaning.
6. For soap application: insert black soap nozzle in wand & pull
trigger to start soap flow.
7. To shut off unit, turn off burner/pilot switch. Close the
propane tank valve, pull trigger on gun until water is cool.
SHUT OFF BOTH SWITCHES WHEN UNATTENDED OR
WHEN REFUELING. UNIT MAY START AT ANY TIME.
Warning: Cool down burner before shutting off pump
when in the steam or heating mode.
7
WASHING OPERATION &
TECHNIQUES
When washing always start from the bottom up, and do
the final rinse from the top down. This will keep the water from
streaking the surfaces that are being cleaned. When applying
chemicals, it is also best to start from the bottom and work up.
In areas where there is no grease or oil present, and the
dirt is loose, cold water will be sufficient. When it comes to
grease, oil, and hard to clean dirt, hot water and/or chemicals
can make the job easier, and speed up the cleaning process.
For applications that require even more heat and where water
use/runoff must be minimized, switch to the steam mode (if
equipped) and adjust the thermostat for up to 250º steam.
For general washing use a broad pattern spray nozzle
such as the 40 degree nozzle. Rinsing and delicate surface
washing is best performed by backing away from the surface
and using the broad spray nozzle. In areas where the cleaning
is more difficult and in smaller areas such as cracks and holes
use the narrow spray nozzles, 0 or 15 degree.
Chemicals can be applied in a couple of different ways. One
way is with a hand spray pump. The other is with the chemical
system on the equipment; either down stream or high pressure
depending on the system you have. When using the high
pressure (pump inlet) chemical system do not use any caustic
chemical as this may cause damage to the pump. For very
harsh chemicals it is best to use the hand sprayer. First wet
the surface and wash off heavy debris. Test the surface to be
sure the chemical won't harm it. Then apply the chemical & let
work for a couple of minutes for them to take affect before
rinsing. Do not allow chemicals to dry on the surface.
When rinsing off the chemicals always start from the top
down. When finished using the chemical be sure to rinse out
the chemical line and valve with fresh water to prevent
clogging.
SHUT DOWN:
1. Turn Burner switch to the off position.
2. Rinse and close Chemical Valve. Turn off Chemical Solenoid
Switch if equipped.
3. Squeeze the trigger on the Spray Gun until the water
becomes cool..
4. TURN MOTOR SWITCH OFF with the appropriate controls.
5. Turn off water supply.
6. Squeeze trigger to release any trapped pressure in discharge hose.
7. Turn gas valve off when not in use for an extended period.
8. DISCONNECT & STORE HOSES.
9. WINTERIZE: If not used in the winter, store in heated
space or antifreeze the unit. Run the machine until the float
tank is near empty, fill with a 50% mix of water and antifreeze and run until antifreeze appears at the high pressure
outlet. If unit is equipped with a blowout valve, it may be
blown out with compressed air in addition to using antifreeze solution. On direct feed units (no float tank), use a 5'
garden hose to draw the antifreeze mix from a bucket or
blow out the unit with compressed air until only air and no
water comes out of the discharge.
8
SYSTEM INFORMATION
POWER SYSTEM:
ELECTRIC MOTORS: All electric motors contain a
manual or automatic thermal overload
which will shut down the motor if it
overheats. If the overload or starter
shuts down the motor, have an electrician or an authorized Hydro Tek
distributor check for electrical problems. The motor can be reset by depressing the red
overload button located on either the motor or the
starter, (as shown above). The automatic overload will
reset itself after the motor has cooled.
HORSE 115V WIRE 208V WIRE 208V WIRE 230V WIRE 230V WIRE 460V
POWER 1PH SIZE 1PH SIZE 3PH SIZE 1PH SIZE 3PH SIZE 3PH
1.5
2
5
6.5 / 6
7.5
10
15
15A
20A
N/A
N/A
N/A
N/A
N/A
12/3
12/3
N/A
N/A
N/A
N/A
N/A
N/A
N/A
26A
N/A
N/A
50A
N/A
N/A
N/A
10/3
N/A
N/A
#8
N/A
N/A
N/A
N/A
N/A
N/A
32A
40A
N/A
N/A
N/A
N/A
N/A
#8
#8
10A
12A
24A
27A
35A
48A
N/A
14
14
10/3
10/3
#8
#8
N/A
N/A
N/A
N/A
22A
N/A
30A
38A
N/A
N/A
N/A
12/4
N/A
#10
#8
N/A
N/A
N/A
13A
N/A
16A
20A
WIRE
SIZE
N/A
N/A
N/A
14/4
N/A
#12
#12
Never spray water on the unit, or damage to the electric
motor(s) may occur. Consult the factory if running an
electric machine from a generator A dedicated breaker
of sufficient ampere rating should be installed by an
electrician. Refer to the chart above for electrical
requirements: some models are 208 Volt compatible.
Check with your local Distributor for more information.
The 24 Volt AC Burner control Transformer is wired
for 230 Volts AC input. Rewire the transformer for 208
Volt AC if input voltage is changed to 208 Volt AC.
If your unit is equipped with a ground fault interrupter, it
will have to be reset whenever it is plugged in or if a
ground fault interruption occurs. Test regularly for
proper operation.
POWER TRANSMISSION:
DIRECT DRIVE: Pump is bolted directly to the motor/
engine. If pump needs to be removed, do not force off
by prying or damage could occur. When reassembling,
coat the entire motor shaft with heavy grease, or a
generous amount of anti-seize.
BELT DRIVE: Check belt
condition, alignment and tension
periodically. Replace belts
when they show signs of wear
or cracking. Tighten belts by
loosening the mounting bolts on the pump and generator
to permit rail adjustment. Belts should deflect 1/4" - 1/2"
with 2 pounds of force.
PUMPING SYSTEM:
PUMP: The pump is a positive displacement, oil bath
crankcase, triplex plunger type. It contains 3 plungers
which move forward and backward in a cylinder to
propel water past 3 inlet valves and 3
discharge valves into a high pressure
manifold.
The crankcase oil window should be
checked for oil level and clarity and the pump for oil or
water leaks before each use. The sight window is
located at the rear (opposite the head) of the pump and
should be filled to the middle with Pump Oil , available
at your Hydro Tek dealer. If the oil becomes milky in
color, moisture is entering the crankcase. Change the oil
and contact your authorized Hydro Tek dealer if the
problem persists.
To increase pump life, prevent cavitation (air
bubbles), overheating, and dirty water. Cavitation can
be prevented by keeping filters clean and checking for
air in pump feed lines. Do not run the pump in the
bypass mode (pump running with the trigger gun off), for
a period of more than 5 minutes or the pump will begin
to overheat (maximum water temperature is 145ºF).
Do not run pump dry. Protect from freezing. Do not run
a frozen pump. Wait until it is thawed out to run.
UNLOADER AND PRESSURE RELIEF VALVE: The
unloader valve is preset at the factory to govern
the proper output pressure of your machine. It
will release the pressure of the pump output
back into the inlet if the trigger on the spray gun
is released. NEVER increase the set pressure
on the unloader to exceed the specifications for
your machine. The unloader should be adjusted only by qualified personnel.
PRESSURE RELIEF VALVE. In the unlikely event that
your unloader fails, or if the burner overheats
and builds excessive pressure, the pressure
relief valve will vent the pressure into the
atmosphere. If this occurs, turn off the machine and have it checked by an authorized dealer. The
pressure relief valve will automatically reset itself.
SYSTEM INFORMATION
BURST DISK TECHNOLOGY: This additional safety
feature functions to protect the coil and other components
from overpressurizing from the heating system
and high system spikes of pressure. If this
component ruptures, you should take the machine in to an authorized Hydro Tek dealer. Do
not plug off and continue to run.
CHEMICAL INJECTION SYSTEM:
With an inlet chemical injection system the chemicals are
introduced at the inlet of the pump and controlled with a
chemical metering valve. The pump is fed by a float tank
to create a slight vacuum which draws up the chemical into
the inlet manifold of the pump, mixes it with the water, and
sprays it out of the nozzle under high pressure.
Open the chemical valve only when the pickup tube is
submersed in a solution or air will enter the pump and
you will lose pressure and the pump will run rough.
Do not use highly corrosive detergents or acid type
cleaners, and be sure to rinse and close the chemical valve
after each use or the chemical line and check valve may
become obstructed. Chemicals should be between
5-9PH. Consult Hydro Tek for chemical compatibility.
Chemical abuse is not covered under warranty.
An optional DOWNSTREAM INJECTOR is available
if harsh chemicals need to be applied. The
downstream injector will apply chemicals
only at low pressure. If equipped standard
with downstream injection, adjust concentration level by turning brass collar on the
injector, or the knob on pump or control panel. Read and
follow all safety instructions on the detergent bottle.
9
FLOAT TANK WATER FEED: A float tank is usually
used to regulate the incoming water supply to the pump and
introduce chemicals into the inlet of the
pump. The float tank and filter (located
inside the tank) should be flushed out if
debris accumulates in the bottom. If the float
tank overflows or runs out of water, adjust
or replace the float valve inside the tank and check the inlet
water feed pressure.
WATER TREATMENT: The inlet water can be deionized for spot free rinse or softened to make detergent clean
more effectively. Do not use deionized water through the
coil on a hot water machine or coil corrosion will result.
Water softeners, however, will reduce coil scale deposits
and should be installed if your water is especially hard
HEATING SYSTEM:
COIL/HEAT EXCHANGER SYSTEM: The heat
exchanger contains a continuous coil of
pipe which forms a cold water jacket
around the outside of the heating area. It
is double wrapped with ceramic blanket
insulation and a stainless steel cover.
When the water is heated, scale
(calcium) will begin to form on the inside of the coil pipe
depending upon the hardness of the water in your area.
The coil can be DESCALED by using a scale remover
(Part # CB105) available at your authorized Hydro
Tek dealer. It is necessary to perform this service
only when a noticeable pressure drop is detected
across the coil. Follow directions to avoid damage.
Wear safety glasses.
TEMPERATURE SWITCH: The burner is equipped
with a high temperature limit switch which will shut off the
burner when the water temperature
becomes too hot. Hot water machines are equipped with an adjustable thermostat so that the operator
can control the outlet water temperature. The burner will automatically
cycle on and off to maintain the desired temperature.
WATER SUPPLY: An adequate water supply must be
maintained to the pump at all times. If the inlet flow is too low
or if there is air in the water supply, the pump will run rough,
pulsate and lose pressure. Maximum inlet water temperature is 145ºF. If the pump is run dry, it can quickly overheat.
The water is filtered by a garden hose adapter screen.
Clean and replace as required or install a large capacity
strainer to insure a clean supply of water.
DIRECT WATER FEED: Maintain an inlet water pressure between 25 PSI and 60 PSI using a ¾" I.D. hose.
Install a back flow preventer on your supply hose if State STEAM INSTRUCTIONS: If your unit is steam - caor Local ordinances require it. Install a water regulator if pable, install the green steam nozzle, turn thermostat to
your water pressure exceeds 60 PSI.
250° F.
10
SYSTEM INFORMATION
PRESSURE/FLOW: The burner is equipped with either
a pressure switch or flow switch to control the burner. When
the trigger on the spray gun is squeezed, water begins to
move through the coil and pressurize. The flow/pressure
switch turns the burner on and begins to heat the water.
Whenever the water spray stops or if the water is shut off,
the burner will shut off.
WARNING: Burner should fire only when the
trigger is squeezed and spraying water, if it comes on at any
other time, shut off the machine and have it serviced.
NATURAL GAS/ PROPANE GAS BURNER: The gas
burner uses a vertical coil with a natural draft aspirating
type burner. It has electronic ignition for an auto lighting
burner pilot with a 90 second lockout for safety. If the
burner does not light within 90 seconds turn the burner
switch off and on again to start the ignition sequence over.
The vertical coil can be connected to an exhaust flue, and
must have a draft diverter mounted at a maximum 30"
above the unit. Exhaust flue must never run horizontal,
check your local code for exhaust flue size requirements.
Do not store any wood, pallets, hoses, or any other
flammable material under or near the burner area.
NG Pipe Chart: For 450,000 BTU
Length
0-50 FT.
51-150 FT.
151-200 FT.
Pipe Size
1 1/4"
1 1/2"
2"
IGNITION SENSOR / ROD: After extended ignition
arcing, insulating deposits may form on the ignition rod,
reducing the arc intensity. Also, because of the high heat
zone beneath the burner, premature failure of the rubber
insulation covering on the ignition wire may cause arcing to
a ground before reaching the pilot ignition rod.
PRESSURE DELIVERY SYSTEM:
DISCHARGE HOSE: Use only a wire braid hose rated
for the output pressure and temperature of the machine.
Single wire braid hoses are generally
rated from 2500 to 3000 PSI and
double wire braid from 4000 to 4500
PSI. Additional hose lengths can be
added with quick couplers with a
minimal loss in pressure of about .5
PSI per foot. Inspect hoses for wear and replace if
necessary. Avoid kinking or running over the hose to
extend the hose life.
WARNING: Hydro Tek hot water machines require special 250º Rated hose to operate in the steam
mode. If the hose is not replaced when worn or if it is not
replaced by a Hydro Tek original equipment hose, it may
burst and serious injury and burns could result.
QUICK COUPLERS: The quick couplers on the high
pressure hose and spray nozzle make
it easy to change nozzles or hoses.
When connecting hoses or nozzles,
be certain that the collar on the
quick coupler snaps back to the
locked position or the nozzle or
hose may come loose when pressure is applied to it. If the
quick connect begins to leak, replace the O-ring (specify
Viton or EDPM material) located in the female socket
coupler. Grease the coupler periodically to make it work
smoothly. Replace if it becomes worn. Twist couplers are
used on the wands so they can be interchanged.
TRIGGER GUNS: The trigger gun is merely a valve that
turns water spray on and off. If it begins to leak
or fails to shut off, replace or repair the valve
assembly. Never lock the gun in the on position
or point it at any person or any part of the body.
Machines that spray steam only are equipped
with an open gun that does not shut off the water
spray.
SPRAY WAND: Wands are available in 2 to 6 foot
lengths for various cleaning applications. If the unit is
equipped with a dual wand you can adjust the pressure by
turning the knob on the valve to divert part of the water
through the low pressure nozzle.
SYSTEM INFORMATION
NOZZLES: The spray nozzle is a precisely machined
orifice made of hardened stainless steel. The
orifice size is matched to the output of your
machine to attain the proper flow and pressure
that your machine was designed for. The orifice or
hole of the nozzle will begin to get larger as the nozzle
becomes worn. For optimum performance, replace the
spray nozzle to maintain the full output pressure of your
machine. The nozzle installed in your machine from the
factory is designed to allow only about 90% of the water
being pumped to discharge out of the nozzle. The remaining 10% is bypassed back into the inlet water supply by the
unloader/regulator valve. If an incorrect nozzle size is used
the maximum flow and pressure of the machine cannot be
achieved and the pressure unloader valve can wear prematurely. When replacing the nozzle match to one size under
the flow and pressure output of the pump.
The nozzle is usually connected to the wand with a quick
coupler. Be sure the collar on the quick coupler snaps
back to the locked position, or the nozzle could be lost
when the trigger on the spray gun is squeezed. Never
connect the spray nozzle directly to the trigger gun without
a wand or injury could result. Never place hands or fingers
over the nozzle tip.
The nozzles generally come in three different spray
angles, 0º, 15º, and 40º. The different spray angles of a
given size of nozzle do not change the output pressure of the
machine, just the impact force and surface coverage of the
water spray. The 0º nozzle sprays a straight stream which
impacts the surface very hard but does not cover a very
wide area. Use the 0º nozzle with care because it can
damage the surface you are spraying with its high impact
and long reaching spray.
The 15º nozzle sprays out a flat stream at a 15º width. It
gives you less impact power but covers a wider area with
one pass of the spray wand. As you back away the
spraying nozzle from the surface, the spray impact will
decrease.
The 40º nozzle spreads the water stream over an even
wider area to give you less impact for delicate surfaces.
Some machines come with one 15º nozzle which covers
most cleaning applications. Additional nozzles can be
added and fitted with quick couplers so that the nozzles can
be interchanged for various applications.
The steam nozzle sprays less water than the other high
pressure nozzles, so the water is discharged at a higher
temperature. (Up to 250º F).
11
12
ACCESSORIES:
WET SANDBLASTER
The wet sandblaster is a system that introduces sand into the water stream for abrasive
blasting. It is especially effective for graffiti or
paint removal. Performance of the sand unit
is directly related to the output of your high
pressure washer. The sand is mixed with the
water at the sand head in a tungsten carbide nozzle.
A vacuum is created in the sand nozzle which draws a
sand and air mixture up the sand hose. If the sand becomes
wet or the sand nozzle becomes plugged the vacuum will
be lost and the sand will quit flowing. The sand probe can
be poked directly into a bag or bucket of sand to draw it
up the sand hose. Do not cover the air intake port on the
top of the sand probe or the sand flow will be disrupted.
Uncoil the sand hose completely before use to improve the
sand flow and replace the sand hose when it becomes worn.
The carbide sand mixing nozzle can be unscrewed and
replaced when worn.
Use bagged silica sand for best results through the
sandblaster. Use 16 to 20 grit (course) sand for rust or
concrete. Use 30 grit (fine) sand for fine metal surfaces or
wood. Do not use wet sand or mix different grits of sand.
A sand pot is available for convenient sand storage.
Always use safety goggles and protective clothing when
operating the wet sandblaster.
TURBO NOZZLE
The turbo nozzle multiplies the power of
your machine by rotating the spray jet and
making the water impact the surface harder
to give better cleaning results. Simply replace the spray nozzle with the turbo nozzle and squeeze
the trigger on the spray gun with the burner off for high
pressure spray. "Turbo Laser" type nozzles cannot be
used with water over 190º or life of the turbo nozzle will be
greatly decreased and the warranty voided. The "Rotomax" type nozzle can be used up to 170º F.
HOSES AND HOSE REELS
The high pressure discharge hose
can be extended by connecting additional hose lengths by means of twist
couplers. Hose extensions generally come in 50 and 100
foot lengths. Specify maximum pressure and temperature
of your machine when ordering. Pressure loss for additional hose length is minimal.
ACCESSORIES
WARNING: If your unit is equipped with 250º
steam option, only use 250º rated hose.
Low pressure inlet garden hose is available in 50 and 100
foot lengths. Premium quality, 200 PSI rated hose is
recommended to be used and is available at your local
dealer.
Hose reels are available for convenient
and quick storage of both discharge and
inlet hoses. If the reel begins to leak, replace the seal kit in the swivel, or connect
the hose directly to the machine until the
leak is repaired.
The high pressure hose (200' maximum)
should be completely unreeled before use or it can contract
on the drum and cause damage to the hose reel. The low
pressure hose (200' max) should be of sufficient quality that
it will not flatten out when reeled up, or the supply of water
to the machine will be cut off.
SPRAY WANDS
Spray wands are available in different lengths and with
variable pressure adjustment. The dual wand has a low
pressure and high pressure nozzle. When the dual wand is
installed on the machine, the output pressure can be
lowered simply by turning the valve on the dual wand to
divert water into the low pressure nozzle. This lowers the
pressure (PSI) but has little or no effect on the discharge
flow (GPM) or outlet water temperature on hot water
machines.
The short wands are ideal for washing in confined areas
such as a car lot. The longer wands help to clean areas that
could not normally be reached.
A downstream chemical injector is available if harsh chemicals need to be applied and water supply tanks are available
for remote cleaning sites (see page 9).
WARNING: Wands under 48" in length should not
be used with machines producing over 3000 psi.
TROUBLE SHOOTING GUIDE
PROBLEM
13
PROBABLE CAUSE*
REMEDY
Power System: Electric Motor Driven
Electric motor does not start.
No electric power.
Thermal overload in the motor/or starter has
been tripped.
Power switch inoperative.
Electric motor or wiring failure.
Machine will not Auto-Start (if equipped) Must have adequate water supply.
Coil scale build up.
Check filter screen & inlet pressure.
Inlet Flowswitch damaged or jammed with debris
Pumping System
Pump runs but has low spray pressure. Nozzle not installed.
Dual wand valve is open.
Leaky discharge hose or quick coupler.
Chemical Valve open
Inlet strainer clogged.
Worn, plugged or wrong size nozzle.
Belt slippage.
Unloader valve worn or improperly adjusted.
Air leak in inlet plumbing.
Pump runs but there is erratic,
fluctuating pressure.
Inadequate incoming water supply.
Stuck inlet or discharge valves.
Restricted inlet or air entering the inlet plumbing
on the pump.
Leaking H.P. seals.
Leaking L.P. seals.
Check cord, plug, socket, and breaker. Check
Voltage
Reset manual overload by depressing the thermal
switch on the outside of the motor or starter after
the motor has cooled. CAUTION! Automatic overload
will restart the motor automatically when it has
cooled.
Check power switch.
Replace or repair motor and/or wiring.
25 PSI minimum.
Descale coil for better water flow.
Remove spray nozzle and pull trigger to check
auto-start function.
Check mechanical function & electrical signal to
relay.
Clean obstruction or scale deposits from coil
with coil cleaner.
Install Nozzle.
Dual wand valve must be closed and high
pressure nozzle installed.
Replace hose, quick coupler, or o-ring in the
quick coupler.
Close Valve
Clean and check more frequently.
Replace nozzle of proper size.
Tighten or replace with correct belt.
Install pressure gauge on pump head to adjust
pressure. Check valve seat on Unloader.
Reseal fittings and inspect inlet hoses for air leaks.
Increase water supply flow.
Clean out or replace worn valves.
Check fittings and hose for air tight seal, clean
inlet strainer screen.
Replace seals.
Pressure feed the pump and replace L.P. seals
if water leaks from the pump head.
Excessive crankshaft play or loud,
knocking noise in pump.
Broken or worn bearing or connecting rod in
crankcase.
Oil leaking from pump.
Loose drain plug or damaged seal.
Inlet injection will not siphon chemical.
Check valve in the strainer clogged.
Locate point of oil leakage and replace damaged
O-ring or seal.
Clean or replace. Rinse after each use.
Chemical valve not open or clogged.
Open Chemical valve or clean.
Strainer not submerged in solution.
Submerge strainer and replenish chemical.
Detergent hose cut or Kinked.
Inspect hose, replace as necessary.
Water is emitted from the chemical
pickup tube.
Check Valve malfunctioning.
Repair or replace check valve.
Downstream injector will not siphon
chemical.
Brass knob on injector is closed.
Open by turning counter clockwise.
Unit not in low pressure mode.
Soap solution too thick.
Detergent hose cut or Kinked.
Strainer plugged or not submerged.
Internal injector parts corroded or stuck.
Outlet water temperature too high.
Open dual wand or install low pressure tip.
Dilute or use different soap.
Inspect hose, replace as required.
Check screen on strainer pickup tube.
Disassemble, clean or replace.
Use with cold water (150 Degrees F. Max.) If
installed on discharge side of coil.
Pressure relief relieving water.
Unloader failure/ Coil overheating/ excessive
pressure
Turn machine off, wait a few minutes and
restart. If problem continues take in for repair.
Burst Disk Relieving water
Replace pump or bearing.
Excessive overpressurization and
Take it in for system check
system spikes
* The most recurring probable cause is listed first.
Repairs should be made only by a qualified technician.
14
TROUBLE SHOOTING GUIDE
PROBLEM
PROBABLE CAUSE*
Heating/Burner System-Natural Gas or LP Fired
Pilot will not light, burner will not fire.
WARNING Disconnect MV Wire At Gas Valve Before Trouble Shooting.
Burner switch not on.
Trigger not pulled.
Thermostat not turned up.
Poor Ground
Gas valve turned off.
Check for 24 VAC between pilot valve (PV) and PV/
MV. Valve will operate between 20.5 and 28.5 VAC.
Pilot orifice plugged.
Remove orifice & clean.
Defective ignition module.
Defective transformer.
Check for 24 VAC incoming @ 24v & 24v
ground. (If you dedect voltage to module, but not
through module, replace).
Check for 24v output. If no voltage, replace.
Replace.
Defective flow switch.
Replace.
Defective thermostat.
Faulty rocker switch.
Replace.
Replace.
Test for spark. Test for continuity between
ignition wire and ground.
WARNING: High voltage ignitor can cause
electrical shock.
Defective pressure switch.
Ignitor not working.
Check for 24 VAC between main valve (MV)
and PV/MV when trigger pulled & unit on.
If no VAC @ valve, replace module. If you get
voltage, replace valve.
Failure to complete circuit to main valve
Check for controls continuity to main valve
(thermostat, pressure switch, flow switch)
Check for loose ignition wires
Damaged or loose pilot assembly
Insufficient or excessive gas pressure
Burner fires, but goes out.
NG or LP odor is present.
WARNING: Check all NG
connections with soap solution
before operation.
Turn switch on / press reset switch.
Pull trigger. Burner should fire only when trigger
is pulled.
Adjust Thermostat up.
Check & clean ground connections
Turn gas valve on
No voltage to valve.
Defective vacuum switch.
Pilot lights, but burner will not fire.
REMEDY
Check for continuity between ignition module
ground and pilot assembly ground.
Refer to installation guidelines (consult with
qualified gas technician)
Assure good ground.
Faulty ignition module.
Replace module.
Excess draft.
Protect from windy conditions / install draft
diverter.
Gas leak ahead of valve.
Turn gas off. Call gas supplier.
Lockout not working.
Valve stuck.
Replace module.
Turn main gas valve off. Replace valve.
Faulty thermostat.
Replace.
Discharge water temperature too high. Water restriction.
Incoming gas pressure to high.
Worn spray nozzle.
Clean or replace spray nozzle, descale coil,
remove obstructions.
Lower gas pressure.
Replace spray nozzle with proper size.
.
Increase gas pressure or install additional jets
Prevent down draft with installation of down
draft diverter. Prevent side draft with
nonflammable barrier.
Discharge water temperature not
reaching maximum operating
temperature.
Gas pressure too low.
Burner continues to fire even when
water is not being sprayed.
Faulty burner control circuit .
Main gas valve stuck open.
Turn machine off immeadiately, Replace flow,
vacuum, pressure, or temperature switches.
Turn gas off - replace main gas valve.
Valve has had water sprayed on it.
Has been submerged in water and
does not work.
Flood or accidental spraying.
Replace valve: Do not attempt to repair or clean
out.
Ignition module has been subjected to
water or moisture.
Flood or accidental spraying.
Replace module: Do not attempt to repair.
Draft under burner manifold.
SERVICE RECORD
SERVICE RECORD
Date of Service
Mo./Day/Year
15
MODEL# _____________________ SERIAL# ____________________
Number of Run Hrs.
Since Last Service
Service Performed
16
MAINTENANCE INFORMATION
PREVENTATIVE MAINTENANCE:
While your pressure washer has been produced with
quality materials and craftsmanship, you as the owner have
certain responsibilities for the correct care of the equipment.
Attention to regular preventative maintenance procedures will
assist in preserving the performance of your equipment. Contact
your Hydro Tek dealer for maintenance. A small investment in
preventative maintenance will add many hours to the life of your
pressure washer. Perform maintenance more often under severe
conditions. Do not spray high pressure water onto the machine.
Not all maintenance items apply to all machines.
MAINTENANCE SCHEDULE
Pump Oil
Inspect
Change
Daily
After first 50 hours, then every 3-5 months or 500 hours
Axial pumps come filled with synthetic oil which does not require changing.
Burner Adjustment / Cleaning Annually
Remove Burner Soot
Annually
Descale Coil
Annually (more Often If Required)
Replace Spray Nozzle
6 months
Replace Quick Connects
Annually
Clean Water Screen/Filter
Weekly
Clean Float/Supply Tank
Every 6 months
Replace HP Hose
Annually
Belts
Tighten
6 months (more often if required)
Check/Replace Annually
Motor
Clean
Annually
MAINTENANCE INFORMATION
DESCRIPTION
OIL TYPE
CAPACITY
Pump, General
Non detergent SAE 30w
34-41oz
Pump, AR
Non Detergent SAE 30w
10-41oz (axial pumps; no change req.)
Pump, Cat
Cat Hydraulic, non-detergent 10w-40 ISO 68
11-25oz
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