oPerATor`S MANUAl - Pressure Washers Direct

oPerATor`S MANUAl - Pressure Washers Direct
®
OPERATOR’S MANUAL
Model
HDS 2.5/20 P Cage
HDS 2.8/25 P Cage
HDS 2.6/30 P Cage
HDS 3.5/30 P Cage
HDS 3.5/30 Pe Cage
HDS 3.5/35 Pe Cage
order #
1.575-554.0
1.575-555.0
1.575-550.0
1.575-551.0
1.575-552.0
1.575-553.0
model
SGP-302017
SGP-302517
SGP-303037
SGP-353037
SGP-353037E
SGP-403537E
To locate your local Kärcher Commercial Pressure Washer Dealer nearest you,
visit www.karchercommercial.us
9.800-079.0
CONTENTS
Introduction & Important Safety Instructions
3-5
Component Identification
6
Assembly Instructions
7
Operating Instructions
8-9
Detergents and Cleaning Tips
10
Shut-Down and Clean Up
11
Storage
11
Maintenance
12-14
Troubleshooting
15-17
Maintenance & Oil Change Charts
18
Exploded View - 554.0, 555.0
19
Exploded View - 550.0, 551.0, 552.0, 553.020-21
Exploded View Parts Lists22-25
Control Panel - 554.0, 555.0 & Parts List 26-27
Control Panel - 550.0, 551.0, 552.0, 553.0 & Parts List 28-29
Hose & Spray Gun Assembly & Parts List
30
Downstream Injector Assembly 31
Hose Reel Option 32
VBA35 Unloader Exploded View and Parts List
33
KG Pump Exploded View and Parts List
34-35
KG-1 Pump Exploded View and Parts List
36-37
Burner Specifications
38
Warranty
Model Number ______________________________
Serial Number ______________________________
Date of Purchase ____________________________
The model and serial numbers will be found on a decal attached
to the pressure washer. You should record both serial number and
date of purchase and keep in a safe place for future reference.
9.800-079.0 • Rev. 4/08
Thank you for purchasing this Pressure Washer.
WArNING WARNING:This machine exceeds
85 db appropriate ear protection
must be worn.
We reserve the right to make changes at any time
without incurring any obligation.
Owner/User Responsibility:
The owner and/or user must have an understanding of
the manufacturer’s operating instructions and warnings
before using this pressure washer. Warning information
should be emphasized and understood. If the operator
is not fluent in English, the manufacturer’s instructions
and warnings shall be read to and discussed with
the operator in the operator’s native language by the
purchaser/owner, making sure that the operator comprehends its contents.
ear protection
must be worn
WArNING
Owner and/or user must study and maintain for future
reference the manufacturers’ instructions.
The operator must know how to stop the machine
quickly and understand the operation of all controls.
Never permit anyone to operate the engine without
proper instructions.
This manual should be considered a permanent
part of the machine and should remain with it if
machine is resold.
When ordering parts, please specify model and
serial number. Use only identical replacement
parts.
This machine is to be used only by trained operators.
Important Safety
Information
WArNING
keep water
spray away from
electrical wiring.
6. Keep operating area clear of all persons.
WARNING: Keep wand, hose, and
water spray away from electric
wiring or fatal electric shock may
result.
4. All installations must comply
with local codes. Contact
your electrician, plumber,
utility company or the selling
distributor for specific details.
WArNING
risk of explosion:
Operate only where
open flame or torch
is permitted
WARNING: To reduce the risk of
injury, read operating instructions carefully before using.
1. Read the owner's manual
thoroughly. Failure to follow
instructions could cause malfunction of the machine and
read operator’s
manual thoroughly
result in death, serious bodily
prior to use.
injury and/or property damage.
2. Know how to stop the machine and bleed pressure
quickly. Be thoroughly familiar with the controls.
3. Stay alert — watch what you are doing.
use protective
eye wear
and clothing
when operating
this equipment.
WARNING: High pressure spray
can cause paint chips or other
particles to become airborne
and fly at high speeds. To avoid
personal injury, eye, hand and
foot safety devices must be
worn.
5.Eye, hand, and foot protection
must be worn when using this
equipment.
PRESSURE WASHER OPERATOR’S MANUAL
INTRODUCTION & Important Safety Information
WArNING
risk of fire.
do not add fuel
when operating
machine.
WARNING: Flammable liquids
can create fumes which can ignite, causing property damage
or severe injury.
WARNING: Risk of explosion
— Operate only where open
flame or torch is permitted.
WARNING: Risk of fire — Do not
add fuel when the product is
operating or still hot.
WARNING: Do not use gasoline
crankcase draining or oil containing gasoline, solvents or
alcohol. Doing so will result in
fire and/or explosion.
WARNING: Risk of fire — Do not
Spray flammable liquids.
7. Allow engine to cool for 1-2 minutes before refueling. If any fuel is spilled, make sure the area is
dry before testing the spark plug or starting the
engine. (Fire and/or explosion may occur if this is
not done.)
Gasoline engines on mobile or portable equipment
shall be refueled:
a. outdoors;
b. with the engine on the equipment stopped;
c. with no source of ignition within 10 feet of
the dispensing point; and
d. with an allowance made for expansion of the fuel should the equipment be exposed to a higher ambient temperature.
9.800-079.0 • Rev. 4/08
PRESSURE WASHER
OPERATOR’S MANUAL
Important Safety Information
In an overfilling situation, additional precautions are
necessary to ensure that the situation is handled
in a safe manner.
WARNING: Risk of injury. Disconnect battery
ground terminal before servicing.
8. When in use , do not place machine near flammable
objects as the engine is hot.
9. Oil burning appliances shall be installed only in
locations where combustible dusts and flammable
gases or vapors are not present. Do not store or
use gasoline near this machine.
10. Use No. 1 or No. 2 heating oil (ASTM D306) only.
NEVER use gasoline in your fuel oil tank. Gasoline
is more combustible than fuel oil and could result
in a serious explosion. NEVER use crankcase or
waste oil in your burner. Fuel unit malfunction could
result from contamination.
11. Do not confuse gasoline and fuel oil tanks. Keep
proper fuel in proper tank.
WArNING
Risk Of Injury.
Hot Surfaces
Can Cause Burns
WARNING: Risk of injury. Hot
surfaces can cause burns. Use
only designated gripping areas
of spray gun and wand. Do not
place hands or feet on non-insulated areas of the pressure
washer.
12. Transport/Repair with fuel tank EMPTY or with fuel
shut-off valve OFF.
CAUTION: Hot discharge fluid.
Do not touch or direct discharge
stream at persons.
HOT discharge fluid:
do NOT TOUCH OR
DIRECT DISCHARGE
STREAM AT PERSONS.
WARNING: This machine produces hot water and must have
insulated components attached
to protect the operator.
13. To reduce the risk of injury, close supervision is
necessary when a machine is used near children.
Do not allow children to operate the pressure
washer. This machine must be attended during
operation.
WArNING
Trigger Gun Kicks
back - Hold with
both hands
WARNING: Grip cleaning wand
securely with both hands before
starting. Failure to do this could
result in injury from a whipping
wand.
14.Never make adjustments on
machine while in operation.
15. Be certain all quick coupler fittings are secured
before using pressure washer.
WArNING
risk of injection
or severe injury
To persons. keep
clear of nozzle.
WArNING
WARNING: High pressure developed by these machines will
cause personal injury or equipment damage. Keep clear of
nozzle. Use caution when operating. Do not direct discharge
stream at people, or severe injury or death will result.
WARNING: Protect machine from
freezing.
16. To keep machine in best
operating conditions, it is
important you protect machine
from freezing. Failure to protect
machine from freezing
Protect from
freezing
could cause malfunction of the
machine and result in death,
serious bodily injury, and/or property damage. Follow storage instructions specified in this manual.
17. Inlet water must be clean fresh water and no hotter
then 90°F.
WArNING WARNING: Risk of asphyxiation.
Use this product only in a well
ventilated area.
18. Avoid installing machines in
small areas or near exhaust
fans. Adequate oxygen is
risk of
needed for combustion or
asphyxiation: use
this product only
dangerous carbon monoxide
in a well
will result.
ventilated area.
19. Manufacturer will not be liable for any changes
made to our standard machines or any components
not purchased from us.
20. The best insurance against an accident is precaution and knowledge of the machine.
WARNING: Be extremely careful
when using a ladder, scaffolding
or any other relatively unstable
location. The cleaning area
should have adequate slopes
and drainage to reduce the possibility of a fall due to slippery
RISK OF INJURY
surfaces.
FROM FALLS WHEN
USING LADDER.
21. Do not allow acids, caustic or abrasive fluids to pass
through the pump.
22. Never run pump dry or leave spray gun closed
longer than 1-2 minutes.
WArNING
9.800-079.0 • Rev. 4/08
23. Machines with shut-off spray gun should not be
operated with the spray gun in the off position for
extensive periods of time as this may cause damage to the pump.
24. Protect discharge hose from vehicle traffic and
sharp objects. Inspect condition of high pressure
hose before using or bodily injury may result.
25. Before disconnecting discharge hose from water
outlet, turn burner off and open spray gun to allow water to cool below 100° before stopping the
machine. Then open the spray gun to relieve pressure. Failure to properly cool down or maintain the
heating coil may result in a steam explosion.
26. Do not overreach or stand on unstable support.
Keep good footing and balance at all times.
27. Do not operate this machine when fatigued or under
the influence of alcohol, prescription medications,
or drugs.
28. In oil burning models, use only kerosene, No. 1
home heating fuel, or diesel. If diesel is used, add
a soot remover to every tankful.
PRESSURE WASHER OPERATOR’S MANUAL
Important Safety Information
Follow the maintenance instructions
specified in the manual.
9.800-079.0 • Rev. 4/08
PRESSURE WASHER
OPERATOR’S MANUAL
Component Identification
Gasoline
Tank
Detergent
Injector
Pressure
Switch
Collar
Unloader
Discharge
Nipple
Quick
Coupler
Water Supply
Hose
(not included)
Pump
Spray
Gun
Battery Box
Wand Coupler
Nozzle
Quick
Coupler
Swivel
Connector
Variable Pressure
Control wand
Brass
Soap
Nozzle
Control Wand
Handle
High Pressure
Hose
Trigger
Pump — Develops high pressure.
Starter Grip — (Not Shown) Used for starting the
engine manually.
Spray Gun — Controls the application of water and
detergent onto cleaning surface with trigger device.
Includes safety latch.
Detergent Injector — Allows you to siphon and mix
detergents.
Variable Pressure Control Wand — Must be connected to the spray gun. This wand handle controls
dishcharge flow from one tube to both wand tubes.
When water is discharged from both tubes you will have
a pressure loss and allows chemical siphoning when
used in combination with a detergent injector.
High Pressure Hose — Connect one end to water
pump discharge nipple and the other end to spray
gun.
Note: If trigger on spray gun is released for more
than 2 minutes, water will leak from valve. Warm
water will discharge from pump protector onto floor.
This system prevents internal pump damage.
9.800-079.0 • Rev. 4/08
Spray
Gun
Pressure
Nozzle
Soap
Nozzle
Safety
Latch
Wand
Coupler
Wand
Coupler
Wand
Collar
High Pressure
Hose
STEP 1: Attach the high
pressure hose to the spray
gun using teflon tape on hose
threads.
STEP 2: Pull the spring-loaded collar
of the wand coupler back to insert your
choice of pressure nozzle.
DipStick
STEP 3: Release the coupler collar
and push the nozzle until the collar
clicks. Pull the nozzle to make sure it
is seated properly.
Cold
Water
Source
PRESSURE WASHER OPERATOR’S MANUAL
Assembly Instructions
Discharge Fitting
Coupler Collar
Garden
Hose
High Pressure Hose
Oil Window
STEP 4: Remove shipping cap
and install oil dipstick. Check
pump oil level by using dipstick
or observe oil level in oil window (if equipped). Use 30 wt.
non detergent oil.
STEP 5: Connect the high pressure
hose to the pump discharge fitting. Push
coupler collar forward until secure.
STEP 6: Connect garden hose to the
cold water source.
Garden
Hose
Pump
Water Inlet
STEP 7: Connect the garden hose
to pump water inlet. Inspect inlets.
CAUTION: Do not run the pump
without water or pump damage
will result.
9.800-079.0 • Rev. 4/08
WASHER
OPERATOR’S MANUAL PRESSURE
operating instructions
Oil Dipstick
Gas
Tank
STEP 1: Check engine oil level. Oil level should be level with the bottom
of the oil filler neck. Be sure the machine is level when checking the oil
level. (Refer to the engine's operating manual included with machine.) We
recommend that the oil be changed after the first 5 hours of use, then once
every 50 hours. Note: Improper oil levels will cause low oil sensor to shut
off engine. IMPORTANT! Do not run engine with high or low oil levels
as this will cause engine damage.
STEP 2: Fill gas tank with unleaded
gasoline. Do not use leaded gasoline. Caution: Read warnings on
pg. 4 and engine manual.
Cold
Water
Source
Garden
Hose
STEP 3: Connect garden hose
to the cold water source and turn
water on completely. Never use hot
water.
STEP 4: Trigger the spray gun to
eliminate trapped air then wait for a
steady flow of water to emerge from
the spray nozzle.
Choke
Lever
Fuel
Valve
STEP 5: Rotate the fuel shut-off valve to the "On" position. Slide the fuel valve lever to the "ON" position.
When the engine is not in use, leave the fuel valve in
the "OFF" position.
STEP 6: Pull the choke lever out to the "Choke" position
(on a warm engine, leave the choke lever in, in the run
position). Push the choke lever to the "Closed" position.
To restart a warm engine, leave the choke lever in the
"Open" position.
9.800-079.0 • Rev. 4/08
Throttle
STEP 7: Turn the engine to "Run" position.
STEP 8: Pull the starter grip. If the engine fails to start
after 2 pulls, squeeze the trigger gun to release pressure
and repeat step. Return starter gently. After the engine
warms up enough to run smoothly, move choke to run
position and throttle to fast position.
PRESSURE WASHER OPERATOR’S MANUAL
operating instructions
CAUTION: Small engines may kick back. Do not hold
pull starter grip tightly in hand.
NOZZLES
Temperature
Gauge
Burner
Swutch
Safety
Latch
STEP 9: If hot water is required.
Adjust temperature gauge to proper
temperature (200°). Turn on Burner
switch to begin heating water.
Brass Soap
Nozzle
WARNING! Never replace nozzles without engaging the safety
latch on the spray gun trigger.
Variable Pressure
Wand (VP)
The four color-coded quick connect
nozzles provide a wide array of
spray widths from 0° to 40° and are
easily accessible when placed in
the convenient rubber nozzle holder,
which is provided on the front of the
machine.
NOTE: For a more gentle rinse,
select the white 40° or green 25°
nozzle. To scour the surface, select
the yellow 15° or red 0° nozzle. To
apply detergent select the black
nozzle.
Trigger
High
Variable Pressure
Pressure
Control Handle
Nozzle
Selection of high or low pressure is accompanied by
turning the handle. Note: High pressure nozzle must
be inserted at end of wand to obtain high pressure. To
apply soap read operator's manual.
9.800-079.0 • Rev. 4/08
PRESSURE WASHER
OPERATOR’S MANUAL
detergents and Cleaning Tips
WARNING: Some detergents
may be harmful if inhaled or ingested, causing severe nausea,
fainting or poisoning. The harmful elements may cause property
damage or severe injury.
STEP 1: Connect detergent injector to discharge nipple on machine, Connect high pressure hose to injector with quick
coupler(check to make sure locking coupler sleeves are
in proper position before applying water pressure
WArNING
Discharge
Nipple
Detergent
Injector
Control
Handle
Quick
Coupler
High Pressure
Hose
STEP 2: Use detergent designed
specifically for pressure washers.
Household detergents could damage the pump. Prepare detergent
solution as required by the manufacturer. Fill a container with pressure washer detergent. Place the
filter end of detergent suction tube
into the detergent container.
STEP 3: Apply safety latch to spray gun trigger. Turn
variable pressure control handle until discharge water
exits both tubes. Secure black detergent nozzle into
quick coupler if you have a single wand. NOTE: Detergent cannot be applied using Red, Yellow, Green or
White nozzles.
STEP 4: With the engine running,
pull trigger to operate machine.
Liquid detergent is drawn into the
machine and mixed with water.
Apply detergent to work area.
Do not allow detergent to dry on
surface.
IMPORTANT: You must flush
the detergent injection system after each use by
placing the suction tube into a bucket of clean water, then run the pressure washer in low pressure
for 1-2 minutes.
thermal pump protection
If you run the engine on your pressure washer for 3-5
minutes without pressing the trigger on the spray gun,
circulating water in the pump can reach high temperatures. When the water reaches this temperature, the
pump protector engages and cools the pump by discharging the warm water onto the ground. This thermal
device prevents internal damage to the pump.
cleaning tips
Pre-rinse cleaning surface with fresh water. Place detergent suction tube directly into cleaning solution and
apply to surface at low pressure (for best results, limit
your work area to sections approximately 6’ square
and always apply detergent from bottom to top). Allow
detergent to remain on surface 1-3 minutes. Do not allow detergent to dry on surface. If surface appears to
be drying, simply wet down surface with fresh water. If
needed, use brush to remove stubborn dirt. Rinse at
high pressure from top to bottom in an even sweeping
motion keeping the spray nozzle approximately 1’ from
cleaning surface. Use overlapping strokes as you clean
and rinse any surface. For best surface cleaning action
spray at a slight angle.
Recommendations:
• Before cleaning any surface, an inconspicuous
area should be cleaned to test spray pattern and
distance for maximum cleaning results.
• If painted surfaces are peeling or chipping, use
extreme caution as pressure washer may remove
the loose paint from the surface.
• Keep the spray nozzle a safe distance from the
surface you plan to clean. High pressure wash a
small area, then check the surface for damage. If no
damage is found, continue to pressure washing.
CAUTION - Never use:
• Bleach, chlorine and other corrosive chemicals
• Liquids containing solvents (i.e., paint thinners,
gasoline, oils)
• Tri-sodium phosphate products
• Ammonia products
• Acid-based products
These chemicals will harm the machine and will damage the surface being cleaned.
rinsing
It will take a few seconds for the detergent to clear.
Apply safety latch to spray gun. Remove black soap
nozzle from the quick coupler. Select and install the
desired high pressure nozzle. NOTE: You can also stop
detergent from flowing by simply removing detergent
siphon tube from bottle.
10
9.800-079.0 • Rev. 4/08
On-Off
Switch
STEP 1: Remove detergent suction
tube from container and insert into
1 gallon of fresh water. Turn variable
pressure wand handle for low pressure or connect the black detergent
nozzle. Pull trigger on spray gun and
siphon water for one minute.
STEP 2: Turn off the engine.
Water
Inlet
STEP 3: Tur n off water
supply.
PRESSURE WASHER OPERATOR’S MANUAL
shutting down and clean-up
High Pressure
Outlet
Safety
Latch
STEP 4: Press
trigger to release
water pressure.
STEP 5: Disconnect the garden hose from the water inlet
on the machine.
STEP 6: Disconnect the high
pressure hose from high pressure outlet.
STEP 7: Engage the
spray gun safety lock.
STORAGE
CAUTION: Always store your pressure washer in a
location where the temperature will not fall below
32°F (0°C). The pump in this machine is susceptible
to permanent damage if frozen. FREEZE DAMAGE
IS NOT COVERED BY WARRANTY.
1. Stop the pressure washer, squeeze spray gun trigger to release pressure.
2. Detach water supply hose and high pressure
hose.
3. Turn on the machine for a few seconds, until remaining water exits. Turn engine off immediately.
4. Drain the gas and oil from the engine.
5. Do not allow high pressure hose to become
kinked.
6. Store the machine and accessories in a room which
does not reach freezing temperatures.
CAUTION: Failure to follow the above directions will
result in damage to your pressure washer.
When the pressure washer is not being operated or is
being stored for more than one month, follow these
instructions:
1. Replenish engine oil to upper level.
2. Drain gasoline from fuel tank, fuel line, fuel valve
and carburetor.
3. Pour about one teaspoon of engine oil through
the spark plug hole, pull the starter grip several
times and replace the plug. Then pull the starter
grip slowly until you feel increased pressure which
indicates the piston is on its compression stroke and
leave it in that position. This closes both the intake
and exhaust valves to prevent rusting of cylinder.
4. Cover the pressure washer and store in a clean, dry
place that is well ventilated away from open flame
or sparks. NOTE: The use of a fuel additive, such
as STA-BIL®, or an equivalent, will minimize the
formulation of fuel deposits during shortage. Such
additives may be added to the gasoline in the fuel
tank of the engine, or to the gasolinee in a storage
container.
After Extended Storage
CAUTION: Prior to restarting, thaw out any
possible ice from pressure washer hoses,
spray gun or wand.
Engine Maintenance
During the winter months, rare atmosheric conditions
may develop which will cause an icing condition in the
carburetor. If this develops, the engine may run rough,
lose power and may stall. This temporary condition can
be overcome by deflecting some of the hot air from the
engine over the carburetor area. NOTE: Refer to the
engine manufacturer's manual for service and maintenance of the engine.
9.800-079.0 • Rev. 4/08
11
PRESSURE WASHER
OPERATOR’S MANUAL
Maintenance
PREVENTATIVE MAINTENANCE
1. Check to see that the water pump is properly lubricated.
2. Follow Winterizing Procedures to prevent freeze
damage to the pump and coils.
3. Always neutralize and flush detergent from system
after use.
4. If water is known to be high in mineral content, use
a water softener in your water system or de-scale
as needed.
5. Do not allow acidic, caustic or abrasive fluids to be
pumped through system.
6. Always use our high grade quality cleaning products.
7. Never run pump dry for extended periods of time.
8. Use clean fuel: kerosene, No. 1 fuel oil or diesel.
Replace fuel filter every 100 hours of operation.
Avoid water contaminated fuel as it will seize up
the fuel pump.
9. If machine is operated with smoking or eye burning
exhaust, coils will soot up, not letting water reach
maximum operating temperature. (See section on
Air Adjustments.)
10. Never allow water to be sprayed on or near engine
or burner assembly or any electrical component.
11. Periodically delime coils as per instructions.
12. Check to see that engine is properly lubricated.
It is advisable, periodically, to visually inspect the
burner. Check air inlet to make sure it is not clogged or
blocked. Wipe off any oil spills and keep this equipment
clean and dry.
The areas around the pressure washer should be kept
clean and free of combustible materials, gasoline and
other flammable vapors and liquids.
The flow of combustion and ventilating air to the burner
must not be blocked or obstructed in any manner. Consult factory if vent stacking is going to be used.
MAINTENANCE AND SERVICE
Unloader Valves:
Unloader valves are preset and tested at the factory
before shipping. Occasional adjustment of the unloader
may be necessary to maintain correct pressure. Call
your local dealer for assistance.
Winterizing Procedure:
Damage due to freezing is not covered by warranty. Adhere to the following cold weather procedures whenever
the washer must be stored or operated outdoors under
freezing conditions.
During winter months, when temperatures drop below
32°F, protecting your machine against freezing is necessary. Store the machine in a heated room. If this is not
possible then mix a 50/50 solution of anti-freeze/water
into a 5 gallon bucket. Place a short section of garden
hose into the bucket and connect it to the machine.
Elevate the bucket and turn the pump on to siphon the
anti-freeze through the machine. If compressed air is
available, an air fitting can be screwed into the inlet
connector and, by injecting compressed air, all water
will be blown out of the system.
High Limit Hot Water Thermostat:
For safety, each machine is equipped with a high limit
control switch. In the event that the temperature of the
water should exceed its operating temperature, the
high limit control will turn the burner off until the water
cools.
Pumps:
Use only SAE 30W non-detergent oil. Change oil after
the first 50 hours of use. Thereafter, change the oil every
three months or at 500 hour intervals. Oil level should be
checked by using the dipstick found on top of the pump
or the red dot visible through the oil gauge window. Oil
should be maintained at that level.
Cleaning of Coils:
In alkaline water areas, lime deposits can accumulate
rapidly inside the coil pipes. This growth is increased by
the extreme heat build up in the coil. The best prevention
for liming conditions is to use high quality cleaning detergents. In areas where alkaline water is an extreme
problem, periodic use of our Deliming Powder (part
#9-028008) will remove lime and other deposits before
coil becomes plugged. (See Deliming Instructions for
use of Deliming Powder.)
Deliming Coils:
Periodic flushing of coils is recommended.
1. Fill a container or optional float tank with 4 gallons
of water, then add 1 lb. of deliming powder. Mix
thoroughly.
2. Remove wand assembly from spray gun and put
spray gun into container. Secure the trigger on the
spray gun into the open position.
3. Attach a short section (3-5 ft.) of garden hose to
machine to siphon solution from an elevated container. Turn pump switch on, allowing solution to
be pumped through coils back into the container.
Solution should be allowed to circulate 2-4 hours.
4. After circulating solution flush entire system with
fresh water. Reinstall wand assembly to spray
gun.
12
9.800-079.0 • Rev. 4/08
Rupture Disk:
Burner Nozzle:
If pressure from pump or thermal expansion should
exceed safe limits, the rupture disk will burst allowing high pressure to be discharged through hose to
ground. When disk ruptures it will need to be replaced.
The replacement rupture disk should be torqued to 35
ft. lbs.
Keep the tip free of surface deposits by wiping it with a
clean, solvent-saturated cloth, being careful not to plug
or enlarge the nozzle. For maximum efficiency, replace
the nozzle each season.
Fuel:
Machines are preset and performance tested at the
factory - elevation 100 feet. A one-time initial correction
for your location will pay off in economy, performance
and extended service life. If a smoking or eye-burning
exhaust is being emitted from the stack, two things
should be checked. First, check the fuel to be certain
that kerosene or No. 1 home heating fuel is being used.
Next, check the air adjustment on the burner.
Use clean fuel oil that is not contaminated with water
and debris. Replace fuel filter and drain tank every 100
hours of operation.
Use No. 1 or No. 2 Heating Oil (ASTM D306) only.
NEVER use gasoline in your burner tank. Gasoline is
more combustible than fuel oil and a serious explosion could result. NEVER use crankcase or waste oil
in your burner. Fuel unit malfunction could result from
contamination.
Fuel Control System:
These machines utilize a fuel solenoid valve located
on the fuel pump to control the flow of fuel to the combustion chamber. This solenoid valve, which is normally
closed, is activated by a flow switch when water is flowing through it. When an operator releases the trigger on
the spray gun, the flow of water through the flow switch
stops, turning off the current to the fuel solenoid. The
solenoid then closes, shutting off the supply of fuel to
the combustion chamber. Controlling the flow of fuel in
this way allows for an instantaneous burn or no burn
situation, thereby eliminating high and low water temperatures, and combustion smoke normally associated
with machines incorporating a spray gun.
CAUTION: Periodic inspection is recommended to insure that the fuel solenoid valve functions properly. This
can be done by operating the machine and checking to
see that when the trigger on the spray gun is in the off
position, the burner is not firing.
Air Adjustment:
To adjust: Start machine and turn burner ON. Loosen
two locking screws found in the air shutter openings
(refer to illustration below) and close air shutter until
black smoke appears from burner exhaust vent. Note
air band position. Next, slowly open the air shutter until
white smoke just starts to appear. Turn air shutter halfway back to the black smoke position previously noted.
Tighten locking screws.
PRESSURE WASHER OPERATOR’S MANUAL
Maintenance
If the desired position cannot be obtained using only
the air shutter, lock the air shutter in as close a position
as can be obtained, then repeat the above procedure
on the air band setting.
FUEL AIR ADJUSTMENT
Pressure
Gauge
Port
Air Band
Electrode Setting:
(See illustration below.)
5/32"
Air Band
Adjustment
Screw
Electrode
Pressure
Adjustment
Screw
Return Line
1/4"
7-00098 Fuel
Pump
Nozzle
To Fuel
Tank
5/32"
Top View
Side View
Periodically check wiring connections. If necessary to
adjust electrodes, use diagram.
13
9.800-079.0 • Rev. 4/08
PRESSURE WASHER
OPERATOR’S MANUAL
Maintenance
Fuel Pressure Adjustment:
Coil Reinstallation:
To adjust fuel pressure, turn the adjusting screw clockwise to increase, counterclockwise to decrease. Do not
exceed 200 psi. NOTE: When changing the fuel pump,
a bypass plug must be installed in the return port or the
fuel pump will not prime.
Reinstall by reversing the above steps 4 through 1.
Removal of Soot and Heating Coil:
In the heating process, fuel residue in the form of soot
deposits may develop on the heating coil and block air
flow which will affect burner combustion. When soot
has been detected on visual observation, the soot
on the coil must be washed off after following the coil
removal steps.
Final Note:
The 12 VDC burner systems can draw as much as 18
amps! For such burners to run properly, the battery and
engine charging system must be kept in good condition.
The engine must run at the correct RPM to adequately
charge the battery. It is equally important not to throttle
down the engine on models without batteries, since all
power to run the burner comes solely from the engine.
Do not throttle down the engine at anytime while the
machine is operating.
1. Remove the tank head assembly by lifting the tank
head off.
2. Remove the two pipe nipples and associated fittings.
3. Lift the coil out of the outer wrap.
CAUTION: The coil weighs about 80 lbs. Use proper
lifting techniques.
4. Clean, repair and replace the coil by reversing the
above steps.
14
9.800-079.0 • Rev. 4/08
ProbleM
PoSSIble CAUSe
SolUTIoN
loW oPerATING
PreSSUre
Water supply is insufficient
Use larger supply hose; clean filter at water
inlet.
Match the nozzle number to the machine
and/or replace with new nozzle.
Tighten or replace belt; use correct belt.
Check plumbing system for leaks. Retape
leaks with teflon tape.
Adjust unloader for proper pressure. Install
repair kit when necessary or replace.
Install new packing kit.
Check inlet and discharge valve.
Spray nozzle is old, worn or
incorrect
Belt slips
Plumbing or hose is leaking
Unloader is faulty or misadjusted
Packing in pump is worn
Discharge valve in pump or inlet is
fouled or dirty
Discharge valve or inlet is worn
bUrNer WIll
NoT lIGHT
Replace with valve kit.
Spray nozzle has obstruction
Steam pressure control valve is
leaking (where applicable)
Engine RPM is slow
Remove obstruction.
Rebuild or replace as necessary.
There is little or no fuel
Fill tank with fuel.
Improper fuel or water in fuel
Fuel line is clogged
Drain fuel tank and fill with proper fuel.
Clean or replace fuel line.
Fuel filter is plugged
Replace fuel filter as needed.
Burner air bands are misadjusted
Readjust air bands for clean burn.
Little or no fuel pressure from fuel
pump
Burner transformer is faulty
Increase fuel pressure to specification and/or
replace fuel pump.
Test transformer for proper arc between
contacts. Replace as needed.
All wire contacts should be clean and tight
with no breaks in wire.
Replace if needed.
Electrical wiring is disconnected or
has short in it
Flex coupling is slipping on fuel
pump shaft or burner motor shaft
ON-OFF switch is defective
Heavy sooting on coil and burner
can cause interruption of air flow and
shorting of electrodes
Set engine speed at proper specifications /
see serial plate.
PRESSURE WASHER Troubleshooting Guide
Troubleshooting
Check for electrical current reaching burner
assembly with burner switch on. Replace
switch if needed.
Clean as required.
Electrode setting is improper
Check and reset according to diagram in
manual.
5 amp circuit breaker tripped
Push in reset button.
Bridge rectifier defective
Test and replace.
1V DC relay defective
Test and replace.
Fuel is not reaching combustion
chamber
Check fuel pump for proper flow. Check
solenoid flow switch on machines with spray
gun control for proper on-off flow control.
15
9.800-079.0 • Rev. 4/08
ProbleM
PoSSIble CAUSe
SolUTIoN
bUrNer WIll
NoT lIGHT
(continued from
previous page)
Burner nozzle is clogged
Clean as required.
Thermostat has malfunctioned
Test and replace if needed.
Fuel solenoid has malfunctioned
Test and replace if needed.
Fuel is improper or water is in fuel
Drain tank and replace contaminated fuel.
Air adjustment is improper
Readjust air bands on burner assembly.
Fuel pressure is low
Adjust fuel pump pressure to specifications.
Burner nozzle is plugged or dirty
Replace nozzle. Check parts breakdown for
nozzle size.
Burner nozzle spray pattern is
faulty
Replace nozzle. Check parts breakdown for
nozzle size.
Coil and burner assembly have
heavy accumulation of soot
Remove coils and burner assembly, clean
thoroughly. Call local dealer.
Electrode setting is misaligned
Realign electrodes to specifications.
Smoke stack has obstruction
Check for blockage or other foreign objects.
Engine RPM is low
Increase RPM to correct specs. See serial
plate.
Fuel is improper or has water in it
Replace with clean and proper fuel.
Fuel pressure is low
Increase fuel pressure.
Fuel pump is weak
Check fuel pump pressure. Replace pump if
needed.
Fuel filter is partially clogged
Replace as needed.
Soot buildup on coils is not
allowing heat transfer
Clean coils.
Burner nozzle is improper
Call your local dealer for proper nozzle.
Incoming water to machine is
warm or hot
Lower incoming water temperature.
Fuel pump pressure is too high
Call your local dealer for proper fuel pressure.
Fuel pump is defective
Replace fuel pump.
Fuel nozzle is incorrect size
See parts breakdown or serial plate for proper
size.
Water supplied is insufficient
Check water GPM to machine.
Water flow is restricted
Check nozzle for obstruction and proper size.
Check serial plate for correct size.
Oil seal is worn
Check and replace if necessary.
Air humidity is high
Check and change oil twice as often.
Packing is worn or bad
Check and replace if necessary.
MACHINe
SMokeS
PRESSURE WASHER
Troubleshooting Guide
Troubleshooting
loW WATer
TeMPerATUre
WATer
TeMPerATUre
Too HoT
PreSeNCe of
WATer IN oIl
16
9.800-079.0 • Rev. 4/08
ProbleM
PoSSIble CAUSe
SolUTIoN
deTerGeNT NoT
drAWING
Air is leaking
Tighten all clamps. Check detergent lines for holes.
Injector head may be blocked,
dirty or damaged
Clean and make sure ball and spring behind
detergent hose barb or injector body are working
properly.
Filter screen on detergent
suction hose is plugged
Clean or replace.
Detergent has high viscosity
Dilute detergent to specifications.
Not using soap nozzle
Insert soap nozzle into wand coupler.
Detergent level is low
Add detergent if needed.
Pump is sucking air
Check water supply and possibility of air seepage.
Valves are sticking
Check and clean or replace if necessary.
Unloader valve seat is faulty
Check and replace if necessary.
Nozzle sized incorrectly
Check and replace if necessary (see serial plate for
proper size).
Packing piston is worn
Check and replace if necessary.
Valves are worn
Check and replace if necessary.
Valve has a blockage
Check and replace if necessary.
Pump is sucking air
Check water supply and air seepage at joint in suction
line.
Packing piston is worn
Check and replace if necessary.
Air is in suction line
Check water supply and connections on suction line.
Inlet or discharge valve
springs are weak or broken
Check and replace if necessary.
Excessive matter is in valves
Check and replace if necessary.
Bearings are worn
Check and replace if necessary.
Piston packing is worn
Check and replace if necessary.
O-Ring plunger retainer is
worn
Check and replace if necessary.
Piston is cracked
Check and replace if necessary.
Pump protector is worn
Lower water supply pressure. Do not run the spray
gun closed longer than 5 minutes.
oIl drIPPING
Oil seal is worn
Check and replace if necessary.
exCeSSIve
vIbrATIoN IN
delIvery lINe
Valves are functioning
irregularly
Check and replace if necessary.
bUrNer MoTor
WIll NoT rUN
Fuel pump has seized
Replace fuel pump.
Burner fan loose or
misaligned
Position correctly and tighten set screw.
Control switch is defective
Replace switch.
There is a loose wire
Check and replace or tighten wiring.
Burner motor is defective
Replace motor.
Relief valve is defective
Replace or repair relief valve.
PUMP rUNNING
NorMAlly bUT
PreSSUre loW
oN
INSTAllATIoN
flUCTUATING
PreSSUre
PUMP NoISy
WATer drIPPING
froM UNder
PUMP
relIef vAlve
leAkS WATer
PRESSURE WASHER Troubleshooting Guide
Troubleshooting
17
9.800-079.0 • Rev. 4/08
Troubleshooting Guide
PRESSURE WASHER
Maintenance Charts
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 preventative
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.
MAINTeNANCe SCHedUle
Engine Oil
Inspect
Daily
Change
Every 5 hours
Filter
Every 50 hours
Inspect
Every 50 hours or monthly
Clean
Every 3 months
Air Cleaner
Battery Level
Check monthly
Engine Fuel Filter
500 hours or 6 months
Spark Plug Maintenance
500 hours or 6 months
Clean Fuel Tank(s)
Annually
Replace Fuel Lines
Annually
Inspect
Oil level daily
Change
After first 50 hours, then every 500 hours or annually
Pump Oil
Clean Burner Filter
Monthly (More often if fuel quality is poor)
Remove Burner Soot
Annually
Burner Adjustment/Cleaning
Annually
Replace Burner Nozzle
Annually
Descale Coil
Annually (more often if required)
Replace High Pressure Hose
Every 6 months
Replace Quick Couplers
Annually
Clean Water Screen/Filter
Weekly
Replace HP Hose
Annually (if there are any signs of wear)
OIL CHANGE RECORD
date oil Changed
Month/day/year
estimated operating
Hours Since last
oil Change
date oil Changed
Month/day/year
18
9.800-079.0 • Rev. 4/08
estimated operating
Hours Since last
oil Change
PRESSURE WASHER
Hose & Spray Gun Assembly
7
8
1
OPERATOR’S MANUAL
2
Pressure
Nozzle
3
6
4
5
Hose & Spray Gun Parts List
ITEM
PART NO.DESCRIPTIONQTY
1
9.802-166.0
9.802-100.0
Coupler, 3/8" Female
 Quick Coupler O-Ring LG
1
1
2
8.739-125.0
8.739-203.0
Hose, 3/8" x 50', 1 Wire Tuff Flex
(All Models Except 553.0)
Hose, 3/8" x 50', 2 Wire, Tuff Flex (553.0)
1
1
3
9.802-229.0
Spray Gun, Shutoff, AP 1000
1
4
9.802-222.0
9.802-694.0
Wand, VP Zinc 1/4", w/Coupler, w/Soap Nozzle  Repair Kit, VP Wand, SS Seat 1
1
5
9.802-286.0
Nozzle, 1/8", Soap Only, Brass
1
6
9.802-165.0
9.802-096.0
Coupler, 1/4" Male
 Quick Coupler, O-Ring, Small
1
1
7
9.802-225.0
9.802-224.0
Detergent Injector Assy. #3 (550.0, 551.0, 552.0, 553.0) Detergent Injector Assy. #2 (554.0, 555.0)
1
1
8
9.802-292.0
9.802-293.0
9.802-294.0
9.802-291.0
9.802-296.0
9.802-297.0
9.802-298.0
9.802-295.0
9.802-288.0
9.802-289.0
9.802-290.0
9.802-287.0
Nozzle, SAQMEG 1503.5, Yellow (553.0, 554.0, 555.0)
Nozzle, SAQMEG 2503.5, Green (553.0, 554.0, 555.0)
Nozzle, SAQMEG 4003.5, White (553.0, 554.0, 555.0)
Nozzle, SAQMEG 0003.5, Red (553.0, 554.0, 555.0)
Nozzle, SAQMEG 1504, Yellow (551.0, 552.0)
Nozzle, SAQMEG 2504, Green (551.0, 552.0)
Nozzle, SAQMEG 4004, White (551.0, 552.0)
Nozzle, SAQMEG 0004, Red (551.0, 552.0)
Nozzle, SAQMEG 1503, Yellow (550.0)
Nozzle, SAQMEG 2503, Green (550.0)
Nozzle, SAQMEG 4003, White (550.0)
Nozzle, SAQMEG 0003, Red (550.0)
1
1
1
1
1
1
1
1
1
1
1
1
 Not Shown
30
9.800-079.0 • Rev. 4/08
PRESSURE WASHER OPERATOR’S MANUAL
Downstream Injector Assembly
1
2
3
4
2
Downstream Injector Parts List
ITEM
PART NO.DESCRIPTIONQTY
9.802-216.0
1
Injector, Detergent, Non-Adjusting #3
1
1
9.802-215.0
Injector, Detergent, Non-Adjusting #2
2
9.802-210.0
Clamp, Hose, UNI .46 - .542
3
9.802-251.0
Tube, 1/4" x 1/2", Clear Vinyl 4
9.802-160.0
Strainer, 1/4", Hose Barb
6 ft.
1
31
9.800-079.0 • Rev. 4/08
PRESSURE WASHER
Hose Reel Option
1
OPERATOR’S MANUAL
5
6
4
3
2
Hose Reel Parts List
ITEM PART NO.DESCRIPTIONQTY
1
9.802-166.0
Coupler, 3/8", Female, Brass
1
2
9.802-244.0
Hose, 3/8", 2 Wire Pressure Loop
1
3
9.802-269.0
Hose Reel, 100' Non-Pivot E-ZEE w/Pin Lock
1
4
9.802-767.0
Screw, 3/" x 3/4" HH NC, Whiz Loc
4
5
9.802-781.0
Nut, 3/8" Flange, Whiz Loc, NC
4
6
9.803-841.0
Bracket, E-ZEE Hose Reel Right, Wrinkle Black
1
32
9.800-079.0 • Rev. 4/08
Phone: 360-833-1600
fax: 800-248-8409
www.karchercommercial.us
WHAT THIS WARRANTY COVERS
All Kärcher commercial pressure washers are warranted by Kärcher to the original purchaser to be free from defects in materials
and workmanship under normal use, for the periods specified below. This Limited Warranty, subject to the exclusions shown below,
is calculated from the date of the original purchase, and applies to the original components only. Any parts replaced under this warranty will assume the remainder of the pressure washer’s warranty period.
FIVE YEAR PARTS AND ONE YEAR LABOR WARRANTY
Components manufactured by Kärcher, such as frames, handles, float tanks, fuel tanks, belt guards, and heating coils. Internal
components on the oil-end of Kärcher axial pumps have a 5 year warranty. Period of warranty on axial pumps shall be one year.
Kärcher crankshaft pumps have a 7 year warranty on non-wear parts. Heating coils are pro-rated at 25% after 2 years. Stainless
steel coils have a 10 year warranty.
ONE YEAR PARTS AND ONE YEAR LABOR WARRANTY
All other components, excluding normal wear items as described below, will be warranted for one year on parts and labor. Parts and labor warranty on these parts will be for one year regardless of the duration of the original component manufacturer’s part warranty.
WARRANTY PROVIDED BY OTHER MANUFACTURERS
Motors, generators, and engines, which are warranted by their respective manufacturers, are serviced through these manufacturers’
local authorized service centers. Kärcher is not authorized and has no responsibility to provide warranty service for such components.
Motors manufactured outside of the United States will be warranted by Kärcher.
WHAT THIS WARRANTY DOES NOT COVER
This warranty does not cover the following items:
1. Normal wear items, such as nozzles, spray guns, discharge hoses, wands, quick couplers, seals, filters, gaskets, O-rings,
packings, pistons, pump valve assemblies, strainers, belts, brushes, rupture disks, fuses, pump protectors.
2. Any components or other devices incorporated into a Kärcher product that are not manufactured by Kärcher, including,
but not limited to gasoline engines, pumps, etc.
3. Defects caused by improper or negligent operation or installation, accident, abuse, misuse, neglect, unauthorized modifications, repair or maintenance of the product by persons other than authorized representatives of Kärcher, including, but
not limited to, the failure of the Customer to comply with recommended product maintenance schedules.
4. Kärcher products that have been returned by the original Customer and are ultimately re-sold by an Authorized Servicing
Dealer or other sales or service outlet to another purchaser.
5. Kärcher products that are sold by any distributor or retailer that is not an official authorized dealer or retailer of Kärcher products.
6. Defects caused by acts of nature and disaster including, but not limited to, floods, fires, wind, freezing, earthquakes, tornadoes, hurricanes and lightning strikes.
7. Defects caused by water sediments, rust corrosion, thermal expansion, scale deposits or a contaminated water supply
(such as water in the unit with chloride content higher than that of 80 mg/liter or use of chemicals not approved or recommended by Kärcher).
8. Defects caused by improper voltage, voltage spikes or power transients in the electrical supply.
9. Devices or accessories not distributed or approved by Kärcher.
10. Any cost of labor arising from the removal and reinstallation of the alleged defective part by Customer.
11. Transportation of the product to an Authorized Servicing Dealer, field labor, replacement rental and any freight charges.
Any components, accessories or other devices provided with the product but not manufactured by Kärcher (such as engines, pumps,
etc.) are subject to warranties and service through their respective manufacturers authorized service centers and according to the
applicable terms and conditions of such manufacturers warranties. Such components or other devices not manufactured by Kärcher
should be referred by the Customer to an authorized service center or their respective manufacturers for repair or replacement.
THe fOregOINg WArrANTy IS IN LIeU Of ALL OTHer WArrANTIeS Of ANy KIND, WHeTHer ArISINg by LAW, CUSTOM Or CONDUCT. KärCHer MAKeS NO ADDITIONAL WArrANTIeS, eITHer exPreSSeD Or IMPLIeD, INCLUDINg,
WITHOUT LIMITATION, ANy exPreSSeD Or IMPLIeD WArrANTIeS Of MerCHANTAbILITy Or fITNeSS Of eqUIPMeNT
fOr A PArTICULAr PUrPOSe AND ANy SUCH WArrANTIeS Are exPreSSLy DISCLAIMeD. KärCHer fUrTHer DISCLAIMS ANy WArrANTy THAT THe PrODUCT PUrCHASeD by CUSTOMer WILL MeeT ANy PArTICULAr reqUIreMeNT
Of CUSTOMer eveN If KärCHer HAS beeN ADvISeD Of SUCH reqUIreMeNT.
THe rIgHTS AND reMeDIeS PrOvIDeD UNDer THIS WArrANTy Are exCLUSIve AND IN LIeU Of ANy OTHer rIgHTS
Or reMeDIeS Of CUSTOMer. KärCHer SHALL NOT UNDer ANy CIrCUMSTANCeS be LIAbLe TO ANy PerSON Or
eNTITy INCLUDINg, bUT NOT LIMITeD TO, THe CUSTOMer Or ANy eND USer Of THe PrODUCT fOr ANy SPeCIAL,
INDIreCT, INCIDeNTAL Or CONSeqUeNTIAL DAMAgeS Or eCONOMIC LOSS, LOSS Of PrOfITS Or LOSS Of USe Of
THe PrODUCT, ArISINg IN CONNeCTION WITH THe SALe, DeLIvery, INSTALLATION, TrAININg Or USe Of PrODUCT.
KärCHer’S LIAbILITy, WHeTHer IN CONTrACT Or IN TOrT, ArISINg OUT Of ANy WArrANTIeS Or rePreSeNTATIONS, INSTrUCTIONS Or DefeCTS frOM ANy CAUSe, SHALL be LIMITeD exCLUSIveLy TO THe COST Of rePAIr Or
rePLACeMeNT PArTS UNDer AfOreSAID CONDITIONS.
The purpose of the foregoing limitations on liability and Customer remedies is to protect Kärcher from unknown or undeterminable
risks. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion
may not apply to the Customer.
Kärcher sales and service representatives are not authorized to waive or alter the terms of this warranty, or to increase the obligations of Kärcher under the warranty.
Kärcher reserves the right to make design changes in any of its products without prior notification to the Customer.
9.800-079.0 • Rev. 4/08
PRESSURE WASHER WARRANTY
LIMITED NEW PRODUCT
WARRANTY—COMMERCIAL
PRESSURE WASHERS
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