Hydro Tek Sc Series, HD Series, CN Series, HX Series, CP Series, SCU series, SS series, CW series, HP series User manual

Hydro Tek Sc Series, HD Series, CN Series, HX Series, CP Series, SCU series, SS series, CW series, HP series User manual
$15.00
OPERATION and MAINTENANCE
MANUAL
CP
CW
CN
HD
HP
HX
SS
SC
SCU
SERIES
SERIES
SERIES
SERIES
SERIES
SERIES
SERIES
SERIES
SERIES
© Hydro Tek 04/2010
IMPORTANT: TO REDUCE RISK OR INJURY, READ OPERATING
INSTRUCTIONS CAREFULLY BEFORE USING
POWER WASHERS
Cold Water
Hot Water - electric
Self-contained Skids
Natural Gas
Trailers
HOSE REELS
SURFACE CLEANERS
WASH WATER RECYCLE
TABLE OF CONTENTS
1
INTRODUCTION .......................................................................................................................... 2
Statement of No-Nonsense Warranty
SAFETY WARNINGS ............................................................................................................... 3, 4
Electrical Precautions
Fire Precautions
Ventilation Precautions
Spray Injection Precautions
Personal Hazard Precautions
OPERATING INSTRUCTIONS ................................................................................................ 5, 6
Before Start Up
Operation
Shut Down & Antifreeze Protection
SYSTEM INFORMATION
Power System ................................................................................................................... 7
Electric Motor/Gasoline Engine/Diesel Engine
Power Transmission System – direct, & belt drive
Generator – auxiliary power, circuit breaker
Pumping System ........................................................................................................... 8, 9
Pump
Unloader and Pressure Relief Valve
Chemical Injection System
Water Supply
Heating System ........................................................................................................... 9, 10
Coil/Heat Exchanger System
Diesel Fired Burner
Pressure Delivery System ......................................................................................... 10, 11
Discharge Hose\Gun/Wand Assembly
Nozzles
Accessories............................................................................................................... 11, 12
Wet sandblaster, turbo nozzle, reels, Hydro Twister, Wastewater recovery
TRAILERS .................................................................................................................................. 13
TROUBLESHOOTING GUIDE ............................................................................................. 14, 15
BURNER TROUBLESHOOTING GUIDE ............................................................................ 16, 17
SERVICE/MAINTENANCE INFORMATION .............................................................................. 18
EXPLODED VIEW ........................................................................................................... Enclosed
TRAILER REGISTRATION – CERTIFICATE OF ORIGIN ....................... Enclosed (If applicable)
TEST SPECIFICATIONS ................................................................................................ Enclosed
ENGINE SHEET .............................................................................................................. Enclosed
PARTS LIST / EXPLODED VIEW ................................................................................... Enclosed
INSTALLATION INSTRUCTIONS .................................................................................. Enclosed
WIRING DIAGRAMS BY SERIES ................................................................................... Enclosed
USE ONLY HYDRO TEK CERTIFIED ORIGINAL EQUIPMENT REPLACEMENT PARTS, FAILURE
TO DO SO COULD LEAD TO WARRANTY EXCLUSION AND SEVERE BODILY INJURY
INTRODUCTION – WARRANTY
THANK YOU: The employees and management of
HYDRO TEK SYSTEMS, INC. thank you for
selecting our products. The production and quality
assurance team have taken the greatest care to
ensure that your new power washer exceeds the
standards set by you, the customer, by Hydro Tek
engineering and management, and by our safety
certification to U.L. 1776.
YOUR RESPONSIBILITY: This operator’s 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.
Every person who will operate the equipment must
read and follow the safety warning and operating
instruction sections of this owner’s manual prior to
use. You are responsible for operating the product
properly and safely. You are also responsible to
follow the maintenance schedule on the back page
of this manual to keep your warranty active.
FREIGHT DAMAGE: If delivered by a trucking
company, please inspect for any concealed freight
damage and note this on the paperwork from the
trucking company before signing. 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.
QUESTIONS: Help us provide you with the fastest
service.
Please locate the enclosed warranty
registration card and return it to Hydro Tek to
register your machine. If problems occur, contact
the dealer you bought your machine from, a local
authorized Hydro Tek service center, or call the
Hydro Tek factory and ask for technical services.
THERE
ARE
NO
USER
SERVICEABLE
COMPONENTS ON THIS EQUIPMENT.
GETTING STARTED: If your dealer has not
prepared the machine for startup, you may need to
connect the hose to the pressure outlet on the
washer and connect the other end of the hose that
swivels to the trigger gun inlet and tighten. Mobile
Wash Skids are engine powered and shipped from
the factory with the fuel tanks empty and without
the battery. Fill the battery to the fill line with
electrolyte (available through your dealer or a local
auto parts store). Connect the battery cables, and
follow the operation instructions for starting.
Pressure Steamers are electric powered and will
require an appropriate electric outlet or disconnect
box and an electric plug that is rated for your
machine’s voltage and amperage and matches to
your electrical socket.
Smaller machines are
2
equipped with a ground fault interrupter on the
electrical cord and you will need to press the reset
button after it is plugged in. (See Operating
Instruction section and enclosed page on
Installation Guidelines).
NO-NONSENSE GUARANTEE:
Hydro Tek
Systems, Inc. (Hydro Tek) promises to repair Hydro
Tek power washers if defective in materials or
workmanship for one year from the date of original
retail purchase including the cost of PARTS and
LABOR, but you must pay transportation costs and
travel time.
Items and Conditions Not Covered:
1. Normal wear items such as discharge hose,
guns, wands, spray arms, nozzles, quick couplers,
o-rings, pump packing, brushes, filters, belts, and
tires.
2. Cost of regular maintenance/adjustments or
damage from lack of maintenance.
3. Damage due to freezing, abrasive fluids,
chemical deterioration, and scale build-up.
4. Damage from fluctuation in electrical or water
supply.
5. Any product or part that has been altered,
modified, over pressurized, misused, or has been in
an accident.
6. Dealer installation or damage from improper
installation of the machine or alteration by a dealer
or promise of additional warranty from dealer. The
factory warranty is not transferable from the dealer
to the retail purchaser on used or rented
equipment.
7. Labor is not paid if the dealer that serviced your
machine is not an authorized service center.
8. Labor is not paid on added accessories such as
surface cleaners, hose reels, wastewater recovery
and filtration.
WARRANTY PROVIDED BY OTHERS: Gasoline
and diesel engines and some electric motors are
warranted by the manufacturer of the component
and their warranty is provided through the
manufacturer’s service centers.
BIG 6 COIL REPLACEMENT: Should the heater
coil leak under normal conditions within the first 6
years of service, Hydro Tek will provide a
replacement coil free of charge. Failure from
freezing is considered neglect and is therefore
excluded. Freight and installation labor is not
covered.
WARRANTY – SAFETY WARNINGS
GENERAL
CONDITIONS:
Hydro
Tek’s
responsibility with respect to claims is limited to
making the required repairs or replacements to the
original retail user, and no claim of breach of
warranty shall be cause for any cancellation or
rescission of the contract of sale of any Hydro Tek
product. 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.
This supersedes any and all previous warranty
statements for products purchased after March 1,
2009. Hydro Tek is not liable for indirect, incidental
or consequential damages including any cost of
substitute equipment, loss of revenue, pecuniary
expense or loss, or inability to use a Hydro Tek
product.
Hydro Tek disclaims all implied
warranties, including those of merchantability and
fitness for use for a particular purpose. Some
states do not allow exclusions or limitations on how
long an implied warranty lasts, so the above
exclusions may not apply to you. It is the buyer’s
responsibility to ensure installation and use of
Hydro Tek products conforms to local codes.
Products exported outside the US and Canada are
covered solely by the warranty of the local export
dealer and this warranty does not apply.
HOW TO OBTAIN WARRANTY SERVICE:
1. List washer model#______________________.
List serial #____________________ (on base plate
of machine near the motor).
2. Contact your local service dealer and return the
Hydro Tek washer or part within the warranty
period along with your sales receipt. To locate
service, call Hydro Tek and ask for technical
services or go to: www.hydrotek.us
3. You also have the option to obtain a return
goods authorization and ship the questionable part
freight prepaid directly to the factory. The part will
be evaluated upon receipt. If found defective,
Hydro Tek will repair or replace part under the
conditions of warranty and return to you.
4. If the defective component is an engine or
motor made by another manufacturer, we, or your
authorized Hydro Tek dealer, can help you obtain
warranty
service
through
the
specific
manufacturer’s local authorized service center.
5. If you are unable to resolve the warranty claim,
write to Hydro Tek Systems, Inc. 2353 Almond Ave.
Redlands, CA 92374, Attn.: Technical Services.
Please enclose a copy of the dated purchase
receipt and explain the nature of the defect.
3
WARNING
THIS EQUIPMENT CAN BE HAZARDOUS TO THE OPERATORS
SAFETY AND ONLY AUTHORIZED PERSONNEL WHO HAVE
READ AND UNDERSTOOD THE OPERATON MANUAL SHOULD
BE PERMITTED TO OPERATE THIS UNIT. NEVER ALLOW
CHILDREN TO PLAY ON OR AROUND THIS EQUIPMENT.
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. (7.5hp single phase excluded; order
GFCI separately). 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, grounding provides a path of least
resistance for electric current to reduce the risk of
electric shock. The 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 equipmentgrounding 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 have 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. Do not
spray high-pressure water on to the machine.
8. Disconnect power supply before making any
repairs or adjustments.
SAFETY WARNINGS
9. Transformer on burner is 20,000 volts.
Disconnect battery cable before servicing burner or
engine on 12-volt systems.
Warning: FIRE OR EXPLOSION HAZARD CAN CAUSE
PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
FIRE PRECAUTIONS:
1. DO NOT use improper fuels or solvents in this
equipment, and only fill with the correct fluids when
the unit is in an OFF condition, main power is
disconnected, and engine and burner are cool.
2. Fill the diesel burner fuel tank with #2 diesel
fuel, kerosene, or approved alternate fuel. NEVER
use gasoline. Do not confuse gasoline and diesel
fuel tanks.
3. NEVER operate this equipment in the presence
of flammable vapors, dust, gases, or other
potentially combustible materials.
4. AVOID contact with the exterior of the coil/heat
exchanger assembly, mufflers, and exhaust port or
stack to prevent burns.
5. DO NOT store fuel or other flammable materials
near the burner or any other open flame.
6. Diesel fired or gasoline power units are
designed for outdoor use and installation only.
7. Burner on/off switch must be placed in the OFF
position when the pressure washer is not being
used. Do not depend on engine run switch to turn
the burner off – this may cause a safety hazard.
8. Warning: Burner (water heater) should start
only when water is sprayed.
Stop the
system/engine immediately if burner continues to
fire when trigger gun is off.
VENTILATION PRECAUTIONS:
1. Do not run engine or 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. Provide adequate ventilation to prevent engine
overheating and inefficient burner combustion (min.
2’ air space). Do not restrict normal engine airflow.
4. For engine driven units mounted in a van or box
truck type vehicles, provide an external engine
exhaust line that is larger in diameter than the
factory exhaust pipe and vent the exhaust to the
outside of the vehicle, but not below the vehicle’s
interior floor height. Also, insure adequate fresh air
circulation within the van for engine cooling
purposes to prevent heat build-up and for engine
fresh air intake. Clearance of at least 12” is
recommended on all sides of the unit. Provide a
burner exhaust vent, at least 8” diameter, to the
outside through the van roof, or though the side
4
panel that is at least 10” in diameter, and position
this vent to avoid water, dirt and debris collection.
No flammable liquids, aerosols, or flammable
materials should be stored within 24” of the unit and
should not be stored under the unit. During
refueling, ALL ignition sources and switches should
be OFF and there should be a person with the
proper fire extinguisher and training within the
vicinity of the unit in case of fire. Unit should not be
left running unattended or out of site.
SPRAY INJECTION PRECAUTION:
1. Fluid from high-pressure spray or leaks can
penetrate the skin 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.
2. WARNING – Risk of injection or severe injury to
persons – Keep clear of nozzle. DO NOT direct
discharge stream at people. This machine is to be
used by trained operators. Keep operating area
clear of all people. 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.
CAUTION: Hot discharge fluid – DO NOT touch or
direct discharge stream at people. Gun kicks back
– Hold with both hands. Stay alert – Watch what
you are doing.
3. 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.
4. Know the detergents you are using. Read and
follow the directions on the detergent labels.
PERSONAL HAZARD:
1. Shut unit off and disconnect power before
removing belt guards or electrical covers.
2. Shut unit off before moving it.
3. NEVER lock the trigger on the gun valve in the
on position.
4. Do not exceed recommended operating
pressure or temperature.
5. Observe all regulations when towing trailermounted units.
6. Keep hands clear of belts:
Some units
equipped with auto-on may start at any time when
power is connected.
7. Do not operate the product when fatigued or
under the influence of alcohol or drugs.
OPERATING INSTRUCTIONS
BEFORE START UP: Read all instructions
1. CHECK PUMP OIL:
Check pump oil by
locating the oil view window. Depending on your
pump model, fill to the red dot or to the top of the
site glass window.
2. CHECK FLUID LEVELS: Check engine oil and
coolant levels if unit is so equipped. (See the
maintenance schedule on page 9).
3. CONNECT HOSE AND GUN ASSEMBLY.
4. CONNECT THE WATER SUPPLY & TURN
WATER ON: Maintain an adequate supply of water
using a ⅝” to ¾” I.D. hose with a pressure between
25 and 60psi. Burner power switches should be off
before starting. If tank fed, be sure there is water in
the tank and the valve is switched for supply tank
feed. Do not run dry.
5. BATTERY INFORMATION:
Batteries are available through your dealer or local
auto parts store. Depending on the type of battery
you purchase, you may have to fill it with
electrolyte. WEAR EYE PROTECTION!
We recommend Exides’ CCA deep cycle batteries
(if the opening on your battery box measures 9”x6”,
U1L/GTH 235, if opening measures 8”x12”, group
46-60 550). Always connect the positive battery
cable before the negative and coat the battery
terminals with corrosion inhibitor to prevent
corrosion. Do not reverse polarity.
6. If wheel kit, accessories, or discharge hose are
not installed, see your local dealer for instructions &
installation.
WARNING
BE SURE TRIGGER
ON SPRAY GUN IS
OFF AND CHEMICAL
VALVE IS CLOSED
WARNING
DO NOT
OVERINFLATE TIRES
INFLATE TO MANUF.
SPECIFICATIONS
WARNING
DO NOT OPERATE
MACHINE WITHOUT
ADEQUATE WATER
SUPPLY
OPERATION:
1. STARTING:
Electric Powered Units:
Connect power supply and ensure that all wiring
connections and voltages are of sufficient rating to
comply with the equipment’s requirements. Turn
pump power switch on. If unit is equipped with
auto-start, keep all power switches off when left
unattended. (Unit will only turn on when trigger gun
is pulled.)
Gasoline Engine Units:
Turn engine power switch to the on position, choke
if necessary and turn key to start position only until
engine starts. On units with a rewind starter, pull
cord rapidly.
Diesel Engine Units:
Turn power switch to heat the glow plugs for a
maximum of 30 seconds and release. Turn the
5
power switch to the start position only until engine
starts. (Do not use starter fluids.)
2. PURGE AIR FROM SYSTEM:
Squeeze the trigger on the spray gun until a
constant stream of water comes out. (Purging
works best with nozzle removed from wand and/or
dual wand in the low-pressure mode.)
3. SELECT DESIRED NOZZLE
Connect nozzle securely to spray wand.
If
equipped, close pressure-adjusting knob on dual
wand. Hold gun firmly, squeeze trigger for highpressure spray. CAUTION – Gun kicks back – hold
with both hands.
WARNING – risk of explosion – DO NOT spray
flammable liquids.
4. START BURNER:
To create hot water on high pressure washers
equipped with heat exchangers, release the trigger
on the gun, turn the burner to the “on” position, and
turn the thermostat to the desired temperature.
Squeeze the trigger on the spray gun and the
burner will begin heating the water. It will stop firing
whenever the water spray is off or if the
temperature setting is exceeded.
Warning: Cool down burner before shutting off.
5. STEAM: (If Equipped)
Insert green steam nozzle and turn thermostat to
250° steam setting. The steam nozzle is sized for
approximately 25% less water volume than the hot
water mode.
6. BYPASS MODE:
System will go into bypass mode when machine is
left running and trigger gun is closed. Bypass
mode is when the inlet water coming into the pump
re-circulates through the unloader across the pump
head. If left in bypass too long – more than five
minutes – friction created by the movement of the
water will begin to heat the water at a rapid rate. If
equipped with a THERMAL DUMP VALVE, water
exceeding 145°F will cause the valve to open
allowing the cool water in. The valve will reset itself
when water temperature comes down to a safe
level. If equipped with a bulk water tank, water can
be bypassed back through the tank allowing for a
larger volume of water to be re-circulated through
the pump head thus reducing heat on the pump
seals. If equipped with By-pass-cool system, a
small portion of the bypass water is routed back
through the float tank to keep the pump cool.
Warning: Do not leave in bypass for longer
than five minutes to prevent pump from
overheating. Shut off unit when not spraying
water.
OPERATING INSTRUCTIONS
7. SET CHEMICAL INJECTION:
If unit is equipped with inlet chemical injection,
place chemical pickup tube in pre-mixed chemical
solution and open chemical valve for desired
chemical concentration. Rinse and close valve
after use, do not use harsh chemicals through the
inlet injector system. Drawing air into the chemical
tube by leaving the chemical valve open will cause
the pump to lose pressure and may cause pump
damage.
MAINTAIN PH BETWEEN 5 & 9
If unit is equipped with a downstream chemical
injector, connect the chemical injection assembly
into the high-pressure discharge hose quick
connects. Place the chemical pickup into chemical
solution and turn brass collar to adjust
concentration. The chemical will inject only when
you drop the outlet pressure by opening the valve
on the dual wand or changing to a low-pressure
nozzle. Soap the surface from the bottom up.
Rinse and close chemical valve when not in use.
8. If equipped with an AF2 (2) gun operation,
select “50%” nozzle from panel and insert into
coupler on spray gun for full pressure output when
using two guns at the same time. Flow can be
reduced by selecting flow reduction nozzles only
when one operator is using the machine. Maximum
temperature is 200°F.
WASHING 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 250° steam.
For general washing use a broad pattern spray
nozzle such as the 40-degree nozzle. Backing
away from the surface and using the broad spray
nozzle works best to perform rinsing and delicate
surface washing. 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
6
other is with the chemical system on the
equipment; either downstream or high pressure
depending on the system you have. When using
the high-pressure 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 a
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
and let it work in for couple of minutes before
rinsing. Do not allow chemicals to dry on the
surface.
When rising 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 & close chemical valve.
3. Squeeze the trigger on the spray gun until the
water becomes cool.
4. Turn motor/engine switch off with the
appropriate controls. Turn off diesel engine units
by pulling the throttle kill lever.
5. Turn off water supply.
6. Squeeze trigger to release any trapped
pressure in discharge hose.
7. Disconnect & store hoses.
8. Antifreeze equipment:
In the event that the equipment is not to be used for
an extended period, 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.
APPEARANCE:
To maintain appearance of the power washer, use
stainless steel cleaner on the stainless steel
panels.
SYSTEM INFORMATION
POWER SYSTEMS:
ELECTRIC MOTORS: All single
phase 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. Voltage reading
under load should be +/- 10% of name plate
voltage on motor. Wait for motor to cool before resetting. Depressing the red overload button located
on either the motor or the starter can reset the
motor. Use thumb pressure – do not force. If
equipped with an automatic thermal overload, it will
reset itself after the motor has cooled.
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. Three times total system wattage
is required.
HORSE
POWE
R
1.5
2
5
6.5 / 6
7.5
10
15
115
v
1ph
15a
20a
------
WIR
E
SIZE
12/3
10/3
------
208 WIR 208 WIR 230 WIR 230 WIR 460 WIR
v
E
v
E
v
E
v
E
v
E
1ph SIZE 3ph SIZE 1ph SIZE 3ph SIZE 3ph SIZE
----10a 14
--------12a 14
----26a 10/3 --24a 10/3 --------27a 10/3 22a 12/4 13a 14/4
40a
8
24a
8
34a
8
24a
8
12a 14
50a
8
32a
8
50a
6
30a 10 14a 12
--40a
8
--38a
8
17a 12
A fused disconnect switch of sufficient ampere
rating should be installed by an electrician to
provide power to the machine. Note: 208-230 VAC
rated CN/CW/HN series washers include a control
circuit power selector switch, located on the back of
the control box. Switch it to the appropriate
position to match your source voltage. Switches
are factory set to match recorded test sheet
voltage.
Refer to the chart above for electrical
requirements. 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.
GASOLINE ENGINE: With the
proper care and maintenance,
your gasoline engine will give
years of trouble free service.
Please follow the Service and
Maintenance Guide and the
enclosed engine sheet or contact your local
authorized engine dealer for maintenance and
repairs.
Use clean, fresh, unleaded gasoline with an octane
rating of 87 or higher in the engine fuel tank. Do
not use unapproved gasoline such as E20 or E85
ethanol blends. Up to 15% MTBE (methyl tertiary
7
butyl ether) or 10% ethanol is acceptable. Any
failures from use of these fuels will not be
warranted. Consult engine manual for proper oil
type and capacity.
The engine manufacturer
recommends a break-in period of 25 hours at which
time the engine oil and filter should be replaced.
Thereafter, change oil every 50 hours and the filter
every 100 hours (see engine manual). Do not rely
on the low oil shutdown (if equipped) as a reminder
to add oil. The engine manufacturer will typically
not warranty engine damage from lack of oil even if
the low oil system failed.
On machines with a 115V generator or a 12V
burner, the throttle is preset at the factory (See
Generator section). Some engines include backfire
prevention solenoids.
DIESEL ENGINE: The diesel engine, although it
has a higher initial cost, can save money with lower
fuel consumption and longer life. Use clean diesel
fuel #2 and do not allow engine to run out of fuel or
the system will have to be bled to restart the
engine.
Clean the fuel filter periodically with kerosene (See
Engine Manual). Use 10w – 30 oil with API
classification CC/CD grade rated for diesel engines
in the engine crankcase and change every 50
hours. If the engine is water cooled, use a 50/50
mix of antifreeze/de-ionized water solution and
check daily. Never use more antifreeze than water
or damage to the engine could occur from
overheating.
POWER TRANSMISSION:
WARNING: Shut off power supply
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 them to slide.
Turn the
horizontal rail adjusting bolts to tighten belts until
they deflect ¼" to ½” with finger pressure.
DIRECT DRIVE: Pump is bolted directly to the
motor/engine. If pump needs to be removed, do
not force off by prying or damage may occur.
When reassembling, coat the entire motor shaft
with heavy grease or a generous amount of antiseize and use “thread locker” or “lock tight” on
mounting bolts.
GENERATOR:
Some self-contained hot water
units (SC and SCU Series) are
equipped with a 115v, 2900w
generator to power the diesel
SYSTEM INFORMATION
burner. The generator output voltage must be
between 110 to 130 Volts, (or between 59 to 63
Hz.), when the unit is under full load. If the
generator voltage falls out of this range, the RPM
of the engine will need to be adjusted to proper
speed. If the engine cannot maintain the proper
RPM, do not use the burner or any power from the
generator until the engine is repaired.
An AUXILIARY OUTLET is available on some SC
or SCU Series machines for running wastewater
recovery systems, light, or other accessories off of
the generator. A maximum of 1500 watts of 115v
power is available when the burner is on or 2000
watts when it is off. A switch/circuit breaker located
on the control panel will need to be reset if the
circuit is overloaded.
Use of a ground fault
interrupter is recommended when plugging in
accessories or lights to the auxiliary voltage outlet.
To extend generator life, make sure the burner and
all auxiliary power is off when the engine is started
or stopped. Keep generator dry.
PUMPING SYSTEM:
PUMP: The pump is a positive
displacement, oil bath crankcase,
and 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
crank case 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 red dot with non-detergent
30w 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.
Keeping filters clean and checking for air in pump
feed lines can prevent cavitation and increase
pump life. Do not run 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 145°F).
Do not run pump dry. Protect from freezing. Do
not run a frozen pump until it is completely thawed.
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 back into the inlet
if the trigger on the spray gun is released.
8
NEVER increase the set pressure on the unloader
to exceed the specifications for your machine.
All hot water machines are
equipped
with
a
SAFETY
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.
BURST DISC TECHNOLOGY: This additional
safety feature functions to protect the coil 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 light vacuum, not to
exceed negative 3psi, which draws up the chemical
into the inlet manifold of the pump, mixes it with
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
causing the pump to lose pressure and 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 5-9 PH. 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,
by installing black soap nozzle
or opening spray wand valve if
equipped. 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 label.
WATER SUPPLY: An adequate water supply to
the pump must be maintained at all times. If the
SYSTEM INFORMATION
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
145°F. Do not restrict inlet water supply. 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 ⅝” to ¾” I.D.
hose. Install a back flow preventer on your supply
hose if State or Local ordinances require it. Install
a water regulator if your water pressure exceeds 60
PSI.
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.
Bulk tank water supply: Large capacity water
supply tanks can be used with most units if water is
not readily available at the washing site. Belt
driven, low speed pumps (less than 1750 RPM) can
draw from a tank if you ensure that the vacuum
does not exceed negative 3psi. A 80 mesh, 200
micron strainer and a ¾” I.D. or larger suction hose
must be used to maintain a clean and adequate
water supply. Larger flow (8-10gpm) machines
require 1” feed and filtration. Be sure that the water
supply is free from air or damage to the pump may
result.
Periodically you should clean out the
strainer and water supply tank to remove debris
that may accumulate on the bottom. If a water
supply tank and a float tank are both utilized, a
special three way valve can be used to switch
between tanks.
USING DE-IONIZED OR SOFTENED WATER IN
YOUR POWER WASHER: Do not use de-ionized
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
9
the heating area. It is double wrapped with ceramic
blanket insulation and a stainless steel cover.
The inside of the coil assembly can become
covered with soot if the burner is out of adjustment
or if it is fired by diesel fuel. This can be cleaned by
removing both end caps on the coil enclosure and
brushing or spraying off debris, or by adding a soot
removal agent (Part #CB200) to the diesel fuel.
Both a diesel fuel pressure gauge and smoke test
device is required for proper burner adjustment,
and must be performed by a qualified technician.
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. To remove buildup in the coil, use a scale
remover (Part #CB100) available at your authorized
Hydro Tek dealer. Perform this descaling 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.
STEAM INSTRUCTIONS: If your unit is steam
capable, install the green steam nozzle, turn
thermostat to 250° F.
PRESSURE/FLOW SWITCH:
The burner is
equipped with either a pressure switch or a 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 machine
and have it serviced.
DIAGNOSTIC LIGHT: The burner diagnostic light
on the rocker switch (if equipped) can help in
determining problems with the burner. The red light
indicates that power is going to the fuel solenoid
valve. The burner should be firing and heating the
water whenever the red light is on. When the
trigger on the spray gun is released or if the
temperature set point is exceeded, the red light will
go off and the burner will stop firing.
SYSTEM INFORMATION
DIESEL FIRED BURNER: The
diesel-fired burner is a forced
draft
pressure-atomizing
burner. Diesel fuel is sprayed
out of an atomizing nozzle,
mixed with air, and ignited by a
high voltage spark. The flame
is directed towards the coils of pipe, which in turn,
heats the water flowing through it. Use clean #2
DIESEL FUEL for the burner or substitute #1
diesel, light fuel oil, or Kerosene if diesel is not
available.
AIR BAND adjustments may need to be made to
compensate for higher elevations, or if more than a
trace of smoke is observed in the burner exhaust.
The ELECTRODES may need to be cleaned and
adjusted periodically. These adjustments have to
be made precisely and should be performed only
by qualified personnel. Set between #1 & #2 on the
smoke gauge.
The FUEL PUMP is a self priming,
low volume pump which is propelled
by the burner motor. The fuel pump
pressure is typically set at 100 PSI
but can be turned as high as 140
PSI during the winter when the incoming water
temperature is lower. Before adjusting the fuel
pressure, connect a fuel pressure gauge and an
outlet water temperature gauge, turn the pump and
burner on, and turn the fuel pressure screw
clockwise until the desired water temperature is
obtained. Be sure not to exceed the recommended
specifications of the machine.
The FUEL FILTER will need to be replaced often if
the diesel fuel quality is poor. A fuel filter with a
water separator is recommended if the fuel quality
is consistently poor.
The FUEL SOLENOID is an electric fuel valve that
shuts off the fuel whenever the trigger on the spray
gun is released or if the set temperature on the
heat switch is exceeded.
The IGNITION TRANSFORMER provides a high
voltage spark that travels down the electrodes to
ignite the diesel fuel. Disconnect all power before
servicing.
The 12V burner operates from the battery on the
SS Series (and a limited number of SC Series).
The engine has a 15 to 20 amp charging system
that keeps the battery charged which runs the
burner. The burner motor and transformer stop
10
when the trigger gun is released and is controlled
through a high amperage contactor. To help keep
the battery fully charged, and for safely cooling
down the burner, turn off the burner during the last
minute of rinsing. When leaving the machine
unattended, shut off burner and engine switch.
Replace 12 VDC battery regularly (2 year maximum
interval) on 12V burner systems to help ensure
consistent performance.
PRESSURE DELIVERY STYSTEM:
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 4000psi. Additional hose
lengths can be added with quick twist 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
a special 250° 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 swivel
connectors on the high-pressure
hose and quick couplers on the spray
nozzle make it easy to change nozzles or hoses.
When connecting hoses or nozzles, be certain that
the collar on the quick couplers snap into the
locked position to prevent them from becoming
loose. 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 also used on
most 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 any gun in the on position for any
reason. Never point spray at a person or any
part of the body.
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.
ACCESSORIES
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 in
which your machine was designed. The orifice, or
hole, of the nozzle will enlarge with wear. For
optimum performance, replace the spray nozzle to
maintain the full output pressure of your machine.
The nozzle installed on 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 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 into 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 four different spray
angles: 0°, 15°, 25°, and 40°. The different spray
angles of a given size of nozzle does not change
the output pressure of the machine, just the impact
force and surface coverage of the water spray.
The optional 0° nozzle sprays a straight stream
which impacts the surface very hard but does not
cover a very wide area. Use the 0° red nozzle with
care because it can damage the surface you are
spraying with its high impact and long reaching
spray.
The 15° yellow nozzle sprays out a flat stream at a
15° pattern. It gives you less impact power than
the above, 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 25° green nozzle is wider than the 15° and is
most commonly referred to as the “steam nozzle”.
The steam nozzles are sized to spray less water
than the other high-pressure nozzles, so the water
is discharged at a higher temperature. (Up to
250°F.)
The 40° nozzle spreads the water stream over a
wide area to give you less impact for delicate
surfaces.
11
OPTIONAL ACCESSORIES:
WET SANDBLASTER: The wet sandblaster is a
system that introduces sand
(or other media such as
baking soda) into the water
stream for abrasive blasting. It
is especially effective for
graffiti or paint removal.
Performance of the 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) for fine metal
surfaces or wood. Do not use wet sand or mix
different grits of sand. A sand hopper is available
for convenient sand storage. An air valve is
available for adjusting feed rate on the hopper and
should be fully open when using fine media such as
baking soda. Always use safety goggles and
protective clothing when operating the wet sandblaster.
TURBO
NOZZLE:
(please
note
temperature limits below) The turbo nozzle
multiplies the power of your machine by
rotating the spray jet and making the water
impact a surface harder to give better
cleaning results.
“Turbo Laser” type nozzles cannot be used with
water over 190° or the life of the turbo nozzle will
be greatly decreased and the warranty voided. The
“Rotomax” type nozzle can be used up to 170°.
Turn off burner or reduce temperature setting
before using. Simply remove regular spray nozzle,
replace with the turbo nozzle and squeeze the
trigger on the spray gun. Do not point the turbo
nozzle upward when starting.
EXTENSION HOSES: connecting additional hose
lengths by means of twist couplers can extend the
length of your high-pressure discharge hose. Hose
ACCESSORIES
extensions generally come in 50’ and 100’ lengths.
Specify maximum pressure and temperature of
your machine when ordering.
Low-pressure inlet garden hoses are available in
50’ and 100’ lengths. Premium quality, 200psi
rated hoses are recommended.
HOSE REELS:
Hose
reels are available for
convenient and quick
storage of both discharge
and
inlet
hoses.
Different
hose
reels
options are available for
trailer mounting, machine
mounting, or as base
mount options. To keep the hose from unreeling,
lock the drum in place and secure the gun or the
end of the hose or it may drag on the road. The
low-pressure hose should be of sufficient quality
that it will not flatten out when reeled up, or water
supply to the machine will be cut off.
If the reel swivel begins to leak, replace or connect
the hose directly to the machine until the leak is
repaired. Hose reel swivels with lubrication are
pre-lubricated at the factory. Additional lubrication
intervals depend on application and frequency of
use. However, a minimum for re-lubrication at 40
hours is recommended. Standard Moly-Lith grease
is recommended. Do not over grease. Using a
hand held grease gun, dispense one pump of
grease into the grease fitting. Depress the ball
bearing at the end of the grease fitting to allow the
grease and air to escape. WARNING: Replace
discharge hose with original equipment hose rated
for 250°F, available at Hydro Tek dealers.
HYDRO TWISTER – Surface Cleaners:
The Hydro Twister® is a
flat surface cleaner that
connects to a pressure
washer and uses a spray
bar rotating at a high
speed within 1” of the
ground.
It will clean
concrete more consistent
than an operator with a
spray wand, with less
fatigue, and 10-20 times
faster. Simply move the
twister over the surface
and watch a clean path
appear behind the unit.
The Hydro Twister can be used with hot water up to
250º on most models for extra stubborn grease or
12
grime, eliminated the need for soap pretreatment in
most applications.
Rated to be used with a
pressure washer up to 4000psi and up to 10gpm.
See your dealer for proper nozzle size
configurations to match your pressure washer.
Available models are: ANT19, ANT20, ANT28,
ANT38, and the Contractor Series ANT3C.
Twisters with vacuum recovery capability are also
available ANTV3 and ANT12
WASTEWATER
CONTAINMENT
AND
RECOVERY:
Hydro Tek manufactures Hydro
Vacuum®, a product line of mobile wastewater
recovery accessories. Starting with containment
berms to divert
wash water away
from storm drains
and
toward
a
vacuum
pickup
device.
The
vacuum
system
can be used to
simply pickup and transfer the water to a bulk tank
or filter the water for washing reuse or sanitary
sewer disposal.
Vacuum system choices are either fully portable
(on wheels) or truck or trailer mount systems.
Dispose of collected wastewater properly: Permits
can be obtained to dump wastewater into a sanitary
sewer system if properly treated and tested. It is
illegal to allow wash water to run into storm drains.
TRAILER INFORMATION
13
TRAILERS: Hydro Tek trailers are designed to
match your Hydro Tek washer and increase
productivity.
Several trailer and tank skid
configurations are available.
The trailer electrical connection comes with a 4
pole flat receptacle. Because of the vast array of
different connectors, you may need to have one
installed by your dealer or purchase
at a local auto parts store and install
yourself.
Electric brake trailers
require an electric brake controller
installed in the tow vehicle.
Be sure that the trailer you order conforms to your
particular State Department of Transportation
regulations, including but not limited to braking and
lighting requirements. If water is being transported
on the highway, trailer brakes are recommended.
Adjust brake drums as required.
Before taking trailer on the road, be certain that the
hitch on your tow vehicle is rated for the full trailer
weight and of the proper height so that the trailer
remains level when hitched, or wheel damage
could result. Trailer tongue weight on the tow
vehicle hitch should never be under 8% of the total
trailer (loaded) weight. Insufficient tongue weight
can result in “fishtailing” and loss of control of the
trailer AND tow vehicle.
TIRE PRESSURE
T200
T300
T400
T500
14” tires
13” tires
14” tires
14” tires
50 psi
35 psi
50 psi
50 psi
Before each use: Check air pressure in tires.
Check all bolts including the lug nuts for tightness
and condition periodically. Double check safely
chain and wire harness before departing. Check
latch on coupler and adjust if required to fit your
trailer ball properly. Never tow without properly
adjusted rear view mirrors, brake actuators, or
lights.
Grease wheel bearings as required.
TRAILER MAINTENANCE SCHEDULE
3 MTH. 6 MTH.
OR 3000 OR 6,000
MILES
MILES
12 MTH.
OR
12,000
MILES
ITEM
FUNCTION REQUIRED
Brakes
Test that they are operational
Brake
Adjustment
Adjust to proper operating
clearance
Brake Magnets
Inspect for wear and current
draw
Brake Linings
Inspect for wear and
contamination
Brake
Controller
Check for correct amperage,
modulation
Brake Cylinders
Check for leaks / sticking
x
Brake lines
Inspect for cracks leaks or
kinks
x
Trailer Brake
Wiring
Inspect for bare spots, fray,
etc.
x
Breakaway
Systems
Check battery charge and
switch operation
Hub/Drum
Check for abnormal wear or
scoring
x
Wheel Bearings Inspect for corrosion or wear:
& Cups
clean & repack
x
Seals
Inspect for leakage; replace if
removed
x
Springs
Inspect for wear / loss or arch
x
Suspension Parts
/ Ball Hitch
Inspect for bending loose
fasteners/ wear; Lubricate
Hangers
Inspect welds
Wheel Nuts &
Bolts
Tighten to specified Torque
value (Lug = 70-90 ft lbs)
Wheels
Inspect for cracks, dents or
distortion
Tire Inflation
Pressure
Inflate to tire manufacturer's
specs.
Tire Condition
Inspect for cuts, wear, bulging,
etc.
Before every use
x
x
X
x
Before every use
x
x
x
x
Before every use
x
TROUBLESHOOTING GUIDE
PROBLEM
14
PROBABLE CAUSE
REMEDY
(The most recurring probable cause is listed first)
(Repairs should only be made by a qualified technician)
Power System: Gasoline or Diesel Engine Driven
Engine will not start or crank over
Battery dead.
Dirty battery connection.
Battery cables disconnected.
Engine, pump, or gearbox is seized.
Key-switch, solenoid and starter on engine defective
Engine will not start but will crank over Engine power switch is off or defective.
Low oil shut down is activated.
Low water switch engaged or defective (not on all models).
Low on fuel.
Fuel filter is clogged.
Engine flooded or starved.
Engine bogs down under load whenever Engine needs to be repaired or replaced.
spray gun is triggered
Operating in high elevation.
Carbon deposits on cylinder head
Charge or replace battery, add electrolyte if battery is new.
Clean connections / Carefully check polarity.
Connect or replace damaged cables.
Replace or repair seized part.
Repair or replace.
Check engine power switch.
Add oil to engine, check more frequently.
Add water to bulk tank feeding pressure washer.
Fill with appropriate fuel, bleed injector pump on diesel engine.
Replace or clean fuel filter
Choke only as required.
See engine manual or engine dealer.
Lower the pressure on the unit and check for correct engine
speed (RPM).
Remove head and wire brush deposits.
Power System: Electric Motor Driven
Electric motor does not start
Machine will not auto-start (if equipped
with ETS or ITS)
No electric power.
Thermal overload in the motor or starter has been tripped.
Power switch inoperative.
Electric motor or wiring failure.
No water to inlet.
Must have adequate water supply.
Scale build-up in coil.
Check filter screen & inlet pressure.
Inlet flow switch defective / jammed with debris.
Check cord, plug, socket, and breaker.
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.
Connect water supply.
25 PSI minimum.
De-scale coil for better water flow.
Remove spray nozzle and pull trigger to check auto-start
function.
Check mechanical function & electrical signal to relay.
Pumping System
Trigger gun leaks or will not shut off
Pump runs but has low spray pressure
Pump runs but has low spray pressure
Pump runs but there is erratic,
fluctuating pressure
Debris in gun valve assembly.
Water turned off.
Nozzle is plugged or sized incorrectly.
Inlet chemical injection valve is open without the end of the
pickup tube inserted into detergent.
Coil on hot water machines is obstructed.
Priming of pump after run dry.
Nozzle not installed.
Dual wand valve is open.
Leaky discharge hose or quick coupler. Water sprays out
around nozzle.
Inlet strainer clogged.
Worn or wrong size nozzle.
Belt slippage.
Unloader valve worn or improperly adjusted.
Air leak in inlet plumbing.
EZ start valve is leaking.
Broken or worn bearing or connecting rod in crankcase
Clean and check more frequently.
Replace with 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.
Remove hose to check for internal leaks.
Remove hose to check for internal leaks.
Increase water supply flow.
Clean out or replace worn valves.
Check fittings and hose for airtight seal, clean inlet strainer
screen.
Replace seals.
Pressure feed the pump and replace L.P. seals if water leaks
from the pump head.
Replace pump or bearing.
Loose drain plug or damaged seal
Locate point of oil leakage and replace damaged o-ring/seal.
Inadequate incoming water supply.
Stuck inlet or discharge valves.
Restricted inlet or air entering the inlet plumbing on pump.
Leaking High Pressure seals
Leaking Low Pressure seals
Excessive crankshaft play or loud,
knocking noise in pump
Oil leaking from pump
Clean valve assembly or replace gun.
Turn water on.
Clean or replace with proper size.
Close soap valve or submerge detergent pickup tube into
solution.
Clean obstruction or scale deposits from coil with coil cleaner.
Crack open fitting on high-pressure outlet of pump.
Install nozzle.
Close dual wand valve and install high-pressure nozzle.
Replace hose, quick coupler, or o-ring in the quick coupler.
TROUBLESHOOTING GUIDE
PROBLEM
Inlet injection will not siphon chemical
15
PROBABLE CAUSE
REMEDY
(The most recurring probable cause is listed first)
(Repairs should only be made by a qualified technician)
Check valve in strainer clogged.
Chemical valve not open or clogged.
Strainer not submerged in solution.
Detergent hose cut or kinked.
Check-valve malfunctioning.
Clean or replace. Rinse after each use.
Open chemical valve or clean.
Submerge strainer and replenish chemical.
Inspect hose, replace as necessary.
Repair or replace check-valve.
Pressure relief relieving water
Brass knob on injector is closed.
Unit not in low-pressure mode.
Detergent hose cut or kinked.
Strainer plugged or not submerged.
Internal injector parts corroded or stuck.
Outlet water temperature too high.
Un-loader failure/Coil overheating/Excessive pressure.
Burst disk relieving water
Excessive over-pressurizing and system spikes.
Open by turning counter clockwise.
Open dual wand or install low-pressure tip.
Inspect hose, replace as required.
Check screen on strainer pickup tube.
Disassemble, clean or replace.
Use with cold water (150° Maximum)
Turn machine off, wait a few minutes and restart. If problem
continues, take in for repair.
Take in for system check.
Water is emitted from the chemical
pickup tube
Downstream injector will not siphon
chemical
Battery
Battery keeps losing voltage (For 12v
systems)
Battery voltage low.
RPM too low.
Engine charging system faulty.
Electrodes misadjusted.
Fuel pump pressure too high. Air band too far open.
Burner amp draw too high.
Have battery checked and load test, charge if low and replace if
necessary. Allow water to cool 2 minutes before shutting off
engine.
Engine RPM should be 3600 RPM with no load.
Check engine charging system – must have 16 amp output.
Adjust electrodes to maximum 1/8” gap.
Fuel pump pressure should be approximately 100 to 110 PSI.
Adjust for proper burn.
Check amp draw of burner motor – should be 11 amp or less.
Check amp draw of transformer – should be 4.8 or less.
Water Temperature
Discharge water temperature exceeds
recommended operating temperature
Discharge water temperature not
reaching maximum operating
temperature
Burner input too high for conditions.
Water flow restricted.
High temperature limit switch faulty or set too high.
Burner input too low for conditions.
Decrease fuel pump pressure and/or fuel nozzle size.
Clean or replace nozzle of proper size. De-scale coil and clear
obstructions.
Replace or reset temperature limit switch.
Increase fuel pump pressure and/or fuel nozzle size.
Burner System – Diesel Fired
Refer to Burner Troubleshooting Chart on following pages
TROUBLESHOOTING GUIDE
16
BURNER TROUBLESHOOTING
SC / SCU Series - 120V AC
BURNER DOES
“NOT” COME ON
IS THERE FUEL IN THE TANK?
BURNER DOES
“NOT” TURN OFF
NO
ADD FUEL
YES
IS THE SPRAY TIP INSTALLED?
NO
YES
IS THE TRIGGER BEING PULLED?
NO
YES
IS THE BURNER SWITCH ON &
THE THERMOSTAT TURNED UP?
NO
INSTALL SPRAY TIP, BURNER REQUIRES 1000 PSI
TO OPERATE, IF UNIT IS EQUIPPED w/DUAL
LANCE WAND, CLOSE VALVE TO INCREASE
PRESSURE. VERIFY PROPER NOZZLE SIZE
LIGHT ON THE BURNER SWITCH TURNS OFF
WHEN THE TIGGER IS RELEASED?
YES
TRIGGER MUST BE PULLED TO OPERATE
PRESSURE/FLOW SWITCH
REPLACE FUEL
SOLENOID VALVE
NO
REPLACE PRESSURE
SWITCH OR FLOW
SWITCH
TURN SWITCH ON & TURN THERMOSTAT UP
THOROUGHLY CHECK UNIT: REPLACE ANY
DAMAGED HOSES, O-RINGS, OR TRIGGER GUN
YES
IS THE THERMAL O/L ON THE
BURNER MOTOR OR THE
BREAKER TRIPPED?
!! CAUTION!! TURN UNIT OFF
IMMEDIATELY AND REPAIR.
YES
RESET THE OVERLOAD AND/OR BREAKER
NO
DO YOU HAVE 110-120VAC
OUTPUT FROM THE GENERATOR
WHILE PULLING THE TRIGGER?
NO
CHECK BELT TENSION-ADJUST IF NEEDED. ADJUST ENGINE RPM TO RUN WITHIN SPEC-VOLTAGE OUTPUT
CHANGES WITH GENERATOR SPEED. CHECK CAPACITOR FOR 16MFD-ARC TERMINALS WITH SCREW
DRIVER BEFORE TESTING. IF ALL THESE TEST GOOD, REPLACE GENERATOR
NO
TURN THE THERMOSTAT FULLY CLOCKWISE & CHECK FOR CONTINUITY-REPLACE IF NO CONTINUITY.
CHECK FOR CONTINUITY ON THE PRESSURE/FLOW SWITCH WHEN THE TRIGGER IS PULLED REPLACE IF
NO CONTINUITY
YES
UNPLUG THE FUEL SOLENOID & CHECK THE TRANSFORMER FOR SPARK. !! CAUTION: HIGH VOLTAGE!!
CHECK ELECTRODE ADJUSTMENT AND AIR BAND ADJUSTMENT (SEE BURNER SPEC SHEET). REPLACE
FUEL NOZZLE, REPLACE INSULATION IF IT IS SATURATED WITH FUEL
NO
ADJUST FUEL PRESSURE TO SPEC. CHECK/REPLACE FILTER & REPAIR ANY AIR LEAKS. IF PROPER
PRESSURE CANNOT BE OBTAINED, REPLACE FUEL PUMP
YES
DOES THE LIGHT ON THE BURNER
SWITCH COME ON WHEN THE
TRIGGER IS PULLED?
YES
IS THERE FUEL VAPOR COMING
OUT OF THE BURNER EXHAUST?
NO
IS THE FUEL PRESSURE
100-140 PSI?
YES
CRACK COPPER FUEL LINE.
DOES FUEL COME OUT WHEN
TRIGGER IS PULLED?
NO
REPLACE FUEL SOLENOID VALVE
TROUBLESHOOTING ENDS: REPEAT PROCEDURE UNTIL TROUBLE FREE OPERATION IS OBTAINED
TROUBLESHOOTING GUIDE
17
BURNER TROUBLESHOOTING
SS Series – 12V DC
(also applicable to SC with 12v burners)
BURNER DOES
“NOT” COME ON
IS THERE FUEL IN THE TANK?
BURNER DOES
“NOT” TURN OFF
NO
ADD FUEL
NO
INSTALL SPRAY TIP, BURNER REQUIRES 1000 PSI
TO OPERATE, IF UNIT IS EQUIPPED w/DUAL
LANCE WAND, CLOSE VALVE TO INCREASE
PRESSURE. VERIFY PROPER NOZZLE SIZE.
!! CAUTION!! TURN UNIT OFF
IMMEDIATELY AND REPAIR.
YES
IS THE SPRAY TIP INSTALLED?
YES
IS THE TRIGGER BEING PULLED?
NO
YES
IS THE BURNER SWITCH ON &
THE THERMOSTAT TURNED UP?
NO
YES
TRIGGER MUST BE PULLED TO OPERATE
PRESSURE/FLOW SWITCH
YES
RESET THE BREAKER AND/OR REPLACE THE FUSE – LOOK FOR SHORT. CHECK ENGINE OUTPUT-MUST BE
12VDC OR HIGHER & LOAD TEST THE BATTERY. CHECK ENGINE RPM: 3200 FOR BELT DRIVE, 3400 RPM
FOR DIRECT DRIVE. REPAIR CHARGING CIRCUIT AND/OR REPLACE BATTERY IF NEEDED. LOW VOLTAGE
WILL AFFECT BURNER PERFORMANCE.
YES
CHECK THE TRANSFORMER FOR SPARK. !! CAUTION HIGH VOLTAGE!! CHECK ELECTRODE ADJUSTMENT
AND AIR BAND ADJUSTMENT (SEE BURNER SPEC SHEET FOR SETTING ELECTRODE GAP- IMPORTANT).
CHECK ELECTRODES FOR CRACKS. REPLACE FUEL NOZZLE. REPLACE INSULATION IF IT IS SATURATED
WITH FUEL.
NO
CHECK FOR 12VDC AT THE SMALL TERMINALS ON THE BURNER RELAY WHEN THE TRIGGER IS PULLED
AND THE BURNER SWITCH IS ON AND THE THERMOSTAT IS TURNED UP. DO YOU GET VOLTAGE?
NO
DOES THE BURNER MOTOR
TURN?
YES
YES
JUMP THE TWO BIG RELAY TERMINALS
TOGETHER (CAUTION-ONLY FOR 1-2
SECONDS). IF THE BURNER MOTOR
STARTS, REPLACE THE RELAY – IF
NOT, REPLACE THE BURNER MOTOR.
IS THE FUEL PRESSURE 140 PSI
(+ - 10 PSI)?
REPLACE THE
PRESSURE OR
FLOW SWITCH
CHECK OUT UNIT: REPLACE ANY DAMAGED
HOSES, O-RINGS AND/OR TRIGGER GUN.
NO
IS THERE FUEL VAPOR COMING
OUT OF THE BURNER EXHAUST?
REPLACE BURNER
RELAY
NO
TURN SWITCH ON & TURN THERMOSTAT UP.
YES
IS THE BREAKER ON THE
CONTROL PANEL TRIPPED OR IS
THE INLINE FUSE BLOWN?
DISCONNECT THE WIRE(s) FROM ONE SMALL
TERMINAL ON THE BURNER RELAY.
DOES THE BURNER CONTINUE TO FIRE?
NO
NO
CHECK HEAT SWITCH/THERMOSTAT FOR CONTINUITY (THERMOSTAT
MUST BE ADJUSTED TO HIGHEST SETTING BEFORE TESTING –
REPLACE IF NO CONTINUITY). CHECK PRESSURE SWITCH FOR
CONTINUITY WHEN MACHINE IS RUNNING AND WITH TRIGGER PULLED
– REPLACE IF NO CONTINUITY.
ADJUST FUEL PRESSURE TO SPEC. CHECK/REPLACE FILTER & REPAIR ANY AIR LEAKS. IF PROPER
PRESSURE CANNOT BE OBTAINED, REPLACE FUEL PUMP.
YES
TROUBLESHOOTING ENDS: REPEAT PROCEDURE UNTIL TROUBLE FREE OPERATION IS OBTAINED.
MAINTENANCE INFORMATION
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.
18
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**
Engine Oil
Inspect
Daily
Change
After first 8 hours then every 50 hours especially in high ambient temperatures
Filter
Every 100 hours
Air Cleaner Inspect
Every 50 hours
Clean
Every 3 months
Diesel Engine Coolant
Check daily (maximum 50% antifreeze)
Battery Level
Check monthly
12V DC Burner Systems: Replace battery every 2 years
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
Pump Oil
Inspect
Daily
Change
After first 25 hours, then every 6 months or 500 hours
Axial pumps come filled with synthetic oil, which does not require changing
Clean/Replace Burner Filter
Monthly (More often if fuel quality is poor)
Remove Burner Soot
Annually
Burner Adjustment/Cleaning Annually
De-scale Coil
Annually (More often if required)
Replace Spray Nozzle
Every 6 months
Replace Quick Connects
Annually
Clean Water Screen/Filter
Weekly
Clean Float/Supply Tank
Every 6 months
Replace HP Hose
Annually
Belts
Tighten
Every 6 months
Inspect/Replace Annually
Trailer Tires/Bearings
Monthly (Check tires for condition, tighten lug nuts, grease & check bearings)
MAINTENANCE INFORMATION
DESCRIPTION
Gas Engine
Diesel Engine
Pump, Cat
Pump, AR
Pump, General
OIL TYPE
10w 30 motor oil **
10w 30 API cc/cd
Cat Hydraulic, non-detergent 10w 40 ISO 68
Non-detergent SAE 30w
General, non-detergent SAE 30w
CAPACITY
.63 to 3 qt.
3.25 qt.
11 – 42 oz.
10 – 41 oz.
11 – 42 oz.
** Check the engine manufacturer’s service guide for additional maintenance items and specific high ambient
temperature oil selection.
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