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Operator Manual Shark Sse

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® OPERATOR’S MANUAL MODEL # HDS 4.8/30 Ea / SSE-503007A ORDER # 1.575-620.0 HDS 4.8/30 Eb / SSE-503007B 1.575-621.0 HDS 4.8/30 Ec / SSE-503007C 1.575-622.0 To locate your local Kärcher Shark Commercial Pressure Washer Dealer nearest you, visit www.karchercommercial.com or www.karchershark.com 9.800-187.0 CONTENTS Introduction & Important Safety Information 3-5 Component Identification 6 Set Up Procedures 7 Operating Instructions 7 Steam Combination 7 Shutdown Procedures 7 General Washing Techniques 8 How to Use the Detergent Injector 9 Preventative Maintenance and Service 10 Maintenance and Service 11-12 Preventative Maintenance Schedule 13 Troubleshooting 14-17 Exploded Views 18-19 Exploded View, Parts List 20-21 Float Tank Exploded View & Parts List 22 Hose and Spray Gun Assembly 23 Pump Assembly, Exploded View and Parts List 24-25 Control Panel, Exploded View and Parts List (1.575-620.0,-621.0) 26-27 Control Panel, Exploded View and Parts List (1.575-622.0) 28-29 Steam Pump Exploded View & Parts List 30 Burner Specifications 31 KT.1 Series Pump Exploded View and Parts List 32-33 VRT 3 Exploded View and Parts List 34 PA8 5-3026 Unloader Exploded View and Parts List 35-36 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. 2 620-622 • 9.800-187.0 • Rev. 9/10 Thank you for purchasing this Pressure Washer. We reserve the right to make changes at any time without incurring any obligation. Owner/User Responsibility: 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: 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 result in death, READ OPERATOR’S MANUAL THOROUGHLY serious bodily injury and/or PRIOR TO USE. 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. 4. All installations must comply with local codes. Contact your electrician, plumber, utility company or the selling distributor for specific details. If your machine is rated 250 volts or less, single phase will be provided with a ground fault circuit interrupter (GFCI). If rated more than 250 volts, or more than single phase this product should only be connected to a power supply receptacle protected by a GFCI. WARNING: Keep wand, hose, and water spray away from electric wiring or fatal electric shock may result. 5. To protect the operator from electrical shock, the machine KEEP WATER must be electrically grounded. SPRAY AWAY FROM It is the responsibility of the ELECTRICAL WIRING. owner to connect this machine to a UL grounded receptacle of proper voltage and amperage ratings. Do not spray water on or near electrical components. Do not touch machine with wet hands or while standing in water. Always disconnect power before servicing. WARNING WARNING RISK OF EXPLOSION: OPERATE ONLY WHERE OPEN FLAME OR TORCH IS PERMITTED OPERATOR’S MANUAL 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. DANGER: Improper connection of the equipment-grounding conductor can result in a risk of electrocution. Check with a qualified electrician or service personnel if you are in doubt as to whether the outlet is properly grounded. Do not modify the plug provided with the product - 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 PRESSURE WASHER INTRODUCTION & IMPORTANT SAFETY INFORMATION 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. 6. 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. WARNING RISK OF FIRE. DO NOT ADD FUEL WHEN OPERATING MACHINE. 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. 7. 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. 8. Do not allow acids, caustic or abrasive fluids to pass through the pump. 9. Never run pump dry or leave spray gun closed longer than 1-2 minutes. 10. Keep operating area clear of all persons. 620-622 • 9.800-187.0 • Rev. 9/10 3 PRESSURE WASHER OPERATOR’S MANUAL IMPORTANT SAFETY INFORMATION WARNING 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. 11. Eye, hand, and foot protection must be worn when using this equipment. WARNING WARNING: This machine exceeds 85 db appropriate ear protection must be worn. WARNING RISK OF INJECTION OR SEVERE INJURY TO PERSONS. KEEP CLEAR OF NOZZLE. WARNING HOT DISCHARGE FLUID: DO NOT TOUCH OR DIRECT DISCHARGE STREAM AT PERSONS. WARNING RISK OF INJURY: HOT SURFACES CAN CAUSE BURNS WARNING: 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. 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. 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 4 WARNING: Grip cleaning wand securely with both hands before starting. Failure to do this could result in injury from a whipping wand. 13. Never make adjustments on machine while in operation. 14. Be certain all quick coupler fittings are secured before using pressure washer. WARNING: Protect machine from freezing. 15. To keep machine in best operating conditions, it is important you protect machine from freezing. Failure to protect PROTECT FROM machine from freezing 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. EAR PROTECTION MUST BE WORN 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. 16. 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. 17. 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 VENTILATED AREA. will result. 18. Manufacturer will not be liable for any changes made to our standard machines or any components not purchased from us. 19. 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 FROM FALLS WHEN USING surfaces. LADDER. 20. Do not overreach or stand on unstable support. Keep good footing and balance at all times. 21. Do not operate this machine when fatigued or under the influence of alcohol, prescription medications, or drugs. WARNING 620-622 • 9.800-187.0 • Rev. 9/10 OPERATOR’S MANUAL Follow the maintenance instructions specified in the manual. PRESSURE WASHER IMPORTANT SAFETY INFORMATION 5 620-622 • 9.800-187.0 • Rev. 9/10 PRESSURE WASHER OPERATOR’S MANUAL COMPONENT IDENTIFICATION Optional Kit #30-199 Water Supply Hose (not included) Float Tank Burner Switch Pump Switch High Pressure Nozzles Quick Coupler Hour Meter Detergent Pickup Tube Burner Fuel Tank Spray Gun High Pressure Nozzle Trigger High Pressure Hose Variable Pressure Wand 6 620-622 • 9.800-187.0 • Rev. 9/10 Detergent Bucket (not included) SET UP PROCEDURES Place machine in a convenient location providing ample support, drainage and room for maintenance. Location: OPERATING INSTRUCTIONS 1. Read safety, installation and preventative maintenance instructions before starting machine. 2. Connect the water supply hose to the float tank inlet swivel connector and turn on water supply. 3. Check fuel tank level. 4. Connect the high pressure hose quick coupler to the discharge nipple by sliding quick coupler collar back and inserting the quick coupler onto the coupler nipple and pushing the quick coupler collar forward to secure it. 5. Connect the wand, nozzle, hose and spray gun (where applicable). Use teflon tape on pipe thread connections to avoid water leaks (see component identification). 6. Plug the power cord into the proper power supply. (Refer to serial plate for information.) 7. Grip spray gun and wand handle securely. 8. Before installing pressure nozzle into wand coupler, run machine allowing water to flush through the system until clear. 9. For auto start machines only: Press the pump switch “ON” and then pull trigger on the spray gun to activate pressure switch which starts machine. When a steady stream of water flows from the spray gun and wand, turn the thermostat knob GENERAL WASHING TECHNIQUES These machines are equipped with a spray gun and various nozzle patterns. Use the wide patterns on easy soil removal jobs and the narrow patterns on the more difficult jobs or tight areas such as cracks and holes. OPERATOR’S MANUAL 1. Location of machine is important. Avoid installing near combustible material or in poorly ventilated areas. Machines are intended to be protected from the outside environment. 2. Electrical connection to machine should be the proper voltage, phase and amperage. See specifications for particular model. A power plug is not provided to ensure proper connection by an electrician. 3. Water source for machines should be supplied by a 5/8" I.D. garden hose with a city water pressure of not less than 30 PSI. If the water supply is inadequate, or if the garden hose is kinked, the machine will run very rough and the burner will not fire. CAUTION: Use only fresh water in pressure washer. 4. Fill diesel fuel tank with kerosene, No. 1 home heating fuel or diesel. to the 200° mark, then push the burner switch. (Burner will light automatically.) For time delay shut down machines: Simply press pump switch "ON" and the machine will start. 10. Turn the variable pressure control handle clockwise to increase pressure. 11. To apply detergent, place detergent hose into detergent container and open detergent valve. PRESSURE WASHER OPERATING INSTRUCTIONS In most cases faster results and better detergent economy will be obtained by applying the detergent and letting it “set” for a few minutes prior to rinsing. This enables it to do its soil penetrating and loosening work. Most cleaning work terminates with a high pressure rinse as part of the normal cleaning procedure. In some cases, however, the last operation may be the application of a detergent (a sanitizer, for example). After such work, run the machine using rinse water for 20-30 seconds to clear the pump and lines. SHUTDOWN PROCEDURES 1. Place detergent line in a bucket of clear water allowing detergent to be flushed from system. Then turn detergent valve off. 2. Push burner switch off and pull spray gun allowing water to flow, which will cool down the heating coil. 3. After water has cooled, release the trigger on the spray gun, which will activate a timer to shut the machine off after one minute. Turn the pump switch off if the machine is going to be left unattended. 4. Turn water off. 5. P r o t e c t f r o m f r e e z i n g ( s e e W i n t e r i z i n g Procedures). STEAM COMBINATION 1. Turn the steam unloader valve counterclockwise lightly until you feel resistance. (Detergent will not siphon when the steam unloader valve is open.) NOTE: The steam mode is built into the unloader. Just turn the unloader adjustment knob counterclockwise until you feel resistance. 620-622 • 9.800-187.0 • Rev. 9/10 7 PRESSURE WASHER OPERATOR’S MANUAL GENERAL CLEANING TECHNIQUES 2. Turn the thermostat knob to 270°. (The thermostat is a high limit device and does not regulate temperature.) 3. To stop, reverse steps 1 to 3 and set all controls to their original settings. 4. Turn burner switch off, open trigger on spray gun and allow water to cool. PREVENTATIVE MAINTENANCE 1. Use clean fuel — kerosene, No. 1 home heating fuel, or diesel. Clean or replace fuel filter every 100 hours of operation. Avoid water contaminated fuel as it will cause the fuel pump to seize. De-soot coils monthly or use an additive if diesel is being used. 2. Check to see that water pump is properly lubricated (see pump lubrication below). 3. Follow Winterizing Procedures to prevent freeze damage to pump and coils. 4. Always flush detergent from system after use. 5. If water is known to be high in mineral content, use a water softener on your water system or de-scale as needed. 6. Do not allow acidic, caustic or abrasive fluids to be pumped through system. 7. Always use a high grade quality cleaning detergents. 8. Never run pump dry for extended periods of time. 9. Periodically delime coils per instructions. 1 0. If machine is operated with smoky or eye-burning exhaust, coils will soot up, preventing water from reaching maximum operating temperature. (See section on Burner Adjustments). MAINTENANCE AND SERVICE Pump Lubrication: Use only SAE 30 weight non-detergent oil. Change oil after first 50 hours of use. Thereafter, change oil every three months or at 500 hour intervals. Oil level should be checked through use of dipstick found on top of pump or red dot visible through oil gauge window. Oil should be maintained at that level. Fuel: Use clean fuel oil that is not contaminated with water and debris. Use kerosene, No. 1 home heating fuel or diesel. Drain fuel tank and replace fuel filter every 100 hours of operation. Ignition Circuit: Periodically inspect wires, spring contact and electrodes for condition, security and proper spacing. Transformer test: (CAUTION 10,000 VOLTS) use defect free insulated screwdriver and keep fingers off blade! Lay blade across one contact: OK if arc will span 1/2" between end of blade and other contact. (See illustration.) Transformer Check Electrode Setting 5/32 Electrode 1/4 Nozzle 5/32 Periodically Check Wiring Connections. If Necessary To Adjust Electrodes, Use Diagram 8 620-622 • 9.800-187.0 • Rev. 9/10 WARNING 1. Start machine as outlined in Operating Instructions. 2. Place detergent pick-up tube into container of detergent. 3. Adjust the metering valve to desired detergent concentration. 4. When you finish washing, rinse by simply turning the metering valve clockwise to increase pressure. 5. For clean up, place detergent pick-up tube into container of clear water and turn the metering valve counterclockwise. Pull the trigger on the spray gun for 2 minutes. OPERATOR’S MANUAL RISK OF ASPHYXIATION. USE THIS PRODUCT ONLY IN A WELL VENTILATED AREA. 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. The machine can siphon and mix detergents with the use of a detergent injector kit. PRESSURE WASHER HOW TO USE THE DETERGENT INJECTOR Detergent Metering Valve Detergent Bucket (not included) Detergent Pick-up Tube Strainer 9 620-622 • 9.800-187.0 • Rev. 9/10 PRESSURE WASHER OPERATOR’S MANUAL PREVENTATIVE MAINTENANCE & SERVICE 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. Fuel Pressure Adjustment: To adjust fuel pressure, turn the pressure adjusting screw clockwise to increase, counterclockwise to decrease. Do not exceed 200 psi. NOTE: When changing fuel pump, a by-pass plug must be installed in return line port or fuel pump will not prime. Air Adjustment: Note: The oil burner on this machine is preset for operation at altitudes below 1000 ft. If operated at higher altitudes, it may be necessary to adjust the air band setting. Adjust air band for a #1 or #2 smoke spot on the Bacharach scale. A one-time initial correction for your location will pay off in economy, performance, Air Band and extended service life. If a smoky 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. An oily, smoky fire indicates a lack of air and the air band should be moved to allow the air to flow through the burner. Sharp eye-burning fumes indicate too much air flowing through the combustion chamber. The air band should be readjusted to allow less air to flow through the burner. To adjust Beckett burner: Start machine and turn burner ON. Loosen two locking screws found in the air shutter openings (refer to illustration) 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. If the desired position cannot be obained 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. Burner Nozzle: 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. Rupture Disk: 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. 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 preventative for liming conditions is to use high quality cleaning detergents. In areas where alkaline water is an extreme problem, periodic use of Deliming Powder (Part #98040590) will remove lime and other deposits before coil becomes plugged. Fuel Pump 10 Air Band Adjustment Screw 620-622 • 9.800-187.0 • Rev. 9/10 Deliming Coils: Low Pressure Diagnosis: Periodic flushing of coils is recommended. Refer to Troubleshooting Chart for low pressure. If, by referring to the chart, the trouble is found to be either the unloader or pump, your next step is to determine which is the problem. This can be done by eliminating the unloader from the system and attaching the discharge hose directly to the pump. If high pressure is present, then the unloader needs repairing. Fill the float tank with 4 gallons of water, then add 1 lb. of deliming powder. Mix thoroughly. Remove nozzle from the wand assembly and put the wand and spray gun into float tank. Attach a nylon stocking to the end of the wand to collect debris. Turn pump switch on, allowing solution to be pumped through coils and back into the float tank. Solution should be allowed to circulate 2 - 4 hours. Step 4 After circulating solution, clean and drain float tank and flush entire system with fresh water. Replace nozzle in wand. Spray Nozzles: Each machine is equipped with four spray nozzles. Different spray nozzles are calibrated for each machine depending on the flow and pressure of that particular model. Spray nozzles vary in bore size and angle of spray. Popular spray angles are 0°, 15°, 25°, 40°. When ordering, please specify size and angle of nozzle. Nozzle size for each machine is located on the serial plate. Unloader Valve: The unloader valve traps pressure in the line when the spray gun is closed. Machines with unloader valves are preset and tested at the factory before shipping. Tampering with the factory setting may cause personal injury and/or property damage and will void the manufacturer's warranty. 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. Siphoning a small amount of antifreeze into the system is recommended. This is done by pouring a 50/50 mix of antifreeze and water into the float tank and then siphoning 100% antifreeze through the detergent line with the pump on. If compressed air is available, an air fitting can be screwed into float tank strainer fitting and, by injecting compressed air, all water will be blown out of the system. CAUTION: When using this procedure to test components, keep spray gun open at all times. Removal of Soot and Heating Coil: In the heating process, fuel residue in the form of soot deposits may develop between the heating coil pipe 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 which follow. OPERATOR’S MANUAL Step 1 Step 2 Step 3 PRESSURE WASHER PREVENTATIVE MAINTENANCE & SERVICE Coil Removal: Removal of the coil, because of freeze breakage or to clean soot from it, can be done quickly and easily. 1. Disconnect hose from pump to inlet side of the coil. 2. Carefully disconnect thermostat sensor, making sure you do not crimp capillary tube. 3. Remove all the fittings from the inlet and discharge side of coil. 4. Remove the burner assembly from the combustion chamber. 5. Remove the 3-3/8" bolts from each side of coil and tank assembly (these bolts are used to fasten tank and handles to chassis). 6. Remove the two bolts which are underneath the bottom wrap (to keep the coil from moving). 7. Remove tank top wrap exposing insulation and coil. 8. Bend back insulation tabs. 9. Carefully fold back the insulation and remove insulation retainer plates and coil. 1 0. Replace or repair any insulation found to be torn or broken. 1 1. To reinstall new or cleaned coil, reverse steps 9 through 1. 11 620-622 • 9.800-187.0 • Rev. 9/10 High Limit Hot Water Thermostat: For safety, each machine is equipped with a high limit control switch. In the event the temperature of the water should exceed its operating temperature the high limit control will turn the burner off until the water cools. CAUTION: The thermostat uses a capillary tube. Do not bend or strike with any object. OPERATOR’S MANUAL PRESSURE WASHER PREVENTATIVE MAINTENANCE & SERVICE 12 620-622 • 9.800-187.0 • Rev. 9/10 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 Inspect Oil level daily Change After first 50 hours, then every 500 hours or annually Check and Tighten Belts Every 3 months Remove Burner Soot Annually Burner Adjustment/Cleaning Annually Replace Burner Nozzle Annually Descale Coil Annually (More often if required) Replace High Pressure Nozzle Every 6 months Replace Quick Couplers Annually Clean Water Screen/Filter Weekly Replace HP Hose Annually (If there are any signs of wear) Grease Motor Every 10,000 hours Check Fuel Filter Every 3 months Check Safety Controls Daily OPERATOR’S MANUAL Pump Oil PRESSURE WASHER PREVENTATIVE MAINTENANCE OIL CHANGE RECORD Check pump oil level before first use of your new pressure washer. Change pump oil after first 50 hours and every 3 months or 500 hours thereafter. Use SAE 30 weight oil, non-detergent. Date Oil Changed Month/Day/Year Estimated Operating Hours Since Last Oil Change 13 620-622 • 9.800-187.0 • Rev. 9/10 PRESSURE WASHER Troubleshooting Guide TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION LOW OPERATING Faulty pressure gauge Test with 2nd gauge. If bad install new gauge. PRESSURE Insufficient water supply Use larger garden hose; clean water filter at inlet. Clean screen inside float tank. Old, worn or incorrect spray nozzle Match nozzle number to machine and/or replace with new nozzle. Belt slippage Tighten or replace; use correct belt. Plumbing or hose leak Check plumbing system for leaks. Retape leaks with teflon tape. Faulty or misadjusted unloader valve Adjust unloader for proper pressure. Install repair kit (Where applicable) when needed. Test PSI with unloader removed, taking pressure directly off the pump. Worn packing in pump Install new packing kit. Fouled or dirty inlet or discharge valves Clean inlet and discharge valves. in pump Worn inlet or discharge valves Replace with valve kit. Low power supply Check voltage of building and compare with requirements. Obtain a different power source. Detergent metering valve left open suck- Close and/or replace metering valve. ing air, or faulty metering valve BURNER WILL NOT LIGHT Little or no fuel Fill tank with fuel. Improper fuel or water in fuel Drain fuel tank and fill with proper fuel. Plugged fuel filter Replace as needed. Misadjusted burner air bands Readjust air bands for clean burn. Little or no fuel pressure from fuel Increase fuel pressure to specification on fuel pump pump and/or replace fuel pump. Faulty burner transformer Test transformer for proper arc between contacts. Replace as needed. Disconnected or short in electrical wir- All wire contacts should be clean and tight. No breaks ing in wire. Burner motor thermal protector tripped If tripped, check voltage, connections, and extensions for cause. Check fuel pump shaft rotation for binding causing motor to overheat. Flex-coupling slipping on fuel pump shaft Replace if needed. or burner motor shaft On-Off switch defective Check continuity through burner switch. Heavy sooting on coil and burner, can Clean as required. cause interruption of air flow and shorting of electrodes Improper electrode setting Clean and set according to diagram in Operators Manual. Fuel not reaching combustion chamber Check fuel pump for proper flow. Check solenoid flow switch on units with spray gun control, for proper on-off fuel flow control. Clogged burner nozzle Replace. Water not flowing through unloader Open spray gun to allow water to flow. Flow switch malfunction Remove test for continuity and replace as needed. Fuel solenoid malfunction Replace if needed. 14 620-622 • 9.800-187.0 • Rev. 9/10 PROBLEM POSSIBLE CAUSE SOLUTION MACHINE SMOKES Improper fuel or water in fuel Drain tank and replace contaminated fuel. Improper air adjustment Readjust air bands on burner assembly. Low fuel pressure Adjust fuel pump pressure to specification on fuel pump. Air leaks in fuel lines Check fuel lines for leaks or air bubbles. Tighten or replace as needed. Plugged or dirty burner nozzle Replace. Faulty burner nozzle spray pattern Replace nozzle. Heavy accumulation of soot on coils Remove coils and burner assembly. Clean thoroughly. and burner assembly LOW WATER TEMPERATURE WATER TEMPERATURE TOO HOT PUMP MOTOR STOPS AFTER A FEW MINUTES OF OPERATION, OR STARTS SLOW Misaligned electrode Realign electrodes to specifications. Obstruction in smoke stack Check for insulation blockage or other foreign objects. Improper fuel or water in fuel Drain fuel tank and replace with proper fuel. Low fuel pressure Increase fuel pressure. Weak fuel pump Check fuel pump pressure. Replace pump if needed. Fuel filter partially clogged Replace as needed. Soot build up on coils Clean coils with soot remover. Lime build up in coils Clean inside of coils with coil clean. Improper burner nozzle See parts list. PRESSURE WASHER Troubleshooting Guide TROUBLESHOOTING Incoming water to machine warm or Lower incoming water temperature. hot Fuel pump pressure too high See specifications on fuel pump for proper fuel pressure. Fuel pump defective Replace fuel pump. Detergent line sucking air Tighten all clamps. Check detergent line for holes. Defective high limit switch Replace. Incorrect fuel nozzle size See specifications for proper size. Insufficient water supplied Check G.P.M. to machine. Restricted water flow Check nozzle for obstruction, proper size. Insufficient voltage Use heavier drop cord and check voltage at receptacle. Check name plate for amperage draw. Plugged nozzle Remove and clean nozzle. Turn on water pump and flush lines, replace nozzle. Wrong spray nozzle See serial plate for minimum nozzle size. Automatic overload switch tripped Allow motor to cool - switch will automatically reset. Motor wet Allow to dry. Short in electrical wiring Wire contacts should be clean and tight. No breaks in wires. Coil liming up causing excessive See section on Preventative Maintenance. pressure Water pump low or out of oil causing Fill to correct level. pump to bind up 15 620-622 • 9.800-187.0 • Rev. 9/10 PRESSURE WASHER Troubleshooting Guide TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION RELIEF VALVE LEAKS OR SPRAYS OUT WATER Spray nozzle plugged Remove nozzle and clean out obstruction. Misadjusted or defective relief valve Adjust or replace as needed. Scale or dirt plugging inside of coils “See “”Preventative Maintenance Cleaning of Coil””.” DETERGENT NOT DRAWING Air leak Tighten all clamps. Check detergent lines for holes. Detergent metering valve packing not tight or packing worn Tighten nut. Replace valve or packing. Filter screen on detergent suction hose plugged Clean or replace. Dried up detergent plugging metering valve or injector Clean and flush. Restrictor in float tank missing Install restrictor. High viscosity of detergent Dilute detergent to specifications. MACHINE WILL NOT DRAW UP DETERGENT Clamps holding detergent lines are loose Tighten clamps. BURNER MOTOR WILL NOT RUN Hole in detergent line(s) Repair hole. Strainer basket plugged Remove and clean. Overload protector tripped Push reset button. Fuel pump seized Replace fuel pump. Burner fan loose of misaligned Position correctly, tighten set screw. Defective control switch Replace switch. Loose wire Check and replace or tighten wiring. Defective burner motor Replace motor. EXCESSIVE VIBRATION IN DELIVERY LINE Irregular function of check valves, meter- Check and replace if necessary. ing valves TEMPERATURE RELIEF VALVE LEAKS WATER (PUMP PROTECTOR) Spray gun in OFF position with machine operating for an extended period of time Open spray gun to cool circulating water. Relief valve defective Replace valve. Particle between valve and seat Remove internal parts and clean. BURNER STAYS ON WHEN SPRAY GUN IS IN OFF POSITION Fuel pump pressure too high Lower fuel pressure to specifications. Flow switch malfunction Test for continuity and replace as needed. Fuel solenoid defective Replace fuel solenoid. PUMP RUNNING NORMALLY BUT PRESSURE LOW Pump sucking air Check water supply and possibility of air seepage. Valves sticking Check and clean or replace if necessary. Unloader valve seat faulty Check and replace if necessary. Nozzle incorrectly sized See serial plate for minimum nozzle size. Worn piston packing Check and replace if necessary. 16 620-622 • 9.800-187.0 • Rev. 9/10 PROBLEM POSSIBLE CAUSE SOLUTION PUMP NOISY Air in suction line Check water supply and connections on suction line. Broken or weak inlet or discharge valve springs Check and replace if necessary. Excessive temperature of liquid Reduce to below 60°C (140°F). Foreign matter in valves Check and clean if necessary. Worn bearings Check and replace if necessary. Oil seal worn Check and replace if necessary. High humidity in air Check and change oil twice as often. Piston packing worn Check and replace if necessary. Piston packing worn Check and replace if necessary. O.R. Plunger retainer worn Check and replace if necessary. Cracked ceramics Check and replace if necessary. Oil seal worn Check and replace if necessary. Cracked manifold Check and replace if necessary. PRESENCE OF WATER IN OIL WATER DRIPPING FROM UNDER PUMP OIL DRIPPING PRESSURE WASHER Troubleshooting Guide TROUBLESHOOTING 17 620-622 • 9.800-187.0 • Rev. 9/10 PRESSURE WASHER Troubleshooting Guide EXPLODED VIEW - LEFT SIDE 42 1 5 6 63 49 41 50 43 78 84 80 3 Line to Detergent Supply 40 4 60 61 96 13 85 87 81 68 76 66, 67 78 79 86 77 77 Line to Pump 88 Thermostat (Enlarged View) 64 65 82 39 69 For Detail See Float Tank Illus. 8 For Detail See Control Panel Illus. 58 71 72 71 72 Line to Pump 18 620-622 • 9.800-187.0 • Rev. 9/10 PRESSURE WASHER EXPLODED VIEW - RIGHT SIDE 38 79 32 7 89 OPERATOR’S MANUAL 14 10 13 30 12 15 28 29 9 13 62 16 27 26 94 20 45 13 18 23 37 93 Steam Option 17 19 25 51 35 83 44 95 90 36 46 47 73 24 21 22 22 22 33 66 74 Line from Float Tank 3 2 72 4 91 71 92 75 70, 71 47 4 48 47 57 For Detail See Pump Illus. 59 90 98001870-2 55 47 52 54 53 46 To Detergent Pump 56 620-622 • 9.800-187.0 • Rev. 9/10 19 PRESSURE WASHER OPERATOR’S MANUAL EXPLODED VIEW PARTS LIST ITEM PART NO. ITEM PART NO. DESCRIPTION QTY 1 9.803-002.0 Face Plate, Belt Guard 1 33 8.711-785.0 Hose, 3/8" Push-On 2 9.802-872.0 Tab, Belt Guard Mount 3 34 9.802-797.0 3 9.802-794.0 Nut, Cage, 1/4" x 12 Gauge  Screw, SS #10 x 1/2" Hex Head Tek 8 14 35 8.706-248.0 Plug 3/8 1 4 9.802-753.0 Screw, 1/4" x 3/4" HH NC, Whiz Loc 6 36 9.149-003.0 Discharge Manifold 1 37 9.803-132.0 Insulation Retainer Plate 2 5 9.803-015.0 Belt Guard, Short, No Relief 1 38 9.803-005.0 Top Wrap, SS 1 Thumb Screw, 1/4"-20 x 1/2" 39 9.802-998.0 4 Weldment, Frame, Super Skid 1 40 9.802-080.0 Tank, Fuel, 8 Gallon, Black 1 41 9.802-053.0 Bushing, Rubber Nitrile 9.802-056.0 Diptube Assy, Plastic 10.75" Long 1 6 7 9.802-746.0 Burner Assembly, See Burner Specifications Page 28 24" 2 8 9.804-0030.0 Screw, 1/4" x 3/4", BHSCS 4 42 9 9.802-138.0 Hose Barb, 1/4" BRB x 1/4" MNPT 1 43 9.802-054.0 Elbow, Fuel Tank Zinc 1 9.802-459.0 Switch, MV60 (Steam Option) 1 10 9.802-143.0 Hose Barb, 1/4" BRB x 1/4" MNPT, 90° 1 44 11 9.802-519.0  Strain Relief 1 45 12 9.802-108.0 Nipple, 1/4” Hex 1 13 6.390-126.0 Clamp, Hose, .46 - .54 9 14 8.725-306.0 Filter, Fuel, Oil H20 1 46 9.802-720.0 Bolt, 3/8" x 1", NC HH 7 15 9.803-014.0 Coil, Rodless 1 47 9.802-807.0 Washer, 3/8", SAE Flat 12 16 9.803-006.0 Weldment, Bottom Wrap, SS, Super Skid 48 9.802-779.0 Nut, 3/8", SAE Flat 4 1 49 9.802-383.0 Pulley, Motor, 2BK36H 1 Nipple, 1/2" x 2-1/2", Galvanized, Sch 80 1 50 9.802-401.0 Bushing, Motor, H x 1-3/8" 1 51 9.196-012.0 Screw, 10-24" x 1/4" 1 52 9.802-099.0 Washer, Snubbing 3 9.802-814.0 Washer, 3/8", Lock, Split Ring 3 17 18 9.802-013.0 9.802-015.0 Nipple, 1/2" x 4", Galvanized, Sch 80 1 9.804-045.0 9.802-335.0 Motor, 10 HP/1PH/230V (620.0) Motor, 10 HP/3PH/230V, 460V (621.0, 622.0) 1 1 19 8.706-141.0 Coupling 1 53 20 9.802-032.0 Tee, 1/2", Female, Steel Pipe 1 54 9.803-009.0 Bracket, Belt Tension 1 Elbow, 1/2" JIC, 1/2", 90°, P/ TF5405-8-8 1 55 9.802-710.0 Bolt, 5/16" x 1", NC HH 2 56 9.802-776.0 Nut, 5/16", ESNA, NC 2 9.802-733.0 Bolt, 3/8" x 3-1/2", Tap 1 21 20 DESCRIPTION QTY 9.802-040.0 22 8.902-433.0 Valve, Safety Relief 1 57 23 9.802-171.0 Nipple, 3/8" x 3/8" NPT ST Male 1 58 9.802-754.0 Bolt, 1/4-20 x 1/2" Hex 4 59 9.802-789.0 Nut, 3/8" HEX, NC 2 24 9.802-191.0 Valve, Safety Relief, 5000 PSI 1 60 9.804-060.0 Pulley, Pump, 2BK65H 1 61 9.802-403.0 Bushing, Pump, HX 25mm 1 25 8.706-207.0 Elbow, 3/8" Street 62 9.802-254.0 26 9.802-883.0 Insulation, Front Head, No Hole 1 Hose, 1/4", Push-On, Fuel Line, 60" 2 27 9.802-894.0 Insulation, Burner Head, w/ Hole 1 1 28 9.802-896.0 Insulation, Blanket-No Foil, 24" x 57" 1 29 9.802-653.0 Gasket, Burner Flange 30 9.802-902.0 Insulation/Blanket-Die Cut 28" x 24" 1 31 9.802-727.0  Bolt, 3/8" x 1-3/4" Tap 32 9.802-781.0 Nut, 3/8", Flange, Whiz Loc, NC 5 2 2 63 9.802-418.0 Belt, BX39 1 64 9.804-056.0 Panel, Control 1 65 9.802-799.0 Screw, #14 x 1", Tek, Blk, Zinc 13 66 8.750-094.0 Thermostat, Adjustable, 302°F 1 67 9.802-447.0  Conduit, Corrugated Tubing, 1/4", 100 ft. Roll 40" 68 9.804-044.0 Valve, Metering, 1/4" Hose 1 69 9.800-185.0 Label, Operating Inst 620-622 • 9.800-187.0 • Rev. 9/10 1 ITEM PART NO. DESCRIPTION QTY 9.802-060.0 Isolator 6 71 9.802-804.0 Washer, 5/16" Flat 12 72 9.802-776.0 Nut, 5/16" ESNA 6 73 9.802-519.0 9.802-521.0 Strain Relief (622.0) 1 Strain Relief (620.0, 621.0) 1 74 9.802-429.0 9.804-049.0 9.802-426.0 Motor Cord, 12/4 (622.0) Motor Cord, 6-3 (620.0) Motor Cord, 8/4 (621.0) 75 9.802-999.0 Weldment, Sub-Frame, Super Skid 1 76 9.800-039.0 Label, Detergent Valve 1 77 8.750-096.0 Knob, Thermostat 1 78 8.712-190.0 Bezel, Thermostat 1 79 8.718-779.0 Screw, 4 mm x 6 mm 2 77 9.800-186.0 Label, Temperature Control 1 78 9.800-002.0 Label, Use Kerosene Only 1 79 9.800-110.0 Label, Stripe 1 80 9.800-007.0 Label, Warning, Exposed Pulleys 1 4 36" 36" 36" 81 9.802-064.0 Grommet, Nozzle Holder 82 8.712-357.0 Nozzle, SAQCMEG 0055, Red Nozzle, SAQCMEG, 5055, Yellow Nozzle, SAQCMEG 25055, Green Nozzle, SAQCMEG 40055, White 8.712-358.0 8.712-359.0 8.712-360.0 OPERATOR’S MANUAL 70 PRESSURE WASHER EXPLODED VIEW PARTS LIST (CONT) 1 1 1 1 83 9.802-522.0  Strain Relief, Motor, 1.0" 1 84 9.802-089.0 Cap, Fuel Tank, Plastic H60-AV 1 85 9.802-251.0 Hose, Clear Vinyl 6 ft. 86 9.802-252.0 Hose, Braided Vinyl 4 ft. 87 9.803-672.0 Strainer, 1/4" Brass, w/Check Valve 1 88 9.802-794.0 Nut, Cage, 1/4" x 12 Gauge 4 89 9.802-766.0 Screw, 3/8" x 1" Hex, Wash Head 8 90 9.802-245.0 Hose, 3/8" x 48", 2 Wire, Pressure 91 9.802-259.0 Hose, 1/2", Push-On 92 9.802-151.0 Swivel, 1/2" JIC, Push-On 2 93 9.802-899.0 Gasket, Burner Plate 2 94 9.803-044.0 Elbow, 3/8" Male Pipe (Steam Option) 1 95 9.802-039.0 Elbow, 1/2" JIC x 3/8" Male Pipe (Steam Option) 1 96 8.704-660.0 Label, Kärcher-Shark 2 4 ft. 1  Not Shown 21 620-622 • 9.800-187.0 • Rev. 9/10 PRESSURE WASHER OPERATOR’S MANUAL FLOAT TANK EXPLODED VIEW 2 18 1 10 8 18 11 13 9 4 3 12 19 7 18 5 17 15 16 6 14 To Pump FLOAT TANK EXPLODED VIEW PARTS LIST ITEM PART NO. 1 9.804-042.0 DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY Tank, Float, 2-1/2 Gal., Blank 13 9.802-061.0 Ball, Float, Black Plastic 1 1 14 9.802-152.0 Swivel, 3/4" SAE FEM 2 2 8.749-328.0 Valve, Float, Plastic 1 15 9.802-261.0 Hose, 3/4" Push on/FT 2 3 9.802-162.0 Strainer, 1/2" Basket 1 16 9.802-773.0 Nut, 1/4" ESNA, NC 3 4 9.802-127.0 Nipple, 1/2" JIC x 1/2" MPT 1 17 9.802-802.0 Washer Flat, 1/4" ZC 3 1 18 8.718-768.0 Screw 1/4" x 3/4" HH NC 3 19 8.930-354.0 Plate, Adaptor Gas, Float Tank 1 5 9.802-051.0 Bulkhead, 1/2" PVC 6 9.802-132.0 Elbow, 3/4" JIC x 1/2", 90° 1 7 8.930-356.0 Support Plate, Float Tank 1 8 9.802-799.0 Screw, #14 x 1", TEK, Blk, Zinc 2 Swivel, 1/2" MP x 3/4" GHF w/Strainer 1 9 9.802-146.0 10 9.803-671.0 Stem, 5" Float 1 11 9.802-512.0 Cable, TY, 48" 1 12 9.802-150.0 Anchor, Connector, 1/2" 1 22 620-622 • 9.800-187.0 • Rev. 9/10 4 3 2 PRESSURE WASHER HOSE, SPRAY GUN, & WAND EXPLODED VIEW OPERATOR’S MANUAL 1 HOSE, SPRAY GUN, & WAND EXPLODED VIEW PARTS LIST ITEM PART NO. DESCRIPTION QTY 1 8.739-314.0 Hose, 3/8" x 50', 1 Wire, Tuff-Flex w/Coupler 1 2 9.802-229.0 Spray Gun, Shut-Off, AP 1000 1 3 9.803-805.0 Lance, Spray, Insulated, 35.5" SS 1 4 9.802-164.0 9.802-096.0 9.804-043.0 Coupler, 1/4" Female, Brass 1  O-Ring, Replacement Only 1  Seal, 1/4" Replacement Only 1  Not Shown 23 620-622 • 9.800-187.0 • Rev. 9/10 PRESSURE WASHER PUMP ASSEMBLY EXPLODED VIEW To Float Tank 19 17 20 OPERATOR’S MANUAL 17 (620.0, 621.0, 622.0) 20 To Detergent Valve To Coil Inlet 12 19 11 7 5 18 6 8 16 1 15 14 4 13 3 2 9 98001870-3 10 24 620-622 • 9.800-187.0 • Rev. 9/10 ITEM PART NO. DESCRIPTION QTY 1 9.803-413.0 Pump, Kärcher KT5030 1 2 9.803-013.0 Rail, Pump, Self Aligning 1 3 9.802-632.0 Cap, Valve w/1/4" Gauge Port 1 9.802-039.0 Elbow, 1/2" JIC x 3/8", 90° 1 5 9.802-123.0 Tee, 1/2" w/1/8" Hole, Street 1 6 9.802-131.0 Elbow, 1/2" JIC x 1/2", 90° 1 7 9.802-142.0 Hose Barb, 1/4" Barb x 1/8" MNPT, 90° 1 8 9.802-458.0 Switch, Pressure, N/O, 1/4" NPT SS 1 9 9.804-057.0 Lockwasher 4 10 9.804-058.0 Screw, Pump 4 11 9.802-132.0 Elbow, 3/4" JIC x 1/2" Male 1 12 8.750-299.0 Unloader, VRT 3, 8 GPM @ 4500 PSI 1 Unloader, PA8GPM@4000 PSI, Pulsar w/Switch (Auto Start/Stop Option) 1 9.804-046.0 13 9.802-869.0 Block, Unloader, 1/2" x 1/2", Brass 1 14 9.802-013.0 Nipple, 1/2" x 2-1/2" Galvanized, Sch 80 1 Elbow, 1/2" FNPT x 1/2" MJIC 1 15 9.802-043.0 16 9.802-038.0 Nipple, 1/2" JIC x 1/2" Pipe 1 17 9.802-039.0 Elbow, 1/2" JIC x 3/8" 1 18 9.802-048.0 Swivel, 1/2" JIC x 3/8" 1 19 9.802-129.0 Elbow, 1/2" JIC x 3/8", 90° 1 20 9.802-181.0 Pump Protector, 3/8" PTP 1 OPERATOR’S MANUAL 4 PRESSURE WASHER PUMP ASSEMBLY EXPLODED VIEW PARTS LIST 25 620-622 • 9.800-187.0 • Rev. 9/10 PRESSURE WASHER CONTROL PANEL EXPLODED VIEW (1.575-620.0,-621.0) 12 OPERATOR’S MANUAL 13 1 17 2 5 14 11 21 15 9 4 7 6 6 22 8 10 26 620-622 • 9.800-187.0 • Rev. 9/10 18 3 ITEM PART NO. DESCRIPTION QTY 9.804-051.0 Box, 12" x 10" x 5-1/4" 1 2 9.804-055.0 Plate, Stand-off 1 3 8.724-281.0 8.724-281.0 Contactor (620.0) Contactor (621.0) 1 1 4 8.724-307.0 8.724-306.0 Overload (620.0) Overload (621.0) 1 1 5 9.802-551.0 Transformer, Micron 240/480V-120V, 50/60 HZ, .050KVA 1 6 9.802-451.0 Switch, Rocker, Carling w/ Green Lens 2 7 9.802-283.0 Hour Meter 1 8 9.802-515.0 Strain Relief, Straight LQ Tite 1 9 9.802-524.0 Locknut, 1/2" 1 10 9.802-521.0 Strain Relief, 3/4" Galv. LQ Tite (620.0, 621.0) 1 11 9.802-526.0 1 2 1 9.803-280.0 Locknut, 3/4" (620.0) (621.0) Locknut, 1" Conduit 12 9.800-184.0 Label, Control Panel 1 13 9.800-016.0 Label, Disconnect Pwr Supply 1 14 9.802-762.0 Screw, 10-32" x 1-1/4" BSCS 1 Screw, 10-32" x 1/2" BHSCS 7 15 9.802-759.0 16 9.800-040.0  Label, Ground 1 17 9.802-791.0 Nut, Cage, 10-32" x 16 Gauge 7 18 9.802-695.0 Nut, 10-32" KEPS 4 19 8.933-007.0  Fuse, KTK-RI 600 V midget 2 20 9.802-463.0  Fuse, Paper Buss, FNM1/2, 250V 1 21 9.802-521.0 9.803.975.0 Strain Relief (621.0) Strain Relief (620.0) 22 9.804-049.0 Cord, GFCI, 240V/1PH/50A (620.0) 1 Cord, Service, SO 8/4 (621.0) 15 ft. 9.802-426.0 OPERATOR’S MANUAL 1 PRESSURE WASHER CONTROL PANEL PARTS LIST (1.575-620.0,-621.0) 1 1  Not Shown 27 620-622 • 9.800-187.0 • Rev. 9/10 PRESSURE WASHER CONTROL PANEL EXPLODED VIEW (1.575-622.0) 12 4 OPERATOR’S MANUAL 13 1 13 17 2 3 25 15 18 14 18 11 15 24 15 21 ND OU GR 5 18 9 24 16 18 7 24 26 6 22 15 15 8 98001870-1 19 23 20 10 28 620-622 • 9.800-187.0 • Rev. 9/10 ITEM PART NO. DESCRIPTION QTY 9.804-051.0 Box, 12" x 10" x 5-1/4" 1 2 9.804-055.0 Plate, Stand-off 1 3 8.724-272.0 Contactor 1 4 8.724-304.0 Overload 1 5 9.802-550.0 Transformer, Micron 240/480V-120/240V, .500KVA 1 6 9.802-451.0 Switch, Rocker, Carling w/Green Lens 2 7 9.802-283.0 Hour Meter 1 8 9.802-515.0 Strain Relief, Straight LQ Tite 1 9 9.802-524.0 Locknut, 1/2" 1 10 9.802-518.0 Strain Relief Strt, LQ Tite 1 11 9.802-526.0 9.803-280.0 Locknut, 3/4" Locknut, 1" Conduit 2 1 12 9.800-184.0 Label, Control Panel 1 13 9.800-016.0 Label, Disconnect Power Supply 1 14 9.802-762.0 Screw, 10-32" x 1-1/4" BSCS 1 15 9.802-759.0 Screw, 10-32" x 1/2" BHSCS 10 16 9.800-040.0 Label, Ground 1 17 9.802-791.0 Nut, Cage, 10-32" x 16 Gauge 7 18 9.802-695.0 Nut, 10-32" KEPS 9 19 9.804-050.0 Fuse, 5 Amp, 600V 2 20 9.802-460.0 Fuse, Paper Buss, FNM-8, 250V 1 21 9.802-518.0 Strain Relief 22 9.802-429.0 Service, SEO 12/4 23 8.716-213.0 Block, Fuse, 1 Pole adder 1 24 8.718-980.0 Washer, 5/16" 4 25 9.802-457.0 Din Rail 3" 26 9.802-771.0 Screw 10/32" x 3/4" BHSCS 1 OPERATOR’S MANUAL 1 PRESSURE WASHER CONTROL PANEL PARTS LIST (1.575-622.0) 1 15 ft. 29 620-622 • 9.800-187.0 • Rev. 9/10 PRESSURE WASHER STEAM PUMP EXPLODED VIEW 2 3 OPERATOR’S MANUAL 4 9 1 5 11 12 11 7 6 8 To Detergent Valve 9 10 STEAM PUMP EXPLODED VIEW PARTS LIST ITEM PART NO. DESCRIPTION QTY ITEM PART NO. DESCRIPTION QTY 1 9.802-136.0 Bushing, 3/4" x 1/2" 1 9 9.802-142.0 2 9.802-036.0 Nipple, 1/2" JIC x 3/8" MPT Steel 1 Hose Barb, 1/4" x 1/8" NPT, 90° 1 10 9.802-254.0 Hose, 1/4" Push-On 8" 11 6.390-126.0 Clamp, Hose, .46 -, .54 3 12 9.802-132.0 Elbow, 3/4" JIC x 1/2" Male 1 3 9.802-033.0 Tee, 3/8" Street, Steel 4 9.802-022.0 Nipple, 3/8" x 1/4", Hex, Steel 1 1 1 5 9.802-187.0 Valve, Flow Control w/Metering 6 9.802-143.0 Hose Barb, 1/4" Barb x 1/4" Pipe, 90° 1 7 9.802-131.0 Elbow, 1/2" JIC x 1/2" MPT 1 8 9.803-050.0 Tee, 1/2" Street w/Two 1/8" MPT Holes 1 30 620-622 • 9.800-187.0 • Rev. 9/10 BECKETT BURNER SPECIFICATIONS Burner Burner Model No. Assy No. Fuel Nozzle Transformer Motor Fuel/Pump Solenoid/Cord Fuel Solenoid/Coil Electrode 1.575-620.0 9.804-053.0 8.717-366.0 9.803-055.0 9.804-054.0 9.802-645.0 9.802-640.0 9.802-669.0 1.575-621.0 9.804-053.0 8.717-366.0 9.803-055.0 9.804-054.0 9.802-645.0 9.802-640.0 9.802-669.0 1.575-622.0 9.802-556.0 8.717-366.0 9.803-060.0 9.803-056.0 9.802-645.0 9.802-640.0 9.802-669.0 PRESSURE WASHER Specifications SPECIFICATIONS 31 620-622 • 9.800-187.0 • Rev. 9/10 9.802-345.0 9.803-410.0 9.803-411.0 9.803-412.0 9.803-413.0 9.803-414.0 9.802-346.0 9.803-416.0 KT4035.1 Right KT4035.1 Left KT4040.1 Right KT4040.1 Left KT5030.1 Right KT5030.1 Left KT6035.1 Right KT6035.1 Left OPERATOR’S MANUAL PRESSURE WASHER KT.1 SERIES PUMP EXPLODED VIEW TORQUE SPECS Item # Ft.-Lbs. 17 75 18 45 27 18 37 10 48 30 53 7.6 KT.1 SERIES PUMP EXPLODED VIEW & PARTS LIST ITEM PART NO. 1 9.804-604.0 DESCRIPTION QTY Crankcase ITEM PART NO. DESCRIPTION QTY 1 19 9.802-890.0 Washer 8 2 9.803-195.0 Plunger Guide 3 20 9.803-198.0 Copper Washer 3/8" 1 3* See Kit Plunger Oil Seal 3 21 9.802-925.0 Brass Plug 3/8" 1 4* See Kit O-Ring Ø1.78 x 31. 47 3 26 9.802-884.0 Washer 8 5* See Kit Pressure Ring, Brass 3 27 9.802-944.0 Hexagonal Screw 8 6* See Kit "U" Seal Low Pressure 3 28 9.803-182.0 Closed Bearing Housing 1 7* See Kit Intermediate Ring, Brass 3 29 9.803-186.0 O-Ring Ø2.62 x 71.12 2 8* See Kit Support Ring, Teflon Bronze 3 30 9.803-160.0 Roller Bearing, Tapered 2 9* See Kit "U" Seal High Pressure 3 10* See Kit Support Ring 3 11 9.802-926.0 Brass Plug, 1/2" 1 31 9.803-148.0 9.803-149.0 Crankshaft (GT4040.1, 5030.1, 6035.1) 1 Crankshaft (GT 4035.1) 1 12 9.803-199.0 Copper Washer 1/2" 1 32 9.803-167.0 Crankshaft Key 1 13 9.802-933.0 Manifold Head 1 33 9.802-923.0 Oil Dip Stick 1 14* See Kit O-Ring Ø2.62 x 17.13 6 34 9.803-139.0 Crankshaft Seal 1 15* See Kit Valve Assembly 6 35 9.803-177.0 Shim 2 16 See Kit O-Ring Ø2.62 x 20.29 6 36 9.803-181.0 Bearing Housing 1 17 9.802-928.0 Valve Plug 6 37* See Kit 18 9.802-943.0 Manifold Stud Bolt 8 38* See Kit 32 620-622 • 9.800-187.0 • Rev. 9/10 Plunger Bolt Copper Spacer 3 3 PRESSURE WASHER KT.1 SERIES PUMP EXPLODED VIEW & PARTS LIST ITEM PART NO. DESCRIPTION QTY See Kit O-Ring Ø1.78 x10.82 3 40* See Kit Teflon Ring 3 41* See Kit Plunger 3 42* See Kit Copper Spacer 3 43 9.803-143.0 Plunger Rod 3 44 9.803-157.0 Connecting Rod 3 45 9.802-912.0 Snap Ring 6 46 9.802-915.0 Connecting Rod Pin 3 47 9.802-889.0 Spring Washer 6 48 9.802-937.0 Connecting Rod Screw 6 49 9.803-194.0 O-Ring Ø2.62 x 152.07 1 50 9.803-166.0 Crankcase Cover 1 51 9.803-197.0 Gasket, G3/8 1 52 9.803-202.0 Sight Glass G3/4 1 53 9.802-939.0 Cover Screw * Part available in kit REPAIR KIT NUMBER OPERATOR’S MANUAL 39* 5 (See below) 8.916-488.0 8.916-487.0 8.916-322.0 8.916-323.0 9.802-607.0 9.802-611.0 9.802-603.0 9.802-606.0 KIT DESCRIPTION Plunger "U" Seal 20mm 4040.1 6035.1 4035.1 Plunger "U" Seal 22mm 5030.1 "U" Seal Packing Assy 20mm 4040.1 6035.1 4035.1 "U" Seal Packing Assy 22mm 5030.1 Plunger 20mm 4040.1 6035.1 4035.1 Plunger 22mm 5030.1 Complete Valve (all pumps) Plunger Oil Seals (all pumps) ITEM NO.S INCLUDED 4, 6, 8, 9, 10 4, 6, 8, 9, 10 4, 5, 6, 7, 8, 9, 10, 4, 5, 6, 7, 8, 9, 10, 37, 38, 39, 40, 41, 42 37, 38, 39, 40, 41, 42 14, 15, 16 3 3 3 1 1 1 1 6 3 NUMBER OF CYLINDERS KIT WILL SERVICE 33 620-622 • 9.800-187.0 • Rev. 9/10 8.750-297.0, 8 GPM, 2320 PSI 8.750-298.0, 8 GPM, 3630 PSI 8.750-299.0, 8 GPM, 4500 PSI ITEM PART NO. DESCRIPTION 25 8.750-712.0 Outlet Fitting 18 8.750-713.0 Knob, Unloader 20 14 OPERATOR’S MANUAL PRESSURE WASHER VRT3 UNLOADER EXPLODED VIEW AND PARTS LIST 19 QTY 1 1 8.750-709.0 Repair Kit, VRT3, 2320/3630 PSI 8.750-710.0 Repair Kit, VRT3, 4500 PSI (Kit Items: 1, 4, 8-12, 16, 21-22) 8 9 18 10 9 26 17 1 22 16 23 24 2 21 3 15 15 4 5 25 13 6 6 12 7 11 Unloader Adjustment Procedures 1. 2. 3. 4. 5. Remove lock nut (Item 19). Remove adjustment knob (Item 18). Loosen the two (2) nuts (Item 15), move them upward on stem (Item 8) until you see 4 or more threads below the nut. Re-attach adjusting knob (Item 18). Start machine. Open the trigger of the spray gun. Increase pressure by turning adjustment knob (Item 18) clockwise until pressure is at the desired operating pressure. 6. Remove the adjustment knob (Item 18), tighten the lower nut (Item 15) tightly against the upper nut (Item 15). Reattach adjustment knob (Item 18) and screw down until contact is made with the nuts (Items 15). Screw down lock nut (Item 19) onto the stem (Item 8) until the threads cut into the nylon insert of the lock nut (Item 19). *If adjustment knob (Item 18) DOES NOT make contact with upper nut (Items 15), remove adjusting knob (Item 18), re-adjust (raise) nuts (Items 15) on stem (Item 8) and re-attach adjustment knob (Item 18), then repeat step #6. **If adjustment knob (Item 18) DOES make contact with upper nut; release the trigger of the spray gun and watch the pressure gauge for the pressure increase (“spike”). This “spike” SHOULD NOT exceed 500 psi above the operating pressure. If “spike” pressure exceeds the 500 psi limit, remove the adjusting knob (Item 18) and re-adjust (lower) the nuts (Items 15) on the stem (Item 8). Re-attach the adjusting knob (Item 18), then repeat step #6. 34 620-622 • 9.800-187.0 • Rev. 9/10 PRESSURE WASHER PA8 5-3026 UNLOADER EXPLODED VIEW OPERATOR’S MANUAL PA8 5-3026 UNLOADER EXPLODED VIEW & PARTS LIST ITEM PART NO. DESCRIPTION  QTY ITEM PART NO. DESCRIPTION QTY 1 12.5000.00 3 x 1 El. Cable L. 1200 mm 1 17 60.0164.33 Washer 1 2 29.0082.84 Black Nut-40 bar 1 18 60.0015.51 Sst Spring 1 3* 10.3109.92 O-Ring 2.4 x 7.3 mm 1 19* 60.0134.21 Puls. 280 Piston+ Shutter 1 4 29.0041.84 Plast. Box 1 20* 60.0259.20 8.5 mm seat+O-Ring 1 5 29.0087.51 Sst Clip 1 21 60.0028.31 3/8 Bsp Plug (60.0010.70) 1 6 12.5001.00 16A -250V- Micro Switch 1 21 60.0025.31 3/8 Npt Plug (60.0010.80) 1 7* 10.3210.42 O-Ring 2.62 x 42.52 mm 1 8 16.3020.00 2.5 x 12 mm Screw 4 22 14.4042.00 Washer 16 x 22 mm (60.0010.70) 1 9 29.0042.84 Cover 1 10* 10.3038.00 O ring 1.78 x 3,68 mm 1 23 60.0075.35 Pulsar 280 Npt Body (60.0010.80) 1 11 14.3519.53 Sst Washer 4 x 8 mm 1 24* 10.4021.00 Back Ring 11.4 x 15.9 mm 2 12 60.2303.51 Spring 1 25* 10.3175.08 O ring 2.62 x 10,.77 mm 1 13 60.0132.31 Pul. 280 Switch Nipple 1 26 60.0061.23 Sst Piston 1 14* 10.3068.01 O-Ring 1,.78 x 17.17 mm 2 27* 10.3170.08 O Ring 2.62 x 7.6 mm 1 15* 10.4004.00 Back Ring 4.2 x 7,9 mm 1 16* 10.3109.90 O Ring 2,4 x 3.66 mm 28* 10.4020.00 Back Ring 8 x 12.6 mm 1 620-622 • 9.800-187.0 • Rev. 9/10 1 35 PRESSURE WASHER OPERATOR’S MANUAL PA8 5-3026 UNLOADER EXPLODED VIEW & PARTS LIST ITEM PART NO. DESCRIPTION QTY 29 60.0064.31 Piston Housing 1 30 15.1021.00 Pin 3 x 14 mm 1 31 60.0033.61 Blue Spring 1 32 60.0011.31 Spring Guide (sz.cappucc) 1 33 11.4574.00 M 8 Nut (sz.cappucc) 2 34* 10.3213.08 O Ring 3 x 6 mm 1 35 60.0052.31 Check Valve 1 36 60.0053.51 Spring 1 37* 10.3070.02 O ring 1.78 x 18.77 mm 1 38 60.0058.31 3/8 Bsp F Outlet Fitting (60.0010.70) 1 38 60.0059.31 3/8 Npt F Outlet Fitting (60.0010.80) 1 39 11.4573.31 M 8 Brass Nut 2 40 14.3720.40 Washer 8 x 24 mm 1 41 60.0004.24 Puls. 3 Valve, Knob Assy 1 42 11.4589.10 M 8 Nut 1 43 60.0014.24 Puls.3 Complete Knob ** 1 ** On request KIT P/N DESCRIPTION K1 60.0072.24 Puls.280+PR16 spare parts kit 1 36 620-622 • 9.800-187.0 • Rev. 9/10 ® Phone: 360-833-1600 f ax: 800-248-8409 www.karchercommercial.com 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 eq UIPMeNT fOr A PAr TICULAr PUrPOSe AND ANy SUCH WArrANTIeS Are exPreSSL y DISCLAIMeD. KärCHer fUr THer DISCLAIMS ANy WArr ANTy THAT THe Pr ODUCT PUr CHASe D by CUSTOMer WILL Mee T ANy PAr TICULAr req UIre Me NT Of CUSTOMer eveN If KärCHer HAS beeN AD vISeD Of SUCH req UIreMeNT . THe rIgHTS AND reMeDIeS Pr OvIDeD 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, b UT NOT LIMITeD TO, THe CUSTOMer Or ANy eND USer Of THe Pr ODUCT fOr ANy SPeCIAL, INDIreCT , INCIDeNTAL Or CONSeq UeNTIAL DAMAgeS Or eCONOMIC LOSS, LOSS Of Pr OfITS Or LOSS Of USe Of THe Pr ODUCT, ArISINg IN CONNeCTION WITH THe SALe, DeLIvery, INSTALLATION, TrAININg Or USe Of Pr ODUCT. KärCHer’S LIAbILITy, WHeTHer IN CONTrACT Or IN TOr T, ArISINg OUT Of ANy WArrANTIeS Or rePreSeNTA TIONS, INSTr UCTIONS Or DefeCTS fr OM ANy CAUSe, SHALL be LIMITeD exCLUSIveL y TO THe COST Of rePAIr Or rePLACeMeNT PAr TS 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. 620-622 • 9.800-187.0 • Rev. 9/10 PRESSURE WASHER WARRANTY LIMITED NEW PRODUCT WARRANTY—COMMERCIAL PRESSURE WASHERS ® www.karchercommercial.com www.karchershark.com Form # 9.800-187.0 • Revised 9/10 • Printed in U.S.A. or Mexico