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Kärcher 1.575-615.0 Operator's Manual

Hds 4.0/32; 5.0/32; 5.5/35 pe cage
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OPERATOR'S MAN U AL
To locate your local Kärcher Commercial Pressure Washer Dealer nearest you,
WARNING:
This product and accessories may contain a chemical known to the State of
11/02/17
California to cause cancer and birth defects or other reproductive harm.
For more information about this regulation: www.P65Warnings.ca.gov
HDS 4.0/32 Pe Cage - 1.575-615.0
HDS 5.0/32 Pe Cage - 1.575-616.0
HDS 5.5/35 Pe Cage - 1.575-617.0
please visit www.karchercommercial.com
9.800-103.0-M

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  • Page 1 OPERATOR’S MAN U AL HDS 4.0/32 Pe Cage - 1.575-615.0 HDS 5.0/32 Pe Cage - 1.575-616.0 HDS 5.5/35 Pe Cage - 1.575-617.0 To locate your local Kärcher Commercial Pressure Washer Dealer nearest you, please visit www.karchercommercial.com WARNING: This product and accessories may contain a chemical known to the State of 11/02/17 9.800-103.0-M...
  • Page 3 The model and serial numbers will be found on a decal at tached to the pressure washer. You should record both serial number and date of purchase and keep in a safe place for future ref er ence. 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 4: Introduction & Important Safety Information

    SPRAY AWAY FROM utility company or the selling ELECTRICAL WIRING. fuel should the equipment be exposed to a distributor for specifi c details. higher ambient temperature. 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 5: Important Safety Information

    14. Never make adjustments on pass through the pump. machine while in operation. 22. Never run pump dry or leave spray gun closed TRIGGER GUN KICKS BACK - HOLD WITH longer than 1-2 minutes. BOTH HANDS 9.800-103.0 - M • Karcher HDS 615-617...
  • Page 6 28. In oil burning models, use only kerosene, No. 1 home heating fuel, or diesel. If diesel is used, add a soot remover to every tankful. Follow the maintenance instructions specifi ed in the manual. 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 7: Component Identification

    fl oor. This sys tem pre vents internal pump dam age. High Pressure Hose — Connect one end to water pump dis charge nipple and the other end to spray gun. 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 8: Assembly Instructions

    Fol low safe ty and in stal la tion in struc- tions fur nished with the bat tery. 98001030-8 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 9: Operation Instructions

    CAUTION: Small engines may kick back. Do not hold pull start er grip tightly in hand. 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 10: Operation Instructions

    WARNING! Never replace the 210° mark. noz zle without engaging the s a f e t y l a t c h o n t h e s p r ay gun trig ger. 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 11: Detergents & General Cleaning Techniques

    When the water reaches this tem per a ture, the pump pro tec tor engages and cools the pump by dis- charg ing the warm water onto the ground. This ther mal de vice pre vents internal dam age to the pump. 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 12: Storage

    3. Pour about one teaspoon of engine oil through main te nance of the engine. the spark plug hole, pull the starter grip several times and re place the plug. Then pull the starter 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 13: Maintenance

    WATER HARDNESS ev er the washer must be stored or operated outdoors under freez ing conditions. IMPULSE During winter months, when temperatures drop below TRANSMITTER 32°F, protecting your machine against freezing is nec- 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 14: Maintenance

    When operating without the burner there must be heat- ing fuel in the fuel tank. Otherwise the fuel pump has no lubrication and will run dry. This can cause damage to the coupling and to the fuel pump. 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 15: Troubleshooting

    Faulty burner transformer Test transformer for proper arc between contacts. Replace as needed. (continued on next Disconnected or short in electrical All wire contacts should be clean and tight. page) wiring No breaks in wire 9.800-103.0 - M • Karcher HDS 615-617...
  • Page 16 Remove coils and burner assembly, and burner assembly clean thoroughly. Misaligned electrode setting Realign electrodes to specifi cations. Obstruction in smoke stack Check for insulation blockage or other foreign objects. Low engine RPM Increase RPM 9.800-103.0 - M • Karcher HDS 615-617...
  • Page 17 O-Ring plunger retainer worn Check and replace if necessary. PUMP Cracked piston Check and replace if necessary. Pump protector Lower water supply pressure. Do not run with spray gun closed longer than 2 minutes 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 18: Troubleshooting

    Position correctly, tighten set screw. NOT RUN Defective control switch Replace switch. Loose wire Check and replace or tighten wiring. Defective burner motor Replace motor. RELIEF VALVE Relief valve defective Replace or repair LEAKS WATER 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 19: Preventative Maintenance

    Check Clean Spark Plug Check Valve Clearance Fuel Tank Filter Water Filter/Clean Check Date Oil Changed No. Of Operating Hours Brand Name And Month/day/year Since Last Oil Change Type Of Oil (See Above) 9.800-103.0 - M • Karcher HDS 615-617...
  • Page 20 EXPLODED VIEW - LEFT SIDE Blower Assy. for Burner & Detail Coil Illus. for Detail Control Box Illus. for Detail Coil Outlet Coil Inlet 9.800-103.0 - M • Karcher HDS 615-617...
  • Page 21 Detail Honda Engine Rectifi er See Float Tank Illus. for Detail Unloader Assy. Illus. for Detail TI SS S AN E IN D PU S CA See Engine Assy. for Detail 98001030-9 9.800-103.0 - M • Karcher HDS 615-617...
  • Page 22 Bolt, 5/16" x 1/2" Whiz 9.802-132.0 Elbow, 3/4" JIC x 1/2", 90° 1 9.802-756.0 Screw, 5/16 x 1, Whiz 9.802-146.0 Swivel, 1/2" MP x 3/4" 9.804-023.0 Plate, Belt Guard Top 9.802-261.0 Hose, 3/4" Push-On 30" 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 23: Exploded Views & Parts List

    9.802-779.0 Nut, 3/8" ESNA (615.0, 617.0) 9.802-776.0 Nut, 5/16" ESNA (616.0) Washer, 3/8" SAE, 9.802-807.0 Flat (Honda) 8.718-980.0 Washer, 5/16" SAE, Flat (Vanguard) 9.802-764.0 Screw, 10/32" x 3/4" Hex 8.911-537.0 Rail, Cage w/Holes 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 24: Control Box

    CONTROL BOX 9, 24 Wiring Diagram 98001030-6 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 25: Control Box & Parts List

    BH SOC Blk 9.802-695.0 Nut, 10/32" Keps (616.0) (615.0, 617.0) 9.802-785.0 Nut, 8/32, Keps 8.718-733.0 Screw, 6-32" x 5/8", RH Slot 9.802-784.0 Nut, 6/32" Hex 8.709-069.0 Clamp, Screw, #4 8.707-058.0 Strainer, 1/4" Brass w/Check Valve 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 26: Float Tank Assembly

    Tank (Use spring only 4.730-127.0 Filter, Water if not using scale inhibitor) 1 5.063-226.0 Lid, Scale Inhibitor Tank 9.800-152.0 Label, RM-110 5.310-062.0 Nut, Float Tank Scale Inhibitor 5.443-285.0 Hose Stem, 45° 6.686-025.0 Valve, Solenoid, DN3 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 27: Pump Assembly

    Nipple, 3/4" Pipe x 1/2" 9.802-744.0 Bolt, 10mm x 20mm, Zinc 4 Pipe 8.718-961.0 Washer, M10, Split Zinc 9.803-557.0 Elbow, 3/8" SAE x 3/4", 9.802-807.0 Washer, 3/8" Flat Zinc 90° 8.706-915.0 Bushing, 1/2" x 1/4", Brass 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 28: Unloader Assembly

    Swivel, 1/2" JIC Female, 3/8" Male 9.802-129.0 Elbow, 1/2" JIC x 3/8", 90° 1 8.707-254.0 Pump Protector, 3/8" PTP 1 8.750-299.0 Unloader, VRT 3, 8 GPM@ 4500 PSI 8.716-125.0 Switch, Pressure N/O, 3/8" NPT SS 9.800-103.0 - M • Karcher HDS 615-617...
  • Page 29 Tie, Cable, 8 x 550 9.803-247.0 Shaft, Blower, Karcher Tension Band 6.472-927.0 Hose, Stem 6.472-925.0 Pump, Fuel 6.389-261.0 Screw, Union 8.753-179.0 Coil, Assy, Fuel Pump, 6.390-126.0 Clamp, Hose 12 VDC 8.753-180.0 Valve, Solenoid (Replacement Only) 9.800-103.0 - M • Karcher HDS 615-617...
  • Page 30 1.75 A 80° (615) 4.654-280.0 Cover D.K. ▲ Nozzle, Burner, 8-717-347.0 7.311-380.0 Nut, Cap, M 6 2.25 a 80° (616.0, 617.0) 7.312-167.0 Washer, Lock, A 6.4 ▲ Not Shown ▲ Electrodes, Spare 2.880-177.0 Parts Kit 9.800-103.0 - M • Karcher HDS 615-617...
  • Page 31 Washer, 3/8" x 1" HDS Skid 9.802-779.0 Nut, 3/8" ESNA 9.803-521.0 Assembly, Coil Tank, 8.706-143.0 Coupling, 1/2" x 3/8" HDS Skid Steel 9.803-600.0 Swivel, M22 x 3/8" Hex ▲ Not Shown Male Pipe 9.800-103.0 - M • Karcher HDS 615-617...
  • Page 32 4.112-000.0 Jet pipe TR 1050 mm DN8 40MPa 15m 2.113-022.0 Power Nozzle 4.118-005.0 EASY!Force Advanced TR 25045 (615.0) 2.113-025.0 Power Nozzle TR 25055 (616.0) 2.113-026.0 Power Nozzle TR 25060 (617.0) ▲ Not Shown 9.800-103.0 - M • Karcher HDS 615-617...
  • Page 33 9.800-001.0 Label, Gas Only 8.751-381.0 Carbon Canister, 1.2L (616.0, 617.0) 9.802-775.0 Nut, 1/4" Flange ZN 9.800-002.0 Label, Use Only Kerosene 1 8.919-503.0 Assy, Fuel Level Low Sensor 9.803-604.0 Grommet, Low Level Fuel Switch 9.800-103.0 - M • Karcher HDS 615-617...
  • Page 34 ENGINE ASSEMBLIES 615.0 Models Engine Purge Connection 616.0 Models 617.0 Models Engine Purge Connection 98001030-5 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 35: Engine Assemblies & Parts List

    ▲ Screw, #10-1/2", 9.802-798.0 Tek, HH, SS (617.0) 8.750-737.0 Adapter, Honda M20-1.5 x 3/8" FPT 6.390-126.0 Clamp, Hose, .46-.54 ST (617.0) 8.709-152.0 Filter, Fuel Disposable (617.0) 9.802-254.0 Hose, 1/4" Push-On, Fuel Line (617.0) 2 ft. 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 36: Specifications

    8.715-483.0 2AK94H 9.803-548.0 25MM 9.802-403.0 GX390 (389 CC) 8.750-579.0 1.575-616.0 KT6036 8.921-717.0 8.715-483.0 2BK90H 8.715-593.0 25MM 9.802-403.0 Vanguard (570 CC) 8.754-819.0 1.575-617.0 KT6036 8.921-717.0 8.715-483.0 2BK80H 8.715-592.0 25MM 9.802-403.0 GX630 (688 CC) 8.752-149.0 9.800-103.0 - M • Karcher HDS 615-617...
  • Page 37 P2 x 1” 9.802-404.0 AX 38 9.802-410.0 AX37 9.802-409.0 616.0 3TB34 9.802-392.0 P2 x 1” 9.802-404.0 BX 38 9.802-417.0 AX37 9.802-409.0 617.0 3TB34 9.802-392.0 P2 x 1” 9.802-404.0 BX 36 8.715-697.0 AX37 9.802-409.0 9.800-103.0 - M • Karcher HDS 615-617...
  • Page 38 8.752-827.0 Crankshaft Ø25 (6036) 9.803-193.0 O-Ring 3068 9.803-167.0 Crankshaft Key 9.802-928.0 Valve Plug 8.752-834.0 Oil Dip Stick 8.753-817.0 Manifold Stud Bolt 9.803-139.0 Crankshaft Seal 9.802-890.0 Lock Washer 9.803-177.0 Shim 8.719-008.0 Copper Washer 3/8 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 39: Kt.2 Series Pump Exploded View & Parts List

    18 mm 18 mm 18 mm Complete Valve Seals ITEMS NUMBERS 3, 5, 7 3, 4, 5, 6, 7, 34, 35, 36, 37 11, 12, 13 INCLUDED NO. OF CYLINDERS KIT WILL SERVICE 9.800-103.0 - M • Karcher HDS 615-617...

  • Page 40: Vrt 3 Unloader Exploded View & Parts List

    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. 9.800-103.0 - M • Karcher HDS 615-617...
  • Page 42 Form #9.800-103.0 • Printed in U.S.A.

This manual is also suitable for:

1.575-617.01.575-616.0

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