Table of Contents
Troubleshooting
Related Manuals for Kärcher HDS 4.0/32 Pe Cage - 1.575-615.0
Summary of Contents for Kärcher HDS 4.0/32 Pe Cage - 1.575-615.0
- Page 1 ® OPERATOR’S MANUAL 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 8-14 9.800-103.0-B...
-
Page 3: Table Of Contents
The model and serial numbers will be found on a decal attached to the pressure washer. You should record both serial number and date of purchase and keep in a safe place for future reference. 9.800-103.0 - B • Karcher HDS 615-617... -
Page 4: Introduction & Important Safety Information
SPRAY AWAY FROM utility company or the selling fuel should the equipment be exposed to a ELECTRICAL WIRING. distributor for specific details. higher ambient temperature. 9.800-103.0 - B • 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 - B • 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 specified in the manual. 9.800-103.0 - B • Karcher HDS 615-617...
-
Page 7: Component Identification
This system prevents internal pump damage. High Pressure Hose — Connect one end to water pump discharge nipple and the other end to spray gun. 9.800-103.0 - B • Karcher HDS 615-617... -
Page 8: Assembly Instructions
Red + Positive the owner. Automotive type 12 Volt Group 24 battery Terminal is recommended for placement within the weather resistant box. Follow safety and installation instruc- tions furnished with the battery. 98001030-8 9.800-103.0 - B • Karcher HDS 615-617... -
Page 9: Operation Instructions
Return starter gently. After the engine warms up enough to run smoothly, move choke to run position and throttle to fast position. CAUTION: Small engines may kick back. Do not hold pull starter grip tightly in hand. 9.800-103.0 - B • Karcher HDS 615-617... - Page 10 STEP 9: Turn the burner “ON”. Turn thermostat dial to WARNING! Never replace the 210° mark. nozzle without engaging the s a f e t y l a t c h o n t h e s p r ay gun trigger. 9.800-103.0 - B • Karcher HDS 615-617...
-
Page 11: Detergents & General Cleaning Techniques
When the water reaches this temperature, the pump protector engages and cools the pump by dis- charging the warm water onto the ground. This thermal device prevents internal damage to the pump. 9.800-103.0 - B • Karcher HDS 615-617... -
Page 12: Shutting Down & Cleanup
3. Pour about one teaspoon of engine oil through maintenance of the engine. the spark plug hole, pull the starter grip several times and replace the plug. Then pull the starter 9.800-103.0 - B • Karcher HDS 615-617... -
Page 13: Maintenance
Adhere to the following cold weather procedures when- WATER HARDNESS ever the washer must be stored or operated outdoors under freezing conditions. IMPULSE During winter months, when temperatures drop below TRANSMITTER 32°F, protecting your machine against freezing is nec- 9.800-103.0 - B • 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 - B • 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 - B • Karcher HDS 615-617... - Page 16 Remove coils and burner assembly, and burner assembly clean thoroughly. Misaligned electrode setting Realign electrodes to specifications. Obstruction in smoke stack Check for insulation blockage or other foreign objects. Low engine RPM Increase RPM 9.800-103.0 - B • 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 - B • 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 - B • 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 - B • Karcher HDS 615-617... -
Page 20: Exploded Views & Parts List
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 - B • Karcher HDS 615-617... - Page 21 Assy. Illus. for Detail Honda Engine Rectifier 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 - B • Karcher HDS 615-617...
- Page 22 Swivel, 1/2" MP x 3/4" 9.804-023.0 Plate, Belt Guard Top GHF, w/Strainer 9.802-261.0 Hose, 3/4" Push-On 30" 8.706-600.0 Box, Battery, M-100 9.802-064.0 Grommet, Rubber, 9.803-532.0 Isolator, 5/16" Thread, Nozzle Holder Female x Female, 1" x 1" 9.800-103.0 - B • Karcher HDS 615-617...
- Page 23 617.0) 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 9.803-560.0 Screw, 3/8" x 2" 9.800-103.0 - B • Karcher HDS 615-617...
-
Page 24: Control Box
CONTROL BOX 9, 24 Wiring Diagram 98001030-6 9.800-103.0 - B • 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 - B • 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 - B • Karcher HDS 615-617... -
Page 27: Pump Assembly
Valve, 3/4" Ball, Brass, 9.802-128.0 Nipple, 1/2" JIC x 1/2" 3-Way MPT Pipe Pump, Please See Specifications Pages 8.706-881.0 Nipple, 3/4" Pipe x 1/2" Pipe 9.803-503.0 Rail, Pump 9.803-557.0 Elbow, 3/8" SAE x 3/4", 90° 9.800-103.0 - B • 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 - B • Karcher HDS 615-617... -
Page 29: Blower Assembly & Parts List
6.388-608.0 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 Valve, Solenoid w/Stem 6.390-126.0 Clamp, Hose 8.753-180.0 Valve, Solenoid (Replacement Only) 9.800-103.0 - B • Karcher HDS 615-617... -
Page 30: Burner & Coil Assembly & Parts List
1.75 A 80° (615) 4.654-280.0 Cover D.K. 8-717-347.0 ▲ Nozzle, Burner, 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 2.880-177.0 ▲ Electrodes, Spare Parts Kit 9.800-103.0 - B • Karcher HDS 615-617... -
Page 31: Coil & Blower Assembly & Parts List
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 - B • Karcher HDS 615-617... -
Page 32: Hose & Spray Gun Assembly & Parts List
Gun, Shut-Off ▲ Not Shown 4.760-550.0 Lance, Spray, Insulate 1055mm 7.362-501.0 O-Ring, Power Nozzle 2.880-296.0 ▲ Spare Part Set, O-rings, 5-Pack,for Replacement 2.883-398.0 Nozzle, Power Tip 25045-1 (615.0) 2.883-401.0 Nozzle, Power Tip 25055-1 (616.0) 9.800-103.0 - B • Karcher HDS 615-617... -
Page 33: Fuel Tanks Assembly & Parts List
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 - B • 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 - B • Karcher HDS 615-617...
-
Page 35: Engine Assemblies Parts List
▲ Screw, #10-1/2", 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 - B • 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 (479 CC) 9.802-325.0 1.575-617.0 KT6036 9.921-717.0 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 - B • Karcher HDS 615-617... -
Page 37: Specifications
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 - B • 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 - B • 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 - B • 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 - B • Karcher HDS 615-617... - Page 42 ® Form #9.800-103.0 - B • Revised 8/14 • Printed in U.S.A.