table of contents Safety 6 Safety Rules 7 Safety Warnings Features 12 Features Installation & Preparation 13 Attire 13 Set-Up 14 Engine/Burner Fuel Tank 15 Nozzle Review 16 Nozzle Connection 16 Water Supply 17 Unloader 17 Thermal Relief Valve 18 Pre-Start Inspection Procedures Operation 19 Priming The Pump 19 Start-Up/Cold Water Operation 21 Hot Water Operation 21 Cleaning with Detergents 22 ...
Page 3
table of contents Parts List 30 Specifications 32 Flow Chart 32 EMF System 33 Operation Theory 34 Frame Assembly 36 Pump Plumbing 38 Pump Assembly 41 Unloader Assembly 43 Pressure Switch 44 Heat Exchanger/EMF System 46 Boiler Assembly 48 Gun/Wand/Hose Assembly 49 Fuel Tank 50 Electric Box Assembly 51 Fuel Pump 51 Fuel Solenoid 52 EMF System 54 Wire Schematic 54 ...
Page 4
introduction Attention: Read through the complete manual prior to the initial use of your Pressure washer Using the Operator’s manual The operating manual is an important part of your Pressure washer and should be read thoroughly before initial use, and referred to often to make sure adequate safety and service concerns are being addressed. Reading the owner’s manual thoroughly will help avoid any personal injury or damage to your pump. By knowing how best to operate this machine you will be better positioned to show others who may also operate the unit. You can refer back to the manual at any time to help troubleshoot any specific operating functions, so store it with the machine at all times.
Page 5
product identification Record Identification Numbers Pressure washer If you need to contact an Authorized Dealer or Customer Service line (1- 866-770-1711) for information on servicing, always provide the product model and identification numbers. You will need to locate the model and serial number for the pump and record the information in the places provided below. Date of Purchase: Dealer Name: Dealer Phone: Product Identification Numbers Model Number: Serial Number:...
safety Save these Instructions SAFETy RULES This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. The safety alert symbol ( ) is used with a signal word (DANGER, CAUTION, WARNING), a pictorial and/or a safety message to alert you to hazards. DANGER indicates a hazard which, if not avoided, will result in death ...
Page 7
safety WARNING Serious injury or death may occur from normal sparks in the multiple ignition sources or engine/burner exhaust. Injury or death may occur as a result of improper fueling. Serious injury or death may occur from a ground fire caused by a muffler spark. Serious injury or death may occur if system safety’s are not properly maintained. • Always operate pressure washer in a well ventilated area free of flammable vapors, combustible dust, gases or other combustible materials. • Do not store the pressure washer near an open flame or any equipment such as a stove, furnace, water heater, etc., which utilizes a pilot light or sparking device. • Do not use this pressure washer to spray flammable material! • Do not smoke while filling burner fuel tank. • Never fill the fuel tanks while the pressure washer is running or hot. Allow to cool two minutes before refueling. • Always refuel slowly to avoid the possibility of spilled fuel which may cause a risk of fire. • Do not refuel indoors or in a poorly ventilated area. • Engine Fuel Tank: Refuel with gasoline only. Do not use diesel or fuel oil. • Burner Fuel Tank (Black): When refueling the Burner Fuel Tank, use No. 1 or No. 2 fuel oil/diesel or kerosene. Do not use gasoline. • Do not operate the unit if diesel fuel is spilled. Wipe the pressure washer clean and move it away from the spill. Avoid creating any ignition until the diesel fuel has evaporated. • A spark arrester must be added to the muffler of this engine if it is to be used on any forest covered, brush covered or grass covered unimproved land. The arrester must be maintained in effective working order by the operator. In the state of California, the above is required by law. (Section 4442 of the California Public Resources Code.) Other states may have similar laws. Federal laws apply on Federal lands. • This pressure washer has a Safety Relief device which should never be altered, modified, removed or made inoperative. If the device fails, replace immediately with only genuine manufacturer replacement part.
Page 8
safety WARNING Serious injury or death may occur from inhaling engine/ burner exhaust or dangerous vapors. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. • Never operate this pressure washer in an enclosed area. Always make certain there is adequate ventilation (fresh outside air) for breathing and combustion. This will prevent the buildup of dangerous carbon monoxide gases. Beware of poorly ventilated areas, or areas with exhaust fans which can cause poor air exchange. • Follow all safety instructions provided with the materials you are spraying. Use of a respirator may be required when working with some materials. Do not use this pressure washer to dispense hazardous detergents. WARNING Serious injury or death could occur from high pressure spray penetrating the skin. • Keep clear of nozzle and spray! Never put your hand, fingers or body directly over the spray nozzle. • Do not direct discharge stream at persons or self. • This product is to be used only by trained operators. • Always keep operating area clear of all persons. • Close supervision is necessary when used near children. DO NOT allow children to operate this unit! • SEEK EMERGENCY MEDICAL CARE if the spray appears to have penetrated the skin! DO NOT TREAT AS A SIMPLE CUT!! • High pressure hoses and fuel lines should be inspected daily for signs of wear. If evidence of failure exists, promptly replace all suspect hoses and fuel lines to prevent the possibility of injury from the high pressure spray. If a hose or fitting is leaking, NEVER PLACE YOUR HAND DIRECTLY ON THE LEAK. • NEVER operate the gun with the trigger wired in the open position. To prevent accidental discharge, the trigger gun should be securely locked when not in use. • Before removing the spray nozzle or servicing the unit, ALWAYS shut off the unit and trigger the gun to release trapped pressure. (Even af- ter you shut off the unit, there is high pressure water left in the pump, hose and gun until you release it by triggering the gun.)
Page 9
safety WARNING Serious injury or death may occur from contact with electricity. • DO NOT direct spray on or into electrical installations of any kind! This includes electrical outlets, light bulbs, fuse boxes, transformers, the unit itself, etc. • DO NOT allow metal components of the pressure washer to come in contact with live electrical components. WARNING Serious injury may occur from touching the gasoline engine, muffler or heat exchanger. These areas can remain hot for some time after the pressure washer is shutdown. • Never allow any part of your body to contact the gasoline engine, muffler or heat exchanger. WARNING Serious injury may occur from a pressure washer malfunction or exploding accessories if incorrect system components, attachments or accessories are used. Serious injury or death may occur if attempting to start the pressure washer when the pumping system is frozen. • Never make adjustments to the factory set pressures. • Never exceed manufacturers maximum allowable pressure rating of attachments. • Do not allow any hoses to make contact with heat exchanger to prevent the possibility of bursting. Avoid dragging the hoses over abrasive surfaces such as cement. • Use only manufacturer recommended repair parts for your pressure washer. • In freezing temperatures, the unit must always be warm enough to ensure there is no ice formation in the pump. Do not start the pressure washer if it has been transported in an open or under heated vehicle without first allowing the pump to thaw.
Page 10
safety WARNING Serious injury may occur to the operator from moving parts on the pressure washer. • Before making any adjustments, be certain the engine is turned off and the ignition cable(s) is removed from the spark plug(s). Turning the machinery over by hand during adjustment or cleaning might start the engine and machinery with it. • Do not operate the unit without all protective covers in place. WARNING Serious injury or death may occur from detergents con- tacting the skin. Serious injury can occur from loose debris being pro- pelled at a high speed from the spray gun. Injury may occur if the operator loses his balance caused by the thrust of water traveling through the spray nozzle. Injury may occur from the pressure washer. • SEEK EMERGENCY MEDICAL CARE if you are using cleaning agents and the spray appears to have penetrated the skin! DO NOT TREAT AS A SIMPLE CUT! Be prepared to tell a physician exactly what kind of detergents you were using by reading the Material Safety Data Sheet (MSDS) provided with your detergent. • Never use any solvents or highly corrosive detergents or acid type cleaners with this pressure washer. • Protective equipment such as rubber suits, gloves and respirators are advisable, especially when using cleaning detergents. • Keep all detergents out of the reach of children! • ALWAYS wear protective goggles when operating the unit to shield the eyes from flying debris and detergents. • DO NOT direct spray toward fragile materials such as glass for shat- tering could occur. • Stay alert-watch what you are doing. Do not operate the unit when fatigued or under the influence of alcohol or drugs. • NEVER squeeze the trigger unless securely braced. • DO NOT overreach or stand on unstable support. • Wet surfaces can be slippery, wear protective foot gear and keep good footing and balance at all times.
Page 11
safety • NEVER trigger the gun while on a ladder or roof. • ALWAYS hold on firmly to the gun/lance assembly when starting and operating the unit. Failure to do so can cause the lance to fall and whip dangerously. • Know how to stop the pressure washer and bleed pressures quickly. Be thoroughly familiar with controls. • DO NOT leave pressurized unit unattended. Shut off the pressure washer and release trapped pressure before leaving. • DO NOT operate the unit if you see any fuel, oil or water leaks from the machine. DO NOT resume operation until the unit has been in- spected and repaired by a qualified service person. • NEVER run the engine with the governor disconnected or operate at excessive speeds. • Place unit in a clean, dry, flat area for servicing. Before servicing the unit: turn the unit off, relieve the water pressure from the trigger gun, and allow the unit to cool down. Service in clean, dry, flat area. If ap- plicable, block wheels to prevent unit from moving. • Do not move the unit by pulling on the hose.
installation & preparation Installation & Preparation ATTIRE Proper attire is essential to your safety. It is advised to utilize whatever means necessary to protect eyes, ears, and skin. Additional safety attire (such as respiratory mask) may be required when using detergent cleaning agents with this washer. SET-UP 1. This unit should only be placed on a level surface to ensure proper lubrication for the water pump while operating. NEVER spray water directly on the unit. 2. Do not use unit in an area: a. with insufficient ventilation. b. where there is evidence of oil or fuel leaks. c. where flammable gas vapors may be present. This unit has multiple ignition sources that could cause an explosion or fire. 3. Do not allow the unit to be exposed to rain, snow or freezing temperatures. If any part of the unit becomes frozen, excessive pressure may build up in the unit which could cause it to burst resulting in possible serious injury to the operator or bystanders. 4. Be certain to block the wheels to prevent the unit from moving while operating. 5. Pump oil level should be checked before each use. Make certain the oil is on the “Full” mark on the dipstick or in the center of the oil sight glass. If the level appears to be low, fill with SAE30W non-detergent pump oil. DANGER DO NOT PLACE UNIT IN AN AREA WHERE FLAMMABLE GAS VAPORS MAY BE PRESENT. A SPARK COULD CAUSE AN EXPLOSION OR FIRE! DO NOT STORE/OPERATE UNIT IN FREEZING ENVIRONMENTS!
installation & preparation WARNING DO NOT OPERATE IN AN ENCLOSED AREA. USE THIS PRODUCT ONLY IN WELL VENTILATED AREAS! THE EXHAUST CONTAINS CARBON MONOXIDE, A POISONOUS, ODORLESS AND INVISIBLE GAS. BREATHING THIS GAS CAN CAUSE SERIOUS INJURY, ILLNESS & POSSIBLE DEATH. ENGINE/BURNER FUEL TANK DANGER DO NOT SMOKE WHILE FUELING! DO NOT FILL THE FUEL TANK WHILE UNIT IS RUNNING OR HOT. ALLOW UNIT TO COOL FOR TWO MINUTES BEFORE RE-FUELING. DO NOT FILL FUEL TANK TO POINT OF OVERFLOWING. ALLOW APPROXIMATELY 1/4” OF TANK SPACE FOR FUEL EXPANSION. ALWAYS STORE FUEL AWAY FROM THE WASHER WHILE THE UNIT IS RUNNING OR HOT. 1. Review “Risk of Explosion or Fire” Warnings pg. 4, before fueling. 2. Locate the Safety Decals on your unit and heed their warnings. 3. Gasoline Engines: A minimum of 85 octane fuel is recommended for use with this unit. DO NOT MIX OIL WITH GASOLINE. Burner Fuel: Use No. 1 or No 2 fuel oil/diesel or kerosene. 4. Purchase gasoline fuel in quantities that may be used within 30 days. Use of clean, fresh lead-free gasoline is recommended. Leaded gasoline may be used if lead-free is unavailable. DO NOT use gasoline containing methanol or alcohol. 5. Check the engine oil level before starting the engine. (See Engine manual.) 6. Fill fuel tanks according to accompanying manufacturer’s instruction manual. 7. Refer to the Engine Manual supplied with this unit for proper engine adjustment procedures. 8. Review the engine manual accompanying this pressure washer for correct engine start-up and maintenance procedures.
installation & preparation NOZZLE REVIEW Various nozzles may be quick-connected into the end of the wand to change the spray pattern or use the detergent feature. When using Quick Connects (Q.C.), be certain the connection is securely locked. If not, the high pressure water may shoot the nozzle from the wand, causing severe injury or serious damage. To determine spray fan, refer to the actual num- ber stamped on the nozzle. The first two digits indicate the spray fan in degrees, i.e.; 00=0”, 15=15°, 40=40°. 1. The 0° nozzle (RED): This is a blasting nozzle. It delivers a very con- centrated stream of water. Be cautious when using the straight narrow stream. It is not recommended for use on painted or wood surfaces, or items attached with adhesive backings. Uses: Removing weeds from sidewalk cracks, stubborn stains from concrete, masonry, alumi- num and steel, caked mud from equipment, and cleaning lawn mower undersides. 2. The 15° nozzle (YELLOW): This is a chiseling nozzle. The spray should WARNING NOZZLE REVIEW be directed at a 45° angle to the surface and used like a scraper to RISK OF INJECTION CAUSING Various nozzles m remove paint, grease and dirt. Uses: Surface preparation (removing SEVERE INJURY! spray pattern or u mildew stains and paint chips). NEVER LOOK DIRECTLY AT THE be certain the co NOZZLE ORIFICE UNLESS IT 3. The 40° nozzle (WHITE): This is a wash nozzle. This wide spray pattern ...
from equipment, and cleaning lawn mowe 2. The 15° nozzle (YELLOW): This is a chi be directed at a 45° angle to the surface an paint, grease and dirt. Uses: Surface prep QUICK-CONNECT (Q.C.) installation & preparation and paint chips). 3.
installation & preparation WARNING THE TRIGGER GUN SHOULD ALWAYS BE LOCKED IN THE OFF POSITION WHEN NOT IN USE! 4. Follow the incoming water requirements listed below: a. Water pressure must be a minimum of 20 pounds per square Inch (PSI) and a maximum of 125 PSI. (A typical outdoor faucet will generally supply this PSI if turned completely “ON”.) b. Incoming GPM must be approximately one gallon more than the outgoing GPM stated on the pressure washer nameplate. (You can check GPM by timing how long it takes to fill a 5 gallon container.) c. Incoming water temperature must not exceed 125°F. Excessive pump damage may result if the water temperature exceeds this acceptable level. 5. Never allow the unit to operate without the incoming water line TALLATION & PREPARATION attached and the water supply is completely turned on. g water requirements listed below: WATER INLET STRAINER must be a minimum of 20 pounds per square inch (PSI) m of 125 PSI.
installation & preparation PRE-START INSPECTION PROCEDURES Before starting the unit, perform the following procedures: 1. Check the oil level in the pump and engine. 2. Inspect the water inlet strainer. Clean or replace if necessary. See “Water Supply”, #2, pg 16. 3. Check all hose connections to ensure they are securely tightened. See “Water Supply”, #3, pg. 16. 4. Inspect for system water leaks, oil leaks and fuel leaks. If a fuel leak is found, DO NOT START UNIT! See “Risk of Explosion or Fire”, pg. 7. Be sure that all damaged parts are replaced and that the mechanical problems are corrected prior to operation of the unit. If you require service, contact Customer Service. 5. Inspect high pressure hoses for kinking, cuts and leaks. If a cut or leak is found, DO NOT USE HOSE! Replace hose before starting unit. See “Risk of Injection” pg. 8. Be sure that all damaged parts are replaced and that the mechanical problems are corrected prior to operation of the unit. If you require service, contact Customer Service.
operation Operating Instructions PRIMING THE PUMP It is essential to prime the pump and flush the unit each time the water supply has been disconnected from the unit OR whenever the unit has set for any period of time. This unit has a steel coil which, after setting, will cause the water remaining in the coil from the previous usage to turn brown or black. This contaminated water must be flushed from the system before start-up. This procedure should be performed without the high pressure hose, gun and nozzle assembly installed. 1. Turn on the water supply. 2. Low pressure water will begin flowing from the water outlet. This al- lows the unit to prime and purge any air from the system. The unit is primed when water flow is uninterrupted by air. 3. Once the system is flushed, turn off the water supply and connect the high pressure discharge hose/gun to the water outlet of the unit. 4. Turn on the water supply. CAUTION BE CERTAIN THE HOSE, GUN & LANCE ASSY. ARE NOT CONNECTED TO THE UNIT WHILE PRIMING THE PUMP. PRIMING ALLOWS MINERAL DEPOSITS TO BE RELEASED FROM THE SYSTEM WHICH WOULD OBSTRUCT OR DAMAGE THE GUN AND NOZZLE ASSEMBLY RESULTING IN COSTLY REPAIRS. START-UP/COLD WATER OPERATION WARNING KEEP CLEAR OF NOZZLE! NEVER PLACE HAND OR FINGERS IN FRONT OF NOZZLE! DO NOT DIRECT DISCHARGE STREAM AT PEOPLE OR PETS! CAUTION DO NOT ALLOW SPRAY PATTERN TO REMAIN ON A FIXED AREA FOR AN EXTENDED PERIOD OF TIME. POSSIBLE DAMAGE MAY OCCUR TO THE AREA.
Page 20
operation 1. Refer to the “Safety Precautions” pgs. 7-11 before starting the unit. 2. Locate the Safety Decals on your unit and heed their warnings. 3. Ensure that the switch is in the “OFF” position. 4. Perform the following engine start-up procedures. a. Point the trigger gun in a safe direction, disengage the safety lock on the gun and squeeze the trigger. b. Brace yourself for kickback from the high pressure created by the pump once the engine has started. c. Hold the trigger gun open while starting the engine according to the manufacturer’s instructions in the engine manual accompanying this unit. 5. Once the unit has started, perform the following procedures with the gun open: a. Inspect for system water leaks, oil leaks and fuel leaks. If a fuel leak is found, TURN UNIT OFF IMMEDIATELY! See “Risk of Explosion or Fire”, pg. 7. Be sure that all damaged parts are replaced and that the mechanical problems are corrected prior to operation of the unit. If you require service, contact Customer Service. b. Inspect high pressure hoses for kinking, cuts and leaks. If a cut or leak is found, DO NOT TOUCH HOSE AT LEAK!!! TURN UNIT OFF IMMEDIATELY! Replace hose before starting the unit. See “Risk of Injection or Severe Cutting Injury” pg. 8. Be sure that all damaged parts are replaced and that the mechanical problems are corrected prior to operation of the unit. If you require service, contact Cus- tomer Service. 6. Trigger the gun several times and try adjusting the water pressure by rotating the grip on the lance. NEVER place hand or fingers in front of the nozzle or look directly into the nozzle! High pressure water creates a risk of severe injury! 7. Do not allow unit to operate in bypass mode (with trigger closed) for more than three minutes without triggering the gun. Failure to follow this simple rule can cause premature failure of pump packings, result- ing in costly pump repair. 8. Your pressure washer can deliver high pressure spray and a variety of spray patterns using cold water. If you wish to use the Hot Water, Steam application or Cleaning with Detergents, for the correct proce- dures.
operation HOT WATER OPERATION WARNING THE WATER TEMPERATURE COULD BECOME VERY HOT DURING HOT WATER OPERATION. BE CAUTIOUS WHEN ADJUSTING PRESSURE OR CONTROLLING THE TRIGGER GUN/ LANCE ASSEMBLY. 1. Follow the steps outlined for “START-UP/COLD WATER OPERATION”. 2. Move the Burner Switch to the ON position. On initial start-up, water will begin turning hot in approximately 20 seconds and will reach maximum temperature in approximately 2-1/2 minutes, provided the trigger remains squeezed. The burner will stop firing when the trigger is released. At this point, the unit is operating as a hot water pressure washer. Be extremely cautious when adjusting the pressure and controlling the trigger gun/ lance assembly to avoid the possibility of burns. NOTICE While spraying, it is normal for the burner to fire intermittently. The high limit switch will cause combustion to cease when the temperature of the discharged water exceeds the temperature setting of the switch. Combustion will begin again when the water temperature drops below the minimum setting . CLEANING WITH DETERGENTS UNDER LOW PRESSURE NOTICE This feature is designed for use with mild detergents only. Since the cleaning solution travels through the heat exchanger coil, DO NOT use corrosives as they will cause extensive damage as well as pose a considerable safety hazard. NOTICE This injection system is designed to apply detergents under low pres- sure only. It will not allow detergent solutions to be introduced into the system unless the adjustable nozzle is set in the low pressure mode.
operation 1. Prepare detergent solution according to label directions. Never pump acids, alkaline, abrasive fluids or solvents through the unit. 2. Adjust the amount of detergent desired by locating the adjustment knob at the end of the clear vinyl hose. Turn the knob completely counterclockwise to set at maximum siphon rate. 3. Fully immerse the detergent strainer into the detergent solution. 4. With the trigger gun locked in the “OFF” position, securely quick- connect the detergent spray nozzle (#65 40° BLACK) into the end of the wand. 5. To apply solution; unlock the trigger gun and squeeze the trigger. In a few moments a detergent/water mixture will exit the nozzle. Start spraying the lower portion of the surface being cleaned and move up, using long overlapping strokes. Applying from the bottom up helps avoid streaking. Allow to soak briefly. (Avoid working on hot surfaces or in direct sunlight to minimize the chances of the detergent drying, which may result in damaging painted surfaces.) Be certain to rinse a small section at a time. 6. To rinse; lock the trigger gun in the “OFF” position, securely quick- connect the desired high pressure nozzle into the end of the wand. Unlock the trigger gun and spray. It will take about 30 seconds to purge all detergent from the line. For best rinsing results, start at the top and work down. 7. Siphon a gallon of water through the low pressure detergent injection system after each use. This prevents the possibility of corrosion or detergent residue causing mechanical problems during the next use. SHUTDOWN 1. Move the Burner Switch to the OFF position. 2. Squeeze the trigger and discharge the water for a period of three minutes to cool the heat exchanger and high pressure hose. (Insufficient cool down period of the high pressure hose will cause excessive wear and eventual rupturing of the hose.) 3. DO NOT close the choke to stop the engine. Backfire or engine damage may occur. Turn the engine “OFF” as directed in the engine manual. 4. Close the engine fuel shut-off valve. 5. Turn the water supply “OFF”. 6. Pointing the gun in a safe direction, trigger the gun momentarily to relieve trapped pressure. 7. Disconnect and drain the nozzle assembly, gun, wand and hoses. 8. Store complete assembly in a non-freezing environment.
maintenance Storage & Maintenance Instructions SPECIFIC MAINTENANCE ENGINE: The engine instructions that accompany your unit detail specific procedures for maintenance of the engine. Following the engine manufacturer’s recommendations will extend engine work life. PUMP: Change the pump oil after the first 50 hours of operation. After initial change, every 3 months or 250 hour intervals are recommended. If oil appears dirty or milky, changes may be required in greater frequency. Use pump oil SAE30W non-detergent and fill only to the center of the oil sight glass. DO NOT overfill. QUICK COUPLERS: There is an o-ring seal inside the female quick coupler. This o-ring will deteriorate or, if the unit is allowed to pump without the high pressure hose or nozzle attached, the o-ring may be blown out occasionally. Simply insert a replacement o-ring to correct the leak. (Additional o-rings can be purchased from your dealer.) NOZZLE: Water flow through the spray nozzle will erode the orifice, making it larger, resulting in a pressure loss. Nozzles should be replaced whenever pressure is less than 85% of the maximum. The frequency of replacement will depend upon such variables as mineral content in the water and number of hours the nozzle is used. BURNER AIR ADJUSTMENT: The air shutter has been factory preset for proper operation between sea level and 2000 feet elevation at standard conditions (60°F ambient water and air temperatures). To assure maximum combustion efficiency at colder temperatures and higher altitudes, it will be necessary to adjust the air supply to the combustion chamber. A smoke spot test is recommended during any air shutter adjustment. This will aid in maximizing the burner efficiency and avoid the inefficient operation and excessive sooting of the combustion chamber. 1. The machine must be running and the burner on. 2. Take a smoke spot test to determine if more or less air is required for proper combustion. a. If the test is greater than a #3 smoke, turn the shutter arm counterclockwise to increase the air flow into the combustion chamber. b. If the test is yellowish in color, turn the shutter arm clockwise to ...
maintenance 5. Repeat steps 2 and 3 until step 4 is attained. LEAKS: Promptly eliminate any leaks found in the pumping system by removing suspect parts, applying thread sealant to the threads and reinstalling. NOTICE If using Teflon tape, be certain no tape gets inside any plumbing to prevent the possibility of a plugged spray nozzle. WINTERIZING 1. For storage and transportation purposes in subfreezing ambient tem- peratures, it will be necessary to winterize this unit. This unit must be protected to the lowest incurred temperature for the following reasons: a. If any part of the pumping system becomes frozen; excessive pressure may build up in the unit which could cause the unit to burst resulting in possible serious injury to the operator or bystanders. b. The pumping system in this unit may be permanently damaged if frozen. FREEZE DAMAGE IS NOT COVERED BY WARRANTY. If you must store your unit in an area where the temperature may fall below 32°F, you can protect your unit by following the procedure outlined below. 1. Gather the following items: a. Two 5 gallon containers. b. One gallon of antifreeze. (Use an environmentally safe antifreeze.) c. Water supply. d. Three foot hose, 1/2-3/4 I.D. with a 3/4 inch male garden hose fit- ting. 2. Procedure: a. To start winterizing, unit must be run according to the “Start-up Cold Water Operation”. b. After running, shut off the unit and water supply. c. Relieve system pressure by pointing the trigger gun in a safe direc- tion and squeezing the trigger until water flow ceases to exit the Lance Assy. d. Lock the trigger gun in the OFF position and adjust the Lance to the low pressure mode. e. Remove the water supply hose from the unit and attach the 3 foot hose securely to the inlet connection. f. Shut off the detergent injector (if applicable). g. Fill one 5 gallon container with water.
Page 25
maintenance h. Holding the 3 foot hose in an upright position, completely fill the hose with water. Then plug the open end of the hose with your thumb or finger. Place the plugged end into the 5 gallon container of water. i. Start the unit. Trigger the gun several times until all the air is worked out of the system (unit is primed). j. With the trigger gun held open, siphon enough water out of the 5 gallon container until there is just enough water left to mix with the antifreeze. k. Point the trigger gun into the empty container. (Be certain to wear safety attire for protection from splashing.) l. Trigger the gun until the antifreeze begins to exit the trigger gun. Release the trigger for 3 seconds, then trigger the gun for 3 seconds. Continue cycling the trigger gun several times until all the antifreeze mixture is siphoned from the container. m. Stop the unit. n. Detach the 3 foot hose from the unit and drain any excess antifreeze back into the 5 gallon container storage & maintenance o. Disconnect the hose and trigger gun from the unit and drain any excess antifreeze back into the 5 gallon container. p. Drain hose, trigger gun and lance assembly and store with the unit in a safe non-freezing area. q. Store antifreeze solution for next use or dispose of according to state EPA laws. NOTICE Proper winterizing is based on the recommended manufacturer’s instructions listed on the “Protection Chart” shown on the back label of most antifreeze containers. 3. OPTIONAL PROCEDURE: a. Shut the unit and water supply off. b. Relieve system pressure by pointing the trigger gun in a safe direction and squeezing the trigger until water flow ceases to exit the nozzle. c. Disconnect and drain the hose, trigger gun and lance assembly. d. Remove the coil drain plug from the heat exchanger inlet. e. Start the unit and allow it to run until all the water exits the unit. Once the water has stopped flowing from the unit, turn off. NOTICE When using this procedure, use caution as ice chips can form from drops of water which could cause the unit to burst if starting before completely thawed.
maintenance MAINTENANCE CHART PROCEDURE DAILY 3 6 9 12 MONTHS MONTHS MONTHS MONTHS Check engine oil level Change engine oil***** Check water pump oil level Change water pump oil ** Oil leak inspection Fuel leak inspection Water leak inspection Hose inspection Water inlet filter inspection Inspect belt Replace high pressure nozzle*** Replace fuel filter Inspect fuel pump filter* Replace fuel nozzle* Check burner air adjust- ment Check burner electrodes* Test water pressure* Test fuel pressure* Test water temperature* Descale coil**** * Must be performed by an authorized service technician. ** The pump oil must be changed after the first 50 hours of operation and every 250 hours or 3 months, whichever comes first. *** High pressure nozzle should be replaced whenever pressure is less than 85%.
troubleshooting Troubleshooting TROUBLESHOOTING CHART SYMPTOM PROBABLE CAUSE REMEDY Engine will not start Various engine problems Refer to the Engine Manual accompanying your unit. Unit components are frozen. Allow to thaw. If any part of the unit becomes frozen; excessive pressure may build up in the unit which could cause the unit to burst resulting in possible serious injury to the operator or bystanders. No discharge at Inadequate water supply. Ensure hose is 3/4” diameter nozzle when trigger and incoming water supply is mechanism is turned on. squeezed. Low or fluctuating Kink in water inlet hose. Remove kink. pressure. Kink in high pressure Replace kinked high pressure discharge hose. hose. Water inlet screen Remove screen, clean or obstructed. replace. Pump sucking air. (Prime Tighten all water intake ...
Page 28
troubleshooting SYMPTOM PROBABLE CAUSE REMEDY Detergent will not Detergent strainer is not Check, submerge if necessary. siphon into Low completely submerged in Pressure Detergent detergent solution. mode. Detergent strainer Inspect, clean or replace. obstructed. Detergent hose cut, Inspect, clean or replace. obstructed or kinked. Detergent adjusting knob Open adjusting knob. Refer to turned to closed position. “Cleaning with Detergents”. Too many high pressure Use one extension maximum. hose extensions attached to the water outlet. Nozzle assembly is plugged. Clean or replace. Ball & Spring in Venturi Remove, clean or replace. stuck. Water flows back into Ball & Spring in Venturi Remove, clean or replace. detergent container. reversed, missing or corroded. Water flows from the Trigger gun is Repair or replace. nozzle when the trigger ...
Page 29
troubleshooting SYMPTOM PROBABLE CAUSE REMEDY Burner will not ignite Ignition module Consult your Customer Service Ignition electrodes With unit running and trigger damaged or worn. gun closed, look through burner sight glass to ensure there is sparking across electrodes. No voltage Consult your Customer Service. Pressure switch override. Pressure should be over 250 PSI/18 Bar to allow burner to come on. High limit switch override. Unit will automatically reignite when cool. Improper burner air Adjust as explained on page 26. adjustment. Fuel solenoid valve failure. Replace. Burner runs erratically. Water in the fuel oil. Drain fuel filter/water separator. Drain fuel tank, and replace with clean fuel. Dirty fuel filter/water Replace element. separator. Dirty fuel nozzle. Replace. Fuel pickup screen Consult Customer Service. obstructed. Improper air adjustment ...
Parts List SPECIFICATIONS MODEL NUMBER HW2765HAD Operating Pressure (PSI/Bar) 2500/172 Water Volume (GPM/lpm) 2.4/9.1 Outlet Water Temperature (F/C) 130°F/ 54°C (+/- 20°F) rise above inlet ambient (210°F/ 99°C maximum) Pressure Nozzle Engine: Honda Model GX200 Engine Type Four Stroke, Overhead Cam, Single Cylinder Oil Type SAE10W-30 Oil Capacity (oz./liter) 20 / 0.6 Low Oil Protection Oil Alert Fuel Type Unleaded Gasoline 86 Octane Minimum Fuel Capacity (Qt./liter) .95/3.6 Starting Recoil Rope Max No Load RPM 3600 (+/- 100) High Pressure Pump: Direct Driven, Oil Bath, Triplex Piston Oil Type SAE30W Non-Detergent Oil Capacity (oz./lter) 14.0 / 0.41...
Page 31
SPECIFICATIONS CONT. MODEL NUMBER HW2765HAD Electro Magnetic Firing (EMF) System: Belt Driven (Patent #5,954,494) Ignition Transistorized Magneto Control Voltage 12 Volt DC Blower Forced Air Heat Exchanger: Vertical, Top fi red, Dual Spiral Coil BTU Input 185,500 Effi ciency 80-83% with #2 Fuel Oil/ Diesel Smoke Density 0-3 per ASTM D2156 Controls: On/Off Switch Industrial grade rocker switch Pressure Switch Shuts off burner fuel supply upon trigger release High Limit Switch Shuts off burner fuel supply when outlet water temp. exceeds 210°F / 99°C Fuel Solenoid: 12 Volt Safety Relief: Relieves excess system pressure Unit Net Weight (Lbs/Kg) 257 / 117 Unit Shipping Weight (Lbs/Kg) 377 / 171 Unit Net Dimensions (In/Cm) 47.5L x 28W x 36.25H/121L x 71W x 92H...
Page 33
parts list GENERAL THEORy OF OPERATION WATER FLOW: Connect a pressurized water source to the INLET GAR- DEN HOSE CONNECTION (1) and turn on the water supply. The water then travels into the TRIPLEX HIGH PRESSURE PUMP (2) which has an UNLOADER (6) that bypasses the water when the trigger gun is closed. To protect the pump from heated water during this bypass stage, a HEAT DUMP VALVE (5) will open at 140°F/60°C allowing the heated water to escape. The Heat Dump Valve automatically resets when the water cools. The PRESSURE SWITCH (7) controls the fuel supply to the burner. From there, the water will flow into the HEAT EXCHANGER INLET (10) where it is heated when the burner is on. As the water exits the HEAT EXCHANGER OUTLET (11), it enters a safety system which protects the operator from danger. The safety system contains a HIGH TEMPERA- TURE LIMIT SWITCH (12) which senses the water temperature and shuts off the fuel supply to the burner if it gets too hot. If the unloader fails to bypass the water or the burner remains on when the trigger gun is closed, the SAFETY RELIEF (13) will relieve and allow water to exit safely. The heated water then flows through the HIGH PRESSURE HOSE (14) and to the TRIGGER GUN ASSEMBLY (15) which allows the operator to control the water spray. When the trigger gun is open, the water flows through the LANCE (16) and exits the NOZZLE (17). FUEL FLOW: The Fuel Pump draws fuel from the FUEL TANK (18) through a replaceable FUEL FILTER (4) and into the FUEL PUMP (3). Fuel exits the fuel pump, into a FUEL SOLENOID VALVE (8) which con- trols fuel flow to the FUEL NOZZLE (9) where it ignites and burns in the heat exchanger. EMF SYSTEM: The patented Electro Magnetic Firing (EMF) System is an integrated system which gives all the requirements for combustion. The BELT (1) from the power source turns the HUB (2) which has two EXTERIOR MAGNETS (3) attached. As these magnets spin past the IG- NITION MODULE (4), a magnetic flux is created from which the ignition module produces a high voltage. This voltage arcs across the electrodes giving the spark that is needed for ignition.
Page 39
parts list PUMP ASSEMBLy ITEM DESCRIPTION PART # Screw 27-8432 Flange 46-0715 Oil Seal 26-0192 Retaining Ring 46-0667 Needle Bearing 48-0059 Set Screw 27-8886 Crankshaft 46-0718 Plug 39-0086 O-Ring 25-0325 Bolt 27-8888 Crankshaft Cover 46-0719 O-Ring 25-0370 Oil Sight Glass 46-0670 Oil Reflector 46-0824 Spring Retainer 46-0671 O-Ring 25-0398 Connecting Rod 46-0720 Piston Pin 46-0721...
Page 40
parts list ITEM DESCRIPTION PART # Plug 39-0097 Lockwasher 29-0153 Bolt 27-8875 Manifold 46-0730 O-Ring 25-0372 Plug 39-0088 Support Ring (see kit 70-0182) SEE KIT V Packing (see kit 70-0181) 46-0729 Packing Retainer 46-0728 LP Seal (see kit 70-0181) 46-0727 LP Retainer 46-0726 O-Ring (see kit 70-0181) 25-0399 Oil Seal 26-0193 REPLACEMENT KITS KIT # DESCRIPTION ITEMS # OF # OF ASSEM- CYLINDERS BLIES 70-0181 Kit - High Pressure ...
parts list FUEL TANK FUEL TANK FUEL TANK HSE_HSP SMALL FUEL FUEL TANK ASSEMBLY ITEM DESCRIPTION FUEL CAP FUEL TANK FUEL GAUGE GROMMET ITEM DESCRIPTION FUEL GAUGE FUEL CAP ELBOW FUEL GAUGE GROMMET FUEL PICK UP FUEL GAUGE NIPPLE ELBOW DECAL - CAUTION: RISK OF FIRE (SEE 71-0058) FUEL PICK UP FUEL TANK...
warranty STATEMENT OF WARRANTy The manufacturer warrants all parts, (except those referred to below), of your new pressure washer to be free from defects in materials and work- manship during the following periods: For Lifetime against freezing and cracking: Pump Manifold For Seven (7) Years from the date of original purchase: High Pressure Pump For Three (3) Years from the date of original purchase: Heat Exchanger Coil For Two (2) Years from the date of original purchase: Frame Plumbing Guard or Shields Pulleys For One (1) Year from the date of original purchase: Adjustable Thermostat GFCI Cord Selector switch Starter Contactor Overload For Six (6) months from the date of original purchase: Ignition Transformer Burner Motor For Ninety (90) days from the date of original purchase: Unloader Valve Electrodes Fuel solenoid High Limit thermostat Fuel Pump Pressure Switch Safety Relief Valve For Thirty (30) days from the date of original purchase: High Pressure Hose Trigger Gun Strainers / Filters Wand Defective parts not subject to normal wear and tear will be repaired or replaced at our option during the warranty period. In any event, reimbursement is limited to the purchase price paid.
warranty WARRANTy EXCLUSIONS 1. The motor is covered under separate warranty by its respective manufacturer and is subject to the terms set forth therein. 2. Normal wear parts: Pump Packings Spray Nozzles Pump Valves Detergent Valves Fuel Filters Quick Couplers/screw connects O-rings Belts 3. This warranty does not cover parts damaged due to normal wear, misapplication, misuse, operation at other than recommended speeds, pressures or temperature. Parts damaged or worn because of the use of caustic liquids or by operation in abrasive or corrosive environments or under conditions causing pump cavitation are not warranted. Failure to follow recommended operating and maintenance procedures also voids warranty. 4. The use of other than Genuine Repair Parts will void warranty. Parts returned, prepaid to our factory or to an Authorized Service Center will be inspected and replaced free of charge if found to be defective and subject to warranty. There are no warranties which extend beyond the description of the face hereof. Under no circumstances shall the manufacturer bear any responsibility for loss of use of the unit, loss of time or rental, inconvenience, commercial loss or consequential damages.
Page 57
If you need assistance with the assembly or operation of this Pressure Washer please call 1-866-770-1711...