Karcher Shark HPB-201107D, HDS 2.5/16 Ea Cag, HPB-251607A, HDS 3.5/20 Ea Cage, HPB-352007A Operator's Manual
...
OPERATOR’S MANUAL
®
MODEL # ORDER #
HDS 2.0/10 Ed Cage / HPB-201107D 1.575-500.0
HDS 2.0/14 Ed Cage / HPB-201407D 1.575-501.0
HDS 2.5/10 Ed Cage / HPB-251007D 1.575-502.0
HDS 2.5/16 Ea Cage / HPB-251607A 1.575-503.0
HDS 3.5/20 Ea Cage / HPB-352007A 1.575-504.0
HDS 3.9/20 Ea Cage / HPB-392007A 1.575-505.0
To locate your local Kärcher Shark Commercial Pressure Washer Dealer nearest you,
visit www.karchercommercial.com or www.karchershark.com
MODEL # ORDER #
HDS 3.5/30 Ea Cage / HPB-353007A 1.575-508.0
HDS 3.5/30 Eb Cage / HPB-353007B 1.575-509.0
HDS 3.5/30 Ec Cage / HPB-353007C 1.575-510.0
9.800-078.0
CONTENTS
Introduction & Important Safety Information 4-6
Component Identifications 7-9
Assembly Instructions 10
Installation 11
Operating Instructions 12
Detergents & General Cleaning Techniques 13
Shut Down & Clean-up Procedures 14
Storage 14
Troubleshooting 15-16
Maintenance Charts 17
Oil Change Record 17
Preventative Maintenance 18
Maintenance & Service 18-20
1.575-500.0 Exploded View and Parts List 21-23
1.575-501.0, 502.0, 503.0, 504.0 Exploded View & Parts List 24-26
1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0 Exploded View 27
1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0 Parts List 28-30
1.575-500.0 Control Panel, Exploded View & Parts List 31-32
1.575-501.0, 502.0, 503.0, 504.0 Control Panel,
Exploded View & Parts List 33-34
1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0 Control Panel,
Exploded View & Parts List 35-36
1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0 Float Tank Option
Exploded View & Parts List 37-38
1.575-501.0, 502.0, 503.0, 504.0 Auto Start/Stop Options
Exploded View & Parts List 39
1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0
Auto Start/Stop Options Exploded View & Parts List 40
2
HDS 500-510 • 9.800-078.0 • Rev. 4/10
1.575-501.0, 502.0, 503.0, 504.0 Auto Start/Stop -
Steam Options Exploded View & Parts List 41
1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0
Auto Start Stop - Steam Options Exploded View & Parts List 42
1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0
Pump Assembly Exploded View & Parts List 43
1.575-501.0, 502.0, 503.0, 504.0
Steam Option Exploded View & Parts List 44
1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0
Steam Options Exploded View & Parts List 45
Hose & Spray Gun Assembly Exploded View & Parts List 46
UU1 Unloader Valve Exploded View and Parts List 47
KE.1 Pump Exploded View and Parts List 48-49
CONTENTS
KM. 2 Pump Exploded View and Parts List 50-51
Specifications 52-53
Burner Specifications 54
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.
3
HDS 500-510 • 9.800-078.0 • Rev. 4/10
INTRODUCTION & IMPORTANT SAFETY INFORMATION
MANUAL THOROUGHLY
WARNING
OPERATE ONLY WHERE
OPEN FLAME OR TORCH
WARNING
WARNING
Thank you for purchasing this Pressure Washer.
We reserve the right to make changes at any time
without incurring any obligation.
Owner/User Responsibility:
The owner and/or user must have an understanding of
the manufacturer’s operating instructions and warnings
before using this pressure washer. Warning information
PRESSURE WASHER
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.
Owner and/or user must study and maintain for future
reference the manufacturers’ instructions.
OPERATOR’S MANUAL
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 i njury, r ead o p er ating
instructions carefully before
using.
1. R e a d t h e o w n e r ' s
manual th oroug hly. Fail -
READ OPERATOR’S
PRIOR TO USE.
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
4
more than single phase this product should only be
ure to follow instructions
co uld cause malf unction
of the machine and result
in death, serious bodily injury and/or property damage.
2. Know how to stop the machine and bleed pressure
qu i c k ly. Be tho r o ugh l y
familiar with the controls.
connected to a power supply receptacle protected
by a GFCI.
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
KEEP WATER
SPRAY AWAY FROM
ELECTRICAL WIRING.
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.
RISK OF EXPLOSION:
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.
RISK OF FIRE.
DO NOT ADD FUEL
WHEN OPERATING
MACHINE.
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.
HDS 500-510 • 9.800-078.0 • Rev. 4/10
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
must be electrically grounded.
It is the responsibility of the
owner to connect this machine
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.
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.
WARNING
WARNING
IMPORTANT SAFETY INFORMATION
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
PRESSURE WASHER
10. Keep operating area clear of all persons.
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
USE PROTECTIVE
EYE WEAR
AND CLOTHING
WHEN OPERATING
THIS EQUIPMENT.
foot safety devices must be
worn.
11. E ye , h a n d , a n d fo o t
pr ote cti on must be worn
when using this equipment.
WARNING: This machine ex-
ceeds 85 db appropriate ear
protection must be worn.
EAR PROTECTION
MUST BE WORN
WARNING: Hot discharge fluid.
D o n o t t o u ch or di r e c t
discharge stream at persons.
WARNING: This machine produces hot water and must have
HOT DISCHARGE FLUID:
DO NOT TOUCH OR
DIRECT DISCHARGE
STREAM AT PERSONS.
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
RISK OF INJURY:
HOT SURFACES
CAN CAUSE BURNS
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: Grip cleaning wand
securely with both hands before starting. Failure to do this
could result in injury from a
whipping wand.
13. Never make adju stments
o n m a c h i ne w h i l e i n
TRIGGER GUN KICKS
BACK - HOLD WITH
BOTH HANDS
operation.
14. Be certain all quick coupler fittings are secured before using pressure washer.
WARNING: High pr e s sure
developed by these machines
will ca use personal injury
RISK OF INJECTION
OR SEVERE INJURY
TO PERSONS. KEEP
CLEAR OF NOZZLE.
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.
WARNING: Protect machine
from freezing.
PROTECT FROM
FREEZING
15. To keep machine in best
operating conditions, it is
important you protect machine
from freezing. Failure to protect machine from
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.
16. Inlet water must be clean fresh water and no hotter
then 90°F.
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 ox-
RISK OF
ASPHYXIATION: USE
THIS PRODUCT ONLY
IN A WELL
VENTILATED AREA.
yg en is neede d for combustion or dangerous carbon monoxide 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
ar ea should have adequate
slopes and drainage to reduce
RISK OF INJURY
FROM FALLS WHEN
USING LADDER.
the possibility of a fall due to
slippery surfaces.
20. Do not overreach or stand on unstable support.
Keep good footing and balance at all times.
OPERATOR’S MANUAL
5
HDS 500-510 • 9.800-078.0 • Rev. 4/10
IMPORTANT SAFETY INFORMATION
PRESSURE WASHER
21. Do not operate this machine when fatigued or under
the influence of alcohol, prescription medications,
or drugs.
OPERATOR’S MANUAL
Follow the maintenance instructions
specified in the manual.
6
HDS 500-510 • 9.800-078.0 • Rev. 4/10
98000780-2
Burner
Chamber
PRESSURE WASHER
COMPONENT IDENTIFICATION - 1.575-500.0
Fuel Tank
Fresh Water
Faucet
(not included)
OPERATOR’S MANUAL
Wand Holder
Unloader
Discharge
Nipple
Nozzle
Coupler
GFCI
Variable Pressure
Insulated Wand
Control
Handle
Burner
Motor
Rupture
Disc
High Limit
Thermostat
Insulated
Spray Gun
High Pressure
Pump
Hose
Garden Hose
(not included)
Pump — Develops high pressure.
Rupture Disc — Opens when pressure exceeds safe
operating temperature.
Spray Gun — Controls the application of water and
detergent onto cleaning surface with trigger device.
Includes safety latch.
High Limit Thermostat — Controls water temperature.
High Pressure Hose — Connect one end to water
pump discharge nipple and the other end to spray
gun.
Variable Pressure Control Wand — Must be connected to the spray gun. This wand handle controls
discharge flow from one tube to both wand tubes. When
water is discharged from both tubes you will have a
pressure loss and allows chemical siphoning when
used in combination with a detergent injector.
Note: If trigger on spray gun is released for more
than 2 minutes, water will leak from valve. Warm water will discharge from pump protector onto floor.
This system prevents internal pump damage.
7
HDS 500-510 • 9.800-078.0 • Rev. 4/10
COMPONENT IDENTIFICATION - 1.575-501.0 - 1.575-504.0
98000780-3
CAUTION HOT WATER:
Must use insulated
spray gun and wand.
PRESSURE WASHER
OPERATOR’S MANUAL
Pump &
Burner Switch
Control Panel
Burner
Chamber
GFCI
High Limit
Thermostat
Downstream
Detergent Injector
Fuel Tank
Pump
Fresh Water
Faucet
(not included)
Pressure
Switch
Unloader
Garden Hose
(not included)
Discharge
Nipple
Detergent
Pick-up Hose
Wand
Holder
Burner Motor
Nozzle Coupler
Detergent Bucket
(not included)
8
Variable Pressure
Insulated Wand
HDS 500-510 • 9.800-078.0 • Rev. 4/10
Control
Handle
Insulated
Spray Gun
High Pressure
Hose
COMPONENT IDENTIFICATION - 1.575-505.0 - 1.575-510.0
98000780-4
CAUTION HOT WATER:
Must use i n s u l a t e d
spray gun and wand.
PRESSURE WASHER
Burner Switch
Pump Switch
High
Pressure
Nozzle
Control
Panel
GFCI
Quick Coupler
Detergent
Pick-Up Hose
Detergent Injector
Burner
Chamber
Downstream
Burner
Motor
Fuel Tank
Discharge
Nipple
Wand Holder
High Limit
Thermostat
Pressure
Switch
Unloader
Garden Hose
(not included)
OPERATOR’S MANUAL
Pump
Fresh Water
Faucet
(not included)
Detergent
Bucket
(not included)
Nozzle
Coupler
Variable Pressure
Insulated Wand
HDS 500-510 • 9.800-078.0 • Rev. 4/10
Control
Handle
High Pressure
Hose
Insulated
Spray Gun
9
ASSEMBLY INSTRUCTIONS
Fuel
Cap
PRESSURE WASHER
STEP 1: Connect water supply
hose.
OPERATOR’S MANUAL
STEP 4: Attach the high pressure
hose to the spray gun using teflon
tape on hose threads.
STEP 2: Check fuel tank and
pump oil levels.
STEP 5: Connect the high pressure
hose to the pump discharge fitting.
Push coupler collar forward until
secure.
STEP 3: Connect high pressure
hose to discharge nipple by sliding
quick coupler collar back. Inser t
quick coupler onto discharge nipple
and secure by pushing quick coupler
collar forward.
10
HDS 500-510 • 9.800-078.0 • Rev. 4/10
INSTALLATION
PRESSURE WASHER
Place machine in a convenient location providing ample
support, draining and room for maintenance.
This machine is intended for outdoor use. Machine
must be stored indoors when not in use.
Location:
The location should protect the machine from damaging environmental conditions, such as wind, rain, and
freezing.
1. This machine should be run on a level surface
where it is not readily influenced by outside sources
such as strong winds, freezing temperatures, rain,
etc. It should be located to allow accessibility for
refilling of fuel, adjustments and maintenance. Normal precautions should be taken by the operator
of the machine to prevent moisture from reaching
the electrical controls.
2. It is recommended that a partition be made be-
tween the wash area and the machine to prevent
water spray from coming in contact with the machine. Excess moisture reaching any electric components or electrical controls will reduce machine
life and may cause electrical shorts.
3. During installation of the machine, beware of poorly
ventilated locations or areas where exhaust fans
may cause an insufficient supply of oxygen. Sufficient combustion can only be obtained when there
is a sufficient supply of oxygen available for the
amount of fuel being burned. If it is necessary to
install a machine in a poorly ventilated area, outside fresh air may have to be piped to the burner
and a fan installed to bring air into the machine.
Avoid small locations or areas near exhaust fans.
Electrical:
This machine, when installed, must be electrically
grounded in accordance to local codes. Check for
proper power supply using a volt meter.
Placement:
Do not locate near any combustible material. Keep all
flammable material at least 20 feet away.
Allow enough space for servicing the machine.
Local code will require certain distances from floor
and walls. (Two feet away from walls should be adequate.)
Water Source:
The water source for the pressure washer should be
supplied by a minimum 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 attached pressure washer will run very rough and
the burner will not fire.
Connection:
Connect the wand, nozzle, hose and spray gun (where
applicable). On pipe thread connections, use teflon
tape to avoid water leaks. (See Component Identification).
Venting:
Adding exhaust vent pipe to your oil fired burner is
not recommended because restricted air flow causes
carbon build-up, which affects the operation, and increases maintenance on the coil. If a stack must be
used, refrain from using 90° bends. If the pipe can not
go straight up then use only 45° bends and go to the
next size pipe. The overall pipe length must not exceed
6 feet in length*.
*Note: After vent pipe installation test burner using a
smoke tester and adjust air setting to achieve a #3 or
below results.
OPERATOR’S MANUAL
11
HDS 500-510 • 9.800-078.0 • Rev. 4/10
OPERATING INSTRUCTIONS
PRESSURE WASHER
STEP 1: Turn water on. STEP 3: Grip spray gun handle
OPERATOR’S MANUAL
STEP 4: Before installing noz-
zle, turn on water supply and run
machine, allowing water to flush
STEP 2: Connect the power cord
into the proper electrical outlet, then
push in the GFCI reset button. (Refer to serial plate for information).
Brass Soap
Nozzle
High
Pressure
Nozzle
Variable Pressure
Control Handle
securely and pull trigger. Then turn
variable pressure control handle
counterclockwise.
Variable Pressure
Wand (VP)
Trigger
Selection of high or low pressure is accompanied by turning the handle.
Note: High pressure nozzle must be inserted at end of wand to obtain high
pressure. To apply soap read operator's manual.
through the system until clear.
Turn switch to pump position. When
a steady stream of water flows from
the spray gun and wand the machine is ready for cold water cleaning by turning the variable pressure
control handle clockwise to raise
the pressure.
For hot water washing, turn the
switch to the burner position. (The
burner will light automatically when
the trigger on the spray gun is
pulled.)
12
HDS 500-510 • 9.800-078.0 • Rev. 4/10
WARNING
DETERGENTS & GENERAL OPERATING TECHNIQUES
98000780-6
PRESSURE WASHER
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.
STEP 1: Connect detergent injector to discharge nipple on
machine, Connect high pressure
hose to injector with quick coupler(check to make sure
locking coupler sleeves are in proper position before
applying water pressure.
High
Pressure
Hose
STEP 2: Use detergent designed
specifically for pressure washers. Household detergents could
damage the pump. Prepare detergent solution as required by the
manufacturer. Fill a container with
pressure washer detergent. Place
the filter end of detergent suction
tube into the detergent container.
STEP 3: Apply safety latch to spray gun trigger. Turn
variable pressure control handle until discharge water
exits both tubes. Secure black detergent nozzle into
quick coupler if you have a single wand. NOTE: Detergent cannot be applied using Red, Yellow, Green
or White nozzles.
STEP 4: With the engine running,
pull trigger to operate machine.
Liquid detergent is drawn into the
machine and mixed with water. Apply detergent to work area. Do not
allow detergent to dry on surface.
THERMAL PUMP
PROTECTION
If you run the engine on your pressure washer for 3-5
minutes without pressing the trigger on the spray gun,
circulating water in the pump can reach high temperatures. When the water reaches this temperature, the
pump protector engages and cools the pump by discharging the warm water onto the ground. This thermal
device prevents internal damage to the pump.
CLEANING TIPS
Pre-rinse cleaning surface with fresh water. Place detergent suction tube directly into cleaning solution and
apply to surface at low pressure (for best results, limit
your work area to sections approximately 6 feet square
and always apply detergent from bottom to top). Allow
detergent to remain on surface 1-3 minutes. Do not
allow detergent to dry on surface. If surface appears
to be drying, simply wet down surface with fresh water.
Detergent
Injector
HDS 500-510 • 9.800-078.0 • Rev. 4/10
If needed, use brush to remove stubborn dirt. Rinse at
high pressure from top to bottom in an even sweeping
motion keeping the spray nozzle approximately 1 foot
from cleaning surface. Use overlapping strokes as you
clean and rinse any surface. For best surface cleaning
action spray at a slight angle.
Recommendations:
• Before cleaning any surface, an inconspicuous
area should be cleaned to test spray pattern and
distance for maximum cleaning results.
• If painted surfaces are peeling or chipping, use
extreme caution as pressure washer may remove the loose paint from the surface.
• Keep the spray nozzle a safe distance from the
surface you plan to clean. High pressure wash
a small area, then check the surface for damage. If no damage is found, continue to pressure
washing.
CAUTION - Never use:
• Bleach, chlorine and other corrosive chemicals
• Liquids containing solvents (i.e., paint thinner,
gasoline, oils)
• Tri-sodium phosphate products
• Ammonia products
• Acid-based products
These chemicals will harm the machine and will damage the surface being cleaned.
It will take a few seconds for the detergent to clear.
Apply safety latch to spray gun. Remove black soap
nozzle from the quick coupler. Select and install the
desired high pressure nozzle. NOTE: You can also stop
detergent from flowing by simply removing detergent
siphon tube from bottle.
OPERATOR’S MANUAL
RINSING
13
SHUTTING DOWN AND CLEAN-UP
PRESSURE WASHER
STEP 1: Remove detergent suction
tube from container and insert into
1 gallon of fresh water. Turn variable
pressure wand handle for low pressure or connect the black detergent
nozzle. Pull trigger on spray gun and
siphon water for one minute.
OPERATOR’S MANUAL
STEP 2: Turn burner switch off and
continue spraying water, allowing
the water to cool. After water has
cooled to less than 100°F, turn the
attached pressure washer off.
STEP 3: Turn off water supply.
STEP 4: Turn garden hose water
off. Open the spray gun to relieve
remaining pressure.
STORAGE
CAUTION: Always store your pressure washer in a
location where the temperature will not fall below
32°F (0°C). The pump in this machine is susceptible
to permanent damage if frozen. FREEZE DAMAGE
IS NOT COVERED BY WARRANTY.
1. Stop the pressure washer, squeeze spray gun trigger to release pressure.
2. Detach water supply hose and high pressure
hose.
3. Turn on the machine for a few seconds, until remaining water exits. Turn motor off immediately.
4. Drain the fuel from the fuel tank.
5. Do not allow high pressure hose to become
kinked.
6. Store the machine and accessories in a room which
does not reach freezing temperatures.
CAUTION: Failure to follow the above directions will
result in damage to your pressure washer.
When the pressure washer is not being operated or is
being stored for more than one month, follow these
instructions:
1. Replenish pump oil to upper level.
2. Drain fuel from fuel tank, fuel line and filter.
3. Cover the pressure washer and store in a clean, dry
place that is well ventilated away from open flame
or sparks.
After Extended Storage
CAUTION: Prior to restarting, thaw out any
possible ice from pressure washer hoses,
spray gun or wand.
14
HDS 500-510 • 9.800-078.0 • Rev. 4/10
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
LOW OPERATING
PRESSURE
DETERGENT
NOT DRAWING
PUMP RUNNING
NORMALLY BUT
PRESSURE LOW
ON INSTALLATION
FLUCTUATING
PRESSURE
PUMP NOISY
Faulty pressure gauge Install new gauge.
Insufficient water supply Use larger garden hose; clean filter washer at
water inlet.
Old, worn or incorrect spray
nozzle
Plumbing or hose leak Check plumbing system for leaks. Retape leaks
Faulty or mis-adjusted unloader
valve (where applicable)
Worn packing in pump Install new packing kit.
Fouled or dirty inlet or discharge
valves in pump
Worn inlet or discharge valves Replace with valve kit.
Air leak Tighten all clamps. Check detergent lines for
Valve in the injector head may be
blocked, dirty or damaged
Filler screen on detergent suction
hose plugged
Dried up detergent plugging metering valve
High viscosity of detergent Dilute detergent to specifications.
Hole in detergent line(s) Repair hole.
Low detergent level Add detergent if needed.
Discharge water temperature
above 180°F
Pump sucking air Check water supply and possibility of air
Valves sticking Check and clean or replace if necessary.
Unloader valve seat faulty Check and replace if necessary.
Nozzle incorrectly sized Check and replace if necessary (See serial plate
Worn piston packing Check and replace in necessary.
Valves worn Check and replace if necessary.
Blockage in valve Check and replace if necessary.
Pump sucking air Check water supply and air seepage at joints in
Worn piston packing Check and replace if necessary.
Air in suction line Check water supply and connections on suction
Broken or weak inlet or discharge
valve springs
Excessive matter in valves Check and clean if necessary.
Worn bearings Check and replace if necessary.
Match nozzle number to machine and/or replace
with new nozzle.
with teflon tape.
Adjust unloader for proper pressure. Install repair
kit when needed.
Clean inlet or discharge valves.
holes.
Clean or replace valve in injector.
Clean or replace.
Disassemble and clean thoroughly.
Lower discharge water temperature.
seepage.
for proper size).
suction line.
line.
Check and replace if necessary.
PRESSURE WASHER Troubleshooting Guide
15
HDS 500-510 • 9.800-078.0 • Rev. 4/10
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
LOW WATER
TEMPERATURE
WATER
TEMPERATURE
TOO HOT
PRESSURE WASHER Troubleshooting Guide
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 temperature. Replace pump if
needed.
Fuel filter partially clogged Replace as needed.
Soot build up on coils Clean coils with soot remover.
Lime build up on coils Clean inside of coils using coil cleaner.
Improper burner nozzle See Burner Specifications.
Incoming water to machine warm
or hot
Fuel pump pressure too high Lower fuel pressure.
Fuel pump defective Replace fuel pump.
Detergent line sucking air Tighten all clamps. Check detergent line for holes.
Defective high limit switch (thermostat)
Incorrect fuel nozzle size See Burner Specifications.
Insufficient water supplied Check GPM to machine.
Restricted water flow Check nozzle for obstruction, proper size.
Lower incoming water temperature.
Replace.
16
HDS 500-510 • 9.800-078.0 • Rev. 4/10
MAINTENANCE CHARTS
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 Pressure
Washers 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
Replace Fuel Lines Annually
Pump Oil Inspect Daily inspect the oil level
Change After first 50 hours, then every 500 hours or annually
Clean Burner Filter Monthly (More often if fuel quality is poor)
Remove Burner Soot Annually
Burner Adjustment/Cleaning Annually
De-scale Coil Annually (More often if required)
Replace High Pressure Nozzle Every 6 months
Replace Quick Connects Annually
Clean Water Screen/Filter Weekly
Clean Float/Supply Tank Every 6 months
Replace HP Hose Annually if there is any sign of wear
Grease Motor Every 10,000 hours
Replace Burner Nozzle Annually
PRESSURE WASHER Troubleshooting Guide
Date Oil Changed
Month/Day/Year
OIL CHANGE RECORD
Estimated Operating
Hours Since Last
Oil Change
HDS 500-510 • 9.800-078.0 • Rev. 4/10
Date Oil Changed
Month/Day/Year
Estimated Operating
Hours Since Last
Oil Change
17
PREVENTATIVE MAINTENANCE
1. Use clean fuel — kerosene, No. 1 home heating
fuel or diesel fuel. Clean or replace fuel filter every
100 hours of operation. Avoid water contaminated
fuel as it will seize up the fuel pump. De-soot coils
monthly. Use an additive if diesel is being used.
2. Check to see that the attached pressure washer
water pump is properly lubricated.
3. Follow winterizing instructions to prevent freeze
PRESSURE WASHER
damage to pump and coils.
4. Always neutralize and 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 the system.
OPERATOR’S MANUAL
7. Always use high grade quality cleaning products.
8. Never run attached pressure washer pump dry for
extended periods of time.
9. If machine is operated with smoky or eye burning
exhaust, coils will soot up, preventing water from
reaching maximum operating temperature. (See
section on Maintenance and Service).
1 0. Never allow water to be sprayed on or near the
motor or burner assembly or any electrical component.
1 1. Delime coils as per instructions.
It is advisable, periodically, to visually inspect the
burner. Check air inlet to make sure it is not clogged
or blocked. Wipe off any oil spills and keep equipment
clean and dry.
The areas around the pressure washer should be kept
clean and free of combustible materials, gasoline and
other flammable vapors and liquids.
The flow of ventilating air to the burner must not be
blocked or obstructed in any manner.
MAINTENANCE AND SERVICE
Unloader Valves:
Unloader valves trap pressure in the line when a shutoff spray gun is closed. Machines with unloader valves
are preset and tested at the factory before shipping.
Tampering with the factory settings 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 nec-
18
HDS 500-510 • 9.800-078.0 • Rev. 4/10
essary. Store the machine in a heated room. If this is
not possible then mix a 50/50 solution of anti-freeze/
water or windshield washer fluid with water in a 5 gallon bucket. Place a short section of garden hose into
the bucket and connect it to the machine. Elevate the
bucket and turn the pump on to siphon the anti-freeze
through the machine. If compressed air is available, an
air fitting can be screwed into the inlet connector and
by injecting compressed air, all water will be blown out
of the system.
If you have an optional float tank, pour the antifreeze
into this tank and run machine until antifreeze exits
discharge nipple.
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.
Pumps:
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 by using the dipstick found on the top of
the pump or by the red dot visible through the oil gauge
window. Oil should be maintained at that level.
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
prevention for liming conditions is to use high quality
cleaning detergents. In areas where alkaline water is an
extreme problem, periodic use of deliming powder will
remove lime and other deposits before coil becomes
plugged.
Deliming Coils With A Pressure Washer:
Periodic flushing of coils is recommended.
Step 1 Fill a 5 gallon bucket with 4 gallons of water,
then add 1 lb. of deliming powder. Mix thoroughly.
Step 2 Remove the high pressure nozzle from the
pressure wand and put the wand into the
bucket. Secure the trigger on the spray gun
into the open position.
Step 3 Attach a short section (3-5 ft.) of garden hose
to the attached pressure washer to siphon solution from the elevated bucket. Start up pressure washer, allowing solution to be pumped
through pressure washer and into HPB coils
and back into the bucket. Solution should be
allowed to circulate 2-4 hours.
MAINTENANCE
PRESSURE WASHER
Step 4 After circulating solution flush entire system
with fresh water.
Removal of Soot In 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 coil has
been removed using the following steps:
1. Remove the tank head assembly by unscrewing
the three tek screws and lifting the tank head off.
2. Remove the two pipe nipples and associated fit-
tings.
3. Lift the coil out of the outer wrap.
CAUTION: The coil weighs about 80 lbs. Use proper
lifting techniques.
4. Clean, repair and replace the coil by reversing the
above steps.
Coil Reinstallation
Reinstall by reversing the above steps 4 through 1.
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 the disk ruptures, it will need to be replaced.
Electrode Setting - Wayne:
(See illustration below)
Gap
1/8"
3/8"
3/16"
Top View
Electrodes Check: Periodically check wiring connections.
If necessary to adjust electrodes, use diagram.
1/2"
1/8"
Nozzle
Adapter
Electrodes
2-7/8"
Side View
Electrode Setting - Beckett:
(See illustration below)
5/32" Gap
5/16"
Top View
Electrode
Nozzles
1/16"
Side View
OPERATOR’S MANUAL
Fuel:
Use clean fuel oil that is not contaminated with water
and debris. Replace fuel filter and drain tank every
100 hours of operation. Use Kerosene No. 1 or No.
2 Heating Fuel (ASTM D306) or diesel only. NEVER
use gasoline in your burner tank. Gasoline is more
combustible than fuel oil and could result in a serious
explosion. NEVER use crankcase or waste oil in your
burner. Fuel unit malfunction could result from contamination.
Ignition Circuit:
Periodically inspect wires, spring contact and electrodes for condition, security and proper spacing. For
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.
HDS 500-510 • 9.800-078.0 • Rev. 4/10
Electrodes Check: Periodically check wiring connections.
If necessary to adjust electrodes, use diagram.
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.
Fuel Control System:
This machine utilizes a fuel solenoid valve located
on the fuel pump to control the flow of fuel to the
combustion chamber. This solenoid is activated by a
pressure switch located on the unloader valve. When
an operator releases the trigger on the spray gun, the
pressure drops, allowing the pressure switch to activate
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 gives 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. 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.
19
MAINTENANCE
Fuel Pressure Adjustment:
To adjust fuel pressure, turn the adjusting screw with a
standard screwdriver (located on the fuel pump) clockwise to increase, counterclockwise to decrease. Do not
exceed 200 PSI.
Air Adjustment
The oil burner on this machine is preset for operation at
PRESSURE WASHER
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. 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,
OPERATOR’S MANUAL
black, 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 white fumes indicate
too much air flowing through the combustion chamber.
The air band should be moved to allow less air to flow
through the burner.
To adjust: start machine and turn burner ON. Loosen
the two locking screws found in the air shutter openings
(refer to illustrations) 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 obtained 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.
FUEL AIR ADJUSTMENT: WAYNE
Air Band
Pressure
Gauge Port
Air Band
Adjustment
Screw
Fuel Pump
Pressure
Adjustment
Screw
FUEL AIR ADJUSTMENT: BECKETT
Air Band
Transformer
Fuel
Pump
20
Air Band
Adjustment
Screw
HDS 500-510 • 9.800-078.0 • Rev. 4/10
Pressure
Gauge Port
Pressure
Adjustment Screw
98000780-7
EXPLODED VIEW - 1.575-500.0
PRESSURE WASHER
Detail See
71
83
8, 23
10
55
For
Control
Box
78
4
13
79
1
16
2
3
12
75
17
14
21
20
56
19
6
72
28
32
25
26
27
24
5
OPERATOR’S MANUAL
19
22
7
85
9
15
81
11
18
To
Burner
69
33
80
19
18
34
50
47
48
51
77
19
63
36
37
35
64
66
30
46
40
39
32
31
19
41
42
38
62
61
48
47
59
64
29
76
54
65
66
60
58
82
52
68
53
60
Optional
Filter
Upgrade
84
49
67
57
43
73
74
76
45
44
For Detail
See Steam
Valve
Options
Illus.
64
70
71
HDS 500-510 • 9.800-078.0 • Rev. 4/10
21
EXPLODED VIEW - 1.575-500.0 PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.800-006.0 Label, Hot/Caliente w/Arrows Warning 1
2 9.803-029.0 Tank Head Assy 1
3 9.802-904.0 Insulation, Top Head 1
4 9.802-825.0 Clip, Retaining U-Type 4
5 9.802-081.0 Tank, Fuel 6 Gal Blank 1
6 9.802-254.0 Hose, 1/4", Push-On, Fuel Line 12˝
PRESSURE WASHER
7 9.800-110.0 Label, Logo, Large 1
8 9.802-753.0 Screw, 1/4" x 3/4" HH NC, Whiz Loc 4
9 9.802-900.0 Insulation, Bottom 1
10 8.933-028.0 Coil Wrap, SS 1
11 8.711-785.0 Hose, 3/8" Push-On 30"
12 8.706-248.0 Plug, 3/8" 1
13 9.802-908.0 Insulation, Blanket 1
OPERATOR’S MANUAL
14 9.196-012.0 Screw, 10-24 x 1/4" 1
15 9.800-021.0 Label, Hot Water Outlet 1
16 8.902-433.0 Valve, Safety Relief 1
17 9.802-041.0 Elbow, 3/8" Street 45° 1
18 9.802-138.0 Hose Barb, 1/4" Barb x 1/4" ML Pipe 2
19 6.390-126.0 Clamp, Hose, .46-, .54 7
20 9.802-171.0 Nipple, 3/8" x 3/8" NPT ST Male 1
21 8.750-094.0 Thermostat 150C/ 302F 1
22 8.709-152.0 Filter, Fuel, Disposable 1
23 9.802-793.0 Nut, Cage, 1/4" x 16 Gauge 4
24 9.803-092.0 Fuel Strap, Long, Black 2
25 9.802-767.0 Screw, 3/8" x 3/4" HH NC, Whiz Loc 2
26 9.800-002.0 Label, Use Only Kerosene 1
27 9.802-083.0 Cap, Non-Vented, Plastic 1
28 9.800-041.0 Label, Warning, Pictorial 1
29 9.802-066.0 Pad, Soft Rubber, 50 DURO 2
30 9.803-093.0 Fuel Strap, Short, Black 2
31 9.802-177.0 Valve, 1/4" Shut-Off 1
32 9.802-053.0 Bushing, Rubber, Nitrile 3
33 9.802-042.0 Elbow, 1/2" JIC, 3/8" Female 1
34 9.802-243.0 Hose, 3/8" x 32", 2 Wire, Pressure Loop 1
35 9.802-428.0 Cord, Service, SEO, 12/3, Coleman 33"
36 9.802-032.0 Label, Motor Overload Reset, Lexan 1
37 For Motor Details, Please see specifications pages.
38 9.804-025.0 Pump Protector, 1/4" 145° 1
39 9.802-458.0 Switch, Pressure N/O, 1/4" NPT SS 1
40 For Unloader Details, Please see specifications pages.
41 9.802-039.0 Elbow, 1/2" JIC x 3/8" MPT 1
42 9.802-146.0 Swivel, 1/2" MP x 3/4" GHF, w/Strainer 1
43 8.725-306.0 Filter, Fuel Oil H20 1
44 For Pump Details, Please see specifications pages.
45 9.802-720.0 Bolt, 3/8" x 1", NC HH 4
22
HDS 500-510 • 9.800-078.0 • Rev. 4/10
EXPLODED VIEW - 1.575-500.0 PARTS LIST
ITEM PART NO. DESCRIPTION QTY
46 9.802-141.0 Hose Barb, 1/4" x 3/8" Double 1
47 9.802-709.0 Bolt, 5/16" x 3/4" NC GR 5 CS ZN 8
48 9.802-804.0 Washer, 5/16", Flat, SAE 12
49 9.800-020.0 Label, Cold Water Inlet, HS 1
50 9.802-107.0 Fastener, Ratchet, Black Nylon 2
51 9.802-070.0 Grip, 1" Square, Handle 2
52 9.802-519.0 Strain Relief, 1/2" Metal 2 Screw 1
53 9.803-090.0 Assembly, Frame 1
54 9.802-817.0 Washer, 3/8" x 1" 2
55 9.802-778.0 Nut, Whiz Loc 5/16 4
56 9.802-254.0 Hose, 1/4" Push-On 21"
57 9.803-096.0 Axle, 5/8" x 22" 1
58 For Burner, Please see specifications pages.
59 9.802-819.0 Washer, 7/16" x 2-1/2", Zinc, PG Foot 2
60 9.802-810.0 Washer, 5/8", Flat, SAE 2
61 9.802-431.0 GFCI, 120V 20A, w/36' 12-3 Cord 1
62 9.800-015.0 Label, Warning, Service Cord 1
63 9.802-254.0 Hose, 1/4" Push-On 6"
64 9.802-807.0 Washer, 3/8", SAE, Flat 10
65 9.802-729.0 Bolt, 3/8" x 2-1/4", HH, GRD 5 2
66 9.802-781.0 Nut, 3/8" Flange, Whiz Loc, NC 6
67 9.802-143.0 Hose Barb, 1/4" Barb x 1/4" Pipe, 90° 1
68 9.802-424.0 Cord Service, SEO 16/4 58"
69 9.802-011.0 Nipple, 3/8 Hex 1
70 9.802-270.0 Wheel & Tire Assy, 4" Steel Rim w/Tube 2
71 9.802-782.0 Collar, 5/8" Bore Shaft 3010 2
72 9.802-054.0 Elbow, Fuel Tank, Zinc 1
73 9.802-776.0 Nut, 5/16" ESNA, NC 4
74 9.803-067.0 Assy, Power Platform, Mini, Black 1
75 9.149-003.0 Manifold Coil Discharge 1
76 9.802-779.0 Nut, 3/8" ESNA, NC 6
77 9.802-514.0 Strain Relief Small 1
9.802-525.0 Lock nut 1
78 9.803-095.0 Assembly Coil 4
79 9.802-268.0 Screw, 3/8" x 1-1/4" Whiz Loc 1
80 9.802-254.0 Hose, 1/4" x 28" Push On 1
81 9.803-030.0 Retainer Burner 1
82 9.802-792.0 Nut Cage, 3/8" x 12 gage 4
83 9.803-108.0 Retainer Ring, Insulation 1
84 9.803-264.0 Nipple, 1/4" x 3" Black Pipe 1
85 8.704-660.0 Label, Kärcher-Shark 1
Not Shown
PRESSURE WASHER
OPERATOR’S MANUAL
23
HDS 500-510 • 9.800-078.0 • Rev. 4/10
98000780-8
EXPLODED VIEW - 1.575-501.0, 502.0, 503.0, 504.0
1
23
10, 17
2
81
33
6
24
63
14
PRESSURE WASHER
OPERATOR’S MANUAL
48
66
80
For
Detail See
Control
Panel
Illus.
3
28
11
38
39
19
58
61
37
45
5
13
79
53
52
72
62
67
7
8
71
34
9
12
29
50
42
43
35
46
26
36
18
56
55
4
65
22
39
20
64
32
30
55
27
For Detail
See Steam
Valve
Options
Illus.
44
40
21
54
41
Optional Filter
Upgrade
31
69
70
49
16
51
15
24
57
47
75
68
49
73
77
HDS 500-510 • 9.800-078.0 • Rev. 4/10
To Fuel
Tank
68
74
66
25
76
68
48
EXPLODED VIEW - 1.575-501.0, 502.0, 503.0, 504.0
ITEM PART NO. DESCRIPTION QTY
1 9.800-002.0 Label, Use Only Kerosene 1
2 9.800-006.0 Label, "Hot/Caliente" with Arrows Warning 1
3 9.800-015.0 Label, Warn, Service Cord 1
4 9.800-021.0 Label, Hot Water Outlet 1
5 9.800-110.0 Label, Logo Large 1
6 9.800-035.0 Label, Warning (Lexan) 1
7 For Motor, Please see specifications pages.
8 For Pump, Please see specifications pages.
9 For Unloader, Please see specifications pages.
10 9.802-526.0 Lock Nut 3/8" (504.0) 1
9.802-525.0 Locknut 1/2" (501.0, 502.0, 503.0) 1
11 9.803-039.0 Frame, Black 1
12 9.802-146.0 Swivel, 1/2" MP x 3/4" GHF w/Strainer 1
13 9.802-904.0 Insulation, Tank Head 1
14 9.802-803.0 Washer, 1/4" 4
15 9.802-448.0 Conduit, 25" 1
16 9.802-517.0 Connector 1/2" L/T 90° Black 1
17 9.803-278.0 Strain Relief, 3/4" w/Gasket (501.0, 502.0, 503.0) 1
9.802-518.0 Strain Relief 3/4" (504.0) 1
18 9.802-224.0 Downstream Injector Assy, Non-Adjust #2
(501.0, 502.0, 503.0) 1
9.802-225.0 Downstream Injector Assy, Non-Adj. #3 (504.0) 1
19 9.803-134.0 Coil 1
20 9.802-720.0 Bolt, 3/8" x 1" 4
21 9.802-066.0 Pad, Soft Rubber, 50 Duro 2
22 9.802-070.0 Grip, 1" Square, Handle 2
23 8.706-612.0 Tank Fuel, 9 Gallon Poly, Black 1
24 9.802-089.0 Cap, Fuel Tank Plastic H60-AV 1
25 9.802-270.0 Wheel & Tire, 4" Steel Rim w/Tube 2
26 8.750-094.0 Thermostat 302° 1
27 9.802-709.0 Bolt, 5/16" x 3/4" 4
28 9.802-430.0 GFCI, 240V 1PH 30A w/36' 10-3 Cord (504.0) 1
9.802-431.0 GFCI, 120V, 20A w/36' 12-3 Cord (501.0, 502.0) 1
9.802-433.0 GFCI, 240V 1 PH 20A, w/36' 12-3 Cord (503.0) 1
29 9.804-025.0 Pump Protector, 1/4" 1
30 9.800-020.0 Label, Cold Water Inlet HS 1
31 8.725.306.0 Filter, Fuel/Oil/H2O 1
32 9.802-043.0 Elbow, 1/2" JIC x 1/2" FM 1
33 9.802-458.0 Pressure Switch, 1/4" 1
34 9.802-041.0 Elbow, 3/8" Street 45° 1
35 9.802-039.0 Elbow, 1/2 JIC, 3/8" 90° 1
36 9.802-171.0 Coupler Plug, 3/8" Male 1
37 9.802-825.0 Clip, Retainer 5
38 9.802-779.0 Nut, 3/8" ESNA 2
39 9.802-807.0 Washer, 3/8" Flat 6
40 9.802-819.0 Washer, 3/8" x 2-1/2" 2
41 9.802-729.0 Bolt, 3/8" x 2-1/4" 2
HDS 500-510 • 9.800-078.0 • Rev. 4/10
PRESSURE WASHER
OPERATOR’S MANUAL
25
EXPLODED VIEW - 1.575-501.0, 502.0, 503.0, 504.0
ITEM PART NO. DESCRIPTION QTY
42 8.902-433.0 Relief Valve USA 1
43 9.196-012.0 Screw, 10-24 x 1/4" 1
44 8.711-785.0 Hose, 3/8", Push-On 30"
45 9.803-029.0 Tank Head Assy. 16" x 8" 1
46 8.706-248.0 Plug, 3/8" 1
47 9.803-061.0 Axle, 5/8" x 25.710 1
PRESSURE WASHER
48 9.802-782.0 Collar, 5/8" 2
49 9.802-781.0 Nut, 3/8" Flange, Whiz Loc 4
50 9.802-242.0 Hose, 3/8" x 29", Press Loop 1
51 Burner Assembly, See Burner Spec's Page 49
52 9.803-030.0 Retainer, Burner Insulation 1
53 9.802-900.0 Insulation, Tank Bottom, 1" Blanket 1
54 9.802-817.0 Washer, 3/8" x 1" 2
OPERATOR’S MANUAL
55 9.802-804.0 Washer, 5/16", Flat 12
56 9.802-776.0 Nut, 5/16", ESNA 4
57 9.802-792.0 Nut, Cage, 3/8" x 12 Gauge 4
58 8.915-908.0 Wrap, Outer Coil, SS 1
59 9.802-778.0 Nut, Whiz Loc 5/16 4
60 9.802-014.0 Nipple, 1/2" x 3", Galvanized 1
61 9.803-108.0 Retainer Ring, Insulation 1
62 9.802-768.0 Screw, 3/8" x 1-1/4", Whiz Lock 4
63 9.802-770.0 Screw, 1/4" x 1" 4
64 9.802-775.0 Nut, 1/4" Flange 4
65 9.802-107.0 Fastener, Ratchet, Black Nylon 2
66 9.802-810.0 Washer, 5/8" Flat 2
67 9.802-015.0 Nipple, 1/2" x 4", Galvanized 1
68 6.390-126.0 Clamp, Hose, .46-, .54 6
69 9.803-264.0 Nipple, 1/4" x 3" 1
70 9.802-143.0 Hose Barb, 1/4" Barb x 1/4" Pipe, 90° 1
71 9.149-003.0 Manifold Coil Discharge 1
72 8.704-660.0 Label, Kärcher-Shark 1
73 9.802-138.0 Hose Barb, 1/4" Barb x 1/4" ML Pipe 2
74 9.802-211.0 Filter, Diesel Fuel 1
75 9.802-254.0 Fuel Line, 1/4" 28"
76 9.802-254.0 Fuel Line, 1/4" 21"
77 9.802-254.0 Fuel Line, 1/4" 6"
78 9.802-428.0 Cord 12-3 SJOWA (Motor) (501.0, 502.0, 503.0) 44"
9.802-436.0 Cord 10-3 (Motor) (504.0) 44"
79 9.802-779.0 Nut, Cage, 1/4" x 16 Gauge 5
80 9.802-753.0 Screw 1/4" x 3/4" HH NC Whiz Loc 5
81 9.800-032.0 Label, Motor Overload Reset 1
Not Shown
26
HDS 500-510 • 9.800-078.0 • Rev. 4/10
98000780-9
EXPLODED VIEW - 1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0
PRESSURE WASHER
72
31
For
Detail See
Control Panel
Illus.
16
51
2
67
32
33
3
42
28
5
88
63
86, 69
85
60
65
64
62
18, 29,
84, 87
83
4
71
14
25
75
8
71
75, 26
19
68
26
50
75
30
71
50
49
21
53
27, 41, 71
15
1
61
10
49
30
OPERATOR’S MANUAL
6
9
57
54
56
58
55
For
Detail See
Pump
Illus.
66
Optional
Filter
Upgrade
47
89
46
45
59
73
37
48
7
39
71
22
70
40
82
75
23
12
81
For
Detail See
Optional
Float Tank
Illus.
77
74
76
80
11
For
Detail See
Steam Valve
Options
Illus.
52
77
79
78
38
To Fuel
Tank
16
36
48
51
44
20
34
17
43
24
35
13
27
HDS 500-510 • 9.800-078.0 • Rev. 4/10
1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0 PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.800-002.0 Label, Use Only Kerosene 1
2 9.800-006.0 Label, "Hot/Caliente" with Arrows Warning 1
3 9.800-015.0 Label, Warning, Service Cord 1
4 9.800-021.0 Label, Hot Water Outlet 1
5 9.800-110.0 Label, Logo Large 1
6 9.800-035.0 Label, Warning (Lexan) 1
PRESSURE WASHER
7 9.802-066.0 Pad, Soft Rubber, 50 Duro 2
8 9.802-070.0 Grip, 1" Square, Handle 2
9 8.706-612.0 Tank, Fuel, 9 Gallon Poly, Black 1
10 9.802-089.0 Cap, Fuel Tank, Plastic H60-AV 1
11 9.800-020.0 Label, Cold Water Inlet 1
12 9.803-062.0 Frame Assy 1
13 9.802-225.0 Downstream Injector Assembly, Non Adj. #3 1
OPERATOR’S MANUAL
14 9.803-064.0 Power Platform (505.0, 506.0, 507.0) 1
9.803-063.0 Power Platform (508.0, 509.0, 510.0) 1
15 9.802-107.0 Fastener, Ratchet, Black Nylon 2
16 9.802-271.0 Wheel & Tire, 6" Steel Rim 2
17 8.750-094.0 Thermostat, 302° 1
18 For Motor, Please see specifications pages.
19 9.802-872.0 Tab, Belt Guard Mount 3
20 8.902-433.0 Valve, Safety Relief 1
21 9.800-007.0 Label, Warning, Exposed Pulley 1
22 9.802-792.0 Nut, Cage, 3/8" x 12 Gauge 4
23 9.802-905.0 Insulation Blanket, 18" OD x 4.5" ID 1
24 9.802-041.0 Elbow, 3/8", Street 45° 1
25 9.802-775.0 Nut, 1/4", Flange 4
26 9.802-720.0 Bolt, 3/8" x 1" (508.0, 509.0, 510.0) 6
(505.0, 506.0, 507.0) 8
27 9.802-733.0 Bolt, 3/8" x 3-1/2", Tap 2
28 9.802-995.0 Coil, 18" 1
9.802-897.0 Insulation Blanket 1
29 9.802-518.0 Strain Relief, 3/4" (505.0, 506.0, 507.0, 509.0, 510.0) 1
9.803-279.0 Strain Relief, 1" (508.0) 1
30 9.802-803.0 Washer, 1/4" 4
31 8.933-031.0 Outer Wrap, 18" Coil S.S. 1
32 9.802-973.0 Tank End 18" 1
33 8.717-442.0 Insulation Disk 1
34 8.706-248.0 Plug, 3/8" 1
35 9.802-171.0 Nipple, 3/8" x 3/8" NPT Street Male 1
36 9.149-003.0 Manifold Coil Discharge 1
37 9.802-043.0 Elbow, 1/2" JIC x 1/2" Female 1
38 9.802-240.0 Hose, 3/8" x 22" 1
39 9.802-143.0 Hose Barb, 1/4" Barb, 1/4" Pipe, 90° 1
40 9.802-729.0 Bolt, 3/8" x 2-1/4" 2
41 9.802-789.0 Nut, 3/8" Hex 2
28
HDS 500-510 • 9.800-078.0 • Rev. 4/10
1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0 PARTS LIST
ITEM PART NO. DESCRIPTION QTY
42 8.719-935.0 Retainer Ring, Insulation 1
43 9.196-012.0 Screw, 10-24 x 1/4" 1
44 8.711-785.0 Hose, 3/8" Push-On 2.50 ft
45 9.802-212.0 Filter, Fuel/H2O 1
46 9.802-781.0 Nut, 3/8" Flange, Whiz Loc 4
47 9.803-264.0 Nipple, 1/4" x 3", Black Pipe 1
48 9.802-810.0 Washer, 5/8" Flat 2
49 9.802-770.0 Screw, 1/4" x 1" 7
50 9.802-094.0 Belt Guard 1
51 9.802-782.0 Collar, 5/8" 2
52 9.803-066.0 Axle, SR 1
53 9.803-131.0 Pump Rail, Black 1
54 For Pulley, Please see specifications pages.
55 For Pulley, Please see specifications pages.
56 For Belt, Please see specifications pages.
57 For Bushing, Please see specifications pages.
58 9.802-402.0 Bushing, 24mm 1
59 For Burner, Please see specifications pages.
60 9.802-825.0 Clip, Retainer 4
61 9.800-046.0 Label, Belt Guard 1
62 9.803-030.0 Retainer, Burner Insulation 1
63 9.802-768.0 Screw, 3/8" x 1-1/4" Whiz Loc 4
64 9.802-014.0 Nipple, 1/2" x 3", Galvanized 1
65 9.802-015.0 Nipple, 1/2" x 4", Galvanized 1
66 9.802-804.0 Washer, 5/16 Flat 4
67 9.802-794.0 Nut, Cage, 1/4" x 12 Gauge 6
68 9.802-754.0 Screw, 1/4" x 1/2", Whiz Loc 3
69 9.802-752.0 Screw, 1/4" x 1-1/4", Whiz Loc 4
70 9.802-817.0 Washer, 3/8" x 1" 2
71 9.802-807.0 Washer, 3/8", Flat (505.0, 506.0, 507.0) 25
(508.0, 509.0, 510.0) 23
72 9.802-430.0 GFCI, 230V, 30 Amp (505.0) 1
9.802-434.0 GFCI, 240V, 40 Amp (508.0) 1
9.802-437.0 Service Cord, 10/4 (509.0) 15 ft.
9.802-429.0 Service Cord, 12/4 (506.0, 507.0, 510.0 ) 15 ft.
73 9.802-819.0 Washer, 7/16" x 2-1/2" 2
74 9.802-138.0 Hose Barb, 1/4" 2
75 9.802-779.0 Nut, 3/8" ESNA 13
76 9.802-254.0 Fuel Line, 1/4" 28"
77 6.390-126.0 Clamp, Hose, .46-, .54 6
78 9.802-211.0 Filter, Fuel 1
79 9.802-254.0 Fuel Line, 1/4" 21"
80 9.802-254.0 Fuel Line, 1/4" 6"
81 9.802-448.0 Conduit, Water Tite 2.25 ft.
82 9.802-517.0 Connector 1/2" L/T 90° Black 1
PRESSURE WASHER
OPERATOR’S MANUAL
29
HDS 500-510 • 9.800-078.0 • Rev. 4/10
1.575-505.0, 508.0, 509.0, 510.0 PARTS LIST
ITEM PART NO. DESCRIPTION QTY
83 9.800-032.0 Label, Motor Overload Reset (505.0) 1
84 9.802-436.0 Cord Service 10-3 (505.0) 41"
9.802-437.0 Cord Service 10-4 (509.0) 41"
9.802-425.0 Cord Service 8-3 (508.0) 41"
85 8.704-660.0 Label, Kärcher-Shark 1
86 9.802-793.0 Nut, Cage 1/4" x 16 Gauge 4
PRESSURE WASHER
87 9.802-526.0 Lock Nut 3/4" (505.0,509.0, 510.0) 1
9.802-437.0 Lock Nut 1" (508.0) 1
88 9.802-778.0 Nut, Whiz 5/16 Flange 4
89 9.802-709.0 Bolt, 5/16" x 3/4" 1
Not Shown
OPERATOR’S MANUAL
30
HDS 500-510 • 9.800-078.0 • Rev. 4/10
PRESSURE WASHER
CONTROL PANEL - 1.575-500.0
4,11
2
3
1
19
16
20
13
3
12
21
8
15
14
23
22
10
9
(Reversed View
5
17
of Label)
18
OPERATOR’S MANUAL
6
7
CONTROL PANEL - 1.575-500.0 PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.800-016.0 Label, Disconnect Power Supply 1
2 9.802-759.0 Screw, 10/32" x 1/2" NHSOC, Black 4
3 9.802-449.0 Switch, 3 PS, 115V-230V, 1PH 1
4 9.802-285.0 Thermostat, Adjustable, 302°F 1
5 9.802-762.0 Screw, 10/32" x 1-1/4" RH, SL, Black 1
6 9.802-514.0 Strain Relief, Straight, LQ TITE, Small 3
7 9.803-278.0 Strain Relief, Straight, LQ TITE, w/Gasket 1
8 9.802-295.0 Nozzle, SAQCMEG 0004, Red 1
9.802-296.0 Nozzle, SAQCMEG 1504, Yellow 1
9.802-297.0 Nozzle, SAQCMEG 2504, Green 1
9.802-298.0 Nozzle, SAQCMEG 4004, White 1
9 9.802-064.0 Grommet, Rubber, Nozzle Holder 4
10 9.800-123.0 Label, Control Panel 1
11 9.802-447.0 Conduit, 1/4" Split 36"
12 9.802-526.0 Locknut, 3/4" 8465 1
13 9.802-791.0 Nut, Cage, 10/32" x 16 Gauge 4
14 9.802-525.0 Locknut, 1/2" 8463 3
15 9.802-695.0 Nut, 10/32" Keps 4
HDS 500-510 • 9.800-078.0 • Rev. 4/10
31
CONTROL PANEL - 1.575-500.0 PARTS LIST
ITEM PART NO. DESCRIPTION QTY
16 9.803-094.0 Electric Box Cover, Black 1
17 9.802-103.0 Bushing, Snap, 5/8" 1
18 9.800-040.0 Label, Ground 1
19 9.800-018.0 Label, Tipover Hazard 1
20 9.800-049.0 Label, Cleaning Solution 1
21 8.750-096.0 Knob, Thermostat 302°F 1
PRESSURE WASHER
22 8.712-190.0 Bezel, Plastic 1
23 9.196-012.0 Screw, 10/24 x 1/4" Hex 2
Not Shown
OPERATOR’S MANUAL
32
HDS 500-510 • 9.800-078.0 • Rev. 4/10
MODE D'EMPLOI
OPERATING INSTRUCTIONS
INSTRUCCIONES DE OPERACION
PUMP
OFF
BURNER
OFF
200
165
130
95
235
270
300
GROUND
8
10
12
14
16
0
2
4
6
OFF
200
1
6
5
130
95
235
270
300
PUMP
BURNER
CONTROL PANEL - 1.575-501.0, 502.0, 503.0, 504.0
28
9
3
33
27
26
PRESSURE WASHER
34, 35
24
12
OPERATOR’S MANUAL
7
15, 16
8
19
13
6
20
3
14
31
37
36
12
11
21
24
18
1
9
2
9
21
30
29
22
10
12
32
17
11
38
25
5
4
CONTROL PANEL - 1.575-501.0, 502.0, 503.0, 504.0 PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 For Fuse, Please see specifications pages. (503.0, 504.0)
2 For Fuse, Please see specifications pages. (503.0, 504.0)
3 9.802-449.0 Switch, 3 PS, 115V-230V, 1 PH Salzer 1
4 9.802-299.0 Nozzle, SAQCMEG 0005, Red (502.0) 1
9.802-300.0 Nozzle, SAQCMEG 1505, Yellow (502.0) 1
9.802-301.0 Nozzle, SAQCMEG 2505, Green (502.0) 1
9.802-302.0 Nozzle, SAQCMEG 4005, White (502.0) 1
9.802-291.0 Nozzle, SAQCMEG 0035, Red (501.0) 1
9.802-292.0 Nozzle, SAQCMEG 1535, Yellow (501.0) 1
9.802-293.0 Nozzle, SAQCMEG 2535, Green (501.0) 1
9.802-294.0 Nozzle, SAQCMEG 4035, White (501.0) 1
9.802-295.0 Nozzle, SAQCMEG 0004, Red (503.0) 1
9.802-296.0 Nozzle, SAQCMEG 1504, Yellow (503.0) 1
9.802-297.0 Nozzle, SAQCMEG 2504, Green (503.0) 1
9.802-298.0 Nozzle, SAQCMEG 4004, White (503.0) 1
8.712-349.0 Nozzle, SAQCMEG 0004.5, Red (504.0) 1
8.712-350.0 Nozzle, SAQCMEG 1504.5, Yellow (504.0) 1
8.712-351.0 Nozzle, SAQCMEG 2504.5, Green (504.0) 1
8.712-352.0 Nozzle, SAQCMEG 4004.5, White (504.0) 1
5 9.802-064.0 Grommet, Rubber, Nozzle Holder 4
HDS 500-510 • 9.800-078.0 • Rev. 4/10
33
CONTROL PANEL - 1.575-501.0, 502.0, 503.0, 504.0 PARTS LIST
ITEM PART NO. DESCRIPTION QTY
6 For Transformer, Please see specifications pages. (503.0, 504.0)
7 9.802-880.0 Cover, Electrical Box, Black 1
8 9.800-016.0 Label, Disconnect Power 1
9 9.802-759.0 Screw, 10/32" x 1/2" (503.0, 504.0) 10
(501.0, 502.0) 6
10 9.802-791.0 Nut, Cage, 10/32" x 16 Gauge 6
PRESSURE WASHER
11 9.802-762.0 Screw, 10/32" x 1-1/4" 1
(auto start/stop option) 1
12 9.802-695.0 Nut, 10/32" Keps (503.0, 504.0) 8
(501.0, 502.0) 4
13 9.802-518.0 Strain Relief, Straight, L/T, LG (504.0) 2
9.803-278.0 Strain Relief 3/4" w/Gasket (501.0, 502.0, 503.0) 2
14 9.800-099.0 Label, Control Panel 1
15 8.750-094.0 Thermostat 302°F 1
OPERATOR’S MANUAL
16 9.802-447.0 Split Conduit, 1/4" 4 ft
17 9.800-040.0 Label, Ground 1
18 9.802-517.0 Connector, 1/2", L/T 90°, Black 1
19 9.802-514.0 Strain Relief, Straight, L/T, Small 1
20 9.802-103.0 Bushing, 5/8" Snap 1
21 9.802-526.0 Locknut, 3/4" 2
22 9.802-525.0 Locknut, 1/2" 1
23 9.800-018.0 Label, Tip over Hazard 1
24 9.800-049.0 Label, Cleaning Solution 1
25 9.802-283.0 Hour Meter (optional) 1
26 9.802-451.0 Switch Rocker Carling w/Green Lens (Auto Start/Stop option) 2
(Time Delay option) 1
9.802-452.0 Switch Rocker Red Lens (Time Delay option) 1
27 9.802-457.0 Din Rail 4"
(Time Delay option) 6"
28 8.724-268.0 Contactor, DP C25DNY152AL (Auto Start/Stop, Time Delay option) 1
29 9.802-491.0 Block Terminal 4 Pole (Auto Start/Stop, Time Delay option) 1
30 9.802-749.0 Screw 8/32" x 3/4" (Auto Start/Stop, Time Delay option) 2
31 9.802-785.0 Nut 8/32" Keps (Auto Start/Stop, Time Delay opt.) 2
32 9.802-472.0 Timer Solid State 120V 5-60 minute Adj. (Auto Start/Stop option) 1
33 9.802-473.0 Timer Multi-Function 24V - 120/240 (Time Delay option) 1
34 9.802-467.0 Base Relay (Time Delay option) 1
35 9.802-468.0 Relay, 120 (Time Delay option) 1
36 8.750-096.0 Knob, Thermostat 302°F 1
37 8.712-190.0 Bezel, Plastic 1
38 9.196-012.0 Screw, 10/24 x 1/4" Hex 2
Not Shown
34
HDS 500-510 • 9.800-078.0 • Rev. 4/10
8
CONTROL PANEL - 1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0
PRESSURE WASHER
13
14
13
2, 8
34
35, 36
27
32
17
2
1
OPERATOR’S MANUAL
24
25
21
32
16
15
17
19
31
30
16
17
7
20
17
22
23
17
18
28
1
33
38
39
37
9
12
26
6
3
4
11
10
5
13
1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0 PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.802-451.0 Switch, Rocker, Carling w/Green Lens 2
(Time Delay option) 1
9.802-452.0 Rocker Switch, Red Lens (Time Delay option) 1
2 9.802-447.0 Conduit, 1/4" Split 4 ft.
3 For Fuse, Please see specifications pages.
4 For Fuse, Please see specifications pages.
5 For Transformer, Please see specifications pages.
6 For Contactor, Please see specifications pages.
7 9.802-518.0 Strain Relief, Straight, L/T (All Models Except 508.0) 1
9.802-521.0 Strain Relief, 3/4" Watertight (508.0) 1
8 8.750-095.0 Thermostat, 302° 1
9 9.802-283.0 Hour Meter (Optional) 1
35
HDS 500-510 • 9.800-078.0 • Rev. 4/10
1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0 PARTS LIST
ITEM PART NO. DESCRIPTION QTY
10 9.802-303.0 Nozzle, SAQCMEG 0055, Red (505.0, 506.0, 507.0) 1
9.802-304.0 Nozzle, SAQCMEG 1505.5, Yellow (505.0, 506.0, 507.0) 1
9.802-305.0 Nozzle, SAQCMEG 2505.5, Green (505.0, 506.0, 507.0) 1
9.802-306.0 Nozzle, SAQCMEG 4005.5, White (505.0, 506.0, 507.0) 1
9.802-295.0 Nozzle, SAQCMEG 0004, Red (508.0, 509.0, 510.0) 1
9.802-296.0 Nozzle SAQCMEG 1504, Yellow (508.0, 509.0, 510.0) 1
9.802-297.0 Nozzle, SAQCMEG 2504, Green (508.0, 509.0, 510.0) 1
PRESSURE WASHER
9.802-298.0 Nozzle, SAQCMEG 4004, White (508.0, 509.0, 510.0) 1
11 9.802-064.0 Grommet, Rubber, Nozzle Holder 4
12 9.802-880.0 Cover, Electrical Box 1
13 9.802-759.0 Screw, 10/32" x 1/2" 13
(Time Delay option) 2
14 9.800-016.0 Label, Disconnect Power Supply 1
15 9.802-791.0 Nut, Cage, 10/32" x 16 Gauge 6
16 9.802-762.0 Screw, 10/32" x 1-1/4" 1
OPERATOR’S MANUAL
(Auto Start/Stop option) 1
17 9.802-695.0 Nut, 10/32" Keps 4
(Auto Start/Stop Delay option) 1
(Time Delay option) 2
18 9.800-112.0 Label, Control Panel 1
19 9.800-040.0 Label, Ground 1
20 9.802-517.0 Connector, 1/2", L/T 90°, Black 1
21 9.802-514.0 Strain Relief, Straight, L/T, Small 1
22 9.802-526.0 Locknut, 3/4" 1
23 9.802-525.0 Locknut, 1/2" 1
24 9.802-103.0 Bushing, Snap, 5/8" 1
25 9.802-518.0 Strain Relief, Straight, L/T, Large 1
26 9.800-018.0 Label, Tipover Hazard 1
27 9.800-049.0 Label, Cleaning Solution 1
28 9.802-526.0 Lock Nut 3/4" (All Models) 1
29 9.802-457.0 Din Rail 4"
(Time Delay option) 2"
30 9.802-491.0 Block Terminal 4 Pole(Auto Start/Stop, Time Delay option) 1
31 9.802-472.0 Timer Solid State 120V, 5-60, minute Adj. (Auto Start/Stop option) 1
32 9.802-749.0 Screw 8/32" x 3/4" (Auto Start/Stop, Time Delay option) 2
33 9.802-785.0 Nut 8/32" Keps (Auto Start/Stop, Time Delay opt) 2
34 9.802-473.0 Timer, Multi Function 24V-120/240V (Time Delay option) 1
35 9.802-467.0 Base Relay (Time Delay option) 1
36 9.802-468.0 Relay 120V (Time Delay option) 1
37 8.750-096.0 Knob, Themostat 302°F 1
38 8.712-190.0 Bezel, Plastic 1
39 9.196.012.0 Screw, 10/24 x 1/4" Hex 2
Not Shown
36
HDS 500-510 • 9.800-078.0 • Rev. 4/10
FLOAT TANK OPTION - 505.0, 506.0, 507.0, 508.0, 509.0, 510.0
30
21
38
PRESSURE WASHER
21
30
34
18
32
39
42
Steam Option
20
21
22
23
13
33
36
31
16
35
15
14
OPERATOR’S MANUAL
4
10
13
9
7
7
25
36
27
49
21
39
38
4
35
17
18
19
1, 8
4
51
49
24
2
5
28
41
29
39
11
12
40
26
6
4
3
22
48
47
21
19
20
23
Auto Start/Stop
47
53
46
18
7
To Float
Tank
Option
45
27
44
7
50
33
50
43
11
10
9
13
21
34
54
21
48
47
19
20
22
To Float Tank
23
Auto Start/Stop
Steam Option
47
46
18
53
31
32
33
50
43
37
45
27
7
10
9
7
ITEM PART NO. DESCRIPTION QTY
1 9.802-085.0 Tank, Float 1
2 9.803-269.0 Shelf, Float Tank, Black 1
3 9.802-767.0 Screw, 3/8" x 3/4" HH NC, Whiz Loc 4
4 9.802-039.0 Elbow, 1/2" JIC x 3/8" Female, 90° 1
5 9.803-277.0 Screw, 5/16" x 1/2" Whiz Loc 4
6 9.802-259.0 Hose, 1/2", Push-On 20"
7 9.802-201.0 Clamp, Screw, #6 3
8 9.802-184.0 Valve, Float 1
9.802-062.0 Ball Float 1
9 9.802-140.0 Hose Barb, 5/8" Barb x 1/2" ML Pipe 1
HDS 500-510 • 9.800-078.0 • Rev. 4/10
37
FLOAT TANK 505.0, 506.0, 507.0, 508.0, 509.0, 510.0 PARTS LIST
ITEM PART NO. DESCRIPTION QTY
10 9.803-265.0 Elbow, 1/2" Female, Brass 1
11 9.802-111.0 Nipple, 1/2" NPT, 5/16", Modified Close 1
12 9.802-043.0 Elbow, 1/2" x 1/2" Female, 90° 1
13 9.802-240.0 Hose, 3/8" x 22", 2 Wire, Pressure Loop 1
14 9.802-146.0 Swivel, 1/2" MP x 3/4" GHF w/Strainer 1
15 9.802-961.0 Hose Connection Bracket 1
PRESSURE WASHER
16 9.802-700.0 Bolt, 1/4" x 3/4", NC HH 2
17 9.802-781.0 Nut, 3/8", Flange, Whiz Loc, NC 4
18 9.802-108.0 Nipple, 1/4" Hex 1
19 9.802-186.0 Valve, Flow Control 1
20 9.802-138.0 Hose Barb, 1/4" Barb x 1/4" ML Pipe 1
21 6.390-126.0 Clamp, Hose, .46-, .54 ST 1
(Float Tank w/Steam) 3
22 9.802-251.0 Tube, 1/4" x 1/2", Clear Vinyl 72"
OPERATOR’S MANUAL
23 9.803-672.0 Strainer, 1/4" Brass w/Check Valve 1
24 9.802-087.0 Cover, Float Tank, Portotenica 1
25 9.802-131.0 Elbow, 1/2" JIC x 1/2", 90° 1
26 9.802-151.0 Swivel, 1/2" JIC Female, Push-On 1
27 9.802-260.0 Hose, 5/8" Push-On 12"
28 9.802-773.0 Nut, 1/4", ESNA, NC 2
29 9.802-802.0 Washer, 1/4" Flat, SAE 4
30 9.802-143.0 Hose Barb, 1/4" Barb x 1/4" Pipe, 90° 1
31 9.802-187.0 Valve, Flow Control w/Metering 1
32 9.802-010.0 Nipple, 1/4" Hex Steel 1
33 9.802-632.0 Cap, Valve w/ 1/4" Gauge Port 1
34 9.802-254.0 Hose, 1/4", Push-on 14"
35 9.802-459.0 Switch, MV60 Flow 1
36 9.803-044.0 Elbow, 3/8" Male Pipe 1
37 9.804-555.0 Cross, 1/2" Female w/ 1/4"-20 Hole 1
38 9.800-026.0 Label, Open For Steam 1
39 9.803-054.0 Adapter 1/4" x 1/8" 1
40 9.804-554.0 Screw, 10/32" x 2-1/2" 1
41 9.802-695.0 Nut, 10/32" Keps 1
42 9.802-121.0 Tee, 1/4" Street 1
43 9.803-989.0 Nipple, 1/2" Hex 1
44 9.802-119.0 Cross, 1/2" Female 1
45 9.802-135.0 Bushing, 1/2" x 1/4" 1
46 9.802-127.0 Nipple, 1/2" JIC x 1/2" Pipe 1
47 9.802-151.0 Swivel, 1/2" JIC Female, Push-On 2
48 9.802-259.0 Hose, 1/2", Push-On 16"
49 9.802-129.0 Elbow, 1/2" JIC x 3/8" 90° 1
50 9.802-362.0 Unloader VB8 w/Switch 1
51 9.802-458.0 Switch, Pressure N/O 1/4", NPT SS 1
52 9.802-030.0 Elbow, 3/8" Street 1
53 9.804-553.0 Adapter, 3/8" x 3/8" Street 1
54 9.802-137.0 Hose Barb, 1/4" Barb x 1/8" ML Pipe 1
Not Shown
38
HDS 500-510 • 9.800-078.0 • Rev. 4/10
AUTO START/STOP OPTIONS
501.0, 502.0, 503.0, 504.0
7
5
15
8
PRESSURE WASHER
OPERATOR’S MANUAL
9
6
5
5
14
13
3
4
2
10
11
12
1
AUTO START/STOP OPTIONS PARTS LIST
501.0, 502.0, 503.0, 504.0
ITEM PART NO. DESCRIPTION QTY
1 9.802-146.0 Swivel, 1/2" MP x 3/4" GHF w/Strainer 1
2 9.802-117.0 Tee, 1/2" Female Pipe 1
3 9.803-989.0 Nipple, 1/2" Hex 1
4 9.802-127.0 Nipple, 1/2" JIC x 1/2" MPT Pipe 1
5 9.802-151.0 Swivel, 1/2" JIC Fem, Push-on 2
6 9.802-259.0 Hose, 1/2" Push-on 16"
7 9.802-039.0 Elbow, 1/2" JIC, 3/8" 1
8 9.802-129.0 Elbow, 1/2" JIC x 3/8" 1
9 9.802-362.0 Unloader, VB8 w/Switch 1
10 For Pump, Please See Specifications Pages
11 9.802-182.0 Pump Protector, 1/2" 1
12 9.802-458.0 Switch, Pressure 1/4" NPT 1
13 9.802-030.0 Elbow, 3/8" Street 1
14 9.804-553.0 Adapter, 3/8" x 3/8" Street 1
15 9.802-242.0 Hose, 3/8" x 29", Pressure Loop 1
HDS 500-510 • 9.800-078.0 • Rev. 4/10
39
AUTO START/STOP OPTIONS
505.0, 506.0, 507.0, 508.0, 509.0, 510.0
7
8
16
6
PRESSURE WASHER
9
15
OPERATOR’S MANUAL
5
5
14
13
12
11
10
4
2
3
1
AUTO START/STOP OPTIONS PARTS LIST
505.0, 506.0, 507.0, 508.0, 509.0, 510.0
ITEM PART NO. DESCRIPTION QTY
1 9.802-146.0 Swivel, 1/2" MP x 3/4" GHF w/Strainer 1
2 9.802-117.0 Tee, 1/2" Female Pipe 1
3 9.803-989.0 Nipple, 1/2" Hex 1
4 9.802-127.0 Nipple, 1/2" JIC x 1/2" MPT Pipe 1
5 9.802-151.0 Swivel, 1/2" JIC Fem, Push-on 2
6 9.802-259.0 Hose, 1/2" Push-on 16"
7 9.802-039.0 Elbow, 1/2" JIC, 3/8" 1
8 9.802-129.0 Elbow, 1/2" JIC x 3/8" 1
9 9.802-362.0 Unloader, VB8 w/Switch 1
10 Pump, Please See Specifications Pages
11 9.802-182.0 Pump Protector, 1/2" 1
12 9.802-632.0 Cap, Valve with 1/4" Ga Port 1
13 9.802-458.0 Switch, Pressure 1/4" NPT 1
14 9.802-030.0 Elbow, 3/8" Street 1
15 9.804-553.0 Adapter, 3/8" x 3/8" Street 1
16 9.802-240.0 Hose, 3/8" x 22", Pressure Loop 1
40
HDS 500-510 • 9.800-078.0 • Rev. 4/10
AUTO START/STOP - STEAM OPTIONS & PARTS LIST
501.0, 502.0, 503.0, 504.0
10
21
12
22
PRESSURE WASHER
11
1
8
N
E
OP
R
FO
20
EAM
1
1
0
ST
9
9
0
1
19
23
9
6
14
7
22
5
6
13
16
18
17
15
3
ITEM PART NO. DESCRIPTION QTY
4
2
1 9.803-546.0 Hose, 3/8" x 18" Pressure Loop 1
2 9.802-146.0 Swivel, 1/2 x 3/4 GHF w/Strainer 1
3 9.802-123.0 Tee, 1/2" w/1/8" Hole Street 1
4 9.802-131.0 Elbow, 1/2" JIC x 1/2 - 90° 1
5 9.802-142.0 Hose Barb, 1/4 Barb x 1/8" Pipe 90° 1
6 9.802-151.0 Swivel, 1/2" JIC Fem, Push-on 2
7 9.802-259.0 Hose, 1/2" Push-on 16"
8 9.802-129.0 Elbow, 1/2 JIC x 3/8" 90° 1
9 9.802-362.0 Unloader, VB8 w/Switch 1
10 9.803-044.0 Elbow, 3/8" Male Pipe 1
11 9.802-459.0 Switch, Flow 1
12 9.802-039.0 Elbow, 1/2 JIC, 3/8" 1
13 9.802-030.0 Elbow, 3/8" Street 1
14 9.804-553.0 Adapter, 3/8" x 3/8" Steel 1
15 9.802-182.0 Pump Protector 1/2" 1
16 Pump, Please See Specifications Pages
17 9.804-022.0 Cap, Valve w/1/4" Ga. Port 1
18 9.802-010.0 Nipple, 1/4" Hex Steel 1
19 9.802-187.0 Valve, Flow Control w/Metering 1
20 9.800-026.0 Label, Open for Steam 1
21 9.802-143.0 Hose Barb, 1/4" Barb x 1/4" Pipe 1
22 6.390-126.0 Clamp, Hose 2
23 9.802-254.0 Hose, 1/4" Push-on 14"
HDS 500-510 • 9.800-078.0 • Rev. 4/10
OPERATOR’S MANUAL
41
AUTO START/STOP - STEAM OPTIONS & PARTS LIST
505.0, 506.0, 507.0, 508.0, 509.0, 510.0
10
12
11
1
8
PRESSURE WASHER
9
23
22
21
N
E
OP
FOR
20
EAM
1
1
0
ST
9
9
0
1
19
18
6
OPERATOR’S MANUAL
7
22
5
14
13
16
17
15
6
3
4
2
ITEM PART NO. DESCRIPTION QTY
1 9.802-240.0 Hose, 3/8" x 22" Pressure Loop 1
2 9.802-146.0 Swivel, 1/2 x 3/4 GHF w/Strainer 1
3 9.802-123.0 Tee, 1/2" w/1/8" Hole Street 1
4 9.802-131.0 Elbow, 1/2" JIC x 1/2 - 90° 1
5 9.802-142.0 Hose Barb, 1/4 Barb x 1/8" Pipe 90° 1
6 9.802-151.0 Swivel, 1/2" JIC Fem, Push-on 2
7 9.802-259.0 Hose, 1/2" Push-on 16"
8 9.802-129.0 Elbow, 1/2 JIC x 3/8" 90° 1
9 9.802-362.0 Unloader, VB8 w/Switch 1
10 9.803-044.0 Elbow, 3/8" Male Pipe 1
11 9.802-459.0 Switch, Flow 1
12 9.802-039.0 Elbow, 1/2 JIC, 3/8" 1
13 9.802-030.0 Elbow, 3/8" Street 1
14 9.804-553.0 Adapter, 3/8" x 3/8" Steel 1
15 9.802-182.0 Pump Protector 1/2" 1
16 For Pump, Please See Specifications Pages
17 9.804-022.0 Cap, Valve w/1/4" Ga. Port 1
18 9.802-010.0 Nipple, 1/4" Hex Steel 1
19 9.802-187.0 Valve, Flow Control w/Metering 1
20 9.802-026.0 Label, Open for Steam 1
21 9.802-143.0 Hose Barb, 1/4" Barb x 1/4" Pipe 1
22 6.390-126.0 Clamp, Hose 2
23 9.802-254.0 Hose, 1/4" Push-on 14"
42
HDS 500-510 • 9.800-078.0 • Rev. 4/10
1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0 PUMP ASSEMBLY
2
7
1
6
3
PRESSURE WASHER
OPERATOR’S MANUAL
8
5
4
1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0 PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.802-182.0 Pump Protector, 1/2" PTP 1
2 9.802-458.0 Pressure Switch, 1/4" 1
3 9.802-039.0 Elbow, 1/2" JIC x 3/8", 90° 1
4 9.802-146.0 Swivel, 1/2" GHF 1
5 For Unloader, Please see specifications pages
6 For Pump, Please see specifications pages
7 9.802-632.0 Cap, Valve w/1/4" Port 1
8 9.803-051.0 Plug, 1/8" Countersunk 1
43
HDS 500-510 • 9.800-078.0 • Rev. 4/10
O
PEN
FOR
STEAM
1
0-9
9011
501.0, 502.0, 503.0, 504.0 STEAM OPTION
1
2
11
3
PRESSURE WASHER
12
4
10
6
14
5
8
13
OPERATOR’S MANUAL
2
7
1
9
501.0, 502.0, 503.0, 504.0 PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.802-143.0 Hose Barb, 1/4" Barb x 1/4" Pipe, 90° 2
2 6.390-126.0 Clamp, Hose, .46-, .54 ST 2
3 9.802-187.0 Valve, Flow Control w/Metering 1
4 9.802-010.0 Nipple, 1/4" Hex Steel 1
5 9.804.022.0 Cap, Valve with 1/4" Gauge Port 1
6 9.802-459.0 Switch, Flow, MV-60 1
7 9.802-146.0 Swivel, 1/2" MP x 3/4" GHF w/Strainer 1
8 For Unloader, Please see specifications pages.
9 For Pump, Please see specifications pages.
10 9.800-026.0 Label, Open For Steam 1
11 9.802-254.0 Hose, 1/4" Push-On 1 ft.
12 9.802-039.0 Elbow, 1/2" JIC x 3/8" 1
13 9.803-044.0 Elbow, 3/8, Male Pipe 1
14 9.802-182.0 Pump Protector, 1/2" 1
44
HDS 500-510 • 9.800-078.0 • Rev. 4/10
1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0 STEAM OPTIONS
1
2
10
3
PRESSURE WASHER
8
11
9
2
7
14
4
5
12
6
13
1.575-505.0, 506.0, 507.0, 508.0, 509.0, 510.0 PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.802-143.0 Hose Barb, 1/4" Barb x 1/4" Pipe, 90° 2
2 6.390-126.0 Clamp, Hose, .46-, .54 ST 2
3 9.802-187.0 Valve, Flow Control w/Metering 1
4 9.802-010.0 Nipple, 1/4" Hex Steel 1
5 9.802-632.0 Cap, Valve with 1/4" Gauge Port 2
6 9.802-459.0 Switch, MV-60 Flow 1
7 9.802-146.0 Swivel, 1/2" MP x 3/4" GHF w/Strainer 1
8 For Unloader, Please see specifications pages.
9 For Pump, Please see specifications pages.
10 9.800-026.0 Label, Open For Steam 1
11 9.802-254.0 Hose, 1/4" Push-On 14"
12 9.802-039.0 Elbow, 1/2" JIC x 3/8" 1
13 9.803-044.0 Elbow, 3/8" Pipe, Male 1
14 9.802-142.0 Hose barb 1/4", Barb x 1/8" Pipe 90° 1
OPERATOR’S MANUAL
45
HDS 500-510 • 9.800-078.0 • Rev. 4/10
HOSE & SPRAY GUN ASSEMBLY
6
8
9
10
2
PRESSURE WASHER
1
3
5
7
OPERATOR’S MANUAL
Pressure Nozzle
4
HOSE & SPRAY GUN ASSEMBLY PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.802-165.0 Coupler, 1/4" Male 1
9.802-096.0 Quick Coupler O-Ring, Small 1
2 9.802-286.0 Nozzle Only, 1/8" Soap 1
3 9.802-222.0 Wand, Zinc, VP, w/Coupler 1
9.803-267.0 Repair Kit, Wand, SS Seat 1
4 8.739-125.0 Hose, 3/8" x 50' 1 Wire, Tuff-Flex 1
5 9.802-229.0 Spray Gun, Shut-off, AP-1000 1
6 9.802-225.0 Detergent Injector, Non Adjust #3 (504.0, 505.0, 506.0, 507.0, 508.0, 509.0, 510.0) 1
9.802-224.0 Detergent Injector, Non Adjust #2 (500.0, 501.0, 502.0, 503.0) 1
7 9.802-160.0 Strainer, 1/4" Hose Barb 1
8 9.802-166.0 Coupler, 3/8" Female 1
9.802-100.0 Quick Coupler, O-Ring, Large 1
9 6.390-126.0 Clamp, Hose, .46-, .54 ST 2
10 9.802-251.0 Tube, 1/4" x 1/2" Clear Vinyl 6 ft.
Not Shown
46
HDS 500-510 • 9.800-078.0 • Rev. 4/10
UU1 UNLOADER VALVE EXPLODED VIEW
9.175-018.0, 3500 PSI
Universal Unloader
PRESSURE WASHER
OPERATOR’S MANUAL
UU1 UNLOADER VALVE EXPLODED VIEW PARTS LIST
ITEM PART # DESCRIPTION KIT QTY
1 Piston Housing A 1
2 Piston C 1
3 8.749-795.0 Piston O-Ring Back up 1
4 8.749-796.0 Main Block 1
5 9.152-372.0 Piston Ring 1
6 Ball Seat C 1
7 O-Ring, 10.5 ID x 1.5 CS A,C 1
8 Plunger B 1
9 9.152-016.0 Plunger Housing 1
10 Bypass Spring C 1
11 9.149-001.0 Low Pressure Port 1
12 9.152-017.0 Sliding Connector, 30 mm 1
8.762-005.0 Sliding Connector, 40 mm 1
13 9.149-002.0 Sliding Connector H 1/2" 1
9.149-005.0 Sliding Connector H 3/8" 1
14 9.196-011.0 Plug, 5/8 - 18 UNF 1
15 O-Ring 12 ID x 2 CS A 2
16 O-Ring 6 ID x 2 CS A 1
HDS 500-510 • 9.800-078.0 • Rev. 4/10
ITEM PART # DESCRIPTION KIT QTY
17 9.149-006.0 Sliding Connector Guide 1
18 O-Ring Back up A 1
19 Conical Seal C 1
20 O-Ring 6.75 x 1.78 BN80 A 1
21 Spring Seat C 1
22 Plunger Spring B 1
23 8.762-001.0 Banjo Bolt, 1/2" 1
8.762-011.0 Banjo Bolt, 1/2" - 1/4" NPT 1
8.762-000.0 Banjo Bolt 3/8" 1
24 8.762-000.0 Banjo Bolt 3/8" 1
25 9.802-893.0 Seal Washer 3/8" 2
26 9.803-921.0 Seal Washer, 1/2" (0120, 0130) 2
9.802-893.0 Seal Washer 3/8" (0140) 2
27 O-Ring 15 ID x 2 CS A,B 3
28 8.706-865.0 Plug, 1/4" 1
KIT A 9.104-038.0 O-Ring Repair Kit
KIT B 9.104-039.0 Outlet Kit
KIT C 9-104-040.0 Stem Repair Kit
47
9.803-814.0 KE 2020F.1
9.803-815.0 KE 2020S.1
9.803-816.0 KE 2825F.1
9.803-817.0 KE 2825S.1
9.803-818.0 KE 3525F.1
PRESSURE WASHER
KE.1 SERIES PUMP EXPLODED VIEW
OPERATOR’S MANUAL
KE.1 SERIES PUMP EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 9.803-938.0 Crankcase 1
2* 9.804-586.0 Plunger Oil Seal 3
3* See Kit O-Ring Ø 1.78 x 28.30 3
4* See Kit Pressure Ring 15mm 3
See Kit Pressure Ring 18mm 3
5* See Kit U-Seal, dia 15mm 6
See Kitw U-Seal, dia 18mm 6
6* See Kit Intermediate Ring 15mm 6
See Kit Intermediate Ring 18mm 6
7* See Kit U-Seal, 15mm 3
See Kit U-Seal, 18mm 3
8 9.802-926.0 Brass Plug G1/2 1
9 9.803-199.0 Copper Washer 1/2" 1
10 9.803-946.0 Manifold Housing 1
11 9.803-947.0 O-Ring Ø1.78 x 15.54 6
12* See Kit Valve Assembly 6
13* 9.803-948.0 O-Ring Ø2.62 x 18.77 6
14 9.803-949.0 Valve Plug 6
15 9.803-950.0 Copper Washer 1/4 1
48
HDS 500-510 • 9.800-078.0 • Rev. 4/10
TORQUE
SPECS
Item # Ft.-lbs
14 65
17 18
25 7.6
36 8
38 7
48 13
ITEM PART NO. DESCRIPTION QTY
16 9.803-951.0 Brass Plug G1/4 1
17 9.803-952.0 Manifold Stud Bolt 8
18 9.802-884.0 Washer 8
19 9.803-198.0 Copper Washer 3/8 1
20 9.802-925.0 Brass Plug G3/8 2
25 9.802-939.0 Screw 12
26 9.803-953.0 Bearing Cover 2
27 9.803-954.0 Bearing Seal 1
28 9.802-914.0 Snap Ring 1
29 9.803-955.0 Ball Bearing 2
30 9.804-576.0 Crankshaft (2020F) 1
9.804-577.0 Crankshaft (2020S) 1
9.804-578.0 Crankshaft (2825F) 1
9.804-579.0 Crankshaft (2825S) 1
9.804-580.0 Crankshaft (3525F) 1
31 9.803-957.0 Oil Dipstick 1
32 9.804-581.0 O-Ring Ø3.53 x 55.56 1
33 9.804-582.0 Needle Bearing 1
34 9.804-583.0 Motor Flange 56C 1
35 9.803-210.0 Washer 4
KE.1 SERIES PUMP PARTS LIST (CONT)
ITEM PART NO. DESCRIPTION QTY
36 9.804-584.0 Flange Screw 4
37 9.804-585.0 Crankshaft Seal 1
38* See Kit Plunger Nut 3
39* See Kit Copper Spacer 3
40* See Kit Plunger 15mm (2020F,
2825F, 3525F) 3
See Kit Plunger 18mm
(2020S, 2825S) 3
41* See Kit Copper Spacer 3
42* See Kit O-Ring Ø1.78 x 5.28 3
43* See Kit Teflon Ring 3
44 9.803-964.0 Plunger Rod 3
45 9.803-965.0 Connecting Rod Pin 3
46 9.803-966.0 Connecting Rod 3
47 9.803-218.0 Spring Washer 6
48 8.933-020.0 Connecting Rod Screw 6
49 9.803-969.0 O-Ring Ø2.62 x 107.62 1
50 9.803-968.0 Crankcase Cover 1
51 9.803-197.0 Gasket 1
52 9.803-202.0 Sight Glass 1
PRESSURE WASHER
OPERATOR’S MANUAL
REPAIR KIT NUMBER 8.725-354.0 8.725-356.0 8.725-355.0 8.725-357.0 9.803-934.0 9.803-935.0
Plunger Seal
15mm
2020F.1
KIT DESCRIPTION
ITEM NUMBERS
INCLUDED
NO. OF CYLINDERS
KIT WILL SERVICE
REPAIR KIT NUMBER 9.803-936.0 9.803-937.0
KIT DESCRIPTION
ITEM NUMBERS
INCLUDED
NO. OF CYLINDERS
KIT WILL SERVICE
2825F.1
3525F.1
3, 5, 7 3, 5, 7
3 1 1 1 1 1
Complete
Valve
11, 12, 13 2
6 3
Plunger Seal
18mm
2020S.1
2825S.1
Plunger Oil
Seals
Complete Seal
Packing 15mm
2020F.1
2825F.1
3525F.1
3, 4, 5,
6, 7
Complete Seal
Packing 18 mm
2020S.1
2825S.1
3, 4, 5, 6, 7
Plunger 15mm
2020F.1
2825F.1
3525F.1
38, 39, 40, 41,
42, 43
Plunger 18mm
2020S.1
2825S.1
38, 39, 40, 41,
42, 43
49
HDS 500-510 • 9.800-078.0 • Rev. 4/10
9.803-405.0 KM4030R.2
9.803-406.0 KM4030L.2
9.802-343.0 KM4035R.2
9.803-407.0 KM4035L.2
9.802-342.0 KM5030R.2
9.803-408.0 KM5030L.2
8.749-940.0 KM6035R.2
8.749-941.0 KM6035L.2
8.904-689.0 KM3540R.2
PRESSURE WASHER
OPERATOR’S MANUAL
KM.2 PUMP EXPLODED VIEW
TORQUE
SPECS
Item # Ft.-lbs
17 75
18 30
26 8
36 7
47 13
52 7.6
KM.2 PUMP EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 8.717-130.0 Crankcase 1
2 9.803-196.0 Plunger Guide 3
3* See Kits
4* See Kits O-Ring Ø1.78 x 31.47 3
5* See Kits Pressure Ring 3
6* See Kits U-Seal 3
7* See Kits Intermediate Ring 3
8* See Kits Back-up Ring 3
9* See Kits U-Seal 3
10* See Kits Support Ring 3
13 9.802-932.0 Manifold Head 1
14* See Kits O-Ring Ø2.62 x 17.13 6
15* See Kits Valve Assembly 6
16* See Kits O-Ring Ø2.62 x 20.29 6
17 9.802-928.0 Valve Plug 6
18 9.802-938.0 Manifold Stud Bolt 8
19 9.802-884.0 Washer 16
20 9.803-198.0 Copper Washer 3/8 1
21 9.802-925.0 Brass Plug 3/8 1
50
Plunger Oil Seal 3
HDS 500-510 • 9.800-078.0 • Rev. 4/10
ITEM PART NO. DESCRIPTION QTY
26 9.802-944.0 Screw, Hex 8mm x 18mm 8
27 8.717-210.0 Closed Bearing Housing 1
28 9.803-192.0 O-Ring Ø1.78 x 60.05 2
29 8.933-011.0 Tapered Roller Bearing 2
30 9.803-146.0 Crankshaft (5030, 3540) 1
9.803-147.0 Crankshaft
31 9.803-167.0 Crankshaft Key 1
32 9.802-921.0 Oil Dip Stick 1
33 9.803-140.0 Crankshaft Seal 1
34 9.803-178.0 Shim 2
35 8.717-209.0 Bearing Housing 1
36* See Kits Plunger Bolt 3
37* See Kits Copper Spacer 3
38* See Kits O-Ring Ø1.78 x 7.66 3
39* See Kits Teflon Ring 3
40* See Kits Plunger (4035, 6035) 3
See Kits Plunger (4030, 5030) 3
See Kits Plunger (3540) 3
41* See Kits Copper Spacer 3
(4030, 4035, 6035)
1
KM.2 PUMP EXPLODED VIEW PARTS LIST (CONT)
ITEM PART NO. DESCRIPTION QTY
42 9.803-144.0 Plunger Rod 3
43 9.803-158.0 Connecting Rod 3
44 9.802-913.0 Snap Ring 6
45 9.802-916.0 Connecting Rod Pin 3
46 9.803-218.0 Spring Washer 6
47 9.803-238.0 Connecting Rod Screw 6
48 8.933-016.0 O-Ring, Ø2.62 x 126.67 1
49 9.803-165.0 Crankcase Cover 1
50 9.803-197.0 O-Ring, Ø1.78 x 14 1
51 9.803-202.0 Sight Glass 3/4 1
52 9.802-939.0 Cover Screw 5
* Available in kit (See below)
REPAIR KIT NO. 8.725-360.0 8.725-362.0 8.725-358.0 8.725-361.0 8.725-363.0 8.725-359.0
KIT
DESCRIPTION
ITEM NUMBERS
INCLUDED
NO. OF
CYLINDERS KIT
WILL SERVICE
Plunger Seal
4035
6035
18mm
4, 6, 8,
9, 10
3 3 3 1 1 1
Plunger Seal
4030
5030
20mm
4, 6, 8,
9, 10
Plunger Seal
3540
15mm
4, 6, 8,
9, 10
Complete Seal
Packing
4035
6035
18mm
4, 5, 6, 7,
8, 9, 10
Complete Seal
Packing
4030
5030
20mm
4, 5, 6, 7,
8, 9, 10
Complete Seal
Packing
3540
15mm
4, 5, 6, 7,
8, 9, 10
PRESSURE WASHER
OPERATOR’S MANUAL
REPAIR KIT NO. 9.802-629.0 9.802-620.0 8.933-023.0 9.802-603.0 9.802-609.0
KIT
DESCRIPTION
ITEM NUMBERS
INCLUDED
NO. OF
CYLINDERS KIT WILL
SERVICE
Plunger
4035
6035
18mm
36, 37, 38,
39, 40, 41
1 1 1 6 3
Plunger
4030
5030
20mm
36, 37, 38, 39,
40, 41
Plunger
3540
15mm
36, 37, 38, 39,
40, 41
Complete
Valve
14, 15, 16 3
Plunger
Oil Seals
51
HDS 500-510 • 9.800-078.0 • Rev. 4/10
SPECIFICATIONS
PUMP
Machine Pump Pump Unloader Unloader Pulley Motor Motor Pulley Model Bushing Belt Belt Motor Stepdown Primary Second
Part # Model Parts# Replacement Production Pulley Part # Size Voltage Part # Pulley Part # Part # Bushing Part # Size Part # Contactor Overload Transformer Fuse Part# Fuse Part#
1.575-500.0 KE2020F 9.803-814.0 9.175-018.0 9.175-016.0 NA NA 1.5 HP 120v/1ph/60Hz 9.802-338.0 NA NA 500.0 NA NA NA NA NA NA NA NA NA
1.575-501.0 KE2020F 9.803-814.0 9.175-018.0 9.175-016.0 NA NA 2 HP 120v/1ph/60Hz 9.802-339.0 NA NA 501.0 NA NA NA NA NA NA NA NA NA
1.575-502.0 KE-2825F 9.803-816.0 9.175-018.0 9.175-016.0 NA NA 2 HP 120v/1ph/60Hz 9.802-339.0 NA NA 502.0 NA NA NA NA NA NA NA NA NA
1.575-503.0 KE-2825F 9.803-816.0 9.175-018.0 9.175-016.0 NA NA 3 HP 230v/1ph/60Hz 9.802-340.0 NA NA 503.0 NA NA NA NA NA NA 9.802-551.0 9.802-461.0 9.802-463.0
1.575-504.0 KE-3525F 9.803-818.0 9.175-018.0 9.175-016.0 NA NA 5 HP 230v/1ph/60Hz 9.802-341.0 NA NA 504.0 NA NA NA NA NA NA 9.802-551.0 9.802-461.0 9.802-463.0
1.575-505.0 KM-4035 9.802-343.0 9.175-018.0 9.175-016.0 2AK74H 9.802-374.0 6 HP 230v/1ph/60Hz 9.802-336.0 2AK54H 9.802-372.0 505.0 Hx1-1/8" 9.802-400.0 AX 34(2) 9.802-407.0 8.724-281.0 NA 9.802-551.0 9.802-461.0 9.802-463.0
1.575-506.0 KM-4035 9.802-343.0 9.175-018.0 9.175-016.0 2AK74H 9.802-374.0 6 HP 230v/3ph/60Hz 9.802-329.0 2AK54H 9.802-372.0 506.0 Hx1-1/8" 9.802-400.0 AX 34(2) 9.802-407.0 8.724-268.0 8.724-304.0 9.802-551.0 9.802-461.0 9.802-463.0
1.575-507.0 KM-4035 9.802-343.0 9.175-018.0 9.175-016.0 2AK74H 9.802-374.0 6 HP 460v/3ph/60Hz 9.802-329.0 2AK54H 9.802-372.0 507.0 Hx1-1/8" 9.802-400.0 AX 34(2) 9.802-407.0 8.724-268.0 8.724-312.0 9.802-550.0 9.802-460.0 9.802-465.0
1.575-508.0 KM-4035 9.802-343.0 9.175-018.0 9.175-016.0 2BK80H 9.802-389.0 7.5 HP 230v/1ph/60Hz 8.715-097.0 2BK52H 9.802-386.0 508.0 Hx1-3/8" 9.802-401.0 BX 36(2) 9.802-416.0 8.724-281.0 8.724-306.0 9.802-551.0 9.802-461.0 9.802-463.0
PRESSURE WASHER Specifications
1.575-509.0 KM-4035 9.802-343.0 9.175-018.0 9.175-016.0 2BK80H 9.802-389.0 7.5 HP 230v/3ph/60Hz 8.715-105.0 2BK52H 9.802-386.0 509.0 Hx1-3/8" 9.802-401.0 BX 36(2) 9.802-416.0 8.724-272.0 8.724-305.0 9.802-551.0 9.802-461.0 9.802-463.0
1.575-510.0 KM-4035 9.802-343.0 9.175-018.0 9.175-016.0 2BK80H 9.802-389.0 7.5 HP 460v/3ph/60Hz 8.715-105.0 2BK52H 9.802-386.0 510.0 Hx1-3/8" 9.802-401.0 BX 36(2) 9.802-416.0 8.724-268.0 8.724-312.0 9.802-550.0 9.802-460.0 9.802-465.0
MOTOR
52
HDS 500-510 • 9.800-078.0 • Rev. 4/10
SPECIFICATIONS
PRESSURE WASHER Specifications
MOTOR
CONTROLS
53
HDS 500-510 • 9.800-078.0 • Rev. 4/10
BURNER SPECIFICATIONS
Burner Burner Fuel Pump/ Fuel
Model # Assy # Fuel Nozzle Transformer Motor Solenoid/Cord Solenoid Coil Electrode
1.575-500.0 9.802-558.0 9.802-583.0 9.802-647.0 9.802-642.0 9.802-645.0 9.802-640.0 9.802-570.0
1.575-501.0 9.802-555.0 9.802-583.0 9.802-647.0 9.802-642.0 9.802-645.0 9.802-640.0 9.802-570.0
1.575-502.0 9.802-558.0 9.802-584.0 9.802-647.0 9.802-642.0 9.802-645.0 9.802-640.0 9.802-670.0
1.575-503.0 9.802-561.0 9.802-584.0 9.802-661.0 9.802-635.0 9.802-645.0 9.802-640.0 9.802-670.0
1.575-504.0 9.802-561.0 8.717-272.0 9.802-661.0 9.802-635.0 9.802-645.0 9.802-640.0 9.802-670.0
1.575-505.0 9.802-561.0 8.717-272.0 9.802-661.0 9.802-635.0 9.802-645.0 9.802-640.0 9.802-670.0
1.575-506.0 9.802-561.0 8.717-272.0 9.802-661.0 9.802-635.0 9.802-645.0 9.802-640.0 9.802-670.0
1.575-507.0 9.802-557.0 8.717-272.0 9.802-647.0 9.802-642.0 9.802-645.0 9.802-640.0 9.802-670.0
1.575-508.0 9.802-561.0 8.717-272.0 9.802-661.0 9.802-635.0 9.802-645.0 9.802-640.0 9.802-670.0
1.575-509.0 9.802-561.0 8.717-272.0 9.802-661.0 9.802-635.0 9.802-645.0 9.802-640.0 9.802-670.0
1.575-510.0 9.802-557.00 8.717-272.0 9.802-647.0 9.802-642.0 9.802-645.0 9.802-640.0 9.802-670.0
PRESSURE WASHER Specifications
54
HDS 500-510 • 9.800-078.0 • Rev. 4/10
PRESSURE WASHER WARRANTY
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 EQUIPMENT
FOR A PARTICULAR PURPOSE AND ANY SUCH WARRANTIES ARE EXPRESSLY DISCLAIMED. KÄRCHER FURTHER DISCLAIMS ANY WARRANTY THAT THE PRODUCT PURCHASED BY CUSTOMER WILL MEET ANY PARTICULAR REQUIREMENT
OF CUSTOMER EVEN IF KÄRCHER HAS BEEN ADVISED OF SUCH REQUIREMENT.
THE RIGHTS AND REMEDIES PROVIDED UNDER THIS WARRANTY ARE EXCLUSIVE AND IN LIEU OF ANY OTHER RIGHTS
OR REMEDIES OF CUSTOMER. KÄRCHER SHALL NOT UNDER AN
Y CIRCUMSTANCES BE LIABLE TO ANY PERSON OR
ENTITY INCLUDING, BUT NOT LIMITED TO, THE CUSTOMER OR ANY END USER OF THE PRODUCT FOR ANY SPECIAL,
INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ECONOMIC LOSS, LOSS OF PROFITS OR LOSS OF USE OF
THE PRODUCT, ARISING IN CONNECTION WITH THE SALE, DELIVERY, INSTALLATION, TRAINING OR USE OF PRODUCT.
KÄRCHER’S LIABILITY, WHETHER IN CONTRACT OR IN TORT, ARISING OUT OF ANY WARRANTIES OR REPRESENTATIONS, INSTRUCTIONS OR DEFECTS FROM ANY CAUSE, SHALL BE LIMITED EXCLUSIVELY TO THE COST OF REPAIR OR
REPLACEMENT PARTS 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.
®
LIMITED NEW PRODUCT
WARRANTY—COMMERCIAL
PRESSURE WASHERS
Phone: 360-833-1600
Fax: 800-248-8409
www.karchercommercial.com
HDS 500-510 • 9.800-078.0 • Rev. 4/10
®
www.karchercommercial.com www.karchershark.com
Form HDS 500-510 # 9.800-078.0 • Revised 4/10 • Printed in U.S.A. or Mexico
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