ALKOTA 435EK Installation and operating instructions

Service ManualService Manual
For full warranty information, contact your delivering distribu-
tor or contact the manufacturer at [e-mail]
Operation &
Service Manual
Operation &
Service Manual
Cold Water Series GED
Model 435EK
p/n 435EK-000000
20140708 s/n 274473 & Up

______________________________________________________
INSTALLATION DATE PART NUMBER
______________________________________________________
MAKE/MODEL SERIAL NUMBER
______________________________________________________
SELLER
______________________________________________________
ADDRESS CITY/STATE/ZIP
NOTES:
English to Metric Conversions
1 gal/m = 3.7843 L/m
1 hp = .7457 kw
100 psi = 6.8964 bar
1 ft = .3048 m
1 in = 2.54 cm
1 lb = .4536 kg
(˚F – 32)
1.8 =˚C

Table of Contents
Specications ����������������������������������������������������������������������������������������� 1
Operation������������������������������������������������������������������������������������������������� 2
Machine Unpacking, General Safety ������������������������������������������������ 2
Safety Continued, Pre Start-Up, Start-Up ���������������������������������������� 3
Operation - Apply Chemical, Rinse ������������������������������������������������� 4
Shut-Down ������������������������������������������������������������������������������������������ 4
Machine Maintenance ����������������������������������������������������������������������� 5
Belt Tension, Spray Tip, Flushing , Storage ������������������������������������ 5
Machine Maintenance Schedule ������������������������������������������������������ 6
Machine Maintenance Trouble Shooting �������������������������������������� 7
Machine Maintenance Trouble Shooting Continued��������������������� 8
Gun & Wand Assembly ������������������������������������������������������������������������ 10
Chemical Injector - P/N J06-00244 ������������������������������������������������������ 11
General Assembly �������������������������������������������������������������������������������� 12
Water Pump������������������������������������������������������������������������������������������� 13
Unloader������������������������������������������������������������������������������������������������ 14
Specications����������������������������������������������������������������������������������� 14
Parts List������������������������������������������������������������������������������������������� 15
Maintenance - Exploded View��������������������������������������������������������� 16
Trouble Shooting������������������������������������������������������������������������������ 17
Water Pump������������������������������������������������������������������������������������������� 18
Specications����������������������������������������������������������������������������������� 18
p/n N07-00238 ( EP1508G8 ) ������������������������������������������������������������ 18
Exploded View���������������������������������������������������������������������������������� 19
p/n N07-00238 ( EP1508G8 ) ������������������������������������������������������������ 19
Pump Maintenance Record ������������������������������������������������������������� 20
Pump Maintenance������������������������������������������������������������������������������� 21
Plunger Service, Removal, Installation ������������������������������������������ 22
Packing Service�������������������������������������������������������������������������������� 23
Head Installation - Torgue Sequence ��������������������������������������������� 24
Troubleshooting ����������������������������������������������������������������������������������� 25
Pump ������������������������������������������������������������������������������������������������� 25
Warranty ������������������������������������������������������������������������������������������������ 27

Month/Day/Year Operating Hours Maintenance Performed
Machine Record

1
Specications
Specications
PERFORMANCE
Discharge Volume 3.7 GPM / 14.2 LPM
Pump Head Pressure 3000 PSI / 207 BAR
GENERAL
Minimum Inlet Water Pressure over 65 psi may require water inlet
regulator
10 psi / 0.68 bar
Weight (Dry)
400 lbs. / 181 kg
Spray Tip
(#4.0-15 DEG) p/n J00-15040-2
Hose, Discharge
3/8” x 50’ 4000 PSI
Wand & Trigger Gun Wand - ¼” x 36”
Pump Triplex, Oil Bath
PUMP ENGINE
Engine F05-00559
Engine Horsepower 9.5 hp / 7.0 kw
Engine Displacement 16.9 Cu In / 277 cc
Engine Shaft - keyed 1” x 3.48”
Engine Fuel Gasoline
Engine Make Kohler
Dry Weight 61.5 lbs. / 27.8 Kg
Fuel Capacity 7.4 Quart / 7.0 Liter
Oil Capacity 1.4 Quart / 1.3 Liter
Lubrication Splash
Starting Recoil start, low oil device

2Safety
Machine Unpacking, General Safety
Operation
SAFETY AND OPERATION
GAS ENGINE DRIVEN COLD WATER CLEANER
05-17-06 Z08-00485
1. Before operating this machine, read and observe all
safety, unpacking, and operating instructions. Failure
to comply with these instructions could create a
hazardous situation.
2. The operator of this equipment should not operate this
equipment when fatigued or under influence of alcohol
or drugs.
3. The operator of this equipment should be thoroughly
familiar with its operation and trained in the job to
be accomplished.
4. The operator of this equipment should wear protective
face shields and other protective clothing as required
for safe operation.
5. Always point the gun assembly in a safe direction and
do not direct spray on the cleaner.
6. Do not operate the machine if any mechanical failure
is noted or suspected.
8. Do not leave this machine unattended when it is
operating.
9. All installations must conform to all applicable
Local codes. Contact your electrician, plumber,
utility company or seller for details.
3
GENERAL SAEFTY
Supersedes 05-12-05 Z08-00485
Read and understand this “OPERATOR’S
MANUAL” and “LABELS
ON THE MACHINE” before
starting.
MACHINE UNPACKING
ALL CLEANERS ARE CAREFULLY INSPECTED AND
CARTONED TO PROTECT AGAINST SHIPPING
DAMAGE. IF THERE IS DAMAGE OR MISSING PARTS,
THE TRANSPORTATION COMPANY AGENT SHOULD
MAKE A NOTATION TO THAT EFFECT ON THE BILL.
REFER TO THE PARTS LIST IN THIS MANUAL AND
ADVISE WHAT PARTS ARE MISSING OR DAMAGED.
IF AVAILABLE, GIVE THE INVOICE NUMBER ON ALL
ORDER BILLS. THIS PROCEDURE WILL ENABLE
NEEDED PARTS TO BE SHIPPED QUICKLY.
READ ALL Installation, Operation, and Maintenance
instructions before operating the machine.
NOTE: Refer to CLEANER MODEL for SERIAL NUMBER
location.
NOTE: Dimensions are in inches unless otherwise noted.
The safety alert symbol. This symbol is used
to identify safety information about hazards that can
result in personal injury.
A signal word (DANGER, WARNING, or CAUTION) is used
with the alert symbol to indicate the likelihood and the
potential severity of injury. In addition, a hazard symbol
may be used to represent the type of hazard
DANGER indicates a hazard which, if not avoided,
will result in death or serious injury.
WARNING indicates a hazard which, if not avoided,
could result in death or serious injury.
CAUTION indicates a hazard which, if not avoided,
might result in minor or moderate injury.
CAUTION, when used without the alert symbol,
indicates a situation that could result in damage to
the equipment.
IMPORTANT SAFETY
INSTRUCTIONS
WARNING: RISK OF INJECTION OR
SEVERE INJURY. KEEP CLEAR OF
NOZZLE. DO NOT DIRECT DISCHARGE
STREAM AT PERSONS. THIS EQUIPMENT
IS TO BE USED ONLY BY TRAINED
OPERATORS.
AVERTISSEMENT:RISQUE D’INJECTION ET
DE BLESSURES GRAVES. SE TENIR À
L’ÉCART DU JET. NE PAS DIRIGER LE JET
DE SOTIE VERS D’AUTRES PERSONNES
CONFIER L’UTILISATION LE JET DE SOTIE
VERS D’AUTRES PERSONNES. CONFIER
L’UTILISATION DE CE MATÉRIEL À UN
OPÉRATEUR QUALIFIÉ.
ADVERTENCIA:RIESGO DE LA INYECCIÓN
O SEVERO LESIÓN. CLARO DE LA
SUBSISTENCIA DEL INYECTOR. NO DIRIJA
LA CORRIENTE DE LA DESCARGA EN LAS
PERSONAS. ESTO EL EQUIPO DEBE SER
UTILIZADO SOLAMENTE POR LOS
OPERADORESENTRENADOS.

3
Safety & Installation
Safety Continued, Pre Start-Up, Start-Up
05-12-06 Z08-02830A
10. If a water leak is found, DO NOT OPERATE THE
MACHINE. Shut off the motor and repair.
11. Do not start the machine unless the gun assembly is
firmly gripped by the machine operator. Failure to do
this could result in injury from a flying hose and gun
assembly.
12. All guards, shields, and covers must be replace after
adjustment are made to prevent accidental contact
with hazardous parts.
13. If chemicals are used in conjunction with this
equipment, read and follow the product label
directions.
14. Do not refuel the machine while it is running or hot.
Allow it to cool sufficiently to prevent ignition of any
spilled fuel. .
15. Drive belts must be inspected and tightened
periodically to operate at optimum levels.
16. Inspect machine for damaged or worn components
and repair or replace to avoid potential hazards.
Do not operate the machine if any mechanical
failure is noted or suspected.
17. Always use the correct size spray tip specified in
the GENERAL section of the MODEL
SPECIFICATIONS or MODEL EXPLODED VIEW.
18. Do not start the engine until you have observed all
safety instructions and operating found in the
operating manual.
SAVE THESE SAFETY
INSTRUCTIONS
1. The first time the machine is operated, after repairs
have been made, or if the machine has set for a period
of time (30 days or more) follow the following
procedures.
A. Check the tension of the belt (if so equipped)
per instructions in MACHINE MAINTENANCE.
B. Flush the machine per instructions in MACHINE
MAINTENANCE.
2. CAUTION: Always use the factory supplied wash
hose with your machine. Do not substitute other
hoses as a potential safety problem may develop.
CAUTION: If machine has been exposed
to sub-freezing temperatures, it must be thoroughly
warmed to above freezing before operating. Failure
to warm machine can cause damage to the pump
packings and other components.
♦ Refer to the MAINTENANCE SCHEDULE for any
maintenance to be performed before
operation
♦OIL LEVEL: Check the oil level in the water pump.
♦BELT: Make sure belt tension and condition is as
specified in MACHINE MAINTENANCE.
♦ METERING VALVE ( if so equipped): Make sure the
metering valve is closed before operation. If air enters
the system through this valve, poor performance and
machine damage will occur. Refer to the metering
valve insert for proper operation.
♦WATER SUPPLY: This machine must have a water
supply meeting or exceeding the maximum discharge
volume specified in the PERFORMANCE section, and
a minimum water inlet pressure of 40 PSI /12.1KGM.
1. Turn water supply.
2. With the gun assembly in hand (on trigger gun models
hold the trigger gun valve in open position) and with
a good flow of water turn the switch to the “pump”
position.
CAUTION: A good flow of water must be flowing
from the end of a gun for 30 seconds, before
proceeding. Lack of water can cause damage to
the water pump and like components.
4
Supersedes 08-19-04 Z08-02830A
WARNING: Avoid the exhaust areas as they are
dangerously hot during and a short time after
operation.
WARNING: Never put hands or fingers in wash
spray. DO NOT point the gun assembly toward
your body or at anyone else. Failure to do this could
result in serious injury.
WARNING: DO NOT run engine in an enclosed
area. Exhaust gases contain carbon monoxide,
an odorless and deadly poison.
PRE START-UP
OPERATION
START-UP

4Operation
Operation - Apply Chemical, Rinse
Shut-Down
05-12-06 Z08-02830B
CAUTION: On a machine equipped with a trigger
gun valve, if the trigger gun valve remains in the closed
position for more than 3 minutes, water pump damage
may occur.
4. TO APPLY CHEMICAL:
A. Mix chemicals per label instructions. Use
necessary safety precautions.
B. Insert chemical screen into chemical container
C. Adjust metering valve (if so equipped).
D. If the gun assembly is equipped with variable or
multiple nozzle assembly, adjust as desired.
TO RINSE:
A. Close the chemical metering valve (if so
equipped). NOTE: It is advisable to dip the
chemical screen in a container of clean water
and open the valve 1 minute to clean the valve of
any remaining residue.
B. If the gun assembly is equipped with variable or
multiple nozzle assembly, open and close to clean
nozzle of any remaining residue.
C. Start from the top, working downward using
long, overlapping strokes.
1. Shut down per engine owners manual.
2. Turn off the water supply.
3. If freezing conditions may exist, refer to STORAGE
in MACHINE MAINTENANCE.
4. Refer to engine owners manual for proper engine
storage.
5
Supersedes 08-19-04 Z08-02830B
SHUT-DOWN

Maintenance 5
Machine Maintenance
Belt Tension, Spray Tip, Flushing , Storage
CAUTION: DO NOT RUN PUMP WITHOUT
WATER, AS THIS WILL CAUSE DAMAGE TO
THE PUMP AND VOID WARRANTY.
5. When clean water flows from the gun, turn switch
to the “OFF” position.
6. Reinstall spray tip.
7. With the gun assembly in hand, turn on the switch.
On trigger gun models hold the trigger gun valve
in open position.
8. When clean water flows from the gun, turn switch
to the “OFF” position.
9. If freezing conditions may exist, refer to
“STORAGE” section.
10. Turn off and disconnect the water supply.
Disconnect elctrical supply.
1. Correct belt tension will allow a 1/64- inch
deflection for each inch of span between pulley
centers with a 6-pound force applied in the middle
of the span.
EXAMPLE: A 6-pound force applied at the middle
of an 8 inch span should produce a deflection of
8/64 inch or 1/8 inch.
2. Belts can be tightened or loosened by loosening
the nuts holding the pump assembly to the motor
mount. Then tighten or loosen
the j-bolt on the motor mount. Retighten the pump
assembly after the desired tension is reached.
1. Remove the spray tip from the gun assembly.
2. Blow out debris with compressed air from the
outside in. Any debris remaining in the inlet side
of the nozzle should be cleaned out. If lime or
chemical scale is present in the inlet side, the
nozzle may be soaked in descaling solution or
replaced. If the tip is worn, replace with one
specified in the GENERAL section of MODEL
SPECIFICATIONS or MODEL EXPLODED
VIEW.
3. Before replacing spray tip flush the machine per
“FLUSHING”.
4. Reinstall Spray tip to gun assembly.
1. Connect machine to a pressurized water supply
meeting the requirements specified in the
GENERAL section of the MODEL
SPECIFICATIONS.
2. Turn on the water supply.
3. Remove the spray tip from gun assembly.
4. With gun assembly in hand, start engine. On
trigger gun models hold the trigger gun valve in
open position.
05-17-06 Z08-027666
1
Supersedes 02-16-01 Z08-027666
MACHINE
MAINTENANCE
Gas Engine Driven Cold Water Cleaners
DEFLECTION
SPAN
SPRAYTIPMAINTENANCE
1. Rinse the chemical line by inserting the screen
into a container of clear water and open the
metering valve 1 minute to clean it of any
remaining residue. Be sure the chemical metering
valve is closed when finished.
2. Disconnect the water supply.
3. Remove the spray tip nozzle from gun assembly
and wire to machine.
4. Attach an air chuck to the air valve stem on the
pump assembly. With the trigger gun in the open
position, apply air until a mixture of air and very
little water is coming from the gun wand .
5. Fill a 1-gallon container with Ethylene Glycol type
antifreeze. Minimum should be a mixture of ½
antifreeze and ½ water strength before each use,
as the antifreeze will dilute with use.
6. Install a 2-ft garden hose to the water inlet. Insert
the other end into a container of antifreeze solution.
7. With the gun assembly in hand, turn on the switch.
On trigger gun models hold the trigger gun valve
in open position.
8. Turn off the switch just prior to running out of
antifreeze mixture.
9. Disconnect gun and hose.
10. Place machine and battery in a dry place protected
from weather conditions.
STORAGE
FLUSHING

Maintenance Schedule
6
Machine Maintenance Schedule
x
MACHINE MAINTENANCE SCHEDULE
EACH HR AFTER FIRST EVERY EVERY EVERY
DAILY 8 HRS 50 HRS 50HRS 100 HRS 500 HRS YEARLY
ENGINE DRIVEN OIL FIRED COLD WATER
CLEANERS
OIL BATH WATER PUMP:
Oil Level - check and add as needed per PUMP
SERVICE insert.
Oil Change- drain and refill per PUMP SERVICE
insert. CAUTION: Used oil must be disposed into
an enviromental safe container and brought to an oil
recycling center.
Oil contamination- Milky color indicates water.
HOSES:
Blistering, Loose Covering
Abrasion of cover exposing reinforcement.
Cuts exposing reinforcement.
BELTS:
Cracks or fraying
Belt Tension- For correct tension, see MACHINE
MAINTENANCE insert.
LEAKS:
Check for water and buildup of scale at pipe
connections.
SCREEN-WATER:
Check Inlet Hose Screen for debris.
Check float Tank Hose Screen ( if so equipped)
for debris.
Check Water Filter (if so equipped) for debris see
breakdown elsewhere in this manual.
SPRAY TIP:
Check tip for debris.
GUARDS AND SHIELDS:
Check that all guards and sheilds are in place and
secure.
PUMP MOTOR WITH GREASE FITTINGS:
Remove drain plug. Use 1 or 2 full strokes of shell
“DOBLIUM RB”, Cheveron”SR1 No.2” or Texaco
“PREMIUM RB”. Operate for 20 minutes and replace
drain plug.
FREEZING TEMPERATURES:
Freezing temperatures break coils and water
pumps. See STORAGE in the MACHINE MAINTE-
NANCE section for cold weather instructions.
Supersedes 11-23-03 Z08-02767 05-12-06 Z08-02767

Troubleshooting 7
Machine Maintenance Trouble Shooting
ENGINE DRIVEN COLD WATER CLEANERS
1. Poor cleaning
action.
2. Machine will not
draw chemical.
3. Low operating
pressure.
4. Excessive,
unusual noise.
5. Belts slipping.
A. Hard water.
B. Low pressure.
C. Little or no chemical being drawn.
D. Improper chemical.
E. Improper chemical mixture.
F. Low discharge pressure.
A. No chemical solution.
B. Metering valve not open.
C. Chemical line strainer clogged.
D. Air leak in Chemical line.
E. Metering valve clogged.
A. Insufficeint water supply.
B. Incoming water hose too small.
C. Water supply hose too long.
D. Belt slippage.
E. Worn belt.
F. Spray tip worn or wrong size.
G. Dirty or worn check valves in water
pump.
H. Water supply hose kinked.
I. Inlet filter screen clogged.
J. Motor runs slow.
K. Air leak in inlet plumbing.
L. Defective water pump.
M. Leaking discharge hose.
N. Chemical metering valve open and
sucking air.
O. Defective unloader.
A. Pump.
B. Defective motor.
C. Pulleys rubbing.
D. Misalignment of pump &motor
A. Belts too losse.
B. Excessive back pressure.
C. Defective water pump.
A. Connect the machine to a water softner.
B. See “Low operating pressure.”
C. See “machine will not draw chemical.”
D. Obtain proper chemical.
E. Mix chemical per the label. Follow all the mixing,
handling, application,and disposal instructions.
F. See “Low operating pressure.”
A. Replenish supply.
B. Turn metering valve knob to open.
C. Remove screen and cleaan.
D. Tighten all fittings and hoses for the chemical line.
E. Disassemble and clean.
A. The water supply must meet or exceed the maximum
discharge volume specified in the PERFORMANCE
section, and minimum water inlet pressure specified
in the General section of the MODEL SPECIFICATIONS
section.
B. Use larger water supply hose.
C. Use shorter water supply hose.
D. Tighten belt per instructions in MACHINE
MAINTENANCE insert.
E. Replace bely per CLEANER EXPLODED VIEW.
F. Replace with spray tip specified in the GENERAL
section of MODEL SPECIFICATIONS.
G. See PUMP TROUBLE SHOOTING.
H. Straighten hose.
I. Clean water filter screen or hose inlet screen.
J. See “Pump engine starts slow or overheats and
stops.”
K. Tighten all fittings.
L . See PUMP TROUBLESHOOTING.
M. If a water leak is found, DO NOT OPERATE THE
MACHINE. Disconnect the power andreplace hose.
N. Resupply chemical, place soap screen in water, or
shut off metering valve.
O. Repair or replace unloader valve.
A. See PUMP TROUBLESHOOTING.
B. Call service technician or take engine to Reapir/
Warranty station.
C. Adjust shields or pulley(s).
D. Realign pump and engine.
A. Tighten per instruction on MACHINE MAINTENANCE.
B. See “Excessive Back Pressure.”
C. See PUMP SERVICE.
REMEDY
CLEANER TROUBLESHOOTING
POSSIBLE CAUSE
TROUBLE
Supersedes 01-16-04 Z08-02768 05-09-06 Z08- 02768
x

Troubleshooting
8
Machine Maintenance Trouble Shooting Continued
A. Spray tip built up with lime.
B. Water pump turning too
fast.
.
A. Defective belt.
B. Defective Pump.
C. Defective accumalator.
A. Clogged spra tip.
B. Worn or incorrect spray tip.
A. No fuel
B. Plugged fuel filter.
C. Defective or corroded
battery cable
D. Defective engine.
A. Improper fuel.
B. Excessive back pressure.
C. Defective engine
D. Dirt in fuel line or filters.
E. Incorrect oil level
F. Engine overloaded.
G. Dirty air cleaner.
H. Faulty spark plug.
A. Remove and clean, or replace spray tip with tip
specified in GENERAL section of MODEL
SPECIFCATIONS.
B. See MODEL SPECIFICATIONS.
A. Remove and replace using belt specified in
CLEANER EXPLODED VIEW or the GENERAL
section of MODEL SPECIFICATIONS.
B. See PUMP TROUBLESHOOTING.
C. Recharge/replace.
A. Remove and clean spray tip per SPRAY TIP
MAINTENANCE in MACHINE
MAINTENANCE.
B. Remove and replace with tip specified in the
GENERAL section of MODEL
SPECIFICATIONS or MODEL EXPLODED.
A. Replenish fuel as specified in engine owners
manual.
B. Change engine fuel filter.
C. Drain and replenish fuel.
D. Clean cables and cable ends.
E. Call service technician.
A. Replenish fuel as specified in engine owners
manual.
B. See “Excessive Back Pressure.”
C. Call service technichian, or take engine to
Repair/Warranty station.
D. Clean line or replace filter.
E. Check oil level per engine owners manual.
F. See “Excessive Back Pressure”
G. Change air cleaner filters per engine owners
manual.
H. Change plug and set gap per engine owners
manual.
CLEANER TROUBLESHOOTING (CONT.)
ENGINE DRIVEN COLD WATER CLEANERS
TROUBLE POSSIBLE CAUSE REMEDY
6. Excessive back
pressure.
7. Excessive
vibration.
8. Spray pattern is
broken or
irregular.
9. Engine will not
start.
10. Engine starts
slow or overheats
and stops.
x
Supersedes 01-16-04 Z08-02769 05-09-06 Z08- 02769

9
Final Assembly
Final Assembly
7
3
5
4
1
6
2
SERIAL NUMBER
WATER
INLET
WATER
OUTLET
33 7/8"
37 13/16"
FINAL ASSEMBLY
p/n 435EK-000000
07/08/2014
ITEM
NO. PART NUMBER PART DESCRIPTION QTY.
1 435EK-00603 ASSEMBLY, GENERAL 1
2 2102-00710 ASS'Y, HOSE - 3/8 X 50' 100R1 1
3 D02-00001E DECAL, SERIAL NO 1
4 EM325GC-00701 ASSEMBLY, TRIGGER GUN &
WAND 1
5 F04-00451 GROMMET, RUBBER 4
6 JA0-150402TIP, SPRAY 1
7 JA0-65400-2B TIP, SPRAY 1
24 13/16"

10 Gun & Wand
Gun & Wand Assembly
2
1
3
3/4/2013
p/n: EM325GC-00701
ASSEMBLY, TRIGGER GUN & WAND
ITEM
NO. PART NUMBER PART DESCRIPTION QTY.
1 J06-00331 LANCE, SPRAY - 36" 1
2 JA6-00138 GUN,TRIGGER,8GPM,4000PSI,
3/8"IN X 1/4"OUT,320DF 1
3 W04-24225-A COUPLER, 1/4F X 1/4FNPT 1
2102-00710 PART LIST
ITEM PART NUMBER PART DESCRIPTION
1 W04-31231-B Coupler, 3/8M X 3/8FNPT
2 K02-03150E5 Assembly, Hose – 3/8 X 50’

11
Gun & Wand
9
Trigger Gun & Wand
INJ, CHEM - DOWN STREAM
p/n: J06-00244
10/21/2009
ITEM
NO. PART NUMBER PART DESCRIPTION QTY.
1 J06-00234 INJECTOR, CHMICAL - 3 - 5
GPM 3500 PSI 2.1MM ORIFICE 1
2C04-00130 STRAINER, W/CHECK VALVE -
1/4" BARB 1
3 Z01-08413-2 HOSE, POLYBRAID - 1/4 X 84" 1
1
3
2
Downstream Injector Operation
A downstream injector works by maintaining a certain psi on the pump side of the injector by means of an orice
installed into the injector body. When the psi drops by at least a 30% differential on the outlet side of the injector
it creates a vacuum draw that pulls your pre mixed chemical solution into the injector body and mixes it with the
ow of water traveling through the injector and out the hose and gun assembly of the pressure washer.
Pressure Washer Chemical Injector Kit consists of the chemical suction screen, 6 FT of clear tube, adjustable
knob, injector and 3/8” quick connect couplers.
Operation:
1. Quick connect the pressure washer chemical injector on the outside (discharge side) of the pump.
2. Place the soak suction lter into a container chemical and attach the black low pressure soap
nozzle to the tip of the wand.
3. Start your pressure washer as normal and the pressure washer chemical injector will do the rest.
You are always supposed to soap from the bottom up and rinse from the top down.
4. When you are done applying cleaning solution onto the surface, turn off the chemical adjustable
knob and replace the soap nozzle with a 0º (red color) or 15º (yellow color) nozzle to remove
loosened dirt.
You should never use anything but pressure washer safe cleaning solutions. Use of other chemicals such as
bleach will damage seals and o-rings in the gun, wand, hoses and pumps. What chemicals can be used? Use
only chemicals designed for pressure washer use (pressure washer approved). They will not damage your
pressure washer, plus they are biodegradable and environmentally friendly.
Turn counter -clockwise
to start drawing chemical.
Chemical Injector
J06-00244
Chemical Injector - P/N J06-00244

12 General Assembly
General Assembly
3
6
5
4
1
7
2
10
8
9
ASSEMBLY, GENERAL
p/n: 435EK-00603
9/30/2013
ITEM
NO. PART NUMBER PART DESCRIPTION QTY.
1 445EH-00130 WELDMENT, FRAME 1
2435EK-00501 ASSEMBLY, PUMP 1
3 AR58-02400 ROD, CRS - 5/8" X 24 1/2" 1
4 F05-00559 9.5HP KOHLER 1
5G02-00018A ASS'Y, TIRE & RIM - 10" 2
6 H04-31316 SCREW, CAP - 5/16-18 X 1 1/2
HEX HEAD 4
7 H06-31300 NUT, LOCK - 5/16" 5
8 H06-62503 COLLAR, SHAFT - 5/8" 2
9 H10-31302 MOUNT,RUBBER-WASHER
5/16 DIA. HOLE 1
10 Z01-00029 CAP, VINYL - ROUND 2

13
Pump
ASSEMBLY, PUMP
p/n: 435EK-00501
7/08/2014
ITEM
NO. PART NUMBER PART DESCRIPTION QTY.
1 N07-00238EP1508G8 WATER PUMP 1
2E10-00005-4 TEE, PIPE 1
3 W02-10030-8 BARB, HOSE 1
4 E14-00010-68 NIPPLE, HEX - 3/8MNPT 1
5 E15-00010-48 NIPPLE, CLOSE - 1/2"NPT 1
6 C04-00121 SCREEN, GARDEN HOSE 1
7 C05-00270-1 NUT, GARDEN HOSE 1
8 C05-00270-2 ADAPTER, SWIVEL 1
9 K33-00900 HOSE, WATER - 3/8 X 9" 1
10 W02-00032 CLAMP, HOSE 2
11 C07-04504-A VALVE, UNLOADER 1
12 E08-00011-58 ELBOW, PIPE 1
13 W04-34135-A COUPLER, 3/8F x 3/8NPT 1
14 W02-10021-8 BARB, HOSE 1
9
11
4
2
12 1
10
5
10
8
6
7
13
14
Water Pump

14 Unloader
Specications
Maximum Flow 10.5 gal/m / 40L/m
Unloading Press
Rated 4050 psi / 280 bar
Max 4500 psi / 310 bar
Maximum
Temperature 195˚F / 88˚C
Weight 1.54 lbs / 700 G
Bypass 3/8 FNPT
Inlet 3/8 FNPT
Discharge 3/8 MNPT
Valve, Unloader
p/n C07-04504M-A
PULSAR4HPM
GENERAL PUMP A member of the Interpump Group
Trapped Pressure Unloader Valve
DIMENSIONS
SELECTION
This product is intended to be incorporated on a finished machine. This product is to be used with clean fresh water, for use involving different or
corrosive liquids, contact the GP Customer Service Department. Appropriate filtration should be installed when using impure liquids. Choose the valve
appropriate to the working data of the pump (permissible pressure, flow and rated temperature of the system). The pressure of the pump must not
exceed the maximum pressure of the valve.
OPERATION
The valve regulates the maximum pressure of the system by varying the flow discharged by the bypass. The adjustment is made by altering, by means
of a piston, the position of a sphere which partially closes the bypass opening. The valve is sensitive to water flow. At gun opening, the water flows
through the valve which maintains the system in pressure until the gun closes, the interruption of the flow provokes the complete aperture of the
bypass which allows to discharge the flow at low pressure. At gun closure, the special mechanism of zero setting, which does not include a check
valve, keeps in connection the delivery line and the bypass line, in that way permitting to lower the pressure all around the system and not only in the
source line of the valve.
SELECTION AND OPERATION
INSTALLATION
This valve, on a system that produces hot water, must be fitted upstream from the source of heat. On a system that generates hot water, it is advisable
to use accessories that limit the accidental increase of fluid temperature. Always install a safety valve. We recommend the use of a nozzle with flow
rate which allows a regular discharge from the valve bypass of at least 5% of the flow supplied by the pump. In order to achieve a constant pressure
and easy adjustment. If the nozzle wears out, the pressure decreases. To reset pressure back to working level, it is necessary to replace the worn
nozzle. When a new nozzle is fitted, resetting of the system to its original working pressure is required.
DISCHARGE SYSTEM AND WATER ADDUCTION
The bypass discharge can be sent back to the pump intake or returned into a tank; in such cases it is advisable that the tank be fitted with baffles to
reduce eventual turbulence and air bubbles which could be harmful to the pump.
PRESSURE ADJUSTMENT/CALIBRATION
The desired working pressure must be adjusted with the system running and the gun opened. Adjust the pressure by screwing or unscrewing the
adjustment screw. The operation is easier if the correct nozzle has been chosen (see above). When screwing the adjustment screw a consequent
pressure increase must be matched. If, before reaching the desired pressure, there is no pressure increase, DO NOT FORCE. Rather, check the
correct ratio of nozzle/flow rate - pressure and, if necessary, replace with a smaller size nozzle.
ATTENTION: the nut in position 23 is a mechanical security device that limits the maximum pressure; it must absolutely NOT be removed.
Ref 300938 Rev. A
11-13
Specications
Unloader

15
Unloader
Valve, Unloader
p/n C07-04504M-A
ATTENTION: the nut in position 21 is a mechanical security device that limits the
maximum pressure; it must absolutely NOT be removed.
MAINTENANCE STANDARD: every 400 working hours, check and lubricate the seals with
water resistant grease.
NOTE: CONVERTING
C07-04504-A to C07-04504M-A
Replace outlet tting item #24 p/n C07-04500-17 with item #20 C07-04505M-10
NOTE: Outlet connection ttings will have to be changed.
Item Part Number Description Qty Kit
1C07-04504-11 Guide, Piston 1
2C07-04504-01 O-Ring 2*
3C07-04504-09 Piston – SS 1
4C07-04504-02 Ring, Back-Up 1 *
5N07-20028 O-Ring 1 *
6 ------------------- Housing 1
7C07-04500A-05 Kit Seat & O-Ring 1 *
7A C07-02300-08 O-Ring 1/16CS x 11/16OD 1
9C07-04500-03 Ball, SS-13/32 1
10 C07-04504-03 Spring, 1.6x11x20MM 1
11 C07-04504-04 Coupling, Inlet 3/8 NPT 1
12 N16-28110084 Washer, Flat 2
13 C07-04504-05 Plug-3/8NPT 2
14 C07-04504-07 Ring, back-up 1 *
15 P04-00215 O-Ring, 1.78 x 6.07mm 1 *
16 C07-04504-08 O-Ring, 3 x 6mm 2 *
17 C07-04504-12 Valve, Check 1
18 C07-01009A-18 Spring, Compression 1
19 C07-04504-16 O-Ring, 1/16cs x 5/8 1 *
20 C07-04504M-10 Fitting, Outlet – 3/8”M 1
21 C07-04504-14 Nut, Hex 2
22 C07-04504-13 Follower, Spring 1
23 C07-04504-15 Nut, Hex - Brass 1
24 C07-04500-13 Spring, Comp. Blue 1
C07-9904504 Kit, Repair - Parts
Package *
Parts List

16 Unloader
Valve, Unloader
p/n C07-04504M-A
PULSAR4HPM
FLOW SENSITIVE FLOW SENSITIVE
• NEW improved design!
• Reduced pressure loss
• Makes for easier gun operation
• Extremely reliable
• Easy maintenance
GENERAL PUMP A member of the Interpump Group
FEATURES
PARTS LIST
SPECIFICATIONS
Trapped Pressure Unloader Valve
8
General Pump
is a member of
the Interpump Group
ITEM PART # DESCRIPTION QTY
1 Y60014631 Piston Holder, Brass 1
2* Y10306401 O-ring, 1.78x14mm 2
3 Y60002151 Piston, SST, R 1
4* Y10402100 Back-up Ring, 11.5x15.9x1.2mm 1
5* 701111 O-ring, 2.62x10.77mm 1
6 Y60013635 Housing, 3/8” NPT-F, Brass 1
7* Y60025920 Seat, 8mm + O-ring, 1.78mm 1
9* Y14746100 Ball, 13/32”, SST 1
10 Y60041051 Spring, 1.6x11.5x20mm, SST 1
11 Y60013731 Inlet Coupling, 3/8 NPT-F, Brass 1
13 Y60002531 Grub Screw, 3/8N NPT 2
14* Y10400601 Back-up Ring, Opn, 6.2x9x1.2mm 1
15* Y10305101 O-ring, 1.78x6.07mm 1
16* Y10321300 O-ring, 3x6mm 2
17 Y60005299 Shutter Pin, Brass + O-ring 3x6mm 1
18 Y60005351 Spring, 0.7x9x20 SST 1
19* Y10306601 O-ring, 1.78x15.6mm, Ni 1
20 Y60103931 Nipple, 3/8 NPT-M 1
21 Y11457400 Hex Nut, M8 2
22 Y60001131 Spring Holder Ring, Brass 1
23 Y11457631 Hex Nut, M8, Brass 1
24 Y60003361 Spring, 5.7x26x53mm, Blue, PULSAR4HP 1
30 Y10440900 Seat Frame 1
* YKITPULSAR4 Spares Kit 1
General Pump
recommends using a
safety relief device in
conjunction with
this unloader valve
when installed on a
positive displacement
pump. General Pump is
not liable and assumes
no responsibility when
used in a customer’s
high pressure system.
Ref 300938 Rev. A
11-13
PART NUMBER PULSAR4HPM
Maximum Volume 10.5 GPM
Rated Pressure 4050 PSI
Maximum Pressure 4500 PSI
Maximum Temperature 195o
Note: The valve has been designed for continuous use at a water temperature of 140oF.
It can operate for short periods at a maximum temperature of 195oF.
Port Sizes Inlet (2) 3/8” NPT-F
Outlet 3/8” NPT-M
Bypass (2) 3/8” NPT-F
Overall Dimension 6.79” x 3.25” x 1.97”
Weight 1.5 Lbs.
UNLOADER PRESET AT FACTORY – DO NOT READJUST
Unloading Adjustment – Adjustment only after repair or replacement
1. Install an appropriate pressure gauge in pump head outlet. The gauge should
have a range twice the operating pressure.
2. Install the spray nozzle in the end of the wand.
3. Ensure the relief valve is set properly.
4. Loosen top lock nut (upper Item 21) and turn the nut (lower Item 21) counter
clockwise until minimum spring tension.
5. With machine turned on, open the trigger gun, start the pump, and observe
pressure gauge reading. Slowly loosen the nut (lower Item 21) until pressure
starts to drop on the gauge.
6. Tighten adjusting nut (lower Item 21) on the unloader. Pressure should start to
increase. Tighten adjusting nut (lower Item 21) until pressure stops climbing.
7. Close and open the trigger gun to check unloading pressure and bypass function
of the unloader valve. The unloading pressure should not exceed operating
pressure more than 400 PSI.
8. Lock the setting by tightening the lock nut (upper Item 21).
Maintenance - Exploded View