Case HI C4015RAHW User manual

User Manual
HOT WATER WASHER
85.610.521

2
TABLE OF CONTENTS
Introduction & Product Info
3 Introduction & Product Specifications
Important Safety Warnings
4 Important Safety Warnings & Symbols
Getting to Know Your Washer
7 Product Features & Components Diagram
Before Starting The Unit
8 Pre-Operation Safety & Inspection Procedures
Quick-Connect Nozzle Review
9 Spray Tip Overview & Applications
Connecting To Water Supply
10 Water Supply & Pump Cooling
Start-Up & Operation
11 Start-Up Procedure Preparation
12 Starting The Unit
Hot Water Operation & Detergent Usage
13 Hot Water Operation & Detergent Use
Shutting Down & Storage
14 Shutting the Unit Down & Storing It
Maintenance
15 Specific Maintenance
16 Maintenance Schedule
Troubleshooting
17-19 Troubleshooting Table
Unit Breakdowns
20 Unit Breakdown
21 Reference List
22 Frame Breakdown
23 Reference List
Burner Breakdown
24 Burner Breakdown & Parts List
25 Burner Wiring Diagrams
Pump Breakdowns
26 General EZ4040 Breakdown
27 AR RSV4040 Breakdown

3
INTRODUCTION & PRODUCT INFO
Using the Operator’s Manual
Thank you for purchasing our hot water pressure washer! This operating manual is an
important part of the unit. It should be read thoroughly before initial use, and referred to
often to make sure adequate safety and service concerns are being addressed.
Reading the owner’s manual thoroughly will help avoid any personal injury or damage
to your pump, engine, and other components. By knowing how best to operate this
machine you will be better positioned to show others who may also operate the unit.
You can refer back to the manual at any time to help troubleshoot any specific operating
functions, so store it with the machine at all times.
ATTENTION: Read through the complete manual
prior to the initial use of your pressure washer.
Record Identification Numbers
If you need to contact an Authorized Dealer or Customer Service line (1-866-850-6662)
for information on servicing, always provide the product model and identification
numbers.
You will need to locate the model and serial number for the pump and record the
information in the spaces provided below.
Date of Purchase:
Dealer Name:
Dealer Phone:
PRODUCT IDENTIFICATION NUMBERS
Model Number:
Serial Number:
PRODUCT SPECIFICATIONS
MODEL GPM PSI CC’S ENGINE BTU/HR PUMP
MODEL DRIVE BURNER FUEL CONS.
UNIT
DIMENTIONS
SHIPPING
DIMENSIONS
SHIP WT
(LBS)
C4013HGHG 4 4000 389 HONDA
GX390 330,000
GENERAL
PUMP
EZ4040
DIRECT 2.21 GPH 47”L X 31”W
X 50”H
52”L X 36”W X
55”H 530
MODEL GPM PSI CC’S ENGINE BTU/HR PUMP
MODEL DRIVE BURNER FUEL CONS.
UNIT
DIMENTIONS
SHIPPING
DIMENSIONS
SHIP WT
(LBS)
C4015RAHW 4 4000 420 POWEREASE 330,000 AR RSV
4G40 DIRECT 2.21 GPH 47”L X 31”W X 50”H
52”L X 36”W X
55”H 530

4
IMPORTANT SAFETY WARNINGS
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
explosion fire
toxic fumes
hot surface
flying objects injection
moving parts
electric shock
DANGER This is indicates a hazard which, if not avoided, will result in serious
injury or death.
WARNING This indicates a hazard which, if not avoided, will result in a severe injury or
property damage.
CAUTION This indicates a hazard which, if not avoided, might result in a minor or
moderate injury.
NOTICE This indicates a situation that could result in equipment damage or damage
to other property. Ensure all safety messages are observed and adhered to.
Hazard Symbols and Meanings
DANGER
• Always operate the pressure washer in a well-ventilated area free of flammable vapors, combustible
dust, gases, or other combustible materials.
• Do not store the pressure washer near an open flame or any equipment such as a stove, furnace, water
heater, etc., which utilizes a pilot light or sparking device.
• Do not use this pressure washer to spray flammable material.
• Do not smoke while filling burner fuel tank.
• Never fill the fuel tanks while the pressure washer is running or hot. Allow unit to cool for two minutes.
• Always refuel slowly to avoid the possibility of spilled fuel which may cause a risk of fire.
• Always leave room for fuel to expand in the gas tank. Do not overfill.
• Engine Fuel Tank: If using a Gasoline Engine, refuel with gasoline only. Do not use diesel or kerosene.
• Burner Fuel Tank (Black): When refueling the Burner Fuel Tank, use No. 1 or No. 2 fuel oil/diesel or
kerosene. Do not use gasoline.
• Do not operate the unit if gasoline or diesel fuel is spilled. Wipe the pressure washer clean and move it
away from the spill. Avoid creating any ignition until the gasoline or diesel fuel has evaporated.
• When the battery is being activated, hydrogen and oxygen gases in the battery are extremely
explosive. Keep open sparks and flames away from the battery at all times, especially when charging.
• Be certain to disconnect the battery ground terminal before servicing. When disconnecting the cable
from the battery, start with the negative terminal. When connecting them, start with the positive cable.
• When charging the battery, remove the battery vent plugs.
• Use only a voltmeter or hydrometer to check a battery charge.
• DO NOT jump start the battery unless both batteries are of equal voltage and amperage.

5
IMPORTANT SAFETY WARNINGS
WARNING
Serious injury or death may occur from a fire caused by a muer spark.
Serious injury or death may occur if system safety’s are not properly maintained.
• A spark arrester must be added to the muer of this engine when using on land covered with any
flammable agricultural crop (hay and grain), and if they are used in or near brush or forested areas. The
arrester must be maintained in eective working order by the operator of the equipment. In the state
of California, the above is required by law. (Section 4442 and 4443 of the California Public Resources
Code.) Other states/provinces may have similar laws. Federal laws apply on Federal lands.
• This pressure washer has a Safety Relief Valve . This should never be altered, modified, removed or
made inoperative. If the device fails, replace immediately with genuine manufacturer replacement part.
WARNING
Serious injury or death may occur from inhaling engine/burner exhaust or dangerous
vapors. The engine exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
• Never operate this pressure washer in an enclosed area. Always ensure there is adequate ventilation
(fresh outside air) for breathing and combustion. This will prevent the buildup of dangerous carbon
monoxide gases. Beware of poorly ventilated areas, or areas with exhaust fans which can cause poor
air exchange. This unit should only be used outdoors to ensure ventilation is never an issue.
• Follow all safety instructions provided with the materials you are spraying. Use of a respirator may be
required when working with some materials. Do not use this pressure washer to dispense hazardous
detergents.
WARNING
Serious injury or death could occur from high pressure spray penetrating the skin.
• Keep clear of nozzle and spray! Never put your hand, fingers or body directly over the spray nozzle.
• Do not direct discharge stream at self, other persons, or pets.
• This product is to be used only by trained operators.
• Always keep operating area clear of other people.
• Do not allow children to operate this unit or be in the vicinity while you operate it.
• Seek emergency medical care if spray seems to have penetrated the skin. Do not treat as a simple cut!
• High pressure hoses and fuel lines should be inspected daily for signs of wear. If evidence of failure
exists, promptly replace all suspect hoses and fuel lines to prevent the possibility of injury from the
high pressure spray. If a hose or fitting is leaking, do not place your hand on the leak.
• Never operate the gun with the trigger held in the open position. To prevent accidental discharge, the
trigger gun should be securely locked when not in use.
• Before removing the spray nozzle or servicing the unit, always shut the unit o and pull the trigger of
the gun to release trapped pressure (even after you shut o the unit, there is high pressure water left in
the pump, hose and gun until you release it by pulling the trigger the gun).
WARNING
Serious injury or death may occur from contact with electricity.
• Do not direct spray on or into electrical installations of any kind! This includes electrical outlets, light
bulbs, fuse boxes, transformers, and the unit itself.
• Do not allow metal components of the pressure washer to come in contact with live electrical
components.

6
IMPORTANT SAFETY WARNINGS
WARNING
Serious injury may occur from touching the gasoline engine, muer, or heat exchanger.
These areas can remain hot for some time after the pressure washer is shutdown.
• Never allow any part of your body to contact the gasoline engine, muer, or heat exchanger.
WARNING
Serious injury may occur to the operator from moving parts on the pressure washer.
• Before making any adjustments, be certain the engine is turned o and the ignition cable(s) is
removed from the spark plug(s). Turning the machinery over by hand during adjustment or cleaning
might start the engine and machinery with it.
• Do not operate the unit without all protective covers in place.
WARNING
Serious injury may occur from a pressure washer malfunction or exploding accessories if
incorrect system components, attachments, or accessories are used.
Serious injury or death may occur if attempting to start the pressure washer when the
pumping system is frozen.
• Never make adjustments to the factory set pressures.
• Never exceed manufacturers maximum allowable pressure rating of attachments.
• Do not allow any hoses to make contact with heat exchanger to prevent the possibility of bursting.
Avoid dragging the hoses over abrasive surfaces such as cement.
• Use only manufacturer recommended repair parts for your pressure washer.
• In freezing temperatures, the unit must always be warm enough to ensure there is no ice formation
in the pump. Do not start the pressure washer if it has been transported in an open or under heated
vehicle without first allowing the pump to thaw.
WARNING
Serious injury or death may occur from detergents contacting the skin.
Serious injury can occur from loose debris being propelled at a high speed from the spray
gun.
Injury may occur if the operator loses their balance caused by the thrust of water traveling
through the spray nozzle.
• Never use any solvents or highly corrosive detergents or acid type cleaners with this pressure washer.
• Protective equipment such as rubber gloves and respirators are advisable, especially when using
cleaning detergents.
• Keep all detergents out of the reach of children!
• Always wear protective goggles when operating the unit to shield the eyes from flying debris and
detergents.
• Do not direct spray toward fragile materials such as glass.
• Stay alert: watch what you are doing. Do not operate the unit when fatigued or under the influence of
alcohol or drugs.
• Never squeeze the trigger unless securely braced.
• Do not overreach or stand on unstable support.
• Wet surfaces can be slippery. Wear protective foot gear and keep good footing/balance at all times.
• Never pull the trigger of the gun while on a ladder, roof, or other unstable surface.
• Always hold on firmly to the gun/lance assembly when starting and operating the unit. Failure to do so
can cause the lance to fall and whip dangerously.
• Do not leave pressurized unit unattended. Shut o the pressure washer and release trapped pressure
before leaving.
• Do not operate the unit if you see any fuel, oil, or water leaking from the machine. DO NOT resume
operation until the unit has been inspected and repaired by a qualified technician.
• Do not transport the unit by pulling on hoses or cords.

7
GETTING TO KNOW YOUR WASHER
HEATING COIL
1/2” Heavy-duty schedule 80
American made Carbon Steel
Cold-rolled pipe, no weak points
from heating to make bends
5500 PSI Rated, “Full Sized” 96’
length for maximum heat rise and
proper heat production
Stainless steel coil skin
provides extra durability and resists
corrosion
Adjustabke thermostat
up to 200°F with LED rocker switch
and hour/tach meter
American made
heavy-duty 7000 PSI rupture disc Heavy-duty roll-cage
powder coated 1.5” OD
steel tube frame, with centre
balanced lift hook (above
industry standards)
Honda GX390 /
Powerease Engine
electric start w/ 18 amp charge
Triplex direct-drive pumps carry
a 5-year warranty
Adjustable pressure
relief valve
12” oil drain hose for
ease of maintenance
7 Gallon, removable,
rust-proof polyethylene
fuel tank with fuel gauge in cap
Marine sealed battery box
with 55 AH AGM deep cycle battery
3/4” HD Threaded
mount axle
Brake assembly
12V DC oil-fired
becket burner with low
voltage inhibitor, prevents
burner from starting up if
battery voltage is dropped
Mounting bracket
for truck mounting 13” heavy-duty
flat free tires

8
PRE-OPERATION SAFETY
1. This unit should only be placed on a level surface to ensure proper lubrication for the
water pump while operating. Placing the unit on a level surface will also ensure that
fuel, oil, and other fluids don’t spill during operation. NEVER spray water directly on
the unit.
2. Do not use unit in an area:
a. with insucient ventilation.
b. where there is evidence of oil or fuel leaks.
c. where flammable gas vapors may be present.
This unit has multiple ignition sources that could cause a fire or explosion.
3. If using a wheel kit, be certain to block the wheels to prevent the unit from moving
while operating.
4. Do not allow the unit to be exposed to rain, snow, or freezing temperatures. If any
part of the unit becomes frozen, excessive pressure may build up in the unit which
could cause it to burst. This would result in possible serious injury to the operator or
bystanders.
5. Pump oil level should be checked before each use. Make certain the oil is on the “Full”
mark on the dipstick or in the center of the oil sight glass. If the level appears to be
low, fill with SAE30W non-detergent pump oil.
6. Your pressure washer is equipped with an Electric Starter. On initial start-up, wear
proper eye and skin protection when filling the battery with acid. Fully charge the
battery to allow Electric Starter to function.
BEFORE STARTING THE UNIT
1. Review “Risk of Explosion or Fire” warnings, before fueling.
2. Locate the Safety Decals on your unit and heed their warnings.
3. Engines: See the included engine Owner’s Manual for fuel requirements.
Burner Fuel: When filling tank, use No. 1 or No 2 fuel oil/diesel or kerosene.
4. Check the engine oil level before starting the engine.
5. Review the Engine Manual accompanying this pressure washer for correct engine
start-up and maintenance procedures.
MANUAL & SAFETY REVIEW
PRE-START INSPECTION PROCEDURES
Before starting the unit, perform the following procedures:
1. Check the oil level and condition for the pump and engine. We recommend SAE
10W30 oil for engines and SAE 30 mineral oil for pumps.
2. Inspect the water inlet strainer. Clean or replace if necessary.
3. Check all hose connections to ensure they are securely tightened.
4. Inspect for system water leaks, oil leaks and fuel leaks. If a fuel leak is found, do not
start the unit. See “Risk of Explosion or Fire”, pg. 6. Be sure that all damaged parts
are replaced and mechanical problems are corrected prior to operation of the unit.
5. Inspect high pressure hoses for kinking, cuts, and leaks. If a cut or leak is found, do
not use the hose. Replace hose before starting unit. See “Risk of Injection” pg. 5.
Be sure that all damaged parts are replaced and that the mechanical problems are
corrected prior to operation of the unit.

9
QUICK-CONNECT NOZZLE REVIEW
HOW TO USE SPRAY TIPS
The quick–connect on the nozzle extension allows you to switch between five dierent
quick-connect spray tips. Spray tips can be changed while the pressure washer is
running once the spray gun trigger safety lock is engaged. The spray tips vary the spray
pattern as shown above.
FOLLOW THESE INSTRUCTIONS TO CHANGE SPRAY TIPS:
1. Pull back collar on quick–connect coupler and pull the current spray tip o. Store the
spray tips in the holder provided on the handle. Storing nozzles in the designated
holder will help prevent any debris from clogging the tip.
2. Select the desired spray tip:
• For a gentle rinse, select the white 40° spray tip.
• For light cleaning, select the green 25° spray tip.
• For high pressure cleaning, select the yellow 15° spray tip.
• To scour the surface, select the red 0° spray tip.
• To apply detergent, select the black spray tip. No other spray tip will draw soap.
3. Pull back on collar, insert spray tip and release collar. Tug on spray tip to ensure it is
securely in place.
USAGE TIPS
• For most eective cleaning, keep spray tip 8 to 24 inches away from cleaning surface.
• If the spray tip gets too close to the surface being cleaned, especially using a high
pressure spray tip (red or yellow), it may be damaged. Do not use the red spray tip on
glass. Doing so could result in broken or cracked glass.
0o
RED
40o
WHITE
Soaper
BLACK
15o
YELLOW
12
12 Operator's Manual
INSTALLATION & PREPARATION
WATER SUPPLY:
1. Select a water supply hose which is a quality grade of garden hose measuring
at least 3/4" ID and no longer than 50 feet.
2 Check the water inlet strainer to ensure it is clean and free of any obstructions.
As a strainer becomes obstructed, it restricts proper ow of water to the
pump. This can result in cavitations which will prematurely cause failure
of pump packings.
a. Using a screwdriver, remove the screen from the water inlet.
b. Clean or replace if necessary.
3. Connect the hoses.
a. Connect one end of the water supply hose to the water inlet of the unit.
b. Connect the other end of the hose to your pressurized water supply.
NOTE 1: Do not use a non-pressurized water supply (i.e. from a pond or
well) with this unit.
NOTE 2: When connecting the water inlet to the water supply mains, local
regulations of your water company must be observed. In some
areas, the unit must not be connected directly to the public drinking
water supply. This is to ensure there is no feedback of detergents
into the water supply. (Direct connection is permitted if a backow
preventer is installed. Check with local authorities for approval.)
NOTE 3: If there is a high mineral content in your water, it is highly
recommended that a water softener and an additional water strainer
be added to the water inlet to help prevent the possibility
of excessive scale buildup inside the heat exchanger coil. Clean
both strainers before starting your pressure washer.
NOZZLE REVIEW:
Various nozzles may be quick-connected into the end of the wand to change the
spray pattern or use the detergent feature. When using Quick Connects (Q.C.),
be certain the connection is securely locked. If not, the high pressure water
may shoot the nozzle from the wand, causing severe injury or serious damage.
To determine spray fan, refer to the actual number stamped on the nozzle. The
rst two digits indicate the spray fan in degrees, i.e.; 00=0”, 15=15°, 40=40°.
1. The 0° nozzle (RED): This is a blasting nozzle. It delivers a very concentrated
stream of water. Be cautious when using the straight narrow stream. It is
not recommended for use on painted or wood surfaces, or items attached
with adhesive backings. Uses: Removing weeds from sidewalk cracks,
stubborn stains from concrete, masonry, aluminum and steel, caked mud
from equipment, and cleaning lawn mower undersides.
2. The 15° nozzle (YELLOW): This is a chiseling nozzle. The spray should
be directed at a 45° angle to the surface and used like a scraper to remove
paint, grease and dirt. Uses: Surface preparation (removing mildew stains
and paint chips).
3. The 40° nozzle (WHITE):
This is a wash nozzle. This wide spray pattern disperses the water pressure
over a large area and is recommended for moderate washing. Uses: Washing
aluminum siding, cleaning windows, washing vehicles, spraying sidewalks,
driveways, and patios.
NOZZLE CONNECTION:
1. Be certain the trigger gun is locked in the “OFF” position. See WARNING, left.
2. The nozzle assembly should be disconnected from the gun/wand assembly
at this by retracting the locking ring on the quick-connect tting to remove
the nozzle.
WARNING
RISK OF INJECTION CAUSING
SEVERE INJURY!
NEVER LOOK DIRECTLY AT THE
NOZZLE ORIFICE UNLESS IT
IS DISCONNECTED FROM THE
GUN/WAND ASSEMBLY!
CONNECTION OF Q.C. NOZZLES
QUICK-CONNECT FITTING
WARNING
RISK OF SEVERE INJURY!
THE TRIGGER GUN SHOULD
ALWAYS BE LOCKED IN THE OFF
POSITION WHEN NOT IN USE!
QUICK-CONNECT (Q.C.)
0°
15°
40°
25o
GREEN

10
CONNECTING TO WATER SUPPLY
WATER SUPPLY
1. Select a water supply hose which is a quality grade of garden hose measuring at least
3/4” ID and no longer than 50 feet.
2. Check the water inlet strainer to ensure it is clean and free of any obstructions. As a
strainer becomes obstructed, it restricts the flow of water to the pump. This can result
in cavitations which will prematurely cause failure of pump components.
a. Using a screwdriver, remove the screen from the water inlet.
b. Clean or replace if necessary.
3. Connect the garden hose to the inlet of your high pressure pump. Thread the
connection together by hand until tight. Ensure the connection is tight at both ends
(at the pump inlet and at the water supply source).
4. Follow the incoming water requirements listed below:
a. Water pressure must be a minimum of 20 pounds per square Inch (PSI) and a
maximum of 125 PSI. (A typical outdoor faucet will generally supply this PSI if turned
completely “ON”.)
b. Incoming GPM (Gallons Per Minute) must be approximately one gallon more than
the outgoing GPM stated on the pressure washer nameplate. (You can check GPM by
timing how long it takes to fill a 5 gallon container).
5. Never allow the unit to operate without the incoming water line attached and the
water supply opened all the way.
NOTICE
• If there is a high mineral content in your water, it is highly recommended that a water
softener and an additional water strainer be added to the water inlet. This will help
prevent the possibility of excessive scale buildup inside the heat exchanger coil.
Pumps are water cooled. When the machine is running, ensure the trigger of the gun is
pressed to allow a constant flow of fresh water into and out of the pump. Do not let the
machine run for more than 30 seconds without pressing down on the trigger.
triplex pump
Most pumps are protected by a thermal valve. The thermal valve releases water if a
pump starts to run too hot. It will prevent catastrophic heat failure. However, the pump
may have suered damage and need maintenance, repair, or replacement. If it does not
reset and continues to leak water, the thermal valve may need to be replaced.
threaded into pump
with teflon tape
leaks water to
prevent overheating