HERO PW3540-AC User manual

H.E.R.O. Industries PW-3540-AC Pressure Washer Owners Manual
Page 1
H.E.R.O. Industries
a division of Middlefield Bancorp Limited
2719 Lake City Way,
Burnaby, B.C., Canada
Phone: ( 604 ) 420-6543 Fax: ( 604 ) 420-8725
Toll Free: 1-800-494-4376
E-mail: [email protected] Website: //www.hero.ca
U.S. mail: P.O. Box 75, Custer, WA 98240-0052

H.E.R.O. Industries PW-3540-AC Pressure Washer Owners Manual
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Table of Contents
Safety Instructions 3
Important Operating / Maintenance Precautions 4
Start-Up 4 – 5
Shutting Down 5
Nozzle Selection 6
Trouble Shooting 7
Pump Schematic & Parts List 8 – 10
Unloader and Injector Control Schematic & Parts List 11 - 13
Chassis Parts, Gun, & Hose 14
Pump Service 15
Accessories 16
Repair Kits 16
WARRANTY
This product is warranted to be free from defects in materials and workmanship under normal
use and service, for a period of two years from the date of purchase, when operated and
maintained in accordance with the Maintenance and Operation Instructions supplied with the
unit. The warranty does not cover misuse or negligence.
This warranty is extended only to the original purchaser. Hoses, spray guns, wands and other
accessories are warranted for 30 days. Warranty is void if repairs are attempted by anyone other
than an Authorized Service Center.
H.E.R.O. Industries liability under warranty is limited to repair of product and /or replacement
of parts, and is given to the purchaser in lieu of all other remedies including incidental and
consequential charges. There are no expressed warranties other than those specified herein.

H.E.R.O. Industries PW-3540-AC Pressure Washer Owners Manual
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IMPORTANT SAFETY PRECAUTIONS
This book has important information for the use and safe operation of this
machine. Read and understand all warnings before you start working.
Read all the instructions before using machine
To reduce risk of injury, close supervision is necessary when the machine
is used near children
Know how to stop the machine and bleed pressure quickly. Be quite
familiar with the Stay alert! Watch what you are doing.
Keep operating area clear of all persons.
Follow the maintenance instructions specified in the manual.
Do not operate the machine when fatigued or under the influence of alcohol
or drugs.
Do not overreach or stand on unstable support. Keep good footing and
balance at all times.
To prevent fire hazard, do not use with or near inflammables such as;
gasoline, grain dust, solvents and thinners.
Never add gasoline to a hot engine as this can result in a fire or explosion.
Never direct spray at pressure washer unit.
Warning
Risk of injection or injury.
Do not direct discharge stream at persons or animals. The high
pressure water stream can cause injury or death!
WARNING - WHEN USING THIS MACHINE:

H.E.R.O. Industries PW-3540-AC Pressure Washer Owners Manual
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Change oil in pump after the first 50 hours, then every 500 hours.
Use SAE30 Non-Detergent Motor oil.
Change engine oil as specified by the Honda. See Honda owners manual.
Do Not run washer longer than 3 minutes with gun closed, as this can result in damage to the
seals. Heat generated by the re-circulating water can damage seals.
Avoid freezing pump. Drain unit prior to storage, or run an antifreeze solution through pump.
Ensure the pump and hoses are completely bleed of all liquid.
1. Verify that the vented YELLOW dip stick is installed in
pressure washer pump. Remove the RED shipping plug
( if present ) from top of the pump and replace it with the
YELLOW oil level dipstick provided. Fig. 1
2. Before first use, check engine and pump oil levels.
Note: For shipping purposes, engine oil has not been
added.
Before each use, check engine oil level by unscrewing
the oil dipstick. Add motor oil (consult Honda manual
for correct grade) as required to bring to proper level,
approximately mid-way on dipstick.
3. Check water supply volume. To operate correctly, the unit
requires a water supply 25% greater than the units output.
( i.e. Model PW-3540-AC = 5 GPM, of water flow ).
To test water supply output;
a) Turn water flow to full maximum output.
b) Place a 5 gallon pail or container under water flow for
exactly 1 minute ( 60 seconds).
c) Measure contents to determine water flow.
4. Connect a standard garden hose to the water inlet or
bottom connection on the pump head ( Female hose
connector ). Fig. 2.
5. Connect the high pressure hose to the water “Outlet”
or upper connection on the pump head.
( Male quick connect nipple). Fig. 2.
6. Turn the unloader knob on top of the pump head counter-
clockwise to reduce the pressure prior to starting the
machine.
IMPORTANT OPERATION / MAINTENANCE PRECAUTIONS
START-UPAND OPERATION INTRODUCTION
Yellow
Red
Fig. 1
Fig. 2
Attach Garden Hose
Attach Pressure Hose

H.E.R.O. Industries PW-3540-AC Pressure Washer Owners Manual
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START-UPAND OPERATION INTRODUCTION
SHUTTING DOWN THE MACHINE AFTER USE
7. Select the desired tip for the job. Insert tip into wand ( quick-connect fittings ). See page 6.
RED-0º, Narrow Fan, Direct or Concentrated Cleaning.
YELLOW - 15º, Medium Fan, General Use.
WHITE - 40º, Wide Fan, Soft Pattern, For Rinsing.
BLACK - 65º, Chemical Injector Tip. Must be used when operating chemical injector
8. If you are not going to be using injector system, remove the injector components
from the out put side of the unloader. All components feature quick release
fittings. Store for future use.
9. Turn on the water supply and trigger the spray gun to purge all air from the sys-
tem, PRIOR to starting engine.
10. Start the engine by following this procedure:
- Turn the ON/OFF switch to ON.
- Turn the GAS to ON.
- Turn the CHOKE to FULL.
- Push the THROTTLE lever to the ON position.
- Pull the STARTING cord.
- Once the engine has started, reduce the CHOKE until it is OFF, and open the THROTTLE to
full ON. Use these instructions in conjunction with instructions provided in the Honda manual.
11. At this point, the gun is triggered to evacuate any remaining air in the system. Then trigger the
gun and begin turning the BLACK unloader knob in a clockwise direction as far as it will turn.
You should now have full pressure.
12. To introduce chemicals/detergent to the spray,
- Turn unit off, and trigger gun to relieve all internal fluid pressure.
- Re-connect the chemical injector components as removed in step 8.
- Connect the detergent/chemical suction line to the fitting marked “Injector” and place the filter
end into the chemical/detergent jug.
- Install “Black” injector tip into gun. VERY IMPORTANT.
- Re-start pump and set pressure to low.
Injector siphoning is best at very low pressure. Once the injector material stream has been
established, the pump operating pressure can be increased.

H.E.R.O. Industries PW-3540-AC Pressure Washer Owners Manual
Page 6
For your convenience, we have provided a selection of nozzles to choose from.
Your machine is equipped with a 0°, 15°, 40°, and a chemical nozzle.
If you require a different cleaning action, we suggest selecting the correct tip for the job.
1. RED = 0°Angle - High impact, solid stream.
2. YELLOW = 15°Angle - Narrow width spray pattern.
3. WHITE = 40°Angle - Wide width spray pattern.
4. BLACK = Chemical Injector
0° Angle 15° Angle 40° Angle
NOZZLE SELECTION

H.E.R.O. Industries PW-3540-AC Pressure Washer Owners Manual
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TROUBLE SHOOTING
FAULT CAUSE REMEDY
Pump running normally but
pressure does not achieve rated
pressure.
Pump sucking air.
Valves worn or dirty.
Insufficient water flow.
Unloader valve packing worn.
Nozzle incorrect or worn.
Worn piston packing.
Check that hoses and fittings
are air tight.
Check, clean or replace.
Increase water supply.
Check and replace.
Check and replace.
Check and replace.
Fluctuating pressure Valves worn, dirty or stuck.
Pump sucking air.
Worn piston packing.
Insufficient water flow.
Check, clean or replace.
Check that hoses and fittings
are air tight.
Check and replace.
Increase water supply. May
require new water supply
source.
Pressure drops after period of
normal use. Nozzle worn. Valves worn, dirty or stuck.
Unloader valve packing worn.
Worn piston packing.
Check and replace.
Check, clean or replace.
Check, clean or replace.
Check and replace.
Pump noisy Pump sucking air.
Valves dirty or worn.
Worn bearings.
Water too hot.
Check that hoses and fittings
are air tight.
Check, clean or replace.
Check and replace if necessary.
Reduce temperature.
Presence of water in oil High humidity in air.
Piston packing and oil seal
worn.
Check and change oil twice as
often.
Check and replace.
Water dripping from under
pump. Piston packing worn. The O-rings of piston guide or
retainer worn.
Thermal relief valve opened.
Check and replace.
Check and replace.
Check and replace.
Oil dripping. Oil seal worn. Check and replace.
Engine will not start. Low fuel level.
Low oil level.
Worn spark plug or gap.
Add fuel.
Add oil.
Replace.

H.E.R.O. Industries PW-3540-AC Pressure Washer Owners Manual
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PW3540-AC - WW965 Pump Assembly

H.E.R.O. Industries PW-3540-AC Pressure Washer Owners Manual
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Assy PW-3080 Pump Only, Less fittings
1 PW-44.1206.41 Manifold ( Ø 13 Piston ) 1
2 PW-99.3175.00 Screw 8
3 PW-96.7014.00 Washer 8
4 PW-90.3841.00 O-Ring Kit 123 6
5 Sold Only In Kit 123 – Part Number PW-RKI123 Kit 123 6
6 Sold Only In Kit 123 – Part Number PW-RKI123 Kit 123 6
7 Sold Only In Kit 123 – Part Number PW-RKI123 Kit 123 6
8 Sold Only In Kit 123 – Part Number PW-RKI123 Kit 123 6
9 PW-90.3847.00 O-Ring Kit 124 6
10 PW-98.2226.00 Cap Kit 124 6
11 PW-36.7115.01 Valve Unit Kit 123 6
12 PW-99.1807.00 Screw 4
13 PW-50.1500.74 Side Cover 1
14 PW-44.2118.01 Indicator Spacer 1
15 PW-90.4097.00 O-Ring 1
16 PW-91.8328.00 Bearing 1
17 PW-90.1614.00 Oil Seal Kit 23 3
18 PW-44.0100.22 Crankcase 1
19 PW-98.2103.00 Oil Dip Stick 1
22 PW-44.0501.66 Piston Guide ( Ø 13 Piston ) 3
23 PW-44.0300.22 Connecting Rod 3
24 PW-90.3920.00 O-Ring 1
25 PW-44.1600.22 Rear Cover 1
26 PW-99.1837.00 Screw 5
27 PW-90.3585.00 O-Ring 1
28 PW-98.2041.00 Cap 1
29 PW-97.7340.00 Piston Pin 3
30 PW-96.6967.00 Washer ( Ø 13 Piston ) 3
Assy PW-3110 Pump & Unloader Assembly, PW-3540-AC c/w thermal valve,
WW965
REF # PART # DESCRIPTION QTY

H.E.R.O. Industries PW-3540-AC Pressure Washer Owners Manual
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33 PW-44.0402.66 Plunger ( Ø 13 Piston ) 3
37 PW-50.2000.74 Foot 2
38 PW-96.7016.00 Washer 4
39 PW-99.3037.00 Screw 4
40 PW-90.3612.00 O-Ring Kit 125, 130, 152 - 156 3
41 PW-44.0803.70 Packing Retainer Ø 13 Kit 152, 156 3
42 PW-44.2162.70 Intermediate Ring Ø 13 Kit 154 – 156 3
43 PW-90.5076.00 Backup Ring Ø 13 Kit 153 – 156 3
44 PW-90.2602.00 Packing Ø 13 Kit 153 – 156 3
45 PW-44.10002.51 Head Ring Ø 13 Kit 155 – 156 3
46 PW-98.2100.00 Cap 1
47 PW-98.2176.00 Cap 1
48 PW-96.7380.00 Washer 1
49 PW-96.7514.00 Washer 1
50 PW-98.1966.00 Cap 1
51 PW-90.2603.00 Low Pressure Seal Ø 13 Kit 153 – 156 3
52 PW-1075 Valve, Thermal Protection, 1/2, 1
53 PW-1405 Tubing, P.R.V. 1
75 PW-90.0635.00 Circlip 1
76 PW-44.0221.65 Crankshaft, WW965, 1
77 PW-91.8568.00 Bushing 1
78 PW-90.4097.00 O-Ring 1
79 PW-99.2755.00 Screw 4
80 PW-96.7020.00 Washer 4
81 PW-10.0518.22 Motor Flange 1
82 PW-90.1690.00 Oil Seal 1
83 PW-96.6938.00 Washer 4
84 PW-99.1912.00 Screw 4
REF # PART # DESCRIPTION QTY
Part # Description Kit Ref# Included # Pieces
PW-RKI023 Repair Kit, Oil Seal, 2500, 3000 23 17 3
PW-RKI123 Repair Kit, Valve, 123 4,5,6,7,8,11 6
PW-RKI124 Valve Cap ( Brass ) & O-ring, 124 9, 10 6
PW-RKI125 Low Pressure Brass Ring & O-Ring 125 40, 41 3
PW-RKI152 Repair Kit, Packing, 13mm, 152 40, 41 3 each
PW-RKI153 Repair Kit 153 43, 44, 51 3 each
PW-RKI154 Repair Kit 154 42 3 each
PW-RKI155 Repair Kit 155 45 3 each
PW-RKI156 Repair Kit 156 40, 41, 42, 43, 44, 45, 51 3 each

H.E.R.O. Industries PW-3540-AC Pressure Washer Owners Manual
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UNLOADER PW-1195
667-10

H.E.R.O. Industries PW-3540-AC Pressure Washer Owners Manual
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REF # PART # DESCRIPTION QTY
1-40 PW-1140 UNLOADER ONLY, less chemical injector ASSY
1 PW-60.0030.31 Inlet Fitting/Plug, 3/8 NPT-F 1
2 PW-10.3068.00 O-Ring 2
3 PW-60.0015.51 Ball Spring 1
4 PW-14.7461.00 Ball, S.S. 1
5 PW-10.3059.01 O-Ring 1
6 PW-60.0254.51 S.S. Seal 1
7 PW-60.0057.35 Brass Body 1
8 PW-60.0025.31 Plug 8
10 PW-10.4021.00 Backup Ring 2
11 PW-10.3175.08 O-Ring 2
12 PW-60.0061.23 S.S. Piston 2
13 PW-10.3170.08 O-Ring 1
14 PW-10.4020.00 Backup Ring 1
15 PW-60.0064.31 Piston Housing 1
16 PW-15.1021.00 Locking Pin 5
17 PW-60.0033.61 Blue Spring 1
20 PW-10.3213.08 O-Ring 1
21 PW-60.0052.31 Check Valve 1
22 PW-60.0053.51 S.S. Spring 2
23 PW-10.3070.02 O-Ring 1
24 PW-60.0059.31 Outlet Fitting 1
27 PW-60.0002.84 Plastic Plug For Knob 1
28 PW-11.4589.10 Zinc Nut 1
29 PW-60.0001.31 Insert 1
30 PW-60.0003.84 Plastic Knob 1
31 PW-14.3720.40 Washer 1
32 PW-11.4573.31 Brass Nut 2
UNLOADER - PW-1195

H.E.R.O. Industries PW-3540-AC Pressure Washer Owners Manual
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UNLOADER, INJECTOR, LAYOUT
REF # PART # DESCRIPTION QTY
1 667-10 Connector, 3/8 male x 3/8 male 1
2 PW-1165 Fitting, 3/8 hose x 3/8 NPT 1
3 PW-1250 Elbow,
4 PW-1052 Body, Quick Disconnect, Female x 3/8 Male threads 1
5 PW-1255 Chemical Injector only 1
6 PW-1175 Garden Hose Inlet Manifold 1
7 PW-1060 Washer, Filter 1
8 PW-1155 Fitting, 3/8 hose x 1/4 MPT 1
9 PW-1185 Bypass Hose 1
2
9
6
7
5
4
3
1
8

H.E.R.O. Industries PW-3540-AC Pressure Washer Owners Manual
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PART # DESCRIPTION QTY
PW-4335 Cart, Aluminum 1
PW-4075 Grommet, Tip Holding 4
PW-3052 Engine, Gas, Honda, 13 HP, c/w Oil Alert 1
PW-1020 Strainer & Hose, Chemical Suction 1
PW-1430 Gun / Wand Assembly. C/W: PW-1000, 1010, 1045, 1055 Assy
PW-1055 Plug, Quick-Disconnect, 3/8 Steel, Male 1
PW-1470 Assembly, Pressure Washer Hose, 50’, complete with fittings
PW-1057 = Male plug, PW-1050 = female Q.D., PW-1235 hose ) Assy
PW-1100-0004 Spray Nozzle, 0 Degree, RED 1
PW-1100-1504 Spray Nozzle, 15 Degree, YELLOW 1
PW-1100-4004 Spray Nozzle, 40 Degree, WHITE 1
PW-1100-6540 Wash Nozzle, 65 Degree, BLACK, 1
97B Decal “ Quality By Design ” 1
PW-4085 Decal, Warning, Pressure Washing 1
CHASSIS PARTS, GUN, HOSE & TIPS
PW-1430 PW-1010 PW-1045
PW-1055 PW-1000
PW-1450
PW-1235
PW-1050
PW-1057

H.E.R.O. Industries PW-3540-AC Pressure Washer Owners Manual
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PUMP SERVICE
All inlet and discharge valves can be serviced without disrupting the inlet or discharge plumbing. The
inlet and discharge valves are identical on all H.E.R.O. models. See pages 8-10.
VALVE ASSEMBLIES
1. To service any valve, remove valve cap ( ref # 10 ) and extract valve assembly ( ref # 4-A-D-9 ).
2. Examine o-rings and replace if there is any evidence of cuts, abrasions or distortion.
3. Remove valve assembly ( ref # A-D ) from valve cavity.
4. Remove o-ring ( ref # 4 ) from valve cavity.
5. Only one valve kit is necessary to repair all the valves in the pump. The kit includes new o-rings,
valve seat, poppet, spring and retainer, ( ref # 4, A-D ) all pre-assembled.
6. Install new o-ring in valve cavity.
7. Insert assembly into valve cavity.
8. Replace valve cap ( ref # 10 ) and torque to 74 foot pounds.
50
4
A
10
9
D
C
B 11
11
9
10
1
3
2

H.E.R.O. Industries PW-3540-AC Pressure Washer Owners Manual
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ACCESSORIES
PW-1012, PW-1012, PW-1014
ROTATING
NOZZLE
SANDBLAST HEAD
WHIRL-A-WAY
PART # DESCRIPTION
PW-1062 In-Line Strainer ( Inlet water filter )
PW-1010 Wand, w/insulator, 36',
PW-1012 Wand, w/ insulator, 48',
PW-1014 Wand, w/insulator, 79',
PW-1015 Wand, twin-lance, less fittings,
PW-9012 Telescopic Wand, 6 ft to 12 ft
PW-9016 Telescopic Wand, 8 ft to 16 ft
PW-9024 Telescopic Wand, 12 ft to 24 ft
PW-9050 Gutter Hook – Telescopic Wand
PW-9060 Hard Surface Brush – Telescopic Wand
PW-9065 Window Brush – Telescopic Wand
PW-9070 Adapter
PW-1065 Gauge, 0-3000 psi
PW-1070 Gauge, 0-4000 psi
PW-1110 Nozzle, rotating, 3000 psi, less q/c fitting,
HPWD 2500 – 3000 only
PW-1120 Plug, quick-disconnect, 1/4 male, for
rotating nozzle
PW-1115 Assembly, sandblast head, HPWD 1500
PW-1116 Assembly, sandblast head, HPWD 2500
PW-1117 Assembly, sandblast head, HPWD 3000
10-WW-18 Whirl-a-way, 18'
10-WW-24 Whirl-a-way, 24'
PW-FSC24 Flat Surface Cleaner, 24” diameter
PW-FSCBVK Ball Valve Kit – Flat Surface Cleaner
PW-5000 Degreaser, 4 Liter
PW-5005 Universal Cleaner, 4 Liter
PW-5010 Vehicle Wash, 4 Liter
PW-5015 Pressure Washer Pump Oil, 1 Liter
PW-5020 3 Pack, Degreaser, Universal, Vehicle.

H.E.R.O. Industries PW-3540-AC Pressure Washer Owners Manual
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MODEL # ___________________________________________________________
SERIAL # ___________________________________________________________
PURCHASED ON ____________________________________________________
PURCHASED FROM: _________________________________________________