Hydro Tek CPK SERIES Manual

$15.00
OPERATION & MAINTENANCE
MANUAL
IMPORTANT: CAUTION! TO REDUCE RISK OR
INJURY, READ OPERATING INSTRUCTIONS
CAREFULLY BEFORE USING
©2007 HydroTek
POWER WASHERS
CPKSERIES
HG SERIES
SH SERIES
SK SERIES
SR SERIES
ST SERIES

2
ACCESSORIES
TURBO
NOZZLE ADJUSTABLE PRESSURE WAND CHEMICAL INJECTORS SAND BLASTING HYDRO TWISTER SURFACE CLEANERS HOSE EXTENTIONS HOSE REELS
Servicing your Pressure Washer
Should you have any questions or are unable to resolve a problem after using the
Troubleshooting section of this manual, call Technical Support at: [phone] 7:30 – 4:00 PST.
The Techinical Support department can solve many problems over the phone. Please have the
following information available before calling:
*The pressure washer model number: _______________________
(on the product label)
*The serial number: _______________________
(located at the base of the machine)
*The purchases date from your purchase receipt (required for warranty service).
*A description of the problem.
Ordering Parts and Accessories
To order parts and accessories for your pressure washer, call or visit your local dealer.
To get the best use of your pressure washer, please read the manual carefully. It contains all the
information necessary for you to operate the unit safely and to get the maximum benefit. This manual
also contains many helpful hints about pressure washer mainenance.
Tthe following additional accessories can be purchased to make your equiment more flexible for a
cleaning effort that is swift and efficient.

TABLE OF CONTENTS 3
INTRODUCTION ............................................................................................................................... 4
Statement of Warranty
SAFETY WARNINGS ....................................................................................................................... 5
Electrical Precautions
Fire Precautions
Ventilation Precautions
Spray Injection Precautions
Personal Hazard Precautions
OPERATING INSTRUCTIONS ....................................................................................................... 6
Before Start Up
Operation
Shut Down & Antifreeze Protection
SYSTEM INFORMATION ................................................................................................................. 7
Power System
Electric Motor/Gasoline Engine
Power Transmission System - direct, & belt drive
Generator - circuit breaker
Pumping System ........................................................................................................................ 8
Pump
Unloader, Pressure Relief Valve and Burst Disk
Chemical Injection System - inlet & downstream injection
Water Supply - direct, float tank, & supply tank feed
Heating System .......................................................................................................................... 9
Coil/Heat Exchanger System - temperature & flow switch controls
Diesel Fired Burner - air band, transformer, fuel pump, filter, & solenoid
Pressure Delivery System ......................................................................................................... 9
Discharge Hose, Hose Reels
Gun/Wand Assembly - trigger gun, wand, & quick coupler
Nozzles - spray nozzles, steam nozzle and turbo nozzle
Hydro Twister
Trailers
TROUBLE SHOOTING GUIDE ....................................................................................................... 12-15
WIRING DIAGRAMS ......................................................................................................................... 16-22
SERVICE RECORD.............................................................................................................................23
SERVICE/MAINTENANCE INFORMATION ................................................................................ 24
TEST SPECIFICATIONS ............................................................................................................. Enclosed
ENGINE SHEET ............................................................................................................................ Enclosed
PARTS LIST / EXPLODED VIEW .............................................................................................. Enclosed
USE ONLY CERTIFIED ORIGINAL EQUIPMENT REPLACEMENT
PARTS, FAILURE TO DO SO COULD LEAD TO WARRANTY
EXCLUSION AND SEVERE BODILY INJURY

INTRODUCTION:
The employees and management of HYDRO TEK
thankyouforselectingourproducts. Theproductionand
qualityassurancepersonnelhavetakenthegreatestcarein
theassemblyprocesstoensurethatyournewHighPres-
sureCleanerisofaqualityandstandardacceptabletoboth
youthecustomerandusthemanufacturer.
Thisoperatorsmanualwascompiledforyourbenefit.
Bystudyingandfollowingthesafety,installation,opera-
tion,maintenance,andtroubleshootinginformationcon-
tained within, you can look forward to many years of
troublefreeservicefromyourequipment.
Uponreceiptoftheequipment,pleaseinspectforany
concealedfreightdamage. Shouldyoufinddamagehas
occurred during shipping, do not return the damaged
merchandisetoHydroTek,butfileaclaimimmediately
withthefreightcarrierinvolved.
Pleaselocatetheenclosedwarrantyregistrationcard.
Fill out and return it to activate the warranty on your
machine. Alsoenclosedareinstallationinstructions.
Pleasenotethattheowner/userhascertainobligations
underthetermsofthewarrantyforthisequipment,andas
suchyouareencouragedtoalwayshaveeverypersonwho
willoperatetheequipment,readandbecomefamiliarwith
thecontentsofthisownersmanual,priortotheirusingthis
equipment.
ContactyourAUTHORIZEDHYDROTEK DEALER
or a trained HYDRO TEK service engineer if problems
occur,orifinstallationisrequired.
THEREARENOUSERSERVICEABLECOMPO-
NENTSONTHISEQUIPMENT.
Theequipmentisshippedwiththefueltanksempty,the
batterycablesdisconnected,andthepumpantifreezed.
Ifyoudidnotorderabatterywithyourunitseepage5for
batteryrequirementsandinstructions.
V-LINE LIMITED PARTS WARRANTY:
Hydro Tek warranties the Hydro Boss line and Hot2Go line
powerwashersto be free from defects inmaterialandworkman-
shipforone(1)year,calculatedfromthedateoftheoriginalretail
purchase.HydroTekaccessoriesarewarrantedforaperiodof90
daysfromthedateoftheiroriginalpurchase. HydroTekwillmake
therequiredrepairs,oratHydroTek'soptionprovidereplacement
componentsiffoundtobedefectivebythereasonablejudgement
of Hydro Tek. This warranty only extends to the original retail
purchaser,andis subject to theexclusionsshownbelow. Anyparts
replacedunderthiswarrantywillassume the remainder of the parts
warrantyperiod.
ThisWarrantydoesnotapplytoandHydroTekisnot
responsiblefor:
1. Normal wearitemssuch as Unloader Valves,Discharge
Hoses, Guns, Wands, Nozzles, Quick Couplers, Brushes,
Filters,Belts,Seals, O-rings, and Packings.
2. Labor charges or costs related to the removal of the
defective part, field labor charges, transportation to service
4 INTRODUCTION
ONEYEARLIMITEDPARTSWARRANTY-Provided
by Hydro Tek, excluding normal wear items listed
below. Labor excluded.
ONEYEARWARRANTYONENGINES&ONEYEAR
OR LESS ON ELECTRIC MOTORS - Uptotwoyear
limitedwarrantyprovidedbytherespectiveengine
manufacturer and up to one year by electric motor
manufacturer. Labor excluded.
ONEYEARCOILWARRANTY- oneyearparts
warranty. Labor, freezing & descaling excluded.
ONEYEARPUMPWARRANTY-Uptooneyear
limitedwarranty oncrankcaseofthepumpprovidedby
therespectivepumpmanufacturer. Labor excluded.
center and costs to return it to Hydro Tek, or service
charges for scheduled maintenance or any adjustments.
3. Damage due to freezing, abrasive fluids,chemical deteriora-
tion, and scale build up.
4. Damage from fluctuation inelectricalorwatersupply.
5. Damageresultingfromfailuretofollow
manufacturers maintenance instructions.
6. Damage resulting frommisuse,neglect,accidents,modifi-
cations, alterations, abuse, or incorrect installation.
7. Products operated outside of specified limits or intended
use as specified in the operation manual.
8. Repairs made necessary by the use of parts which are
either not obtained from or approved by Hydro Tek.
9. ActionsorinactionsbyanyHydroTekdistributorgivingrise
to or causing a warranty exclusion or promise of additional
warranty.
10. Warranty on engines, motors, and pumps, which are war-
ranted by their respective manufacturers and are serviced
through the manufacturer's service centers.
LIMITATION OF LIABILITY
Hydro Tek's responsibility with respect to claims is limited in
making the required repairs or replacements, and no claim of
breachofwarrantyshallbecauseforanycancellationorrecision
of the contract of sale of any Hydro Tek product. Hydro Tek
reserves the right to change or improve the design of any of its
products or illustrations without assuming any obligation to
modify any product previously manufactured.
THEREISNOOTHEREXPRESSEDWARRANTY.
This supersedes any and all previous warranty statements for
productspurchasedafterJanuary1,2007. HydroTekisnotliable
for indirect, incidental or consequential damages including but
notlimitedto: The cost of substitute equipment,loss ofrevenue,
pecuniary expense or loss, or any damages whatsoever arising
outof theuseorinability touseaHydroTek product.HydroTek
disclaimsallimpliedwarranties,includingthoseofmerchantabil-
ity and fitness for use or a particular purpose. It is the buyer's
responsibility to ensure installation and use of Hydro Tek prod-
ucts conforms to local codes. Proof of purchase date required to
obtain warranty. Complete warranty information is contained
onthewarrantycardandsupersedesallinformationonthispage.

IMPORTANT SAFETY WARNINGS: SAVE THESE INSTRUCTIONS 5
4. AVOIDcontactwiththeexteriorofthecoil/heatexchangerassembly,
exhaust stack and mufflers to prevent burns.
5. DONOTstorefuelorotherflammablematerialsneartheburnerorany
otheropenflame.
6. ToavoidburnsNEVERstandoverburnerexhaustoutletorinfrontof
engineexhaust. Burnermaystartatanytimeoncepoweristurnedon.
7. Do not touch burner exhaust port, mufflers, or wands/hoses as
contact may cause burns. Use designated gripping areas.
8. Diesel fired or gasoline powered units are designed for outdoor
use and installation only.
9. Burner on/off switch must be placed in the OFF position when
the pressure washer is not being used. Do not depend on engine
runswitchtoturntheburneroff-Thismaycauseasafetyhazard.
VENTILATION PRECAUTIONS:
1. DO NOT run engine or burner in an enclosed area. Exhaust gases
contain carbon monoxide, an odorless deadly poison.
2. ObserveallState,Local,andNationalcodesprovidingforindoor
useorinstallationofthisunit.
3. Provide adequate ventilation to prevent engine overheating
and inefficient burner combustion
(minimum2'ofairspace).
SPRAY INJECTION PRECAUTION:
1. Fluidfromhighpressuresprayorleakscanpenetratetheskinand
causeseriousinjury. Ifanyfluidappearstopenetratetheskinget
emergencymedicalhelpatonce.DONOTtreatasasimplecut.Tell
the physician exactly what fluid was injected. For treatment
instructions have the physician call your local poison center.
Without proper treatment, complications can develop.
2. WARNING-Riskofinjectionor severeinjurytopersons-Keep
clearofnozzle.DONOTdirectdischarge streamatpersons.This
machine is to be used by trained operators. Keep operating area
clearof all persons.
CAUTION:Hotdischargefluid-DONOTtouchordirectdischarge
stream at persons. Gun kicks back - Hold with both hands. Stay
alert - Watch what you are doing.
3. Always wear protective eye goggles when operating the
equipment. Additional protective items such as a rubber suit
and boots, gloves, and respirators are advisable, particularly
when using cleaning detergents with a corrosive content.
4. Know the detergents you are using. Read and follow the
directions on the detergent labels.
PERSONAL HAZARD:
1. DONOTremovebeltguardsorelectricalcoverswhileengineis
operating or when the power is connected.
2.DONOTmoveenginepoweredmachinerywhiletheengineis
operating.
2. DO NOT lock the trigger on the gun valve in the on position.
3. DONOTexceedrecommendedoperatingpressureortemperature.
4. KEEPHANDSCLEAROFBELTSANDMOVINGPARTS.
5. Do not operate the product when fatigued or under the influ-
ence of alcohol or drugs.
ELECTRICAL PRECAUTIONS:
1. ObserveallState,Local,andNationalcodesfortheinstalla-
tionofyourelectricallypoweredwasher.
2. For a grounded product rated 250 volts, single phase, or less:
This Product Is Provided With A Ground Fault Circuit Inter-
rupterBuiltIntoThePowerCordPlug. IfReplacementOfThe
Plug Or Cord Is Needed, Use Only Identical Replacement
Parts.
3. GROUNDINGINSTRUCTIONS:
Cord Connected, Grounded Products:
This product must be grounded. If it should malfunction or
breakdown, grounding provides a path of least resistance for
electriccurrenttoreducetheriskofelectric shock. Thisproduct
isequippedwithacordhavinganequipment-groundingconduc-
tor. The plug must be plugged into an appropriate outlet that is
properly installed and grounded in accordance with all local
codes and ordinances.
Danger - Improper connection of the equipment-grounding
conductor can result in a risk of electrocution. Check with a
qualifiedelectricianorservicepersonnelifyouareindoubtas
towhethertheoutletisproperlygrounded. Donotmodifythe
plug provided with the product, do not cut off the ground pin
- if it will not fit the outlet, have a proper outlet installed by a
qualifiedelectrician. Donotuseanytypeofadaptorwiththis
product.
4. To comply with the national electric code, this pressure
washer should only be connected to a receptacle that is
protected by a ground fault circuit interrupter (GFCI).
5. EXTENSIONCORDS:
Use of extension cords is not recommended.
6. NEVER operate an electrically powered washer after it has
tripped a breaker or a ground fault device without having the
reason for the trip determined by an authorized service engi-
neer or competent electrician.
7. Useonlyinadryarea. Donothandleelectricalcordsandplugs
whentheyarewet,whenyourhandsarewet,orwhenstanding
inwater. Donotsprayhighpressurewaterontothemachine.
8. Disconnectpowersupplybeforemakinganyrepairsoradjust-
ments.
9. Transformer on burner is 20,000 volts. Disconnect battery
cable before servicing burner or engine on 12 volt systems.
FIRE PRECAUTIONS:
1. DONOTuseimproperfuelsorsolventsinthisequipment,andonly
fillwiththecorrectfluidswhentheunitisinanOFFcondition,main
power is disconnected, and engine and burner are cool.
2. Fillthedieselburnerfueltankwith#2dieselfuelorkerosene.NEVER
usegasoline. Donotconfusegasolineandfueloiltanks. Keepproper
fuelinpropertank.
3. NEVERoperatethisequipmentinthepresenceofflammablevapors,
dust, gases, or other potentially combustible materials.

BEFORE START UP:
1. Read all instructions before using this product.
2. CHECK OIL AND FLUID LEVELS:
Checkpumpoilbylocatingtheoilview
window or dipstick and fill to the red
dot. Check fuel levels.
Check engine oil and
coolant levels if unit is
so equipped.(Seethemaintenanceschedule
onpage16).
3. CONNECT HOSE AND GUN
ASSEMBLY.
4. CONNECT THE WATER SUP-
PLY & TURN
WATER ON:
Maintain an adequate supply of water using a ¾"
I.D.hosewithapressurebetween25and60PSI. Burner
powerswitchesshouldbeoffbeforestarting. Iftankfed,
besurethereiswaterinthetankandthevalveisswitched
for supply tank feed. Do not run dry for longer than one
minute.
5. BATTERY INFORMATION
If you did not order a battery with your machine you
will have to buy one and fill it with electrolyte (avail-
able at local auto parts store).
!WEAR EYE PROTECTION!
If the opening on your battery box
measures 9" by 6" we
recommendExides'
U1L/GTH 235CCA
battery. If the opening
measures 8" by 12" we
recommend Exides' group 46-60 550 CCA battery. Deep
cycle batteries are recommended to extend battery life.
Always connect the positive battery cable before the
negative and coat the battery terminals with corrosion
inhibitortopreventcorrosion.
6. If wheel kit, accessories, or discharge hose are not
installed,seeyourlocaldealer forinstructions& installa-
tion.
OPERATION:
1. STARTING:
A. ElectricPowered Units:
Connectpowersupplyandensurethatallwiringconnec-
tionsandvoltages areofsufficientratingtocomplywith
theequipment'srequirements. Turnpump powerswitch
on. If unit is equipped with auto-start, keep all power
switchesoffwhenleftunattended. (Unitwillonlyturnon
when trigger gun is pulled.)
B. Gasoline Engine Units: To reduce the risk of starter
damageremovespraynozzlefromwandandpullspraygun
triggerwhilecrankingengine.Afterstart,releasetriggerand
replacespraynozzle. Be surenozzle is properlypositioned
inquickdisconnectbeforespraying:
2. PURGE AIR FROM SYSTEM:
Squeezethetriggeronthe spraygununtilaconstantstream of
water comes out. (Purging works best with nozzle removed
from wand and/or dual wand in the low pressure mode.)
3. SELECT DESIRED
NOZZLE
Connect nozzle securely
to spray wand. If equipped,
close pressure adjusting
knobondualwand. Holdgunfirmly,squeezetriggerfor
highpressurespray. O-ringshouldbereplacedwith1/4"
or 3/8" EPDM.
CAUTION - Gun kicks back - hold with both hands.
WARNING - Risk of explosion - DO NOT spray
flammableliquids.
4. START BURNER: To create hot water on high pressure
washersequipped withheat exchangers,release thetrigger
on the gun, turn the burner to the on position, and turn the
thermostat to the desired temperature.
Squeezethetriggeronthespraygunandtheburnerwill
begin heating the water. It will stop firing whenever the
water spray is off or if the temperature setting is ex-
ceeded.
5. STEAM:(IfEquipped)
Insert steam nozzle and turn thermostat to 250º steam
setting. The steam nozzle is sized for approximately
25% less water volume than the hot water mode.
6. BYPASS MODE:
System will go into bypass mode when machine is left
runningandtrigger gunisclosed. Bypass modeiswhen
theinletwatercomingintothepumprecirculatesthrough
the unloader across the pump head. If left in bypass too
long - More Than Five Minutes - friction created by the
movement of the water will begin to heat the water at a
rapid rate. If equipped with a THERMAL DUMP
VALVE, water exceeding 145°F will cause the valve to
open allowing the hot water out of the system into the
atmosphere and allow cool water in. The valve
will reset itself when water temperature comes
down to a safe level.
If equipped with a bulk water tank, water can be
bypassed back through the tank allowing for a
largervolumeofwatertoberecirculatedthroughthepump
head thus reducing heat on the pump seals.
!Warning:Donotleaveinbypassforlongerthanfive
minutestopreventpumpfromoverheating.
6 OPERATING INSTRUCTIONS
Warning:Cool downburner beforeshutting off.
EB22F EB24F
Lock collar after nozzleis inserted

SHUT DOWN / SYSTEM INFORMATION 7
7. SET CHEMICAL INJECTION:
Ifunitisequippedwithinletchemicalinjection,place
chemicalpickuptubeinpre-mixedchemicalsolutionand
open chemical valve for desired chemical concentration.
Rinse and close valve after use, do not use harsh chemi-
calsthrough theinletinjector system.If unitis equipped
with a downstream chemical injector, connect the chemical
injectionassembly intothe highpressure dischargehose
quick connects. Place the chemical pickup into chemical
solution and turn brass collar to adjust concentration. The
chemicalwill injectonly whenyou droptheoutletpressure
by opening the valve on the dual wand or changing to a low
pressure nozzle. Soap the surface from the bottom up.
Close chemical valve when not in use.
8. If equipped, AF2 (2) gun operation, select "50%"
nozzle from panel and insert into coupler on spray gun
for full pressure output when using two guns at the
same time. Flow can be reduced by selecting flow
reduction nozzles only when one operator is using the
machine. Maximum temperature is 200° F.
SHUT DOWN:
1. TURN BURNER SWITCH TO THE OFF POSITION.
2. RINSE & CLOSE CHEMICAL VALVE.
3. SQUEEZE THE TRIGGER ON THE SPRAY GUN
UNTIL THE WATER BECOMES COOL.
4. TURN MOTOR/ENGINE SWITCH OFF with the
appropriatecontrols.
5. TURN OFF WATER SUPPLY.
6. SQUEEZE TRIGGER TO RELEASE ANY
TRAPPED PRESSURE IN DISCHARGE HOSE.
7. ANTIFREEZE EQUIPMENT:
In the event that the equipment is not to be used for an
extendedperiod,storeinheatedspaceorantifreezetheunit.
Runthemachine until thefloat tank isnearempty, fillwith
a 50% mix of water and antifreeze and run until antifreeze
appears at the high pressure outlet. If unit is equipped with
a blow out valve, it may be blown out with compressed air
inadditiontousingantifreezesolution. Ondirectfeedunits
(no float tank), use a 5' garden hose to draw the antifreeze
mix from a bucket. Or blow out the unit with compressed
air until only air and no water comes out of the discharge.
CHASSIS & TRAILER ASSEMBLY:
To maintain teh appearance of hte machne, use stainless steel
claner on teh stainless panels.
Checktire pressure. Check allbolts includingthe lug nutsfor
tightnessandconditionperiodically. Greasewheelbearingsas
required and adjust after first month.
TIREPRESSURE
T200 T300 T400 T500
35psi 35psi 40psi 40psi
POWER SYSTEMS:
ELECTRICMOTORS: Allsinglephase
electric motors contain a manual or auto-
maticthermaloverloadwhichwillshutdown
the motor if it overheats. If the overload or
starter shuts down the motor, have an elec-
tricianoranauthorizedHydroTekdistributor
check for electrical problems. Voltage reading under load
should be +/- 10% of name plate voltage on motor. The
motor can be reset by depressing the red overload button
located on either the motor or the starter, (as shown above).
Use thumb pressure only - DO NOT force. Wait for motor
tocoolbefore re-setting.The automaticoverloadwill reset
itself after the motor has cooled.
Never spray water on the unit, or damage to the electric
motor(s) may occur.
Consultthe factory ifrunning anelectric machinefroma
generator. Three times total system wattage is required.
A fused disconnect switch of sufficient ampere rating
should be installed by an electrician to provide power to the
machine. Refer to the chart above for electrical require-
ments:(208Volt isacceptable,butunitmotormustbeunder
nameplateamps;turnpsidown).Ifyourunitisequippedwith
agroundfaultinterrupter,itwill havetobe resetwheneverit
is plugged in, or if a ground fault interruption occurs. Test
regularly for proper operation.
GASOLINE ENGINE: With the proper care and main-
tenance,yourgasolineenginewillgiveyearsoftroublefree
service. Pleasefollow the Serviceand MaintenanceGuide
and theenclosedenginesheetorcontactyourlocalauthorized
engine dealer for maintenance and repairs.
Use unleaded gasoline with an octane rating of 87 or
higher in the engine fuel tank. Consult engine manual for
properoiltypeandcapacity.Changeoilevery50hoursand
thefilterevery 100 hours(see engine manual). Donot rely
on the low oil shutdown (if equipped) as a reminder to add
oil. Engine damage from lack of oil will typically not be
warranted even if the low oil system failed.
On machines with a 115V generator or a 12V burner, the
throttle is preset at the factory (See Generator section on this
page for adjustment).
POWER TRANSMISSION:
DIRECT DRIVE: Pump is bolted
directly to the motor/engine. If pump
needs to be removed, do not force off by
prying or damage may occur. When
reassembling,coat the entire motorshaft
with heavy grease, or a generous amount
MAINTAIN PH BETWEEN 5 & 9
A=TOTAL SYSTEM AMPERES
HORSE
POWER 115V 1PH WIRE SIZE 208V 1PH WIRE SIZE 208V 3PH WIRE SIZE 230V 1PH WIRE SIZE
1.5 15A 12/3 N/A N/A N/A N/A 10A 14
2 20A 12/3 N/A N/A N/A N/A 12A 14
4 N/A N/A 21A 10/3 N/A N/A 20A 10/3
5 N/A N/A 24A 10/3 N/A N/A 23A 10/3
6.5 N/A N/A N/A N/A N/A N/A 27A 10/3
7.5 N/A N/A N/A N/A N/A N/A 35A #8

8 SYSTEM INFORMATION
ofanti-seizeanduseserviceremovable"locktight"onmounting
bolts.
BELT DRIVE: Check belt condition, alignment and
tension periodically. Replace belts when they show signs of
wearorcracking. Tightenbeltsbylooseningthemountingbolts
on the pump and generator to permit them to slide. Turn the
horizontalrailadjustingboltstotightenbeltsuntiltheydeflect ¼"
to ½" inch with finger pressure.
GENERATOR:
Some self-contained Hot Water Units are equipped with a
115 volt generator to power the diesel burner. The generator
outputvoltagemustbebetween110to130Volts, (orbetween
59to63hz),whentheunitisunderfullload. Ifthegenerator
voltagefallsoutofthisrangetheRPM
oftheenginewillneedtobeadjustedto
proper speed. If the engine cannot
maintain the proper RPM do not use
the burner or any power from the
generator until the engine is repaired.
A switch/circuit breaker will need to be
reset if the circuit is overloaded.
To extend generator life make sure the
burner is off when the engine is started or
stopped. Keepgeneratordry. Donotspray offwithtrigger
gun.
Ifunitisequippedwithauxiliarygeneratorpoweroutlets,
they are located on the back of the electrical box. Do not
plug in accessories over 1200 watts or 10 amps.
PUMPING SYSTEM:
PUMP: The pump is a positive displacement, oil bath
crankcase, triplex plunger type. It contains 3 plungers which
move forward and backward in a cylinder to propel water past
3 inlet valves and 3 discharge valves into a high pressure
manifold.
Thecrankcaseoil windowordip stickshouldbe checked
for oil level and clarity. Check the pump for oil or water
leaksbeforeeachuse. The sight window is located at the rear
(oppositethehead)ofthepumpandshouldbefilledtothereddot
withARrecommendedoil,orCatPumprecommended
oil available at your Hydro Tek dealer. Wobble plate
pumpsusesyntheticoilwhichonlyneedstobechanged
iftheoilbecomescontaminated. Ifthe
oilbecomesmilkyincolor,moistureis
enteringthecrankcase. Changetheoil
and contact your authorized Hydro
Tek dealer if the problem persists.
To increase pump life, prevent cavitation (air bubbles),
overheating,anddirtywater. Cavitationcanbepreventedby
keepingfilterscleanandcheckingforairinpump
feed lines. Do not run the pump in the bypass
mode(pumprunningwiththetriggergunoff),for
aperiodofmorethan 5minutesorthepumpwill
beginto overheat(maximum watertemperature
is 145ºF). Do not run pump dry. Protect from freezing. Do
not run a frozen pump until it is completely thawed.
UNLOADER AND PRESSURE RELIEF VALVE: The
unloader valve is preset at the factory to govern the proper
output pressure of your machine. It will release
the pressure of the pump output back into the
inlet if the trigger on the spray gun is released.
NEVER increase the set pressure on the un-
loader to exceed the specifications for your
machine. The unloader should be adjusted only by qualified
personnel.
All hot water machines are equipped with a SAFETY
PRESSURE RELIEF VALVE. In the unlikely event that
your unloader fails, or if the burner overheats and builds
excessive pressure, the pressure relief valve will vent the
pressure into the atmosphere. If this occurs, turn off the
machine and have it checked by an authorized dealer. The
pressure relief valve will automatically reset itself.
BURST DISK TECHNOLOGY: This additional safety
feature functions to protect the coil and other components
from overpressurizing from the heating system and high
system spikes of pressure. If this component ruptures, you
should take the machine in to an authorized Hydro Tek
dealer. Do not plug off and continue to run.
An optional DOWNSTREAM
INJECTORisavailableifharshchemi-
cals need to be applied. The down-
streaminjectorwillapplychemicalsonly
at low pressure. If equipped standard
withdownstreaminjection, adjust con-
centration level by turning brass collar on the injector, or the
knob on pump or control panel. Read and follow all safety
instructions on the detergent label.
WATER SUPPLY: An adequate water supply must be
maintainedtothepumpatalltimes. Iftheinletflowistoolow
or if there is air in the water supply, the pump will run rough,
pulsate and lose pressure. Maximum inlet water temperature
is 145ºF. If the pump is run dry, it can quickly overheat.
The water is filtered by a garden hose adapter screen.
Clean and replace as required or install a large capacity
strainer to insure a clean supply of water.
DIRECT WATER FEED: Maintain an inlet water pressure
between 25 PSI and 60 PSI using a ¾" I.D. hose. Install a back
flow preventer on your supply hose if State or Local ordinances
requireit. Installawaterregulatorifyourwaterpressureexceeds
60 PSI.
FLOAT TANK WATER FEED: A
float tank is used on some models to
regulate the incoming water supply to
the pump and introduce chemicals into
the inlet of the pump.
The float tank and filter should be flushed out if debris
accumulates in the bottom. If the float tank overflows or

SYSTEM INFORMATION 9
runs out of water, adjust or replace the float valve inside
the tank and check the inlet water feed pressure.
WATER TREATMENT: The inlet water can be deion-
izedforspotfreerinseorsoftenedtomakedetergentsclean
more effectively. Do not use deionized water through the
coil on a hot water machine or coil corrosion will result.
Water softeners, however, will reduce coil scale deposits
and should be installed if your water is especially hard.
HEATING SYSTEM:
COIL/HEAT EXCHANGER SYS-
TEM: The heat exchanger contains a
continuouscoil of pipewhich formsa cold
water jacket around the outside of the
heating area. It is double wrapped with
ceramic blanket insulation and a stainless steel cover.
Theinsideofthecoilassemblycanbecomecovered with
soot if it is fired with diesel fuel and the burner is out of
adjustment. Thiscanbecleanedbyremovingbothendcaps
of the heat exchanger enclosure and brushing or spraying
offdebrisorbyaddingasootremovalagent(Part#CB200)
to the diesel fuel.
Whenthewaterisheated,scale(calcium)willbegin
toformontheinsideofthecoilpipedepend-
ing upon the hardness of the water in your
area. ThecoilcanbeDESCALEDbyusing
ascale remover (Part# CB105)available at
your authorized Hydro Tek dealer. It is necessary
toperformthisserviceonlywhenanoticeablepressuredrop
isdetectedacrossthecoil.Followdirectionstoavoiddamage.
Wear safety glasses.
TEMPERATURE SWITCH: The burner is equipped
with a high temperature limit switch which will shut off the
burner when the water temperature becomes too hot. Some
units come with an adjustable thermostat.
STEAM INSTRUCTIONS:
Ifyourunitissteam-capable,installthegreensteamnozzle,
turn thermostat to 250° F.
PRESSURE/VACUUM/FLOW SWITCH: The burner is
equipped with either a pressure switch, flow and/or a vacuum
switchtocontroltheburner. Whenthetriggeronthespraygun
is squeezed, water begins to move through the coil and
pressurize. Thevacuum/flow/pressureswitchturnstheburner
on and begins to heat the water. Whenever the water spray
stops or if the water is shut off, the burner will shut off.
WARNING: Burnershouldfireonlywhenthetrigger
is squeezed and spraying water, if it comes
on at any other time, shut off machine and
have it serviced.
DIESEL FIRED BURNER: The diesel
firedburnerisaforceddraftpressureatomizing
burner. Diesel fuel is sprayed out of an atom-
izingnozzle,mixedwithair,andignitedbyahighvoltagespark.
The flame is directed towards the coils of pipe which, in turn,
heats the water flowing through it. Use clean #2 DIESEL
FUEL for the burner or substitute #1 diesel, light fuel oil, or
Kerosene if diesel is not available.
AIR BAND adjustments may need to be made to compen-
sate for higher elevations, or if more than a trace of smoke is
observed in the burner exhaust. The ELECTRODES may
need to be cleaned and adjusted periodically. These adjust-
mentshavetobemadepreciselyandshouldbeperformedonly
byqualifiedpersonnel. Setbetween#1&#2onsmokegauge.
TheFUELPUMPisaselfpriming,lowvolumepumpwhich
is propelled by the burner motor. The fuel pump pressure is
typicallysetat100PSIbutcanbeturnedashighas140PSIduring
the winter when the incoming water temperature is lower.
Beforeadjustingthefuelpressure,connectafuelpressuregauge
andanoutletwatertemperaturegauge,turnthepumpandburner
on, and turn the fuel pressure screw clockwise until the desired
water temperature is obtained. Be sure not to exceed the
recommended specifications of the machine.
The FUEL FILTER will need to be cleaned often if the
diesel fuel quality is poor. A fuel filter with a water separator is
recommendedifthefuelqualityisconsistentlypoor.
TheFUELSOLENOIDisanelectricfuelvalve
whichshutsoff thefuelwheneverthe triggeron
thespraygunisreleasedorifthesettemperature
on the heat switch is exceeded.
The IGNITION TRANSFORMER provides a high voltage
sparkwhichtravelsdowntheelectrodestoignitethedieselfuel.
Disconnect all power before servicing.
The12 VOLTBURNER operatesfromthebatteryon theST/
SM/SR Series. The engine has a 15 to 16 amp charging system
which keeps the battery charged which runs the burner. The
burner motor and transformer stops when the trigger gun is
released. Its best to release the trigger gun periodically, and also
cool down the burner before shutting off the engine to keep the
battery fully charged. Shut off burner & engine switch when
unattended.
PRESSURE DELIVERY SYSTEM:
TRIGGERGUNS:Thetriggergunismerelyavalvethatturns
water spray on and off. If it begins to leak or fails to shut off,
replace or repair the valve assembly. Never lock the gun in
the on position or point it at any person or any part of the
body.
Machines that spray steam only are equipped with an
open gun that does not shut off the water spray.
SPRAY WAND: Wands are available in 2 to 6 foot
lengths for various cleaning applications. If the unit is
equipped with a dual wand you can adjust the pressure by
turning the knob on the valve to divert part of the water
through the low pressure nozzle.
NOZZLES: The spray nozzle is a precisely machined orifice
madeofhardenedstainlesssteel. Theorificesizeismatchedtothe
BF020 BF025 BF015

10 SYSTEM INFORMATION
outputofyourmachinetoattaintheproperflowandpressurethat
yourmachinewasdesignedfor. Theorificeor,hole,ofthenozzle
willbegintogetlargerasthenozzlebecomesworn. Foroptimum
performance, replace the spray nozzle to maintain the full output
pressureofyourmachine. Thenozzleinstalledinyourmachine
fromthefactoryisdesignedtoallowonlyabout90%ofthewater
beingpumpedtodischargeoutofthenozzle. Theremaining10%
isbypassedbackintotheinletwatersupplybytheunloader/regulator
valve. If an incorrectnozzle sizeisused themaximumflow and
pressure of the machine cannot be achieved and the pressure
unloadervalvecanwearprematurely. Whenreplacingthenozzle
matchtoonesizeundertheflowandpressureoutputofthepump.
The nozzle is usually connected to the wand with a quick
coupler. Be sure the collar on the quick coupler snaps back
to the locked position, or the nozzle could be lost when the
trigger on the spray gun is squeezed. Never connect the
spray nozzle directly to the trigger gun without a wand or
injury could result. Never place hands or fingers over the
nozzletip.
Thenozzlesgenerallycomeinfourdifferentsprayangles,0º,
15º, 25° and 40º. The different spray angles of a given size of
nozzledonotchangetheoutputpressureofthemachine,justthe
impact force and surface coverage of the water spray.
The 0º nozzle sprays a straight stream which impacts the
surfacevery hardbut doesnot covera verywide area. Usethe
0º nozzle with care because it can damage the surface you are
sprayingwithitshighimpact andlongreaching spray.
The15ºnozzlespraysoutaflatstreamata15ºwidth. Itgives
youlessimpactpowerbutcoversawiderareawithonepassof
the spray wand. As you back away the spraying nozzle from
the surface, the spray impact will decrease.
The25° iswider thanthe15°andis mostcommonly usedto
indicatethe steamnozzle
The steam nozzles are sized to spray less water than the
other high pressure nozzles, so the water is discharged at a
higher temperature. (Up to 250º F).
The 40º nozzle spreads the water stream over an even wider
area to give you less impact for delicate surfaces.
Some machines come with one 15º nozzle which covers
mostcleaningapplications. Additionalnozzles canbeadded
and fitted with quick couplers so that the nozzles can be
interchangedforvariousapplications.
TURBO NOZZLE (OPTIONAL)
Theturbo nozzlemultiplies thepower
ofyourmachinebyrotatingthesprayjetandmakingthewater
impact the surface harder to give better cleaning results.
Simply replace the spray nozzle with the turbo nozzle and
squeezethetriggeronthespraygunwiththeburneroffforhigh
pressure spray. Do not point the turbo nozzle upward when
starting. "Turbo Laser" type nozzles cannot be used with
water over 190º or life of the turbo nozzle will be greatly
decreased and the warranty voided. The "Rotomax" type
nozzle can be used up to 170º F.
EXTENSIONHOSESANDHOSEREELS(OPTIONAL)
The high pressure discharge hose can be extended by
connecting additional hose lengths by means of twist cou-
plers. Hose extensions generally come in 50 and 100 foot
lengths. Specifymaximumpressureandtem-
peratureofyourmachinewhenordering.Low
pressure inlet garden hose is available in 50
and 100 foot lengths. Premium quality, 200
PSIratedhoseisrecommendedtobeusedand
isavailableatyourlocaldealer.Hosereelsare
availableforconvenientandquickstorageofbothdischarge
and inlet hoses. To keep the hose from unreeling, lock the
drum in place and secure the gun or the end of the hose or
it may drag on the road. If the reel begins to leak, replace
the seal kit in the swivel, or connect the hose directly to the
machine until the leak is repaired.The high pressure hose
should be completely unreeled before use or it can contract
on the drum and cause damage to the hose reel. The low
pressure hose should be of sufficient quality that it will not
flatten out when reeled up, or the supply of water to the
machine will be cut off. WARNING:Replace discharge
hosewithoriginalequipmenthoseratedfor250°F availableat
Hydro Tek dealer.
HYDRO TWISTER (OPTIONAL)
The Hydro Twister is a surface cleaner that connects to a
pressure washer and uses two nozzles rotating at a high RPM
within1" oftheground. Itcanclean concreteup to10timesthe
speed of an operator using a wand, and with more consistency
and less operator fatigue. The Hydro Twister can be used with
upto4000PSI, 10gallonsperminute, andupto250ºF. The17"
diameterHydroTwisterisdesignedforuseinconfinedareasand
the 27" for large expanses of concrete or decks. An adjustable
pressureknobisincludedforuseinsensitiveareas.Instructions:
Tosetclearanceonthesealintheswivel,removetopallenhead
plug; with flat head screw driver turn in screw until it bottoms
outthenbackoffscrew1/8turn. ThespraynozzlesintheHydro
Twister will have to be sized according to the output of your
machine.