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.

SYSTEM INFORMATION 11
TRAILERS:
Trailers are designed to match to your washer to increase
productivity. They have been field-tested to prove their
reliabilityinthetoughestapplications.
The unique torsion axle suspension provides the smoothest
ride available and prevents damage to the pressure washer
from a harsh ride. The enhanced wheel travel keeps road
vibrationandrattletoaminimum.
Trailersoutfittedwithelectricbrakesrequireaproperlyinstalled
electricbrakecontroller.Lightwireharnessesareprovidedforall
trailers(flat4poletype).Alternatetypesofadaptersareavailable
at auto or trailer parts supply stores.
ST40004Seriestrailersoffera190gallonwater
tank with an integrated hot water pressure washer system. This
package employs a direct drive pump and 12 volt diesel fired
waterheatingsystem.Optionalhosereelscanbeinstalledonthe
rear deck of the trailer for added storage convienience. Torsion
axle suspension is a standard feature on this model. Optional
StainlessSteelweatherguardpanelsforthelowerburnersystem
and upper pressure system are also available.
Systemsequippedwithoptionalhosereels providetheuserwith
added benefit of side discharge for quick hose use. Hose reels
also increase the hose life and reduce risk of damage due to
kinking or dragging. Use hose reel latches or appropriate tie
downs to prevent road damage to guns, hoses, and wands while
trailering.
ITEM FUNCTION REQUIRED
3 MTH.
OR 3000
MILES
6 MTH.
OR 6,000
MILES
12 MTH.
OR
12,000
MILES
Brakes Test that they are operational
Brake
Adjustment Adjust to proper operating clearance x
Brake Magnets Inspect for wear and current draw x
BrakeLinings Inspect for wear and
contamination x
Brake
Controller Check for correct amperage, modulation x
BrakeCylinders Check for leaks / sticking x
Brakelines Inspect forcracks leaks orkinks x
Trailer Brake
Wiring Inspect for bare spots, fray,ect. x
Breakaway
Systems Check batterycharge and switch operation
Hub/Drum Check for abnormal wear or
scoring x
Wheel Bearings
&Cups Inspect for corrosion or wear: clean & repack x
Seals Inspect for leakage;replace if
removed x
Springs Inspect for wear / loss or arch x
Suspension
Parts Inspect for bending loose fasteners/ wear x
Hangers Inspect welds x
Wheel Nuts &
Bolts Tighten to specifiedTorque value (Lug =70-90ft lbs) x
Wheels Inspect forcracks,dents or
distortion x
Tire Inflation
Pressure Inflate to tire manufacturer's specs.
TireCondition Inspect for cuts,wear, bulging,
ect. x
TRAILER MAINTENANCE SCHEDULE
Before every use
Before every use
Before every use
LunetteEyeassembliesarealsoavailableforthehooktrailering
hitch.
Specialmaintenanceandtraileringconsiderations:Checkwith
localandstatevehiclecodestoconfirmyourbrakeconfiguration
iscompliant.Somestatesrequireelectricand/orsurgebrakeson
alltrailers.Nevertowwithoutproperlyadjustedrearviewmirrors,
brakeactuators,or lights. Tire pressureandwheellugnutsmust
also be checked on a regular basis. Trailer tongue weight on the
tow vehicle hitch should never be under 8% of the total trailer
(loaded) weight. Insufficient tongue weight can result in
"fishtailing" and loss of control of the trailer AND tow vehicle.

12 TROUBLE SHOOTING GUIDE
PROBLEM PROBABLE CAUSE* REMEDY
Charge or replace battery, add electrolyte if
battery is new.
Clean connections.
Connect or replace damaged cables.
Replace or repair seized part.
Repair or replace.
Check engine power switch.
Add oil to engine, check more frequently.
Fill with the appropriate fuel.
Replace or clean fuel filter.
Choke only as required.
See engine manual or engine dealer.
Lower the pressure on the unit and check for
correct engine speed (RPM).
Remove head and wire brush deposits.
Check cord, plug, socket, and breaker.
Reset manual overload by depressing the thermal
switch on the outside of the motor or starter after the
motorhascooled.CAUTION!Automaticoverloadwill
restart the motor automatically when it has cooled.
Check power switch.
Replace or repair motor and/or wiring.
Connect water Supply.
25psiminimum.
Descale coil for better water flow.
Remove spray nozzle and pull trigger to check
auto-start function
Check mechanical function & electrical signal to relay.
Clean valve assembly or replace gun.
Turn water on.
Clean or replace with proper size.
Close soap valve or submerge detergent pickup
tube into solution.
Clean obstruction or scale deposits from coil
with coil cleaner.
Crack open fitting on high pressure outlet of pump.
Install Nozzle.
Dual wand valve must be closed and high
pressure nozzle installed.
Replace hose, quick coupler, or o-ring in the
quick coupler.
Clean and check more frequently.
Replace with nozzle of proper size.
Tighten or replace with correct belt.
Install pressure gauge on pump head to adjust
pressure. Check valve seat on unloader.
Resealfittings and inspectinlet hoses forairleaks.
Increase water supply flow.
Clean out or replace worn valves.
Check fittings and hose for air tight seal, clean
inlet strainer screen.
Replace seals.
Pressure feed the pump and replace L.P. seals
if water leaks from the pump head.
Replace pump or bearing.
Locate point of oil leakage and replace damaged
O-ring or seal.
* The most recurring probable cause is listed first. Repairs should be made only by a qualified technician.
PowerSystem:GasolineEngineDriven
Engine will not start or crank over.
Engine will not start but will crank
over.
Engine bogs down under load,
whenever spray gun is triggered.
Electric motor does not start.
Machine will not auto-start(If
equipped).
Trigger gun leaks or will not shut off.
Pumprunsbutthereisnospraypressure.
Pump runs but has low spray pressure.
Pump runs but there is erratic,
fluctuating pressure.
Excessive crankshaft play or loud,
knocking noise in pump.
Oil leaking from pump.
Pumping System
Battery dead.
Dirty battery connection.
Battery cables disconnected.
Engine, pump, or gearbox is seized.
Keyswitch, solenoid and starter on engine
defective.
Engine power switch is off or defective.
Low oil shut down is activated.
Low on fuel.
Fuel filter is clogged.
Engine flooded or starved.
Engine needs to be repaired or replaced.
Operating in high elevation.
Carbon deposits on cylinder head.
No electric power.
Thermal overload in the motor or starter has
been tripped.
Power switch inoperative.
Electric motor or wiring failure.
No water to inlet.
Must have adequate water supply.
Coil scale build up.
Check filter screen & inlet pressure.
Inlet flow switch defective or jammed with
debris.
Debris in gun valve assembly.
Water turned off.
Nozzle is plugged.
Inlet chemical injection valve is open, without the
end of the pickup tube inserted into detergent.
Coil on hot water machines is obstructed.
Priming of pump after run dry.
Nozzle not installed.
Dual wand valve is open.
Leaky discharge hose or quick coupler.
Water sprays out around nozzle.
Inlet strainer clogged.
Worn or wrong size nozzle.
Belt slippage.
Unloader valve worn or improperly adjusted.
Air leak in inlet plumbing.
Inadequate incoming water supply.
Stuck inlet or discharge valves.
Restricted inlet or air entering the inlet plumbing
on the pump.
Leaking H.P. seals.
Leaking L.P. seals.
Broken or worn bearing or connecting rod in
crankcase.
Loose drain plug or damaged seal.
Power System: Electric Motor Driven

REMEDYPROBABLE CAUSE*
Check valve in strainer clogged.
Chemical valve not open or clogged.
Strainer not submerged in solution.
Detergent hose cut or kinked.
Check valve malfunctioning.
Brass knob on injector is closed.
Unit not in low pressure mode.
Detergent hose cut or kinked.
Strainer plugged or not submerged.
Internal injector parts corroded or stuck.
Outlet water temperature too high.
Unloader failure/Coil overheating/Excessive pressure
Excessive overpressurizing and system
spikes.
Burner switch not on.
Diesel fuel level low.
Trigger on spray gun not pulled.
Fuel filter plugged or loose.
Spray nozzle plugged.
Overload on burner motor tripped.
Nozzle not in wand.
Low water pump pressure.
Fuel pump or nozzle stopped.
Vacuum/Flow/Pressure or thermostat switch
faulty.
Fuel solenoid valve faulty.
Low generator voltage output.
Burner relay faulty (12-V Burner only)
Fuel to air ratio out of adjustment.
Fuel nozzle partially clogged.
Ignition transformer not providing spark to fuel.
Fuel to air ratio out of adjustment.
Excessive soot on coils.
Improper voltage at burner.
Burner input too high for conditions.
Water flow restricted.
Hightemperaturelimitswitchfaultyorsettoohigh.
Faulty Flow / Pressure / Vacuum switch.
Faulty fuel solenoid.
Burner input too low for conditions.
Battery voltage Low.
RPM too low.
Engine charging system faulty.
Electrodes misadjusted.
Air band too far open.
Burner amp draw too high.
Clean or replace. Rinse after each use.
Open chemical valve or clean.
Submerge strainer and replenish chemical.
Inspect hose, replace as necessary.
Repair or replace check valve.
Open by turning counter clockwise.
Open dual wand or install low pressure tip.
Inspect hose, replace as required.
Check screen on strainer pickup tube.
Disassemble, clean or replace.
Use with cold water (150º Maximum) If installed
on discharge side of coil.
Turn machine off, wait a few minutes and
restart. If problem continues, take in for repair.
Take in for system check.
Turn switch on; Thermostat on if equipped.
Fill burner tank with #2 diesel.
Squeeze trigger to fire burner.
Clean or tighten fuel filter. (Check fuel pressure)
Clean spray nozzle.
Reset overload, locate source of overload.
Install nozzle in wand.
See pumping systems trouble shooting.
Check fuel pressure, filter, fuel lines. Replace
fuel pump and/or nozzle.
Check electrical continuity with pump spraying
and burner on.
Replace fuel valve if it does not open when
power is applied.
Adjust generator RPM for proper voltage under
full load conditions.
Replace burner relay.
Set air band and fuel pressure to specs.
Replace nozzle of proper size.
Replace ignition transformer, clean and adjust
electrodes.
Set air band and fuel pressure to specs.
Clean soot off to improve air flow.
Adjust RPM of generator (if equipped)
Decrease fuel pump pressure and/or fuel nozzle size.
Clean or replace nozzle of proper size. Descale
coil and clear obstructions.
Replace or reset temperature limit switch.
Replace switch.
Replace solenoid.
Increase fuel pump pressure and/or fuel nozzle
size.
Have battery checked and load test, replace if
necessary.
Engine RPM should be 3400-3600 RPM w/no load.
Check engine charging system - Must have 16
Amp output.
Adjust electrodes to maximum 1/8" gap.
Adjust for proper burn.
Check amp draw of burner motor - should be 13
amp or less. Check amp draw of transformer
should be 4.2 or less.
PROBLEM
Inlet injection will not siphon chemical.
Water is emitted from the chemical
pickup tube.
Downstream injector will not siphon
chemical.
Pressure relief relieving water.
Burst disk relieving water.
Burner will not fire.
Burner will not fire, plus diesel fumes
are emitted from the exhaust port.
Burner fires and smokes.
Discharge water temperature exceeds
recommended operating temperature.
Burner continues to fire even when
trigger on spray gun is released
Discharge water temperature not
reaching maximum operating temperature.
Battery keeps losing voltage.
(For 12 volt burner systems)
Heating/Burner System-Diesel Fired
WARNING: High voltage on ignitor
can cause electrical shock.
Disconnect power before servicing.
WARNING:Replaceinsulation.
Unburned fuel can saturate it and
cause a fire.
TROUBLE SHOOTING GUIDE 13

14 120VAC BURNER TROUBLE SHOOTING FLOW
CHART
IS THERE DIESEL FUEL
IN THE TANK?
IS THE THERMAL O/L ON
THE BURNER MOTOR OR
THE BREAKER TRIPPED?
DO YOU HAVE 110-
120VAC OUTPUT FROM
THE GENERATOR WHILE
PULLING THE TRIGGER?
IS THE SPRAY
TIP INSTALLED?
IS THE BURNER SWITCH
TURNED ON & THE
THERMOSTAT TURNED
UP?
IS THE TRIGGER
BEING PULLED?
IS THE FUEL
PRESSURE 100-
140PSI?
DOES THE LIGHT ON THE
BURNER SWITCH COME
ON WHEN THE TRIGGER
IS PULLED?
CRACK COPPER FUEL
LINE. DOES FUEL COME
OUT WHEN TRIGGER IS
PULLED?
ADD
FUEL
INSTALL SPRAY TIP. BURNER
REQUIRES 1000 PSI TO OPERATE. IF
UNIT IS EQUIPPED W/DUAL LANCE
WAND, CLOSE VALVE TO INCREASE
PRESSURE. VERIFY PROPER NOZZLE
SIZE.
TRIGGER MUST BE PULLED TO
OPERATE PRESSURE/FLOW SWITCH.
TURN SWITCH ON & TURN THERMOSTAT
UP
RESET THE O/L AND/OR BREAKER.
PROCEED TO NEXT STEP.
TURN THE THERMOSTAT FULLY CLOCKWISE & CHECK FOR CONTINUITY- REPLACE IF NO
CONTINUITY. CHECK FOR CONTINUITY ON THE PRESSURE/FLOW SWITCH WHEN THE TRIGGER
IS PULLED-REPLACE IF NO CONTINUITY.
CHECK BELT TENSION-ADJUST IF NEEDED. ADJUST ENGINE RPM TO RUN IN SPEC-VOLTAGE
OUTPUT CHANGES WITH GENERATOR SPEED. CHECK CAPACITOR FOR 16MFD-ARC
TERMINALS WITH SCREW DRIVER BEFORE TESTING. IF ALL THESE TEST GOOD, REPLACE
GENERATOR.
ADJUST FUEL PRESSURE TO SPEC. CHECK/REPLACE FILTER & REPAIR ANY AIR LEAKS. IF
PROPER PRESSURE CANNOT BE OBTAINED, REPLACE FUEL PUMP.
IS THERE FUEL
VAPOR COMING OUT
OF THE BURNER
EXHAUST?
UNPLUG THE FUEL SOLENOID & CHECK THE TRANSFORMER FOR SPARK !!!CAUTION HIGH
VOLTAGE!!!
CHECK ELECTRODE ADJUSTMENT AND AIR BAND ADJUSTMENT(SEE BURNER SPEC
SHEET). REPLACE FUEL NOZZLE. REPLACE INSULATION IF IT IS SATURATED WITH DIESEL
FUEL.
REPLACE FUEL
SOLENOID VALVE
TROUBLESHOOTING ENDS: REPEAT PROCEDURE UNTIL TROUBLE FREE OPERATION IS
OBTAINED
No
No
No
No
YES
No
No
No
Yes
Yes
Yes
NO
Yes
No
Yes
NO
Yes
Yes
Yes
BURNER DOES
"NOT" COME ON BURNER DOES "NOT" TURN OFF
!!CAUTION!! TURN UNIT
OFF IMMEDIATELY AND
REPAIR.
LIGHT ON THE BURNER SWITCH TURNS OFF
WHEN THE TRIGGER IS RELEASED?
REPLACE FUEL
SOLENOID
VALVE
REPLACE
PRESSURE
SWITCH
Yes No
CHECK OUT UNIT: REPLACE ANY
DAMAGED HOSES, O-RINGS AND/OR
TRIGGER GUN.

12VDC BURNER TROUBLE SHOOTING FLOW CHART
15
IS THERE DIESEL FUEL
IN THE TANK?
IS THE BREAKER ON
THE CONTROL PANEL
TRIPPED OR IS THE
INLINE FUSE BLOWN?
IS THE SPRAY
TIP INSTALLED?
IS THE BURNER SWITCH
TURNED ON & THE
THERMOSTAT TURNED
UP?
IS THE TRIGGER
BEING PULLED?
IS THE FUEL
PRESSURE 140PSI (+-
10PSI)?
DOES THE BURNER
MOTOR TURN?
ADD
FUEL
INSTALL SPRAY TIP. BURNER REQUIRES
1000PSI TO OPPERATE. IF THE UNIT IS
EQUIPED W/DUAL LANCE WAND CLOSE THE
VALVE TO INCREASE PRESSURE. VERIFY
PROPER NOZZLE SIZE.
TRIGGER MUST BE PULLED TO
OPPERATE PRESSURE/FLOW SWITCH.
TURN SWITCH ON & TURN THERMOSTAT
UP
RESET THE BREAKER AND/OR REPLACE THE FUSE-LOOK FOR SHORT. CHECK ENGINE OUTPUT-
MUST BE 12VDC OR HIGHER & LOAD TEST THE BATTERY. CHECK ENGINE RPM: 3200 FOR BELT
DRIVE, 3400RPM FOR DIRECT DRIVE. REPAIR CHARGING CIRCUIT AND/OR REPLACE BATTERY
IF NEEDED. LOW VOLTAGE WILL EFFECT BURNER PERFORMANCE.
CHECK FOR 12VDC AT THE SMALL TERMINALS ON THE BURNER RELAY WHEN THE TRIGGER IS
PULLED AND THE BURNER SWITCH IS ON AND THE THERMOSTAT IS TURNED UP. DO YOU GET
VOLTAGE?
ADJUST FUEL PRESSURE TO SPEC. CHECK/REPLACE FILTER & REPAIR ANY AIR LEAKS. IF
PROPER PRESSURE CANNOT BE OBTAINED, REPLACE FUEL PUMP.
IS THERE FUEL
VAPOR COMING OUT
OF THE BURNER
EXHAUST?
CHECK THE TRANSFORMER FOR SPARK !!!CAUTION HIGH VOLTAGE!!! CHECK ELECTRODE
ADJUSTMENT AND AIR BAND ADJUSTMANT (SEE BURNER SPEC SHEET FOR SETTING-
ELECTRODE GAP IS VERY IMPORTANT). CHECK ELECTRODES FOR CRACKS. REPLACE FUEL
NOZZLE. REPLACE INSULATION IF IT IS SATURATED WITH DIESEL FUEL
TROUBLESHOOTING ENDS: REPEAT PROCEEDURE UNTIL TROUBLEFREE OPERATION IS
OBTAINED
No
No
No
No
Yes
No
Yes
No
Yes
Yes
Yes
Yes
JUMP THE TWO BIG RELAY
TERMINALS TOGETHER (CAUTION-
ONLY FOR 1-2 SECONDS). IF THE
BURNER MOTOR STARTS, REPLACE
THE RELAY- IF NOT REPLACE THE
BURNER MOTOR.
CHECK HEAT SWITCH/THERMOSTAT FOR
CONTINUITY(THERMOSTAT MUST BE ADJUSTED TO HIGHEST
SETTING BEFORE TESTING-REPLACE IF NO CONTINUITY). CHECK
PRESSURE SWITCH FOR CONTINUITY WHEN MACHINE IS
RUNNING AND WITH TRIGGER PULLED-REPLACE IF NO
CONTINUITY.
No
No
Yes No
Yes
Yes
BURNER DOES
"NOT" COME ON
BURNER DOES
"NOT"TURN
OFF
!!CAUTION!! TURN UNIT
OFF IMMEDIATELY AND
REPAIR
DISCONNECT THE WIRE(S) FROM
ONE OF THE SMALL TERMINALS
OF THE BURNER RELAY. DOES
THE BURNER CONTINUE TO FIRE?
REPLACE
BURNER RELAY REPLACE THE
PRESSURE/
FLOW SWITCH
Yes
CHECK OUT THE UNIT: REPLACE
ANY DAMAGED HOSES, O-RINGS
AND/OR TRIGGER GUN.
No

WIRING DIAGRAMS ST
16

17
WIRING DIAGRAMS ST

WIRING DIAGRAMS SR
18

19
WIRING DIAGRAMS SK

20
WIRING DIAGRAM SH