Hydro tek Cps series User manual

OPERATION and MAINTENANCE

MANUAL

CPS Series

CPX Series

HD Series

HP Series

HN Series

SM Series

SS Series

SCX Series

SC Series

IMPORTANT: TO REDUCE RISK OR INJURY, READ OPERATING

INSTRUCTIONS CAREFULLY BEFORE USING

Certified to

ISO 9001:2008

INTRODUCTION ................................................................................................................ 2, 3, 4

Statement of Warranty, Emissions Statement

SAFETY WARNINGS......................................................................................................... 4, 5, 6

Electrical Precautions

Fire Precautions

Ventilation Precautions

Spray Injection Precautions

Personal Hazard Precautions

OPERATING INSTRUCTIONS........................................................................................... 7, 8, 9

Before Start Up

Operation

Shut Down & Antifreeze Protection

SYSTEM INFORMATION

Power System........................................................................................................... 9, 10

Electric Motor/Gasoline Engine/Diesel Engine

Power Transmission System – direct, & belt drive

Generator – auxiliary power, circuit breaker

Pumping System..................................................................................................... 10, 11

Pump

Unloader and Pressure Relief Valve

Chemical Injection System

Water Supply

Heating System....................................................................................................... 11, 12

Coil/Heat Exchanger System

Natural Gas / Propane Fired Burner

Diesel Fired Burner

Pressure Delivery System............................................................................................. 13

Discharge Hose\Gun/Wand Assembly

Nozzles

Accessories ...................................................................................................... 13, 14, 15

Wet sandblaster, turbo nozzle, reels, Hydro Twister®, Wastewater recovery

TRAILERS ............................................................................................................................... 16

TROUBLESHOOTING GUIDE ..................................................................................... 17, 18, 19

BURNER TROUBLESHOOTING GUIDE ........................................................................... 20, 21

MAINTENANCE LOG .............................................................................................................. 22

NOZZLE CHART...................................................................................................................... 23

SERVICE/MAINTENANCE SCHEDULE .....................................................................Back cover

TRAILER REGISTRATION – CERTIFICATE OF ORIGIN ...................... Enclosed (If applicable)

TEST SPECIFICATIONS ...............................................................................................Enclosed

ENGINE SHEET.............................................................................................................Enclosed

PARTS LIST / EXPLODED VIEW ..................................................................................Enclosed

WIRING DIAGRAMS......................................................................................................Enclosed

INSTALLATION INSTRUCTIONS..................................................................................Enclosed

USE ONLY HYDRO TEK CERTIFIED ORIGINAL EQUIPMENT REPLACEMENT PARTS, FAILURE

TO DO SO COULD LEAD TO WARRANTY EXCLUSION AND SEVERE BODILY INJURY

TABLE OF CONTENTS 1

THANK YOU: The employees and management of

HYDRO TEK SYSTEMS, INC. thank you for selecting

our products. The production and quality assurance

team have taken the greatest care to ensure that your

new pressure washer exceeds the standards set by

you, the customer, by Hydro Tek engineering and

ISO9001:2008 quality management standard, and by

UL1776 safety certification.

YOUR RESPONSIBILITY: This operator’s manual was

compiled for your benefit. By studying and following the

safety, installation, operation, maintenance, and

troubleshooting information contained within, you can

look forward to many years of trouble-free service from

your equipment. Every person who will operate the

equipment must read and follow the safety warning and

operating instruction sections of this owner’s manual

prior to use. You are responsible for operating the

product properly and safely. You are also responsible

to follow the maintenance schedule on the back page

of this manual to keep your warranty active.

FREIGHT DAMAGE: If delivered by a trucking

company, please inspect for any concealed freight

damage and note this on the paperwork from the

trucking company before signing. Should you find

damage has occurred during shipping, do not return the

damaged merchandise to Hydro Tek, but file a claim

immediately with the freight carrier involved.

QUESTIONS: Help us provide you with the fastest

service. Please locate the warranty registration card

enclosed and return it to Hydro Tek to register your

machine. If problems occur, contact the dealer you

bought your machine from, a local authorized Hydro

Tek service center, or call Hydro Tek at 1-(909) 799-

9222 option 4 or ask for technical services.

GETTING STARTED: If your dealer has not prepared

the machine for startup, you may need to connect the

hose to the pressure outlet on the washer and connect

the other end of the hose that swivels to the trigger gun

inlet and tighten. Mobile Wash Skids are engine

powered and shipped from the manufacturer with the

fuel tanks empty and without the battery. Connect the

battery cables (positive lead first) and follow the

operation instructions for starting. High Pressure

Steamers are electric powered and will require an

appropriate electric outlet or disconnect box and an

electric plug that is rated for your machine’s voltage and

amperage and matches to your electrical socket.

Smaller machines are equipped with a ground fault

interrupter on the electrical cord and you will need to

press the reset button after it is plugged in. (See

Operating Instruction section and enclosed page on

Installation Guidelines).

ONE YEAR PARTS & LABOR WARRANTY: Hydro

Tek Systems, Inc. (Hydro Tek) promises to repair Hydro

Tek branded power washers if defective in materials or

workmanship for one year from the date of original retail

purchase including the cost of PARTS and LABOR, but

you must pay transportation/shipping costs and travel

time.

LIFETIME PARTS/ONE YEAR LABOR WARRANTY:

The Spiralast™ heating coil (up to 4200psi) on the

Hydro Tek branded product line includes a lifetime parts

warranty and a replacement coil will be provided as

long as you own the machine. (Starting February 2014

mfg dates)

ONE YEAR PARTS WARRANTY: Hydro Tek will

provide replacement parts on accessories and on all

other product brands including Hot2Go power washers,

Hydro Vacuum, or Hot Link heaters. (Labor is not

included)

TWO YEAR EVAPORATIVE EMISSIONS CONTROL

SYSTEM WARRANTY: Hydro Tek will repair or replace

a defective evaporative emission control system

(EECS) part on your pressure washer for a period of

two years. (more information on next page)

Items and Conditions Not Covered:

1. Normal wear items such as discharge hose, guns,

wands, spray arms, nozzles, quick couplers, o-rings,

motor & generator brushes, filters, fuses, belts, & tires.

2. Cost of regular maintenance/adjustments, damage

from lack of maintenance or correct operation

3. Damage due to freezing, abrasive fluids, chemical

deterioration, scale build-up, or water ingress.

4. Damage from fluctuation in electrical or water

supply.

5. Any product or part that has been altered, modified,

over pressurized, misused, or has been in an accident.

6. Dealer installation or damage from improper

installation of the machine or alteration by a dealer or

promise of additional warranty from dealer. The

manufacturer warranty is not transferable from the

dealer to the retail purchaser on used or rented

equipment.

7. Labor is not paid if the dealer that serviced your

machine is not an authorized service center.

8. Labor is not paid on added accessories such as

surface cleaners, hose reels, wastewater recovery, hot

link water heaters, and filtration.

WARRANTY PROVIDED BY OTHERS: Gasoline and

diesel engines and some electric motors are warranted

by the manufacturer of the component and their

warranty is provided through the manufacturer’s service

centers. Contact your authorized distributor for the

closest repair center. Additional extended warranties

INTRODUCTION – WARRANTY 2

from 3 to 5 years may be provided by engine or pump

manufacturer.

GENERAL CONDITIONS: Hydro Tek’s responsibility

with respect to claims is limited to making the required

repairs or replacements to the original retail purchaser,

and no claim of breach of warranty shall be cause for

any cancellation or rescission 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.

This supersedes any and all previous warranty

statements for products purchased after November

2015. Hydro Tek is not liable for indirect, incidental or

consequential damages including any cost of substitute

equipment, loss of revenue, pecuniary expense or loss,

or inability to use a Hydro Tek product. Hydro Tek

disclaims all implied warranties, including those of

merchantability and fitness for use for a particular

purpose. Some states do not allow exclusions or

limitations on how long an implied warranty lasts, so the

above exclusions may not apply to you. It is the buyer’s

responsibility to ensure installation and use of Hydro

Tek products conforms to local codes.

INTERNATIONAL END USERS: Warranty is furnished

by authorized Hydro Tek dealers or distributors only;

and the warranty may vary depending on the dealer or

distributor and may be different from Hydro Tek’s

warranty; please consult distributor for details.

HOW TO OBTAIN WARRANTY SERVICE:

1. List washer model#______________________.

List serial #____________________ (on base plate of

machine near the motor/engine).

2. Contact your local service dealer and return the

Hydro Tek washer or part within the warranty period

along with your sales receipt. To locate service, call

customer service at Hydro Tek or go to:

www.hydrotek.us and enter your zip code.

3. You also have the option to obtain a return goods

authorization and ship the questionable part freight

prepaid directly to the manufacturer. The part will be

evaluated upon receipt. If found defective, Hydro Tek

will repair or replace part under the conditions of

warranty and return to you.

4. If the defective component is an engine or motor

made by another manufacturer, we, or your authorized

Hydro Tek dealer, can help you obtain warranty service

through the specific manufacturer’s local authorized

service center.

5. If you are unable to resolve the warranty claim, write

to Hydro Tek Systems, Inc. 2353 Almond Ave.

Redlands, CA 92374 USA, Attn.: Technical Services.

Please enclose a copy of the dated purchase receipt

and explain the nature of the defect.

EVAPORATIVE EMISSION CONTROL STATEMENT

The California Air Resources Board and Hydro Tek

Systems, Inc. are pleased to explain the evaporative

emission control system’s warranty on your 2023

Pressure Washer. In California, new equipment that

use small off-road engines must be designed, built, and

equipped to meet the State’s stringent antismog

standards. Hydro Tek Systems, Inc. must warrant the

evaporative emission control system on your Pressure

Washer for the period listed below provided there has

been no abuse, neglect or improper maintenance of

your equipment leading to the failure of the evaporative

emission control system.

Your evaporative emission control system may include

parts such as: carburetors, fuel tanks, fuel lines (for

liquid fuel and fuel vapors), fuel caps, valves, canisters,

filters, clamps, connectors, and other associated

components.

MANUFACTURER’S WARRANTY COVERAGE:

This evaporative emission control system is warranted

for two years. If any evaporative emission-related part

on your equipment is defective, the part will be repaired

or replaced by Hydro Tek Systems, Inc.

OWNER’S WARRANTY RESPONSIBILITIES:

As the Pressure Washer owner, you are responsible for

performance of the required maintenance listed in your

owner’s manual. Hydro Tek Systems, Inc. recommends

that you retain all receipts covering maintenance on

your Pressure Washer, but Hydro Tek Systems, Inc.

cannot deny warranty coverage solely for the lack of

receipts.

As the Pressure Washer owner, you should be aware

that Hydro Tek Systems, Inc. may deny you warranty

coverage if your Pressure Washer or a part has failed

due to abuse, neglect, or improper maintenance or

unapproved modifications.

You are responsible for presenting your Pressure

Washer to a Hydro Tek Systems, Inc. distribution center

or service center as soon as the problem exists. The

warranty repairs shall be completed in a reasonable

amount of time, not to exceed 30 days. If you have a

question regarding your warranty coverage, you should

contact Hydro Tek Systems, Inc., at 1-909-799-9222.

GENERAL EMISSIONS WARRANTY COVERAGE:

Designed, built, and equipped so as to conform with all

applicable regulations; and free from defects in

materials and workmanship that causes the failure of a

warranted part for a period of two years.

The warranty on evaporative emissions-related parts

will be interpreted as follows:

(1) Any warranted part that is not scheduled for

replacement as required maintenance in the written

instructions required by 13 CCR § 2760 (e) must be

warranted for the warranty period defined above. If any

such part fails during the period of warranty coverage,

WARRANTY-EMISSION CONTROL 3

it must be repaired or replaced by the Holder or the

Holder’s contracted warranty provider according to

subsection (4) below. Any such part repaired or

replaced under the warranty must be warranted for a

time not less than the remaining warranty period.

(2) Any warranted part that is scheduled only for regular

inspection in the written instructions required by 13

CCR § 2760 (e) must be warranted for the warranty

period defined above. A statement in such written

instructions to the effect of “repair or replace as

necessary” shall advise owners of the warranty

coverage for evaporative emissions related parts.

Replacement within the warranty period is covered by

the warranty and will not reduce the period of warranty

coverage. Any such part repaired or replaced under

warranty must be warranted for a time not less than the

remaining warranty period.

(3) Any warranted part that is scheduled for

replacement as required maintenance in the written

instructions required by 13 CCR § 2760 (e) must be

warranted for the period of time prior to the first

scheduled replacement point for that part. If the part

fails prior to the first scheduled replacement, the part

must be repaired or replaced by the manufacturer

according to subsection (4) below. Any such part

repaired or replaced under warranty must be warranted

for a time not less than the remainder of the period prior

to the first scheduled replacement point for the part.

(4) Repair or replacement of any warranted part under

the warranty provisions of this article must be

performed at no charge to the owner at a warranty

station.

(5) Notwithstanding the provisions of subsection (4)

above, warranty services or repairs must be provided at

distribution centers that are franchised to service the

subject engines or equipment.

(6) The owner must not be charged for diagnostic labor

that leads to the determination that a warranted part is

in fact defective, provided that such diagnostic work is

performed at a warranty station.

(7) Throughout the evaporative emission control

system's warranty period set out in subsection (b)(2),

the Holder or the Holder’s contracted warranty provider

must maintain a supply of warranted parts sufficient to

meet the expected demand for such parts and must

obtain additional parts if that supply is exhausted.

(8) Manufacturer-approved replacement parts that do

not increase the exhaust or evaporative emissions of

the engine or evaporative emission control system must

be used in the performance of any warranty

maintenance or repairs and must be provided without

charge to the owner. Such use will not reduce the

warranty obligations of the Holder or the Holder’s

contracted warranty provider.

(9) The use of add-on or modified parts may be grounds

for disallowing a warranty claim made in accordance

with this Article. The Holder or the Holder’s contracted

warranty provider will not be liable under this Article to

warrant failures of warranted parts caused by the use

of an add-on or modified part.

(10) The Holder shall provide any documents that

describe that Holder warranty procedures or policies

within five working days of request by the Executive

Officer.

WARRANTED PARTS:

The repair or replacement of any warranted part

otherwise eligible for warranty coverage may be

excluded from such warranty coverage if Hydro Tek

Systems, Inc. demonstrates that the Pressure Washer

has been abused, neglected, or improperly maintained,

and that such abuse, neglect, or improper maintenance

was the direct cause of the need for repair or

replacement of the part. That notwithstanding, any

adjustment of a component that has a factory installed,

and properly operating, adjustment-limiting device is

still eligible for warranty coverage. The following

emission warranty parts list are covered (use portions

of this list applicable to your Pressure Washer):

(1) ............................................................... Fuel Tank

(2) ................................................................ Fuel Cap

(3) .............. Fuel Lines (for liquid fuel and fuel vapors)

(4) .................................................... Fuel Line Fittings

(5) ................................................................. Clamps*

(6) .......................................... Pressure Relief Valves*

(7) ...................................................... Control Valves*

(8) .................................................. Control Solenoids*

(9) ................................................ Electronic Controls*

(10) .............................. Vacuum Control Diaphragms*

(11) .................................................... Control Cables*

(12) ................................................. Control Linkages*

(13) ...................................................... Purge Valves*

(14) .............................................................. Gaskets*

(15) ......................................... Liquid/Vapor Separator

(16) ................................................... Carbon Canister

(17) ................................. Canister Mounting Brackets

(18) ......................... Carburetor Purge Port Connector

*Note: As they relate to the evaporative emission

control system.

ELECTRICAL PRECAUTIONS:

1. Observe all State, Local, and National codes for

the installation of your electrically powered washer.

2. For a grounded product rated 250 volts, single

phase, or less: This product is provided with a ground

fault circuit interrupter built into the power cord plug.

(8hp single phase excluded; order GFCI separately). If

replacement of the plug or cord is needed, use only

identical replacement parts.

3. GROUNDING INSTRUCTIONS:

Cord Connected, Grounded Products:

WARRANTY – SAFETY WARNINGS 4

This product must be grounded. If it should

malfunction, grounding provides a path of least

resistance for electric current to reduce the risk of

electric shock. The product is equipped with a cord

having an equipment-grounding conductor. 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 electrocution. Check

with a qualified electrician or service personnel if you

are in doubt as to whether the outlet is properly

grounded. Do not modify the 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 qualified

electrician. Do not use any type of adaptor with this

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. EXTENSION CORDS: 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 engineer or competent electrician.

7. Use only in a dry area. Do not handle electrical

cords and plugs when they are wet, when your hands

are wet, or when standing in water. Do not spray high-

pressure water on to the machine.

8. Disconnect power supply before making any repairs

or adjustments.

9. Transformer on burner is 20,000 volts. Disconnect

battery cable before servicing burner or engine on 12-

volt systems.

FIRE PRECAUTIONS:

1. DO NOT use improper fuels or solvents in this

equipment, and only fill with the correct fluids when the

unit is in an OFF condition, main power is disconnected,

and engine and burner are cool.

NE PAS UTILISER D’ESSENCE, DE PRODUITS DE

VIDANGE NI D’HUILE CONTENANT DE L’ESSENCE OU

DES SOLVANTS.

2. If equipped with a diesel heated burner system, fill

the diesel burner fuel tank with #2 diesel fuel, kerosene,

or approved alternate fuel. NEVER use gasoline. Do

not confuse gasoline and diesel fuel tanks.

3. NEVER operate this equipment in the presence of

flammable vapors, dust, gases, or other potentially

combustible materials.

4. AVOID contact with the exterior of the coil/heat

exchanger assembly, mufflers, and exhaust port or

stack to prevent burns.

5. DO NOT store fuel or other flammable materials

near the burner or any other open flame.

6. Diesel fired or gasoline power units are designed for

outdoor use and installation only.

7. HE Series (all electric) is designed for indoor use.

8. Natural Gas/propane heated units are for indoor

use only. Venting is required. Outdoor use must be

protected from wind intrusion.

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 run switch to turn the burner

off – this may cause a safety hazard.

10. Warning: Burner (water heater) should start only

when water is sprayed. Stop the system/engine

immediately if burner continues to fire when trigger gun

is off.

VENTILATION PRECAUTIONS:

1. The HE Series (all electric) functions without the

use of fuel and combustible materials utilizing electricity

for heat generation. Ventilation is only needed for

keeping the eliminating heating build around the

machine

2. Use diesel heated and/or engine powered products

only in well ventilated areas. Exhaust gases contain

carbon monoxide, an odorless, deadly poison.

3. Observe all State, Local, and National codes

providing for indoor use or installation of this unit.

4. Provide adequate ventilation to prevent excess

carbon monoxide levels, engine overheating and

inefficient burner combustion (min. 2’ air space). Do not

restrict normal engine airflow.

5. THIS MACHINE IS NOT TO BE CONNECTED TO A

TYPE B GAS VENT. NE PAS RACCORDER CET

APPAREIL A UN TUYAU D’EVACUATION DE GAZ DU

TYPE B;

6. For engine driven units mounted in a van or box

truck type vehicles, provide an external engine exhaust

line that is larger in diameter than the factory exhaust

pipe and vent the exhaust to the outside of the vehicle,

but not below the vehicle’s interior floor height. Also,

insure adequate fresh air circulation within the van for

engine cooling purposes to prevent heat build-up and

for engine fresh air intake. Clearance of at least 12” is

recommended on all sides of the unit. Provide a burner

exhaust vent, at least 8” diameter, to the outside

through the van roof, or though the side panel that is at

least 10” in diameter, and position this vent to avoid

water, dirt and debris collection. No flammable liquids,

WARNING

THIS EQUIPMENT CAN BE HAZARDOUS TO THE OPERATORS

SAFETY AND ONLY AUTHORIZED PERSONNEL WHO HAVE

READ AND UNDERSTOOD THE OPERATION MANUAL SHOULD

BE PERMITTED TO OPERATE THIS UNIT. NEVER ALLOW

CHILDREN TO PLAY ON OR AROUND THIS EQUIPMENT.

SAFETY WARNINGS 5

Warning: FIRE OR EXPLOSION HAZARD CAN CAUSE

PROPERTY DAMAGE, SEVERE INJURY OR DEATH.

aerosols, or flammable materials should be stored

within 24” of the unit and should not be stored under the

unit. During refueling, ALL ignition sources and

switches should be OFF and there should be a person

with the proper fire extinguisher and training within the

vicinity of the unit in case of fire. Unit should not be left

running unattended or out of sight.

SPRAY INJECTION PRECAUTION:

1. Fluid from high-pressure spray or leaks can

penetrate the skin and cause serious injury. If any

fluid appears to penetrate the skin, get emergency

medical help at once. DO NOT treat as a simple cut.

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 – Risk of injection or severe injury to

persons – Keep clear of nozzle. DO NOT direct

discharge stream at people. This machine is to be

used by trained operators.

AVERTISSEMENT: RISQUE D’INJECTION ET DE

BLESSURES GRAVES. SE TENIR A L’ECART DU JET.

NE PAS DIRIGER LE JET DE SORTIEVERS D’AUTRES

PERSONNES. CONFIER L’UTILISATION DE CE

MATERIEL A UN OPERATEUR QUALIFIE: Keep

operating area clear of all people. Use only 48” long

wands on machines producing over 3000 PSI. Also,

only use straight wands or wands with a bend of 10°

or less. CAUTION: Hot discharge fluid – DO NOT

touch or direct discharge stream at people. 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, 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.

5. WARNING: IF YOU SMELL GAS, SHUT OFF THE

GAS SUPPLY TO THE APPLIANCE, EXTINGUISH ANY

OPEN FLAME, AND TEST ALL JOINTS WITH A SOAP

SOLUTION. IF THE ODOR PERSISTS, CALL YOUR GAS

SUPPLIER IMMEDIATELY. AVERTISSEMENT: SI UNE

ODEUR DE GAZ EST DECELEE, COUPER

L’ALIMENTATION EN GAZ DE L’APPAREIL, ETEINDRE

TOUTES LES FLAMMES ET VERIFIER TOUS LES

RACCORDS A L’AIDE D’UNE SOLUTION

SAVONNEUSE. SI L’ODEUR PERSISTE, AVERTIR

IMMEDIATEMENT LE FOURNISSEUR DE GAZ.

PERSONAL HAZARD:

1. Shut unit off and disconnect power before

removing belt guards or electrical covers.

2. Shut unit off before moving it.

3. NEVER lock the trigger on the gun valve in the ‘on’

position.

4. Do not exceed recommended operating pressure

or temperature.

5. Observe all regulations when towing trailer-

mounted units.

6. Keep hands clear of belts: Some units equipped

with auto-on may start at any time when power is

connected.

7. Do not operate the product when fatigued or

under the influence of alcohol or drugs.

SAFETY WARNINGS 6

BEFORE START UP: Read all instructions

1. CHECK PUMP OIL: Check pump oil by locating the

oil view window. Depending on your pump model, fill to

the red dot or to center of the site glass window.

2. CHECK FLUID LEVELS: Check engine oil and

coolant levels if unit is so equipped. (See the

maintenance schedule on back page).

3. CONNECT HOSE AND GUN ASSEMBLY.

CONNECT THE WATER SUPPLY & TURN WATER

ON: Maintain an adequate supply of water using a ⅝”

to ¾” I.D. hose (or ¾“ steel pipe for Natural Gas heated

HN models) with pressure between 25 & 60psi.

4. Burner power switches should be “off” before

starting. If tank fed, be sure there is water in the tank

and the valve is switched for supply tank feed. Do not

run dry.

5. BATTERY INFORMATION (when equipped):

Batteries are available through your dealer or local auto

parts store. Depending on the type of battery you

purchase, you may have to fill it with electrolyte. WEAR

EYE PROTECTION!

We recommend deep cycle batteries for machines

equipped with 12vdc powered burners. If the opening

on your battery box measures 8.5”x5.5”, select

U1L/GTH 235 CCA. If the opening measures 8”x12”,

use group 24 battery. Always connect the positive

battery cable before the negative and coat the battery

terminals with corrosion inhibitor to prevent corrosion.

Do not reverse polarity.

6. If wheel kit, accessories, or discharge hose are not

installed, see your local dealer for instructions &

installation.

7. NATURAL GAS / PROPANE GAS – Connect gas

supply using appropriate shut off cock and

recommended gas plumbing procedures; including the

use of a soap or lead detections solution on all fittings.

(Contact your gas supplier) A debris drop pipe is

required before the inlet of gas valve. Note that a

draft diverter is not included as a standard feature with

the machine. Draft diverters are required on HN

models. Operation without draft diverter may result in

excessive carbon monoxide output, incorrect

combustion, and inefficient heating. Gas regulator, gas

and water supply lines are not included with the

machine.

OPERATION:

1. STARTING:

Electric Powered Units: Connect power supply and

ensure that all wiring connections and voltages are of

sufficient rating to comply with equipment requirement.

Turn pump power switch on. If unit is equipped with

auto-start, keep all power switches off when left

unattended. (Unit will only turn on when trigger gun is

pulled.) Press the reset button to start motor if

equipped with a wash station remote.

Gasoline Engine Units: Turn engine power switch to the

on position, choke if necessary and turn key to start

position only until engine starts. On units with a recoil

starter, pull cord rapidly, until the engine starts.

Diesel Engine Units: Turn power key switch to the left

till the red glow plug indicator light goes off and then

release (maximum 30 seconds). Turn the power switch

to the (right) start position only until engine starts. (Do

not use starter fluids.)

2. PURGE AIR FROM SYSTEM:

Squeeze the trigger on the spray gun until a constant

stream 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 knob on dual wand. Hold gun

firmly, squeeze trigger for high-pressure spray.

CAUTION – Gun kicks back – hold with both hands.

WARNING – risk of explosion – DO NOT spray

flammable liquids.

4. START HEATER / BURNER:

a. Diesel heated: To create hot water on high

pressure washers equipped with heat

exchangers, release the trigger on the gun then

turn the burner to the “on” position.

b. Natural gas/Propane heated: equipped with an

automatic lighting pilot with a 90 second lockout.

If burner does not light within 90 seconds, turn

burner switch off, then on again to start ignition

sequence over.

c. All electric HE Series: equipped with an automatic

staged heater start up. Engage “HEAT 1” and

“HEAT 2” switches ON. Heat 1 will engage first

after 2 seconds allowing the amp load on the

pump motor to stabilize, then after 3 seconds Heat

2 will engage. This staged startup reduces the

high amp load on the power supply. Full heat rise

is normally accomplished within 1½ to 2 minutes.

d. Turn the thermostat to the desired temperature.

Squeeze the trigger on the spray gun and the

burner/heater will begin heating the water. It will

stop heating whenever the water spray is off or if

the temperature setting is exceeded. Heat rise will

vary depending on the inlet water temperature and

environmental conditions.

5. STEAM: (If Equipped) Insert steam nozzle and turn

thermostat to 250° steam setting. The steam nozzle is

sized for approximately 25% less water volume than the

hot water mode.

OPERATING INSTRUCTIONS 7

WARNING

BE SURE TRIGGER

ON SPRAY GUN IS

OFF AND CHEMICAL

VALVE IS CLOSED

WARNING

DO NOT OPERATE

MACHINE WITHOUT

ADEQUATE WATER

SUPPLY

WARNING

DO NOT

OVERINFLATE TIRES

INFLATE TO MFG.

SPECIFICATIONS

6. WASH STATION REMOTE (if equipped): Install

station on the wall at a convenient wash site. Control

switched in the wash station remote will override and

operate the pump, burner, and soap functions. Soap

(chemical) valve at machine must be preset before

soap switch at remote is activated. WARNING: Do not

leave soap switch in the ‘on’ position when soap is

depleted. Pressure drop will occur due to air intake and

harm system components. Remote systems have an

“auto-off” feature with an adjustable time that can be set

to your preference or come equipped with a windup

timer.

7. BYPASS MODE: (if equipped): System will go into

bypass mode when machine is left running and trigger

gun is closed. Bypass mode is when the inlet water

coming into the pump re-circulates through 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 cool water in to the pump. 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

larger volume of water to be re-circulated through the

pump head thus reducing heat on the pump seals. If

equipped with By-pass-cool system, a small portion of

the bypass water is routed back through the float tank

to keep the pump cool. Warning: Do not leave in

bypass for longer than five minutes to prevent

pump from overheating. Shut off unit when not

spraying water.

8. SET CHEMICAL INJECTION: If unit is equipped

with inlet chemical injection, place chemical pickup tube

in pre-mixed chemical solution and open chemical

valve for desired chemical concentration. Rinse and

close valve after use, do not use harsh chemicals

through the inlet injector system. Drawing air into the

chemical tube by leaving the chemical valve open will

cause the pump to lose pressure and may cause pump

damage.

If unit is equipped with a downstream chemical injector,

connect the chemical injection assembly into the high-

pressure discharge hose quick connects. Place the

chemical pickup into chemical solution and turn brass

collar to adjust concentration. The chemical will inject

only when you drop the outlet pressure by opening the

valve on the dual wand or changing to a low-pressure

nozzle. Soap the surface from the bottom up. Rinse

and close chemical valve when not in use.

9. If equipped with an 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.

NATURAL GAS / LP HEATED MODELS: Heat rise will

vary depending on inlet water temperature and

environmental conditions. Natural gas burners are

preset from the factory for an inlet water temperature of

60-70 degrees and approximately 4” of water column

natural gas pressure on the outlet of the gas valve for a

140° heat rise. If the water inlet temperature is 20°

colder than the factory setting, the heat rise will be

approximately 6% less. Adjustments can be made to

the gas valve outlet pressure by a qualified gas

technician to increase the outlet gas pressure to a 5”

water column with the use of a manometer to gain

higher heat rise and compensate for colder water inlet

conditions if they persist year round. Inlet gas pressure

when measured while the burner is on with a

manometer placed right before the gas valve, needs to

be between 6-7” water column, natural gas pressure (7-

11” LPG) and properly sized gas piping is required to

achieve full factory rated heat rise. (See

INSTALLATION GUIDELINES included with

manual) Protect gas valve from dripping water.

WASHING TECHNIQUES

When washing, always start from the bottom up, and do

the final rinse from the top down. This will keep the

water from streaking the surfaces that are being

cleaned. When applying chemicals, it is also best to

start from the bottom and work up.

In areas where there is no grease or oil present, and

the dirt is loose, cold water may be sufficient. When it

comes to grease, oil, and hard to clean dirt; hot water

and/or chemicals can make the job easier, and speed

up the cleaning process. For applications that require

even more heat and where water use/runoff must be

minimized, switch to the steam mode (if equipped) and

adjust the thermostat for up to 250° steam.

For general washing use a broad pattern spray nozzle

such as the 40-degree nozzle. Backing away from the

surface and using the broad spray nozzle works best to

perform rinsing and delicate surface washing. In areas

where the cleaning is more difficult and in smaller areas

such as cracks and holes, use the narrow spray

nozzles, 15 degree.

Chemicals can be applied in a couple of different ways.

One way is with a hand spray pump. The other is with

the chemical system on the equipment; either

downstream or high pressure depending on the system

you have. When using the high-pressure chemical

system, do not use any caustic chemical as this may

cause damage to the pump. For very harsh chemicals,

it is best to use a hand sprayer. First wet the surface

and wash off heavy debris. Test the surface to be sure

MAINTAIN PH BETWEEN 5 & 9

OPERATING INSTRUCTIONS 8

the chemical won’t harm it. Then apply the chemical

and let it work in for couple of minutes before rinsing.

Do not allow chemicals to dry on the surface.

When rising off the chemicals always start from the top

down. When you are finished using the chemical, be

sure to rinse out the chemical line and valve with fresh

water to prevent clogging.

SHUT DOWN

1. Turn burner switch to the ‘off’ position.

2. Rinse & close chemical valve. Turn off chemical

solenoid switch, if equipped.

3. Squeeze the trigger on the spray gun until the water

becomes cool.

4. Turn motor/engine switch off with the appropriate

controls. Turn off diesel engine units by pulling the

throttle kill lever, if not equipped with key shut-off.

5. Turn off water supply.

6. Squeeze trigger to release any trapped pressure in

discharge hose.

7. Turn the main power supply off when not in use for

any extended amount of time.

8. Turn gas valve off when not in use for an extended

period for natural gas/propane heated machines.

9. Disconnect & store hoses.

10. Antifreeze / Winterize equipment:

In the event that the equipment is not to be used for an

extended period, store in heated space or antifreeze

the unit. Run the machine until the float tank is near

empty, fill with a 50% mix of water and antifreeze and

run until antifreeze appears at the high-pressure outlet.

If unit is equipped with a blowout valve, it may be blown

out with compressed air in addition to using antifreeze

solution.

On direct feed units (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.

APPEARANCE:

To maintain appearance of the pressure washer, use

stainless steel cleaner on the stainless steel panels

POWER SYSTEMS:

ELECTRIC MOTORS: All single phase

electric motors contain a manual or

automatic thermal overload, which will shut

down the motor if it overheats. If the overload or starter

shuts down the motor, have an electrician or an

authorized Hydro Tek distributor check for electrical

problems. Voltage reading under load should be +/-

10% of name plate voltage on motor. Wait for motor to

cool before re-setting. Depressing the red overload

button located on either the motor or the starter can

reset the motor. Use thumb pressure – do not force. If

equipped with an automatic thermal overload, it will

reset itself after the motor has cooled.

Never spray water on the unit, or damage to the electric

motor(s) may occur.

Consult the manufacturer if running an electric

machine from a 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. Note: Some dual rated 208-230 VAC

washers include a control circuit power selector switch,

located on the back of the control box. Switch it to the

appropriate position to match your source voltage.

Switches are set by manufacturer to match recorded

test sheet voltage. Refer to the chart above for

electrical requirements. If your unit is equipped with a

ground fault interrupter, it will have to be reset

whenever it is plugged in, or if a ground fault interruption

occurs. Test regularly for proper

operation.

GASOLINE ENGINE: With proper care

and maintenance, your gasoline engine

will give years of trouble free service.

Please follow the Service and Maintenance Guide and

the enclosed engine sheet or contact your local

authorized engine dealer for maintenance and repairs.

Use clean, fresh, unleaded gasoline with an octane

rating of 87 or higher in the engine fuel tank. Up to 15%

MTBE (methyl tertiary butyl ether) or 10% ethanol is

acceptable. Do not use unapproved gasoline such as

E15, E20 or E85 ethanol blends. Any failures from

use of these fuels will not be warranted. Consult engine

manual for proper oil type and capacity. The engine

manufacturer recommends a break-in period at which

time the engine oil and filter should be replaced.

Thereafter, change oil and filter as required by engine

manufacturer. Refer to engine manual for preventative

maintenance schedules and procedures. Do not rely

on the low oil shutdown (if equipped) as a reminder to

add oil. The engine manufacturer will typically not

warranty engine damage from lack of oil even if the low

oil system failed.

On machines with a 115V generator or a 12V burner,

the throttle is preset by manufacturer (See Generator

section). Some engines include backfire prevention

solenoids.

DIESEL ENGINE: The diesel engine, although it has a

higher initial cost, can save money with lower fuel

consumption and longer life. Use clean diesel fuel #2

Warning: Cool down burner before shutting off.

OPERATING INSTRUCTIONS – SYSTEM INFORMATION 9

Single Phase Code AWG Three Phase Code AWG

WireSize WireSize

1.5 HP-120V -E1 #14

2 HP-120V -E1 #12 6 HP-230V -E3 #12

5 HP-208/230V -E2 #10 7.5HP-230 & 480V -E3, E4 #12

6.5 HP-230V -E2 #10 10 HP-480V -E4 #12

8 HP-230V -E2 # 8 10HP-230V -E3 #10

10 HP-208/230V -E2 # 6 10HP-208V -E3 # 8

and do not allow engine to run out of fuel.Refer to

engine manual for preventative maintenance schedules

and procedures.

Not covered by engine warranty: Damage caused by

contaminated oil, incorrect oil change

intervals/incorrect oil viscosity, bad fuel, use of any

starting agents, the use of greater than 50/50%

antifreeze/water or rust corrosion of the engine or fuel

system. Any normal replacement and/or service of

injectors, or injector tips, the checking and/or

replacement of parts that fail due to impurities in the

fuel, routine fuel system maintenance and fuel filters.

Damage caused by water entering the engine due to

any cause.

POWER TRANSMISSION:

WARNING:Shut off power supply before servicing.

BELT DRIVE: Check belt condition, alignment and

tension periodically. Replace belts when they show

signs of wear or cracking. Tighten belts by loosening

the mounting bolts on the pump and generator to permit

them to slide. Turn the horizontal rail adjusting bolts to

tighten belts until they deflect ¼" to ½” with finger

pressure.

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 motor shaft with heavy

grease or a generous amount of anti-seize. Use

“thread locker” or “lock tight” on mounting bolts and

tighten set screw on key shaft.

GENERATOR:

Some self-contained hot water units are

equipped with a 115v, generator to

power the diesel burner. Allow engine to

warm up and operate before engaging burner switch or

any device plugged into auxiliary outlet. Disengage

burner switch or shut off plugged in devices prior to

turning off engine. The generator output voltage must

be between 110 to 130 Volts, (or between 59 to 63 Hz.),

when the unit is under full load. If the generator voltage

falls out of this range, the RPM of the engine will need

to be adjusted to 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.

An AUXILIARY OUTLET is available on some mobile

wash skids for running wastewater recovery systems,

lights, or other accessories off of the generator. A

maximum of 1500 watts of 115v power is available

when the burner is on or 2000 watts when it is off. A

switch/circuit breaker located on the control panel will

need to be reset if the circuit is overloaded. Auxiliary

outlet is GFCI protected. If tripped, check item plugged

in and reset.

To extend generator life, keep the generator head clean

and clear of water, dust, sand, dirt, and oil.

PUMPING SYSTEM:

PUMP: The pump is a positive

displacement, oil bath crankcase,

and 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. The crank case oil window

should be checked for oil level and clarity and the pump

for oil or water leaks before each use. The sight window

is located at the rear (opposite the head) of the pump

and should be filled to the red dot with specified pump

oil, available at your Hydro Tek dealer (refer to

maintenance schedule on back page). If the oil

becomes milky in color, moisture is entering the

crankcase. Change the oil and contact your authorized

Hydro Tek dealer if the problem persists.

Keeping filters clean and checking for air in pump feed

lines can prevent cavitation and increase pump life. Do

not run pump in the bypass mode (pump running with

the trigger gun off), for a period of more than 5 minutes

or the pump will begin to overheat (maximum water

temperature is 145°F). 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 by

manufacturer to govern the proper output

pressure of your machine. It will release the

pressure of the pump back into the inlet if the

trigger on the spray gun is released. NEVER

increase the set pressure on the unloader to exceed the

specifications for your machine.

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.

SYSTEM INFORMATION 10

Warning: Make sure the burner and all auxiliary power

is off when the engine is started or stopped.

Keep generator dry at all times.

BURST DISC TECHNOLOGY: This additional safety

feature functions to protect the coil & heating system

from the spikes of high pressure. If this component

ruptures, take the machine in to an authorized Hydro

Tek dealer. Do not plug off and continue to run.

CHEMICAL INJECTION SYSTEM: With an inlet

chemical injection system, the chemicals are

introduced at the inlet of the pump and controlled with

a chemical metering valve. The pump is fed by a float

tank to create a low vacuum, not to exceed negative

3psi, which draws up the chemical into the inlet

manifold of the pump, mixes it with water, and sprays it

out of the nozzle under high pressure. Open the

chemical valve only when the pickup tube is submersed

in a solution or air will enter the pump causing the pump

to lose pressure and run rough. Do not use highly

corrosive detergents or acid type cleaners. Be sure to

rinse and close the chemical valve after each use or the

chemical line and check valve may become obstructed.

Chemicals should be between 5-9 PH. Consult Hydro

Tek for chemical compatibility. Chemical abuse is not

covered under warranty.

An optional DOWNSTREAM INJECTOR is available if

harsh chemicals need to be applied. The downstream

injector will apply chemicals only at low pressure, by

installing black soap nozzle or opening spray wand

valve if equipped. If equipped standard with

downstream injection, adjust

concentration 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 to the

pump must be maintained at all times. If the inlet flow

is too low or if there is air in the water supply, the pump

will run rough, pulsate and lose pressure. Maximum

inlet water temperature is 145°F. Do not restrict inlet

water supply. 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 ⅝” to ¾” I.D. hose.

Install a back flow preventer on your supply hose if

State or Local ordinances require it. Install a water

regulator if your water pressure exceeds 60 PSI.

Float tank water feed: A float tank, if equipped, is

usually used to regulate the incoming water supply to

the pump and introduce chemicals into the inlet of the

pump. The float tank and filter (located inside the tank)

should be flushed out if debris accumulates in the

bottom. If the float tank overflows or runs out of water,

adjust or replace the float valve inside the tank and

check the inlet water feed pressure.

Bulk tank water supply: Large capacity water supply

tanks can be used with most units if water is not readily

available at the washing site. Belt driven, low speed

pumps (less than 1750 RPM) can draw from a tank if

you ensure that the vacuum does not exceed negative

3psi. An 80 mesh, 200 micron strainer and a ¾” I.D. or

larger suction hose must be used to maintain a clean

and adequate water supply. Larger flow (8-10gpm)

machines require 1” feed and filtration. Be sure that the

water supply is free from air or damage to the pump

may result. Periodically you should clean out the

strainer and water supply tank to remove debris that

may accumulate on the bottom. If a water supply tank

and a float tank are both utilized, a special three way

valve can be used to switch between tanks.

USING DE-IONIZED OR SOFTENED WATER IN

YOUR PRESSURE WASHER: Do not use de-ionized

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:

HEAT EXCHANGER SYSTEM:

Spiralast™ Coil

The heat exchanger on diesel heated

units contains a continuous coil of pipe

which forms a cold water jacket

around the outside of the heating area and multiple

spiral wound layers to efficiently transfer heat to the

water inside the pipe. It is double wrapped with ceramic

blanket insulation and a stainless steel cover.

The outside of these coils can become covered with

soot if the burner is out of adjustment or if it is fired by

diesel fuel. This can be cleaned by removing both end

caps on the coil enclosure and brushing or spraying off

debris, or by adding a soot removal agent (Part

#CB200) to the diesel fuel. Both a diesel fuel pressure

gauge and smoke test device is required for proper

burner adjustment on diesel heated units, and must be

performed by a qualified technician.

When the water is heated, scale (calcium) will begin to

form on the inside of the coil pipe depending upon the

hardness of the water in your area. To remove buildup

in the coil, use a scale remover (Part #CB100) available

at your authorized Hydro Tek dealer. Perform this

descaling service only when a noticeable pressure drop

is detected across the coil. Follow directions to avoid

damage. Wear safety glasses.

It is important to be sure you prevent your coil from

freezing or blockage caused by scale buildup or ice as

this is excluded from your warranty. Ice can exert

extreme pressure from the inside of the coil pipe and

SYSTEM INFORMATION 11

cause it to split and frozen flow switches or pressure

switches can malfunction which control the burner.

These pictures show different reasons for coil pipe

failure:

The HE Series (all electric) contains multiple heating

elements to generate significant temperature rise in the

heat exchange process. The heat exchanger contains

a tubular pipe system that directs the water flow through

the heating elements.

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. Hot water machines are equipped with an

adjustable thermostat so that the operator can control

the outlet water temperature. The burner will

automatically cycle on and off to maintain the desired

temperature.

STEAM INSTRUCTIONS: If your unit is steam

capable, install the green steam nozzle, turn thermostat

to 250° F.

PRESSURE/FLOW SWITCH: The heater/burner is

equipped with either a pressure switch or a flow switch.

When the trigger on the spray gun is squeezed, water

begins to move through the coil and is pressurized. The

flow/pressure switch turns the heater/burner 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: Burner should fire only when the

trigger is squeezed and spraying water, if it comes

on at any other time, shut off machine and have it

serviced.

DIAGNOSTIC LIGHT: The burner diagnostic light on

the rocker switch (if equipped) can help in determining

problems with the burner. The red light indicates that

power is going to the fuel solenoid valve. The burner

should be firing and heating the water whenever the red

light is on. When the trigger on the spray gun is

released or if the temperature set point is exceeded, the

red light will go off and the burner will stop firing.

NATURAL GAS/PROPANE GAS BURNER: The gas

burner uses a vertical coil with a natural draft aspirating

type burner. It has electronic ignition for an auto-lighting

burner pilot with a 90 second lockout for safety. If the

burner does not light within 90 seconds, turn the burner

switch off and on again to start the ignition sequence

over.

The vertical coil can be connected to an exhaust flue

and must have a draft diverter mounted at a maximum

30 inches above the unit. The exhaust flue must never

run horizontal. Check your local code for exhaust flue

size requirements.

Do not store any flammable material under or near

burner area!

NATURAL GAS /

PROPANE IGNITION SENSOR / ROD: After extended

ignition arcing, insulating deposits may form on the

ignition rod reducing the arc intensity. Also, because of

the high heat zone beneath the burner, premature

failure of the rubber insulation covering on the ignition

wire may cause arcing to a ground before reaching the

pilot ignition rod.

Warning! When performing any tests on ignition

systems, do not touch the ignition rod. Ignition

circuit generates over 10,000 volts, electrical shock

can result!

DIESEL FIRED BURNER: The diesel-

fired burner is a forced draft pressure-

atomizing burner. Diesel fuel is

sprayed out of an atomizing nozzle,

mixed with air, and ignited by a high

voltage spark. 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.

NOTE: Use of summer blend fuels during cold weather

is not recommended. During winter months, check the

fuel grade, as well as consider changing to kerosene or

adding winter diesel fuel additives to avoid coil sooting

and maintain optimum burner performance.

AIR BAND adjustments may need to be made to

compensate 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 adjustments have to be made

precisely and should be performed only by qualified

personnel. Set between #1 & #2 on the smoke gauge.

Pipe chart: For 450,000btu

Length

Pipe Size

0-50’

1¼”

51-150’

1½”

151-200’

2”

SYSTEM INFORMATION 12

Failed weld or failed material

covered under warranty

Failed pipe seam

covered under warranty

Blow out from pipe

weakened by freezing

Pipe rupture due to

freezing or obstruction

The FUEL PUMP, on diesel heated

units, is a self-priming, low volume pump

which is propelled by the burner motor.

The fuel pump pressure is typically set

at 125psi but can be turned as high as

160psi during the winter when the

incoming water temperature is lower. Before adjusting

the fuel pressure, connect a fuel pressure gauge and

an outlet water temperature gauge, turn the pump and

burner on, and turn the fuel pressure screw clockwise

until the desired water temperature is obtained. Air

band adjustment may be needed to maintain a clean

burn. Be sure not to exceed the recommended

specifications of the machine.

The FUEL FILTER will need to be replaced often if the

diesel fuel quality is poor. A fuel filter with a water

separator is recommended if the fuel quality is

consistently poor.

The FUEL SOLENOID is an electric fuel valve that

shuts off the fuel whenever the trigger on the spray gun

is released or if the set temperature on the heat switch

is exceeded.

Warning! When performing any tests on ignition

systems, do not touch the ignition rod. Ignition

circuit generates over 10,000 volts, electrical shock

can result!

The IGNITION TRANSFORMER provides a high

voltage spark that travels down the electrodes to ignite

the diesel fuel. Disconnect all power before servicing.

The 12V burner operates from the battery on some skid

pressure washers. The engine has a 10 to 25 amp

charging system that keeps the battery charged which

runs the burner. The transformer stops when the

trigger gun is released and is controlled through a high

amperage contactor. To help keep the battery fully

charged, and for safely cooling down the burner, turn

off the burner during the last minute of rinsing. When

leaving the machine unattended, shut off burner and

engine switch. Replace 12 VDC battery regularly (2

year maximum interval) on 12V burner systems to help

ensure consistent performance.

PRESSURE DELIVERY SYSTEM:

DISCHARGE HOSE: Use only a wire braid hose rated

for the output pressure and temperature of the

machine. Additional hose lengths can be added with

quick twist couplers with a minimal loss in pressure of

about .5 PSI per foot. Inspect hoses for wear and

replace if necessary. Avoid kinking or running over the

hose to extend the hose life.

WARNING: Hydro Tek hot water machines require

a special 250° rated hose. If the hose is not

replaced when worn it may burst and serious injury

and burns could result.

QUICK COUPLERS: The swivel

connectors on the high-pressure hose

and quick couplers on the spray nozzle

make it easy to change nozzles or hoses. When

connecting hoses or nozzles, be certain that the collar

on the quick couplers snap into the locked position to

prevent them from becoming loose. If the quick

connect begins to leak, replace the O-ring (specify

Viton or EDPM material) located in the female socket

coupler. Grease the coupler periodically to make it

work smoothly. Replace if it becomes worn. Twist

couplers are also used on most wands so they can be

interchanged.

TRIGGER GUNS: The trigger gun is merely a valve

that turns water spray on and off. If it begins to leak or

fails to shut off, replace or repair the valve assembly.

Machines that spray steam only are equipped with an

open gun that does not shut off the water spray.

SPRAY WAND: Spray wands are available in different

lengths (2 to 6 foot) and with variable pressure

adjustment for various cleaning applications. The dual

wand has a low-pressure and high-pressure nozzle.

When the dual wand is installed on the machine, the

output pressure can be lowered simply by turning the

valve on the dual wand to divert water into the low-

pressure nozzle. This lowers the pressure (psi) but has

little or no impact on the flow (gpm) or outlet water

temperature on hot water machines.

The short wands are ideal for washing in confined areas

such as a car lot. The longer wands help to clean areas

that could not normally be reached.

WARNING wands less than 48” long should not be

used with machines producing over 3200psi.

NOZZLES: The spray nozzle is a

precisely machined orifice made

of hardened stainless steel. The

orifice size is matched to the

output of your machine to attain

the proper flow and pressure in which your machine

was designed. The orifice, or hole, of the nozzle will

enlarge with wear. For optimum performance, replace

the spray nozzle to maintain the full output pressure of

your machine. The nozzle installed on your machine

from the manufacturer is designed to allow only about

90% of the water being pumped to discharge out of the

nozzle. The remaining 10% is bypassed back into the

inlet water supply by the unloader/regulator valve. If an

incorrect nozzle size is used, the maximum flow and

pressure of the machine cannot be achieved and the

unloader valve can wear prematurely. When replacing

SYSTEM INFORMATION – ACCESSORIES 13

Never lock any gun in the on position for any

reason. Never point spray at a person or any part

of the body.

the nozzle, match to one size under the flow and

pressure output of the pump.

The nozzle is usually connected to the wand with a

quick coupler. Be sure the collar on the quick coupler

snaps into 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 nozzle tip.

The nozzles generally come in four different spray

angles: 0°, 15°, 25°, and 40°. The different spray

angles of a given size of nozzle do not change the

output pressure of the machine, just the impact force

and surface coverage of the water spray.

The optional 0° nozzle sprays a straight stream which

impacts the surface very hard but does not cover a very

wide area. Use the 0° red nozzle with care because it

can damage the surface you are spraying with its high

impact and long reaching spray.

The 15° yellow nozzle sprays out a flat stream at a 15°

pattern. It gives you less impact power than the above,

but covers a wider area with one pass of the spray

wand. As you back away, the spraying nozzle from the

surface, the spray impact will decrease.

The 25° green nozzle is wider than the 15° and is most

commonly referred to as the “steam nozzle”. 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 250°F.)

The 40° nozzle spreads the water stream over a wide

area to give you less impact for delicate surfaces.

Never connect the spray nozzle directly to the

trigger gun without a wand or injury could result.

Never place hands or fingers over the nozzle tip.

OPTIONAL ACCESSORIES:

HEATING COIL PROTECTION:

Protect your heating coil by removing debris or minerals

from inlet water by adding a filter or anti-scale cartridge.

The universal bracket and filter housing kit (p/n AF001)

attaches to most 1” to 1½ “ tubing to fit most pressure

washer frames, then choose the filter insert that will

most benefit you.

▪A 10-micron filter cartridge removes debris, ideal

when using sandy, non-potable, or well water (p/n

VFH11)

▪The anti-scale cartridge removes minerals to prevent

scale buildup (p/n VFD50)

WET SANDBLASTER: The wet

sandblaster is a system that introduces

sand (or other media such as baking

soda) into the water stream for abrasive

blasting. It is especially effective for

graffiti or paint removal. Performance

of the unit is directly related to the output of your high-

pressure washer. The sand is mixed with the water at

the sand head in a tungsten carbide nozzle.

A vacuum is created in the sand nozzle, which draws a

sand and air mixture up the sand hose. If the sand

becomes wet or the sand nozzle becomes plugged, the

vacuum will be lost and the sand will quit flowing. The

sand probe can be poked directly into a bag or bucket

of sand to draw it up the sand hose. Do not cover the

air intake port on the top of the sand probe or the sand

flow will be disrupted. Uncoil the sand hose completely

before use to improve the sand flow and replace the

sand hose when it becomes worn. The carbide sand-

mixing nozzle can be unscrewed and replaced when

worn.

Use bagged silica sand for best results through the

sandblaster. Use 16 to 20 grit (course) sand for rust or

concrete. Use 30 grit (fine) for fine metal surfaces or

wood. Do not use wet sand or mix different grits of

sand. A sand hopper is available for convenient sand

storage. An air valve is available for adjusting feed rate

on the hopper and should be fully open when using fine

media such as baking soda. Always use safety

goggles and protective clothing when operating the

wet sand-blaster.

TURBO NOZZLE: (please note temperature

limits) The turbo nozzle multiplies the power of

your machine by rotating the spray jet and

making the water impact a surface harder to give

better cleaning results.

“Turbo Laser” type nozzles cannot be used with water

over 190° or the life of the turbo nozzle will be greatly

decreased and the warranty voided. The “Rotomax”

type nozzle can be used up to 170°. Turn off burner or

reduce temperature setting before using. Simply

remove regular spray nozzle, replace with the turbo

nozzle and squeeze the trigger on the spray gun. Do

not point the turbo nozzle upward when starting.

EXTENSION HOSES: connecting additional hose

lengths by means of twist couplers can extend the

length of your high-pressure discharge hose. Hose

extensions generally come in 50’ and 100’ lengths.

Specify maximum pressure and temperature of your

machine when ordering.

Low-pressure inlet garden hoses are available in 50’

and 100’ lengths. Premium quality, 200psi rated hoses

are recommended. WARNING! If your unit is

equipped with 250°F steam option, only use

minimum 250°F rated high-pressure hose.

ACCESSORIES 14

ACCESSORIES 15

HOSE REELS: Hose reels are available

for convenient and quick storage of both

discharge and inlet hoses. Different hose

reels options are available for trailer

mounting, machine mounting, wall

mounting, or as base mount options. 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. The low-

pressure hose should be of sufficient quality that it will

not flatten out when reeled up, or water supply to the

machine will be cut off.

If the reel swivel begins to leak, replace or connect the

hose directly to the machine until the leak is repaired.

Hose reel swivels with lubrication are pre-lubricated by

manufacturer. Additional lubrication intervals depend

on application and frequency of use. However, a

minimum for re-lubrication, with standard Moly Lith

grease, at 40 hours is recommended. Do not over

grease. Using a hand held grease gun, dispense one

pump of grease into the grease fitting. Depress the ball

bearing at the end of the grease fitting to allow the

grease and air to escape.

HYDRO TWISTER – Surface Cleaners:

The Hydro Twister® is a flat surface cleaner that

connects to a

pressure washer

and uses a spray

bar rotating at a

high speed within 1”

of the ground. It will

clean concrete

more consistently

than an operator

with a spray wand,

with less fatigue,

and 10-20 times

faster. Simply move

the twister over the surface and watch a clean path

appear behind the unit. The Hydro Twister can be used

with hot water, some models up to 250ºF, for extra

stubborn grease or grime, eliminated the need for soap

pretreatment in most applications. Rated to be used

with a pressure washer up to 4000psi and up to 10gpm.

See your dealer for proper nozzle size configurations to

match your pressure washer.

Recovery surface cleaners are also available through

the Hydro Vacuum® product line.

HOT LINK™ HEAT EXCHANGERS:

The Hot Link™ attaches to your cold water pressure

washer and converts it into a hot water pressure

washer. The cold water pressure washer provides high-

pressure water into the Hot Link™ which heats the

water before delivering it through the spray gun and

wand. The Hot Link™ is flow controlled so when the gun

is pulled, the burner automatically starts and stops

when the gun is released. Simply attach to the Hot

Link™ with the jumper hose, provided, to almost any

cold water pressure washer, and attach the pressure

washers hose, gun, wand and nozzles to the outlet on

the Hot Link™. The Hot Link™ system continuously

heats at a 100°F temperature rise and pressure rating

up to 4350psi. (Spray gun and hose must be rated for

at least 200°F and pressure washer must not exceed

4350psi).

HYDRO VACUUM® WASTEWATER RECOVERY

Hydro Tek manufactures Hydro Vacuum®, a product

line of mobile wastewater

recovery accessories.

Starting with containment

berms to divert wash water

away from storm drains

and toward a vacuum

pickup device. The

vacuum system can be

used to simply pickup and transfer the water to a bulk

tank or choose a system to filter the water for washing

reuse or sanitary sewer disposal.

Vacuum system choices are either fully portable (on

wheels) or truck or trailer mount systems.

Dispose of collected wastewater properly: Permits can

be obtained to dump wastewater into a sanitary sewer

system if properly treated and tested. It is illegal to

allow wash water to run into storm drains.

TRAILERS: Hydro Tek trailers are designed to match

your Hydro Tek washer and increase productivity.

Several trailer and tank skid configurations are

available.

Every trailer comes with an

electrical connection. Trailers with

surge brakes or smaller trailers

without brakes come with a 4 pole

flat receptacle. Trailers with

electric brakes include a 7-way

electrical connection. Because of

the vast array of different

connectors, you may need to have one installed by your

dealer or purchase at a local auto parts store and install

yourself. Electric brake

trailers require an electric

brake controller installed in

the tow vehicle.

Be sure that the trailer you

order conforms to your particular State Department of

Transportation regulations, including but not limited to

braking and lighting requirements. If water is being

transported on the highway, trailer brakes are

recommended. Adjust brake drums as required.

Before taking trailer on the road, be certain that the

hitch on your tow vehicle is rated for the full trailer

weight and of the proper height so that the trailer

remains level when hitched, or wheel damage could

result. 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.

BALANCING: Keeping tires balanced will increase tire

life and help trailer tow with more control.

Before each use: Check air pressure in tires. Check

all bolts including the lug nuts for tightness and

condition periodically. Double check safely chain and

wire harness before departing. Check latch on coupler

and adjust if required to fit your trailer ball properly.

Never tow without properly adjusted rear view mirrors,

brake actuators, or lights.

Grease wheel bearings as required.

TIRE PRESSURE

T200

T300

T400

T500

14” tires

13” tires

14” tires

50 psi

35 psi

50 psi

TRAILER MAINTENANCE SCHEDULE

ITEM FUNCTION REQUIRED

3 MTH.

OR 3000

MILES

6 MTH.

OR 6,000

MILES

12 MTH.

12,000

MILES

Brakes Test that they are operational

Before every use

Brake

Adjustment

Adjust to proper operating

clearance x

Brake Magnets

Inspect for wear and current

draw x

Brake Linings Inspect for wear and

contamination x

Brake

Controller

Check for correct amperage,

modulation x

Brake Cylinders

Check for leaks / sticking x

Brake lines Inspect for cracks leaks or

kinks x

Trailer Brake

Wiring

Inspect for bare spots, fray,

etc. x

Breakaway

Systems

Check battery charge and

switch operation Before every use

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

(if equipped) Inspect for wear / loss or arch

Suspension Parts

/ Ball Hitch

Inspect for bending loose

fasteners/ wear; Lubricate x

Hangers Inspect welds x

Wheel Nuts &

Bolts

Tighten to specified Torque

value (Lug = 70-90 ft. lbs.) x

Wheels Inspect for cracks, dents or

distortion x

Tire Inflation

Pressure

Inflate to tire manufacturer's

specs. Before every use

Tire Condition

Inspect for cuts, wear, bulging,

etc. x

Tire Balancing Inspect and balance tire and

rim assembly X

TRAILER INFORMATION 16

PROBLEM

PROBABLE CAUSE

(The most recurring probable cause is listed first)

REMEDY

(Repairs should only be made by a qualified technician)

Power System: Gasoline or Diesel Engine Powered

Engine will not start or crank

over

Battery dead.

Dirty battery connection.

Battery cables disconnected.

Engine, pump, or gearbox is seized.

Key-switch, solenoid and starter on engine defective

Charge or replace battery, add electrolyte if battery is new.

Clean connections / Carefully check polarity.

Connect or replace damaged cables.

Replace or repair seized part.

Repair or replace.

Engine will not start but will

crank over

Engine power switch is off or defective.

Low oil shut down is activated.

Low water switch engaged or defective (not on all models).

Low on fuel.

Fuel filter is clogged.

Engine flooded or starved.

Check engine power switch.

Add oil to engine, check more frequently.

Add water to bulk tank feeding pressure washer.

Fill with appropriate fuel, bleed injector pump on diesel engine.

Replace or clean fuel filter

Choke only as required.

Engine bogs down under load

whenever spray gun is

triggered

Engine needs to be repaired or replaced.

Operating in high elevation.

Carbon deposits on cylinder head

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.

Battery keeps losing voltage

(For 12v systems)

Battery voltage low.

RPM too low.

Engine charging system faulty.

Electrodes misadjusted.

Fuel pump pressure too high. Air band too far open.

Burner amp draw too high.

Have battery checked and load test, charge if low and replace if necessary.

Allow water to cool 2 minutes before shutting off engine.

Engine RPM should be 3600 RPM with no load.

Check engine charging system – must have 10 to 25 amp output.

Adjust electrodes to maximum 1/8” gap.

Fuel pump pressure should be approximately 125 to 160 psi. Adjust for

proper burn.

Check amp draw of burner motor – should be 11 amp or less. Check amp

draw of transformer – should be 4.8 or less.

Power System: Electric Motor Powered

Electric motor does not start

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.

Check cord, plug, socket, and breaker. Check voltage.

Reset manual overload by depressing the thermal switch on the outside of

the motor or starter after the motor has cooled. CAUTION! Automatic

overload will restart the motor automatically when it has cooled.

Check power switch.

Replace or repair motor and/or wiring.

Connect water supply.

Machine will not auto-start (if

equipped with ETS or ITS)

Must have adequate water supply.

Scale build-up in coil.

Check filter screen & inlet pressure.

Inlet flow switch defective / jammed with debris.

25 PSI minimum.

De-scale coil for better water flow.

Remove spray nozzle and pull trigger to check auto-start function.

Check mechanical function & electrical signal to relay.

Water Temperature

Discharge water temperature

exceeds recommended

operating temperature

Burner input too high for conditions.

Water flow restricted.

High temperature limit switch faulty or set too high.

Decrease fuel pump pressure and/or fuel nozzle size.

Clean or replace nozzle of proper size. De-scale coil and clear

obstructions.

Replace or reset temperature limit switch.

Discharge water temperature

not reaching maximum

operating temperature

Burner input too low for conditions.

Increase fuel pump pressure and/or fuel nozzle size.

TROUBLESHOOTING GUIDE 17

PROBLEM

PROBABLE CAUSE

(The most recurring probable cause is listed first)

REMEDY

(Repairs should only be made by a qualified technician)

Pumping System

Trigger gun leaks or will not shut off

Debris in gun valve assembly.

Clean valve assembly or replace gun.

Pump runs but has low spray pressure

Water turned off.

Nozzle is not installed, is plugged, or sized incorrectly

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.

Dual wand valve is open.

Leaky discharge hose or quick coupler. Water sprays out

around nozzle.

Inlet strainer clogged.

Belt slippage.

Unloader valve worn or improperly adjusted.

Air leak in inlet plumbing.

EZ start valve is leaking.

Turn water on.

Install nozzle, 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.

Close dual wand valve and install high-pressure nozzle.

Replace hose, quick coupler, or o-ring in the quick coupler.

Clean and check more frequently.

Tighten or replace with correct belt

Install pressure gauge on pump head to adjust pressure.

Check valve seat on unloader.

Reseal fittings and inspect inlet hoses for air leaks.

Pump runs but there is erratic,

fluctuating pressure

Inadequate incoming water supply.

Stuck inlet or discharge valves.

Restricted inlet or air entering the inlet plumbing on pump.

Leaking High Pressure seals

Leaking Low Pressure seals

Remove hose to check for internal leaks. Increase water supply flow.

Clean out or replace worn valves.

Check fittings and hose for airtight seal, clean inlet strainer screen.

Replace seals.

Pressure feed the pump & replace seals if water leaks from pump head.

Excessive crankshaft play or loud,

knocking noise in pump

Broken or worn bearing or connecting rod in crankcase

Replace pump or bearing.

Oil leaking from pump

Loose drain plug or damaged seal

Locate point of oil leakage and replace damaged o-ring/seal.

Water is emitted from the chemical

pickup tube

Check-valve malfunctioning.

Repair or replace check-valve.

Inlet injection will not siphon chemical

Check valve in strainer clogged.

Chemical valve not open or clogged.

Strainer not submerged in solution.

Detergent hose cut or kinked.

Clean or replace valve. Rinse after each use.

Open chemical valve or clean.

Submerge strainer and replenish chemical.

Inspect hose, replace as necessary.

Downstream injector will not siphon

chemical

Brass knob on injector is closed.

Unit not in low-pressure mode.

Soap solution is too thick.

Detergent hose cut or kinked.

Strainer plugged or not submerged.

Internal injector parts corroded or stuck.

Outlet water temperature too high.

Open by turning counter clockwise.

Open dual wand or install low-pressure tip.

Dilute or use different solution.

Inspect hose, replace as required.

Check screen on strainer pickup tube.

Disassemble, clean or replace.

Use with cold water (150° Maximum)

Pressure relief relieving water

Un-loader failure/Coil overheating/Excessive pressure.

Turn machine off, wait a few minutes and restart. If problem continues,

take in for repair.

Burst disc relieving water

Excessive over-pressurizing and system spikes.

Take in for system check.

Heating / Heater System – Electric Heated (HE Series)

Heater will not engage.

Heater switch is not on.

Trigger not pulled.

Thermostat not turned up.

Defective pressure switch.

Defective transformer.

Defective flow switch.

Defective thermostat.

Faulty rocker switch.

Turn switch on. Press the reset switch.

Pull trigger. Heater should engage only when the trigger is pulled.

Adjust thermostat up.

Check for 24v output. If no voltage, replace.

Replace

Discharge water temperature too high.

Water restriction.

Worn spray nozzle.

Faulty thermostat or scale probe.

Clean or replace spray nozzle, de-scale coil, & remove obstructions.

Replace spray nozzle with proper size.

Clean thermostat probe or replace thermostat.

Discharge water temperature not

reaching maximum operating

temperature.

Inadequate power supply.

Faulty heater element.

Faulty heater control circuit.

Verify incoming power is not below required 440v when operating.

Check each heater element.

Check each control circuit to verify both heater banks are on.

Heater continues to engage even

when water is not being sprayed.

Faulty heater control circuit.

Turn machine off immediately. Replace flow, pressure, or temperature

switches.

TROUBLESHOOTING GUIDE 18

PROBLEM

PROBABLE CAUSE

(The most recurring probable cause is listed first)

REMEDY

(Repairs should only be made by a qualified technician)

Heating / Burner System – Natural Gas or Liquid Propane Fired

Pilot will not light. Burner will not fire.

Burner switch is not on.

Trigger not pulled.

Thermostat not turned up.

Poor ground.

Gas valve turned off.

No voltage to valve.

Pilot orifice plugged.

Defective ignition module.

Defective pressure switch.

Defective transformer.

Defective flow switch.

Defective thermostat.

Faulty rocker switch.

Igniter not working.

Turn switch on. Press the reset switch.

Pull trigger. Burner should fire only when the trigger is pulled.

Adjust thermostat up.

Check & clean ground connections.

Turn gas valve on.

Check for 24 VAC between pilot valve (PV) & PV/MV. Valve will operate

between 20.5 & 28.5 VAC.

Remove orifice & clean.

Check for 24 VAC incoming @ 24v & 24v ground. (If you detect voltage

to module, but not through module, replace).

Check for 24v output. If no voltage, replace.

Replace.

Test for spark. Test for continuity between ignition wire & ground.

WARNING! High voltage igniter can cause electrical shock.

Pilot lights, but burner will not fire.

Check for 24 VAC between main valve (MV) & PV/MV

when trigger pulled & unit on.

Failure to complete circuit to main valve.

Damaged or loose pilot assembly.

Insufficient or excessive gas pressure.

Check for continuity between ignition module ground &

pilot assembly ground.

If no VAC at the valve, replace module. If you get voltage, replace valve.

Check for controls continuity to main valve (thermostat, pressure switch,

flow switch).

Check for loose ignition wires.

Refer to installation guidelines. (Consult with a qualified gas technician)

Assure good ground.

Burner fires, but goes out.

Faulty ignition module.

Excess draft.

Gas leak ahead of valve.

Replace module.

Protect from windy conditions. Install draft diverter.

Turn gas off. Call gas supplier.

NG or LP odor is present.

WARNING! Check all NG connections

with soap solution before operation.

Lockout not working

Valve stuck.

Faulty thermostat.

Replace module.

Turn main gas valve off. Replace valve.

Replace.

Discharge water temperature too high.

Water restriction.

Incoming gas pressure to high.

Worn spray nozzle.

Clean or replace spray nozzle, de-scale coil, & remove obstructions.

Lower gas pressure.

Replace spray nozzle with proper size.

Discharge water temperature not

reaching max. operating temperature.

Gas pressure too low.

Draft under burner manifold.

Increase gas pressure or install additional jets.

Prevent down draft with installation of down draft diverter. Prevent side

draft with nonflammable barrier.

Burner continues to fire even when

water is not being sprayed.

Faulty burner control circuit.

Main gas valve is stuck open.

Turn machine off immediately. Replace flow, vacuum, pressure, or

temperature switches.

Turn gas off. Replace main gas valve.

Valve/ Ignition module has been

subjected to moisture, had water

sprayed on it, or has been submerged

in water & does not work.

Flood or accidental spraying.

Replace valve / module: Do not attempt to repair or clean.

Heating / Burner System – Diesel Fired

(Additional Diesel Fired burner troubleshooting flow chart on next few pages)

Burner smokes

Elevation or altitude

Soot on coil exterior

Exhaust restricted

Air intake restriction

Improper voltage at burner motor

Adjust air band and fuel pressure to compensate

Increase air or decrease fuel. Coil may need cleaning

Remove restriction if obvious. Check for sooted coil

Remove restriction if obvious. Adjust air bands. Check fan

Check generator output if equipped. Check battery or charging system.

Excess carbon monoxide

Too much air

Improper or restricted fuel nozzle

Fuel gun assembly out of adjustment

Adjust air bands

Replace fuel nozzle

Adjust gun assembly location

Burner “Puffs” black smoke

Too much fuel pressure

Not enough air flow

Adjust fuel pressure at fuel pump

Adjust air bands

TROUBLESHOOTING GUIDE 19

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