Kodiak KC4035GPB User manual

OPERATOR’S MANUAL
COLD WATER PRESSURE WASHER
BELT DRIVE
KC4035GPB KODIAK
John Brooks Company Limited
2625 Meadowpine Blvd, Mississauga, ON, L5N K5
Tel: [phone] Fax: [phone]
www.kodiakpower.ca
REV01 01/13

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SAFETY FIRST
This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual to warn of the
possibility of personal injury or equipment damage. Read these instructions carefully. It is
essential that you read the operating instructions and safety instructions before you attempt to
assemble or use this unit.
NEVER ADD GASOLINE to a hot engine as this can result in a fire or explosion.
•Always shut off engine before refueling.
•When refueling, keep all flames, sparks and cigarettes away from the power
washer
•Do not over-fill the fuel system. If any fuel spills, wipe it up completely before
starting engine.
•Refer tothe Honda engine manual on engine cooling
•
BEFORE TRANSPORT, ensure that the fuel is shut off and that the unit is in the
upright position to avoid fuel spillage. Fuel vapor or spilled fuel may ignite.
INVESTIGATE AND ABIDE BY YOUR LOCAL LAWS IN THE TRANSPORTATION
OF ENGINES WITH GASOLINE IN THEM.
NEVER AIM SPRAY AT YOURSELF OTHER PEOPLE OR ANIMALS. The high
pressure water stream can cause injury or death.
NEVER DIRECT SPRAY at pressure washer unit.
Failure to install the yellow vented plug in the pump crankcase may cause personal
injury, will damage the pump and void warranty.
Failure to properly connect the high pressure hose can result in injury.
Unloader valve is preset for safe operation. It has been set to not exceed the
maximum allowable water pressure for your unit. DO NOT attempt totamper with the
preset factory setting.
To avoid injury and unintentional spraying, always engage the red trigger lock on the
trigger of the gun when not spraying.
AFTER MACHINES ENGINE IS STOPPED, failure to relieve the high pressure from
the system before disconnecting any hoses may result in injury. Bleed off high
pressure by turning off the water tothe unit and pulling on the trigger.

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When changing spray nozzles, always do so with the pressure in the system relieved,
the engine turned off and the red safety latch engaged on the trigger gun. Always
point the gun / wand away from you while connecting or disconnecting the
spray nozzle.
INJECTION HAZARD.To avoid personal injury, do not put hand or any part of your
body near the spray nozzle, as high pressure spray will penetrate the skin.
WARNING: Do not pump flammable or explosive fluids such as gasoline, fuel oil,
kerosene, etc. Only cold water is to be pumped through the pump itself.
SPECIAL NOTES READ CAREFULLY
1. WARNING: Do not operate a gasoline engine in an enclosed area. Be sure the area
is well ventilated.
WARNING: Gasoline is a highly combustible fuel. The improper use, handling or
storage of gasoline can be dangerous. Never touch or fill a hot engine. Refer to the
Honda Engine Manual.
2. AS A STANDARD PRACTICE DO NOT RUN WASHER longer than 5 minutes with
the gun closed, as this can result in damage of the seals. However, as a
protection feature, your unit has a “Thermal Protector Valve” which will dump water
into the atmosphere if the unit is left on, and the gun closed for longer than five
minutes or so.
3. Turn “OFF” engine before servicing engine or equipment.
4. Release all pressure within the system before servicing any component.
5. Drain all liquids from the system before servicing any component.
6. Securely connect the discharge lines before starting the pump. An unsecured line
may whip, causing personal injury and/or property damage.
7. Check hose for weak or worn condition before each use. Make certain that all
connections are tight and secure.
Replace if hose is frayed.
8. Periodically inspect the pump and the system components. Perform routine
maintenance as required.
Check Engine and Pump oil level daily.
9. Do not use these pumps for pumping water or other liquids for human or animal
consumption.
10. When inserting or taking out the spray nozzles from the rubber grommet
(located on the base) use a twisting action so that the rubber grommet does
not disengage from the grommet hole.

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START UP AND OPERATION:
PUMP
1 Remove the shipping plug on your pump’s crankcase and install the provided vented
plug / dipstick (yellow).
WARNING: The vented plug / dipstick must be installed, by not doing so, may
cause personal injury, cause damage tothe pump, and void its warranty.
2. Check your pump oil level using the sight glass located on the side of the pump.
The oil should be 1/2 way up on the sight glass of the dipstick provided.
ENGINE
WARNING: Do not operate before adding oil to engine (see Honda Engine Owner’s
Manual).
1. Add SAE 10W30 motor oil to engine to the indicated appropriate level on your
dipstick. (See Honda Engine Manual for alternate oils)
Note: Your engine is equipped with“low oil” shut-off. If there is not enough oil, the
engine will automatically shut off. (See Honda Engine Manual)
2. Use UNLEADED gasoline only.
CONNECTIONS
. When making any connections, do so with the pressure in the system relieved, the
engine “OFF”, and the red safety latch engaged on the trigger gun.
WARNING: Failure to properly connect the high pressure hose, wand, and spray
nozzle can result in injury.
1. Connect the wand to the spray gun with at least 8 wraps of TEFLON TAPE on the
threads.
2. Models with dual lances come with 3 quick connect nozzles (0°, 15°, 25°nozzles)
and a soap nozzle already installed on the dual lance (when replacing this soap
nozzle, use TEFLON TAPE on the threads). Models with single lances come with 4
quick connect nozzles. Model C5050BG does not include quick connect nozzles.
Select the desired quick connect nozzle.
(RED) 0°gives a straight stream
(YELLOW) gives a 15°degree fan pattern
(GREEN) gives a 25°degree fan pattern
(BLACK) Soap (ONLY ON SINGLE LANCE MODELS)

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3. Before installing one of the desired quick connect nozzles, follow the instructions
below:
When installing or changing any spray nozzle, always do so with the water turned off
at the source, the pressure in the system relieved, the engine turned “OFF”, and
the red safety latch engaged on the trigger gun.
Always point the gun / wand away from you while connecting or disconnecting the
nozzle.
4. Connect the desired quick connect nozzle to the spray gun by pulling the collar on
the socket back, insert the nozzle and slide collar back into place. Pull sharply on
the connection to ensure connection is made.
Ensure that the connection is securely made.
5. Make sure that the red safety latch on the trigger gun is engaged.
6. Connect high pressure hose to high pressure quick connect fitting on pump.
7. Connect water supply hose to lower water inlet fitting on pump. Make sure the inlet
strainer is in place on the inlet of pump. Failure to use the inlet strainer could reduce
pump operating efficiency and void warranty.
8. Turn on water tothe maximum level.
STARTING UP
1. Your unit is equipped with a variable unloader valve. Reduce the pressure by turning
the unloader knob all the way in a counter-clockwise direction. This will make
starting the gas engine easier due tothe minimal pressure build up.
2. Do not start your engine yet.
3. Disengage red safety latch on gun trigger.
4. Pull trigger on gun to allow the air trapped in the system to bleed out. A constant
flow of water should flow from the nozzle.
5. After you see constant flow of water from the nozzle, release trigger.
6. Engage red safety latch on the trigger gun.

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7. Starting the engine with re-coil start (see Engine Manual).
•Turn switch to “ON “ position.
•Turn fuel knob to “ON” position.
•Put engine throttle to full RPM’s (maximum) for proper pump
performance.
•Turn on choke.
•Pull engines starter until started.
•Turn off choke.
Starting the engine with electric start (see Engine Manual).
•Install battery as shown in Engine Manual (Battery not included).
•Turn switch to “ON “ position.
•Put engine throttle to ¾ RPM’s open.
•Turn on choke.
•Turn and hold key switch in the “START” position until started.
•Once engine has started release key and turn choke off.
8. By turning the unloader valve clockwise, it will increase the pressure. After starting
the engine you may increase the pressure via the unloader knob.
The pressure can be reduced by turning the unloader knob all the way in a
counter-clockwise direction.
PRESSUREWASHING
1. To begin spraying and high pressure washing, disengage safety latch on the gun,
and trigger the gun.
WARNING: To avoid injury always engage the red safety latch located on the spray
gun when not in use or when not spraying.
2. The spray pattern of the high pressure spray can be changed by selecting another
quick connect nozzle which has been supplied.
3. To change the quick connect nozzle selection, follow the instructions: (NOT
APPLICABLE TO C5050BG).
When installing or changing any spray nozzles, always do so with the water turned off
at the source, the pressure in the system relieved, the engine “OFF”, and the red
safety latch engaged on the trigger gun.
Always point the gun / wand away from you while connecting or disconnecting the
nozzle.

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4. You are now ready to change the nozzle. (NOT APPLICABLE TO C5050BG).
To change the quick connect nozzle, remove existing spray nozzle by pulling the
socket back and taking the nozzle out. Connect the desired nozzle to the spray gun
by pulling the collar on the socket back, insert desired nozzle and slide collar back
into place. Pull sharply on the connection to ensure connection is made. .
Ensure that the connection is securely made.
5. Your unit is equipped with a variable unloader valve .The pressure can be reduced by
turning the unloader knob in a counter-clockwise direction. The pressure can be
increased by turning the unloader knob in a clockwise direction.
WARNING: The unloader valve is factory preset for safe operation. Do not attempt
to change or block this valve for higher pressure. This can cause serious personal
injury or serious damage tothe unit.
ADDING DETERGENTS (NOT APPLICABLE TO C5050BG)
1. Stop spraying.
2. Engage red safety latch on the trigger gun.
3. Insert chemical suction hose into the detergent bottle.
4. For models with dual lance: Point the lance away from you, turn the side handle of
the dual lance in a counter-clock wise rotation. This will enable the detergent to be
drawn up.
For units with single lance. Connect the Black Soap nozzle to the spray gun by
pulling the collar on the socket back, insert nozzle and slide collar back into place.
Pull sharply on the connection to ensure connection is made.
5. Disengage red safety latch off the trigger gun.
6. Pull trigger to start spraying detergent / water mixture.
Note: This detergent application reduces the pressure of the system. This is so
that the detergent can be drawn through the hose.
7. Note: These models are also equipped with a variable knob (red) that controls
the detergent’s flow rate. This knob is located in line where the chemical
suction hose meets the pump body.

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RINSING AND PRESSUREWASHING
1. Stop spraying.
2. Engage red safety latch on the trigger gun.
3. Take the chemical suction hose out of the detergent bottle.
4. Disengage red safety latch on the trigger gun.
5. For models with dual lance: With the dual lance pointed away from you, turn the
black side handle of the dual lance in a clock wise rotation. This will stop the
detergent injection.
For units with single lance. Remove Black quick connect nozzle and install desired
quick connect nozzles as described in “CONNECTIONS” Section of this Manual.
6. Start spraying.
STOPPING
1. Switch “OFF” engine (see Engine Manual).
2. Turn off water supply at the source.
3. Pull the trigger to release any left over pressure in the system.
4. Engage red safety latch on trigger gun.
5. Disconnect all hoses and store equipment on the cart.
STORAGE
In climates with winter conditions, extra precautions will be required to store the unit. If
possible, store the unit in a location free from freezing.
If the unit will be stored in a location where freezing may occur, follow these steps:
1. Disconnect, and drain all hoses.
2. Turn engine on for several seconds to remove any excess water in the pump.
3. Using a short piece of hose with a male garden hose fitting attach it tothe inlet fitting
on your pump. Making sure the hose is upright, fill it with a 50/50 mixture of
automotive coolant anti-freeze and water. Keep the hose upright and turn on the
engine for several seconds in order to get the mixture into the pump. When the
outlet fitting spits out the antifreeze solution it has been distributed throughout the
pump and you may stop. Your unit is now protected from freezing.

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TRANSPORT
WARNING: Before transport, make sure that the unit is not under pressure and that the
unit is in a secure and upright position.
INVESTIGATE AND ABIDE BY YOUR LOCAL LAWS IN THETRANSPORTATION OF
ENGINES WITH GASOLINE IN THEM
ACCESSORIES
Your dealer carries a complete line of accessories that compliments your pressure washer and
maximize its usage.
Here are just a few of the accessories that are offered:
•Liquid Detergents
•Rotary Nozzles
•Various Nozzles
WARRANTY
This product is warranted to be free from defects in materials and workmanship under normal
use and service, for a period of one year from the date of purchase, when operated and
maintained in accordance with the Maintenance and Operation Instructions supplied with the
unit. The warranty does not cover misuse or negligence.
This warranty is extended only to the original purchaser. Hoses, spray guns, wands and other
accessories are warranted for 30 days. Warranty is void if repairs are attempted by anyone
other than an Authorized Service Centre.
If a difficulty develops with the product, you should contact the nearest Authorized Repair
Centre or Kodiak office. Only these locations are authorized to make repairs to the
product or replacement of defective parts which will be done at no charge within a reasonable
time after receipt of the product. Units or parts should be returned at the customer’s expense
to the nearest Authorized Service Centre. Pack unit in a strong carton and pad tightly to avoid
damage. Damage in transit is not covered by warranty. Include original purchase receipt with
any claim (but keep a copy for your files).
Kodiak Power Equipment liability under warranty is limited to repair of the product and/or
replacement of parts and is given to the purchaser in lieu of all other remedies including
incidental and consequential charges. There are no express warranties other than those
specified herein.

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TROUBLESHOOTING
Symptom Probably Cause(s) Corrective Action
Pump running normally but
low pressure at nozzle.
Unloader valve has not been
properly set
Make sure unloader is
adjusted properly
elzzonnroW
Incorrect nozzle being used
Black Side Handle on Dual
lance is on chemical injection
setting
If the nozzle is worn, replace
it.
Make sure nozzle is matched
to the flow and pressure of
the pump.
With lance facing away from
you, turn the Black Side
Handle all the way in a
clockwise rotation
Pressure drops after period of
normal use
Nozzle worn Check and replace nozzle
Pump producing chattering
noise
Pump sucking air Check that hoses and fittings
are air tight
Pulsating when gun is off. Leaks downstream of
unloader
Nozzle plugged
Nozzle being used may be too
small
Check for leaks downstream
of the unloader valve.
If no leaks, unloader may
have to be serviced
Remove obstruction
Replace with properly sized
nozzle
Fluctuating Pressure while
spraying
Pump sucking air Check that hoses and fittings
are air tight
Water in crankcase
No soap injection
High humidity in the air
Worn packings
Black Side Handle on the
Dual lance is not on the
chemical injection setting
Change oil intervals.
Replace packings
With the dual lance pointed
away from you, rotate the
Black Side Handle on the
Dual lance all the way in a
counter clockwise rotation
Gas Engine
Engine will not start. Low fuel level
Low oil level
Add fuel
Add oil

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PUMP OPERATION
UNLOADER
Turn Clockwise to
Increase Pressure.
Turn Counter
Clockwise to
Decrease Pressure
PUMP
Oil Plug
OUTLET
THERMAL
PROTECTOR VALVE
(This Image is a representation only)
SOAP
PRESSURE GAUGE
(Not available on all models)
INLET

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BELT MAINTENANCE
This unit uses a belt and pulley assembly totransfer power from the motor to your pump. In
order for this assembly to operate effectively, a V-belt is used totransmit torque. To adjust your
belt tothe correct depth setting, you should use the following formula.
Depth = Belt Length X 0.016
If you have any questions or doubts relating to V-belt selection or pulley ratio, consult with the
belt maker.