Kärcher 1.575-615.0 Operator'S Manual Download Page 21

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9.800-103.0 - M • Karcher HDS 615-617

PRESSURE W

ASHER

OPERA

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EXPOSED PULLEYS AND

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16 HP

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98001030-9

EXPLODED VIEW - RIGHT SIDE

See

Unloader

Assy. Illus.

for Detail

See Pump

Assy. Illus.

for Detail

See Float

Tank Illus.

for Detail

103

102

101

100

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Assy. for

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Honda

Engine

Rectifi er

Summary of Contents for 1.575-615.0

Page 1: ... To locate your local Kärcher Commercial Pressure Washer Dealer nearest you please visit www karchercommercial com WARNING This product and accessories may contain a chemical known to the State of California to cause cancer and birth defects or other reproductive harm For more information about this regulation www P65Warnings ca gov ...

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Page 3: ... 7 Assembly Instructions 8 Operation Instructions 9 10 Detergents General Cleaning Techniques 11 Shutting Down Cleanup 12 Storage 12 Maintenance 13 14 Troubleshooting 15 18 Preventative Maintenance 19 Exploded Views Parts List 20 23 Control Box Parts List 24 25 Float Tank Assembly 26 Pump Assembly 27 Unloader Assembly 28 Blower Assembly Parts List 29 Burner Coil Assembly Parts List 30 Coil Blower ...

Page 4: ...ch what you are doing KEEP WATER SPRAY AWAY FROM ELECTRICAL WIRING DANGER DANGER Keep wand hose and water spray away from electric wiring or fatal electric shock may result 4 All installations must comply with local codes Contact your electrician plumber utility company or the selling distributor for specific details WARNING EAR PROTECTION MUST BE WORN WARNING This machine ex ceeds 85 db appropria...

Page 5: ...ough the pump 22 Never run pump dry or leave spray gun closed longer than 1 2 minutes IMPORTANT SAFETY INFORMATION In an overfilling situation additional precautions are necessary to ensure that the situation is handled in a safe manner WARNING Risk of injury Disconnect battery ground terminal before servicing 8 When in use do not place machine near flam mable objects as the engine is hot 9 Oil bu...

Page 6: ...se from water outlet turn burner off and open spray gun to al low water to cool below 100 before stopping the machine Then open the spray gun to relieve pres sure Failure to properly cool down or maintain the heating coil may result in a steam explosion 26 Do not overreach or stand on unstable support Keep good footing and balance at all times 27 Do not operate this machine when fatigued or under ...

Page 7: ...ure Hose Connect one end to water pump discharge nipple and the other end to spray gun Adjustable Thermostat Safety control which prevents temperatures from going above adjustable setting Wand Must be connected to the spray gun NOTE If trigger on spray gun is released for more than 2 minutes water will leak from valve Warm water will discharge from pump protector onto floor This system prevents in...

Page 8: ... garden hose to pump water inlet CAUTION Do not run the pump without water or pump damage will result Water Inlet BATTERY INSTALLATION SHIELD EYES EXPLOSIVE GASES CAN CAUSE BLINDNESS OR INJURY NO SPARKS FLAMES SMOKING SULFURIC ACID CAN CAUSE BLINDNESS OR SEVERE BURNS FLUSH EYES IMMEDIATELY WITH WATER GET MEDICAL HELP FAST KEEP OUT OF THE REACH OF CHILDREN DO NOT TIP KEEP VENT CAPS TIGHT AND LEVEL ...

Page 9: ...ommend that the oil be changed after the first 5 hours of use then once every 50 hours NOTE Improper oil levels will cause low oil sensor to shut off engine IMPORTANT Do not run engine with high or low oil levels as this will cause engine damage STEP 2 Fill gas tank and burner fuel tank with proper fuel Do not confuse gasoline and fuel oil tanks Keep proper fuel in proper tank Oil Dipstick STEP 3 ...

Page 10: ...y to the START position and hold it there until the engine starts If the engine fails to start within 5 seconds release the key and wait at least 10 seconds before operating the starter again Using the electric starter for more than 5 seconds at a time will overheat the starter motor and can damage it When the engine starts release the key allowing it to return to the ON position If the choke knob...

Page 11: ...e directly into cleaning solution and apply to surface at low pressure for best results limit your work area to sections approximately 6 feet square and always apply detergent from bottom to top Allow detergent to remain on surface 1 3 minutes Do not allow detergent to dry on surface If surface appears to be drying simply wet down surface with fresh water If needed use brush to remove stubborn dir...

Page 12: ...n that position This closes both the intake and exhaust valves to prevent rusting of cylinder 4 Cover the pressure washer and store in a clean dry place that is well ventilated away from open flame or sparks NOTE The use of a fuel additive such as STA BIL or an equivalent will minimize the formulation of fuel deposits during storage Such additives may be added to the gasoline in the fuel tank of t...

Page 13: ...ainst freezing is nec essary Store the machine in a heated room If this is not possible then mix a 50 50 solution of anti freeze and water in the float tank Turn the engine on to siphon the anti freeze mixture through the machine If com pressed air is available an air fitting can be screwed into the float tank by removing the float tank strainer and fitting Then inject the compressed air Water wil...

Page 14: ...g the flow of fuel in this way gives an instantaneous burn or no burn situation thereby eliminating high and low water temperatures and the combustion smoke normally associated with machines incorporating a spray gun Periodic inspection to insure that the fuel solenoid valve functions properly is recommended This can be done by operating the machine and checking to see that the burner is not firin...

Page 15: ...ve kit Obstruction in spray nozzle Remove obstruction Leaking pressure control valve Rebuild or replace as needed Slow engine RPM Set engine speed at proper specifications Pump sucking air Check water supply and possibility of air seepage Valves sticking Check and clean or replace if necessary Unloader valve seat faulty Check and replace if necessary BURNER WILL NOT LIGHT Little or no fuel Fill ta...

Page 16: ... speed Increase engine RPM to increase voltage Flow switch malfunction Remove test for continuity and replace as needed Flow solenoid malfunction Replace if needed FLUCTUATING PRESSURE Valves worn Check and replace if necessary Blockage in valve Check and replace if necessary Pump sucking air Check water supply and air seepage at joints in suction line Worn piston packing Check and replace if nece...

Page 17: ...eck detergent lines for holes Defective temperature switch Replace Incorrect fuel nozzle size See specifications for proper fuel nozzle page 30 Insufficient water supplied Check water G P M to machine Restricted water flow Check nozzle for obstruction proper size PUMP NOISY Air in suction line Check water supply and connections on suction line Broken or weak inlet or discharge valve springs Check ...

Page 18: ... detergent Dilute detergent to specifications Hole in detergent line s Repair hole Low detergent level Add detergent if needed PUMP RUNNING NORMALLY BUT PRESSURE LOW ON INSTALLATION Pump sucking air Check water supply and possibility of air seepage Valves sticking Check and clean or replace if necessary Nozzle incorrectly sized Check and replace if necessary See serial plate for proper size Unload...

Page 19: ...the life of your pressure washer Perform maintenance more often under severe conditions Check pump oil level before first use of your new pressure washer Change pump oil after first 50 hours and every 3 months or 500 hours thereafter Use SAE 30 weight oil non detergent PREVENTATIVE MAINTENANCE Maintenance Operation Every 8 Hrs or Daily 25 Hrs or Weekly 50 Hrs or Monthly 100 Hrs or Yearly Yearly Ch...

Page 20: ...D VIEW LEFT SIDE See Control Box Illus for Detail 96 74 73 72 77 71 79 11 80 70 48 81 69 82 57 58 78 49 52 54 51 52 55 66 65 64 56 60 62 63 61 59 83 84 To Coil Inlet To Coil Outlet 102 47 45 67 76 89 18 68 93 95 94 2 See Burner Coil Illus for Detail See Blower Assy for Detail 104 ...

Page 21: ... RY PR EC AU CI ON A VE RT IS SE ME NT WAR NI NG 98001030 9 EXPLODED VIEW RIGHT SIDE See Unloader Assy Illus for Detail See Pump Assy Illus for Detail See Float Tank Illus for Detail 20 22 21 1 2 45 46 25 103 27 25 26 28 47 23 9 41 44 29 2 40 39 73 31 32 30 42 32 36 3 37 38 102 4 26 102 101 7 5 6 8 2 1 10 11 12 25 14 15 13 12 16 19 17 86 85 9 55 87 88 54 50 25 53 100 97 24 2 98 97 99 43 See Engine...

Page 22: ... 33 9 802 756 0 Screw 5 16 x 1 Whiz 1 34 9 804 023 0 Plate Belt Guard Top 1 35 9 802 261 0 Hose 3 4 Push On 30 ITEM PART NO DESCRIPTION QTY 36 9 802 064 0 Grommet Rubber Nozzle Holder 2 37 8 753 358 0 Cable Battery 61 Red 1 38 9 753 395 0 Cable Battery 24 Black 1 39 9 802 067 0 Bumper Pad Engine 7 40 9 802 811 0 Washer 3 8 x 1 1 2 Fender SAE 7 41 9 802 779 0 Nut 3 8 ESNA NC 7 42 9 803 502 0 Platfo...

Page 23: ...Disk 2 85 9 802 201 0 Clamp Screw 6 1 86 9 802 260 0 Hose 5 8 Push On 60 87 9 803 519 0 Plate Belt Guard 1 88 9 803 506 0 Guard Engine Pulley 1 89 9 802 512 0 Cable Tie 45 4 90 9 802 053 0 Bushing Rubber Nitrite 3 91 9 803 531 0 Elbow 1 4 H x STD Pipe 90 2 92 9 802 054 0 Elbow Fuel Tank Zinc 1 93 9 803 541 0 Screw 5 16 18 x 1 2 CS SOC 4 94 9 803 542 0 Washer 5 16 Star 4 95 9 802 813 0 Washer 5 16 ...

Page 24: ...OR I O TEMPERATURE TE MP ER TU RA RM 110 BURNER FUEL DETERGENT DE TE RG EN TE 0 2 8 1 4 9 8 00 13 8 0 FO R BEST RESULT S USE DETE RGENT CONTROL BOX 22 23 16 12 37 10 30 11 1 32 27 8 2 25 9 24 26 26 19 7 13 3 21 20 6 33 18 4 44 36 38 15 14 25 29 34 31 5 31 40 39 Wiring Diagram 41 35 42 27 28 43 27 27 17 45 ...

Page 25: ... Hole 7 23 9 802 515 0 Strain Relief Straight LQ Tite 1 24 6 618 076 0 Socket Spark Plug 2 25 9 802 754 0 Screw 1 4 x 1 2 HH NC Whiz Loc 8 26 9 802 749 0 Screw 8 32 x 3 4 BH SOC Blk 2 27 9 802 695 0 Nut 10 32 Keps 616 0 5 615 0 617 0 8 28 9 802 785 0 Nut 8 32 Keps 3 29 8 718 733 0 Screw 6 32 x 5 8 RH Slot 4 30 9 802 784 0 Nut 6 32 Hex 4 31 8 709 069 0 Clamp Screw 4 3 32 8 707 058 0 Strainer 1 4 Br...

Page 26: ...ank Scale Inhibitor 1 3 4 730 127 0 Filter Water 1 4 5 063 226 0 Lid Scale Inhibitor Tank 1 5 5 310 062 0 Nut Float Tank 1 6 5 443 285 0 Hose Stem 45 1 7 6 686 025 0 Valve Solenoid DN3 1 3 4 2 1 7 8 6 5 9 10 ITEM PART NO DESCRIPTION QTY 8 6 362 078 0 O Ring 1 9 5 332 001 0 Spring Scale Inhibitor Tank Use spring only if not using scale inhibitor 1 10 9 800 152 0 Label RM 110 Scale Inhibitor 1 ...

Page 27: ...1 2 JIC x 1 2 MPT Pipe 1 5 8 706 881 0 Nipple 3 4 Pipe x 1 2 Pipe 1 6 9 803 557 0 Elbow 3 8 SAE x 3 4 90 1 7 8 706 915 0 Bushing 1 2 x 1 4 Brass 1 6 1 2 9 5 3 10 4 11 7 8 ITEM PART NO DESCRIPTION QTY 8 8 706 958 0 Hose Barb 1 4 Barb x 1 4 Pipe 90 1 9 9 803 558 0 Valve 3 4 Ball Brass 3 Way 1 10 Pump Please See Specifications Pages 11 9 803 503 0 Rail Pump 1 12 9 802 744 0 Bolt 10mm x 20mm Zinc 4 13...

Page 28: ... Branch 1 2 9 802 036 0 Nipple 1 2 JIC 3 8 Pipe 2 3 9 802 039 0 Elbow 1 2 JIC 3 8 90 1 4 9 802 870 0 Block Unloader 3 8 x 3 8 1 25 Steel 1 5 9 802 048 0 Swivel 1 2 JIC Female 3 8 Male 1 6 9 802 129 0 Elbow 1 2 JIC x 3 8 90 1 7 8 707 254 0 Pump Protector 3 8 PTP 1 8 8 750 299 0 Unloader VRT 3 8 GPM 4500 PSI 1 9 8 716 125 0 Switch Pressure N O 3 8 NPT SS 1 9 4 1 2 5 3 7 8 6 2 ...

Page 29: ... 0 Pump Fuel 1 13 8 753 179 0 Coil Assy Fuel Pump 12 VDC 1 8 753 180 0 Valve Solenoid Replacement Only 18 23 8 5 2 19 14 11 4 3 21 24 10 6 22 7 1 20 12 13 17 26 16 25 15 9 27 Return Line Inlet Line 22 25 ITEM PART NO DESCRIPTION QTY 14 7 303 041 0 Screw M5 x 20 3 15 7 303 077 0 Screw Sheet Metal 1 16 7 303 084 0 Screw 5 17 7 306 090 0 Screw M6 x 16 1 18 7 310 100 0 Nut KM8 1 19 9 802 802 0 Washer ...

Page 30: ...1 3 640 148 0 Heater Flow 1 2 4 654 280 0 Cover D K 1 3 7 311 380 0 Nut Cap M 6 4 4 7 312 167 0 Washer Lock A 6 4 4 5 2 880 177 0 Electrodes Spare Parts Kit 1 BURNER COIL PARTS LIST 3 4 2 1 ITEM PART NO DESCRIPTION QTY 6 8 717 329 0 Nozzle Burner 1 75 A 80 615 1 8 717 347 0 Nozzle Burner 2 25 a 80 616 0 617 0 1 Not Shown ...

Page 31: ... Assembly Blower HDS Skid 1 10 9 803 521 0 Assembly Coil Tank HDS Skid 1 11 9 803 600 0 Swivel M22 x 3 8 Hex Male Pipe 2 COIL BLOWER PARTS LIST 7 13 12 19 15 8 22 2 6 10 9 3 1 4 5 14 16 17 18 17 11 20 21 ITEM PART NO DESCRIPTION QTY 12 8 730 380 0 Pipe Discharge 3 8 x 10 1 13 8 918 236 0 Hose Inlet High PSI 27 1 14 8 750 094 0 Thermostat 302 F 1 15 8 706 248 0 Plug 3 8 2 16 9 802 103 0 Bushing Sna...

Page 32: ... 4 ITEM PART NO DESCRIPTION QTY 1 6 110 029 0 Hose assembly TR rotatable DN8 40MPa 15m 1 2 4 118 005 0 EASY Force Advanced 1 ITEM PART NO DESCRIPTION QTY 3 4 112 000 0 Jet pipe TR 1050 mm 1 4 2 113 022 0 Power Nozzle TR 25045 615 0 1 2 113 025 0 Power Nozzle TR 25055 616 0 1 2 113 026 0 Power Nozzle TR 25060 617 0 1 Not Shown ...

Page 33: ...ssy Fuel Level Low Sensor 1 9 9 803 604 0 Grommet Low Level Fuel Switch 1 FUEL TANKS ASSEMBLY FUEL TANKS PARTS LIST 11 4 4 2 7 8 1 6 9 10 3 13 10 Burner Inlet Line Burner Return Line Vapor Purge Line to Engine ITEM PART NO DESCRIPTION QTY 10 6 390 126 0 Clamp Hose 3 11 9 802 054 0 Elbow 1 4 Fuel Zinc 1 12 8 920 497 0 BRKT 1 2L Canister 1 13 8 751 215 0 Grommet Remote Vent 1 14 8 751 059 0 Vent Rem...

Page 34: ...WASHER 34 ENGINE ASSEMBLIES 615 0 Models 98001030 5 616 0 Models 617 0 Models 9 8 7 6 3 2 1 4 5 10 9 8 7 6 5 4 3 2 1 10 9 1 21 23 22 24 20 2 13 14 15 17 15 12 16 18 19 11 4 3 5 12 12 26 25 27 25 Engine Purge Connection 31 30 28 25 28 29 Engine Purge Connection 32 ...

Page 35: ...iggs 616 0 1 8 750 497 0 Muffler Honda GX630 GX670 688 CC Right 617 0 1 8 739 597 0 Bolt Flange M8 x 20 617 0 2 9 802 798 0 Screw 10 1 2 Tek HH SS 617 0 1 11 8 750 737 0 Adapter Honda M20 1 5 x 3 8 FPT 1 12 6 390 126 0 Clamp Hose 46 54 ST 617 0 5 13 8 709 152 0 Filter Fuel Disposable 617 0 1 14 9 802 254 0 Hose 1 4 Push On Fuel Line 617 0 2 ft ITEM PART NO DESCRIPTION QTY 15 8 706 950 0 Hose Barb ...

Page 36: ...loader Pulley Part Bushing Part Engine Part 1 575 615 0 KT4540 8 921 715 0 8 715 483 0 2AK94H 9 803 548 0 25MM 9 802 403 0 GX390 389 CC 8 750 579 0 1 575 616 0 KT6036 8 921 717 0 8 715 483 0 2BK90H 8 715 593 0 25MM 9 802 403 0 Vanguard 570 CC 8 754 819 0 1 575 617 0 KT6036 8 921 717 0 8 715 483 0 2BK80H 8 715 592 0 25MM 9 802 403 0 GX630 688 CC 8 752 149 0 ENGINE ...

Page 37: ...Cont Pulley Part Bushing Part Size Part Size Part 615 0 3TB34 9 802 392 0 P2 x 1 9 802 404 0 AX 38 9 802 410 0 AX37 9 802 409 0 616 0 3TB34 9 802 392 0 P2 x 1 9 802 404 0 BX 38 9 802 417 0 AX37 9 802 409 0 617 0 3TB34 9 802 392 0 P2 x 1 9 802 404 0 BX 36 8 715 697 0 AX37 9 802 409 0 SPECIFICATIONS ENGINE CON T BLOWER ...

Page 38: ...ug 6 15 8 753 817 0 Manifold Stud Bolt 8 16 9 802 890 0 Lock Washer 8 17 8 719 008 0 Copper Washer 3 8 1 KT 2 PUMP EXPLODED VIEW PARTS LIST KT 2 SERIES PUMP EXPLODED VIEW TORQUE SPECS ITEM FT LBS 14 95 15 45 23 8 34 10 42 30 48 8 ITEM PART NO DESCRIPTION QTY 18 8 707 262 0 Brass Plug 3 8 1 19 See Kit Below Valve Seat 6 20 See Kit Below Valve Plate 6 21 See Kit Below Valve Spring 6 22 See Kit Below...

Page 39: ...1 1 6 3 ITEM PART NO DESCRIPTION QTY 33 9 803 181 0 Bearing Housing 1 34 8 752 841 0 Plunger Bolt 3 35 8 752 820 0 Bonded Seal 3 36 8 753 819 0 Plunger 18mm 3 37 8 752 823 0 Copper Spacer 3 38 8 753 820 0 Plunger Rod 3 39 8 752 822 0 Connecting Rod Pin 3 40 8 752 821 0 Connecting Rod 3 41 9 802 889 0 Spring Washer 6 42 9 802 937 0 Connecting Rod Screw 6 43 9 803 194 0 O Ring Ø2 62 x 152 07 1 44 8 ...

Page 40: ...sert of the lock nut Item 19 If adjustment knob Item 18 DOES NOT make contact with upper nut Items 15 remove adjusting knob Item 18 re adjust raise nuts Items 15 on stem Item 8 and re attach adjustment knob Item 18 then repeat step 6 If adjustment knob Item 18 DOES make contact with upper nut release the trigger of the spray gun and watch the pressure gauge for the pressure increase spike This spi...

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Page 42: ...Form 9 800 103 0 Printed in U S A ...

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