9.800-079.0 - T (12/24)
High pressure cleaner
Combustion engine - Hot water
English..... 3
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your product
www.kaercher.com/welcome
MODELS:
1.575-555.0
HDS 2.8/25 P Cage
1.575-550.0
HDS 2.6/30 P Cage
1.575-551.0
HDS 3.5/30 P Cage
1.575-552.0
HDS 3.5/30 PE Cage
1.575-553.0
HDS 3.5/35 PE Cage
1.110-085.0
HDS 3.5/35 P Cage CAL
3
CONTENTS
Model Number ______________________________
Serial Number ______________________________
Date of Purchase ___________________________
The model and serial numbers will be found on a decal attached to
the pressure washer. You should record both serial number and date
of purchase and keep in a safe place for future reference.
MANUAL, KARCHER, HDS 9.800-079.0
Introduction & Important Safety Information .............................................. 4
Component Identication ........................................................................... 7
Assembly Instructions................................................................................ 8
Operating Instructions ............................................................................... 9
Detergents and Cleaning Tips ................................................................... 11
Shutting Down And Clean-Up .................................................................... 12
Storage ...................................................................................................... 12
Maintenance .............................................................................................. 13
Troubleshooting ......................................................................................... 16
Maintenance Charts .................................................................................. 19
Oil Change Record .................................................................................... 19
Exploded View - 555.0 Models .................................................................. 20
Exploded View - 550.0, 551.0, 552.0, 553.0 Models ................................. 21
Exploded View - 550.0, 551.0, 552.0, 553.0 Models ................................. 22
ControL Panel Exploded View - 555.0 Models .......................................... 27
ControL Panel - 550.0, 551.0, 552.0, 553.0 .............................................. 29
Hose & Spray Gun Assembly .................................................................... 31
Downstream Injector Assembly ................................................................. 32
Hose Reel Option ...................................................................................... 33
UU1 Unloader Exploded View .................................................................. 34
VBT Unloader Exploded View ................................................................. 35
KS3540GR.3 Pump Exploded View ......................................................... 36
Pump Exploded View ...............................................................................38
LPP3035G1 Pump Exploded View ............................................................ 40
Wayne Burner Part List (3.5/30 P; 3.5/35 P) ............................................. 42
Specications ............................................................................................ 44
Wiring Diagrams ........................................................................................ 45
MANUAL, KARCHER, HDS 9.800-079.0
4
INTRODUCTION & IMPORTANT SAFETY INFORMATION
Thank you for purchasing this Pressure Washer.
We reserve the right to make changes at any time
without incurring any obligation.
Owner/User Responsibility:
The owner and/or user must have an understanding of
the manufacturer’s operating instructions and warnings
before using this pressure washer. Warning information
should be emphasized and understood. If the operator
is not fluent in English, the manufacturer’s instructions
and warnings shall be read to and discussed with
the operator in the operator’s native language by the
purchaser/owner, making sure that the operator com-
prehends its contents.
Owner and/or user must study and maintain for future
reference the manufacturers’ instructions.
The operator must know how to stop the machine
quickly and understand the operation of all controls.
Never permit anyone to operate the engine without
proper instructions.
SAVE THESE INSTRUCTIONS
This manual should be considered a permanent
part of the machine and should remain with it if
machine is resold.
When ordering parts, please specify model and
serial number. Use only identical replacement parts.
This machine is to be used only by trained operators.
IMPORTANT SAFETY
INFORMATION
WARNING
READ OPERATOR’S
MANUAL
THOROUGHLY
PRIOR
TO USE.
OPERATIONS
SAFETY
MAINTENANCE
WARNING: To reduce the risk of
injury, read operating instructions
carefully before using.
1. Read the owner's manual
thoroughly. Failure to follow instruc-
tions could cause malfunction of the
machine and result in death, serious
bodily injury and/or property damage.
2. Know how to stop the ma-
chine and bleed pressure quickly. Be thoroughly
familiar with the controls.
3. Stay alert — watch what you are doing.
KEEP WATER
SPRAY AWAY FROM
ELECTRICAL WIRING.
WARNING
WARNING: 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 electri-
cian, plumber, utility company or the
selling distributor for specic details.
WARNING
EAR PROTECTION
MUST BE WORN
WARNING: This machine exceeds
85 db appropriate ear protection
must be worn
.
WARNING
USE PROTECTIVE
EYE WEAR
AND CLOTHING
WHEN OPERATING
THIS EQUIPMENT.
WARNING: High pressure spray
can cause paint chips or other
particles to become airborne and
y at high speeds. To avoid per-
sonal injury, eye, hand and foot
safety devices must be worn.
5. Eye, hand, and foot protec-
tion must be worn when using this
equipment.
6. Keep operating area clear of all persons.
WARNING
RISK OF EXPLOSION:
OPERATE ONLY WHERE
OPEN FLAME OR TORCH
IS PERMITTED
WARNING: Flammable liquids can
create fumes which can ignite,
causing property damage or se-
vere injury.
WARNING: Risk of explosion —
Operate only where open ame or
torch is permitted.
WARNING
RISK OF FIRE.
DO NOT ADD FUEL
WHEN OPERATING
MACHINE.
WARNING: Risk of re — Do not
add fuel when the product is op-
erating or still hot.
WARNING: Do not use gasoline
crankcase draining or oil contain-
ing gasoline, solvents or alcohol.
Doing so will result in re and/or
explosion.
WARNING: Risk of re — Do not
Spray ammable liquids.
WARNING: This product contains chemicals known
to the state of California to cause cancer and birth
defects or other reproductive harm. Operation of
this equipment may create sparks that can start
res around dry vegetation. A spark arrestor may
be required. The operator should contact: Local
re agencies for laws or regulations relating to re
prevention requirements.
MANUAL, KARCHER, HDS 9.800-079.0
5
13. To reduce the risk of injury, close supervision is
necessary when a machine is used near children.
Do not allow children to operate the pressure
washer. This machine must be attended during
operation.
WARNING
TRIGGER GUN KICKS
BACK — HOLD WITH
BOTH HANDS
WARNING: Grip cleaning wand
securely with both hands before
starting. Failure to do this could
result in injury from a whipping
wand.
14. Never make adjustments on
machine while in operation.
15. Be certain all quick coupler ttings are secured
before using pressure washer.
WARNING
RISK OF INJECTION
OR SEVERE INJURY
TO PEOPLE
OR ANIMALS. KEEP
CLEAR OF NOZZLE.
WARNING: High pressure devel-
oped by these machines will cause
personal injury or equipment dam-
age. Keep clear of nozzle. Use
caution when operating. Do not
direct discharge stream at people,
or severe injury or death will result.
WARNING
PROTECT FROM
FREEZING
WARNING: Protect machine from
freezing.
16. To keep machine in best
operating conditions, it is important
you protect machine from freezing.
Failure to protect machine from
freezing could cause malfunction
of the machine and result in death,
serious bodily injury, and/or property
damage. Follow storage instructions specied in
this manual.
17. Inlet water must be clean fresh water and no hotter
then 90°F.
WARNING
RISK OF
ASPHYXIATION.
USE THIS PRODUCT
ONLY IN A WELL
VENTILATED AREA.
WARNING: Risk of asphyxiation.
Use this product only in a well
ventilated area.
18. Avoid installing machines in
small areas or near exhaust fans.
Adequate oxygen is needed for
combustion or dangerous carbon
monoxide will result.
19. Manufacturer will not be liable for any changes
made to our standard machines or any components
not purchased from us.
IMPORTANT SAFETY INFORMATION
7. Allow engine to cool for 1-2 minutes before refuel-
ing. If any fuel is spilled, make sure the area is dry
before testing the spark plug or starting the engine.
(Fire and/or explosion may occur if this is not done).
Gasoline engines on mobile or portable equipment
shall be refueled:
a. outdoors;
b. ith the engine on the equipment stopped;
c. with no source of ignition within 10 feet of the dis-
pensing point; and
d. with an allowance made for expansion of the fuel
should the equipment be exposed to a higher ambi-
ent temperature.
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 ammable
objects as the engine is hot.
9. Oil burning appliances shall be installed only in
locations where combustible dusts and ammable
gases or vapors are not present. Do not store or
use gasoline near this machine.
10. Use No. 1 or No. 2 heating oil (ASTM D306) only.
NEVER use gasoline in your fuel oil tank. Gasoline
is more combustible than fuel oil and could result
in a serious explosion. NEVER use crankcase or
waste oil in your burner. Fuel unit malfunction could
result from contamination.
11. Do not confuse gasoline and fuel oil tanks. Keep
proper fuel in proper tank.
WARNING
RISK OF INJURY.
HOT SURFACES
CAN CAUSE BURNS
WARNING: Risk of injury. Hot sur-
faces can cause burns. Use only
designated gripping areas of spray
gun and wand. Do not place hands
or feet on non-insulated areas of
the pressure washer.
12. Transport/Repair with fuel tank EMPTY or with fuel
shut-o valve OFF.
CAUTION
HOT DISCHARGE FLUID:
DO NOT TOUCH OR
DIRECT DISCHARGE
STEAM AT PERSONS
OR ANIMALS.
CAUTION: Hot discharge uid. Do
not touch or direct discharge
stream at persons.
WARNING: This machine pro-
duces hot water and must have
insulated components attached
to protect the operator.
MANUAL, KARCHER, HDS 9.800-079.0
6
20. The best insurance against an accident is precau-
tion and knowledge of the machine.
WARNING
RISK OF INJURY
FROM FALLS WHEN
USING LADDER.
WARNING: Be extremely careful
when using a ladder, scaolding
or any other relatively unstable
location. The cleaning area should
have adequate slopes and drain-
age to reduce the possibility of a
fall due to slippery surfaces.
21. Do not allow acids, caustic or abrasive uids to
pass through the pump.
22. Never run pump dry or leave spray gun closed
longer than 1-2 minutes.
23. Machines with shut-o spray gun should not be
operated with the spray gun in the o position for
extensive periods of time as this may cause dam-
age to the pump.
24. Protect discharge hose from vehicle trac and
sharp objects. Inspect condition of high pressure
hose before using or bodily injury may result.
25. Before disconnecting discharge hose from water
outlet, turn burner o 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.
WARNING
TIP OVER HAZARD
WARNING: Moving this machine
on a incline may cause instability
and could result in the machine
tipping over. Equipment damage
or body harm could occur.
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
the inuence of alcohol, prescription medications,
or drugs.
28. In oil burning models, use only kerosene, No. 1
home heating fuel, or diesel. If diesel is used, add
a soot remover to every tankful.
Follow the maintenance instructions
specied in the manual.
IMPORTANT SAFETY INFORMATION
MANUAL, KARCHER, HDS 9.800-079.0
7
COMPONENT IDENTIFICATION
Pressure
Switch
Brass
Soap
Nozzle
Nozzle
Quick
Coupler
Spray
Gun
High Pressure
Hose
Detergent
Injector
Quick
Coupler
Collar
Discharge
Nipple
Water Supply
Hose
(not included)
Gasoline
Tank
Wand Coupler
Variable Pressure
Control wand
Control Wand
Handle
Trigger
Swivel
Connector
Unloader
Battery Box
Pump — Develops high pressure.
Starter Grip — (Not Shown) Used for starting the
engine manually.
Spray Gun — Controls the application of water and
detergent onto cleaning surface with trigger device.
Includes safety latch.
Detergent Injector — Allows you to siphon and mix
detergents.
Variable Pressure Control Wand — Must be con-
nected to the spray gun. This wand handle controls
dishcharge flow from one tube to both wand tubes.
When water is discharged from both tubes you will have
a pressure loss and allows chemical siphoning when
used in combination with a detergent injector.
High Pressure Hose — Connect one end to water
pump discharge nipple and the other end to 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 oor. This system prevents internal pump
damage.
Pump
MANUAL, KARCHER, HDS 9.800-079.0
8
ASSEMBLY INSTRUCTIONS
Safety
Latch
Spray
Gun
High Pressure
Hose
STEP 1: Attach the high pressure
hose to the spray gun using teflon
tape on hose threads.
Wand
Coupler
Soap
Nozzle
STEP 2: Pull the spring-loaded col-
lar of the wand coupler back to insert
your choice of pressure nozzle.
Pressure
Nozzle
Wand
Coupler
Wand
Collar
STEP 3: Release the coupler collar
and push the nozzle until the collar
clicks. Pull the nozzle to make sure
it is seated properly.
DipStick
Oil Window
STEP 4: Remove shipping cap and
install oil dipstick. Check pump oil
level by using dipstick or observe
oil level in oil window (if equipped).
Use 30 wt. non detergent oil.
Discharge Fitting
High Pressure Hose
Coupler Collar
STEP 5: Connect the high pressure
hose to the pump discharge fitting.
Push coupler collar forward until
secure.
Cold
Water
Source
Garden
Hose
STEP 6: Connect garden hose to
the cold water source.
Pump
Water Inlet
Garden
Hose
STEP 7: Connect the garden hose
to pump water inlet. Inspect inlets.
CAUTION
: Do not run the pump
without water or pump damage
will result.
MANUAL, KARCHER, HDS 9.800-079.0
9
OPERATING INSTRUCTIONS
Oil Dipstick
STEP 1: Check engine oil level. Oil level should be level with the bottom
of the oil filler neck. Be sure the machine is level when checking the oil
level. (Refer to the engine's operating manual included with machine.)
We recommend 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.
Gas
Tank
STEP 2: Fill gas tank with unleaded
gasoline. Do not use leaded gaso-
line.
Caution: Read warnings on pg. 4
and engine manual.
Cold
Water
Source
Garden
Hose
STEP 3: Connect garden hose to
the cold water source and turn water
on completely. Never use hot water.
Safety
Latch
STEP 4: Trigger the spray gun to
eliminate trapped air then wait for a
steady flow of water to emerge from
the spray nozzle.
Fuel
Valve
STEP 5: Rotate the fuel shut-off valve to the "On" po-
sition. Slide the fuel valve lever to the "ON" position.
When the engine is not in use, leave the fuel valve in
the "OFF" position.
Choke
Lever
STEP 6: Pull the choke lever out to the "Choke" position
(on a warm engine, leave the choke lever in, in the run
position). Push the choke lever to the "Closed" position.
To restart a warm engine, leave the choke lever in the
"Open" position.
MANUAL, KARCHER, HDS 9.800-079.0
10
OPERATING INSTRUCTIONS
Throttle
STEP 7: Turn the engine to "Run" position. STEP 8: Pull the starter grip. If the engine fails to start
after 2 pulls, squeeze the trigger gun to release pressure
and repeat step. Return starter gently. After the engine
warms up enough to run smoothly, move choke to run
position and throttle to fast position.
Temperature
Gauge
Burner
Swutch
STEP 9: If hot water is required.
Adjust temperature gauge to proper
temperature (200°). Turn on Burner
switch to begin heating water.
Safety
Latch
WARNING! Never replace
nozzles without engaging the
safety latch on the spray gun
trigger.
NOZZLES
The four color-coded quick con-
nect nozzles provide a wide array
of spray widths from 15° to 40° and
are easily accessible when placed in
the convenient rubber nozzle holder,
which is provided on the front of the
machine.
NOTE: For a more gentle rinse,
select the white 40° or green 25°
nozzle. To scour the surface, se-
lect the yellow 15° nozzle. To apply
detergent select the black nozzle.
Variable Pressure
Control Handle
Trigger
Variable Pressure
Wand (VP)
High
Pressure
Nozzle
Brass Soap
Nozzle
Selection of high or low pressure is accompanied by
turning the handle. NOTE: High pressure nozzle must
be inserted at end of wand to obtain high pressure. To
apply soap read operator's manual.
MANUAL, KARCHER, HDS 9.800-079.0
11
WARNING
WARNING: Some detergents may
be harmful if inhaled or ingested,
causing severe nausea, fainting or
poisoning. The harmful elements
may cause property damage or
severe injury.
STEP 1: Connect detergent injector
to discharge nipple on machine, Con-
nect high pressure hose to injector
with quick coupler(check to make sure locking coupler
sleeves are in proper position before applying water
pressure.
Control
Handle
Detergent
Injector
Discharge
Nipple
High Pressure
Hose
Quick
Coupler
STEP 2: Use detergent designed
specifically for pressure washers.
Household detergents could dam-
age the pump. Prepare detergent
solution as required by the manu-
facturer. Fill a container with pres-
sure washer detergent. Place the
filter end of detergent suction tube
into the detergent container.
STEP 3: Apply safety latch to
spray gun trigger. Turn variable
pressure control handle until dis-
charge water exits both tubes.
Secure black detergent nozzle
into quick coupler if you have a
single wand. NOTE: Detergent
cannot be applied using Yellow,
Green or White nozzles.
STEP 4: With the engine running, pull trigger to operate
machine. Liquid detergent is drawn into the machine
and mixed with water. Apply detergent to work area. Do
not allow detergent to dry on surface.
IMPORTANT: You must ush the detergent injection
system after each use by placing the suction tube
into a bucket of clean water, then run the pressure
washer in low pressure for 1-2 minutes.
THERMAL PUMP PROTECTION
If you run the engine on your pressure washer for 3-5
minutes without pressing the trigger on the spray gun,
circulating water in the pump can reach high tempera-
tures. When the water reaches this temperature, the
pump protector engages and cools the pump by dis-
charging the warm water onto the ground. This thermal
device prevents internal damage to the pump.
CLEANING TIPS
Pre-rinse cleaning surface with fresh water. Place de-
tergent suction tube directly into cleaning solution and
apply to surface at low pressure (for best results, limit
your work area to sections approximately 6’ square
and always apply detergent from bottom to top). Allow
detergent to remain on surface 1-3 minutes. Do not al-
low 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 dirt. Rinse at
high pressure from top to bottom in an even sweeping
motion keeping the spray nozzle approximately 1’ from
cleaning surface. Use overlapping strokes as you clean
and rinse any surface. For best surface cleaning action
spray at a slight angle.
Recommendations:
• Before cleaning any surface, an inconspicuous
area should be cleaned to test spray pattern and
distance for maximum cleaning results.
• If painted surfaces are peeling or chipping, use
extreme caution as pressure washer may remove
the loose paint from the surface.
• Keep the spray nozzle a safe distance from the sur-
face you plan to clean. High pressure wash a small
area, then check the surface for damage. If no dam-
age is found, continue to pressure washing.
CAUTION - Never use:
• Bleach, chlorine and other corrosive chemicals
• Liquids containing solvents (i.e., paint thinners,
gasoline, oils)
• Tri-sodium phosphate products
• Ammonia products
• Acid-based products
These chemicals will harm the machine and will damage
the surface being cleaned.
RINSING
It will take a few seconds for the detergent to clear.
Apply safety latch to spray gun. Remove black soap
nozzle from the quick coupler. Select and install the
desired high pressure nozzle. NOTE: You can also stop
detergent from flowing by simply removing detergent
siphon tube from bottle.
DETERGENTS AND CLEANING TIPS
MANUAL, KARCHER, HDS 9.800-079.0
12
SHUTTING DOWN AND CLEAN-UP
CAUTION: Always store your pressure washer in a
location where the temperature will not fall below
32°F (0°C). The pump in this machine is susceptible
to permanent damage if frozen. FREEZE DAMAGE
IS NOT COVERED BY WARRANTY.
1. Stop the pressure washer, squeeze spray gun trig-
ger to release pressure.
2. Detach water supply hose and high pressure hose.
3. Turn on the machine for a few seconds, until re-
maining water exits. Turn engine o immediately.
4. Drain the gas and oil from the engine.
5. Do not allow high pressure hose to become kinked.
6. Store the machine and accessories in a room which
does not reach freezing temperatures.
CAUTION: Failure to follow the above directions will
result in damage to your pressure washer.
When the pressure washer is not being operated or is
being stored for more than one month, follow these
instructions:
1. Replenish engine oil to upper level.
2. Drain gasoline from fuel tank, fuel line, fuel valve
and carburetor.
3. Pour about one teaspoon of engine oil through
the spark plug hole, pull the starter grip several
times and replace the plug. Then pull the starter
grip slowly until you feel increased pressure which
indicates the piston is on its compression stroke and
leave it in 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 shortage.
Such additives may be added to the gasoline in
the fuel tank of the engine, or to the gasolinee in a
storage container.
After Extended Storage
CAUTION: Prior to restarting, thaw out any
possible ice from pressure washer hoses,
spray gun or wand.
Engine Maintenance
During the winter months, rare atmosheric conditions
may develop which will cause an icing condition in the
carburetor. If this develops, the engine may run rough,
lose power and may stall. This temporary condition can
be overcome by deflecting some of the hot air from the
engine over the carburetor area. NOTE: Refer to the
engine manufacturer's manual for service and mainte-
nance of the engine.
STORAGE
STEP 1: Remove detergent suction
tube from container and insert into 1
gallon of fresh water. Turn variable
pressure wand handle for low pres-
sure or connect the black detergent
nozzle. Pull trigger on spray gun and
siphon water for one minute.
On-O
Switch
STEP 2: Turn off the engine.
STEP 3: Turn off water supply.
STEP 4: Press
trigger to release
water pressure.
Water
Inlet
STEP 5: Disconnect the gar-
den hose from the water inlet
on the machine.
High
Pressure
Outlet
STEP 6: Disconnect the high
pressure hose from high pres-
sure outlet.
Safety
Latch
STEP 7: Engage the
spray gun safety lock.
MANUAL, KARCHER, HDS 9.800-079.0
13
PREVENTATIVE
MAINTENANCE
1. Check to see that the water pump is properly lu-
bricated.
2. Follow Winterizing Procedures to prevent freeze
damage to the pump and coils.
3. Always neutralize and flush detergent from system
after use.
4. If water is known to be high in mineral content, use
a water softener in your water system or de-scale
as needed.
5. Do not allow acidic, caustic or abrasive fluids to be
pumped through system.
6. Always use our high grade quality cleaning prod-
ucts.
7. Never run pump dry for extended periods of time.
8. Use clean fuel: kerosene, No. 1 fuel oil or diesel.
Replace fuel filter every 100 hours of operation.
Avoid water contaminated fuel as it will seize up
the fuel pump.
9. If machine is operated with smoking or eye burning
exhaust, coils will soot up, not letting water reach
maximum operating temperature. (See section on
Air Adjustments.)
10. Never allow water to be sprayed on or near engine
or burner assembly or any electrical component.
11. Periodically delime coils as per instructions.
12. Check to see that engine is properly lubricated.
It is advisable, periodically, to visually inspect the
burner. Check air inlet to make sure it is not clogged
or blocked. Wipe off any oil spills and keep this equip-
ment clean and dry.
The areas around the pressure washer should be kept
clean and free of combustible materials, gasoline and
other flammable vapors and liquids.
The flow of combustion and ventilating air to the burner
must not be blocked or obstructed in any manner. Con-
sult factory if vent stacking is going to be used.
MAINTENANCE AND
SERVICE
Unloader Valves:
Unloader valves are preset and tested at the factory
before shipping. Occasional adjustment of the unloader
may be necessary to maintain correct pressure. Call
your local dealer for assistance.
Winterizing Procedure:
Damage due to freezing is not covered by warranty.
Adhere to the following cold weather procedures when-
ever the washer must be stored or operated outdoors
under freezing conditions.
During winter months, when temperatures drop below
32°F, protecting your machine against freezing is neces-
sary. Store the machine in a heated room. If this is not
possible then mix a 50/50 solution of anti-freeze/water
into a 5 gallon bucket. Place a short section of garden
hose into the bucket and connect it to the machine.
Elevate the bucket and turn the pump on to siphon the
anti-freeze through the machine. If compressed air is
available, an air fitting can be screwed into the inlet
connector and, by injecting compressed air, all water
will be blown out of the system.
High Limit Hot Water Thermostat:
For safety, each machine is equipped with a high limit
control switch. In the event that the temperature of the
water should exceed its operating temperature, the high
limit control will turn the burner off until the water cools.
Pumps:
Use only SAE 30W non-detergent oil. Change oil after
the first 50 hours of use. Thereafter, change the oil
every three months or at 500 hour intervals. Oil level
should be checked by using the dipstick found on top
of the pump or the red dot visible through the oil gauge
window. Oil should be maintained at that level.
Cleaning of Coils:
In alkaline water areas, lime deposits can accumulate
rapidly inside the coil pipes. This growth is increased by
the extreme heat build up in the coil. The best preven-
tion for liming conditions is to use high quality cleaning
detergents. In areas where alkaline water is an extreme
problem, periodic use of our Deliming Powder (part
#9-028008) will remove lime and other deposits before
coil becomes plugged. (See Deliming Instructions for
use of Deliming Powder.)
Deliming Coils:
Periodic flushing of coils is recommended.
1. Fill a container or optional float tank with 4 gallons
of water, then add 1 lb. of deliming powder. Mix
thoroughly.
2. Remove wand assembly from spray gun and put
spray gun into container. Secure the trigger on the
spray gun into the open position.
3. Attach a short section (3-5 ft.) of garden hose to
machine to siphon solution from an elevated con-
tainer. Turn pump switch on, allowing solution to
be pumped through coils back into the container.
Solution should be allowed to circulate 2-4 hours.
4. After circulating solution flush entire system with
fresh water. Reinstall wand assembly to spray gun.
MAINTENANCE
MANUAL, KARCHER, HDS 9.800-079.0
14
Fuel:
Use clean fuel oil that is not contaminated with water
and debris. Replace fuel filter and drain tank every 100
hours of operation.
Use No. 1 or No. 2 Heating Oil (ASTM D306) only.
NEVER use gasoline in your burner tank. Gasoline is
more combustible than fuel oil and a serious explo-
sion could result. NEVER use crankcase or waste oil
in your burner. Fuel unit malfunction could result from
contamination.
Fuel Control System:
These machines utilize a fuel solenoid valve located on
the fuel pump to control the flow of fuel to the combus-
tion chamber. This solenoid valve, which is normally
closed, is activated by a flow switch when water is flow-
ing through it. When an operator releases the trigger on
the spray gun, the flow of water through the flow switch
stops, turning off the current to the fuel solenoid. The
solenoid then closes, shutting off the supply of fuel to
the combustion chamber. Controlling the flow of fuel in
this way allows for an instantaneous burn or no burn
situation, thereby eliminating high and low water tem-
peratures, and combustion smoke normally associated
with machines incorporating a spray gun.
CAUTION: Periodic inspection is recommended to
insure that the fuel solenoid valve functions prop-
erly. This can be done by operating the machine and
checking to see that when the trigger on the spray
gun is in the o position, the burner is not ring.
Electrode Setting:
(See illustration below.)
Top View Side View
Nozzle
Electrode
1/8" min
5/32" max Gap
1/8" AC- 3/16"
DC nozzle-to-tip
spacing
1/4" Above
nozzle center
Periodically check wiring connections. If necessary to
adjust electrodes, use diagram.
Burner Nozzle:
Keep the tip free of surface deposits by wiping it with a
clean, solvent-saturated cloth, being careful not to plug
or enlarge the nozzle. For maximum efficiency, replace
the nozzle each season.
Wayne Burner Air Adjustment:
Machines are preset and performance tested at the
factory - elevation 100 feet. A one-time initial correction
for your location will pay off in economy, performance
and extended service life. If a smoking or eye-burning
exhaust is being emitted from the stack, two things
should be checked. First, check the fuel to be certain
that kerosene or No. 1 home heating fuel is being used.
Next, check the air adjustment on the burner.
To adjust: Start machine and turn burner ON. Loosen
the locking screws found in the air band openings (re-
fer to illustration below) and close air band until black
smoke appears from burner exhaust vent. Note air
band position. Next, slowly open the air band until white
smoke just starts to appear. Turn air band halfway back
to the black smoke position previously noted. Tighten
locking screws.
WAYNE FUEL AIR ADJUSTMENT
Air Band
Air Band
Locking Screw
MAINTENANCE
MANUAL, KARCHER, HDS 9.800-079.0
15
Wayne Burner Fuel Pressure Adjustment:
To adjust fuel pressure, First install a pressure gage
into the port just after the pump fuel exit. Turn the ad-
justing screw (located at the regulator port) clockwise
to increase, and counterclockwise to decrease. Do not
exceed 205 psi or lower the pressure below 130 PSI,
when checked at the post-pump pressure port.
The fuel pressure may need to be adjusted due to
altitude. For every 500 ft altitude above sea level, the
boiling point of water goes down 1 °F. At high altitude
environments, this boiling point change may require
the heat input to be lowered so the water input does
not turn to steam earlier than at the factory settings
and activate the pressure sensors and pressure relief
equipment when the unit is operated and much higher
altitudes from factory settings or local dealer site set-
tings. Check with your dealer before making local site
fuel pressure adjustments.
Also, as ambient temperature changes seasonally, the
fuel temperature in the feed tank and air temperature in-
let can impact fuel flow. In more extreme temperatures,
this local-site adjustment may also require different fuel
nozzles for fuel inlet temperatures that are at seasonal
extremes (higher or lower) in locations where the tem-
perature changes are beyond moderate temperatures
of between 40°F and 90°F. Colder temperatures will
make for a thicker flow and less fine a fuel spray while
hotter temperatures will make for a thinner flow a more
fine spray with the same nozzle. Consider alternate
nozzle configurations from the baseline factory-supplied
nozzle for operating in such temperature extremes if
performance is not meeting needs with air band and
fuel pressure settings alone.
NOTE: When changing fuel pump, a by-pass plug must
be installed in return line port or fuel pump will not prime.
Karcher Clear Fire Oil Burner
Burner Air Adjustment: The oil burner on this machine
is preset for operation at altitudes below 1000 feet. If
operated at higher altitudes, it may be necessary to
adjust the air band for a #1 or #2 smoke spot on the
Bacharach scale.
To adjust, start machine and turn burner ON. Loosen
two locking screws found on the air band and close air
band until black smoke appears from burner exhaust
vent. Note air band position. Next, slowly open the air
band until white smoke just starts to appear. Turn air
band halfway back to the previously noted position.
Tighten locking screws.
KNA Burner Air Adjustment
Reference Numbers
Air Band Locking Screws
Air Band
CAUTION: If white smoke appears from burner ex-
haust vent during start-up or operation, discontinue
use and readjust air bands.
NOTE: If a flue is installed, have a professional service-
man adjust your burner for a #1 or #2 smoke spot on
the Bacharach scale.
Removal of Soot and Heating Coil:
In the heating process, fuel residue in the form of soot
deposits may develop on the heating coil and block air
flow which will affect burner combustion. When soot
has been detected on visual observation, the soot
on the coil must be washed off after following the coil
removal steps.
1. Remove the tank head assembly by lifting the tank
head off.
2. Remove the two pipe nipples and associated fit-
tings.
3. Lift the coil out of the outer wrap.
CAUTION: The coil weighs about 80 lbs. Use proper
lifting techniques.
4. Clean, repair and replace the coil by reversing the
above steps.
Coil Reinstallation:
Reinstall by reversing the above steps 4 through 1.
Final Note:
The 12 VDC burner systems can draw as much as 18
amps! For such burners to run properly, the battery and
engine charging system must be kept in good condition.
The engine must run at the correct RPM to adequately
charge the battery. It is equally important not to throttle
down the engine on models without batteries, since all
power to run the burner comes solely from the engine.
Do not throttle down the engine at anytime while the
machine is operating.
MAINTENANCE
MANUAL, KARCHER, HDS 9.800-079.0
16
TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE SOLUTION
LOW OPERAT-
ING PRESSURE
Water supply is insufficient Use larger supply hose; clean filter at water
inlet.
Spray nozzle is old, worn or incorrect Match the nozzle number to the machine and/or
replace with new nozzle.
Belt slips Tighten or replace belt; use correct belt.
Plumbing or hose is leaking Check plumbing system for leaks. Retape leaks
with teflon tape.
Unloader is faulty or misadjusted Adjust unloader for proper pressure. Install
repair kit when necessary or replace.
Packing in pump is worn Install new packing kit.
Discharge valve in pump or inlet is
fouled or dirty
Check inlet and discharge valve.
Discharge valve or inlet is worn Replace with valve kit.
Spray nozzle has obstruction Remove obstruction.
Steam pressure control valve is leak-
ing (where applicable)
Rebuild or replace as necessary.
Engine RPM is slow "Set engine speed at proper specifications /
see serial plate."
BURNER WILL
NOT LIGHT
There is little or no fuel Fill tank with fuel.
Improper fuel or water in fuel Drain fuel tank and fill with proper fuel.
Fuel line is clogged Clean or replace fuel line.
Fuel filter is plugged Replace fuel filter as needed.
Burner air bands are misadjusted Readjust air bands for clean burn.
Little or no fuel pressure from fuel
pump
Increase fuel pressure to specification and/or
replace fuel pump.
Burner transformer is faulty Test transformer for proper arc between con-
tacts. Replace as needed.
Electrical wiring is disconnected or
has short in it
All wire contacts should be clean and tight with
no breaks in wire.
Flex coupling is slipping on fuel pump
shaft or burner motor shaft
Replace if needed.
ON-OFF switch is defective "Check for electrical current reaching burner
assembly with burner switch on. Replace switch
if needed."
Heavy sooting on coil and burner
can cause interruption of air flow and
shorting of electrodes
Clean as required.
Electrode setting is improper Check and reset according to diagram in
manual.
25 amp circuit breaker tripped Push in reset button.
Bridge rectifier defective Test and replace.
12V DC relay defective Test and replace.
Fuel is not reaching combustion
chamber
Check fuel pump for proper flow. Check sole-
noid flow switch on machines with spray gun
control for proper on-off flow control.
MANUAL, KARCHER, HDS 9.800-079.0
17
TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE SOLUTION
BURNER WILL
NOT LIGHT
(continued from
previous page)
Burner nozzle is clogged Clean as required.
Thermostat has malfunctioned Test and replace if needed.
Fuel solenoid has malfunctioned Test and replace if needed.
MACHINE
SMOKES
Fuel is improper or water is in fuel Drain tank and replace contaminated fuel.
Air adjustment is improper Readjust air bands on burner assembly.
Fuel pressure is low Adjust fuel pump pressure to specifications.
Burner nozzle is plugged or dirty Replace nozzle. Check parts breakdown for
nozzle size.
Burner nozzle spray pattern is faulty Replace nozzle. Check parts breakdown for
nozzle size.
Coil and burner assembly have heavy
accumulation of soot
Remove coils and burner assembly, clean thor-
oughly. Call local dealer.
Electrode setting is misaligned Realign electrodes to specifications.
Smoke stack has obstruction Check for blockage or other foreign objects.
Engine RPM is low Increase RPM to correct specs. See serial
plate.
LOW WATER
TEMPERATURE
Fuel is improper or has water in it Replace with clean and proper fuel.
Fuel pressure is low Increase fuel pressure.
Fuel pump is weak Check fuel pump pressure. Replace pump if
needed.
Fuel filter is partially clogged Replace as needed.
Soot buildup on coils is not allowing
heat transfer
Clean coils.
Burner nozzle is improper Call your local dealer for proper nozzle.
WATER TEM-
PERATURE TOO
HOT
Incoming water to machine is warm
or hot
Lower incoming water temperature.
Fuel pump pressure is too high Call your local dealer for proper fuel pressure.
Fuel pump is defective Replace fuel pump.
Fuel nozzle is incorrect size See parts breakdown or serial plate for proper
size.
Water supplied is insufficient Check water GPM to machine.
Water flow is restricted Check nozzle for obstruction and proper size.
Check serial plate for correct size.
PRESENCE OF
WATER IN OIL
Oil seal is worn Check and replace if necessary.
Air humidity is high Check and change oil twice as often.
Packing is worn or bad Check and replace if necessary.
MANUAL, KARCHER, HDS 9.800-079.0
18
TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE SOLUTION
DETERGENT
NOT DRAWING
Air is leaking Tighten all clamps. Check detergent lines for
holes.
Injector head may be blocked, dirty or
damaged
Clean and make sure ball and spring behind
detergent hose barb or injector body are work-
ing properly.
Filter screen on detergent suction
hose is plugged
Clean or replace.
Detergent has high viscosity Dilute detergent to specifications.
Not using soap nozzle Insert soap nozzle into wand coupler.
Detergent level is low Add detergent if needed.
PUMP RUNNING
NORMALLY BUT
PRESSURE LOW
ON INSTALLA-
TION
Pump is sucking air Check water supply and possibility of air seep-
age.
Valves are sticking Check and clean or replace if necessary.
Unloader valve seat is faulty Check and replace if necessary.
Nozzle sized incorrectly Check and replace if necessary (see serial
plate for proper size).
Packing piston is worn Check and replace if necessary.
FLUCTUATING
PRESSURE
Valves are worn Check and replace if necessary.
Valve has a blockage Check and replace if necessary.
Pump is sucking air Check water supply and air seepage at joint in
suction line.
Packing piston is worn Check and replace if necessary.
PUMP NOISY Air is in suction line Check water supply and connections on suction
line.
Inlet or discharge valve springs are
weak or broken
Check and replace if necessary.
Excessive matter is in valves Check and replace if necessary.
Bearings are worn Check and replace if necessary.
WATER DRIP-
PING FROM
UNDER PUMP
Piston packing is worn Check and replace if necessary.
O-Ring plunger retainer is worn Check and replace if necessary.
Piston is cracked Check and replace if necessary.
Pump protector is worn Lower water supply pressure. Do not run the
spray gun closed longer than 5 minutes.
OIL DRIPPING Oil seal is worn Check and replace if necessary.
EXCESSIVE
VIBRATION IN
DELIVERY LINE
Valves are functioning irregularly Check and replace if necessary.
BURNER MO-
TOR WILL NOT
RUN
Fuel pump has seized Replace fuel pump.
Burner fan loose or misaligned Position correctly and tighten set screw.
Control switch is defective Replace switch.
There is a loose wire Check and replace or tighten wiring.
Burner motor is defective Replace motor.
RELIEF VALVE
LEAKS WATER
Relief valve is defective Replace or repair relief valve.
MANUAL, KARCHER, HDS 9.800-079.0
19
Preventative Maintenance
This pressure washer was produced with the best available materials and quality craftsmanship. However, you
as the owner have certain responsibilities for the correct care of the equipment. Attention to regular preventa-
tive maintenance procedures will assist in preserving the performance of your equipment. Contact your dealer
for maintenance. Regular preventative maintenance will add many hours to the life of your pressure washer.
Perform maintenance more often under severe conditions.
MAINTENANCE SCHEDULE
Engine Oil
SAE 10W-30
Inspect Daily
Change Every 25 hours
Filter Every 50 hours
Air Cleaner Inspect Every 50 hours or monthly
Clean Every 3 months
Battery Level Check monthly
Engine Fuel Filter 500 hours or 6 months
Spark Plug Maintenance 500 hours or 6 months
Clean Fuel Tank(s) Annually
Replace Fuel Lines Annually
Pump Oil (Non foaming)
SAE 10W-40
Inspect Oil level daily
Change After first 50 hours, then every 500 hours or annually
Clean Burner Filter Monthly (More often if fuel quality is poor)
Remove Burner Soot Annually
Burner Adjustment/Cleaning Annually
Replace Burner Nozzle Annually
Descale Coil Annually (more often if required)
Replace High Pressure Hose Every 6 months
Replace Quick Couplers Annually
Clean Water Screen/Filter Weekly
Replace HP Hose Annually (if there are any signs of wear)
NOTE: Read engine manual for any maintenance or service questions.
OIL CHANGE RECORD
MAINTENANCE CHARTS
Date Oil Changed
Month/Day/Year
Estimated Operating
Hours Since Last
Oil Change
Date Oil Changed
Month/Day/Year
Estimated Operating
Hours Since Last
Oil Change
MANUAL, KARCHER, HDS 9.800-079.0
20
EXPLODED VIEW - 555.0 MODELS
1
8
10
6
5
3
58
94
11
13
22
29
57
156
141
155
154
97
160
28
25
63
64
111
89
90
18
20
For
Detail See
Control
Box Illus.
19
34
55
75
35
96
23
27
26
46
2
101
17
74
15
16
50,103,104
20
20
88
84
85
82
149
86
106
149
106
98
105
149
153
44
31
53
131
52
45
38
24
Reversed
View of
Regulator
108
47
158
135
107
2
61
4
52
131
87
56
70
42
For Brake
Detail See
Reversed
View A-A
(Enlarged)
Pg. 21
100
40
53
2
115
116
118
145
52
53
36
37
37
119
120
121
99
152
130
134
132
49
49
141
17
Reversed View
of labels
Reversed View
of label
114
148
MANUAL, KARCHER, HDS 9.800-079.0
21
EXPLODED VIEW - 550.0, 551.0, 552.0, 553.0 MODELS
CHAUD!
CHAUD!
3
13
92
47
14
60
19
18
58
5
6
2
1
11
10
8
20
18
19
20
56
38
37
For
Detail See
Control
Box Illus.
15
131
16
Reversed
View of
Component
50
53
41
82
31
99
31
52
74
61
76
40
42
Honda Electric
Start Only
87
88
53
14
85
130
37
84
44
98
149
105
149
86
2
60
3
91
For Brake
Detail See
View A-A
(Enlarged)
pg. 21
103
104
116
114
115
120
121
71
52
4
138
59
59
17
17
Reversed View
of labels
148
150
151
150
151
MANUAL, KARCHER, HDS 9.800-079.0
22
EXPLODED VIEW - 550.0, 551.0, 552.0, 553.0 MODELS
34
26
29
157
28
43
31
27
25
46
21
2
89
93
48
30
31
24
23
22
22
33
54
35
19
18
45
20
19
18
20
45
33
55
57
68
66
65
67
75
Electric Start
Model Only
64
63
70
111
62
32
95
80
78
77
Steam
Option
550.0
Models Only
113
31
32
32
31
113
81
94
90
57
31
108
106
Steam Option
View A-A
(Enlarged)
72
83
73
79
102
39
112
109
9
123
145
79
79
72
117
129
53, 69
124
125
126
128
127
89
90
123
135
137
136
134
140
139
MANUAL, KARCHER, HDS 9.800-079.0
23
EXPLODED VIEWS PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 8.719-913.0 Top Hat, Coil 1
2 9.800-006.0 Label, Hot/Caliente w/Arrows Warning 3
3 9.802-825.0 Clip, Retaining, U-Type 4
4 9.198-004.0 3/8 USS F/W Zinc 4
5 8.925-218.0 Spare coil 16" MTY large (551.0, 552.0, 553.0) 1
8.925-219.0 Spare coil 16" MTY (550.0, 555.0) 1
6 8.911-800.0 Coil wrap SS 16" large (551.0, 552.0, 553.0) 1
8.911-802.0 Coil wrap SS 16" (550.0, 555.0) 1
8 8.757-240.0 Manifold coil outlet discharge w/slnt 1
9 9.803-044.0 Elbow, 3/8" Male Pipe, (Steam Option) 1
10 8.707-152.0 NIPPLE, 3/8", MALE, SSTEEL 1
1 1 8 . 9 0 2 - 4 3 3 . 0 V a l v e S a f e t y R e l i e f 1
13 8.711-785.0 Hose, 3/8" Push-On, Conduit 2.5 ft.
14 8.757-655.0 Adapter Steel 1/2" JIC x 3/8" (550.0, 555.0) 1
8.575-508.0 Adapter Steel 1/2" JIC x 3/8" (550.0, 555.0)
15 9.802-900.0 Insulation, Tank Bottom, 1" Blanket 1
16 9.803-069.0 Assembly, Frame, Large (550.0, 551.0, 552.0, 553.0) 1
9.803-120.0 Assembly, Frame, Small (555.0) 1
17 9.800-110.0 Label, Die-Cut 2
18 8.758-460.0 Wheel 12 In. Rim Steel 4
19 9.802-782.0 Collar, 5/8" Bore Shaft 4
20 9.802-810.0 Washer, 5/8", Flat, SAE 4
21 8.757-229.0 Engine Kohler CH 270 , 18A (555.0) 1
8.759-215.0 Engine Honda GX270 E/S 18A 2021 NONCARB (550.0) 1
8.759-216.0 Engine Honda GX340 18A 2021 NONCARB (551.0) 1
8.759-217.0 Engine GX340 E/S 18A 2021 NONCARB (552.0) 1
8.759-122.0 Engine Honda GX390 E/S 18A 2021 NONCARB (553.0) 1
8.759-118.0 Engine Vanguard 14HP E/S 20A (085.0) 1
22 8.930-656.0 Pump Karcher KPP2735G, 2.7@3500, 3400RPM (555. 0) 1
8.929-257.0 Pump Karcher KPP3035G1, 3@3500, 3400RPM 1
8.751-194.0 Pump, KS3540G.3 (551.0, 552.0, 553.0) 1
23 8.918-427.0 Hose, 3/8" x 36" 2 Wire Pressure Loop 1
24 8.757-549.0 Pump protector 1/2 140° 1
25 9.802-458.0 Switch, Pressure, N/O, 1/4" NPT SS (Except Steam Option) 1
26 8.757-509.0 Elbow steel 1/2 SAE (M) x 3/8 NPTF (M) 1
8.757-509.0 Elbow steel 1/2 SAE (M) x 3/8 NPTF (M) 1
27 9.127-018.0 UU1 3500PSI, Universal Unloader 1
8.754-696.0 Unloader, VBT Banjo 1/2M 3/8M, 3000PSI (550.0) 1
28 8.757-342.0 Elbow, 1/2" Street, Brass 1
29 8.757-203.0 Swivel, 1/2" M-NPTF x 3/4" GHF 1
30 8.757-204.0 Hose Barb, 1/4" Barb X 1/8" M-NPTF, 90° (550.0, 551.0, 552.0, 553.0) 1
31 6.390-126.0 Clamp, Hose, UNI .46 - .54 (550.0, 551.0, 552.0, 553.0) 6
(555.0) 4
32 9.802-254.0 Hose, 1/4", Push-On, Fuel Line (Steam Option) 14 in.
33 9.802-075.0 Box, Battery, M-100 (552.0, 553.0) 1
9.802-076.0 Plate, Battery Box, Large, PolyPro (552.0, 553.0) 1
34 9.802-081.0 Tank, Fuel, 6 Gallon 1
35 9.802-089.0 Cap, Fuel Tank, Plastic H60-AV 1
36 9.802-832.0 Bolt, 5/16" x 2-3/4" Whiz Loc (555.0) 2
MANUAL, KARCHER, HDS 9.800-079.0
24
EXPLODED VIEWS PARTS LIST
ITEM PART NO. DESCRIPTION QTY
37 9.803-308.0 Mount, Rubber Vibration, 5/16", 70 Duro (555.0) 4
8.932-992.0 Mount, Rubber Vibration, 3/8", 70 Duro
(550.0, 551.0, 552.0, 553.0) 4
38 9.802-064.0 Grommet, Rubber, Nozzle Holder 4
39 9.802-705.0 Bolt, 1/4" x 1" Carriage 4
40 Burner Assy, See Burner Spec's Page 40
41 9.802-809.0 Nut, 5/16" Wing (552.0, 553.0) 4
42 9.802-781.0 Nut, 3/8" Flange, Whiz Loc 4
43 8.757-205.0 Hose Barb, 1/4" Barb x 1/4" M-NPTF, 90°
(550.0, 551.0, 552.0, 553.0) 1
44 9.802-138.0 Hose Barb, 1/4" Barb x 1/4" ML Pipe 1
45 8.918-837.0 Axle, 30" (550.0, 551.0, 552.0, 553.0) 2
8.922-672.0 Axle Long (550.0, 555.0) 2
46 9.800-008.0 Label, Danger Cool Engine 1
47 8.757-615.0 Tee steel 1/2" (551.0, 552.0, 553.0) 1
8.757-338.0 Tee steel 3/8" (550.0, 555.0) 1
48 9.802-190.0 Valve, E-Z Start, 3/8" MPT x 1/8" FPT (550.0, 551.0, 552.0, 553.0) 1
49 8.719-000.0 Washer, 5/16" x 1-1/4", Fender, SAE (555.0) 4
50 9.802-531.0 Regulator, Voltage, 15 V (Pull Start) 1
9.803-835.0 Regulator/Rectier, 18 Amp (Electric Start) 1
51 9.802-709.0 Bolt, 5/16" x 3/4" NC (555.0) 10
52 9.802-776.0 Nut, 5/16" ESNA (555.0) 16
(550.0, 551.0, 552.0, 553.0) 10
53 8.718-980.0 Washer, 5/16" Flat (555.0) 24
(550.0,551.0, 552.0, 553.0) 10
54 9.802-755.0 Screw, 5/16" x 1-1/4", Whiz Loc (552.0, 553.0) 4
55 9.802-177.0 Valve, 1/4" Shut OFF 1
56 9.800-108.0 Label, Nozzle 0, 15, 25, 40 1
57 9.804-022.0 Cap, Valve w/1/4" Port (555.0) 1
9.802-632.0 Cap, Valve w/1/4" Gauge Port (551.0, 552.0, 553.0) 1
58 9.802-904.0 Insulation, Tank Head 1
59 9.802-809.0 Washer 1/2" Flat (550.0, 551.0, 552.0, 553.0) 4
60 8.706-241.0 Plug 3/8" square head (550.0, 555.0) 1
8.757-625.0 Plug 1/2" square head (551.0, 552.0, 553.0)
61 9.800-021.0 Label, Hot Water Outlet 1
62 9.802-154.0 Plug, Push-On, Oil Drain, Honda (550.0, 551.0, 552.0, 553.0) 1
63 8.757-201.0 Hose Barb, 1/4" Barb x 1/8" M-NPTF 1
64 8.706-321.0 CAP, Pipe, 1/8'NPT Brass 1
65 9.803-836.0 Wire, THWN, 6 Gauge, Red (552.0, 553.0) 33"
66 9.803-837.0 Wire, THWN, 6 Gauge, Black (552.0, 553.0) 45"
67 8.716-608.0 Terminal, Baterry, Marine (890904) 2
68 9.802-778.0 Nut, 5/16" Whiz Loc Flange 4
69 9.802-816.0 Washer, 7/16" Lock (551.0, 552.0, 553.0) 2
70 9.802-958.0 Key, 0.185 SQR x 1.75" (555.0) 1
9.802-959.0 Key, 0.247 SQR x 2.125 (550.0, 551.0, 552.0, 553.0) 1
71 9.803-108.0 Retainer Ring, Insulation 1
72 9.802-773.0 Nut, 1/4"-20, ESNA 4
73 9.802-996.0 Bracket, Brake Pad, Black 1
74 9.800-094.0 Label, Warning, Text 1
MANUAL, KARCHER, HDS 9.800-079.0
25
ITEM PART NO. DESCRIPTION QTY
75 9.800-002.0 Label, Use Only Kerosene 1
76 8.750-647.0 Grommet, Rubber, 1 1/2" (550.0, 551.0, 552.0, 553.0) 1
77 9.800-026.0 Label, Open For Steam (Steam Option) 1
78 9.802-010.0 Nipple, 1/4", Hex, Steel (Steam Option) 1
79 9.802-802.0 Washer, 1/4" Flat, SAE 12
80 9.802-187.0 Valve, Flow Control w/Metering (Steam Option) 1
81 9.802-120.0 Tee, 1/4" Branch Male, Legacy Pumps (Steam Option) 1
82 8.757-366.0 Nipple, 1/4" X 3", W/SLNT 1
83 9.802-997.0 Linkage, Brake, Black 1
84 8.725-306.0 Filter, Parker Fuel/Oil/H
2
O (10 Micron), Generic 1
85 9.802-254.0 Hose, 1/4" Push On 9"
86 9.802-254.0 Hose, 1/4" Push On (550.0, 551.0, 552.0, 553.0) 7"
(555.0) 11"
87 9.802-428.0 Service Cord, 12/3 SJOWA (550.0, 551.0, 552.0, 553.0) 40"
(555.0) 32"
88 9.802-519.0 Strain Relief, 1/2" 1
89 9.802-713.0 Bolt, 5/16" x 1-1/2" (555.0) 2
9.802-728.0 Bolt, 3/8-16" x 2", HH Zinc (550.0, 551.0, 552.0, 553.0) 4
90 9.802-813.0 Lock Washer, 5/16" 2
9.802-814.0 Washer, 3/8", Lock Split Ring (550.0, 551.0, 552.0, 553.0) 4
91 9.802-813.0 Lock Washer, 5/16" (552.0, 553.0) 4
92 8.757-338.0 NIPPLE, 1/2" HEX STEEL, W/SLNT (550.0, 551.0, 552.0, 553.0) 1
93 9.802-254.0 Hose, 1/4" Push On 14"
94 9.802-707.0 Bolt, 5/16" - 24 x 3/4" NF (555.0) 4
9.802-768.0 Screw, 3/8" x 1-1/4" Whiz Loc (550.0, 551.0, 552.0, 553.0) 4
95 9.802-143.0 Elbow, 1/4" Hose Barb x 1/4" Pipe, Steam Option (550.0, 551.0, 552.0, 553.0) 1
96 8.757-499.0 Hose Barb 10-1.25 x 1/4" Pipe 1
97 8.917-977.0 Pump Support LG Fab Black Wrinkle (555.0) 1
98 8.757-205.0 Hose Barb, 1/4" Barb x 1/4" M-NPTF, 90° 1
99 8.757-339.0 Elbow, 1/4" Street 90 Deg, Steel W/SLNT 1
100 9.802-103.0 Bushing, 5/8" Snap (555.0) 1
101 9.802-908.0 Insulation, Blanket, 18" x 52", Fiberglass (555.0) 1
102 9.803-111.0 Lever, Brake, Black 1
103 9.802-771.0 Screw, 10/32" x 3/4" BH SOC CS
(550.0, 551.0, 555.0)
3
9.802-762.0 Screw, 10/32" x 1-1/4" RH SL (552.0, 553.0) 2
104 9.802-695.0 Nut, 10/32" Kep (552.0, 553.0) 2
(550.0, 551.0, 555.0) 3
105 9.802-140.0 Hose Barb, 1/4" Barb x 3/8", Double 1
106 9.802-053.0 Bushing, Rubber Nitrile 2
107 9.802-813.0 Washer, 5/16" Lock Split Ring (555.0) 4
108 9.803-092.0 Fuel Tank Strap, Long 2
109 9.802-459.0 Switch, MV60 Flow (Steam Option) 1
110 9.802-104.0 Bushing, 3/4" Snap (555.0) 1
111 9.802-254.0 Hose, 1/4" Push-On (555.0) 7"
(550.0, 551.0, 552.0, 553.0) 11"
112 8.757-509.0 Elbow steel 1/2 SAE (M) x 3/8 NPTF (M) (Steam Option) 1
113 9.802-143.0 Elbow, 1/4" x 1/4" Pipe (Steam Option) 2
114 8.706-241.0 Plug 3/8, SQ head 1
115 9.196-012.0 Screw, 10-24x1/4 Hex Set 1
EXPLODED VIEW PARTS LIST
MANUAL, KARCHER, HDS 9.800-079.0
26
EXPLODED VIEW PARTS LIST
ITEM PART NO. DESCRIPTION QTY
116 8.757-551.0 Elbow Street Steel 3/8" 45° 1
117 8.900-282.0 Label, RPM Factory Set 1
118 8.705-974.0 NIPPLE, 3/8" (555.0) 1
119 9.802-811.0 Washer, Fender (555.0) 2
120 9.800-018.0 Label, Tipover Hazard 1
121 9.800-049.0 Label, Cleaning Solution 1
123 9.802-807.0 Washer 3/8", SAE Flat (550.0, 551.0, 552.0, 553.0) 4
124 9.802-744.0 Bolt, 10 mm x 20 mm (551.0, 552.0, 553.0) 2
9.802-741.0 Bolt, 8 mm x 16 mm HEX Head (550.0) 2
125 9.802-066.0 Pad, Soft Rubber 1
126 9.802-722.0 Bolt, 3/8" x 1-1/4", NC HH 1
127 9.802-817.0 Washer, 3/8" x 1", Steel 1
128 9.197-003.0 Nut, 3/8" ESNA 1
129 8.933-024.0 Rail, Pump Support (551.0, 552.0, 553.0) 1
9.804-533.0 Rail, Pump Support (550.0) 1
130 8.757-192.0 PLUG, 1/4" NPTF COUNTERSUNK BRASS 1
131 8.719-498.0 Stud, Weld, 5/16 X 3/4, BLK(948578) (555.0) 4
8.719-498.0 (550.0,551.0, 552.0, 553.0) 12
132 9.802-753.0 Screw, 1/4-20 x 3/4" 2
133 9.802-778.0 Nut, 5/16" Whiz Loc Flange 1
134 9.803-093.0 Fuel Strap, Short 2
135 8.706-241.0 Plug 3/8" square head (550.0, 555.0) 1
8.757-625.0 Plug 1/2" square head (551.0, 552.0, 553.0) 1
136 9.802-781.0 Nut, 3/8 Flange, Whiz Loc, NC 2
137 8.930-122.0 Strap, Fuel Tank 2
138 9.802-775.0 Nut, 1/4" Flange, ZN 2
139 9.802-754.0 Screw, 1/4"" X 1/2"" HH NC, Whiz Lock" (550.0, 551.0, 552.0, 553.0) 2
140 8.716-499.0 Battery, Sealed, D75S (553) 1
141 9.803-277.0 Screw, 5/16" X 1/2", Whiz Loc Flange 1
142 9.802-809.0 Washer 1/2" Flat (550.0, 551.0, 552.0, 553.0) 4
143 8.719-000.0 Washer, 5/16" x 1-1/4", Fender, SAE (555.0) 4
144 9.198-004.0 3/8 USS F/W Zinc 4
145 9.802-447.0 Conduit, Corrugated Tubing 1/4,100FT/Roll (555.0) 22"
9.802-447.0 (550.0, 551.0, 552.0, 553.0) 25"
148 8.754-911.0 Check Valve, 1 Way, 1/4" Barb 1
149 8.750-933.0 Band Hose Clamp, Hose ID 1/8" - 5/16" 3
150 9.802-819.0 Washer, 7/16" x 2 1/2" 3
151 9.802-710.0 Screw 5/16" x 1" NC 3
152 9.802-819.0 Washer, 7/16" x 2 1/2", Zinc, PG Foot 3
153 8.757-198.0 Elbow, 1/4" Street, Brass 1
154 8.756-484.0 Rubber Set Pad & Brkt, 50mm 1
155 9.802-741.0 Bolt, 8MM X 16MM HEX Head 2
156 8.718-980.0 Washer, 5/16" Flat, SAE (780452) 2
157 9.804-016.0 Filter Screen Washer, Garden Hose/30MESH 1
158 8.757-655.0 Adapter Steel 1/2" JIC x 3/8" (550.0, 555.0) 1
8.575-508.0 Adapter Steel 1/2" JIC x 3/8" 1
MANUAL, KARCHER, HDS 9.800-079.0
27
HOU
R
1/10
ITEM PART NO. DESCRIPTION QTY
1 9.802-528.0 Capacitor 1
2 9.802-531.0 Regulator, Voltage, 15 Volt 1
3 9.803-036.0 Box, Electrical 1
4 9.803-121.0 Assembly, Cover, Electrical Box 1
5 8.750-094.0 Thermostat, Adjustable, 302°F 1
6 9.802-456.0 Light, Indicator, Green 12 Volt 1
7 9.802-453.0 Switch, Curvette RA901VB-B-1-V, Carling 1
8 9.802-283.0 Hour Meter, 24-240 Vac 50/60 Hz 1
9 9.802-470.0 Relay, P & B, VF4-41F11, 12VDC, 40AMP 2
10 9.802-485.0 Breaker, 1658-G41-02-P10-25A 1
11 9.802-752.0 Screw, 1/4" x 1-1/4" Hex, Whiz Loc 1
12 9.802-754.0 Screw, 1/4" x 1/2" HH NC, Whiz Loc 2
13 9.802-775.0 Nut, 1/4" Whiz Loc 2
14 9.802-773.0 Nut, 1/4", ESNA, NC 1
15 9.802-753.0 Screw, 1/4-20 X 3/4" Whiz Loc 2
5,25
4
6
22
7
10
9
9
20
16
12
11
8
15
17
21
2
20
19
14
13
23
1
3
Reversed
View
18
CONTROL PANEL EXPLODED VIEW - 555.0 MODELS
555.0 CONTROL PANEL PARTS LIST
24
28
26
27
29
31
30
MANUAL, KARCHER, HDS 9.800-079.0
28
ITEM PART NO. DESCRIPTION QTY
16 9.802-206.0 Clamp, Hose 1
17 8.755-010.0 Rivnut, Rib FLG HD, 1/4"-20 2
18 8.900-907.0 Label, Control Panel 1
19 9.802-802.0 Washer, 1/4", Flat, SAE 1
20 9.802-695.0 Nut, 10/32" Keps 5
21 9.802-771.0 Screw, 10/32" x 3/4" 3
22 9.802-759.0 Screw, 10/32" x 1/2" 2
23 9.803-048.0 Cap, Capacitor, 1.37 x 1.50 x .060 Blk, w/o Hole 1
24 9.803-840.0 Label, Reset 1
25 9.802-447.0 ▲ Conduit, 1/4" Split 36"
26 9.802-762.0 Screw, 10/32" x 1-1/4" (Ground) 1
27 9.802-695.0 Nut, 10/32", Keps 4
28 9.800-040.0 Ground Label 1
29 8.712-190.0 Thermostat Mounting Plate 1
30 8.718-779.0 Screw 4mm x 6mm 4
31 8.750-096.0 Thermostat Dial 1
▲ Not Shown
555.0 CONTROL PANEL PARTS LIST
MANUAL, KARCHER, HDS 9.800-079.0
29
CONTROL PANEL - 550.0, 551.0, 552.0, 553.0
H
OUR
1/10
28
1, 23
2
6
14
4
28
12
11
9
10
8
13
19
22
15
16
3
17
16
20
18
21
7
25
24
27
26
19
25
29
ITEM PART NO. DESCRIPTION QTY
1 8.750-094.0 Thermostat, Adjustable, 302°F 1
2 9.803-035.0 Cover, Electric Box, Black 1
3 9.802-759.0 Screw, 10/32" x 1/2" BHSOC, Black 2
4 9.802-485.0 Breaker, 1658-G41-02-P10-25A 1
5 8.750-096.0 Thermostat Dial 1
6 9.802-456.0 Light, Indicator, Green 12V 1
7 9.802-791.0 Cage, Nut, 10/32" x 16 Gauge 6
8 9.800-113.0 Label, Control Panel 1
9 9.802-283.0 Hour Meter, 24-240 Vac 50/60 Hz 1
550.0, 551.0, 552.0, 553.0 CONTROL PANEL PARTS LIST
30
5
31
MANUAL, KARCHER, HDS 9.800-079.0
30
ITEM PART NO. DESCRIPTION QTY
10 9.802-453.0 Switch, Curvette RA901VB-B-1-V, Carling 1
11 9.802-519.0 Strain Relief, 1/2" Metal, Two Screw 2
12 9.802-514.0 Strain Relief, Small 1
13 9.803-071.0 Box, Electric, Black 1
14 9.802-788.0 Nut, 5/16" Whiz Loc Flange 2
15 9.802-530.0 Rectier, Bridge (552.0, 553.0) 1
16 9.802-470.0 Relay, P & B, VF4-41F11, 12VDC, 40AMP 2
17 9.802-528.0 Capacitor (550.0, 551.0) 1
18 9.802-529.0 Bracket, Capacitor (550.0, 551.0) 1
19 9.802-695.0 Nut, 10/32" Keps 9
20 9.802-748.0 Screw, 6/32" x 3/8", RND HD MCH (550.0551.0) 2
21 9.802-784.0 Nut, 6/32" Keps (550.0, 551.0) 3
22 9.802-771.0 Screw, 10/32" x 3/4" BH SOC CS (552.0, 553.0) 1
23 9.802-447.0 ▲ Conduit, Split, 1/4" 45"
24 9.802-813.0 Washer, 5/16", Lock, Split Ring 2
25 9.802-806.0 Washer, 5/16", Flat, Cut 4
26 9.802-762.0 Screw, 10/32" x 1-1/4" (Ground) 1
27 9.800-040.0 Label, Ground 1
28 9.802-764.0 Screw, 10/32" x 3/4", HEX 6
29 9.803-048.0 Cap, Capacitor, 1.37 x 1.5 x .06 Blk, w/o Hole (551.0, 555.0) 1
30 8.712-190.0 Thermostat Mounting Plate 1
31 8.718-779.0 Screw 4mm x 6mm 4
▲ Not Shown
550.0, 551.0, 552.0, 553.0 CONTROL PANEL PARTS LIST
MANUAL, KARCHER, HDS 9.800-079.0
31
HOSE & SPRAY GUN ASSEMBLY
3
2
1
8
6
5
4
7
ITEM PART NO. DESCRIPTION QTY
1 8.707-144.0 Nipple, 3/8", Female, Ssteel 1
9.802-100.0 ▲ Quick Coupler O-Ring LG 1
2 8.925-130.0 Hose, 3/8" X 50' 1W 4000PSI SW/SO/CPL 1
3 4.775-054.0 EASY! Force Advanced KNA 1
4 9.802-222.0 Wand, VP Zinc 1/4", w/Coupler, w/Soap Nozzle 1
9.802-694.0 ▲ Repair Kit, VP Wand, SS Seat 1
5 9.802-286.0 Nozzle, 1/8", Soap Only, Brass 1
6 8.707-140.0 Nipple, 1/4", Male, Ssteel 1
9.802-096.0 ▲ Quick Coupler, O-Ring, Small 1
7 8.756-797.0 Injector, Chemical, NON ADJ 0.083(2.1MM) (550.0, 551.0, 552.0, 553.0) 1
9.802-224.0 Detergent Injector Assy. #2 (555.0) 1
8 9.802-292.0 Nozzle, SAQMEG 1503.5, Yellow (553.0, 555.0, 550.0) 1
9.802-293.0 Nozzle, SAQMEG 2503.5, Green (553.0, 555.0, 550.0) 1
9.802-294.0 Nozzle, SAQMEG 4003.5, White (553.0, 555.0, 550.0) 1
9.802-296.0 Nozzle, SAQMEG 1504, Yellow (551.0, 552.0) 1
9.802-297.0 Nozzle, SAQMEG 2504, Green (551.0, 552.0) 1
9.802-298.0 Nozzle, SAQMEG 4004, White (551.0, 552.0) 1
▲ Not Shown
Pressure
Nozzle
HOSE & SPRAY GUN PARTS LIST
MANUAL, KARCHER, HDS 9.800-079.0
32
DOWNSTREAM INJECTOR ASSEMBLY
1
DOWNSTREAM INJECTOR PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 8.756-797.0 INJECTOR, CHEMICAL, NON ADJ 0.083 (2.1MM) 1
8.756-796.0 INJECTOR, CHEMICAL, NON ADJ 0.070 (1.8MM) 1
MANUAL, KARCHER, HDS 9.800-079.0
33
HOSE REEL OPTION
HOSE REEL PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 8.707-144.0 Nipple, 1/4", Male, Ssteel 1
2 9.802-244.0 Hose, 3/8' X 36', 2 Wire, Pressure LO 1
3 9.804-067.0 Hose Reel, Ezee 3/8x100' W/Pinlock 1
4 9.802-767.0 Screw, 3/" x 3/4" HH NC, Whiz Loc 4
5 9.802-781.0 Nut, 3/8" Flange, Whiz Loc, NC 4
6 9.803-841.0 Bracket, E-ZEE Hose Reel Right, Wrinkle Black 1
5
6
4
2
3
1
MANUAL, KARCHER, HDS 9.800-079.0
34
UU1 UNLOADER EXPLODED VIEW
UU1 UNLOADER EXPLODED VIEW PARTS LIST
ITEM PART # DESCRIPTION KIT QTY
1 8.751-394.0 Piston Housing D 1
2 Piston C, D 1
3 Piston O-Ring Back Up A, D 1
4 8.749-796.0 Main Block 1
5 9.152-372.0 Piston Ring D 1
6 Ball Seat C, D 1
7 O-Ring 10.5 ID x 1.5 CS A,C,D 1
8 Plunger B 1
9 9.152-016.0 Plunger Housing 1
10 Bypass Spring C, D 1
11 9.149-001.0 Low Pressure Port 1
12 9.152-017.0 Sliding Connector, 30mm 1
8.762-005.0 Sliding Connector, 40mm, Long 1
13 9.149-002.0 Sliding Connector H 1/2" 1
9.149-005.0 Sliding Connector H 3/8" 1
14 9.196-011.0 Plug 5/8 -18 UNF D 1
15 O-Ring 12 ID x 2 CS A, D 2
16 O-Ring 6 ID X 2 CS A, D 1
ITEM PART # DESCRIPTION KIT QTY
17 9.149-006.0 Sliding Connector Guide 1
18 O-Ring Backup A, D 1
6 x 1.45 x 1.68
19 Ball Housing Assy C, D 1
20 O-Ring 6.75 x 1.78 BN80 A, D 1
21 Spring Seat C, D 2
22 Plunger Spring B 1
23 8.917-699.0 Banjo Bolt 1/2" Short 1
8.917-700.0 Banjo Bolt 1/2"-1/4" NPT Short 1
24 8.917-698.0 Banjo Bolt 3/8" Short 1
25 9.802-893.0 Seal Washer 3/8" 2
26 9.803-921.0 Seal Washer 1/2" 2
9.802-893.0 Seal Washer 3/8" 2
27 O-Ring 15 ID x 2CS A,B,D 3
28 8.706-865.0 Plug, 1/4" Countersunk 1
Kit A 9.104-038.0 O-Ring Repair Kit
Kit B 9.104-039.0 Outlet Kit
Kit C 9.104-040.0 Stem Basic Kit
Kit D 8.920-045.0 UU1 Complete Stem Kit
9.175-018.0
UU1 3500PSI, UNIVERSAL UNLOADER (SPARE)
21
2
3
20
16
18
5
15
19
6
7
25
4
8
22
27
9
15
12
17
11
27
23
13
26
26
24
25
27
1
10
14
21
28
23
MANUAL, KARCHER, HDS 9.800-079.0
35
ITEM PART # DESCRIPTION KIT QTY
1* 8.754-929.0 Stem C 1
2* 9.803-912.0 Backup Ring A 1
3* 8.754-930.0 O-ring, Ø2.62 x 6.02 A 2
4 8.730-882.0 Stem Connector 1
5* 9.803-193.0 O-ring, Ø2.62 x 20.24 A 1
6* 9.803-908.0 Backup Ring A 1
7 9.803-907.0 Guide Bushing 1
8* 9.803-906.0 O-ring, Ø1.78 x 14 A 1
9* 8.754-959.0 Ball SubAssembly C 1
10* 8.754-933.0 Seat C 1
11* 8.754-934.0 O-ring, Ø1.78 x 12.42 A,C 1
12 8.754-935.0 Valve Body 1
13 9.802-893.0 Seal Washer 3/8 1
14 9.803-919.0 Banjo Bolt 3/8 1
15* 8.754-936.0 O-ring, Ø2.62 x 10.78 A 1
16 9.803-920.0 Banjo Bolt, 1/2, w/1/4" Port 1
VBT UNLOADER EXPLODED VIEW
VBT UNLOADER EXPLODED VIEW PARTS LIST
ITEM PART # DESCRIPTION KIT QTY
17 9.803-914.0 Seal Washer 1/2) 1
18 8.754-937.0 Bypass Manifold 1
19 9.802-892.0 Outlet Connector 3/8 MPT 1
20* 9.803-191.0 O-ring, Ø2.62 X 17.13 A,B 1
21* 8.933-017.0 Poppet Spring B 1
22* 8.754-939.0 Poppet B 1
23* 8.754-940.0 O-ring, Ø3 x 6 A,B 1
24* 8.754-961.0 Plate C 1
25* 8.933-018.0 Spring 1500-4000 PSI C 1
26 8.933-021.0 Set Screw 1
27 9.803-925.0 Nut 1
28 9.803-926.0 Knob, Brass, Unloader 1
* Included in Kit
Kit A 8.754-941.0 O-Ring Repair Kit
Kit B 8.754-942.0 Outlet Repair Kit
Kit C 8.754-957.0 Stem Repair Kit
8.754-696.0
UNLOADER, VBT BANJO 1/2M 3/8M, 3000PSI (SPARE)
MANUAL, KARCHER, HDS 9.800-079.0
36
KS3540GR.3 PUMP EXPLODED VIEW
8.751-194.0 KS3540GR.3
KS3540GR.3 PUMP EXPLODED VIEW PARTS LIST
TORQUE
SPECS
Item # Ft.-lbs
14 75
15 30
24 7.6
38 10
ITEM PART NO. DESCRIPTION QTY
1 8.751-217.0 Crankcase 1
2* See Kit Below Plunger Oil Seal 3
3*
See Kit Below
O-Ring Ø1.78 x 31.47 3
4*
See Kit Below
Pressure Ring 3
5*
See Kit Below
U-Seal, 15mm 3
6*
See Kit Below
Intermed. Ring 15mm 3
7*
See Kit Below
U-Seal, 15mm 3
8 9.803-199.0 Copper Washer 1/2" 1
9 9.802-926.0 Brass Plug, 1/2" 1
10 8.751-218.0 Manifold Housing 1
11* 9.803-191.0 O-Ring Ø2.62 x 17.13 6
12* See Kit Below Valve Assembly 6
13* 9.803-193.0 O-Ring Ø2.62 x 20.29 6
14 9.802-928.0 Valve Plug 6
15 9.802-938.0 Manifold Stud Bolt 8
16 9.802-884.0 Washer 8
17 9.803-198.0 Copper Washer 3/8" 1
18 9.802-925.0 Brass Plug 3/8" 2
23 9.803-201.0 Washer, M6 x 16 4
24 9.802-939.0 Hexagonal Screw 9
25 9.803-184.0 Closed Bearing Housing 1
ITEM PART NO. DESCRIPTION QTY
26 8.717-225.0 O-Ring Ø 2.62 x61.6 1
27 9.802-914.0 Snap Ring 1
28 9.803-168.0 Double Row Ball Bearing 1
29 9.803-150.0 Crankshaft (3040G.3) 1
9.803-151.0 Crankshaft (3540G.3) 1
9.803-152.0 Crankshaft (4040G.3) 1
9.803-153.0 Crankshaft (5030G.3) 1
30 9.802-945.0 Set Screw 1
31 9.802-921.0 Oil Dip Stick 1
32 9.804-581.0 O-Ring Ø 3.53 x 55.56 1
33 9.803-161.0 Needle Roller Bearing 1
34 8.751-230.0 Gasket 1
35 8.717-544.0 Screw, Set 1
36 9.803-183.0 Engine Flange 1
38 9.803-240.0 Flange Screw 4
39 9.803-142.0 Crankshaft Seal 1
41 9.803-221.0 Spring Washer 4
46* See Kit Below Plunger Nut, M6 3
47* See Kit Below Washer, Copper, 9.2 x 13.5 3
48* See Kit Below Plunger, 15mm 3
49* See Kit Below Copper Spacer 3
MANUAL, KARCHER, HDS 9.800-079.0
37
KS3540GR.3 PUMP EXPLODED VIEW PARTS LIST (CONT.)
ITEM PART NO. DESCRIPTION QTY
50* See Kit Below O-Ring Ø1.78x5.28 3
51* See Kit Below Teon Ring 3
52 8.751-225.0 Plunger Rod 3
53 8.751-228.0 Connecting Rod Pin 3
54 9.803-158.0 Connecting Rod 3
55 9.803-218.0 Spring Washer 6
56 9.803-238.0 Connecting Rod Screw 6
57 8.933-016.0 O-Ring 2.62 x 126.67 1
58 8.751-229.0 Crankcase Cover 1
59 9.803-197.0 O-Ring, Ø 1.78 x 14 1
60 9.803-202.0 Sight Glass, G3/4 1
* Part available in kit (See below)
REPAIR KIT NUMBER 8.725-358.0 8.725-359.0 8.933-023.0 9.802-603.0 9.802-609.0
KIT DESCRIPTION
Plunger U-
Seal
15mm
Complete
U-Seal Packing
15mm
Plunger 15mm
Complete
Valve
Plunger Oil
Seals
ITEM NUMBERS
INCLUDED
3, 5, 7 3, 4, 5, 6, 7
46, 47, 48, 49,
50, 51
11, 12, 13 2
NUMBER OF
CYLINDERS
KIT WILL SERVICE
3 1 1 6 3
MANUAL, KARCHER, HDS 9.800-079.0
38
PUMP EXPLODED VIEW
23
24
25
26
27
28
29
30
36*
35
34
33
32
31
1
2*
3
4*
5*
6*
7*
8
9
10
11*
12*
13*
16
14
15
17
18
14
13*
22*
21*
20*
19*
11*
12*
37*
38*
39*
40
41
42
35
43
23
47
18
46
45
44
PUMP EXPLODED VIEW PARTS LIST
TORQUE
SPECS
Item # Ft.-lbs
14 65
16 66
23 8
35 8
36 9.5
43 12.5
ITEM PART NO. DESCRIPTION QTY
1 8.754-841.0 Crankcase 1
2* See Kits Below Plunger Oil Seal 3
3 8.758-216.0 Spacer 1
4* See Kits Below "O" Ring Ø1.78X26.7 3
5* See Kits Below "U" Seal, DIA. 14 MM 3
6* See Kits Below Pressure Ring Dia. 14 mm 3
7* See Kits Below "U" Seal, Dia. 14 mm 3
8 9.803-199.0 Copper Washer g1/2 1
9 9.802-926.0 Brass Plug g1/2 1
10 8.759-027.0 Manifold Housing 1
11* 8.717-233.0 "O" Ring ø1.78x15.6 6
12* See Kits Below Valve Assembly 6
13* 9.803-948.0 "O" Ring ø1,78x18.77 6
14 9.803-949.0 Valve Plug 6
15 8.754-850.0 Lock-Washer 2
16 8.758-217.0 Manifold Stud 2
Bolt M14X60
17 9.803-198.0 Copper Washer g3/8 1
18 8.707-262.0 Brass Plug g 3/8 2
19* See Kits Below Valve Seat 6
20* See Kits Below Valve Plate 6
ITEM PART NO. DESCRIPTION QTY
21* See Kits Below Valve Spring 6
22* See Kits below Valve Cage 6
23 9.802-939.0 Screw M6X16 8
24 8.717-137.0 Bearing Cover 2
25 9.803-954.0 Bearing Seal 1
26 8.754-843.0 Crankshaft Seal Spacer 1
27 9.802-914.0 Snap Ring Dia. 25 mm 1
28 9.803-955.0 Ball Bearing 1
29 8.754-831.0 Hollow Shaft 2735G 1
8.754-834.0 Hollow Shaft 3035G 1
30 8.754-219.0 Oil Dip Stick 1
31 8.754-840.0 Needel Roller Bearing 1
32 8.754-826.0 Crankshaft Seal 1
33 8.754-863.0 Motor Flange 1
34 9.803-218.0 Spring Washer Dia. 6 mm 10
35 8.752-824.0 Screw m6x20 4
36* 8.754-855.0 Plunger bolt 3
37* 8.754-092.0 Bonded Seal - 3
ø6,7x11x1 AISI 304
38* 8.754-849.0 Plunger Dia. 14 mm 3
39* 9.803-962.0 Copper Spacer 3
MANUAL, KARCHER, HDS 9.800-079.0
39
ITEM PART NO. DESCRIPTION QTY
40 8.759-032.0 Plunger Rod 3
41 9.803-965.0 Connecting Rod Pin 3
42 9.803-966.0 Connecting Rod 3
43 8.933-020.0 Connecting Rod Screw 6
44 8.754-847.0 "O" Ring ø2.62X111.62 1
45 8.754-842.0 Crankcase Cover 1
46 9.803-906.0 "O" Ring ø1.78X14 1
47 9.803-202.0 Sight Glass G3/4 1
* Available in kit (See below)
PUMP EXPLODED VIEW PARTS LIST (CONT)
REPAIR KIT NUMBER
8.759-031.0 8.758-218.0 8.754-862.0 8.754-859.0 9.803-937.0
KIT DESCRIPTION
Plunger U-
Seal
14mm
Complete
U-Seal Packing
14mm
Plunger 14mm
Complete
Valve
Plunger Oil
Seals
ITEM NUMBERS
INCLUDED
4, 5, 7, 16 4, 5, 6, 7, 16 36, 37, 38, 39 11, 12, 14 2
NUMBER OF
CYLINDERS
KIT WILL SERVICE
3 3 1 6 3
MANUAL, KARCHER, HDS 9.800-079.0
40
8.929-263.0 LPP3035G1
8.929-272.0 HPP3035G1
8.929-257.0 KPP3035G1
LPP3035G1 PUMP EXPLODED VIEW
LPP3035G1 PUMP EXPLODED VIEW PARTS LIST
TORQUE
SPECS
Item # Ft.-lbs
15 65
16 55
24 8
40 10
43 10
50 10
ITEM PART NO. DESCRIPTION QTY
1 8.754-841.0 Crankcase 1
2* See Kits Below Plunger Oil Seal 3
3 8.758-216.0 Spacer 1
4 See kits below O Ring 1.78x26.7 3
5 See Kits Below U-Seal, 14 mm 3
6 See Kits Below Pressure Ring, 14 mm 3
7 See Kits Below U-Seal, 14 mm 3
8 9.803-199.0 Washer, Copper G1/2 1
9 9.802-926.0 Plug, Brass G1/2 1
10 8.759-027.0 Manifold 1
11 8.717-233.0 O-ring Ø1.78 X 15.6 6
12 See Kits Below Valve Assembly 6
13 9.803-948.0 O-ring Ø1.78 X 18.77 6
14 9.803-949.0 Valve Plug 6
15 8.754-850.0 Lock washer 2
16 8.758-217.0 Bolt, manifold M14x60 2
17 9.803-198.0 Washer, Copper G3/8 1
18 8.707-262.0 Plug, Brass G3/8 2
19 See Kits Below Valve Seat 6
20 See Kits Below Valve Plate 6
ITEM PART NO. DESCRIPTION QTY
21 See Kits Below Valve Spring 6
22 See Kits Below Valve Cage 6
23 9.802-939.0 Screw, M6 X 16 8
24 8.717-137.0 Bearing Cover 2
25 9.803-954.0 Bearing Seal 1
26 8.754-843.0 Seal Spacer, Crankshaft 1
27 9.802-914.0 Snap Ring, 25 mm 1
28 9.803-955.0 Bearing, Ball 1
29 8.754-828.0 Shaft, 1" Hollow 3035G1 1
8.754-832.0 Shaft, 1" Hollow 3535G1 1
8.754-833.0 Shaft, 1" Hollow 4035G1 1
30 8.754-219.0 Oil Dipstick 1
31 8.754-840.0 Bearing Needle 1
32 8.754-826.0 Seal, Crankshaft 1
33 9.802-889.0 Washer 4
34 9.803-243.0 Screw 4
35 9.803-215.0 Washer 6 mm 4
36 9.803-244.0 Screw 4
37 9.803-217.0 Washer 4
38 9.803-217.0 Washer 4
39 8.752-824.0 Screw, M6 x 20 4
MANUAL, KARCHER, HDS 9.800-079.0
41
LPP3035G1 PUMP EXPLODED VIEW PARTS LIST (CONT)
REPAIR KIT NUMBER
8.759-031.0 8.758-218.0 8.754-862.0 8.754-859.0 9.803-937.0
KIT
DESCRIPTION
Plunger Seal
14mm
Complete
Seal Packing
14mm
Plunger
14mm
Complete
Valve
Plunger Oil
Seals
ITEM NUMBERS
INCLUDED
4, 5, 7, 16 4, 5, 6, 7, 16 43, 44, 45, 46 12, 13, 14 2
NUMBER OF CYLIN-
DERS KIT WILL SERVICE
3 3 1 6 3
LPP3035G1 PUMP REPAIR KITS
ITEM PART NO. DESCRIPTION QTY
40 9.803-218.0 Washer, 6 mm 10
41 8.754-864.0 Flange, Engine 1
42 8.754-855.0 Bolt, Plunger 3
43 8.754-092.0 Spacer, Copper 3
44 8.754-849.0 Plunger, 14 mm 3
45 9.803-962.0 Spacer, Copper 3
46 8.759-032.0 Plunger Rod 3
47 9.803-965.0 Connecting Rod Pin 3
48 9.803-966.0 Connecting Rod 3
49 8.933-020.0 Screw, Connecting Rod 6
50 8.754-847.0 O-ring Ø2.62 X 111.62 1
51 8.754-842.0 Cover, Crankcase 1
52 9.803-906.0 O-ring Ø1.78 X 14 1
53 9.803-202.0 Sight Glass, G3/4 1
* Available in kit (See below)
MANUAL, KARCHER, HDS 9.800-079.0
42
(14.41)
(12.29)
(11.67)
(.88)
28
3
1
4
11
12
3
16
15
1
2
28
4
30
4
3
15
16
12
1
28
30
20
29 27
WIRING DIAGRAM
Replacement Parts
For best performance specify genuine EHASR WAYNE replacement parts
WAYNE BURNER PART LIST (3.5/30 P; 3.5/35 P)
MANUAL, KARCHER, HDS 9.800-079.0
43
Replacement Parts
For best performance specify genuine EHASR WAYNE replacement parts
WAYNE BURNER PART LIST (3.5/30 P; 3.5/35 P)
ITEM PART NO. DESCRIPTION QTY
1 8.759-192.0 Tube/Hous-101407-001/3A/.88I 1
2 8.756-731.0 Gun-RG/*CST/GBB 1
3 8.756-437.0 Pump-s A2VA3006-N261 12V Combo 1
4 8.700-704.0 Oil Line ASM-6" 1
11 8.759-129.0 Plate Slot Cover 1
12 8.759-193.0 Nut, Hex 3/8-24 CRZC 1
15 8.700-732.0 Band, Air-Inner E/FH 1
16 8.700-729.0 Band, Air-Outner 8-Hole E/F 1
18 8.759-194.0 ▲Post, contact-Allason 2
23 8.756-741.0 Cover, Juntion Box 1
26 8.756-716.0 Motor, 13.5VDC-Ametek 1
27 8.759-195.0 Cover, Hous-E 12V 1
28 9.107-507.0 Ignitor-CC 6385 12VDC 4.8A 1
29 8.759-190.0 Base, Mounting-Ignitor CC Timer 1
30 8.756-661.0 Timer, Ignitor-12V AH1501 1
35 8.700-819.0 ▲CAD, Cell-H 15" LEAD/17* BRKT 1
37 8.759-196.0 ▲Fan-3.44"W X 4.75"D 5/16" Bore 1
38 8.756-715.0 ▲Coupling-Mod E 12VDC 1
50 8.700-692.0 *Gasket, Flange-STD Large 2
▲Not Shown
*Packed with burner
MANUAL, KARCHER, HDS 9.800-079.0
44
SPECIFICATIONS
Burner Specications
Model #
Burner
Assy # Fuel Nozzle Transformer Burner Motor
Fuel Pump/
Solenoid
Cord
Fuel Pump/
Solenoid Coil Electrode
1.575.555.0 8.759-484.0 8.756-723.0 9.107-507.0 8.700-821.0 8.756-437.0 8.756-437.0 8.756-297.0
1.575-550.0 8.759-484.0 8.756-699.0 9.107-507.0 8.700-821.0 8.756-437.0 8.756-437.0 8.756-297.0
1.575-551.0 8.756-756.0 8.756-699.0 9.107-507.0 8.756-716.0 8.756-437.0 8.756-437.0 8.756-731.0
1.575-552.0 8.756-756.0 8.756-699.0 9.107-507.0 8.756-716.0 8.756-437.0 8.756-437.0 8.756-731.0
1.575-553.0 8.756-756.0 8.756-699.0 9.107-507.0 8.756-716.0 8.756-437.0 8.756-437.0 8.756-731.0
MANUAL, KARCHER, HDS 9.800-079.0
45
WIRING DIAGRAM - HDS 3.5/30 PE AND HDS 3.5/35 PE
Wiring Diagrams
C
B
A
LAMP
BATTERY
STARTER
ENGINE
ENGINE
FROM
RECTIFIER
T
S
T
M
O
RELAY
BREAKER
CONTROL PANEL
O
F
F
A
2
1
W
2
0
0
RELAY/RECTIFIER
1
6
5
METER
H
O
U
R
2
7
0
87
3
0
0
2
3
5
30
87A
85
86
AC
AC
+
_
+
_
12VDC
NOTE:
VANGUARD Y WIRE
W
1
3
0
9
5
GR
GR
R
HONDA GR WIRE
BURNER
SWITCH
BURNER
E
H
T
CIRCUIT
R
30
RELAY
87A
85
86
87
MANUAL, KARCHER, HDS 9.800-079.0
46
CAD
CELL
TIMER - 3 SEC
RELAY
COM
N.O.
YLW
BLK
RED
PHOTOCELL
+-
YLW
RED
RED
BLK
IGNITOR
12 VCD
WHT
PUR
FUEL SOLENOID
(SHUT-OFF VALVE)
12-24VDC
BURNER
MOTOR
12VCD
BLK
RED
RED
BLK
62411-052
12 GA FROM NUT
13743
16 GA FROM NUT
WHT
BLK
RED
62411-053
12 GA FROM NUT
+
-
W
O
GROUND TO
BURNER HOUSING
xt9 WITH SCREW
MACHINE CONNECTION
B
C
A
1. APPLIED 12V ENERGIZES
-BURNER MOTOR WICH STARTS FUEL FLOW
-SHUT OFF VALVE WICH ALLOWS FUEL TO FLOW OUT OF PUMP
-3 SEC, TIMER ENERGIZES THE IGNITOR TO IGNITE FUEL
2. AFTER 3 SEC, TIMER DE-ENERGIZES THE IGNITOR (RESISTOR JUMPER)
ON PHOTOCELL ELEIMATES RE-ENERGIZING IGNITOR IF FLAME IS LOST
3. AFTER 12V HAVE BEEN REMOVED
-BURNER MOTOR IS DE-ENERGIZED WICH STOPS FUEL FLOW
-SHUT OFF VALVE IS DE-ENERGIZED WICH STOPS FUEL FLOW OUT OF PUMP
-3 SEC TIMER IS DE-ENERGIZED
4. SEQUENCE STARS AGAIN WHEN 12V APPLIED
ALL WIRES BLACK UNLESS NOTED
W-WHITE
G-GREEN
R-RED
Y-YELLOW
BL-BLUE
GR-GREY
WIRING DIAGRAM - HDS 3.5/30 PE AND HDS 3.5/35 PE
MANUAL, KARCHER, HDS 9.800-079.0
47
WIRING DIAGRAM - HDS 2.6/30 P, HDS 3.5/30 P, HDS 2.8/25 P
CAD
CELL
TIMER - 3 SEC
RELAY
COM
N.O.
YLW
BLK
RED
PHOTOCELL
+-
YLW
RED
RED
BLK
IGNITOR
12 VCD
WHT
PUR
FUEL SOLENOID
(SHUT-OFF VALVE)
12-24VDC
BURNER
MOTOR
12VCD
BLK
RED
RED
BLK
62411-052
12 GA FROM NUT
13743
16 GA FROM NUT
WHT
BLK
RED
62411-053
12 GA FROM NUT
+
-
W
O
GROUND TO
BURNER HOUSING
xt9 WITH SCREW
MACHINE CONNECTION
B
C
A
87
RELAY
87A
85
30
R
BURNER
LAMP
86
FLOW
SW
IT
CH
21P1
-
12VDC
HOUR METER
CAPACITOR
R
CONTROL PANEL
+
BREAKER
CIRCUIT
Y
GR
R
ACPOS
YEL
AC
REDYEL
R
EG
ULATOR/RECITIFIER
VOL
TAGE
NEG
BLK
GR
Y
ENGINE
GR
Y
GR
Y
C
B
A
30
RELAY
87A
86
87
85
ALL WIRES BLACK UNLESS NOTED
W - WHITE
G - GREEN
R - RED
Y - YELLOW
O - ORANGE
BL - BLUE
GR - GREY
1. APPLIED 12V ENERGIZES
-BURNER MOTOR WICH STARTS FUEL FLOW
-SHUT OFF VALVE WICH ALLOWS FUEL TO FLOW OUT OF
PUMP
-3 SEC, TIMER ENERGIZES THE IGNITOR TO IGNITE
FUEL
2. AFTER 3 SEC, TIMER DE-ENERGIZES THE IGNITOR
(RESISTOR JUMPER)
ON PHOTOCELL ELEIMATES RE-ENERGIZING IGNITOR IF
FLAME IS LOST
3. AFTER 12V HAVE BEEN REMOVED
-BURNER MOTOR IS DE-ENERGIZED WICH STOPS FUEL
FLOW
-SHUT OFF VALVE IS DE-ENERGIZED WICH STOPS FUEL
FLOW OUT OF PUMP
-3 SEC TIMER IS DE-ENERGIZED
4. SEQUENCE STARS AGAIN WHEN 12V APPLIED
MANUAL, KARCHER, HDS 9.800-079.0
48
12V BATTERY
SWITCH
PRESSURE
86
87
Y
RED 6GA
CONTROL BOX
BLK 12GA
RED 12GA
BLK 6GA
1
C
85
87a
30
A
B
C
RED
Y
Y
BLK
BRN
WHT
Y
ENGINE
+
-
R
E
D
ENGINE
REGULATOR
85
30
87a
86
87
BLK
BREAKER
HOUR
METER
B
C
WIRING DIAGRAM - HDS 3.5/35 P CAGE CAL
MANUAL, KARCHER, HDS 9.800-079.0
49
CAD
CELL
TIMER - 3 SEC
RELAY
COM
N.O.
YLW
BLK
RED
PHOTOCELL
+-
YLW
RED
RED
BLK
IGNITOR
12 VCD
WHT
PUR
FUEL SOLENOID
(SHUT-OFF VALVE)
12-24VDC
BURNER
MOTOR
12VCD
BLK
RED
BLK
WHT
BLK
RED
+
-
GROUND TO
BURNER HOUSING
xt9 WITH SCREW
MACHINE CONNECTION
B
C
A
+
1. APPLY 12V:
-BURNER MOTOR, STARTS FUEL FLOW
-FUEL SOLENOID, FUEL NOZZLE START TO ATOMIZE DIESEL
-TIMER DELAY, ACTIVATES THE IGNITOR
2. AFTER 3 SEC, TIMER RELAY SHUTS OFF THE IGNITOR (CAD
CELL WILL START THE IGNITOR AGAIN IF FLAME IS LOST)
3. REMOVE 12V
-BURNER MOTOR, STOPS FUEL FLOW
-FUEL SOLENOID, BYPASS THE FUEL
-TIMER DELAY, SHUTS OFF THE IGNITOR
4. SEQUENCE STARTS AGAIN WHEN 12V APPLIED
WIRING DIAGRAM - HDS 3.5/35 P CAGE CAL
advantages.
vielen Vorteilen.
avantages.
Registre su producto y aproveche de muchas ventajas.
Bewerten Sie Ihr Produkt und sagen Sie uns Ihre Meinung.
Rate your product and tell us your opinion.
Évaluer votre produit et dites-nous votre opinion.
Reseñe su producto y díganos su opinión.
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Alfred Kärcher SE & Co. KG
Alfred-Kärcher-Str. 28-40
71364 Winnenden (Germany)
Tel.: +49 7195 14-0
Fax: +49 7195 14-2212
DANKE!
THANK YOU!
MERCI!
GRACIAS!
!
