Trailer Service Manual Pressure Washer - Kärcher · Trailer Service Manual Pressure Washer...

9.807-795.0-C 01/27/17

Trailer

Service Manual Pressure Washer

98077950-1

TO REDUCE THE RISK OF INJURY, READ OP-

ERATING INSTRUCTIONS CAREFULLY BEFORE

USING. This m

achine is to be used only b

y

qualifi ed operators.

LIRE LE MANUEL DE L'OPERATEUR AVANT

UTILISATION. Cet appareil doit ê

tre utilise par

des operateurs qualifi es.

LEA EL MANUAL OPERACION ANTES DE US-

ARSE. Este equipo debe ser usado solamente

por operadores califi cados.

RISK OF ASPHYXIATION. Use this product

only in a well ventila

ted area.

RISQUE D'ASPHYXIE. Utiliser dans un en-

droit bien aéré.

RIESGO DE ASFIXIA. Use el producto en un

area de ventilación adecuada.

RISK OF EXPLOSION. Operate only where open fl a

me or torch is per-

mitted. D

o not spray fl ammable liq

uids. RISK OF FIRE. D

o not add fuel

when the machine is operating.

RISQUE D'EXPLOSION. Utilis

er aux endroits où une fl amme nue est

per-

mise. Ne pas va

poriser de liq

uides infl ammables.

RISQUE DE FEU. Ne

pas ajouter de carburant diesel pendant que la machine est en opération.

RIESGO DE EXPLOSION Use el producto en áreas donde el fuego

o llama

sean permitidos. N

o rocie liquidos infl amables.

RIESGO DE FUEGO. No

añadir gasolina cuando la máguina este tra

bajando.

RISK OF INJECTION OR SEVERE INJURY TO PERSONS. Keep clear

of nozzle. H

OT DISCHARGE FLUID. Do not to

uch or direct discharge

stream at persons.

RISQUE DE BLESSURES. Se tenir loin des b

uses. EAU CHAUDE SOUS

PRESSION A LA SORTIE. Ne pas diriger le

jet d'eau vers des personnes.

RIESGO DE PENETRACIÓN O LESIONES SEVERAS A PERSONAS. Man-

téngase fuera del alcance de boquilla. D

ESCARGA DE AGUA CALIENTE

A ALTA PRESION. No to

que ni dirija el fl u

jo del agua o otras personas.

RISK OF INURY. PROTECTIVE EYEWEAR AND OTHER PROTEC

TIVE

CLOTHING MUST BE WORN when operating this machine.

RISQUE DE BLESSURE. Portez des lunettes de protectio

n et vêtements

protecteurs quand vous utilisez cette machine.

RIESGO DE LESIONES. Use lentes de seguridad y pr

oteja su cuerp

o adec-

uadamente cuando opere este equipo.

WARNING / AVERTISSEMENT / P

RECAUCION

RISK OF INJURY. HOT SURFACES CAN CAUSE

BURNS. Use only designed gripping areas of

spray gun and wand.

SURFACES CHAUDES. Toucher seulement le

s

parties isolées des poignée pistolets et la

nces.

SUPERFICIES CALIENTES. Use solamente las

áreas aisladas del gatillo y la lanza.

SPRAY GUN KICKS BACK . Hold with both hands.

LA POIGNEE PISTOLET REPOUSSE. Tenir à

deux mains.

LA PISTOLA SE MUEVE CON LA PRESIÓN.

Sostenga con las dos manos.

RISK OF ELECTROCUTION. Keep all connections dry and off the

ground. Keep spray away from electric

al wirin

g and components.

RISQUE D'ELECTROCUTION. Tous les fi ls

doivent être maintenus secs

et être suspendus. Ne jamais projeter d'eau sur le

s composantes et

fi ls électriq

ues.

RIESGO DE ELECTROCUCIÓN. Mantenga todas las connecciones se-

cas y arriba del suelo. N

o rocie componentes eléctricos.

DANGER

8.923-560.0

MODEL: 1.103-843.0TRK-2500 HDS

To locate your local Kärcher Commercial Pressure Washer Dealer

nearest you,

2 KÄRCHER TRAILER SERVICE MANUAL • 9.807-795.0-C

Machine Data Label

Notice

This trailer is equipped to meet applicable U.S. Federal safety standards. Check local and state requirements regarding brakes and any additional equipment that may be required. Any modifications or additions including load-equalizing hitches, without written factory consent: usage in an abnormal manner including overloading voids all manufacturers’ warranties and liability.

WARNING: This Owner's Manual contains safety information and instructions for your trailer.

You must read this manual before loading or towing your trailer.

You must follow all safety precautions and instructions.

3

Table of Contents

Machine Data Label . . . . . . . . . . . . . . . . . . . . . . . . . .2

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . .3

How To Use This Manual . . . . . . . . . . . . . . . . . . . . .4

SafetyImportant Trailer Safety Information . . . . . . . . . . . . .5Referencing the Utility Trailer in this Manual . . . . . .5Tire Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Basic Tire Maintenance . . . . . . . . . . . . . . . . . . . . . .5Understanding Tire Pressure and Load Limits . . . . .5Maintaining Proper Tire Pressure . . . . . . . . . . . . . . .5Never Tow the Trailer Before Checking:. . . . . . . . . .6Tow Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Trailer Ball & Couplers . . . . . . . . . . . . . . . . . . . . . . .7Before Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Variable Height Bracket: . . . . . . . . . . . . . . . . . . . . . .7Bolting Instructions:. . . . . . . . . . . . . . . . . . . . . . . . . .7Hitch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Hitch Coupler Troubleshooting . . . . . . . . . . . . . . . . .8Coupler & Ball Engagement . . . . . . . . . . . . . . . . . . .8Safety Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Load-Carrying Capacity . . . . . . . . . . . . . . . . . . . . . .9Owner/User Responsibility:. . . . . . . . . . . . . . . . . . .10

Important Safety Information . . . . . . . . . . . . . . . . .10Reporting Safety Defects . . . . . . . . . . . . . . . . . . . .13

What to Check and How to CheckProper Weight Distribution & Tongue Weight . . . . .14Tongue Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Wheel Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Ball Coupler Hitches . . . . . . . . . . . . . . . . . . . . . . . .15Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Correct Ball Seating . . . . . . . . . . . . . . . . . . . . . . . .16Breakaway Switch & D.O.T. Wet Cell Battery. . . . .16Breakaway Switch Mounted

on an A-Frame . . . . . . . . . . . . . . . . . . . . . . . . . .17Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Burnishing the Brakes. . . . . . . . . . . . . . . . . . . . . . .17Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .18Brake Cleaning & Inspection. . . . . . . . . . . . . . . . . .18Trailer Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

MaintenanceTroubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .20Preventative Maintenance . . . . . . . . . . . . . . . . . . .24Oil Change Record . . . . . . . . . . . . . . . . . . . . . . . . .24Axles, Hubs and Brakes . . . . . . . . . . . . . . . . . . . . .25

PartsTRK-2500 HDS . . . . . . . . . . . . . . . . . . . . . . . . . . . 28TRK-2500 Trailer . . . . . . . . . . . . . . . . . . . . . . . . . 34Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 38Hose & Spray Gun Assembly . . . . . . . . . . . . . . . . 39TRK-2500 With HDS Washer . . . . . . . . . . . . . . . . 40Hose Reel Low Pressure 8.917-555.0 . . . . . . . . . 42Hose Reel High Pressure 8.917-554.0 . . . . . . . . . 43KNA Burner Wiring Diagram . . . . . . . . . . . . . . . . . 44Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 45KT.2 Series Pump. . . . . . . . . . . . . . . . . . . . . . . . . 46VRT3 Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . .48Unloader Adjustment Procedures . . . . . . . . . . . . . .48Parts Specifications . . . . . . . . . . . . . . . . . . . . . . . .49KNA Burner Specifications . . . . . . . . . . . . . . . . . . .49

KÄRCHER TRAILER SERVICE MANUAL • 9.807-795.0-C

4

How To Use This Manual

This manual contains the following sections:

• How to Use This Manual

• Safety

• Operations

• Maintenance

• Parts List

The HOW TO USE THIS MANUAL section will tell you how to find important information for ordering correct repair parts.

Parts may be ordered from authorized dealers. When placing an order for parts, the machine model and machine serial number are important. Refer to the MACHINE DATA box which is filled out during the installation of your machine. The MACHINE DATA box is located on the inside of the front cover of this manual.

The model and serial number of your machine is located on the right side of the machine, facing the hitch.

The SAFETY section contains important information regarding hazardous or unsafe practices of the machine. Levels of hazards are identified that could result in product damage, personal injury, or severe injury resulting in death.

The OPERATIONS section is to familiarize the operator with the operation and function of the machine.

The MAINTENANCE section contains preventive main-tenance to keep the machine and its components in good working condition. They are listed in this general order:

• Troubleshooting

• Preventative Maintenance

The PARTS LIST section contains assembled parts illustrations and corresponding parts list. The parts lists include a number of columns of information:

• REF – column refers to the reference number on the parts illustration.

• PART NO. – column lists the part number for the part.

• QTY – column lists the quantity of the part used in that area of the machine.

• DESCRIPTION – column is a brief description of the part.

• NOTES – column for information not noted by the other columns.

NOTE: If a service or option kit is installed on your machine, be sure to keep the KIT INSTRUCTIONS which came with the kit. It contains replacement parts numbers needed for ordering future parts.

NOTE: The manual part number is located on the lower right corner of the front cover.

Model:

Date of Purchase:

Serial Number:

Dealer:

Address:

Phone Number:

Sales Representative:


5

Safety

Important Trailer Safety Information

Referencing the Utility Trailer in this Manual

All references to the trailer or component parts to either left or right are made with the assumption that you are standing behind the trailer facing forward. Your left hand or right hand is the equivalent on the trailer.

Tire Safety

The most common cause of trailer tire failure is under-inflation. Therefore, it is important that you always maintain the specified air pressure as indicated by the tire manufacturer on the tire's side-walls. This information can also be found on the tire label or the air pressure molded on the tire side-wall.

The most important things you can do to maintaining proper tire pressure are observe all tire and trailer maximum carrying capacities, avoid road hazards, and inspect the tires for cuts, slashes and other irregularities. These practices, along with other care and maintenance, can improve handling, help protect you and others from avoidable breakdowns and accidents, improve fuel economy, and increase the life of your tires.

Make tire safety a regular part of your trailer maintenance routine. The time you spend is minimal compared to the amount of time, inconvenience, and potential safety hazards that can occur from a flat tire or failure.

Basic Tire Maintenance

Properly maintained tires improve the load-carrying capability of your trailer. You can help avoid flat tires and tire failures by maintaining proper tire pressure, observing tire and trailer capacity limits, avoiding road hazards, and inspecting your tires regularly.

Identifying Your Recommended Tire Pressure and Maximum Load Carrying Capacity for Your Trailer

Both the tire placard and the VIN label are permanently attached on top of the frame of your trailer and have the required information printed on them. They also list the maximum load that can be placed on the trailer without exceeding the load limits of the tires or the trailers other components. These labels indicate the manufacturer’s information including:

• Recommended tire size.

• Recommended tire inflation pressure.

• The maximum weight the trailer is designed to carry.

• Gross vehicle weight rating of the trailer.

• Gross axle weight rating of the trailer.

Understanding Tire Pressure and Load LimitsTire inflation pressure is the level of air in the tire that provides it with the load-carrying capacity and affects the overall performance of the trailer. The tire inflation pressure is a number that indicates the amount of air pressure that is inside the tire. It is measured in pounds per square inch (PSI). The tire must be inflated to the air pressure as designated on the labels. Also listed on the labels is the air pressure in kilo Pascals (kPa), which is a metric measurement. Tire manufacturers determine the air pressure to maximize the amount of weight the tires can safely carry. The proper tire pressure for your trailer tires is referred to as the “recommended cold inflation pressure.” It is difficult to obtain the recommended tire pressure if your tires are not cold when the reading is taken because the air will expand when it is warmed by towing down the road, thus increasing the air pressure inside. If air is added to a tire that is low the air pressure should never exceed the recommended pressure.

It is important to check your trailer’s tire pressure at least once a month for the following reasons:

Most tires will naturally lose air over time.

Tires can lose air suddenly if driven over an object that punctures or cuts the tire. Sometimes a sharp blow from a pothole or curb can knock the tire loose from the rim causing immediate deflation.

Maintaining Proper Tire PressureLocate the recommended tire pressure on the trailer's tire information placard or owner's manual.

Record the tire pressure of all tires. If the tire pressure is too high in any of the tires, slowly release air by gently pressing on the tire valve stem with the edge of your tire gauge until you get the correct pressure.

If the tire pressure is too low, note the difference between the measured tire pressure and the correct tire pressure. These “missing” pounds of pressure are what you will need to add.

Add the missing pounds of air pressure to each tire that is under inflated.

Check all tires to make sure they have the same air pressure.


6

Safety

If you have been towing your trailer and think that a tire is under inflated, fill it to the recommended cold inflation pressure indicated on your trailer's tire label placard or the VIN label. You can also check the sidewall of the tire for a correct tire inflation pressure. Your tire will have a slightly lower air pressure because the tire is warm when you are inflating it, but it will be much better than to continue to tow it with the under inflation it may have had. Once the trailer has been parked long enough to allow the tires to cool down, recheck the tire pressure and add additional air to return the tire pressure to the recommended level.

Tire Size

To maintain the trailer's carrying capacity and safety, purchase only the same size tires as what were origi-nally supplied on the trailer.

Safety Tips

Slow down if you have to go over a pothole or other object in road.

Do not run over curbs and try not to strike the curb when parking.

For a free brochure visit:

www. nhtsa.dot.gov

FOR SAFETY: Before towing this trailer be sure to read the instructions and warnings supplied in this manual. Also read the information supplied with your tow vehicle so you know and understand it's limitations.

Never Tow the Trailer Before Checking:• Coupler and latch assembly show no signs of

wear or damage.

• Coupler hitch and hitch ball are of the same size.

• Coupler and safety chains are safely secured to the hitch.

• Check all fasteners for proper tightness.

• Load is securely tied down to the trailer.

• Wheel lug nuts are properly tightened to the right torque.

• Wheel bearings are properly adjusted and maintained.

• Load is within the maximum load carrying capacity of trailer.

• Tires are properly inflated and are road worthy.

• All trailer lighting is working properly.

• Tire pressure and tire condition

• Wheel lugs*

• Bearing lube and tightness

• Hitch

• Safety chains

• 12V running lights

• Distribution and security

• Caster up in travel position

* Check lug nuts for tightness before initial trip, at 10 miles, 25 miles and 50 miles. Recheck every 3 months or 3000 miles.

NOTE: Checking all of the above steps before every trip is key for safety.

IMPORTANT: The load must be distributed equally on the bed of the trailer if possible. Heavy, concen-trated loads may cause damage or possible failure of the trailer.

WARNING: Loads placed on the trailer must be securely tied to the trailer. Always use appropriate tie downs designed to restrict loads from moving when properly attached. Failure to do so will allow shifting of the load causing potential trailer failure and/or loss of the load and personal injury.

This trailer is equipped to meet all applicable federal safety standards in effect the day of manufacture. Check local and state requirements regarding any addi-tional equipment that may be required.

The addition of optional equipment to your trailer may increase the total weight of your trailer package to where it now exceeds the maximum load carrying capacity of the trailer.

Tow Vehicles

WARNING: Serious injury or property damage can result if the total weight of your loaded trailer exceeds the capacity of the hitch and/or your tow vehicle.

It is very important that you know and understand the towing capabilities of your tow vehicle. This is espe-cially true with the braking abilities of the tow vehicle. You should check with your authorized dealer to see what the capabilities are for the total towing load and the maximum allowable tongue weight for the vehicle you plan on using for towing.

It is also important that the lighting system in the tow vehicle has sufficient capacity support the additional load the trailer lighting will add to the system. A heavy duty flasher may be required to make your turn signals function properly.


7

Safety

Trailer Ball & Couplers

WARNING: Failure to properly engage the hitch ball in the coupler ball socket and securely lock the coupler latch mechanism can cause the trailer to become detached from the tow vehicle while trav-eling, which may cause serious injury or property damage.

Ball diameter for which rating (GVWR) shall not exceed the gross trailer weight marked on the trailer coupler.

The hitch balls have the rated load they are capable of towing stamped Into the top of the ball.

Make sure the ball that you use to tow your trailer has the same capacity rating as the coupler.

Do not use a different size ball than the size the coupler is designed to use.

Before Towing

Check mounting bracket hardware for wear and proper tightness. Replace bent, broken, or worn hardware. Tighten hardware to 75-94 ft. lbs. Use only the hardware provided with the Trailer. If replacement hardware is needed, order replacement kit 8.924-356.0.

Make sure that the trailer safety chains are properly connected to the towing vehicle and trailer according to SAE J684. See Safety Chain information in your manual.

Make sure that all trailer lighting is hooked up and working properly.

Warning: Failure to follow all installation instructions could result in coupler failure

Variable Height Bracket:

Coupler operation must not be impaired in any way. Do not use if coupler operation is impaired.

Bolting Instructions:

Align holes in coupler and mounting bracket.

NOTE: Coupler must be secured to mounting bracket using two sets of holes in the mounting bracket.

Insert two (2) 5/8”x4.5”, grade 5 bolts through desired mounting bracket holes and coupler. For each bolt, Place one (1) washer at the bolt head side and another at the bolt thread side before assembling the nuts. Tighten lock nuts to 90-96 ft. lbs. After installation, ensure coupler operation is not impaired in any way. Do not use if coupler operation is impaired. The hardware provided with the trailer has a self-lubricating coating which is taken into account for the tightening torque above, and is lower than standard hardware and also is more consistent with re-torque specifications to first-torque than standard hardware. Order replacements with the 8.924-356.0 replacement kit, or consult your hardware vendor for applicable, higher, torques for the application.

Hitch Maintenance

Keep ball pocket and mechanism clean. The following procedures should be performed at least annually:

• Check set screw torque Grease ball pocket

• Oil pivot points with SAE 30 wt. motor oil

• Inspect retaining pin and replace if necessary

Class Coupler Ball Diameter

II 3,500# GVWR 2”

III 5,000# GVWR 2”

IV 8,000# GVWR 2 5/16”


8

Safety

Hitch Operation

To Couple:

1. Block trailer wheels.

2. Align hitch ball beneath coupler.

3. Open coupler locking lever. While holding locking lever open, lower the coupler over the hitch ball until ball is fully seated into the ball pocket.

4. If locking lever is pinned open, remove pin. Move locking lever to the closed position. Check that the latch is engaged by lifting up on back of locking lever. Also, check that the hitch ball is fully seated and ball clamp is below the ball. If the ball is not seated with lever in the closed position and latch engaged, DO NOT TOW.

Repeat the above steps.

5. OPTIONAL: Place a 5/16” pin or lock in hole shown

To Uncouple:

1. Block trailer wheels.

2. Open locking lever. While holding locking lever fully open, raise trailer off of hitch ball.

NOTE: A 5/16” diameter pin can be used to hold the locking lever open.

Hitch Coupler Troubleshooting

If the coupler becomes damaged it must be repaired or replaced before towing. When the coupler is placed on the ball, the latch should close firmly. Keep the latch mechanism lightly oiled and clean. Items to check for are as follows:

1. Latch does not grasp ball securely:

• Check the ball size. Make sure the ball and coupler are the same size.

2. Latch does not snap into full latch position:

• Check adjustment. Latch mechanism may be too tight.

• Check to see that the coupler housing has not been damaged, keeping the ball hitch from fitting completely into the housing as designed.

3. Keep the tongue blocked up when not in use so the coupler and mechanism are not in the ground being exposed to dirt and moisture.

4. Apply a small amount of an automotive grease to the ball before hitching coupler to prevent wear of the two parts during towing.

5. Make sure the latch safety pin is in position before towing.

Coupler & Ball Engagement

If the coupler and towing ball resist attempts to make engagement, do not force latch assembly. Instead, check the ball diameter to verify that it conforms to Society of Automotive Engineers (SAE) specifications. Standard two-inch diameter ball should be within the limits of 2.000-inches to 1.970-inches. Balls larger than 2.000- inches will not readily fit the coupler. A two-piece coupler ball is not recommended.

If the coupler becomes damaged it must be repaired or replaced before towing. When the coupler is placed on the ball, the latch should close firmly. Keep the latch mechanism lightly oiled and clean.

Improper engagement of the coupler and ball can cause damage if the vehicles separate in transit, thus, caution must be exercised to insure a secure hook-up. Lower the coupler onto the ball with the coupler latch in the vertical position. Continue to lower the trailer tongue until the jack clears the ground, then flip the coupler latch to its locked (horizontal) position. At this point visually observe that the ball is fully engaged in the ball hitch. An even better check to make sure the two are fully engaged is to raise the tongue of the trailer again using the jack. Raise until the ball hitch connec-tion starts to raise the rear of the tow vehicle. If the connection was not properly made, the ball and socket will separate as the tongue of the trailer is raised.

Safety Chains

Listed in the chart below are the different class sizes of safety chains and the rated load each chain must be capable of withstanding. Your trailer is equipped with safety chains that meet the requirements of D.O.T Regulation 393.70.

WARNING: Failure to properly attach safety chains between the trailer and tow vehicle can result in a runaway trailer.

Trailer Class

Trailer Weight

GVWR in LBS

Minimum Braking Strength in LBS.

I to 2,000 2,000

II2,000 to

3,5003,500

III 3,500 to 5,000 5,000

IV 5,000 to 7,000 7,600


9

Safety

WARNING: To avoid accidents, before trailering:

• Hitch only to ball size marked on coupling.

• Ball clamp must capture ball and lever or hand wheel is fully clamped.

• Cross safety chains under coupling.

• Allow only enough slack for turns.

Bottom View

The safety chains on your trailer are an added insurance that it will not become detached from the tow vehicle. All safety chains are provided with an added clasp to keep them from becoming accidentally detached from the tow vehicle. Your trailer hitch on the tow vehicle should have two attaching holes or rings for attaching the safety chains, preferably one on each side of the ball hitch. Crisscross the chains under the tongue, the chain on the left side of the trailer tongue attached to the right side of the ball hitch, the chain on the right side of the trailer tongue attached to the left side of the ball hitch.

This prevents the trailer tongue from dropping to the road should the coupler or ball hitch fail. The chains should be rigged as tight as possible with just enough slack to allow tight turns to be made. This can be accomplished by twisting the chain hook in a clockwise or counterclockwise direction thus twisting the link spacing and making the chain shorter. Also by keeping your chains as short as possible you prevent them from dragging on the road and wearing the chain links. If for any reason you find it necessary to replace a safety chain, use only original equipment.

Load-Carrying Capacity

Located on the front left-hand side of the frame, (either the inside or the outside) is the VIN (Vehicle Identifica-tion Number) tag. It will show the GVWR (Gross Vehicle Weight Rating) which is the maximum load that can be applied to the tires on the trailer. The GVWR and the carrying capacity of the trailer are based on the tire size installed on the trailer.

The GVWR is the maximum carrying capacity of the trailer with its respective tires. It may not necessarily equal the total GVWR of the trailer less the empty weight of the trailer because there may be another controlling factor such as frame strength that reduces the carrying capacity to what is listed on the VIN tag.

The tire label will list the tire size that was installed on the trailer as original equipment when it was sold to you, the consumer. It also lists the maximum carrying capacity of the trailer.

IMPORTANT: The total weight of the load must never exceed the weight of cargo listed on the tire label and/or the maximum load carrying capacity listed on the VIN tag on your trailer. The GVWR (Gross Vehicle Weight Rating) listed is the maximum total weight of the trailer with accesso-ries and all cargo allowable to be carried on the tires that are installed on the trailer.

WARNING: Fishtailing caused from improper tongue weight on the tow vehicle hitch ball can cause loss of control of the tow vehicle and resulting serious injury or property damage.

CAUTION: The maximum load applied to the trailer must never exceed the carrying capacity of the trailer as stated on the VIN label and/or the tire placard. Doing so may cause failure of one or more component parts of the trailer causing potential damage to the trailer and/ or a potential accident. All concentrated loads must be spread over as large an area as possible to eliminate potential damage to the decking.


10

Safety

Thank you for purchasing a Kärcher 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 comprehends 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, specify model and serial number. Use only identical replacement parts.

This machine is to be used only by trained operators.

Important Safety Information

WARNING: To reduce the risk of injury, read operating instructions carefully before using.

1.Read the owner's manual thor-oughly. 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 machine and bleed pressure quickly. Be thoroughly familiar with the controls.

3. Stay alert — watch what you are doing.

DANGER: Keep wand, hose, and water spray away from electric wiring or fatal electric shock may result.

4.Follow engine fuel recommen-dation in the engine manual provided

WARNING: Flammable liquids can create fumes which can ignite, causing property damage or severe injury.

WARNING: Risk of explosion — Operate only where open flame or torch is permitted.

5.Use only kerosene, No. 1 home heating fuel, or diesel for the hot water burner. If diesel is used, add a soot remover to every tankful.

WARNING: Gasoline is highly flammable and explosive. You can be seriously injured when refueling.

• Stop engine and keep heat sparks and flame away.

• Refuel only outdoors.

• Wipe up spills immediately.WARNING

READ OPERATOR’S MANUAL THOROUGHLY PRIOR TO USE.

OPERATIONSSAFETY

MAINTENANCE

DANGER

KEEP WATER SPRAY AWAY FROM ELECTRICAL WIRING.

WARNING

RISK OF EXPLOSION: OPERATE ONLY WHERE

OPEN FLAME OR TORCH IS PERMITTED


11

Safety

WARNING: Risk of fire — Do not add fuel when the product is operating or still hot.

WARNING: Do not use gasoline crankcase draining or oil containing gasoline, solvents or alcohol. Doing so will

result in fire and/or explosion.

6. Operate only in locations where combustible dusts and flammable gases or vapors are not present. Do not store or use gasoline near this machine.

7. Do not allow acids, caustic or abrasive fluids to pass through the pump.

8. Never run pump dry or leave spray gun closed longer than 1-2 minutes.

9. Keep operating area clear of all persons.

WARNING: High pressure spray can cause paint chips or other particles to become airborne and fly at high speeds. To avoid personal injury, eye, hand and foot safety devices must be worn.

10.Always wear properly rated eye protection such as safety goggles or face shield while spraying. Safety glasses do not provide full protection.

WARNING: This machine exceeds 85 dB. Appropriate ear protection must be worn.

WARNING: Hot discharge fluid. Do not touch or direct discharge stream at persons.

WARNING: This machine produces hot water and must have insulated components attached to protect the operator.

WARNING: Risk of injury. Hot surfaces 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.

WARNING

RISK OF FIRE. DO NOT ADD FUEL WHEN OPERATING

MACHINE.

WARNING

USE PROTECTIVE EYE WEAR

AND CLOTHINGWHEN OPERATING THIS EQUIPMENT.

WARNING

EAR PROCTIONMUST BE WORN

WARNING

HOT DISCHARGE FLUID:DO NOT TOUCH ORDIRECT DISCHARGESTEAM AT PERSONS.

WARNING

RISK OF INJURY. HOT SURFACES

CAN CAUSE BURNS


12

Safety

11. 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: Grip cleaning wand securely with both hands before starting. Failure to do this could result in injury from a whipping wand.

12.Never make adjustments on machine while in operation.

13.Be certain all quick coupler fittings are secured before using pressure washer.

WARNING: High pressure developed by these machines will cause personal injury or equipment damage. Keep clear of nozzle. Use caution when operating. Do not direct discharge stream at people or animals or severe injury or death will result.

WARNING: Protect machine from freezing.

14.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 specified in this manual.

15. 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.

16.Avoid operating machines in small areas or near exhaust fans. Adequate oxygen is needed for combustion or dangerous carbon monoxide will result.

17. Manufacturer will not be liable for any changes made to our standard machines or any compo-nents not purchased from us.

18. The best insurance against an accident is precau-tion and knowledge of the machine.

WARNING: Be extremely careful when using a ladder, scaffolding or any other relatively unstable location. The cleaning area should have adequate slopes and drainage to reduce the possibility of a fall due to slippery surfaces.

19. Do not overreach or stand on unstable support. Keep good footing and balance at all times.

20. Do not operate this machine when fatigued or under the influence of alcohol, prescription medica-tions, or drugs.

Follow the maintenance instructions specified in the manual

WARNING

TRIGGER GUN KICKS BACK — HOLD WITH BOTH HANDS

WARNING

RISK OF INJECTION OR SEVERE INJURYTO PERSONS. KEEP CLEAR OF NOZZLE.

WARNING

PROCTECT FROMFREEZING

WARNING

RISK OF ASPHYXIATION.

USE THIS PRODUCT ONLY IN A WELL

VENTILATED AREA.

WARNING

RISK OF INJURYFROM FALLS WHEN

USING LADDER.


13

Safety

Reporting Safety Defects

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying the trailer manufacturer.

If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your local dealer.

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424- 9153) or write to: NHTSA, U.S. Department of Transportation,1200 New Jersey Avenue SE, Washington, DC 20590. You can also obtain other information about motor vehicle safety from http://www.safercar.gov.


14

What to Check and How to Check

Shown below is an example of the tire label that is placed on your trailer showing the items just discussed above. Once you have familiarized yourself with the information supplied on the example tire label and VIN tag, check the tire size and capacity of your trailer as shown on the VIN tag on your trailer.

Proper Weight Distribution & Tongue Weight

Ensuring that your trailer has the proper GVWR is very important. Once that has been established and you have the load on the trailer it is equally important that you have proper weight distribution.

Tongue Weight

The tongue weight on your trailer is 10%-15% of the total weight of the trailer and all the cargo that it is carrying. This is the amount of weight that is then transferred to the tow vehicle through the ball hitch.

Example: The total weight of the trailer with load is 2500 pounds. The tongue weight should not be less than 250 pounds (10%).

Too light of tongue weight can cause the trailer to “fish-tail” (sway Weight Rating) as you travel down the highway. This creates excessive strains on the tow vehicle, hitch and on the trailer itself. It can very easily lead to an accident.

To adjust for too light of a tongue weight the load must be shifted for-ward with respect to the axle. This will increase the weight that is transferred to the tongue. Adjustments should be made until the tongue weight falls within 10% -15% recommended range. Likewise, if you have too much tongue weight adjust the weight backwards with respect to the axle until the tongue weight falls in the recommended range

Tow vehicles vary on how much tongue weight they can support for proper towing.

TIRE AND LOADING INFORMATIONRENSEIGNEMENTS SUR LES PNEUS ET LE CHARGEMENT

The weight of cargo should never exceedXXXX kg or XXXX lbs

TIRE SIZE COLD TIRE PRESS.REAR XXXXXXX XXX KPA (XX PSI)INTER XXXXXXXXXFRONT XXXXXSPARE XXXXX

SEE OWNER’SMANUAL FOR ADDITIONAL

INFORMATIONVOIR LE MANUAL

DE L’USAGERPOUR PLUS DE

RENSEIGNEMENTS

MANUFACTURED BY: KARCHER NORTH AMERICA INC. DATE OF MFG.:XX/XXXX

GAWR (EACH AXLE)

V.I.N. : TYPE : TRAILER TRX-XXXX

WITH TIRES RIMS AT COLD

XXXX KG (XXXX LB) XXXX XXXX XXX KPA (XX PSI) SINGLE

THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL MOTOR VEHICLE SAFETY STANDARDSIN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE.

XXXXXXXXXXXXXXXXX

GVWR (XXXX KG (XXXX LB)


15


Tire Pressure

Proper air pressure for your tires is printed on the sidewall. Check pressure while tires are cold. Do not raise or lower pressure to meet load. Pressure other than recommended pressure will lead to excessive tire wear or tire failure. Balancing recommended.

Wheels

Check wheels for hole elongation or “out of round”. This condition can be caused by lug nuts not being tight or being too tight. Trailer wheels can be damaged by chuck holes or curb jumping. You may not be aware of the road shock to the wheels without periodic checks. Replace any wheel that is bent. Replace any wheel if you see elongation of the bolt holes.

Wheel Lugs

Wheel lug nuts must be tightened with a torque wrench. Refer to the chart below for proper torque.

1. Start all bolts or nuts by hand to prevent cross threading.

2. Tighten bolts or nuts following sequence at right.

3. The tightening of the fasteners should be done in stages. Following the recommended sequence, tighten fasteners per wheel torque chart below.

4. Wheel nuts/bolts should be torqued before first road use and after each wheel removal. Check and re-torque after the first 10 miles, 25 miles and again at 50 miles. Check periodically thereafter.

Ball Coupler Hitches

Coupler assembly includes a latch lever and latch lever safety pin or hitch pin. Be sure the latch lever is locked and the pin properly secured before moving your trailer. The pin can be engaged fully only if ball is properly seated in the coupler.

Tires

Before mounting tires onto wheels make certain that the rim size and contour is approved for the tire as shown in the Tire and Rim Association Yearbook or the tire manufacturer’s catalog. Also make sure the tire will carry the rated load. If the load is not equal on all tires due to trailer weight distribution, use the tire rated for the heaviest wheel position.

Note: The capacity rating molded into the sidewall of the tire is not always the proper rating for the tire if used in a trailer application. Use the following guideline:

1. LT and ST tires: use the capacity rating molded into the tire.

2. Passenger Car Tires: Use the capacity rating molded into the tire sidewall divided by 1.10.

Use tire mounting procedures as outlined by the Rubber Manufacturer’s Association or the tire manufac-turers.

NOTE: Tire wear should be checked frequently because once a wear pattern becomes firmly established in a tire it is difficult to stop, even if the underlying cause is corrected.

Wheel Torque Requirements

Wheel SizeTorque Sequence

1st Stage 2nd Stage 3rd Stage

15” 20-25 50-60 80-90

1

2

34

5

WEAR PATTERN CAUSE ACTIONACTION

Center Wear

Over Inflation

Adjust pressure to particular load per tire catalog.

Edge Wear

Under Inflation

Adjust pressure to particular load per tire catalog.

Side WearLoss of

camber or overloading

Make sure load doesn't exceed axle rating. Align at alignment shop.

Toe WearIncorrect toe-in

Align at alignment shop.

CuppingOut of

balance

Check bearing adjustment and balance tires.

Flat Spots

Wheel lockup & tire

skidding

Avoid sudden stops when possible and adjust brakes.


16


Correct Ball Seating

Breakaway Switch & D.O.T. Wet Cell Battery

After hitching to the tow vehicle, pull the safety pin on the breakaway switch. Check to see if system is operational. Push safety pin back in to its original position.

Check battery fluid level every 60-90 days. Remove cover. There are two fill caps. Refill with distilled water only.


17


Breakaway Switch Mounted on an A-Frame

Attach breakaway switch cable securely in a straight line to the tow vehicle. Locate attachments so little “slack” is left in the cable, but enough slack to allow for turning without disengaging the pin. The cable will activate brakes the instant a trailer becomes disen-gaged. Brake adjustment is critical to stopping a disen-gaged trailer.

Check Breakaway System & Brakes Before Each Trip

1. Disconnect 12V plug from tow vehicle.

2. Pull breakaway pin.

3. While pin is pulled, move tow vehicle forward. Brake should be on and wheels locked.

4. Replace pin and secure to tow vehicle. Do not loop over hitch ball.

5. Plug 12V connector into tow vehicle receptacle.

6. Test brakes with brake controller.

NOTE: When disconnecting trailer from tow vehicle, make sure to replace safety pin.

Brakes

Your trailer is equipped with electric brakes.

Complete service and repair information for the electric brakes is found in the Axle Break Service Manual that is furnished with your trailer,

Note: It is important to strictly adhere to the axle break instructions for brake service and repair. In this way, you are protecting the validity of all applicable warran-ties.

Burnishing the Brakes

Brakes on a new trailer may tend to “grab” or pulsate. This is normal. To correct the situation, pull the trailer with the trailer brake control slightly engaged a short distance (about 1000 ft or until trailer does not grab or pull to one side anymore). This action smooths down the brake bands.

NOTE: Do not lock up the wheels

Breakaway Battery(Two fill caps

underneath cover)

Power Cable

Breakaway Pin

Cable to Vehicle

Breakaway Battery on A-Frame


18


Brake Adjustment

Brakes should be adjusted (1) after the first 200 miles of operation after the brake shoes and drums have “seated”, (2) at 3000 mile intervals and (3) as use and performance require. The brakes should be adjusted in the following manner:

1. Jack up trailer and secure on adequate capacity jack stands. Check that wheel and drum rotate freely.

2. Remove adjusting hole cover from adjusting slot on bottom of brake backing plate.

3. With screwdriver or standard adjusting tool, rotate the starwheel of the adjuster assembly to expand the brake shoes. Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn.

NOTE: With drop spindle axles, a modified adjusting tool with about an 80 degree angle should be used.

4. Then rotate starwheel in opposite direction until wheel turns freely with slight lining drag.

5. Replace the adjusting hole cover and lower wheel to ground.

6. Repeat above procedure on all brakes.

Never crawl under your trailer unless it is resting on properly placed jack stands.

Do not lift or place supports on any part of the suspension system.

Brake Cleaning & Inspection

Your trailer brakes must be inspected and serviced at yearly intervals or more often as use and performance require. Magnets and shoes must be changed when they become worn or scored thereby preventing inade-quate vehicle braking.

Clean the backing plate, magnet arm, magnet and brake shoes. Make certain that all the parts removed are replaced in the same brake and drum assembly. Inspect the magnet arm for any loose or worn parts. Check shoe return springs, hold down springs and adjuster springs for stretch or deformation and replace if required.

Asbestos Dust Hazard. Since some brake shoe friction materials contain asbestos, certain precautions need to be taken when servicing brakes:

1. Avoid creating or breathing dust.

2. Avoid machining, filing or grinding the brake linings.

3. Do not use compressed air or dry brushing for cleaning. (Dust can be removed with a damp brush).


19


Trailer Storage

Preparation

If your trailer is to be stored for an extended period of time or over the winter, it is important that the trailer be prepared properly.

1. Remove the emergency breakaway battery and store inside, out of the weather. Charge the battery at least every 90 days.

2. Jack up the trailer and place jack stands under trailer frame so that the weight will be off the tires. Never jack up or place jack stands on the axle tube or on the equalizers.

3. Lubricate mechanical moving parts that are exposed to weather, such as the hitch and suspen-sion parts.

NOTE: On oil lubricated hubs the upper part of the roller bearings are not immersed in oil and are subject to potential corrosion. For maximum bearing life it is recommended that you revolve your wheels periodically (every 2-3 weeks) during periods of prolonged storage.

After Prolonged Storage — Inspection Procedures

Before removing trailer from jack stands:

1. Remove all wheels and hubs or brake drums. Note which spindle and brake that the drum was removed from so that it can be reinstalled in the same location.

2. Inspect suspension for wear.

3. Check tightness of hanger bolt, shackle bolt and U-bolt nuts per recommended torque values.

4. Check brake linings, brake drums and armature faces for excessive wear or scoring.

5. Check brake magnets with an ohmmeter. The magnets should check 3.2 ohms. If shorted or worn excessively, replace.

6. Lubricate all brake moving parts using a high temperature brake lubricant. (Lubriplate or equiva-lent).

Do not get grease or oil on brake linings or magnet face.

7. Remove any rust from braking surface and armature surface of drums with fine emery paper or crocus cloth. Protect bearings from contamination while so doing.

8. Inspect oil or grease seals for wear or nicks. Replace if necessary.

9. Lubricate hub bearings. Refer to procedure in manual.

10. Reinstall hubs and adjust bearing per instructions in manual.


20

Maintenance

Troubleshooting

Problem Possible Cause Solution

LOW OPERATING PRESSURE

Faulty pressure gauge Install new gauge.

Insufficient water supplyUse larger supply hose; clean filter at water inlet.

Old, worn or incorrect spray nozzleMatch nozzle number to machine and/or replace with new nozzle.

Belt slippage Tighten or replace; use correct belt.

Plumbing or hose leakCheck plumbing system for leaks. Re-tape leaks with Teflon tape.

Faulty or mis-adjusted unloader valveAdjust unloader for proper pressure. Install repair kit when needed.

Worn packing in pump Install new packing kit.

Fouled or dirty inlet or discharge valves in pump

Clean inlet and discharge valves.

Worn inlet or discharge valves Replace with valve 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 airCheck 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 tank with fuel.

Improper fuel or water in fuel Drain fuel tank and fill with proper fuel.

Clogged fuel line Clean or replace.

Plugged fuel filter Replace as needed.

Mis-adjusted burner air bands Readjust air bands for clean burn.

Little or no fuel pressure from fuel pumpIncrease fuel pressure to specification and/or replace fuel pump. Test with pressure gauge.

Faulty burner transformerTest transformer for proper arc between contacts. Replace as needed.

Disconnected or short in electrical wiringAll wire contacts should be clean and tight. No breaks in wire.

Flex coupling slipping on fuel pump shaft or burner motor shaft

Replace if needed.

On-Off switch defectiveCheck for electrical current reaching burner assembly with burner switch on.

Heavy sooting on coil and burner can cause interruption of air flow and shorting of elec-trodes

Clean as required.

Improper electrode settingCheck and reset according to diagram in Operator's Manual.

Fuel not reaching combustion chamber

Check fuel pump for proper flow. Check solenoid flow switch on machines with spray gun control, for proper on-off fuel flow control.


21

Maintenance

BURNER WILL NOT LIGHT

Clogged burner nozzle Clean as required.

Thermostat faulty or slow engine speed Increase engine RPM to increase voltage.

Flow switch malfunctionRemove, 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 airCheck water supply and air seepage at joints in suction line.

Worn piston packing Check and replace if necessary.

Gasoline engine altitude

The gasoline engine is preset for operation at altitudes below 1000 ft above sea level. If operated at higher altitudes, it may be necessary to install a high altitude main jet in the carburetor. Contact your local authorized engine sales and service center for details.

MACHINE SMOKES WHILE BURNER UNIT IS

RUNNING OR UNIT SMOKES AT

COLD-START ONLY WHEN

BURNER IS OFF

Improper fuel or water in fuel Drain tank and replace contaminated fuel.

Improper air adjustment Readjust air bands on burner assembly.

Fuel pressure is low <140 psi for burner Adjust fuel pump pressure to specifications.

Burner nozzle is plugged or dirtyReplace nozzle. Check parts breakdown for nozzle size.

Burner nozzle spray pattern is faultyReplace nozzle. Check parts breakdown for nozzle size.

Heavy accumulation of soot on coils and burner assembly

Remove coils and burner assembly, clean thoroughly or Call local dealer.

Misaligned electrode setting Realign electrodes to specifications

Obstruction in smoke stackCheck for insulation blockage or other foreign objects

Low engine RPM Increase RPM

Fuel Pressure is too high for clean burn (fuel PSI above 140 and below 200) and smokes when burner is off

Reduce fuel pressure PSI/Increase air band set for cleaner without max water heat loss

LOW WATER TEMPERATURE

Improper fuel or water in fuel Replace with clean and proper fuel.

Low fuel pressure Increase fuel pressure.

Weak fuel pumpCheck fuel pump pressure. Replace pump if needed.

Fuel filter partially clogged Replace as needed.

Soot build-up on coils not allowing heat transfer

Clean coils.

Improper burner nozzle See Burner Specifications.



22

Maintenance

TroubleshootingProblem Possible Cause Solution

WATER TEMPERATURE

TOO HOT

Incoming water to machine warm or hot Lower incoming water temperature.

Fuel pump pressure too high See specifications for proper fuel pressure.

Fuel pump defective Replace fuel pump.

Detergent line sucking airTighten all clamps. Check detergent lines for holes.

Defective temperature switch Replace.

Incorrect fuel nozzle size See specifications for proper fuel nozzle.

Insufficient water supplied Check water G.P.M. to machine.

Restricted water flow Check nozzle for obstruction, proper size.

PUMP NOISY

Air in suction lineCheck water supply and connections on suction line.

Broken or weak inlet or discharge valve springs

Check and replace if necessary.

Excessive matter in valves Check and clean if necessary.

Worn bearings Check and replace if necessary.

PRESENCE OF WATER IN OIL

Oil seal worn Check and replace if necessary.

High humidity in air Check and change oil twice as often.

WATER DRIPPING FROM UNDER

PUMP

Piston packing worn Check and replace if necessary.

O-Ring plunger retainer worn Check and replace if necessary.

Cracked piston Check and replace if necessary.

Pump protectorLower water supply pressure. Do not run with spray gun closed longer than 2 minutes.

OIL DRIPPING Oil seal worn Check and replace if necessary.

EXCESSIVE VIBRATION IN

DELIVERY LINEIrregular functioning of the valves Check and replace if necessary.

DETERGENT NOT DRAWING

Air leakTighten all clamps. Check detergent lines for holes.

Restrictor in float tank is missingReplace restrictor. Check for proper orifice in restrictor.

Filter screen on detergent suction hose plugged

Clean or replace.

Dried up detergent plugging metering valve Disassemble and clean thoroughly.

High viscosity of detergent Dilute detergent to specifications.

Hole in detergent line(s) Repair hole.

Low detergent level Add detergent, if needed.


23

Maintenance

PUMP RUNNING NORMALLY BUT PRESSURE LOW

ON INSTALLATION

Pump sucking airCheck water supply and possibility of air seepage.

Valves sticking Check and clean or replace if necessary.

Nozzle incorrectly sizedCheck and replace if necessary (See serial plate for proper size).

Unloader valve seat faulty Check and replace if necessary.

Worn piston packing Check and replace if necessary.

BURNER MOTOR WILL NOT RUN

Fuel pump seized Replace fuel pump.

Burner fan loose or misaligned Position correctly, tighten set screw.

Defective control switch Replace switch.

Loose wire Check and replace or tighten wiring.

Defective burner motor Replace motor.

RELIEF VALVE LEAKS WATER

Relief valve defective Replace or repair



24

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 preventative 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.

Oil Change Record

Check pump oil level before first use of your new Power Washer. Change pump oil after first 50 hours and every 3 months or 500 hours thereafter. Use SAE 10W-40 weight oil, non-detergent.

Maintenance Schedule

Engine Oil

Inspect Daily

Change Every 25 hours

Filter Every 50 hours

Air CleanerInspect 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-detergent SAE

10W-40)

Inspect Oil level daily

ChangeAfter 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 Nozzle Every 6 months

Replace Quick Connects Annually

Clean Water Screen/Filter Weekly

Replace HP Hose Annually or as needed

Diverter Valve Cable Lube Cable Weekly

Date Oil ChangedMonth/Day/Year

No. of Operating HoursSince Last Oil Change

Brand Name & Type of Oil (see above)


25

Preventative Maintenance

This trailer 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 preventative maintenance procedures will assist in preserving the performance of your equipment.

Axles, Hubs and Brakes

Maintenance for axles, hubs and brakes is extremely important for protecting the longevity of your trailer. It is extremely important for your personal safety and the protection of others.

Never shortcut axle, hub and brake service and maintenance

Maintenance Schedule

Tire Air PressureInflate to proper pressure indicated on sidewall

Every Trip

Wheel Lugs, Bolts, Nuts ans Wheel Mount

Tighten to proper torque specifications Every 3000 mi or 3 mos.*

Wheel Check for damage and or out-of-round Every 6000 mi or 6 mos.

Coupler Ball

Check for sufficient lube.

Check lock mechanism.

Check for unusual wear. Every trip

Safety Chains at Hitch Ball

Check for abrasion, distortion and general integrity of links.

Every trip

CouplerCheck for proper fastening & hitch pin in position and secure.

Every trip

Brakes Check for proper adjustment & operation Every trip

Breakaway Switch Test switch operation and connections Every trip

Breakaway Battery Pull switch pin, check charge indicator light Every trip

Load Distribution Check load distribution & security Every trip

WeldsCheck all weld beads for cracks or separa-tions

Every 6000 mi. or 6 mos.

Electrical: Lights & Signals

Check to make sure all are working properly. Replace burned out bulbs.

Every trip

*Check lug nuts for tightness before initial trip, at 10 miles, 25 miles and 50 miles. Recheck at least every 3 months or 3000 miles


26

Notes


27

Parts

Parts

1.103-843.0

TRK-2500 HDS


28

TRK-2500 HDS

98077950-2

121

25

64

121

47

113

52

66

80

63

8047

69

70

71

66

36

27

88

9150

2214

2261

53

76

7574

73

7214

59

60

116

62

SeeControl

Panel Illus.For Detail

11

20

27

94

103104

103

110107

108

111

111

110

109

109117

106

106

105109

110

109

110

109

115

117

110

114

118

27

119 27

To Burner PumpFrom BurnerReturn


29KÄRCHER TRAILER SERVICE MANUAL • 9.807-795.0-C

TRK-2500 HDS

98077950-3

To Tan

k

31

77

2

68

78

8423 86

121

120

83

44

46a

37

79

55

48

101

122

2941

4015

81

31

35

3389

8239

9030

13

30

48

18

34

34

5

6

38

12

17

19

42

8216

8

1

9

7

2a

10

51

To Water Tank

To Water Tank

See PumpAssembly

46

26

121

45

49

40

28

6735

65

56

54

58

87

25

21

93

43

35

5392

9697

98, 99,100

95

49

102

8598

32

109117

Engine CarbPort

30

TRK-2500 HDS

REF PART NO. QTY DESCRIPTION NOTES

1 9.803-014.0 1 COIL, RODLESS

2 9.803-005.0 1 TOP WRAP, SS

2a 9.802-071.0 6 ft. TRIM

3 9.802-902.0 1 INSULATION/BLANKET, DIE CUT 28" X 24"

4 9.802-896.0 1 INSULATION/BLANKET, NO FOIL, 24" X 57"

5 9.802-883.0 1 INSULATION, BURNER HEAD, NO HOLE

6 9.803-006.0 1 WELDMENT, BOTTOM WRAP, SS

- 9.802-727.0 2 BOLT, 3/8" - 16 X 1-3/4" NOT SHOWN

7 9.802-894.0 1 INSULATION, BURNER HEAD, W/HOLE

8 9.802-766.0 8 SCREW, 3/8" X 1" HX WASH HEAD, SHEET METAL

9 8.933-009.0 2 GASKET, BURNER PLATE

10 9.803-132.0 2 PLATE, INSULATION RETAINER

- 9.802-797.0 8 SCREW, SS #10, HH TEK NOT SHOWN

11 9.802-054.0 1 ELBOW, ZINC

12 8.706-140.0 1 COUPLING, 1/2"

13 8.918-428.0 1 HOSE 3/8" X 48", 2 WIRE PRESSURE

14 9.802-053.0 3 BUSHING, RUBBER

15 9.802-869.0 1 BLOCK, UNLOADER, 1/2" X 1/2", BRASS

16 8.707-381.0 1 RUPTURE DISC ASSY, 8500#

17 9.149-003.0 1 DISCHARGE MANIFOLD

18 9.802-014.0 1 NIPPLE, PIPE 1/2" X 3" SCH 80

19 9.802-171.0 1 NIPPLE, 3/8" X 3/8" NPT, MALE

20 8.922-541.0 1 PLATE, DIESEL TANK, CARB

21 9.802-260.0 2 ft HOSE, 5/8" PUSH-ON

22 9.803-531.0 2 DIPTUBE ASSY, PLASTIC, 10.00" LONG

23 8.725-306.0 1 FILTER, FUEL OIL/H2O SEPARATOR

25 6.390-126.0 3 CLAMP, HOSE

26 8.706-941.0 1 HOSE BARB, 1/4" BARB X 1/4" PIPE

27 9.802-799.0 9 SCREW, #14 TEK, BLACK, ZINC

28 - - PUMP, SEE SPECIFICATION PAGES

29 8.750-299.0 1 UNLOADER VRT3, 8 GPM @ 4500 PSI

30 9.802-039.0 3 ELBOW, 1/2" JIC X 3/8" NPT STEEL

31 9.802-152.0 2 SWIVEL, 3/4" PUSH-ON

32 8.918-421.0 1 HOSE, PRESSURE, 3/8" X 16"

33 9.802-259.0 6 ft. HOSE, 1/2" PUSH-ON

34 9.802-261.0 4 ft. HOSE,3/4" PUSH-ON

35 9.802-151.0 4 SWIVEL, 1/2" JIC, PUSH-ON

36 9.800-008.0 1 LABEL, COOL ENGINE

37 8.750-737.0 1 ADAPTER, HONDA, M20-1.5 X 3/8 " FPT

38 8.706-248.0 1 PLUG, 3/8"

39 8.706-207.0 1 ELBOW, STREET, 3/8"

40 9.802-036.0 2 NIPPLE, 1/2" JIC X 3/8" MPT STEEL


31

TRK-2500 HDS

41 9.802-048.0 1 SWIVEL, 1/2" JIC FEMALE, 3/8" MALE

42 9.916-012.0 1 SCREW, 10-24 X 1/4"

43 9.802-126.0 1 PLUG, 1/2" FLARE

44 - - ENGINE, SEE SPECIFICATION PAGES

- 9.802-673.0 1 KEY, SHAFT NOT SHOWN

45 8.750-467.0 1 MUFFLER, HONDA, GX630/GX660, RIGHT

- 8.739-597.0 2 BOLT, FLANGE, M8 X 20 NOT SHOWN

46 9.803-008.0 1 HEAT SHIELD

- 9.802-761.0 4 SCREW, M6 X 20MM, BH NOT SHOWN

46a 8.915-387.0 1 DEFLECTOR, EXHAUST 1-3/8"

- 9.802-798.0 1 SCREW, #10 - 1/2" TEK, HH, SS NOT SHOWN

47 9.800-007.0 2 LABEL, WARNING, EXPOSED PULLEYS

48 9.803-004.0 2 PUMP/RAIL GENERATOR

- 9.802-720.0 6 BOLT, 3/8" X 1", NC HH NOT SHOWN

- 9.802-099.0 6 WASHER, SNUBBING NOT SHOWN

- 9.802-814.0 6 WASHER, 3/8", LOCK NOT SHOWN

- 9.802-779.0 6 NUT, 3/8" ESNA, NC NOT SHOWN

49 9.803-009.0 2 BRACKET, BELT TENSION

- 9.802-776.0 4 NUT, 5/16", ESNA, NC NOT SHOWN

- 9.802-710.0 4 BOLT, 5/16", NC NOT SHOWN

- 9.802-804.0 4 WASHER, 5/16", FLAT NOT SHOWN

50 9.802-060.0 6 MOUNT, RUBBER

51 8.750-099.0 1 THERMOSTAT 302°F

52 9.802-754.0 8 SCREW, 1/4"-20 X 1/2" HH,WL

53 9.802-794.0 11 CAGE NUT, 1/4" X 12 GA

54 9.802-728.0 4 BOLT, 3/8" X 2" NC HH

55 9.802-527.0 1 WINCO GENERATOR

- 8.752-150.0 1 CORD, MOLDED NOT SHOWN

56 9.802-999.0 1 WELDMENT, SUB-FRAME

57 9.802-998.0 1 WELDMENT, FRAME, BLACK

58 9.802-807.0 8 WASHER, 3/8", SAE, FLAT

59 8.706-615.0 1 FUEL TANK, 8 GALLON

60 9.802-089.0 1 CAP, FUEL, PLASTIC

61 9.800-002.0 1 LABEL, CAUTION, DIESEL

62 9.800-001.0 1 LABEL, CAUTION, UNLEADED

63 9.803-251.0 1 WELDMENT, BELT GUARD, LONG, BLACK

64 9.803-000.0 1 WELDMENT, FACE PLATE, LONG, BLACK

65 9.802-730.0 2 BOLT, 3/8" X 2-1/2" ZINC

66 8.750-246.0 4 SCREW, 1/4" X 1/2" WHIZ LOC

67 9.802-259.0 12" HOSE, 1/2" PUSH-ON

68 9.802-781.0 7 NUT, 3/8", FLANGE WHIZ LOC

69 9.802-397.0 1 BUSHING, H X 5/8"

70 - - ENGINE BUSHING, SEE SPECIFICATION PAGES



32

TRK-2500 HDS


71 9.802-403.0 1 BUSHING, PUMP, H X 25 MM

72 - - BELT, SEE SPECIFICATION PAGES

73 - - PULLEY, SEE SPECIFICATION PAGES


75 - - BELT, SEE SPECIFICATION PAGES


77 - -BURNER ASSEMBLY, SEE BURNERSPECIFICATION PAGE

- 9.802-424.0 3.66 ft. CORD, SEO, 16/4 NOT SHOWN

- 9.802-519.0 1 STRAIN RELIEF, 1/2" NOT SHOWN

78 8.752-113.0 1 ADAPTER, 1/4"

79 9.802-039.0 1 ELBOW, 1/2" MJIC X 3/8" MNPT

80 9.800-006.0 2 LABEL, HOT

81 9.802-043.0 1 ELBOW, 1/2" FNPT X 1/2" MJIC, 90°

82 9.802-024.0 2 ELBOW, 1/2" FPT X 3/8" MPT

83 9.802-254.0 2 FUEL LINE, 1/4" 60"

84 8.752-114.0 1 NIPPLE, 1/4"

85 9.802-587.0 30" INSULATION, 1/2" FIBER SLEEVING

86 8.706-958.0 2 HOSE BARB, 90°, 1/4" BARB X 1/4" PIPE

87 9.802-779.0 2 NUT, 3/8" ESNA, NC

88 9.802-804.0 12 WASHER, 5/16", FLAT, SAE

89 9.802-013.0 2 NIPPLE, 1/2" X 2-1/2", GALVANIZED SCH 80 PIPE

90 8.933-006.0 1 SWITCH, MV60

91 9.802-776.0 12 NUT, 5/16", ESNA, NC

92 9.802-872.0 2 TAB, BELT GUARD

93 9.802-753.0 4 SCREW, 1/4" X 3/4"

94 9.802-754.0 4 SCREW, 1/4" X 1/2"

95 9.802-720.0 4 BOLT, 3/8" X 1 NC HH

96 9.802-779.0 4 NUT, 3/8"

97 9.802-807.0 8 WASHER, 3/8"

98 9.802-254.0 30" HOSE, 1/4" PUSH-ON

99 9.802-753.0 1 SCREW, 1/4" X 3/4" WHIZ LOC

100 9.802-775.0 1 NUT, 1/4" FLANGE

101 9.802-015.0 1 NIPPLE, 1/2" X 4", SCH 80 ZINC

102 8.718-781.0 1 SCREW, PAN HEAD

103 9.802-512.0 2 CABLE TIE, 48"

104 8.751-057.0 1 GAS CAP, W/GAUGE & TETHER

105 9.802-773.0 2 NUT 14-20 ESNA, NC

106 9.802-802.0 6 WASHER, 1/4" FLAT, SAE ZINC

107 8.751-059.0 1 VENT, REMOTE ASSEMBLY, CARB

108 8.751-215.0 1 GROMMET REMOTE VENT, KELCH

109 8.753-065.0 4 CLAMP, 1 EAR, #10

110 8.753-066.0 4 CLAMP, 1 EAR, #7


33

TRK-2500 HDS

111 8.753-270.0 2 REDUCER, CONNECTOR 1/4" X 3/8"

112 8.751-380.0 1 CARBON CANISTER, 850CC

113 8.922-633.0 1BRKT, 850CC CANISTER MOUNT WRINKLE BLACK

114 9.802-254.0 6" HOSE, 1/4" PUSH-ON

115 9.802-254.0 50" HOSE, 1/4" PUSH-ON

116 8.752-915.0 1 FUEL TANK, 7.25 GALLON

117 8.711-785.0 9" HOSE, 3/8" PUSH-ON

118 8.752-918.0 1 CLAMP, HOSE, #64

119 8.922-540.0 1 PLATE, GAS TANK, CARB

120 8.754-911.0 1 CHECK VALVE, 1 WAY, 1/4" BARB

121 8.709-069.0 4 CLAMP, SCREW, 5/16" W, 1/4"-5/8" D, SS

122 9.802-201.0 1 CLAMP,SCREW, 9/16"W, 7/8"OD, SS



34

TRK-2500 Trailer

98077950-6

PUMP INLET SELECTION HANDLE

VALVE POSITION

FROM FRESH

WATER INLET

TO PUMP

VALVE POSITION

FROM WATER

TANK TO PUMP

8.920-368.0

1

23

4

5

11

12

13

2415

8

9

10

1617

22

23

19

20

25

26

27

28

32

33

52

30

31

34

35

38

39

40

45

41

42

4647

49

67

36

37

6850

28

29

31

33

35

353135

33

35

31

35

33

36

3432

28

38

26

44

4320

20

30

48

28

21

1459

59

31

51

33

51

53

18

5457

60

6126

55

56

To Unloader valve

33

58

60

See Hose Reel Pages

31, 33, 35

7

62

63

60

6566

64

69(Breakaway Kit)



TRK-2500 Trailer


1 8.917-302.0 1 WLMT, FRAME, TRAILER, 3000#

2 8.924-294.0 1 WLMT, TONGUE, ADJUST HEIGHT

3 8.917-304.0 2 FENDER, W/BACK, 15", PAINTED

4 8.917-305.0 1 WLMT, HOOP, HOSE REEL

5 8.725-543.0 1 ROD, TIE-DOWN, TANK

6 9.122-002.0 2 HOSE REEL, 100' FIXED BASE

7 8.755-000.0 1 COUPLER, 2" BALL, 2X3" ADJST HG

8 8.917-341.0 1 BAR, TANK TIE-DOWN

9 8.725-525.0 1 TANK, WATER, 200 GAL

- 8.704-744.0 1 LID, 8" THREADED W/AIR BREATHER NOT SHOWN

10 8.754-184.0 1 JACK, SWIVEL W/CASTER,1200 LB

11 8.725-529.0 2 WHEEL/TIRE ASSY, 15" ST205/75D15 TI

12 8.725-530.0 2 LAMP, TAIL, 3-WAY

13 8.725-531.0 2 LAMP, SIDE MARKER, RED

14 8.725-532.0 2 LAMP, SIDE MARKER, AMBER

15 8.725-533.0 1 LAMP, LICENSE W/HOLDER

16 8.707-497.0 7.5 ft CHAIN, 5/16" ZINC PLATED 2 X 45" LONG

17 8.707-510.0 1 CONNECTOR, SOCKET, 7-PRONG

18 8.707-511.0 1 PLUG, 7-PRONG

19 8.725-540.0 1 AXLE, 3500 LB., 57", ELECTRIC BRAKES

20 8.706-412.0 3 BUSHING, 1" X 3/4" MT X FT, PVC 80 SPEERS O

21 9.802-132.0 1 ELBOW, 3/4" JIC X 1/2", 90°

22 8.707-498.0 2 HOOK, "S", 5/16" ZINC PLATED

23 8.707-526.0 1 STRAINER, 1" T LINE, TRAILERS

24 9.802-798.0 2 SCREW, #10 X 1/2" TEK, HH

25 9.800-047.0 2 LABEL, KÄRCHER, FRAME LABEL

26 9.802-052.0 3 BULKHEAD, 3/4" POLYPRO

27 9.802-146.0 1 SWIVEL, 1/2" MP X 3/4" GHF W/STRAINER

28 9.802-152.0 4 SWIVEL, 3/4" FEM, PUSH-ON

29 9.802-261.0 24" HOSE 3/4", PUSH-ON

30 8.718-760.0 2 SCREW, 10/32 X 5/8 PHIL PAN, SS

31 9.802-722.0 34 BOLT, 3/8" X 1-1/4", NC HH

32 9.802-696.0 2 NUT, 10/32" NF ST ST KEP

33 9.802-779.0 40 NUT 3/8", ESNA, NC

36 9.802-812.0 14 WASHER, 3/8" X 1-1/2", SAE

37 8.706-738.0 2 PLUG, 3/4", HOLE

38 8.706-899.0 2 NIPPLE, 3/4" JIC X 3/4" PIPE

39 9.802-724.0 2 BOLT, 3/8" X 1-1/2", NC, SS

40 8.900-522.0 2 LABEL, CLP WARNING, DO NOT STAND OR STEP

36

TRK-2500 Trailer


41 9.802-780.0 2 NUT, 3/8" STAINLESS, NC

42 8.706-731.0 7 BUSHING, 3/4" SNAP HEYCO

43 8.706-369.0 1 NIPPLE, 3/4", PVC 80, CLOSE

44 8.710-036.0 1 FLOAT VALVE 1" HUDSON

45 8.718-592.0 1 SCREW,1/4" X 1-1/4", 10-24

46 8.719-079.0 1 KNOB, BLK PLASTIC,10-24 THDS

47 8.719-112.0 1 SPRING, 0.31OD X 1.0, STEEL, GEN WIRE J-1450

48 8.917-463.0 1 LATCH, WAND HOLDER

49 8.917-319.0 2 BRACKET, ALIGNMENT, TANK

50 9.802-171.0 1 COUPLER, 3/8" PLUG, MALE, STEEL/ZINC

51 9.803-557.0 2 ELBOW, 3/4" MSAE X 3/4" MPT, BRASS

52 9.802-261.0 51” HOSE, 3/4" PUSH-ON

53 8.706-890.0 1 ELBOW, 1/2" MSAE x 3/4" MPT, BRASS

54 8.917-329.0 1 PLATE, KARCHER, S.S.

55 8.709-890.0 1 ELBOW, 1/2" MSAE x 3/4" MPT, BRASS

56 8.726-136.0 2 HOOK, LATCHING

57 8.718-607.0 2 BOLT, 1/4-20 X 3/4", CARRIAGE,PLT 615952

58 8.920-368.0 1 LABEL, PUMP INLET SELECTION

59 8.752-041.0 4 GROMMET, LIGHT, 2"

60 9.802-802.0 5 WASHER, 1/4" FLAT SAE ZINC

61 9.802-773.0 5 NUT, 1/4-20 ESNA NC

62 8.755-310.0 2 SCREW, 5/8-11 X 4.50 HHCS ST GR5 CUST

63 8.755-309.0 2 NUT, 5/8-11 HEX TOP LK STL GR9 CUST

64 8.755-291.0 1 LABEL, NATM COMPLIANCE

65 - 1 VIN PLATE LABEL

66 - 1 TIRE PLACARD LABEL

67 8.706-395.0 1 PLUG, 2" PVC 80

68 8.706-294.0 1 BUSHING, 1/2" X 3/8", STEEL P/N-5406-

69 8.707-506.0 1 BREAKAWAY KIT, W / BATTERY

- 8.912-403.0 1 BRACKET, BREAK-AWAY, TRAILERS NOT SHOWN

- 9.802-701.0 3 BOLT, 1/4-20 X 1" HEX HEAD ZINC NOT SHOWN



Control Panel


1 9.803-693.0 1 BOX, PLASTIC, BACK

2 9.802-482.0 1 BOX, PLASTIC, FRONT, FABRICATED

3 8.750-094.0 1 THERMOSTAT, 302°F

- 9.804-072.0 42" WIRE , COVER NOT SHOWN

4 9.802-700.0 4 BOLT, 1/4" X 3/4" HH NC

- 9.802-775.0 4 NUT, 1/4" FLANGE ZINC NOT SHOWN

5 9.800-043.0 1 DECAL, 120V ELECTRICAL BOX

6 9.802-455.0 1 120V INDICATOR LIGHT, GREEN

7 9.802-283.0 1 HOUR METER

8 9.802-453.0 1 SWITCH, CURVETTE

9 8.750-096.0 1 KNOB, THERMOSTAT 302°F

10 8.712-190.0 1 BEZEL, THERMOSTAT

11 9.802-251.0 6 ft. HOSE, 1/4" X 1/2" CLEAR VINYL

12 9.803-003.0 1 WELDMENT CONTROL PANEL

- 9.802-762.0 1 SCREW, GROUND POST 10/32" X 1-1/4" NOT SHOWN

- 8.706-735.0 1 BUSHING, 1" SNAP NOT SHOWN

13 9.800-042.0 1 DECAL, OPERATING INSTRUCTIONS

14 9.802-064.0 4 GROMMET, RUBBER, NOZZLE HOLDER

15 9.800-049.0 1 LABEL, MANUFACTURER'S CLEANING SOLUTION

16 8.932-985.0 1 LABEL, KÄRCHER STRIPE

17 8.923-560.0 1 LABEL, WARNING, SUPER SKID

18 9.800-034.0 1 LEXAN, COVER, OUTDOOR

19 8.932-968.0 1 LABEL, OUTDOOR

20 9.803-250.0 4 NUT, (ELECTRICAL BOX)

21 8.718-779.0 2 SCREW, 4MM X 6MM

22 9.803-249.0 4 SCREW, M4 X 10

98077950-4

19

181

16

7 8

11

1322

20

14

15

12

17

4

25

1021

9

6

3

To Downstream Chemical Injector

38

Pump Assembly


1 8.921-716.0 1 PUMP, KÄRCHER KT6036R.2

2 9.802-187.0 1 VALVE, METERING

3 8.707-212.0 1 VALVE, 3-WAY

4 8.706-958.0 1 HOSE BARB, 1/4" X 1/4" 90°

5 6.390-126.0 2 CLAMP

6 8.932-974.0 1 LABEL, OPEN FOR STEAM

7 9.802-254.0 1 HOSE, 1/4" PUSH-ON

8 8.706-120.0 1 NIPPLE, 3/8" X 1/4" MPT

9 9.802-039.0 1 ELBOW, 1/2" JIC X 3/8" NPT 90°

10 8.706-902.0 1 NIPPLE, 3/4" JIC X 1/2" NPT 90°

11 9.902-146.0 1 SWIVEL, GARDEN HOSE

12 8.706-829.0 1 ELBOW, 1/2" STREET

13 8.705-975.0 1 NIPPLE,1/2" HEX

14 8.706-868.0 1 PLUG, 1/2"

15 9.802-123.0 1 TEE, 1/2" W/1/8" TAP

16 8.706-955.0 1 HOSE BARB, 1/4" BARB X 1/8" NPT 90°

98077950-10

95

15

64

1

14

1312

103

11

5

16

72

8



Hose & Spray Gun Assembly


1 8.917-060.0 1 HOSE, 3/8” X 50’, 2 WIRE TUFF FLEX

2 8.710-384.0 1 GUN, TRIGGER, ST-1500

3 9.802-222.0 1 VP WAND

4 9.802-299.0 1 NOZZLE, 0005, RED

- 9.802-300.0 1 NOZZLE, 1505, YELLOW

- 9.802-301.0 1 NOZZLE, 2505, GREEN

- 9.802-302.0 1 NOZZLE, 4005, WHITE

5 9.802-286.0 1 NOZZLE, 1/8" SOAP

6 9.802-166.0 1 COUPLER, 3/8" BRASS

98077950-5

2

4

5

3

1

6

40

TRK-2500 With HDS Washer

98077950-7

TO REDUCE THE RISK OF INJURY, READ OP-

ERATING INSTRUCTIONS CAREFULLY BEFORE

USING. This m

achine is to be used only b

y

qualifi ed operators.

LIRE LE MANUEL DE L'OPERATEUR AVANT

UTILISATION. Cet appareil doit être utilis

e par

des operateurs qualifi es.

LEA EL MANUAL OPERACION ANTES DE US-

ARSE. Este equipo debe ser usado solamente

por operadores califi cados.

RISK OF ASPHYXIATION. Use this product

only in a well ventila

ted area.

RISQUE D'ASPHYXIE. Utiliser dans un en-

droit bien aéré.

RIESGO DE ASFIXIA. Use el producto en un

area de ventilación adecuada.

RISK OF EXPLOSION. Operate only where open fl a

me or torch is per-

mitted. D

o not spray fl ammable liq

uids. RISK OF FIRE. D

o not add fuel

when the machine is operating.

RISQUE D'EXPLOSION. Utilis

er aux endroits où une fl amme nue est

per-

mise. Ne pas va

poriser de liq

uides infl ammables.

RISQUE DE FEU. Ne

pas ajouter de carburant diesel pendant que la machine est en opération.

RIESGO DE EXPLOSION Use el producto en áreas donde el fuego o l

lama

sean permitidos. N

o rocie liquidos in

fl amables. RIESGO DE FUEGO. N

o

añadir gasolina cuando la máguina este tra

bajando.

RISK OF INJECTION OR SEVERE INJURY TO PERSONS. Keep clear

of nozzle. H

OT DISCHARGE FLUID. Do not to

uch or direct discharge

stream at persons.

RISQUE DE BLESSURES. Se tenir loin des b

uses. EAU CHAUDE SOUS

PRESSION A LA SORTIE. Ne pas diriger le

jet d'eau vers des personnes.

RIESGO DE PENETRACIÓN O LESIONES SEVERAS A PERSONAS. Man-

téngase fuera del alcance de boquilla. D

ESCARGA DE AGUA CALIENTE

A ALTA PRESION. No toque ni dirija

el fl ujo del agua o otras personas.

RISK OF INURY. PROTECTIVE EYEWEAR AND OTHER PROTEC

TIVE

CLOTHING MUST BE WORN when operating this machine.

RISQUE DE BLESSURE. Portez des lunettes de protectio

n et vêtements

protecteurs quand vous utilisez cette machine.

RIESGO DE LESIONES. Use lentes de seguridad y pr

oteja su

cuerpo a

dec-

uadamente cuando opere este equipo.

WARNING / AVERTISSEMENT / P

RECAUCION

RISK OF INJURY. HOT SURFACES CAN CAUSE

BURNS. Use only designed gripping areas of

spray gun and wand.

SURFACES CHAUDES. Toucher seulement le

s

parties isolées des poignée pistolets et la

nces.

SUPERFICIES CALIENTES. Use solamente las

áreas aisladas del gatillo y la lanza.

SPRAY GUN KICKS BACK . Hold with both hands.

LA POIGNEE PISTOLET REPOUSSE. Tenir à

deux mains.

LA PISTOLA SE MUEVE CON LA PRESIÓN.

Sostenga con las dos manos.

RISK OF ELECTROCUTION. Keep all connections dry and off the

ground. Keep spray away from electric

al wirin

g and components.

RISQUE D'ELECTROCUTION. Tous les fi ls

doivent être maintenus secs

et être suspendus. Ne jamais projeter d'eau sur le

s composantes et

fi ls électriq

ues.

RIESGO DE ELECTROCUCIÓN. Mantenga todas las connecciones se-

cas y arriba del suelo. N

o rocie componentes eléctricos.

DANGER

8.923-560.0

2

34

13

14

1

5

5

15

16

6

7

7

8

12

To Trailer Outlet

710

4

From Coil

Outlet

6

6

6

To Valve

5

17

9

11



TRK-2500 With HDS Washer


1 8.706-207.0 1 ELBOW, 3/8", STREET 90°, STEEL

2 9.802-171.0 1 NIPPLE, 3/8" X 3/8" NPT ST MALE

3 9.802-166.0 1 COUPLER, 3/8" FEMALE, BRASS

4 8.711-708.0 1 HOSE, 1/2" X 90" 2 WIRE, PRESSURE LOOP

5 9.802-722.0 12 BOLT, 3/8" X 1-1/4", NC HH

6 9.802-807.0 24 WASHER, 3/8" FLAT

7 9.802-779.0 12 NUT 3/8"

8 8.916-565.0 2 BRACKET, MOUNTING

9 8.917-495.0 1 BRACKET, BATTERY MOUNT

10 9.802-038.0 1 NIPPLE, 1/2" JIC X 1/2" STEEL

11 8.707-526.0 1 STRAINER, 1"

12 8.706-600.0 1 BATTERY BOX, M-100

13 9.802-216.0 1 INJECTOR, CHEM, NON ADJ, 3-5 GPM, 0.083

14 6.390-126.0 2 HOSE CLAMP

15 9.802-251.0 1 1/2", CLEAR VINYL

16 8.707-057.0 1 STRAINER, PLASTIC, 1/4" HOSE BARB

17 8.716-499.0 1 BATTERY, SEALED

- 9.802-204.0 1 CLAMP, HOSE, CL13 NOT SHOWN

- 9.802-799.0 1 SCREW, #14 X 1", TEK, BLK., ZINC NOT SHOWN

42

Hose Reel Low Pressure 8.917-555.0

NOTE: Garden hose not included


1 9.122-002.0 1 HOSE REEL,100 FT., FIXED BASE

2 9.802-132.0 1 ELBOW, 3/4" JIC X 1/2", 90°

3 8.706-834.0 1 ELBOW, 3/8" STREET, 45°

4 9.802-147.0 1 SWIVEL, 3/8" MP X 3/4" GHF W/STRAINER

5 9.802-152.0 2 SWIVEL, 3/4" FEM, PUSH-ON

6 9.802-261.0 30" HOSE, 3/4" PUSH-ON, /FT

7 9.802-171.0 1 COUPLER, 3/8" PLUG, MALE

8 9.802-722.0 4 BOLT, 3/8" X 1-1/4"

9 9.802-807.0 8 WASHER, 3/8" SAE, FLAT ZINC

10 9.802-779.0 4 NUT, 3/8", ESNA

11 8.706-984.0 1 ADAPTER, 1/2" FPT X 1/2" MPT, BRASS

12 9.802-052.0 1 BULKHEAD, 3/4" POLYPRO

13 8.706-397.0 1 PLUG, 3/4" MT, SCH 80 PVC

14 8.706-294.0 1 BUSHING, 1/2" X 3/8" STEEL

15 8.706-968.0 1 NIPPLE, 1/2" MPT X 3/4" GHM

98077950-8

10

15

8

2

34

9

6

9

5

11

15

714

12

13



Hose Reel High Pressure 8.917-554.0


1 9.122-002.0 1 HOSE REEL, BOLT ON 100 FT., FIXED BASE

2 9.802-036.0 1 NIPPLE, 1/2" JIC X 3/8" PIPE, STEEL

3 9.802-041.0 1 ELBOW, 3/8" STEEL, STREET, 45°

4 9.802-243.0 1 HOSE, 3/8" X 32", 2 WIRE

5 9.802-040.0 1 ELBOW, 1/2" , JIC , 1/2, 90°,

6 9.802-722.0 4 BOLT, 3/8" X 1-1/4"

7 9.802-807.0 8 WASHER, 3/8" SAE, FLAT ZINC

8 9.802-779.0 4 NUT, 3/8", ESNA

98077950-9

8

1

7

3

4

72

6

5

44

KNA Burner Wiring Diagram



Wiring Diagram

46

KT.2 Series Pump

Torque Specs

Item # FT. LBS

14 95

15 45

23 8

34 10

42 30

48 8

Kit Numbers 8.753-821.0 8.753-822.0 8.753-823.0 8.753-824.0 8.752-835.0

Kit DescriptionPlunger Seals

18 mm Seal Packing

18 mmPlunger 18 mm

Complete ValvePlunger Oil

Seals

Items Numbers Included

3, 5, 7 3, 4, 5, 6, 7, 34, 35, 36, 37 11, 12, 13 2

No. Of Cylinders Kit Will Service

3 1 1 6 3

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KT.2 Series Pump

*Available in kit

REF PART NO. QTY DESCRIPTION NOTES1 8.752-825.0 1 CRANKCASE

2* See Kit 3 PLUNGER OIL SEAL

3* See Kit 3 O-RING Ø1.78 X 37.82

4* See Kit 3 PRESSURE RING, 18MM

5* See Kit 3 U-SEAL, 18MM

6* See Kit 3 INTERMEDIATE RING, 18MM

7* See Kit 3 U-SEAL, 18MM

8 9.802-926.0 1 BRASS PLUG, G1/2

9 9.803-199.0 1 COPPER WASHER 1/2

10 8.753-816.0 1 MANIFOLD HOUSING

11* 9.804-498.0 6 O-RING Ø2.62 X 25.1

12* See Kit 6 VALVE ASSEMBLY

13* 9.803-193.0 6 O-RING 3068

14 9.802-928.0 6 VALVE PLUG

15 8.753-817.0 8 MANIFOLD STUD BOLT

16 9.802-890.0 8 LOCK WASHER

17 8.719-008.0 1 COPPER WASHER 3/8

18 8.707-262.0 1 BRASS PLUG 3/8

19 See Kit 6 VALVE SEAT

20 See Kit 6 VALVE PLATE

21 See Kit 6 VALVE SPRING

22 See Kit 6 VALVE CAGE

23 8.752-830.0 8 HEX SCREW

24 9.802-884.0 8 WASHER

25 9.803-182.0 1 CLOSED BEARING HOUSING

26 9.803-186.0 2 O-RING Ø2.62 X 71.12

27 9.803-160.0 2 ROLLER BEARING

28 8.753-818.0 1 CRANKSHAFT Ø25 (4540)

- 8.752-827.0 1 CRANKSHAFT Ø25 (6036)

29 9.803-167.0 1 CRANKSHAFT KEY

30 8.752-834.0 1 OIL DIP STICK

31 9.803-139.0 1 CRANKSHAFT SEAL

32 9.803-177.0 2 SHIM

33 9.803-181.0 1 BEARING HOUSING

34* 8.752-841.0 3 PLUNGER BOLT

35* 8.752-820.0 3 BONDED SEAL

36* 8.753-819.0 3 PLUNGER, 18MM

37* 8.752-823.0 3 COPPER SPACER

38 8.753-820.0 3 PLUNGER ROD

39 8.752-822.0 3 CONNECTING ROD PIN

40 8.752-821.0 3 CONNECTING ROD

41 9.802-889.0 6 SPRING WASHER

42 9.802-937.0 6 CONNECTING ROD SCREW

43 9.803-194.0 1 O-RING Ø2.62 X 152.07

44 8.752-826.0 1 CRANKCASE COVER

45 9.803-906.0 1 O-RING Ø1.78 X 14.00

46 8.707-262.0 1 BRASS PLUG G3/8

47 9.803-202.0 1 SIGHT GLASS G3/4

48 8.752-824.0 5 COVER SCREW

48

VRT3 Unloader

VRT3 Unloader Exploded View and Parts List

8.750-299.0, 8GPM, 4500 PSI

Unloader Adjustment Procedures

1.Remove lock nut (Item 19).

2.Remove adjustment knob (Item 18).

3.Loosen the two (2) nuts (Item 15), move them upward on stem (Item 8) until you see 4 or more threads below the nut.

4.Re-attach adjusting knob (Item 18).

5.Start machine. Open the trigger of the spray gun. Increase pressure by turning adjustment knob (Item 18) clockwise until pressure is at the desired operating pressure.

6. Remove the adjustment knob (Item 18), tighten the lower nut (Item 15) tightly against the upper nut (Item 15). Re-attach adjustment knob (Item 18) and screw down until contact is made with the nuts (Items 15). Screw down lock nut (Item 19) onto the stem (Item 8) until the threads cut into the nylon insert 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 “spike” SHOULD NOT exceed 500 psi above the operating pressure. If “spike” pressure exceeds the 500 psi limit, remove the adjusting knob (Item 18) and re-adjust (lower) the nuts (Items 15) on the stem (Item 8). Re-attach the adjusting knob (Item 18), then repeat step #6.

Item Part # QTY Description

18 8.750-712.0 1 OUTLET FITTING

25 8.750-713.0 1 KNOB, UNLOADER

- 8.750-710.0 -REPAIR KITVRT3 4500 PSI

Repair Kit Items: 3, 4, 6, 9-12, 16, 21, 24

9

8

23

26

2

3

16

1

10

24

11

6

4

13

14

20

25

12

22

19

15

15

21

17

18

7

9

5

6


49

Specifications

Parts Specifications

KNA Burner Specifications

Pump EnginePump Model

Part # Unloader PulleyPulley Part #

BushingBushingPart #

Engine Model

EnginePart #

EnginePulley

KT6036 8.921-716.0 8.750-299.0 2BK100H 9.802-391.0 25MM 9.802-323.0 GX630 8.752-149.0 3TB34H

Engine GeneratorPulley Part #


BeltSize

BeltPart #

PulleyPulley Part #

BeltPart #


9.802-392.0 P2 X 1 9.802-404.0 BX44(2) 9.802-421.0 BK34H 9.802-378.09.802-414.0

5/8” 9.802-397.0

BurnerAssy #

Fuel Nozzlew/ 100 PSI

Check ValveIgniter

BurnerMotor

Fuel/PumpSolenoid/Cord

FuelSolenoid Coil

Electrode

8.920-645.0 8.754-892.0 8.919-114.0 8.752-930.0 8.700-759.0 9.802-645.0 8.750-778.0


9.807-795.0 • Printed in U.S.A.

Date post:	18-Oct-2019
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