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  5. Operator's Manual

Karcher 1.575-615.0 Operator's Manual

Manual is about: HDS 4.0/32; 5.0/32; 5.5/35 Pe Cage

Summary of 1.575-615.0

  • Page 1

    9.800-103.0-m 11/02/17 hds 4.0/32 pe cage - 1.575-615.0 hds 5.0/32 pe cage - 1.575-616.0 hds 5.5/35 pe cage - 1.575-617.0 operator’s man u al to locate your local kärcher commercial pressure washer dealer nearest you, please visit www.Karchercommercial.Com warning: this product and accessories may c...

  • Page 3: Contents

    3 contents model number ______________________________ serial number ______________________________ date of purchase ___________________________ the model and serial numbers will be found on a decal at tached to the pressure washer. You should record both serial number and date of purchase and keep ...

  • Page 4: Important Safety

    9.800-103.0 - m • karcher hds 615-617 opera t or’s manu al pressure w asher 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...

  • Page 5: Important Safety Information

    9.800-103.0 - m • karcher hds 615-617 5 pressure w asher opera t or’s man u al 15. Be certain all quick coupler fi ttings are secured before using pressure washer. Risk of injection or severe injury to persons. Keep clear of nozzle. Warning warning: high pressure devel- oped by these machines will c...

  • Page 6: Important Safety Information

    9.800-103.0 - m • karcher hds 615-617 opera t or’s manu al pressure w asher 6 important safety information 23. Machines with shut-off spray gun should not be operated with the spray gun in the off position for extensive periods of time as this may cause dam- age to the pump. 24. Protect discharge ho...

  • Page 7: Component Identification

    9.800-103.0 - m • karcher hds 615-617 7 pressure w asher opera t or’s man u al component identification pump — delivers a specifi c gpm to the high pressure nozzle which develops pressure. Spray gun — controls the application of water and de ter gent onto cleaning surface with trigger device. In clu...

  • Page 8: Assembly Instructions

    9.800-103.0 - m • karcher hds 615-617 opera t or’s manu al pressure w asher 8 assembly instructions step 1: attach the high pres sure hose to the spray gun using tefl on tape on hose threads. Step 2: remove wand end and first place the the high pressure nozzle as shown. Replace end of wand. Step 3: ...

  • Page 9: Operation Instructions

    9.800-103.0 - m • karcher hds 615-617 9 pressure w asher opera t or’s man u al step 6: pull the starter grip. If the engine fails to start after 2 pulls, squeeze the trigger gun to release pres sure and repeat step. Return start er gently. After the en gine warms up enough to run smoothly, move chok...

  • Page 10: Operation Instructions

    9.800-103.0 - m • karcher hds 615-617 opera t or’s manu al pressure w asher 10 98001030-4 operation instructions warning! Never replace noz zle without engaging the s a f e t y l a t c h o n t h e s p r a y gun trig ger. Safety latch step 9: turn the burner “on”. Turn thermostat dial to the 210° mar...

  • Page 11: Thermal Pump

    9.800-103.0 - m • karcher hds 615-617 11 pressure w asher opera t or’s man u al warning: some de ter gents may be harm ful if in haled or in gest ed, caus ing severe nau- sea, faint ing or poi son ing. The harm ful el e ments may cause prop er ty dam age or severe injury. Step 1: use detergent de si...

  • Page 12: Shutting Down and Clean-Up

    9.800-103.0 - m • karcher hds 615-617 opera t or’s manu al pressure w asher 12 shutting down and clean-up storage caution: al ways store your pressure washer in a lo ca tion where the temperature will not fall be low 32°f (0°c). The pump in this machine is sus cep ti ble to permanent dam age if fro ...

  • Page 13: Maintenance

    9.800-103.0 - m • karcher hds 615-617 13 pressure w asher opera t or’s man u al maintenance preventative maintenance 1. Check to see that water pump is properly lu bri cat ed. 2. Follow winterizing instructions to prevent freeze dam age to pump and coils. 3. Always neutralize and fl ush detergent fr...

  • Page 14: Maintenance & Service

    9.800-103.0 - m • karcher hds 615-617 opera t or’s manu al pressure w asher 14 maintenance & service when operating unit without a scale protection, the heater coil may become scaled. Rupture disk: if pressure from pump or thermal expansion should exceed safe limits, the rupture disk will burst allo...

  • Page 15: Troubleshooting

    9.800-103.0 - m • karcher hds 615-617 15 pressure w asher t roub leshooting guide troubleshooting problem possible cause solution low operating pressure faulty pressure gauge install new gauge. Insuffi cient water supply use larger supply hose; clean fi lter at water inlet. Old, worn or incorrect sp...

  • Page 16: Troubleshooting

    9.800-103.0 - m • karcher hds 615-617 pressure w asher t roub leshooting guide 16 troubleshooting problem possible cause solution burner will not light (continued from previous page) flex coupling slipping on fuel pump shaft or burner motor shaft replace if needed. On-off switch defective check for ...

  • Page 17: Troubleshooting

    9.800-103.0 - m • karcher hds 615-617 17 pressure w asher t roub leshooting guide troubleshooting problem possible cause solution low water temperature improper fuel or water in fuel replace with clean and proper fuel. Low fuel pressure increase fuel pressure. Weak fuel pump check fuel pump pressure...

  • Page 18: Troubleshooting

    9.800-103.0 - m • karcher hds 615-617 pressure w asher t roub leshooting guide 18 troubleshooting problem possible cause solution oil dripping oil seal worn check and replace if necessary. Excessive vibration in delivery line irregular functioning of the valves check and replace if necessary. Deterg...

  • Page 19: Preventative Maintenance

    9.800-103.0 - m • karcher hds 615-617 19 pressure w asher opera t or’s man u al this pressure washer was produced with the best avail able ma te ri als and quality craftsmanship. However, you as the own er have certain re spon si bil i ties for the correct care of the equip ment. At ten tion to reg ...

  • Page 20: Exploded View - Left Side

    9.800-103.0 - m • karcher hds 615-617 opera t or’s manu al pressure w asher 20 exploded view - left side see control box illus. For detail 96 74 73 72 77 71 79 11 80 70 48 81 69 82 57 58 78 49 52 54 51 52 55 66 65 64 56 60 62 63 61 59 83 84 to coil inlet to coil outlet 102 47 45 67 76 89 18 68 93 95...

  • Page 21: Exploded View - Right Side

    9.800-103.0 - m • karcher hds 615-617 21 pressure w asher opera t or’s man u al chaud! Exposed pulleys and bel ts can cause injur y precaucion/a ver tissement warning vangu ard 16 hp v-twin vangu ard exposed pul leys and be lts can cau se inju ry precauci on/a ver tis se me nt wa rning 98001030-9 ex...

  • Page 22: Exploded View Parts List

    9.800-103.0 - m • karcher hds 615-617 opera t or’s manu al pressure w asher 22 exploded view parts list item part no. Description qty 1 9.802-779.0 nut, 3/8" esna, nc 8 2 9.802-807.0 washer, 3/8” sae, flat 11 3 engine, please see specifi cation pages 4 9.809-728.0 bolt, 3/8" x 2" (honda only) 4 9.80...

  • Page 23: Exploded View Parts List

    9.800-103.0 - m • karcher hds 615-617 23 pressure w asher opera t or’s man u al exploded view parts list ghf, w/strainer 1 item part no. Description qty 72 8.706-600.0 box, battery, m-100 1 73 9.803-532.0 isolator, 5/16" thread, female x female, 1" x 1" 7 74 9.803-504.0 bracket, battery 1 75 9.803-2...

  • Page 24: Control Box

    9.800-103.0 - m • karcher hds 615-617 opera t or’s manu al pressure w asher 24 98001030-6 burner on / off quemador i / o temper ature tempe rtura rm 110 burner fue l deter gent deter gente 0 2 8 1 4 9.800-138.0 ® for be st res ul ts use deter gent control box 22 23 16 12 37 10 30 11 1 32 27 8 2 25 9...

  • Page 25: Control Box Parts List

    9.800-103.0 - m • karcher hds 615-617 25 pressure w asher opera t or’s man u al item part no. Description qty 1 9.803-512.0 box, electrical 1 2 9.803-513.0 cover, electrical box 1 3 9.803-514.0 control panel 1 4 9.800-138.0 label, control panel 1 5 9.802-251.0 tube, 1/4" id x 1/2" od, clear vinyl 96...

  • Page 26: Float Tank  Assembly

    9.800-103.0 - m • karcher hds 615-617 opera t or’s manu al pressure w asher 26 float tank assembly float tank parts list item part no. Description qty 1 3.593-060.0 float tank w/valve 1 2 4.070-094.0 tank, scale inhibitor 1 3 4.730-127.0 filter, water 1 4 5.063-226.0 lid, scale inhibitor tank 1 5 5....

  • Page 27: Pump Assembly

    9.800-103.0 - m • karcher hds 615-617 27 pressure w asher opera t or’s man u al 98001030-10 pump assembly pump assembly parts list item part no. Description qty 1 9.802-039.0 elbow, 1/2" jic x 3/8", 90° pipe 1 2 8.706-832.0 elbow, 3/4" street 1 3 8-706-860.0 tee, 1/2" street 1 4 9.802-128.0 nipple, ...

  • Page 28: Unloader Assembly

    9.800-103.0 - m • karcher hds 615-617 opera t or’s manu al pressure w asher 28 unloader assembly 98001030-2 unloader parts list item part no. Description qty 1 9.803-552.0 tee, 3/8" male, branch 1 2 9.802-036.0 nipple, 1/2" jic, 3/8" pipe 2 3 9.802-039.0 elbow, 1/2" jic, 3/8", 90° 1 4 9.802-870.0 bl...

  • Page 29: Blower Assembly

    9.800-103.0 - m • karcher hds 615-617 29 pressure w asher opera t or’s man u al blower assembly blower parts list item part no. Description qty 1 5.063-274.0 cover 1 2 5.110-306.0 sleeve 3 3 5.112-602.0 bushing 1 4 5.178-032.0 cloth collar 1 5 5.379-011.0 ring, rubber 3 6 5.471-060.0 element, coupli...

  • Page 30: Burner & Coil Assembly

    9.800-103.0 - m • karcher hds 615-617 opera t or’s manu al pressure w asher 30 burner & coil assembly item part no. Description qty 1 3.640-148.0 heater, flow 1 2 4.654-280.0 cover d.K. 1 3 7.311-380.0 nut, cap, m 6 4 4 7.312-167.0 washer, lock, a 6.4 4 5 2.880-177.0 ▲ electrodes, spare parts kit 1 ...

  • Page 31: Coil & Blower Assembly

    9.800-103.0 - m • karcher hds 615-617 31 pressure w asher opera t or’s man u al 98001030-1 coil & blower assembly item part no. Description qty 1 6.647-527.0 bracket 1 2 9.802-042.0 elbow, 1/2" jic x 3/8" female, 90° 1 3 5.423-234.0 tubing 1 4 6-389-262.0 nut, union, a 4-ll 2 5 6.389-263.0 ring, cut...

  • Page 32: Hose & Spray Gun Assembly

    9.800-103.0 - m • karcher hds 615-617 opera t or’s manu al pressure w asher 32 hose & spray gun assembly hose & spray gun parts list 1 2 3 4 item part no. Description qty 1 6.110-029.0 hose assembly tr rotatable dn8 40mpa 15m 1 2 4.118-005.0 easy!Force advanced 1 item part no. Description qty 3 4.11...

  • Page 33: Fuel Tanks  Assembly

    9.800-103.0 - m • karcher hds 615-617 33 pressure w asher opera t or’s man u al 98001030-7 item part no. Description qty 1 8.752-916.0 tank, gas, 11 gallon (616.0, 617.0) 1 2 8.752-189.0 tank, diesel, 11 gallon 1 3 9.802-053.0 bushing, rubber, nitrile (616.0, 617.0) 3 4 9.802-056.0 diptube, plastic,...

  • Page 34: Engine Assemblies

    9.800-103.0 - m • karcher hds 615-617 opera t or’s manu al pressure w asher 34 engine assemblies 615.0 models 98001030-5 616.0 models 617.0 models 9 8 7 6 3 2 1 4 5 10 9 8 7 6 5 4 3 2 1 10 9 1 21 23 22 24 20 2 13 14 15 17 15 12 16 18 19 11 4 3 5 12 12 26 25 27 25 engine purge connection 31 30 28 25 ...

  • Page 35: Engine Assemblies Parts List

    9.800-103.0 - m • karcher hds 615-617 35 pressure w asher opera t or’s man u al engine assemblies parts list item part no. Description qty 1 9.802-154.0 plug, push-on drain, honda (615.0) 1 9.802-039.0 elbow, 1/2" jic, 3/8", 90° (616.0, 617.0) 1 2 8.709-069.0 clamp, screw, #4 (615.0) 1 9.802-151.0 s...

  • Page 36: Specifications

    9.800-103.0 - m • karcher hds 615-617 pressure w asher specifi cations 36 part specifications pump specifications machine pump pulley bushing engine model model part # unloader pulley part # bushing part # engine part# 1.575-615.0 kt4540 8.921-715.0 8.715-483.0 2ak94h 9.803-548.0 25mm 9.802-403.0 gx...

  • Page 37: Specifications

    9.800-103.0 - m • karcher hds 615-617 37 pressure w asher specifi cations model engine pulley bushing belt belt belt belt cont. Pulley part# bushing part # size part # size part # 615.0 3tb34 9.802-392.0 p2 x 1” 9.802-404.0 ax 38 9.802-410.0 ax37 9.802-409.0 616.0 3tb34 9.802-392.0 p2 x 1” 9.802-404...

  • Page 38

    9.800-103.0 - m • karcher hds 615-617 opera t or’s manu al pressure w asher 38 item part no. Description qty 1 8.752-825.0 crankcase 1 2* see kit below plunger oil seal 3 3* see kit below o-ring Ø1.78 x 37.82 3 4* see kit below pressure ring, 18mm 3 5* see kit below u-seal, 18mm 3 6* see kit below i...

  • Page 39

    9.800-103.0 - m • karcher hds 615-617 39 pressure w asher opera t or’s man u al kt.2 series pump exploded view parts list kit numbers 8.753-821.0 8.753-822.0 8.753-823.0 8.753-824.0 8.752-835.0 kit description plunger seals 18 mm seal packing 18 mm plunger 18 mm complete valve plunger oil seals item...

  • Page 40

    9.800-103.0 - m • karcher hds 615-617 opera t or’s manu al pressure w asher 40 vrt3 unloader exploded view and parts list 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 yo...

  • Page 42

    Form #9.800-103.0 • printed in u.S.A..