HLP M10 HLP M10 (AFTER SERIAL # )
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1 HLP M10 HLP M10 (AFTER SERIAL # ) PUMP OIL GRADE: SAE30W Non-Detergent PUMP OIL CAPACITY: 11 oz. BTU INPUT: 200, 000 (Vapor Only) PRESSURE NOZZLE: HLP M10: 5.5 HLP M10: 3.0 1
2 This Parts Listing has been compiled for your benefit. You can be assured your hot water pressure washer was constructed and designed with quality and performance in mind. Each component has been rigorously tested to insure the highest level of acceptance. The contents of this Parts Listing are based on the latest product information available at the time of publication. The manufacturer reserves the right to make changes in price, color, materials, equipment, specifications or models at any time without notice. WARNING THIS IS A PROFESSIONAL HIGH PRESSURE, HOT WATER PRESSURE WASHER. CAUTION SHOULD BE OBSERVED WHEN INSTALLING, USING OR REPAIRING THIS UNIT! READ AND FOLLOW THE SAFETY WARNINGS BEFORE ATTEMPTING ANY REPAIRS ON THIS PRESSURE WASHER! 2
3 SAFETY WARNINGS 1. NEVER alter or modify the equipment. Use only genuine manufacturer parts for repair of your pressure washer. Failure to do so can cause hazardous operating conditions and will VOID warranty. Repairs performed on this pressure washer should be done by a qualified serviceman in accordance with local, state and national regulations. 2. This unit has multiple safety devices which should never be altered, modified, removed or made inoperable. If a device fails, replace immediately with only genuine manufacturer replacement parts. 3. Gas System: Do not operate unit if gas smell exists. If you smell gas at any time, immediately shut off the gas supply to the unit and extinquish any open flame. L.P. gas is heavier than air and will gravitate to the floor. Do not resume operation until unit has been repaired and inspected by a qualified serviceperson. 4. Electrical System: The unit must be connected to a properly grounded electrical source which provides the correct voltage and adequate fuse protection. Disconnect from power source when making repairs. Never assume the pressure washer is safe to work on just because it is not operating. It could restart at any time. Never operate pressure washer with electrical enclosures open, removed or damaged. Do not allow metal components of the pressure washer to come in contact with live electrical components. 5. Do not operate the unit without all protective covers in place. Before servicing the unit, always shut off the unit and trigger the gun to release trapped pressure. Know how to stop the pressure washer and bleed pressures quickly. Be thoroughly familiar with controls. Be sure any accessory items and system components being used will withstand the pressure developed. 3
4 Table of Contents SPECIFICATIONS...5 FLOW CHART...6 GENERAL THEORY OF OPERATION...7 DECAL PLACEMENT...8 FRAME ASSEMBLY...10 MOTOR/PUMP ASSEMBLY...12 PUMP ASSEMBLY (3-0242)...14 UNLOADER ( )...16 PRESSURE SWITCH ( )...18 GAS PIPING AND HEAT EXCHANGER ASSEMBLY (AFTER SERIAL # ) GUN/WAND/HOSE ASSEMBLY...22 GUN/LANCE ASSEMBLY ( )...24 WIRE SCHEMATIC...26 WIRE DIAGRAM
5 SPECIFICATIONS MODEL NUMBER HLP M10 HLP M10 Operating Pressure (PSI/Bar): 700 / / 103 Water Volume (GPM/lpm): 2.3/ / 6.8 Motor: ODP Horsepower Phase 1 Voltage 115 Amperage Pump: Belt Driven, Oil Bath, Triplex Piston Oil Type SAE30W Non-Detergent Oil Capacity (oz./liters) 11.0 / 0.33 Plungers Ceramic Manifold Forged Brass Valves Stainless Steel Unloader: Pre-set at the factory Thermal Relief Valve: Relieves heated water during unloader bypass stage Burner Natural Draft-Aspirating Fuel Type L.P.-Gas (Vapor Only) Maximum Supply Pressure (W.C.) 13.0 Manifold Pressure (W.C.) 8.0 Fuel Orifice Size #66 Heat Exchanger: L.P. BTU Input 200, 000 Electric Controls: Motor Controls Cam Switch Burner Controls Cam Switch Control Voltage 120 Volt AC Safety Devices: Pressure Switch Shuts Off Burner Fuel Supply Upon Trigger Release High Limit Shuts off burner fuel supply when outlet water temperature exceeds 250 / 121C in hot water and steam mode. Relief Valve Relieves Excessive System Pressure High Pressure Nozzle Size: Unit Net Weight (Lbs/kg): 363 Unit Shipping Weight (Lbs/kg): 483 Unit Net Dimension (In/cm): 56.5L x 29W x 49.75H/143.5L x 73.5W x 126.5H Unit Shipping Dimension (In/cm): 57.5L x 35.5W x 59.5H/146L x 90W x 151H 5
6 FLOW CHART GH FLOW DIAGRAM BAR 6
7 GENERAL THEORY OF OPERATION WATER FLOW: Connect a pressurized water source to the INLET GARDEN HOSE CONNECTION (1) and turn on the water supply. The water will flow through a WATER STRAINER (2) and into the TRIPLEX HIGH PRESSURE PUMP (3) which has an UNLOADER (5) that bypasses the water when the trigger gun is closed. To protect the pump from heated water during this bypass stage, a THERMAL RELIEF VALVE (4) will open at 125 F/52 C allowing the heated water to escape. The Thermal Relief Valve automatically resets when the water cools. Attached to the pump is a PRESSURE SWITCH (6) that controls the fuel supply to the burner. From there, the water flows through the HEAT EXCHANGER INLET (7) where it is heated when the burner is on. As the water exits the HEAT EX- CHANGER OUTLET (8), it enters a safety system which protects the operator from danger. The safety system contains a HIGH PRESSURE LIMIT SWITCH (9) which senses the water temperature and shuts off the fuel supply to the burner if the water gets too hot. If the unloader fails to bypass water or the burner remains on when the trigger gun is closed, the SAFETY RELIEF VALVE (10) will relieve and allow water to exit safely. The heated water then flows through the HIGH PRESSURE HOSE (11) and to the TRIGGER GUN ASSEMBLY (12) which allows the operator to control the water supply. When the trigger gun is open, the water flows through the LANCE ASSEMBLY (13) and exits the NOZZLE (17). When using detergents, the solution passes through the DETERGENT STRAINER (14) located on the DETERGENT HOSE (15). The detergent solution then travels through the DETERGENT METERING VALVE (16). GAS FLOW: The gas passes through the REGULATOR (20) to the MAIN GAS VALVE (19) which regulates the gas to the appropriate pressure. The pilot is lit by holding in the knob on the MAIN GAS VALVE (19) and creating spark with the PIEZO IGNITER (18). The gas then flows through the GAS SHUT-OFF VALVE (21) and to the BURNER RING (22). Heat and fumes exit the coil through the EXHAUST STACK (23). 7
8 DECAL PLACEMENT HLP SAFETY DECALS AND SPECS KZ 8
9 HLP SAFETY DECALS AND SPECS KZ DECAL PLACEMENT REF. # DESCRIPTION PART # QTY. 1 Decal- Warning: Hot Surface (See ) N/A Sep. 1 2 Decal- Stripe Decal- White Die Cut 0703 (HLP M10) Decal- White Die Cut 1502 (HLP M10) Decal- Warning/Caution/Operation (See ) N/A Sep. 1 5 Decal- Warning: Risk of Injury (See ) N/A Sep. 1 6 Decal- LP Gas Only (See ) N/A Sep. 1 7 Decal- Data Plate N/A 1 8 Decal- OFF/Pump/Burner/Steam (HLP M10) (See ) N/A Sep. 1 - Decal- OFF/Pump/Burner (HLP M10) (See ) N/A Sep. 1 9 Hang Tag- Warning: Risk of Electrocution Cable Tie Safety Decal Kit (Inc. 1, 4-6, 8)
10 FRAME ASSEMBLY GH FRAME ASSY KZ 10
11 HLP FRAME ASSY KZ FRAME ASSEMBLY REF. # DESCRIPTION PART # QTY. REF. # DESCRIPTION PART # QTY. 1 Cylinder Plate A Wheel Locknut Frame Assembly Washer Grommet Brake Bracket A Mirror Bracket Washer Bolt Lockwasher Washer Bolt Handle Assembly A Grommet Rear Door Access A Washer Gas Piping and Rear Exchanger Assembly (See Exploded Drawing) N/A Sep Handle Grip Motor Pump Assembly (See Exploded Drawing) N/A Sep Handle Brake A Screw Bolt Frame Assembly A Clip Nut Cylinder Bracket A Cylinder Strap A Lockwasher Axle Knob
12 MOTOR/PUMP ASSEMBLY GH MOTOR PUMP ASSY BAR 12
13 HLP MOTOR PUMP ASSY BAR MOTOR/PUMP ASSEMBLY REF. # DESCRIPTION PART # QTY. REF. # DESCRIPTION PART # QTY. REF. # DESCRIPTION PART # QTY. 1 Pump Hat A Cabinet Door Assembly Electric Box A Flatwasher Hood Assembly A Locknut Locknut Washer Strain Relief Clip Nut Lockwasher Strain Relief Plug Hex Nut Hose Barb Nipple Tension Bracket A Washer Elbow Bolt Garden Hose Swivel Elbow Bolt Back Flow Preventor High Pressure Hose Assembly Bushing Inlet Washer Filter Washer Sheave Locknut Bolt Belt (HLP M10) Cord Strain Relief Bushing Belt (HLP M10) Cord w/gfci (HLP M10) Cord Thermal Relief Valve Cord w/gfci (HLP M10) Motor (HLP M10) High Pressure Pump Assembly Hex Nut Motor (HLP M10) Nipple Cam Switch (HLP M10) Locknut Tee Cam Switch (HLP M10) Bolt Hose Barb Screw Keystock Worm Clamp Gasket Assembly Sheave (HLP M10) Hose Electric Box Lid A Sheave (HLP M10) Unloader Assembly Screw Bushing Pressure Switch Terminal Strip Frame Assembly A Lockwasher Bolt *Must Order in One Foot Lengths 22 Screw Bolt
14 PUMP ASSEMBLY (3-0242) BAR 14
15 BAR PUMP ASSEMBLY (3-0242) REF. # DESCRIPTION PART # QTY. REF. # DESCRIPTION PART # QTY. 1 Spacer Nut O-ring Washer Oil Seal Piston O-ring Anti-Extrusion Ring Plug O-ring Seal Washer Protector Piston Guide Plug Connecting Rod Manifold Crankcase Cover Valve Assembly Screw O-ring O-ring Valve Plug Connecting Rod Pin Lockwasher Crankcase Bolt Key Packing Kit Bearing Bearing Needle Snap Ring Crankcase Retainer Oil Dipstick Screw
16 UNLOADER ( ) OMGEN BAR 16
17 OMGEN BAR UNLOADER ( ) REF. # DESCRIPTION PART # QTY. 1 Hex Nut Cover Set Screw Adjusting Insert- Brass Adjustment Nut Set Screw Glide Ring Spring Hex Nut Bushing Unloader Body Retainer Valve Housing Spring Valve O-ring Cylinder Pin Piston Repair Kit Spacer Stop Nut Washer Check Valve Repair Kit (Includes 13-16) Unloader Complete
18 PRESSURE SWITCH ( ) & BAR 18
19 BAR PRESSURE SWITCH ( ) REF. # DESCRIPTION PART # QTY. 1 Pressure Switch Screw N/A 4 3 Cover N/A 1 4 O-ring (See ) N/A Sep. 1 5 Micro Switch N/A 1 6 Retainer Clip N/A 1 7 Body N/A 1 8 O-ring (See ) N/A Sep. 2 9 Back-up Ring (See ) N/A Sep Piston N/A 1 11 Washer N/A 1 12 Spring Washer N/A 1 14 Plastic Housing N/A 1 15 O-ring (See ) N/A Sep Nut N/A 1 17 Wire Assembly N/A 1 O-ring Repair Kit (Inc. 4, 8-9, 15)
20 GAS PIPING AND HEAT EXCHANGER ASSEMBLY (AFTER SERIAL # ) GH GAS PIPING AND HEAT EXCHANGER KZ 20
21 GH GAS PIPING AND HEAT EXCHANGER ASSY KZ GAS PIPING AND HEAT EXCHANGER ASSEMBLY (AFTER SERIAL # ) REF. # DESCRIPTION PART # QTY. REF. # DESCRIPTION PART # QTY. 1 Frame Assembly A Pressure Relief Valve Washer Hi-Limit Swtich Lockwasher Cross Bolt Reducer Piezo Igniter Pipe Nipple Nut Coil Assembly Pipe Nipple Insulation Blanket Regulating Valve Screw Adapter Outer Wrap Assembly A Tube *(Two Feet Required) Insulation Donut Elbow Dome Assembly Close Nipple Pipe Nipple Union Adapter Tube *(Two Feet Required) High Pressure Hose Assembly Orifice Pilot Elbow Thermocouple Retaining Clip Bolt U-bolt Igniter Bracket A Burner Ring Ring Terminal Pipe Nipple Screw Gas Valve Pilot Assembly Regulator Quick Connect Socket Support Bracket A18 1 *Must Order in One Foot Lengths 21
22 GUN/WAND/HOSE ASSEMBLY GH GUN WAND HOSE ASSY BAR 22
23 HLP GUN/WAND/HOSE ASSY BAR GUN/WAND/HOSE ASSEMBLY REF. # DESCRIPTION PART # QTY. 1 Gun/Lance Assembly Lance Assembly Nozzle (HLP M10) Nozzle (HLP M10) Nozzle (HLP M10) Nozzle (HLP M10) Nozzle (HLP M10) Nozzle (HLP M10) Nozzle (HLP M10) Nozzle (HLP M10) Quick Connect Plug High Pressure Hose Assembly L.P. Supply Hose (Not Shown)
24 GUN/LANCE ASSEMBLY ( ) JJT 24
25 JJF GUN/LANCE ASSEMBLY ( ) REF. # DESCRIPTION PART # QTY. REF. # DESCRIPTION PART # QTY. 1 Gun Body (Right Side) O-ring (See ) N/A Sep. 1 2 Pin Ball (See ) N/A Sep. 1 3 Pin Spring Ball (See ) N/A Sep. 1 4 Trigger Lock Female Inlet Trigger Pipe Pin (See ) N/A Sep Screw Plug Gun Body (Left Side) O-ring N/A 1 20 Body Backup Ring (See ) N/A Sep Pipe O-ring (See ) N/A Sep External Body Plug Screw Connect Coupling Seat (See ) N/A Sep. 1 Gun Repair Kit (Inc. 6, 7, 9, 10, 12-15)
26 WIRE SCHEMATIC GH WIRE SCHEMATIC BAR 26
27 WIRE DIAGRAM GH WIRE DIAGRAM BAR 27
28 28
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