EASY-KLEEN AS327GL Commercial and Industrial Cold Water Gas Owner’s Manual

**EASY-KLEEN AS327GL Commercial and Industrial Cold Water Gas Owner’s Manual

**

IMPORTANT SAFETY INFORMATION

The safe operation of our pressure washing systems is the FIRST priority of Easy-Kleen. This
will only be achieved by following the operation and maintenance instructions as explained in
this manual and all other enclosed manuals.

This manual contains essential information regarding the safety hazards, operations, and maintenance associated with this machine. The manual should always remain with the machine, including if it is resold.

ALL CAUTIONS AND SAFETY WARNINGS MUST BE FOLLOWED TO AVOID INJURY OR DAMAGE TO EQUIPMENT.

THIS EQUIPMENT IS TO BE USED ONLY BY TRAINED OPERATORS AND MUST ALWAYS BE ATTENDED DURING OPERATIO

WARNING

READ OPERATOR’S MANUAL THOROUGHLY PRIOR TO USE.
WARNING : To reduce the risk of injury, read operating instructions carefully before using.

1. Read the instructions in this manual carefully before attempting to assemble, install, operate or service this pressure washer. Failure to comply with the instructions could result in personal injury and/or property damage.
   WARNING
   USE PROTECTIVE EYE WEAR AND CLOTHING WHEN OPERATING THIS EQUIPMENT.
   WARNING : Use protective eyewear and clothing when operating equipment in order to avoid personal injuries.
   WARNING
   EAR PROTECTION MUST BE WORN
   WARNING : This  machine exceeds85db. Appropriate ear protection must be worn.
   WARNING
   RISK OF EXPLOSION: OPERATE ONLY WHERE OPEN FLAME OR TORCH IS PERMITTED
   WARNING : Risk of explosion. Operate only where open flame or torch is permitted
   WARNING : Flammable liquids can create fumes which can ignite, causing property damage or severe injury.

2. Be thoroughly familiar with all controls and know how to stop the machine in the event of an emergency
   WARNING
   RISK OF FIRE. DO NOT ADD FUEL WHEN OPERATING MACHINE.
   WARNING : Risk of fire. Do not add fuel when operating machine

3. The minimum clearance to any combustible material is 12 inches.
   WARNING
   KEEP WATER SPRAY AWAY FROM ELECTRICAL WIRING
   WARNING : Keep water spray away from electrical wiring.

4. All electrically powered equipment must be grounded at all times to prevent fatal electric shots. Do not spray water on or near electrical components. Do not touch electrical components while standing in water or when hands are wet. Always make sure machine is disconnected from power source before servicing
   WARNING
   RISK OF ASPHYXIATION: USE THIS PRODUCT ONLY IN A WELL VENTILATED AREA.
   WARNING : Risk of asphyxiation. Use this product only in a well ventilated area.

5. Use equipment in a well-ventilated area to avoid carbon monoxide poisoning or death.
   WARNING
   RISK OF INJECTION OR SEVERE INJURY TO PERSONS. KEEP CLEAR OF NOZZLE
   WARNING : Risk of injection or severe injury to persons. Keep clear of nozzle spray

6. High pressure spray can cause serious injuries. Never point pressurized spray at any person or animal. Handle the spray assembly with care.
   WARNING
   RISK OF INJURY: HOT SURFACES CAN CAUSE BURNS
   WARNING : Risk of injury. Hot surfaces can cause burns.
   ** WARNING
   TRIGGER GUN KICKS BACK-HOLD WITH BOTH HANDS
   WARNING** : Trigger gun kicks back. Hold with both hands.

7. Hold firmly to the gun and wand during start up and operation of the machine. Do not attempt to make adjustments while the trigger gun is in operation

8. Make sure all quick couplet fittings are properly secured before operating pressure washer.
   WARNING
   RISK OF INJURY FROM FALLS WHEN USING LADDER.
   WARNING : Risk of injury from falls when using ladder.

9. Do not overreach or stand on anything unstable. Keep a good balance and make sure to keep a steady footing at all times.
   WARNING
   PROTECT FROM FREEZING
   WARNING : Risk of Injury

10. It is important to keep your machine from freezing in order to keep it in its  best working condition. Failure to protect your machine from freezing maycause damage to the machine and personal injuries may occur as a result.
    WARNING
    RISK OF INJURY
    WARNING : Risk of Injury

11. For machines with a 12 V burner: Disconnect battery ground terminal before servicing.

12. Protect high pressure hoses from sharp objects and vehicles. Inspect condition of hoses prior to use, or serious injury could occur.

13. Do not pass acids or other caustic or abrasive fluids through the pump

14. Never run pump dry of water or oil or let the pump run with the trigger gun released for more than 2 minutes.

15. Do not attempt to operate this machine if fatigued or under the influence of alcohol, prescription medications, or drugs.

16. Some of the maintenance procedures involved in this machine require a certified technician (these steps are indicated throughout this manual). Do not attempt to perform these repairs if you are not qualified.

If you need further explanation of any of the information in this manual, suspend any activity
involving the equipment and call our toll free number for assistance, 1-800-315-5533.

SPECIFICATIONS

Commercial Cold Water Gasoline

MODEL| GPM| PSI| HP/ENGINE| DRIVE
AS327GL| 3| 2700| 6.5 LI FAN| DIRECT
AS327GK| 3| 2700| 6.5 KOHL ER| DIRECT
AS327GH| 3| 2700| 6.5 HONDA| DIRECT
AS440GL| 3.5| 4000| 15 LI FAN| DIRECT
AS440GK| 3.5| 4000| 14 KOHL ER| DIRECT
AS440GH| 3.5| 4000| 13 HONDA| DIRECT
AS440GHGP| 4| 4000| 13 HONDA| DIRECT
AS440GKGP| 4| 4000| 14 KOHL ER| DIRECT
Industrial Cold Water Gasoline

MODEL| MPG| PSI| DRIVE| HP| ENGINE
IS3504G-K| 4| 3500| GEAR BOX| 14| KOHL ER
IS3504G-H| 4| 3000| GEAR BOX| 13| HONDA
IS3506G| 6| 3500| GEAR BOX| 24| KOHL ER
IS3607G| 7| 3600| BELT| 25| KOHL ER
IS3508G| 8| 3500| BELT| 25| KOHL ER
IS3675G-JB| 7.5| 3600| GEAR BOX JABS CO PUMP| 25| KOHL ER
IS2512G| 12| 2500| BELT| 38| KOHL ER
IS3010G| 10| 3000| BELT| 38| KOHL ER
IS5005G| 5| 5000| BELT| 25| KOHL ER
IS6045G| 4.5| 6000| BELT| 25| KOHL ER
IS7040G| 4| 7000| BELT| 25| KOHL ER
Industrial Cold Water Diesel

MODEL| MPG| PSI| DRIVE| HP| ENGINE
IS3204D| 4| 3200| BELT| 9.8| KOHLER
IS5005D| 5| 5000| BELT| 26| KOHLER
IS7004D| 4| 7000| BELT| 26| KOHL ER
IS8008D| 8| 8000| GEARBOX| 58| BOGOTA

INTRODUCTION

Thank you for selecting a quality Easy-Kleen product. We are pleased to have you included among the many satisfied owners of Easy-Kleen cleaning machines. Years of engineering have gone into the development of these fine products and only top quality components and materials are used throughout. Each machine is carefully tested and inspected before leaving our plant to ensure years of dependable performance.

To continue to receive satisfactory performance, remembering that this machine represents a substantial investment on your part, and if properly cared for and maintained it will return this investment many times over. As with all mechanical equipment, your machine requires proper operation and maintenance as outlined in this manual for maximum trouble free life.

This manual has been prepared under the direction of our engineering and service technicians. Their experience in designing, manufacturing, installing and servicing our equipment from our company’s inception is condensed in this manual. They know what information the end user needs in order to get the optimum performance from their pressure washer. Please read carefully

This manual contains information that will be specific for your pressure washer, as well as similar models.

Carefully review any additional manuals that have been included with your system and follow ALL ADDITIONAL OPERATING INSTRUCTIONS AND SAFETY NOTICES. They are specific for the quality components that have been used to manufacture your machine and are an integral part of the operating and maintenance procedures.

The management & staff at Easy-Klee are proud of the equipment that we design manufacturer, and we thank you for making us your # 1 choice in pressure washers. If you have any questions please do not hesitate to call us, 1-800-315-5533.

Our goal is that you will be satisfied with the performance, quality, and service you receive from
Easy Kleen and that if you need to replace this machine in years to come, you will give us the opportunity to continue supplying equipment to your company.

PLEASE READ MANUALS CAREFULLY BEFORE USING MACHINE. EXAMINE MACHINE AND CRATE CAREFULLY FOR SHIPPING DAMAGE OR MISSING PARTS. REPORT PROMPTLY ANY SHORTAGES OR DAMAGE CLAIMS TO FREIGHT CARRIER OR DEALER.

OPERATING INSTRUCTIONS

1. Perform pre-start maintenance inspection on all applicable systems prior to operating the
   machine. This is essential for the safe, effective and efficient operation. You will get optimum performance from your system ONLY if these instructions and inspections are followed. Any indication that the pressure washing system was not operated and maintained according to these instructions may cancel the manufacturers’ warranty.
   Location – These machines are gasoline powered and must be used outside in a well ventilated area
   Controls – Make sure all controls are turned to the off position.
   Pump – oil level – Level the pressure washer. Be sure oil level in the pump is correct on dip
   stick. If the level is low, add the correct oil to the proper level. USE ONLY SEA 30 W NON DETERGENT OIL OR HYDRAULIC 68. DO NOT OVER FILL
   Gas engine – gasoline level – The engine is a 4 cycle and uses regular octane, unleaded fuel. DO NOT USE MIXED FUEL. Refer to the engine operation manual included with your pressure washing unit.
   Gas engine – oil level – The engine is a 4 cycle and uses 10W30 detergent oil. Refer to Glossary or engine manual.
   Diesel engine – Refer to engine operation manual included with your pressure washing unit for oil and fuel recommendations.
   Visually inspect all electrical components to assure they are in good condition, showing No signs of exposure, breakage or splicing
   Visually inspect all hoses, nozzles and guns to assure they are in good condition. If replacements are necessary they must be rated to withstand the machine’s operating pressure

2. Attach high-pressure hose to water outlet quick connector. Attach the other end of high
   pressure hose (with quick couplet) to spray gun. Ensure that quick disconnect connections are tightly locked together. Apply a sharp pull on hose to confirm they are secured.
   Attach wand nozzle specific to task requirements (i.e. chemical or pressure wash). [Quick Coupling Operation – Pull back sleeve end and insert male end into nozzle quick coupler, release sleeve and confirm connection by pulling on nozzle].

3. Attach water source to water inlet located on pump. The water source must be attached with a good quality standard garden type hose (1/2” minimum is required). Connect male fitting into water inlet on pump. Make sure that the inlet screen/filter is intact and fitted correctly. Turn on water source. WATER MUST BE IN SUFFICIENT SUPPLY, AND PRESSURE MUST BE BETWEEN 20 –60 PSI TO ENSURE PROPER AND SAFE OPERATION. Specific attention should be given if using a well water supply. Ensure water is flowing from end nozzle with trigger gun pulled. Deplete system of all air

4. Start gas/diesel engine
   Refer to instructions in engine manual. You may need to hold wand trigger open while starting engine in order to let it turn over more easily. MAKE SURE THAT THE ENGINE EXHAUST IS NOT FACING ANY FLAMMABLE MATERIALS

5. Pressure adjustmen t – The pressure regulator (unloader) is located on the pump (see diagram). It controls the pressure being generated by the pressure washer. This regulator may be adjusted to desired pressure by turning the adjustment knob. Turning the adjustment knob clockwise will increase pressure. NEVER OPERATE SYSTEM AT A HIGHER PSI THAN THE MAXIMUM RATING. This machine has been adjusted to operate at a specific maximum pressure as per the machine specifications. Pressure may be reduced for lighter use by turning the un oader counter clockwise. If continuing to turn the unloader clockwise does not increase the pressure, then this implies the maximum has been reached for the system. Any further turning of the unloader will cause the pressure to spike when the wand trigger is released, resulting in possible damage to the machine. To avoid this effect, loosen the unloader (counter-clockwise) until the pressure just starts to drop (see pump head pressure gauge) and until it no longer exceeds the maximum pressure rating for the machine.

6. You are now ready to start the cleaning operation – Pull trigger on the pressure wand assembly to start cleaning. To stop pressurized water, release trigger. DO NOT LEAVE UNIT RUNNING WHEN NOT IN USE. If left running, water will continuously be forced through the bypass hose and back into the pump, which will cause the pump to overheat.

7. To stop operation. Turn off engine. Squeeze and release wand trigger after shutting off to
   relieve system of pressure

8. Prior to storage – Inspect pressure washer for any damage or required maintenance. If yourmachine is to be exposed to cold weather, please refer to winter pump instructions found in this manual. If possible, do not allow unit to remain outside in the elements.

9. Warning – If unit is left running while not in use, pump damage may occur. Do not leave unit running while not in use!

CHEMICAL APPLICATION

Downstream Chemical Injection: Standard (direct drive units, optional on others) High Pressure Soap (optional feature)

NOTE : Do not remove back flow preventer as chemical may flow back into potable water source. For standard chemical injection, ensure the black nozzle is properly fitted at the end of the wand. The chemical injector will not function if this nozzle is not fitted.

1. Chemical preparation – Select detergent/chemical that best suits your cleaning task. Prepare dilution according to the manufacturer’s instructions. The volume of chemical being used may be adjusted at valve located on the chemical injector. Note: for EK Pumps, the volume is preset and cannot be adjusted.
2. Insert the intake hose, located on the chemical injector at the pump, into the chemical being used.
3. Fit black nozzle on the standard wand, or for the dual wand, turn adjustment knob on, and adjust for required flow rate. For high pressure soap systems, the black nozzle is not needed; use one of the other wand nozzles.
4. To apply chemical, engage trigger on pressure wand assembly. Turn chemical injector’s nipple to adjust flow. For the high pressure soap systems, open ball valve and engage trigger.
5. Chemical can now be applied through pressure wand assembly. It will take 5 – 15 seconds for chemical to travel to spray nozzle. The volume of chemical being used may be adjusted at the chemical injector.
6. For best results apply chemical from bottom to top, and allow for proper penetration time prior to rinsing. Do not allow chemical to dry. Rinse from bottom to top and then top to bottom.

WINTER PUMP PROTECTION

The following procedure MUST be used when the pressure washing unit is stored at temperatures below freezing.

1. All water must be drained or blown (via compressed air) from system. Connect a short piece of male fitted ½” garden type hose on to the water inlet on the pump assembly.
2. Place the open end of the hose into a wide mouthed container of full strength, winter rated, vehicle windshield washing fluid or Anti-Freeze, RATED FOR MINIMUM -40°C.
3. Connect the pressure wand assembly.
4. Start the pump and engage trigger on the pressure gun. Operate the system until the fluid runs the same color as the windshield washing fluid. Your machine is now prepared for storage.
5. Disconnect fluid supply, blow out with compressed air, and cap end.

GENERAL MAINTENANCE

Water Condition
Use a softener on your water system if local water is known to be high in mineral content. The
advantages of soft water are very beneficial: prevents scale buildup in heater coil, cleans better
with considerably less detergent, and prevents streaking on painted surfaces and glass when
rinsing.

MAINTENANCE CHECKLIST

Maintenance for Pump

Daily:

1. Check oil for proper level and adjust accordingly.
2. Examine the quality of the oil.
3. Check pump for oil and/or water leaks.
4. Inspect and clean inlet filters.

Weekly:

1. Examine all fittings, components, hoses, connections, and nozzles for damages, loose parts, or leaks. – Replace accordingly—

Recommendation for Oil Changes and Component Replacement:

1. Change the oil in the pump after the first 50 hours and every 500 hours after the initial oil change. Use SAE 30 W Non-Detergent for GP Pumps and Hydraulic 68 for EK Pumps.
2. Change all other components on the pump as needed.

Maintenance for Gasoline Engine

Daily:

1. Check oil for proper level and adjust accordingly.
2. Examine the quality of the oil
3. Examine the air cleaner element

Weekly:

1. Examine engine components for damages, loose parts, or leaks.

Recommended Schedule for Oil Changes and Component Replacements:

1. Change engine oil after first 5 hours and every 100 hours after the initial oil change. Use 10w-30 engine oil.
2. Replace Spark Plug every 100 hours.
3. Change air cleaner element every 100 hours.
4. Check fuel filters every 300 hours.
5. Change all other components on engine as needed.

GLOSSARY OF TERMS

PSI – Pounds per square inch. Pressure washers are designed and rated to operate at a specific
PSI. Operating at pressures exceeding the maximum rating could result in damage to the unit and/or SEVERE PERSONAL INJURY.

GPM – Gallons per minute. The orifice on the pressure wand assembly has been selected to deliver up to the maximum GPM for your machine.

PRESSURE WAND ASSEMBLY – This refers to the gun, wand, and nozzle.

PUMP – The pump moves the water through the system and delivers it to the pressure wand assembly

UNLOADER VALVE – Is a valve located at the head of the pump for unloading water back into the bypass when the trigger gun is shut off. It also reduces the load on pump when gun is off.

OIL, PUMP – The oil used within the pump to lubricate its operation. It is important to use only
SAE 30 W Non Detergent (for GP Pumps) or Hydraulic 68 (for EK Pumps) in the pump.

OIL, GASOLINE ENGINE – Gasoline Engines need appropriate lubricant. Use 10W30 detergent oil.

BACK FLOW PREVENTER – Device to prevent flow backwards into potable water supply.

MAXIMUM WORKING PRESSURE – Each machine is equipped with a safety pressure relief valve which prevents over pressurization of the high pressure system. It is an important safety device and must not be tampered with in any way

PRESSURE SWITCH – A pressure switch is used to control the motor for the auto stop/start feature (see diagram).

FLOW SWITCH – A flow switch is installed on the outlet of the water pump in auto stop/start models and will shut off the pump and motor in the absence of water flow as well as turning it back on when flow is detected (by squeezing the trigger).

COMPONENT IDENTIFICATION

Commercial Model:

Industrial Model:

Pressure Wand Assembly:

Commercial Model Pump Assembly:

**Industrial Model Pump Assembly:

**

QUICK DIAGNOSTICS AND SOLUTIONS GUIDE

PRESSURE
      No pressure orVery low pressure|  Metal in oil|

• – Examine oil in pump to see if there is metal in oil.
  • If you find traces or pieces of metal, your pump has damaged components.

  Dirt in water|

• Verify if there is dirt in nozzle tip or in valves in pump.
  • If nozzle is plugged, clean or replace it
  • If valves in pump are clogged, clean valves.
  • If valves in pump are damaged, replace valves.

  Wrong nozzle size|

• Make sure you have the right nozzle size. The black nozzle will drop pressure in order to use chemical injector and is only for soap or chemical. If you are not using soap, use a different color.

    Pressure too high| Wrong nozzle size|

• Make sure you have the right nozzle size.

 Unloaded adjusted improperly or damaged|

• Check pressure of pump with a pressure gauge and adjust to desired pressure.
• If you cannot reduce pressure, replace unloaded.

MANUFACTURER’S WARRANTY
The manufacturer warrants all original equipment of the manufacturer to be therefrom defects in material and workmanship as follows:

Within the periods stated above and at the discretion and approval of Easy- Kleen, if there is
shown to be a defect in material or workmanship, the defective parts will be repaired or replaced
at the manufacturers place of business or an original manufacturers repair depot when returned
PREPAID. This warranty will not cover labor if warranty work is conducted at the customer’s playoff business. Road service will be charged at the normal rate in these situations. Damage resultant freezing, accident, neglect, tampering, abuse, alteration, or improper installation an operation will automatically void this warranty.

All labor repairs are to have an Easy-Kleen pre-authorized repair number (PARN). In order to
receive a PARN, please email a copy of your invoice to our service department and make sure to
clearly indicate the date of purchase and the serial number of the machine. A pre-determined
service time will then be appointed to you. If new parts are needed, they will be invoiced to you as
normal. Defective parts are to be sent to us prepaid for warranty and consideration. If a part is
found to be defective, a credit will be issued to cover the costs of parts and shipping.

Note : This warranty will not extend to consequential damage or liability that occurs as a result of original defect.

Due to original equipment manufacturer’s requirements, Easy-Kleen is not permitted to perform
warranty repairs or claims for electrical motors, gas, or, diesel engines. If you require warranty
information for these please call our service department and they will put you in touch with your
local warranty representative

If you have any questions or comments regarding this warranty please call 1-800-315-5533.
Easy-Klee Pressure Systems Ltd
41 Earnhardt Rd
Sussex Corner, NB, Canada
ERE 6A1

E-mail: [email protected]

website: www.easykleen.com

Easy-Kleen Pressure Washers

Service Manual

This manual is intended for technical personnel to assist in the diagnosis and repair of issues with pressure washers.

This manual is not intended for use by non-technical personnel.

It is advised to always refer to competent technical personnel when repairs are advised to avoid equipment damage or potential personnel injury.

If you have any technical questions please do not hesitate to call us at 1- 800-315-5533.

POWER SYSTEM DIAGNOSTICS – Gas Motor Not Starting

maintained
No ignition| Check ignition by removing spark plug from cylinder. If electric start, try starting using the recoil starter.
Electric Starter/Battery| Recharge or replace battery.
Fuse blown in key switch| 18 amp engine, open key switch, replace 30 amp fuse
Spark Plug – strong gas smell| Flooded| Wait 5 minutes before attempting to restart.
No ignition| Check ignition by removing spark plug from cylinder. If electric start, try starting using the recoil starter.
Bad plug| Check spark plug and replace if necessary. Carbon deposits can indicate a fouled plug or too muchfuel.
Plug does not fire| Poor connection| Inspect the ignition connection.
Bad magneto| Check the source of spark plug for engine ignition.
Bad ignition system| Poor connection| Check the source of spark for the engine ignition.
Spark Plug – no gas smell| No fuel to cylinder| Check fuel delivery from carburetor to cylinder. Check carburetor float bowl for fuel.
Fuel line restricted| Inspect fuel line to carburetor for restrictions or clogging. Flexible line may be kinked.
Stuck carburetor float| Unstuck float
Clogged carburetor needle valve| Unclog needle valve.
Bad fuel pump| Replace fuel pump.

FLUID SYSTEM DIAGNOSTICS – Flow and Pressure

couplings, make necessary adjustments.
Trigger gun valve| Check trigger gun, repair or replace.
No water source| Ensure water supply is not restricted and hoses are in good repair and not kinked.
Clogged spray nozzle| Check spray nozzle, repair or replace.
Clogged inlet filter| Check inlet filter, repair or replace.
Float Valve stuck (optional)| Float valves can become stuck in the “UP” position. Manually dislodge and inspect for problems.
Faulty unloaded valve| Remove and check for proper action, repair or replace.
Low pressure, adequate flow| Incorrect or no spray nozzle| Nozzle should be properly sized for the system. Low pressure indicates that the nozzle in use is too large.
Worn spray nozzle| Replace nozzle when it shows signs of internal erosion.
Debris in valves| Clean valves and check o-rings for pits and cracks.
Lance on low pressure| Adjust pressure so the water flows through properly.
Unloaded is not adjusted correctly| Adjust unloaded to proper level.
Pressure gauge inaccurate| Use a new pressure gauge on a quick connect at outlet to check system pressure and replace if gauge is faulty.
Pump packing bad| If low pressure persists, pump packing may need replaced.
Low pressure, low flow| Volume Improperly adjusted| If unit has volume adjustment, it may need readjustment
Discharge leaks| Look for leaks on the discharge side of system.
Downstream chemical injector(Dema)| Remove the injector and retest system. If the flow is restored, replace the injector.
Loose drive belts| If belts do not have proper deflection, replace them.
Pump not running at rated speed| Check engine throttle and see that the motor is rated for the same speed as the pump.
Stripped pump drive coupling| Inspect coupling and repair or replace.
Defective easy start valve(optional)| Check the start or throttle-back valve for proper operation.
Malfunctioning motor or gear| Ensure that the motor or engine is working properly
Unloader stuck in bypass| Piston assembly may be stuck or fouled
Low pressure, low flow – Bogs| Outlet restriction| Build up can restrict flow. If water is not flowing freely, flush with garden hose to isolate the clogor restriction.
Clogged nozzle| Distorted spray pattern can indicate a clogged nozzle.
Nozzle too small| Ensure nozzle is proper size for the system.
Hose restriction| Correct any kinks or restrictions. Replace crushed hoses.
Debris in the system| Debris can lodge in the discharge side of the system (valves, fittings, injectors, filters) Flushing with water may correct it.
PROBLEM| POSSIBLE CAUSE| SOLUTION
---|---|---
Excessive pressure| Small spray nozzle| Nozzle must be properly sized for the rated flow and pressure. Reset unloaded or pressure relief if nozzle size is changed.
Faulty pressure gauge| Check the pressure gauge using a properly calibrated pressure gauge on quick connects at the equipment outlet.
Improperly adjusted unloaded| Adjust to the proper pressure using pressure gauge.
Faulty unloaded| Check the unloaded action. If it is not working properly, it may need repaired or replaced.
Pump chatters, cavitation, vibration| Air in system| Inspect places where air can enter the system. i.e. fittings, hose, connections etc.
Chemical line not submerged| If the chemical valve is on, ensure that the chemical line is fully submerged in the chemical
Inlet line restricted| All inlet connections should be snug and not kinked to reduce the chances of pump starvation.
Inadequate water supply| Water supply to the system must meet or exceed the rated flow (GPM) on the serial number plate. Faucet must be completely opened or water above the tank outlet in a gravity fed system.
Float valve stuck (optional)| If float valve is stuck in the up position, water can not enter the float tank. Unstuck valve impossible of replace if necessary.
Turbulence in float tank (optional)| Excessive turbulence allows the pump to draw air into the system. Correct excessive turbulence.
Inlet or inlet strainer clogged| Regularly clean the inlet and inlet strainer to keep debris from entering the float tank
Water supply to hot| Inlet temperature should not exceed 140F – 160F range.
Inlet line vibrates| Air in system| Inspect places where air can enter the system, i.e.; fittings, hose, connections etc.
Debris in inlet check valves| If there is no float tank and the outlet line does no vibrate, the inlet check valve may be clogged.Remove debris. Check o-rings under valves.
Outlet line vibrates| Air in system| Inspect places where air can enter the system, i.e.; fittings, hose, connections etc.
Debris in inlet check valves| If there is no float tank and the outlet line does no vibrate, the inlet check valve may be clogged.Remove debris.
Pump packing bad| If they show signs of ware or damage, replace them.
Inlet and outlet lines vibrate| Inlet and outlet check valves fouled| Look for the source of debris in the inlet and discharge check valves and remove.

FLUID SYSTEM DIAGNOSTICS – Unloaded

occurs before the unloaded discharge point, check the piston assembly to see if it is fouled or stuck in bypass mode.
Unloaded will not unload| Debris in unloaded| Take bottom nut off unloaded, identify ball, spring and seat. Clean out any debris and
Sever leak on the outlet of unit| Check for leaks and repair.
Unloaded (flow) cycles with system under pressure| Improper flow| Any variation in flow form what the orifice is sized can cause cycling. System must produce the rated flow constantly.
Nozzle to small| A nozzle that is too small can cause the flow to be reduced.
Nozzle clogged| A distorted spray pattern indicates a clogged nozzle.
Improper unloaded orifice| The systems rated output should indicate the proper sized orifice for your system.
Unloaded orifice clogged| Check the orifice for clogs and clear out any debris.
Injector orifice clogged| If the system has a Venture injector downstream of the unloaded, check the orifice for clogs.
Other downstream restriction| Scale buildup can restrict flow. Check; controls, valves, switches, trigger gun, and lance.Descale as necessary and begin preventive maintenance program for scale prevention.
Pump not delivering the ratedpressure| See low pressure or low flow diagnostics.
High water supply pressure| Check inlet water supply for excessive pressure.
Unloaded (flow) cycles with system in bypass| No restrictions on the unloaded| Check unloaded bypass port to see if a flow restrict or is properly installed. Install one if none is present.
|
Downstream leakage (excessive)| Causes the unloaded to since a continuing flow and divert it to the closed gun. Repair or replace.
Accumulator downstream (option)| Remove the accumulator from the system.
Unload er (pressure) produces smooth flow & low volume| Unloaded adjusted too low| Adjust the unloaded using the pressure gauge for the correct pressure.
Spray nozzle clogged| A distorted spray pattern indicates a clogged nozzle.
Spray nozzle too small| A small nozzle causes a reduced flow and cycling may result.
Injector orifice blocked| If the system has a Venture injector downstream of the unloaded, check the orifice for clogs.
System not delivering rated flow| See flow diagnostics.
Unloaded (flow) produces smooth flow & low volume| Unloaded adjusted too low| Adjust unloaded and regulator until proper pressure is achieved.
Unloaded valve stuck in bypass| If unloaded is sticking, repair or replace as necessary.
Restriction in system| Downstream restrictions can cause a reduction in flow. Check; controls, valves, switches, trigger gun, and lance. Descale as necessary and begin preventive maintenance program for scale prevention.
Unloaded (pressure) produces low flow and normal pressure| Unloaded adjusted too low| If the unloaded is diverting flow to bypass it may be adjusted too low, readjust as necessary.
---|---|---
Spray nozzle to large| Ensure the proper nozzle is installed on system.
Internal nozzle erosion| The number of hours of usage can give you a clue to the extent of the ware. If in doubt, change
Insufficient pump pressure| Check pump seals and packing and tighten drive belts.
Unloaded (flow) produces low flow & normal pressure| Unloaded adjusted too low| If unloaded is diverting flow to bypass, readjust using the pressure gauge.
Nozzle too large| Ensure the proper sized nozzle is being used.
Unloaded (pressure) leaks from main spring or adjusting bolt| Shaft O-ring in valve body warn| Check O-rings for ware or damage and replace as necessary.
Unloaded (flow) pressure increases when trigger released| Unloaded piston stuck or frozen| Check unloaded shaft for proper action. Unstuck piston and shaft or replace unloaded.
Bypass port clogged or restricted| Ensure that unloaded bypass port is not clogged
Excessive tension on main spring| If tension is incorrect, adjust or replace as necessary.
Unloaded (flow) leaks water around adjusting bolt| Sleeve O-ringworm| Check O-rings for ware or damage and replace as necessary.

ANY LEAKS SHOULD BE REPAIRED ASAP TO PREVENT DAMAGE TO THE SYSTEM

condition.
From low pressure (inlet)line fittings| Loose clamps or connections| Low pressure line should be properly sealed on barb and tightly clamped.
From float tank(option)| Float tank full of water or stuck| If float is not floating above water, check the float to see if it has filled up with water. If necessary, drain and seal.
From pressure fittings| Fittings not tightened or taped, or cracked| Usually metal to metal fittings should be taped with Teflon tape or lock tight to provide a tight seal. (unless
From quick connects| Bad o-rings| If quick connect o-ring shows wear or damage, replace it.
From pump| Bad packing| If the seal leak is detected under the pump manifold, packing may be worn and in need of replacement.
From trigger gun| Bad rod o-ring| If o-rings show wear or damage, they may need replaced.
Stripped connectors| Physical damage may not be apparent, but unseen warping from freezing or extreme pressure can still cause leakage.
From nozzle| Weep gun (optional)| If a weep gun has been installed, check the gun valve seat to ensure it is functioning properly.
Damage gun valve ball or seat| Inspect trigger gun valve assembly for damage or ware to ball or seat. Lodged debris can stop valve from closing. Repair with kit or replace.
From unloaded| Bad o-rings or seals| If quick connect o-ring shows wear, damage or improper seating.
From variable pressure Lance(option)| Bad o-rings at adjusting knob| Inspect o-rings for ware or damage and replace as necessary.
Unloaded will not unload| Debris in unloaded| Take bottom nut off unloaded, identify ball, spring and seat. Clean out any debris and reassemble.
Sever leak on the outlet of unit| Check for leaks and repair.
**** From pressure relief valve| System over pressure| See pressure and flow diagnostics to find the cause of the excessive pressure and correct it.
Clogged nozzle| Spray pattern will be distorted if nozzle is clogged, clean out.
Trigger gun valve not working| If trigger gun valve action is not correct, repair or replace.
Excessive pressure spike| If water spurts from valve when trigger is released, check unloaded adjustment. Pressure spike should be below the level where pressure relief valve is activated.
Wear or damage to ball or seal| Inspect ball and seal for damage and adjust as necessary.
Improper relief valve adjustment| Adjust valve properly.

FLUID SYSTEM DIAGNOSTICS – Trigger Gun/Spray Nozzle

gun valve piston rod and replace if necessary.
Missing metal insert in trigger gun(European style gun)| Inspect to assure insert is in place.
Blockage in system past gun| Check nozzle or spray accessory for blockage and clear it.
Excess pressure whentrigger gun is released| Excessive pressure spikes| After unloaded increases pressure to a maximum, further adjustment will only increase the pressure spikes. Re-adjust.
Flow not stopping when trigger gun released| Broken return spring on trigger gun| If trigger action is too loose, return spring may need replaced.
Debris in gun valve| Debris in gun valve can stop piston return. Clear debris.
Trigger action sticks| Keeper plug too tight| It may be possible to loosen plug slightly without leakage but it will likely need replaced.
Trigger gun leaks| Worn or bad o-ring| Check trigger gun o-rings for ware or damage and replace.
Stripped or loose connections| Physical damage may not be apparent but unseen warping from freezing or sever depressurization cause leaking.
No chemical| Chemical valve closed Black nozzle| Open chemical valve. If It chatters with no chemical delivery, air is being drawn from the upstream side of the pump. Check fittings, connections and ensure the inlet line is fully submerged into the chemical jug.
Chemical dried up in the injector| Inspect and clean as necessary.
Chemical foot strainer clogged| May be a strainer or check valve. Ensure that the ball is not stuck or clogged.
Chemical line kinked| Chemical line kinking or binding prevents chemical delivery.
Chemical line too long| An overly long chemical line can prevent the pump from drawing chemical into the system. Tryinstalling a shorter line.
Chemical too dilute| Verify chemical strength.
No adjustment for low pressure| Downstream injectors only – Low pressure is required for most injectors to draw chemical. If noadjuster exists it may need low pressure spray nozzle installed on the lance.
Incorrect injector orifice| If not properly sized for the systems rated output, chemical delivery problems will result. Check serial plate for specs.
Excessive chemical| Valve improperly adjusted, check knob on injector| To properly adjust, a chemical flow meter may be used to precisely measure chemical flow.
Chemical dilution to strong| Verify chemical strength.
Spray pattern irregular| Clogged nozzle| Spray pattern will be distorted if nozzle is clogged.
Volume proper, pressure low| Nozzle to large| Ensure that the nozzle is sized properly sized for the system
Internal nozzle wear| A loss of pressure may result form gradual nozzle wear. Replace a nozzle of correct size.
Pressure proper, volume low| Clogged nozzle| Spray pattern will be distorted if nozzle is clogged. Check nozzle for clogging if the unit has pressure unloaded.

BOILER SYSTEM DIAGNOSTICS – Oil Burner Will Not Fire

BOILER SYSTEM DIAGNOSTICS – Oil Burner Will Not Fire

fluid problem first – See fluid systems diagnostics
Thermostat on low setting| Thermostat set too low| Set thermostat to an output temperature requiring heating.
No or low fuel in tank| Burner no getting adequate fuel| Check fuel and bring to proper levels. Inspect fuel tank for water or debris.
Low fuel shut-off control activated.| Full featured equipment may have a shut off if fuel is low.
No air movement through stack| No air being supplied| Ensure that the blower is working and that the air band or damper is properly adjusted and in good repair.
Thermal reset tripped| Press the thermal reset button on burner motor. If the reset trips again an additional problemmust be sought.
Burner motor or capacitor is bad| If motor does not turn, first check thermostat/press switch, the motor starting capacitor and finally the burner motor itself.
Fuel in the fuel tank| Contaminated fueling the tank| Ensure that the proper clean fuel is being used. If not, siphon any debris or water from the tank.
Improper fuel in the tank| If the improper fuel is found in the tank, drain and rinse the tank, then fill with proper fuel.
Low fuel shut-off sensor stuck orfaulty| Check the sensor. The assembly may need to be removed to un-stick the float or to replace itcompletely.
Water in the fuel filter bowl| Water in fuel supply| Drain water from the tank promptly to prevent rusting. If fuel delivery problems persist, check thefuel pump for rust.
Debris in the fuel filter bowl| Clogged strainer| If the fuel strainer or in- line filter is clogged, clean or replace.
Clogged fuel nozzle| Replace if there is any evidence of clogging or debris.
Clogged fuel line| Check lines for clogging and clear if necessary.
Water comes out drain atbottom of tank| Water in fuel supply| Check only if no fuel in the filter bowl – Drain the tank and check for rust. If problem persists, fuelpump should be checked forrust.
Cannot smell or see fuel at stack| No fuel being supplied| Check fuel delivery and correct any problems.
No fuel to bleed valve| Air leak to pump| Ensure that air is not entering through the lines or connections.
Broken fuel line| Ensure that the fuel line is connected and is not broken/punctured.
Clogged fuel filter| Check any clogging that exists in the fuel filter
Clogged fuel inlet line| Check any clogging that exists in the fuel inlet line.
Frozen fuel pump| If the fuel pump is frozen it will need replaced.
Broken fuel pump coupling| Check pump coupling if direct or belt driven. Replace or tighten or replace the drive belts if needed.
Steady fuel flow at bleed valve but none in combustion chamber| Solenoid valve not energizing| Remove the solenoid cover and place blade of an insulated screwdriver in the coil with thesystem operating in hot water mode. A good working solenoid will hold the screwdriver in the solenoid. If not it may need replaced.
---|---|---
| Oil pump may have debris, replace as necessary.
Boiler controls activating| Solenoid valve coil not energizing| If boiler controls work properly, the pressure or vacuum on the fuel pump may be misadjusted.Check solenoid coilagain.
Solenoid valve energizing| Debris in internal fuel pump valve| Check for clogging in the solenoid valve inside fuel pump.
Fuel nozzle clogged| Check fuel nozzle for clogging and clear if necessary.
Restriction in fuel outlet line| Check fuel line from pump to burner for any restriction.
Fuel pump piston frozen closed| Check piston in fuel pump to see if it will travel. Free piston or replace fuel pump.
Air and fuel flow proper| No power reaching transformer| Ensure the proper voltage is reaching the ignition transformer with a volt meter.
Ignition transformer bad| Using a volt meter, ensure that the transformer is supplying the proper voltage.
Electrode gap improperly set| Check the gap and readjust if necessary, taking care that the proper distance is maintained from the fuel nozzle.
Electrode caps cracked| Down fired, multi-pass boiler systems have a cap on the top of each electrode. Examine caps for cracks or carbon build-up and replace if there problems are evident.
Electrode wires loose or damaged| Applies to down fired, multi-pass boiler systems – Check the wire to each electrode to ensure there is a good connection.
Electrodes arcing to fuel lines| Electrodes should not be arcing to fuel lines or nozzle. Check electrode for cracking or carbon build-up.
Transformer bus bars not lining up| Applies to gun type burners – Bus bars on the transformer should line up and connect properly with the electrode terminals
Burner or electrode assembly fires when removed from housing| Improper air delivery| Check air delivery to combustion chamber. Down fired; check air damper and air bag. Gun type; Check air bands.
Ignites with air bands closed down| Excessive electrode gap| Ensure electrode gap is properly set.
Ignites with openhandedness up| Choked down| Open air bands to proper setting.

BOILER SYSTEM DIAGNOSTICS -Gas Burner Will Not Fire

gap and reset if necessary. Check for air in the propane line.
Ignition module bad| Check the ignition module and replace if necessary.
Ignition operating properly| Boiler controls malfunctioning| Check boiler controls for good operation and correct problems.
Boiler controls operating properly| Gas valve malfunctioning| If pilot and boiler controls operate properly, the problem may exist with the gas valve. Replace if necessary

BOILER SYSTEM DIAGNOSTICS Abnormal
Flame Characteristics – Gas Fired

need to be replaced. Gas line may be toosmall.
Flame height changes suddenly| Uneven gas supply pressure| Check orifice for partial blockage. If no blockage found, ensure that the gas supply and regulatorare working properly.
Flame floats around the combustion chamber| Insufficient air| Check stack for fuel restriction and correct. It may require new ventilation if the original system isinadequate.
Flame has yellow tip| Flame speed improper| Check for proper gas pressure while burner is operating.
Flame comes out from under burner housing| Insufficient air and ventilation| Usually occurs at ignition. Check stack for fuel restriction.
Gas burns inside the burner tube – roars| Burner underrated| Inquire about a burner with the proper rated capacity.
Burner pops when gas is shut off| Flame travels back into burner| Flame travel when the gas is shut off does not damage the unit.

BOILER SYSTEM DIAGNOSTICS
Water Output Temperature Too Low – Oil or Gas Fired

the touch, the boiler may not be able to reach desired temperature increase. Use a water supply with a higher temperature.
Rooting| Soot build up on the coil can keep the water from reaching the desired If inlet water is freezing to the touch, the boiler may not be able to reach the desired temperature increase. Use a water supply
Scaling| The outlet fitting to the hose can get scale build-up and reduce heat exchange. Descale and prevent further build-up.

BOILER SYSTEM DIAGNOSTICS – Boiler Controls

be used to check continuity through controls and pinpoint the problem areas.
Solenoid coil doesn’t energize| Bad connection to solenoid coil| Electrical connections to solenoid valve coil should be tight and not corroded.
Coil bad| Check to see if fuel solenoid will energize when the proper voltage is applied. Solenoid may need replacing.
Boiler control not activating properly| If coil energizes when proper voltage is applied, check boiler controls.
Solenoid coil energizes| Problem occurring elsewhere| If solenoid valve coil energizes when the cleaner is operating in hot water the problem is elsewhere. Check the air/fuel delivery.

BOILER SYSTEM DIAGNOSTICS – Pressure Switch

through the boiler side of the switch. If not the switch may not need replaced.
Switch improperly wired| Switch may be improperly wired for its function.
Switch bad| If wiring is proper and still no current flow when activated, switch may need replacement.
Switch does not activate| Plunger fouled or stuck| Check pressure plunger to see if it will travel freely. If not, the passage may need cleared.
Plunger not moving far enough| Check to see if the plunger is traveling far enough to depress the microswitch. Adjust if necessary.
Switch activated manually| Current not flowing through switch| If switch activates manually but boiler does not fire, current may not be flowing through. The switch may need replacing.
Micro switch not properly adjusted| Micro switch may need readjustment so plunger can trip in.
Switch bad| Replace switch with another one.
Problem elsewhere in the system.| If switch works manually and current is flowing properly, the problem is elsewhere. Try other boiler diagnostics.

BOILER SYSTEM DIAGNOSTICS – Vacuum Switch – Optional

improper diaphragm movement is detected.
Low water flow| Correct problems related to inadequate water flow.
Air leak in or punctured diaphragm| Replace vacuum switch if diaphragm shows an air leak or hole.
Switch showscontinuitywhen activated| Problem elsewhere insystem| If vacuum switch works properly, continue with other boiler control diagnostics.
Switch does not shows continuity when activated| Switch contact bad| Replace switch with another one.

BOILER SYSTEM DIAGNOSTICS – Flow Switch – Optional

unstick it.
Reed switch maladjusted| To adjust it for the flow the system is producing, loosen the reed switch and move it in its
Magnet is bad| If reed switch activated the boiler when tested with a hand held magnet, the internal magnet may
Reed switch does not activate when tested with external magnet| Reed switch is bad| If reed switch does not activated the boiler when tested with a hand held magnet, the reed switch may need replacement.
Problem elsewhere in system| See diagnostics listed above.

BOILER SYSTEM DIAGNOSTICS – Thermostat

ensure connections are not loose or corroded.
Boiler fires when thermostat jumped, but will not fire with thermostat in circuit| Thermostat bad| Replace Thermostat.
Boiler will not fire when thermostat jumped| Problem elsewhere in system| Continue with boiler control diagnostics. If boiler still does not fire, the thermostat may need replaced.

BOILER SYSTEM DIAGNOSTICS – High Temperature Limit

connections to high temperature limit switch to ensure that they are not loose or corroded.
Problem elsewhere in system| If there is continuity through the switch but the boiler still does not fire, there is a problem elsewhere in the system. Continue with boiler control diagnostics.
No continuity through switch| Switch bad| Replace switch.

BOILER SYSTEM DIAGNOSTICS – Low Fuel Shut-Off

Clear, repair, or replace sensor assembly.
Reed switch bad| Check level sensor for proper action. Replace switch if needed.

References

• World's Best Pressure Washing Systems | Easy-Kleen Pressure Washers
• Manual-Hub.com – Free PDF manuals!

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