EASY-KLEEN AS440GL Commercial and Industrial Cold Water Gas Owner’s Manual

BOILER SYSTEM DIAGNOSTICS - Low Fuel Shut-Off

Call 1-800-315-5533

Email sales@easykleen.com

Website: www.easykleen.com

Easy-Kleen Pressure Systems
1-800-315-5533

This manual contains operational information that is specific for commercial and industrial cold water, gas driven machines.

Read the following instructions carefully before attempting to assemble, install, operate or service this pressure washer. Failure to comply with these instructions could result in personal injury and/or property damage.

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 OPERATION.

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

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-Kleen are proud of the equipment that we design and manufacture, 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 SAE 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 coupler) 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 adjustment – 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 unloader 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 your machine 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

MANUFACTURER’S WARRANTY

The manufacturer warrants all original equipment of the manufacturer to be free from 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 place of business. Road service will be charged at the normal rate in these situations. Damage resulting from freezing, accident, neglect, tampering, abuse, alteration, or improper installation and 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-Kleen Pressure Systems Ltd
41 Earnhardt Rd
Sussex Corner, NB, Canada
E4E 6A1

E-mail: sales@easykleen.com
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

FLUID SYSTEM DIAGNOSTICS – Flow and Pressure

FLUID SYSTEM DIAGNOSTICS – Unloader

FLUID SYSTEM DIAGNOSTICS – Leaking
ANY LEAKS SHOULD BE REPAIRED ASAP TO PREVENT DAMAGE TO THE SYSTEM.

FLUID SYSTEM DIAGNOSTICS – Trigger Gun/Spray Nozzle

BOILER SYSTEM DIAGNOSTICS – Oil Burner Will Not Fire

BOILER SYSTEM DIAGNOSTICS -Gas Burner Will Not Fire

BOILER SYSTEM DIAGNOSTICS Abnormal
Flame Characteristics – Gas Fired

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

BOILER SYSTEM DIAGNOSTICS – Boiler Controls

BOILER SYSTEM DIAGNOSTICS – Pressure Switch

BOILER SYSTEM DIAGNOSTICS – Vacuum Switch – Optional

BOILER SYSTEM DIAGNOSTICS – Flow Switch – Optional

BOILER SYSTEM DIAGNOSTICS – Thermostat

BOILER SYSTEM DIAGNOSTICS – High Temperature Limit

BOILER SYSTEM DIAGNOSTICS – Low Fuel Shut-Off

References

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

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