IS3504G-H Cold Water Gas Pressure Washer

Product Information

Specifications:

• Product Name: Commercial and Industrial Cold Water Gas Pressure
  Washer

• Model Number: N/A

• Manufacturer: Easy-Kleen Pressure Systems

• Contact Information:

  • Phone: 1-800-315-5533
  • Email: sales@easykleen.com
  • Website: www.easykleen.com

Product Usage Instructions:

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.

Warnings:

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

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.

2. Use protective eyewear and clothing when operating equipment in
   order to avoid personal injuries.

3. This machine exceeds 85db. Appropriate ear protection must be
   worn.

4. Risk of explosion. Operate only where open flame or torch is
   permitted.

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

6. Risk of fire. Do not add fuel when operating machine.

7. The minimum clearance to any combustible material is 12
   inches.

8. Keep water spray away from electrical wiring.

9. 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.

10. Use this product only in a well-ventilated area to avoid
    asphyxiation.

11. Use equipment in a well-ventilated area to avoid carbon monoxide
    poisoning or death.

12. Risk of injection or severe injury to persons. Keep clear of
    nozzle spray.

13. High-pressure spray can cause serious injuries. Never point
    pressurized spray at any person or animal. Handle the spray
    assembly with care.

14. Risk of injury. Hot surfaces can cause burns.

15. Trigger gun kicks back. Hold with both hands.

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

17. Make sure all quick coupler fittings are properly secured before
    operating the pressure washer.

FAQ (Frequently Asked Questions):

Q: What should I do if I encounter a problem with my pressure

washer?

A: If you encounter any problems with your pressure washer,
please refer to the troubleshooting section in the user manual. If
the issue persists, contact Easy-Kleen Pressure Systems customer
support at 1-800-315-5533 or email sales@easykleen.com.

Q: Can I use this pressure washer indoors?

A: No, this product should only be used in a well-ventilated
area to avoid asphyxiation.

Q: How should I clean the pressure washer after use?

A: After each use, make sure to disconnect the machine from the
power source. Use a damp cloth to clean the exterior of the
pressure washer. Do not spray water directly onto the electrical
components. Refer to the maintenance section in the user manual for
more detailed instructions on cleaning and maintaining your
pressure washer.

Commercial and Industrial Cold Water Gas
OWNER’S MANUAL

Call 1-800-315-5533

Email sales@easykleen.com Website: www.easykleen.com

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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.
Table of Contents
IMPORTANT SAFETY INFORMATION …………………………………………………………………………………….. 3 SPECIFICATIONS ……………………………………………………………………………………………………………………… 7 INTRODUCTION ………………………………………………………………………………………………………………………. 8 OPERATING INSTRUCTIONS …………………………………………………………………………………………………… 9 CHEMICAL APPLICATION……………………………………………………………………………………………………… 11 WINTER PUMP PROTECTION ………………………………………………………………………………………………… 11 GENERAL MAINTENANCE…………………………………………………………………………………………………….. 12 MAINTENANCE CHECKLIST …………………………………………………………………………………………………. 12 GLOSSARY OF TERMS …………………………………………………………………………………………………………… 14 COMPONENT IDENTIFICATION…………………………………………………………………………………………….. 15 QUICK DIAGNOSTICS AND SOLUTIONS GUIDE …………………………………………………………………… 19 MANUFACTURER’S WARRANTY ………………………………………………………………………………………….. 20 SERVICE MANUAL ………………………………………………………………………………………………………………… 21

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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.

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 eyewear and clothing when operating equipment in order to avoid personal injuries.

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

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.
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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.
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.
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 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.

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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 coupler fittings are properly secured before operating pressure washer.
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.
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 may cause damage to the machine and personal injuries may occur as a result.

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.

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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.

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SPECIFICATIONS

MODEL
AS327GL AS327GK AS327GH AS440GL AS440GK AS440GH AS440GHGP AS440GKGP

GPM
3 3 3 3.5 3.5 3.5 4 4

MODEL
IS3504G-K IS3504G-H IS3506G IS3607G IS3508G IS3675G-JB IS2512G IS3010G IS5005G IS6045G IS7040G

GPM
4 4 6 7 8 7.5 12 10 5 4.5 4

MODEL
IS3204D IS5005D IS7004D IS8008D

GPM
4 5 4 8

Commercial Cold Water Gasoline

PSI

HP/ENGINE

2700

6.5 LIFAN

2700

6.5 KOHLER

2700

6.5 HONDA

4000

15 LIFAN

4000

14 KOHLER

4000

13 HONDA

4000

13 HONDA

4000

14 KOHLER

DRIVE
DIRECT DIRECT DIRECT DIRECT DIRECT DIRECT DIRECT DIRECT

Industrial Cold Water Gasoline

PSI

DRIVE

HP

3500 3000 3500 3600 3500 3600

GEAR BOX

14

GEAR BOX

13

GEAR BOX

24

BELT

25

BELT

25

GEAR BOX JABSCO PUMP 25

2500 3000 5000 6000 7000

BELT

38

BELT

38

BELT

25

BELT

25

BELT

25

ENGINE
KOHLER HONDA KOHLER KOHLER KOHLER KOHLER KOHLER KOHLER KOHLER KOHLER KOHLER

Industrial Cold Water Diesel

PSI

DRIVE

HP

3200 5000 7000 8000

BELT

9.8

BELT

26

BELT

26

GEARBOX

58

ENGINE
KOHLER KOHLER KOHLER KUBOTA

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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.

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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 NONDETERGENT 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 pressurewashing 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
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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!

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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.
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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.

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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.

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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).

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COMPONENT IDENTIFICATION
Commercial Model:
Wand and Nozzles

Water Pump

Engine

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Industrial Model:

16
10 Gallon Poly Fuel Tank for Engine

Engine

Water Pump

Pressure Wand Assembly:
Spray Gun

Nozzle Quick Coupler

Trigger

High Pressure Hose

Black Nozzle for Downstream Chemical Application

Wand Nozzles

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Commercial Model Pump Assembly:

Chemical Injector (Downstream)

Unloader

17 Oil Dipstick

Water Outlet Quick Connector

Water Inlet

Thermal Relief Valve
Water Pump

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Industrial Model Pump Assembly:
Unloader
Water Outlet Quick Connector

18
Pump Head Pressure Gauge

Water Inlet

Water Filter

Water Pump

Thermal Relief Valve

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QUICK DIAGNOSTICS AND SOLUTIONS GUIDE

PROBLEM

PUMP EK Pump
GP Pump
POSSIBLE CAUSES PRESSURE

TYPE OF OIL Hydraulic 68 (650ml) 30W SAE Non-Detergent
SOLUTIONS

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.

No pressure or
Very low pressure

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.

Unloader adjusted improperly or damaged

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

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

Pump Head Pump Crankcase Internal Pump Parts Heating Coil Honda Engine Kohler Engine Others Electric Motor* Frame and Body Materials Burner Assemblies Wheels and Castors Accessories, Unloader, Safety Valves Hoses, Fittings, O’Ring, and Elastomers Pressure Gauges

10 years 5 years 90 days 5 years, 1 prorated 3 years, 1 year 1 year 10 years 1 year 90 days 90 days 90 days 90 days

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

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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.

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PROBLEM Gas motor not starting
Spark Plug – strong gas smell
Plug does not fire Bad ignition system Spark Plug – no gas smell

POWER SYSTEM DIAGNOSTICS – Gas Motor Not Starting

POSSIBLE CAUSE

SOLUTION

Fuel

Check to see if proper fuel levels are maintained

No ignition

Check ignition by removing spark plug from cylinder. If electric start, try starting using the recoil starter.

Electric Starter/Battery Fuse blown in key switch

Recharge or replacebattery. 18 amp engine, open key switch, replace 30 amp fuse

Flooded

Wait 5 minutes before attempting to restart.

No ignition
Bad plug
Poor connection Bad magneto Poor connection No fuel to cylinder Fuel line restricted Stuck carburetor float Clogged carburetor needle valve Bad fuel pump

Check ignition by removing spark plug from cylinder. If electric start, try starting using the recoil starter.
Check spark plug and replace if necessary. Carbon deposits can indicate a fouled plug or too much fuel. Inspect the ignition connection. Check the source of spark plug for engine ignition. Check the source of spark for the engine ignition. Check fuel delivery from carburetor to cylinder. Check carburetor float bowl for fuel. Inspect fuel line to carburetor for restrictions or clogging. Flexible line may be kinked. Unstick float Unclog needlevalve. Replace fuel pump.

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PROBLEM No Flow
Low pressure, adequate flow
Low pressure, low flow
Low pressure, low flow Bogs

FLUID SYSTEM DIAGNOSTICS – Flow and Pressure

POSSIBLE CAUSE

SOLUTION

No power

Make sure pump is operating. Check drive belts and 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 unloader valve

Remove and check for proper action, repair or replace.

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 spraynozzle

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.

Unloader is not adjusted correctly Adjust unloader 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 packings bad

If low pressure persists, pump packings may need replaced.

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

Outlet restriction

Build up can restrict flow. If water is not flowing freely, flush with garden hose to isolate the clog or 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.

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PROBLEM Excessive pressure

POSSIBLE CAUSE Small spray nozzle
Faultypressure gauge Improperlyadjusted unloader Faulty unloader

SOLUTION Nozzle must be properly sized for the rated flow and pressure. Reset unloader or pressure relief if nozzle size is changed. Check the pressure gauge using a properly calibrated pressure gauge on quick connects at the equipment outlet. Adjust to the proper pressure using pressure gauge. Check the unloader action. If it is not working properly, it may need repaired or replaced.

Air in system

Inspect places where air can enter the system. i.e. fittings, hose, connections etc.

Pump chatters, caviataion, vibration
Inlet line vibrates Outlet line vibrates Inlet and outlet lines vibrate

Chemical line not submerged Inlet line restricted
Inadequate watersupply
Float valve stuck (optional)
Turbulence in floattank (optional) Inlet or inlet strainer clogged Water supply tohot Air in system
Debris in inlet check valves
Air in system
Debris in inlet check valves
Pump packing bad Inlet and outletcheck valves fouled

If the chemical valve is on, ensure that the chemical line is fully submerged in the chemical All inlet connections should be snug and not kinked to reduce the chances of pump starvation. 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. If float valve is stuck in the up position, water can not enter the float tank. Unstick valve if possible of replace if necessary. Excessive turbulence allows the pump to draw air into the system. Correct excessive turbulence. Regularly clean the inlet and inlet strainer to keep debris from entering the float tank Inlet temperature should not exceed 140F – 160F range. Inspect places where air can enter the system, i.e.; fittings, hose, connections etc. 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. Inspect places where air can enter the system, i.e.; fittings, hose, connections etc. If there is no float tank and the outlet line does no vibrate, the inlet check valve may be clogged. Remove debris. If they show signs of ware or damage, replace them.
Look for the source of debris in the inlet and discharge check valves and remove.

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PROBLEM Very low or no flow Unloader will not unload
Unloader (flow) cycles with system under pressure
Unloader (flow) cycles with system in bypass

FLUID SYSTEM DIAGNOSTICS – Unloader

POSSIBLE CAUSE

SOLUTION

Unloader stuck in bypass

Isolate the flow problem. If it occurs before the unloader discharge point, check the piston assembly to see if it is fouled or stuck in bypass mode.

Debris in unloader

Take bottom nut off unloader, identify ball, spring and seat. Clean out any debris and

Sever leak on the outlet of unit Check for leaks and repair.

Improper flow

Any variation in flow form what the orifice is sized can cause cycling. System must produce the rated flowconstantly.

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 unloader orifice

The systems rated output should indicate the proper sized orifice for your system.

Unloader orifice clogged

Check the orifice for clogs and clear out any debris.

Injector orifice clogged

If the system has a Venturi injector downstream of the unloader, 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 rated pressure

See low pressure or low flow diagnostics.

High water supply pressure

Check inlet water supply for excessive pressure.

No restrictions on the unloader

Check unloader bypass port to see if a flow restrictor is properly installed. Install one if none is present.

Downstream leakage (excessive) Causes the unloader to since a continuing flow and divert it to the closed gun. Repair or replace. Accumulator downstream (option) Remove the accumulator from the system.

Unloader adjusted too low

Unloader (pressure)

produces smooth flow & low Spray nozzleclogged

volume

Spray nozzle too small

Injector orifice blocked

System not delivering rated flow

Unloader adjusted too low

Unloader (flow) produces smooth flow & low volume

Unloader valve stuck in bypass Restriction in system

Adjust the unloader using the pressure gauge for the correct pressure.
A distorted spray pattern indicates a clogged nozzle. A small nozzle causes a reduced flow and cycling may result. If the system has a Venturi injector downstream of the unloader, check the orifice for clogs. See flow diagnostics.
Adjust unloader and regulator until proper pressure is achieved.
If unloader is sticking, repair or replace as necessary. 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.

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Unloader (pressure) produces low flow and normal pressure

Unloader adjusted too low
Spray nozzle tolarge Internal nozzle erosion Insufficient pump pressure

If the unloader is diverting flow to bypass it may be adjusted too low, readjust as necessary.
Ensure the proper nozzle is installed on system. The number of hours of usage can give you a clue to the extent of the ware. If in doubt, change Check pump seals and packings and tighten drive belts.

Unloader (flow) produces low flow & normalpressure
Unloader (pressure) leaks from main spring or adjusting bolt

Unloader adjusted too low Nozzle too large Shaft O-ring in valve body warn

If unloader is diverting flow to bypass, readjust using the pressure gauge. Ensure the proper sized nozzle is being used. Check O-rings for ware or damage and replace as necessary.

Unloader (flow) pressure increases when trigger released
Unloader (flow) leaks water around adjusting bolt

Unloader piston stuck or frozen
Bypass port clogged or restricted Excessive tension on main spring Sleeve O-ring worn

Check unloader shaft for proper action. Unstick piston and shaft or replace unloader.
Ensure that unloader bypass port is not clogged If tension is incorrect, adjust or replace as necessary. Check O-rings for ware or damage and replace as necessary.

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FLUID SYSTEM DIAGNOSTICS – Leaking

ANY LEAKS SHOULD BE REPAIRED ASAP TO PREVENT DAMAGE TO THE

SYSTEM.

PROBLEM From inlet From low pressure (inlet) line fittings From float tank(option) From pressure fittings From quick connects From pump
From trigger gun
From nozzle From unloader From variable pressure Lance(option) Unloader will not unload
From pressure relief valve

POSSIBLE CAUSE Garden hose washer Loose clamps or connections
Float tank full of water or stuck Fittings not tightened or taped, or cracked Bad o-rings Bad packing Bad rod o-ring Stripped connectors Weep gun(optional) Damage gun valve ball or seat Bad o-rings or seals Bad o-rings at adjusting knob
Debris in unloader Sever leak on the outlet of unit System over pressure Clogged nozzle Trigger gun valve not working Excessive pressure spike Wear or damage to ball or seal Improper relief valve adjustment

SOLUTION Ensure the washer is present and in good condition.
Low pressure line should be properly sealed on barb and tightly clamped.
If float is not floating above water, check the float to see if it has filled up with water. If necessary, drain and seal. Usually metal to metal fittings should be taped with Teflon tape or lock tight to provide a tight seal. (unless If quick connect o-ring shows wear or damage, replace it. If the seal leak is detected under the pump manifold, packing may be worn and in need of replacement. If o-rings show wear or damage, they may need replaced. Physical damage may not be apparent, but unseen warping from freezing or extreme pressure can still cause leakage. If a weep gun has been installed, check the gun valve seat to ensure it is functioning properly. 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. If quick connect o-ring shows wear, damage or improper seating.
Inspect o-rings for ware or damage and replace as necessary.
Take bottom nut off unloader, identify ball, spring and seat. Clean out any debris and reassemble. Check for leaks and repair. See pressure and flow diagnostics to find the cause of the excessive pressure and correct it. Spray pattern will be distorted if nozzle is clogged, clean out. If trigger gun valve action is not correct, repair or replace. If water spurts from valve when trigger is released, check unloader adjustment. Pressure spike should be below the level where pressure relief valve is activated. Inspect ball and seal for damage and adjust as necessary. Adjust valve properly.

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PROBLEM
No nozzle flow from nozzle when trigger depressed.
Excess pressure when trigger gun is released Flow not stopping when trigger gun released Trigger action sticks Trigger gun leaks
No chemical
Excessive chemical Spray pattern irregular Volume proper, pressure low Pressure proper, volume low

FLUID SYSTEM DIAGNOSTICS – Trigger Gun/Spray Nozzle

POSSIBLE CAUSE

SOLUTION

Broken piston rod in trigger gun

If water flows through discharge hose without gun, check trigger gun valve piston rod and replace if necessary.

Missing metal insert in trigger gun (European style gun) Blockage in system past gun
Excessive pressure spikes

Inspect to assure insert is in place.
Check nozzle or spray accessory for blockage and clear it. After unloader increases pressure to a maximum, further adjustment will only increase the pressure spikes. Re-adjust.

Broken return spring on trigger gun If trigger action is too loose, return spring may need replaced.

Debris in gun valve Keeper plug too tight Worn or bad o-ring
Stripped or loose connections
Chemical valve closed Black nozzle
Chemical dried up in the injector Chemical foot strainer clogged Chemical line kinked
Chemical line too long
Chemical too dilute
No adjustment for low pressure
Incorrect injector orifice
Valve improperly adjusted, check knob on injector Chemical dilutionto strong Clogged nozzle

Debris in gun valve can stop piston return. Clear debris. It may be possible to loosen plug slightly without leakage but it will likely need replaced. Check trigger gun o-rings for ware or damage and replace. Physical damage may not be apparent but unseen warping from freezing or sever overpressure maystill cause leaking. 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 chemicaljug. Inspect and clean as necessary. May be a strainer or check valve. Ensure that the ball is not stuck or clogged. Chemical line kinking or binding prevents chemical delivery. An overly long chemical line can prevent the pump from drawing chemical into the system. Try installing a shorter line. Verify chemicalstrength. Downstream injectors only – Low pressure is required for most injectors to draw chemical. If no adjuster exists it may need low pressure spray nozzle installed on the lance. If not properly sized for the systems rated output, chemical delivery problems will result. Check serial plate for specs.
To properly adjust, a chemical flow meter may be used to precisely measure chemical flow.
Verify chemicalstrength. Spray pattern will be distorted if nozzle is clogged.

Nozzle to large

Ensure that the nozzle is sized properly sized for the system

Internal nozzle wear Clogged nozzle

A loss of pressure may result form gradual nozzle wear. Replace a nozzle of correct size. Spray pattern will be distorted if nozzle is clogged. Check nozzle for clogging if the unit has a pressure unloader.

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BOILER SYSTEM DIAGNOSTICS – Oil Burner Will Not Fire

PROBLEM

POSSIBLE CAUSE

SOLUTION

Not reaching rated pressure flow

Not activating boiler controls

Correct the 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 being supplied

Ensure that the blower is working and that the air band or damper is properly adjusted and in good repair.

No air movement through stack

Thermal reset tripped

Press the thermal reset button on burner motor. If the reset trips again an additional problem must 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.

Contaminated fuelin the tank

Ensure that the proper clean fuel is being used. If not, siphon any debris or water from the tank.

Fuel in the fuel 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 or Check the sensor. The assembly may need to be removed to un-stick the float or to replace it

faulty

completely.

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 the fuel pump for rust.

Debris in the fuel filter bowl
Water comes out drain at bottom of tank

Clogged strainer
Clogged fuel nozzle Clogged fuel line
Water in fuel supply

If the fuel strainer or in-line filter is clogged, clean or replace.
Replace if there is any evidence of clogging or debris. Check lines for clogging and clear if necessary. Check only if no fuel in the filter bowl – Drain the tank and check for rust. If problem persists, fuel pump should be checked for rust.

Cannot smell or see fuelat No fuel beingsupplied stack

Check fuel delivery and correct any problems.

No fuel to bleedvalve

Air leak to pump Broken fuel line Clogged fuel filter Clogged fuel inlet line Frozen fuel pump
Broken fuel pump coupling

Ensure that air is not entering through the lines or connections. Ensure that the fuel line is connected and is not broken/punctured. Check any clogging that exists in the fuel filter Check any clogging that exists in the fuel inlet line. If the fuel pump is frozen it will need replaced. Check pump coupling if direct or belt driven. Replace or tighten or replace the drive belts if needed.

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PROBLEM

POSSIBLE CAUSE

SOLUTION

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 the system 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 coil again.

Debris in internal fuel pump valve Check for clogging in the solenoid valve inside fuel pump.

Solenoid valve energizing

Fuel nozzle clogged Restriction in fuel outlet line

Check fuel nozzle for clogging and clear if necessary. 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.

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.

Air and fuel flow proper

Electrode caps cracked Electrode wires loose or damaged

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.
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 electrodeterminals

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 air bands opened up

Choked down

Open air bands to proper setting.

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PROBLEM
No arc at the ignition pilot assembly
Ignition operating properly Boiler controls operating properly

BOILER SYSTEM DIAGNOSTICS -Gas Burner Will Not Fire

POSSIBLE CAUSE

SOLUTION

Spark gap incorrect

Check the spark gap and reset if necessary. Check for air in the propane line.

Ignition module bad

Check the ignition module and replace if necessary.

Boiler controls malfunctioning

Check boiler controls for good operation and correct problems.

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

PROBLEM Flame intermittently lifts and returns to gas port “candles”
Flame height changes suddenly Flame floats around the combustion chamber Flame has yellow tip Flame comes out from under burner housing Gas burns inside the burner tube – roars Burner pops whengas is shut off

POSSIBLE CAUSE

SOLUTION

Gas velocity exceeds flame speed

If gas flow is not properly regulated, the regulator may need to be replaced. Gas line may be too small.

Uneven gas supply pressure

Check orifice for partial blockage. If no blockage found, ensure that the gas supply and regulator are working properly.

Insufficient air

Check stack for fuel restriction and correct. It may require new ventilation if the original system is inadequate.

Flame speed improper

Check for proper gas pressure while burner is operating.

Insufficient air and ventilation

Usually occurs at ignition. Check stack for fuel restriction.

Burner underrated

Inquire about a burner with the proper rated capacity.

Flame travels back into burner Flame travel when the gas is shut off does not damage the unit.

PROBLEM Burner firing normally but with outlet temp lower than rated
Burner firing constantly

BOILER SYSTEM DIAGNOSTICS

Water Output Temperature Too Low – Oil or Gas Fired

POSSIBLE CAUSE

SOLUTION

Thermostat set too low

Set the thermostat to proper output temperature.

Inlet water too cold Sooting Scaling

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

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PROBLEM No voltage solenoid
Solenoid coil does not energize
Solenoid coil energizes

BOILER SYSTEM DIAGNOSTICS – Boiler Controls

POSSIBLE CAUSE

SOLUTION

Boiler control or electrical problem A multimeter can be used to check continuity through controls and pinpoint the problem areas.

Bad connection to solenoid coil Electrical connections to solenoid valve coil should be tight and not corroded.

Coil bad
Boiler controlnot activating properly
Problem occurring elsewhere

Check to see if fuel solenoid will energize when the proper voltage is applied. Solenoid may need replacing.
If coil energizes when proper voltage is applied, check boiler controls.
If solenoid valve coil energizes when the cleaner is operating in hot water the problem is elsewhere. Check the air/fuel delivery.

PROBLEM Switch activates when pressure is reached but boiler not firing
Switch does not activate
Switch activatedmanually

BOILER SYSTEM DIAGNOSTICS – Pressure Switch

POSSIBLE CAUSE

SOLUTION

Control not flowing through switch

A multimeter can indicate if the proper voltage flows through the boiler side of the switch. If not the switch may not need replaced.

Switch improperly wired Switch bad Plunger fouled or stuck Plunger not moving far enough
Current not flowing through switch Microswitch not properly adjusted Switch bad
Problem elsewhere in the system.

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

PROBLEM
Switch activatedmanually
Switch shows continuity when activated Switch does not shows continuity when activated

BOILER SYSTEM DIAGNOSTICS – Vacuum Switch – Optional

POSSIBLE CAUSE

SOLUTION

Improper diaphragm movement Replace switch if 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.

Problem elsewhere in system

If vacuum switch works properly, continue with other boiler control diagnostics.

Switch contact bad

Replace switch with another one.

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PROBLEM

BOILER SYSTEM DIAGNOSTICS – Flow Switch – Optional

POSSIBLE CAUSE

SOLUTION

Reed switch activates when tested with externalmagnet

Magnet fouled and will not move
Reed switch misadjusted Magnet is bad

Reed switch does not activate when tested with external magnet

Reed switch is bad Problem elsewhere in system

If magnet does not move freely within its housing, remove debris to unstick it.
To adjust it for the flow the system is producing, loosen the reed switch and move it in its If reed switch activated the boiler when tested with a hand held magnet, the internal magnet may If reed switch does not activated the boiler when tested with a hand held magnet, the reed switch may need replacement. See diagnostics listed above.

BOILER SYSTEM DIAGNOSTICS – Thermostat

PROBLEM

POSSIBLE CAUSE

SOLUTION

Thermostat set improperly Thermostat set too low

Set thermostat properly and ensure connections are not loose or corroded.

Boiler fires when thermostat jumped, but will not fire with Thermostat bad thermostat in circuit

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.

PROBLEM
Electrical continuity through switch

BOILER SYSTEM DIAGNOSTICS – High Temperature Limit

POSSIBLE CAUSE

SOLUTION

Connections loose or corroded

Check 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.

PROBLEM Fuel level low
Fuel level proper

BOILER SYSTEM DIAGNOSTICS – Low Fuel Shut-Off

POSSIBLE CAUSE

SOLUTION

Switch may be operating properly Add fuel and retest.

Level sensor stuck

Check level sensor for proper movement. Clear, repair, or replace sensor assembly.

Reed switch bad

Check level sensor for proper action. Replace switch if needed.

Rev. 2/3/2016

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References

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

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