Easy-Kleen MAGNUM 4000 User manual

MAGNUM 4000 SERIES
OWNER’S MANUAL
Call 1-800-315-5533 Email [email protected]
ULTRA GOLD
PLUS 3600
NEW
2014

** Hot Water Pressure Washers Only
Easy Kleen Pressure Systems
1-800-315-5533
This manual contains operationalinformationthat is specific for
Hot and Cold Water Pressure Washers .
Read the following instructions 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.
CONTENTS
Safety Information
Introduction
Operating Instructions
Chemical Application
Winterization of Pressure Pump and Coil
General Maintenance Instructions
Maintenance Checklist
Glossary of Terms
Warranty
Pressure Washer Components Diagram
Troubleshooting Guide

** Hot Water Pressure Washers Only
SAFETY
F I R S T
The safe operationof our pressure washingsystems is the FIRST priorityof Easy Kleen.This
will onlybe achieved by following the operation and maintenanceinstructionsas explainedin
this manual and all other enclosed manuals.
IMPORTANT SAFETY INFORMATION:
ALL CAUTIONS AND SAFETYWARNINGS 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
: o 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.
WARNING
:
Use protective
eyewear and clothing when
operating equipment in order
to avoid personal injuries.
WARNING
:
his machine
exceeds 85db. Appropriate
ear protection must be worn.

** Hot Water Pressure Washers Only
IMPORTANT SAFETY INFORMATION
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.
Use only #2 furnace oil or Diesel fuel in the burner fuel tank.
WARNING
:
Risk of fire. Do not
add fuel when operating machine.
Never use gasoline, crankcase draining, or waste oil in your burner fuel tank.
Never run pump dry or let the pump run with the trigger gun released for
more than 2 minutes. The minimum clearance to any combustible material is
12 inches.
WARNING
:
Keep water spray
away from electrical wiring.
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.
Use equipment in a well ventilated area to avoid carbon monoxide poisoning or
death. This machine must never be connected to a Type B gas vent.
WARNING
:
Risk of injection or
severe injury to persons. Keep
clear of nozzle spray.
High pressure spray can cause serious injuries. Never point pressurized spray
at any person or animal. Handle the spray assembly with care.

** Hot Water Pressure Washers Only
IMPORTANT SAFETY INFORMATION
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.
WARNING
:
Risk of injury. Hot
surfaces can cause burns.
WARNING
:
Hot discharge
fluid. Do not touch or direct
discharge stream at persons.
WARNING
:
rigger gun kicks
back. Hold with both hands.
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.
WARNING
:
Risk of injury
from falls when using ladder.
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.
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
damages to the machine and personal injuries may occur as a result.

** Hot Water Pressure Washers Only
OPERATING I NS T R U C T I O NS
1. Perform pre-start
maintenance inspection on all applicable sys t e m s prior to operating
the machine. This is essential for the safe, effec t i ve and efficient operation. You will get
optimum performance from yo u r system ONLY if these instructions and inspections are
followed. A n y indication that the pressure washing system was not operated and maintained
according to these instructions may cancel t h e manufacturers’ w a rr an t y.
Location – Gasoline powered machines must be outdoors in a well ventilated area.
Controls – Make sure all controls turned to the off position.
Pu m p – O il l e v el - 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 F I LL .
Gas Engine - Gasoline level – The engine is a 4 cycle and u ses regular octane, unleaded
fuel. DO NOT USE MIXED F U EL . Refer to the engine operation manual included with
your pressure-washing un i t .
Gas Engine - Oil level – The engine is a 4 cycle and uses 10W30 detergent oil. Refer to
G l oss a r y or engine m anua l .
**Oil Fired Burner - Oil Tank Level – #2 Furnace oil is recommended f u e l for Oil Fired
Hot Water Pressure Washers. It burns cleaner and the burner requires less maintenance.
Diesel fuel may be used a s an alternative. Do not ove r f ill burner t ank .
Visually inspect all e
l ec t r i c a l components to assure they are i n good condition, showing
no signs of ex p os u r e, breakage o r s p li c i n g.
Visually inspect all hoses, nozzles and guns to assure they are i n good condition. If
replacements are n ecess a r y they must be r a t e d to withstand the machines operating
pressure and t e m p e r a t u r es.
2. Attach the
high-pressure hose to the outlet coupling on the coil heat exchange system.
Ensure that the quick disconnect connections are tightly l oc k e d t oge t h e r . Apply a sharp
pull on the hose to confirm.
Attach the wand nozzle specific to the task requirements (i.e. chemical or pressure wash).
[Quick Coupling Operation – Pull back sleeve end and insert male end into fitting, release
sleeve and confirm connection.]

** Hot Water Pressure Washers Only
3. Attach the water
source to the water inlet located on the pump. The water source must
be attached with a good qua li t y standard garden type hose, 1/2” minimum is required .
Connect the m a l e fitting into the female pump inlet swivel fitting, make sure that t h e
inlet screen/filter is intact and fitted correctly. Turn on the water source. WATER MUST
BE I N 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 the trigger gun
pulled. Deplete system of all air.
4. Start gas engine / electric motor and switch on burner
• Gasoline engine - refer to the instructions in the Engine M anua l MAKE SURE
THAT THE ENGINE EXHAUST IS NOT FACING ANY FLAMMABLE
MATERIALS. Adjust the burner thermostat control to ON at the desired temperature.
• Electric Motor – Turn burner switch to PUMP, adjust the burner thermostat to desired
temperature, turn switch to BURNER.
5. **Burner
operation
Be sure water is flowing through water heater coil before turning on burner switch. Turn
thermostat to desired temperature. Burner will ignite and remain in operation as long as there is
sufficient water flow to satisfy the pressure switch and temperature control.
To shut off burner, turn temperature switch to "Off". Allow the engine/motor to continue to run.
Pull the trigger gun to allow water flow to run through the coil for approximately 2 minutes prior to
completely shutting off the system. This process will allow coil to cool down.
IF
YOU EXPERIENCE IGNITION FAILURE, DO NOT ATTEMPT TO RESTART
BURNER! EXCESS FUEL AND VAPORS MAY H AV E ACCUMULATED AND THE
CHAMBER MAY BE HOT. THE UN I T MUST COOL DOWN BEFORE RESTART CAN
BE A TTE M PTE D.
Warning: Condensation on Coil
When cold water is being pumped through the heater coil and the burner is firing, condensation
may form at times on the coil and drip down into the burner compartment. This can be
particularly noticeable on cold, humid days giving the false appearance of a leaking coil.

** Hot Water Pressure Washers Only
Eec
t r i c a ll y Operated Burners – Some models generate 12V f r o m the gasoline engine
and provide the n ecess a r y power for t h e burner. Others utilize a 120v connection which
must be g
r o und e d . IF YOU REQUIRE UPGRADES OR MODIFICATIONS T O
YOUR EXISTING ELECTRICAL SYSTEM IN ORDER T O OPERATE YOUR
PRESSURE WASHER, THEY MUST B E PERFORMED BY A LICENSED
ELECTRICIAN AND B E COMPLETED IN ACCORDANCE TO ALL A PPL I C AB LE
CODES IN YOUR AREA OF O PE R A T I O N. The power supply must be adequate for
your specific unit. Make sure to verify the data plate for your machine’s specific
requirements (i.e. voltage, amperage, etc).
WA R N I N G :
All electrically powered units must be provided with suitable overload a
n d
overcurrent protection in accordance with the Canadian E l e c t r i ca l Code part 1.
Confirm the GFCI (Ground Fault Circuit Interrupter) is in good working order.
6. 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 the desired pressure by turning the adjustment knob.
Turning the adjustment knob clockwise will increase the pressure. NEVER OPERATE
SYSTEM AT A HIGHER P S I 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 Pressure
Regulator/Unloader counter clockwise.
7. You are now ready to start the cleaning operation - Pull trigger on the pressure wand
assembly to start cleaning. To stop the pressurized water, r e l e a se the trigger. DO NOT
LE AV E UNIT RUNNING WHEN NOT IN US E .
8. **
To stop Burner operation – Turn the burner control switch to off (or PUMP for
electric machines) and run pump for two minutes with the trigger gun pulled to allow
the coil to cool down. After the cooling period is complete, turn off main
power to engine/motor. Squeeze and release the trigger for the second time in order to
r e li eve the pump system of p r ess u r e.
9. Prior to storage – Inspect the pressure washer for any damage or required
maintenance. If your machine needs to be exposed to cold weather, please refer to the
winterization instructions found in this manual. If possible,d o not allow unit to remain
outside in the elements.
10. Warning – If unit is left running while not in use, pump damage m a y occur. Do
not leave unit running while not in u se!
11. Battery Specifications for electric start systems only – Rating: 165CCA,
190 CA or better, dimensions: 8” x 5” x 6”.

** Hot Water Pressure Washers Only
CHEMICAL A
PPL I C A T I O N
DOWNSTREAM CHEMICAL INJECTION – STANDARD
NOTE:Do not removeback
flow preventer as chemical may flow back into
the potable water sou r ce.Ensure the black nozzle is properly fitted at the
end of the wand. The chemical injector will not function if this nozzle is
not correctly in place.
1. Chemical
preparation – Select the detergent/chemical that best suits your
cleaning task. Prepare the dilution according to the m anu f a c t u r e r ’s
instructions. The volume of chemical being used may be adjusted at t h e
valve located on the chemical i n j ec t o r .
2. Insert the intake hose, located on the chemical injector at the pump,
i n t o
the chemical being u se d .
3. Turn the adjustment knob on the wand or lance to the open p os i t i o n
OR when single lance is used, black nozzle will need to be used on
wand.
4. To apply chemical, engage the trigger on the pressure wand a sse m b l y.
Turn the chemical injector’s nipple to adjust flow.
5. Chemical can now be applied through the pressure wand assembly. It will
take 5 – 15 seconds for the chemical to travel to the spray nozzle. Volume
of chemical being used or water being supplied may be
adjusted at the
Chemical I n j ec t o r .
6. For best results apply chemical from bottom to top, allow the c
h e m i c a l
proper penetration time prior to rinsing. Do not allow the chemical t o
dry. Rinse from the top to the b o tt o m .
7.
Optional high pressure chemical injection systems available. P l e a se
contact Easy Kleen.

** Hot Water Pressure Washers Only
WINTER PUMP/COIL
PROTECT I O N
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 co m p r esse d air) from sys t e m .
Connect a short piece of male fitted ½” garden type hose on to t h e
female inlet on the pu m p .
2. Place the open end of the hose into a wide mouthed container of f u ll
strength, winter rated, vehicle windshield washing fluid or Anti-Freeze,
RATED FOR MINIMUM -40° C .
3. Connect the pressure wand
a sse m b l y.
4. Start the engine and engage the trigger on the pressure gun. O p e r a t e
the system until the fluid runs the same co l o r as the windshield w a s h i n g
fluid. Your machine is now prepared for s t o r a ge.
5. Blow out, disconnect fluid supply & pump out excess or cap end

GENERAL MAINTENANCE
**BURNER
M A I N TE NAN C E
Repair of the burner is to be done by authorized and trained burner professionals only.
GENERAL MAINTENANCE AND C A R E
If the water heater is likely to be exposed to freezing weather then it should be
winterized with anti-freeze. Circulation of an anti-freeze solution through the coil by means of
the pumping module is the most fail-safe method and should be used. Alternate methods may
not completely protect the components. Damage from freezing is not a warrantable item.
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, prevents streaking on painted surfaces and
glass when rinsing.
**DescalingHeaterCoil If heater coils develop excessive scale buildup it should be replaced
as excessive scale in heater coil will reduce efficiency of the unit and affect recovery capacity.
Descaling via use of acid may be hazardous and is thus not recommended.
** Hot Water Pressure Washers Only

MAIN ENANCE CHECKLIS
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—
RECOMMENDA ION FOR OIL CHANGES AND COMPONEN REPLACEMEN S
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.
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 COMPONEN REPLACEMEN S
1. Change the engine oil after the first 5 hours and every 100 hours after the initial oil
change. Use 10W-30 engine oil.
2. Replace the spark plug every 100 hours.
3. Change the air cleaner element every 100 hours.
4. Check fuel filters every 300 hours.
5. Change all other components on the engine as needed.

GLOSSARY OF TE RM S
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. Important to use only SAE
30 W Non Detergent (GP Pump) or Hydraulic 68 (EK Pump) in the pump (see diagram).
OIL, GASOLINE ENGINE – Machines which are powered by gasoline engines need
appropriate lubricant. Use 10W30 detergent oil.
BURNER – The burner heats the water in hot water pressure washers. It is located under the coil
and may be powered by furnace oil or diesel fuel.
BACK FLOW PREVENTER – Device to prevent flow backwards into potable water supply.
MAXIMUM WORKING PRESSURE The water heater coils are designed to operate safely at
normal working pressures of 4000 PSI. 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.
TEMPERATURE CONTROL- The water heater is equipped with a temperature control which
shuts down the burner in the event of excessive outlet temperature caused by insufficient water
flow through the heater coil. Do not set thermostat above 195˚F
HIGH PRESSURE SWITCH - A high pressure switch is used to control the burner. It is part of
the burner control system (see diagram).

OFF
–
PUMP
–
BURNER Switch
Interrupteur “Arrêt – Pompe – Brûleur”
Pressure S
witch
Pressostat
Site Glass
Vitrine à Niveau
Electric Motor
Moteur Électrique
10 Gal.
Fuel ank
Réservoir à Fuel
10 Gal.
Coil
Serpentin
EK
Pump
Pompe EK
Oil Cap
Bouchon d’Huile
Water Inlet
Entrée pour l’Eau
Chemical Injector
Injecteur de Produits Chimique
Hot Water Outlet
Sortie d’Eau Chaude
Unloader
Régulateur à Pression
13” Pneumatic ires
Pneus 13”
High Pressure Connector Hose
uyau Connecteur à Haute Pression
General Pump Also Available
(GP)
Pompe “General Pump” Aussi Disponible (GP)
ype of Oil needed for Pumps:
EK Pump – Hydraulic 68 (650ml)
GP Pump – SAE 30 Non-Detergent
ype d’Huile pour les Pompes:
Pompe EK – Hydraulique 68 (650ml)
Pompe GP – SAE 30 Non-Détergente

Site Glass
Vitrine à Niveau
Pressure Switch
Pressostat
hermostat Knob
Règlage du hermostat
Chemical Injector
Injecteur de Produits Chimique
Coil
Serpentin
10 Gal Fuel ank
Réservoir à Fuel 10 Gal.
Electric Starter
Démarreur Électrique
Gasoline Engine
Moteur à Gaz
Oil Cap
Bouchon d’Huile
Unloader
Régulateur à Pression
Hot Water Outlet
Sortie d’Eau Chaude
Water Inlet
Entrée pour l’Eau
EK Pump
Pompe EK
High Pressure Connector Hose
uyau Connecteur à Haute Pression
Pressure Relief Valve
Valve de Décharge à Pression
Rectifier
Rectificateur
General Pump Also Available (GP)
Pompe “General Pump” Aussi Disponible (GP)
ype of Oil needed for Pumps:
EK Pump – Hydraulic 68 (650ml)
GP Pump – SAE 30 Non-Detergent
ype d’Huile pour les Pompes:
Pompe EK – Hydraulique 68 (650ml)
Pompe GP – SAE 30 Non-Détergente

Electric Motor
Moteur Électrique
Water Inlet
En
trée pour l’Eau
Hot Water Outlet
Sortie d’Eau Chaude
Hot Water Outlet
Sortie d’Eau Chaude
Water Inlet
Entrée pour l’Eau
Fold Down Handle
Poignée Dépliante
General Pump Also Available (GP)
Pompe “General Pump” Aussi Disponible (GP)
ype of Oil needed for Pumps:
EK Pump – Hydraulic 68 (650ml)
GP Pump – SAE 30 Non-Detergent
ype d’Huile pour les Pompes:
Pompe EK – Hydraulique 68 (650ml)
Pompe GP – SAE 30 Non-Détergente
EK Pump
Pompe EK
Gasoline Engine
Moteur à Gaz
EK Pump
Pompe EK
Unloader
Régulateur à Pression
Unloader
Régulateur à Pression

22
TYPE OF OIL
Pump 30W Non-Detergent
Gas Engine 10W30
PROBLEM POSSIBLE CAUSES SOLUTIONS
PRESSURE
No pressure
or
Very low pressure
- Metal in oil
- Dirt in water
- Wrong nozzle size
- Examine the oil in the pump to see if there is metal in the oil.
- If you find traces or pieces of metal, your pump has damaged components.
- Verify if there is dirt in the nozzle tip or in the valves in the pump.
- If the nozzle is plugged, clean it or replace it.
- If the valves in the pump are clogged, clean the valves.
- If the valves in the pump are dammaged, replace the valves.
- Make sure you have the right nozzle size. The black nozzle will drop the pressure in
order to use the chemical injector. If you are not using soap, try using a different color.
Pressure too high - Wrong nozzle size
- Unloader adjusted improperly or damaged
- Make sure you have the right nozzle size.
- Check the pressure of the pump with a pressure guage and adjust to desired pressure.
- If you cannot reduce the pressure, replace the unloader.
LOSS OF BATTERY CHARGE (12 VOLT SYSTEM)
Burner fan does not shut down
or
Burner fan starts up when the machine
is not in use
- Thermostat is stuck or damaged - Make sure the thermostat is working properly. Take dial off thermostat button. Turn the
2 screws about a quater of a turn to the left (counterclockwise). Put dial back on. Try to
shut off thermostat.
- If you don’t hear a click when you turn the dial completely over, replace the
thermostat.
NOTE : The newer 12 volt models now have an on/off swtich that is designed to cut off
the current between the battery and the burner in order to preserve the battery’s charge. If
you have a model that does not have this switch, please call us for more info.
QUICK DIAGNOS IC AND SOLU IONS GUIDE
(FOR MORE INFORMA ION, PLEASE CALL 1-800-315-5533)

23
BURNER
No hot water
- Dead battery
- Damaged thermostat
- Damaged pressure switch
- Damaged ignitor
- Plugged filter or no fuel
- Make sure your battery is fully charged.
- If the battery’s charge is not full, please replace or re-charge your battery.
- Make sure the thermostat is connected properly.
- If the burner fan does not come on when you turn the thermostat dial, replace the
thermostat.
- If the burner fan comes on, check the pressure switch.
- Make sure the pressure switch is connected properly to the burner unit. Take the cover off the
pressure switch by unscrewing the 4 screws on the front part of the switch (switch is located on the
pump). Without touching the contacts that conduct current, push on the little button found on the
mirco switch (the button is located directly above the part that attaches directly into the pump).
- If the burner comes on, replace the pressure switch.
- If the burner does not come on, make sure there is current going through the swtich
(consult a professional for this if you do not know how to do this properly as you can get
severly injured by the electrical current connected to your machine)
. If current properly flows through the pressure switch to the burner, check the ignitor.
- Please call a repair center or PowerJet’s service line for help to conduct tests on the ignitor.
- If you see vapor coming out the top of the coil when you try to turn the burner on while
the machine is in use, fuel is passing through the system properly but the ignitor is unable
to produce a spark. Replace the ignitor.
-If you don’t see vapor, check the fuel line.
- Make sure you have enough fuel in the tank.
- If you have fuel, make sure the filter and fuel line are not plugged or damaged.
IN ORDER O AVOID SERIOUS INJURIES, PLEASE DO NO A EMP O REPAIR YOUR MACHINE IF HE PROBLEMS YOU ARE FACING ARE GREA ER
HAN
YOUR CAPABILI Y O HANDLE SAFELY. PLEASE CALL EASY KLEEN OR A PROFESSIONAL REPAIR CEN ER IF YOU NEED HELP WI H YOUR MACHINE.
FOR THESE STEPS, PLEASE MAKE SURE THE MACHINE IS NOT RUNNING. PLEASE ALSO
TAKE THE NECESSARY
STEPS TO AVOID ELECTRIC S
HOC
K
S AND OTHER INJURIES.