Hugh Crane COMMANDO 4000 Assembly instructions

OPERATOR INSTRUCTION MANUAL
COMMANDO
COMMANDOCOMMANDO
COMMANDO ® 4000
For Sales, Service and Spare Parts contact:
HUGH CRANE (Cleaning Equip ent) Ltd
SOUTH WALSHAM ROAD, ACLE, NORWICH NR13 3ES
TEL: [phone] FAX: [phone] E ail:[e-mail]
SOUTH WALSHAM ROAD, ACLE, NORWICH, NORFOLK, NR13 3ES
TEL: [phone] - FA : 01493 751854 - www.hughcrane.co.uk
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Cleaning Equipment Limited
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HUGH CRANE (Cleaning Equip ent) Ltd – COMMANDO
®
4000 Page 2
IMPORTANT
THIS HANDBOOK SHOULD BE READ AND UNDERSTOOD BY THE
OPERATOR BEFORE USING THE COMMANDO
®
4000 PRESSURE WASHER
AND SHOULD BE KEPT WITH THE EQUIPMENT AND MADE AVAILABLE
TO ANYBODY WHO IS INTENDING TO USE OR MAINTAIN IT.
GUARANTEE
COMMANDO
®
products are guaranteed for one year for parts and labour from the date
of purchase (guarantees are not transferable) subject to good use, protection from
frost and adherence to recommended service procedures. Major components are
subject to individual manufacturer’s warranty conditions. earing parts, including
tyres, pump seals, valves, hoses, filters, jets and tooling are excluded from warranty
cover unless subject to faulty materials or manufacture.
WHEN ORDERING SPARES - Please quote:-
a) Your Company Name and Address
b) Model Type and Serial No. of unit
c) Full description of parts required
d) Your contact name and telephone number
e) Your order number
Unique Machine Numbers
Model Number:
Serial Number:
Pump Serial Number:
Maximum Pump Pressure: 200 bar (2900 psi)
Maximum Pump Flow: 20 litres/minute (4.40 gallons/minute)
No part of this docu ent ay be reproduced or trans itted in any for or by any
eans, electronic or echanical for any purpose other than to assist in the safe operation
and aintenance of the Hugh Crane COMMANDO
®
4000 without the express per ission of
Hugh Crane (Cleaning Equip ent ) Ltd.
Hugh Crane (Cleaning Equip ent ) Ltd.

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®
4000 Page 3
INTRODUCTION
The Hugh Crane (Cleaning Equip ent) Ltd range of COMMANDO high pressure washing
equip ent is anufactured to rigorous quality standards. The basic concept is to use quality
aterials and co ponents together with proven designs to attain the highest standards of
reliability and safe operation. This instruction anual is provided to assist the operator to
use the equip ent safely whilst obtaining the best perfor ance fro it.
The units are supplied with anual rewind hose reels as standard co plete with high-
pressure hoses, guns and lances. The COMMANDO 4000 is ounted on a single axle road
going trailer with a poly water tank. The COMMANDO 4000 is a versatile achine used in
agriculture, hire, construction and civil engineering.
SPECIFICATION – COMMANDO
®
4000
ENGINE:
Model: Honda GX390
Nett Power 8.7 kW @ 3600 rev/ in
Fuel: Petrol
PUMP:
Model UDOR MC20/20S
Type Triplex Cera ic Plunger
Pu p pressure 200 bar/2900psi
Pu p flow 20 l/ in / 4.40 gal/ in
UNLOADER VALVE:
Type ST280
Pressure setting 200 bar/2900psi
HIGHWAY TOW:
Di ensions LxWxH 3475x1550x1350
Weight (tank e pty / full) 400 kg / 1500 kg
Tank capacity 1100 l / 240 gallons
Wheels & Tyres 2 off 185R14 8ply
Coupling specification Knott KRV20

HUGH CRANE (Cleaning Equip ent) Ltd – COMMANDO
®
4000 Page 4
GENERAL HEALTH & SAFETY DATA
RESPONSIBILITIES OF EMPLOYERS:
1. It is the responsibility of all e ployers and e ployees to work within the require ents of
the Health and Safety at Work Act 1974.
2. It is the duty of every e ployer to ensure, as far as is reasonably practical, the health and
safety at work of all his e ployees by carrying out risk assess ent and i ple enting any
necessary control easures.
3. With regard to high pressure washing equip ent, the aintenance of plant is of great
i portance and should any equip ent be suspected of being da aged or defective
IT SHOULD NOT BE USED UNTIL INSPECTED BY A COMPETENT PERSON.
4. Where che ical substances or abrasives are to be used, a COSHH risk assess ent
should be conducted and any necessary control easures i ple ented.
DUTY OF EMPLOYEES:
1. To ensure that all persons who are working in, or in the vicinity of, operations under his
control or passers by to such activity, to take reasonable care with the health and safety
of hi self and persons working in conjunction with hi self or passers-by.
2. All e ployees should co-operate with their e ployer to ensure that safe working practices
are aintained in all respects.

HUGH CRANE (Cleaning Equip ent) Ltd – COMMANDO
®
4000 Page 5
BEFORE MOVING ONTO THE PUBLIC HIGHWAY :
a) Ensure that towing vehicle is of suitable capacity to tow the COMMANDO 4000.
b) Check tyres for condition and correct inflation pressure.
c) Ensure that ball hitch is fully engaged on towing vehicle and that breakaway cable is
securely attached to an anchor point on the vehicle.
d) The handbrake should be released and jockey wheel fully retracted and locked.
e) Check all trailer lights for correct operation.
f) Whenever possible, the unit should be towed with the water tank e pty.
g) Ensure that all ancillary equip ent is securely attached and stowed on the vehicle.
h) Fit a registration plate to the COMMANDO 4000 to suit the towing vehicle.
OPERATIONAL PROCEDURES:
Handbrake
Jockey wheel
Ball hitch
Jockey wheel
locking handle
Breakaway cable

HUGH CRANE (Cleaning Equip ent) Ltd – COMMANDO
®
4000 Page 6
a) Before using the COMMANDO
®
4000 operators should have undergone basic training
in the safe use of high pressure washing equip ent. Training courses are available
fro Hugh Crane (Cleaning Equip ent) Ltd. if required.
b) Suitable protective clothing should be provided and worn by all operators.
High-pressure jets are dangerous if subjected to misuse.
Care should be taken to ensure that ani als and children are kept well out of the
working area. The jet must not be directed at people, ani als, the achine itself,
non-waterproof, fragile ite s or electrical equip ent.
c) User’s attention is drawn to health and safety guidance note P.M.29 which deals with
the use of high pressure cleaners and stea cleaners. Eye protection to BS2092/2
ust be worn when this equip ent is used.
d) All repairs to this equip ent ust be carried out only by suitably qualified personnel.
No odifications or changes to the specification of this achine should be ade
without prior consultation with and approval of the anufacturer.
e) The achine is supplied with guarding in co pliance with current legislation. The
achine ust not be operated with any of the guards, covers or any other safety
equip ent re oved or da aged.
f) Co ponents that are supplied by others, such as the engine, are covered by
individual anufacturer’s infor ation, which is included for your use.
g) Che icals ay be used in conjunction with this equip ent using a che ical injector.
Only che icals supplied or reco ended by the anufacturer should be used, as
other products ay affect the safe use of the equip ent. Consideration should also
be given to environ ental and COSHH regulations.
h) The high-pressure spray gun is provided with safety lock, which enables the trigger to
be locked off to prevent inadvertent use.

HUGH CRANE (Cleaning Equip ent) Ltd – COMMANDO
®
4000 Page 7
PREPARING THE MACHINE FOR USE:
BEFORE TOWING - DAILY
a) Check condition of tyres for sufficient tread depth, cuts, bulges and check inflation
pressure.
b) Check wheel nuts for tightness.
c) Check tow coupling for security and re ove key fro the lock.
d) Check condition of the safety breakaway cable.
g) Check condition of trailer lighting plug and connect to the towing vehicle.
h) Ensure that all lights are functioning correctly and that reflectors are clean.
i) Attach a nu ber plate co patible with towing vehicle.

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®
4000 Page 8
BEFORE STARTING WORK:
a) Ensure the unit is standing on level ground.
b) Check the oil level in the pu p by looking at the site glass set in the end of the
crankcase of the pu p and that the oil is up to the red dot when the pu p is cold and
in a level position. If the oil is low top up to the correct level through the red filler cap
set in the top of the pu p (use Hugh Crane Cleaning Equip ent Ltd. pu p oil)
c) Fill fuel tank with clean petrol
d) Open the bleed valve on the pu p
e) Open the engine fuel valve. Move the engine speed control lever to the ½ speed
position. Pull the recoil starter cord to start the engine. When starting fro cold first
ove the choke lever to the closed position. (Refer to the Honda Engine instruction
anual for further infor ation).
f) Close the bleed valve on the pu p.
g) Release the gun fro the securing position on the fra e and connect the wash lance
or tool required
h) Now operate the wash gun, by pulling the trigger on the gun, to bleed air out of the
hose until air free water is issuing fro the lance.
i) Increase the engine speed to the desired working level, using the hand throttle lever
at the side of unit. Use of the throttle will directly affect output water volu e and
pressure.
ENGINE STARTER
KEY SWITCH
ENGINE SPEED
CONTROL LEVER
FUEL COCK LEVER
CHOKE LEVER

HUGH CRANE (Cleaning Equip ent) Ltd – COMMANDO
®
4000 Page 9
DURING WORK:
a) Do not leave the COMMANDO
®
4000 idling as re-circulating water heats up
rapidly and will eventually boil causing severe damage to the pump.
b) Should any vibration, fluctuation of pressure or any other abnor al sy pto s occur
during operation, this should be investigated i ediately.
Likely causes include:-
i) A lack of water entering the unit causing air to be drawn into the pu p.
ii) A blockage of the ain inlet filter causing water starvation at the pu p.
iii) The inlet water valve between tanks and pu p not fully open.
iv) Leaking seals or da aged valves etc.
AFTER WORK
a) To stop the COMMANDO
®
4000 Turn the starter key to the ‘OFF’ position.
b) Pull the gun trigger to release any pressure trapped in the hose.
c) Open the bleed valve on the pu p.
d) Close the engine fuel valve on the pu p.

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®
4000 Page 10
REGULAR MAINTENANCE
CHECK LIST
ENGINE: Refer to the Honda
Instruction Book
Daily First 20
hours
50
hours
100
hours
300
hours
Oil level *
Oil Change * *
Check air cleaner *
Clean air cleaner *
Replace air cleaner *
Clean sedi ent cup *
Check/adjust spark plug *
Replace spark plug *
Check/adjust idle speed *
Check/adjust valve
clearances
*
Clean fuel tank & filter *
Check tightness of all
fasteners
* *
Check Battery Ter inals * *
GEARBO : Refer to the Udor
Instruction Book
Daily First 50
hours
300
hours
Check oil level *
Change oil * *
PUMP Refer to the Udor
Instruction Book
Daily First 50
hours
300
hours
Clean inlet filter *
Check oil level *
Change oil * *
UNLOADER
VALVE
First 50
hours
300
hours
Check break off
pressure
* *

HUGH CRANE (Cleaning Equip ent) Ltd – COMMANDO
®
4000 Page 11
TRAILER SERVICE CHECK LIST
SERVICE ITEM FIRST 100 MILES EVERY 1000 MILES
(MONTHLY)
EVERY 3000 MILES
(3 MONTHLY)
Tyres * *
Wheel nuts * *
Coupling Bolts * *
Coupling
Lubrication
* *
Jockey Wheel Bolts *
Jockey Wheel
Lubrication * *
Lights - function * * *
Lights - damage * *
Wheel bearings -
adjust * *
Wheel bearings
grease *
Body condition * *
Brakes - adjustment * *
ENGINE: Refer to Engine Manufacturer’s Handbook.
PUMP: Refer to Pu p Manufacturer’s Handbook
GEARBO : Check oil level onthly
UNLOADER: No user serviceable parts.
Under no circumstances should any adjustments be made to the
unloader as serious damage to engine, gearbox or pump could
result.
UNLOADER AND SAFETY VALVE
The unloader and safety valves have no user serviceable parts.
Under no circumstances should any adjustments be made to the
unloader OR the safety valve, as serious personal injury or damage
to the pump could result.

HUGH CRANE (Cleaning Equip ent) Ltd – COMMANDO
®
4000 Page 12
FROST PROTECTION
It is essential to protect the unit from damage by frost. The following instructions will be
adequate to protect the unit to te peratures down to - 5°C. During winter onths it is
strongly reco ended to store the unit inside whenever possible.
1) Run engine for one minute with open ended hoses or gun open to expel all water and
stop the engine.
2) Re ove bowl fro inlet strainer and store safely together with its filter screen.
3) During severe weather, the unit should be stored inside, if possible. Where this is not
possible a 25% anti-freeze/water ixture should be introduced into the pu p, hose and
gun. The antifreeze ixture can be reclai ed after use for recycling when next
required.
4) Before starting work again the antifreeze ust be e ptied out of the syste by running
the pu p and directing the using the solution back into the container. Always ensure
that all anti-freeze solutions are flushed out of the syste before using the unit for
cleaning tasks, as anti-freeze solution can be highly detri ental to certain surfaces and
aterials.

HUGH CRANE (Cleaning Equip ent) Ltd – COMMANDO
®
4000 Page 13
REPLACEABLE ITEMS LIST
See the following illustrations for reference nu bers
Ref. Description Qty Part Number
22 PUMP MC 20/20S 1 HC52011
23 GEARBOX RM122 1” 1 HC52012
24 HONDA GX390 ENGINE 1 HC01602
31 RAB MOUNTS 4 HCOB/024
39 ADAPTER 3/8” - 3/8” BSP M-M 1 HYAD100-0606
40 ADAPTER - 1” BSP M-M 1 HYAD100-0816
41 ADAPTER 3/8” – 3/8” BSP M-F 90° 1 HYAD229-0606
42 INSERT 1” x 1” FEMALE BSP 90° SHORT 1 HYIN1616NU90S
44 BRAIDED HOSE 3/8” 0.8M 2301003
47 ¾” BULKHEAD PLASTIC 1 DP9902BH34
48 ¾” x ¾” BSP HOSETAIL 90° ELBOW 1 DP9901HB07590
49 ADAPTER 3/8” - 3/8” BSP M-M 3 HYAD100-0606
51 3/8” BSP BULKHEAD FITTING C/W NUT 1 HY603
52 UNLOADER VALVE ST280 1 GSST280
53 ADAPTER HEX TEE 3/8” BSP F-F-F 1 HYAD190-06
54 3/8” BALL VALVE SS, 6000 PSI 1 HC02052
55 ADAPTER 3/8” – 3/8” BSP M-F 90° 1 HYAD229-0606
56 P CLIP, RUBBER LINED 16mm 3 HC81412
57 INSERT 3/8” - 3/8” BSP F 1 HYIN0606NU
58 ADAPTER ¼” – ” BSP M-M 1 HYAD100-0408
61 ” ST. ST. M-F 90° ELBOW 1 HC67103
62 ¾” x ” REDUCING BUSH 1 O2ST/NT5349
63 COUPLING INLET ¾” FEMALE 1 HCQC050
64 ¾” HOSE TAIL INLET NIPPLE 1 HCQC053
67 1” BLACK NOVOLINE HOSE 1.5M 2302009
70 1 ¼” FILTER, 50 MESH 1 DP8074005
71 1 ¼” – 25mm FLYNUT HOSE TAIL, 90° 2 DP8012301
72 1 ¼” FLYNUT 1 DP8040301
74 BRASS 1” x 1” HOSE TAIL, TAPER 1 HC95014
75 1” BALL VALVE, ST. ST. 2000 PSI 1 HC02027
76 REDUCING NIPPLE HEX 2” – 1” M-M ST. ST. 1 HC66708
77 2” TEE 1 HC66807
78 2” HEX NIPPLE BSPT ST. ST. 2 HC66207
87 HOSE REEL PAINTED 15m 1 GS75014
95 GUN 1 GSST1500SQR
96 TWIN LANCE 1 GSST54
97 6.5 JET 1 15065/MEG

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®
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87
97
95
67
52
24
23
11
22
96
52
70
44

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®
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78
75
76
23
39
54
52
41
77
44
22
53
51 63

HUGH CRANE (Cleaning Equip ent) Ltd – COMMANDO
®
4000 Page 16
TROUBLE SHOOTING
FAULT
CAUSE ACTION
1. Knocking noise fro
pu p.
Water starvation.
Pu p sucking in air.
Ensure that there is sufficient water supply.
Check suction tank level or pressurised.
Make sure that the suction hose is not
flattened or kinked, especially where it passes
over the edge of the tank.
Check the suction hose for leaks, which ight
allow air to be drawn in.
2. Loss of pressure. Water starvation.
Pu p sucking in air.
Ensure that there is sufficient water in the
tanks.
Check that the strainer is not blocked and that
the pu p inlet valve is open.
Check the suction hose for leaks, which ight
allow air to be drawn in.
Lance nozzle too large
or issing.
Check that the correct nozzle is fitted and is in
good condition.
High pressure water
leak.
Exa ine the high pressure hose and fittings
for leakage.
Unloader not correctly
set up.
Have unloader checked by a suitably equipped
and trained engineer.
Pu p speed too low. Check that engine speed is correct.
3. Pressure too high.
4. Safety valve passing
water.
Pump speed to high. Stop engine immediately. Restart at idle and
reset engine speed.
Lance nozzle too s all
or blocked.
Check that the correct nozzle is fitted and is in
good condition.
Unloader not correctly
set up.
Have unloader checked by a suitably equipped
and trained engineer.

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®
4000 Page 17
MANUFACTURERS’ LITERATURE
UDOR MC20/20 PUMP

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®
4000 Page 18

HUGH CRANE (Cleaning Equip ent) Ltd – COMMANDO
®
4000 Page 19
MANUFACTURERS’ LITERATURE
UDOR RM122 GEARBO

HUGH CRANE (Cleaning Equip ent) Ltd – COMMANDO
®
4000 Page 20