Powerline SKID SERIES User manual

OPERATOR’S MANUAL
SKID SERIES
Gas Engine / Diesel Fired
READ THIS MANUAL
This manual contains important information for the use and safe operation
of your Power Line™ machine. FAILURE TO READ THIS MANUAL AND
FOLLOW ITS INSTRUCTIONS PRIOR TO OPERATING OR ATTEMPTING
ANY SERVICE OR MAINTENANCE PROCEDURE COULD RESULT IN
SERIOUS INJURY OR DEATH TO YOU OR OTHER PERSONS; ALSO
DAMAGE TO THE MACHINE OR TO OTHER PROPERTY.
Power Line Industries 14717 HERITAGECREST WAY  RIVERTON, UTAH 84065  PHONE: [phone]

OPERATOR’S MANUAL
Power Line Industries 14717 HERITAGECREST WAY  RIVERTON, UTAH 84065  PHONE: [phone]
PAGE 2
NOTICE
Information in this operator’s manual is subject to change without notice.
POWER LINE SHALL NOT BE LIABLE FOR TECHNICAL OR EDITORIAL ERRORS OR OMISSIONS CONTAINED
HEREIN. This operator’s manual contains information protected by copyright. No part of this operator’s manual may be
photocopied or reproduced in any form without prior written consent from POWER LINE.
Second Printing (September 2004)
TABLE OF CONTENTS
SECTION 1 OPERATOR’S MANUAL
Unpacking 3
Safety Instructions and Warnings 3
Installation Instructions 5
Operation Instructions 6
Starting Checklist 6
Washing Techniques 7
Stopping Machine 7
Moving, Storage and Winterizing 7
Maintenance Instructions 8
Engine Maintenance 8
Pump Maintenance 8
Heat Exchanger Coil 8
Coil Descaling 8
Electrode Settings 9
Unloader Adjustment 10
Oil Burner Air Band Adjustment 10
SECTION 2 PARTS AND SERVICE MANUAL
Exploded Assembly View (NH Series) 11
Parts List 12
Burner Assembly 13
Gun and Wand Assembly 14
Pump Assembly 15
Complete Parts List 16-18
Wiring Diagrams 19
Troubleshooting 20-21
Warranty 22-23

OPERATOR’S MANUAL
Power Line Industries 14717 HERITAGECREST WAY  RIVERTON, UTAH 84065  PHONE: [phone]
PAGE 3
READ THIS FIRST! FAILURE TO READ AND OBSERVE ALL
WARNING STATEMENTS COULD RESULT IN SEVERE BODILY
INJURY OR DEATH, POSSIBLE INJURY TO OTHER PERSONS,
DAMAGE TO MACHINE OR OTHER PROPERTY.
 This machine should not be operated in areas where open flames are not
permitted.
 Do not store or use combustible materials on or near this machine.
 Do not operate this machine while under the influence of alcohol, drugs or
while fatigued.
INSPECTION
Carefully unpack your new Power Line™ pressure washer by removing the banding and card-
board box from pallet. Remove the pressure washer from the pallet and check for any physical
damages that may have occurred during shipment. Check for all parts specified and shown in
figure 1.
FIGURE 1
Included Parts
 Pallet
 Packing Material
Outer Crate
 Skid Gas Series
 Wand / Trigger Gun
 Nozzle 15º
 Hose 3/8” X 50’
 Operator’s Manual
 Engine Manual
Skid Series
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WARNING
UNPACKING INSTRUCTIONS
SAFETY INSTRUCTIONS

OPERATOR’S MANUAL
Power Line Industries 14717 HERITAGECREST WAY  RIVERTON, UTAH 84065  PHONE: [phone]
PAGE 4
 Do not direct discharge stream at yourself or others. Risk of injection or injury
may occur. This product should only be operated by trained personnel.
 Do not operate this machine without wearing protective eye wear.
 Do not tie back or block trigger gun in OPEN position.
 Do not operate this machine in areas with poor or no ventilation. This machine
requires air for combustion and flue gas evacuation. See specifications for
required volume for your model.
 Do not overreach or stand on an unstable support while operating this
machine. Maintain good footing and balance.
 Do not permit this machine to run while unattended or for extended periods of
time with trigger gun closed. Damage to pump may occur.
 Do not operate this machine in an unsafe manner or around unsupervised
children. Keep all other personnel clear while operating this machine.
 Do not service this machine without disconnecting power supply and shutting
off gas source. This machine is equipped with a manual shutoff valve.
 Do not alter original factory settings prior to operating this machine. Risk of
injury to yourself or other persons may occur.
 Do not remove hoses, guns, nozzles or any components while this machine is
still hot or while it is running.
 Do not operate machine with service covers removed.
 Do not attempt to service this machine before reading the service manual.
 Do not operate this machine without knowing how to stop and bleed water
pressures. Know all controls before using this machine.
 Do not spray caustic, acids or abrasive fluids through this machine.
 Do not permit lime and scale buildup to occur in the heat exchanger coil.
 Do not permit water to freeze inside this machine. Risk of coil, pump and
plumbing damage may occur.
 Use only recommended Power Line™ parts when servicing this machine.
 Power Line™ will not be held liable for any unauthorized
modifications made to this machine.
SAFETY INSTRUCTIONS

OPERATOR’S MANUAL
Power Line Industries 14717 HERITAGECREST WAY  RIVERTON, UTAH 84065  PHONE: [phone]
PAGE 5
FILL FUEL TANKS IN OPEN AREA AWAY FROM OPEN
FLAMES OR SPARKS. USE ONLY CLEAN FUEL VOID OF
WATER AND CONTAMINATES.
Following the requirements below will insure a successful installation.
 Install group 24, 750- 850 cold cranking amp battery.
Red cable is attached to positive terminal.
 Check fuel oil and fill with diesel #1, diesel #2, kerosene or #1 home heating oil.
 Check the gasoline tank and fill with a good grade of gasoline.
 Check the engine oil level and fill with SAE 10W40 if needed.
 Check the pump oil level and fill with SAE 30w non-detergent oil if needed.
 Connect water hose to the water inlet connection located on the machine.
 Turn on water and check float tank for water level.
 Start gas engine and continue until water discharges from coil
 Stop engine and connect high pressure hose to the outlet.
 Restart engine and open trigger gun control to flush system until water is clear.
 Install water nozzle at the end of wand, making sure it is clear of any obstructions.
 Turn burner switch to “ON” position and check for burner ignition.
 Check for leaks in the system and cycle trigger gun to insure bypass is adjusted correctly.
Repair and leaks nad correct unloader adjustment if needed.
 If unit is hot, run until unit is cool then shut down machine.
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WARNING
INSTALLATION INSTRUCTIONS

OPERATOR’S MANUAL
Power Line Industries 14717 HERITAGECREST WAY  RIVERTON, UTAH 84065  PHONE: [phone]
PAGE 6
MAKE SURE ALL SWITCHES ARE IN THE OFF POSITION
BEFORE STARTING MACHINE.
STARTING THE MACHINE
 Read this manual before starting this machine.
 Protective eye wear and clothing is required during operation of this machine.
 Check all fluid levels.
a) Pump Oil: If needed add SAE 30 weight non-detergent oil.
b) Engine Oil: If needed add SAE 30 weight high-detergent oil
b) Fuel Oil Tank: Use only kerosene,diesel #1 or #2 or #1 home heating oil.
c) Fuel Gasoline: Use a good grade of gasoline.
 Connect water supply hose to unit, do not turn water on.
 Quick connect the 50ft. discharge hose and gun assembly to outlet of heater coil, and
remove pressure nozzle from end of wand.
 Turn on water supply, and open trigger gun.
 DO NOT START ENGINE WITH BURNER SWITCH ON. Start gas engine and allow
RPM to develop. SMALL ENGINES MAY KICK BACK. DO NOT HOLD PULL CORD
TOO TIGHTLY.
 Turn burner switch “ON” and open the trigger gun while firmly gripping
the wand assembly. Grasp the grip on the wand with one hand and the trigger gun
with the other. Do not touch unprotected HOT surfaces with bare hands.
 Insert detergent siphoning tube into a DOT approved container and open the metering
valve for detergent application.
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WARNING
OPERATING INSTRUCTIONS

OPERATOR’S MANUAL
Power Line Industries 14717 HERITAGECREST WAY  RIVERTON, UTAH 84065  PHONE: [phone]
PAGE 7
WASHING TECHNIQUES
 Water spray should be hot and soapy prior to washing.
 Washing from bottom up increases dwell time of soap and lessens vertical streaks.
 Turn soap metering valve and burner switch “OFF” to purge system of soap and hot
water.
 Rinsing with cold water from top down will retard detergent reaction which will enhance
the rinsing performance.
 Wash at 30 to 60 degree angles to prevent splashback.
STOPPING THE MACHINE
 Turn burner motor switch “OFF” and continue allowing water to discharge
while cooling down.
 Turn engine off and discharge water pressure from trigger gun.
 Turn water supply “OFF”.
 Place wand in holder and coil up pressure hose or wind up on hose reel.
MOVING, STORAGE
 Protect machine from freezing temperatures by storing in heated area.
WINTERIZING
 Direct Drive Machines: To protect the machine from freezing temperatures while
storing or transporting, connect short length of garden hose (approximately 3 ft.) to
water inlet connection on machine. Remove the pressure nozzle from the wand and
insert the short garden hose end into a container of antifreeze. Place the wand into the
antifreeze container and start engine running machine until antifreeze appears from the
end of the wand. Turn engine “OFF” and replace pressure nozzle. Coil up hose and
move machine to storage area.
 Float Tank Machines: Pour antifreeze into float tank and remove water nozzle from end
of wand and carefully insert into opening of float tank. Start machine and run until
antifreeze water mixture has circulated throughout the machine returning back to the
float tank.
DO NOT STORE COMBUSTIBLE MATERIALS (GASOLINE,
DIESEL OR OTHER PETROLEUM PRODUCTS) NEAR
PRESSURE WASHER WHILE OPERATING.
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WARNING
OPERATING INSTRUCTIONS

OPERATOR’S MANUAL
Power Line Industries 14717 HERITAGECREST WAY  RIVERTON, UTAH 84065  PHONE: [phone]
PAGE 8
HEAT EXCHANGER COILS
 Hard water conditions may eventually cause clogging in the heat exchanger. If
so it may be necessary to descale coil, since scale deposits will compromise
the heating efficiency and produce an unsafe condition.
 Scale buildup from certain detergents may eventually clog up the heat
exchanger coil causing an unsafe condition. Use only Power Line™
recommended detergents for better cleaning efficiency.
COIL DESCALING:
 Mix in a 5 gallon pail, one pound of deliming powder for every gallon of water used.
 Attach one end of a 4-6 foot length of rubber hose to the water intake connector
and insert the other end into the thoroughly mixed deliming solution.
 Remove the trigger gun from the high pressure hose and place the hose end into
the mixed deliming solution.
 Turn pump motor switch “ON”, allowing even water flow from the pickup hose in
the deliming solution through the pump, plumbing, coil and hose, returning back to
the solution container. DO NOT TURN THE BURNER ON.
 Continue to circulate solution for as long as it takes to clear the build-up
(may require multiple treatments).
 Re-install the trigger gun. Flush the system with clean water.
FAILURE TO MAINTAIN HEAT EXCHANGER COIL MAY
RESULT IN A STEAM EXPLOSION WHICH MAY CAUSE
SERIOUS INJURY OR DEATH.
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WARNING
MAINTENANCE INSTRUCTIONS
ENGINE MAINTENANCE
 Every time (before start): Check oil level.
 First 8 hours: Change oil.
 Every 25 hours: Change oil if operating under heavy load or high ambient temperature.
Service air cleaner pre-cleaner.
 Every 50 hours: Change oil. Clean and inspect spark arrester if equipped.
 Every 100 hours: Service air cleaner cartridge, replace oil filter (if equipped),
Clean oil cooler (if equipped), Clean cooling system.
PUMP MAINTENANCE
 Fill crankcase to dot on oil gauge window per specifications with 30W Nondetergent Oil.
 Change oil after 40 Hour Break-in Period.

OPERATOR’S MANUAL
Power Line Industries 14717 HERITAGECREST WAY  RIVERTON, UTAH 84065  PHONE: [phone]
PAGE 9
ELECTRODE SETTINGS
Inspection of all wires, spring contacts and electrodes should be done periodically.
See figure 2.
Figure 2
USE INSULATED SCREWDRIVER
WHEN CHECKING TRANSFORMER.
Proper electrode setting should be
done with a defect-free insulated
screwdriver across one contact.
Settings are correct when arc spans
1/2” between the end of the
screwdriver blade and the
other contact. See figure 3.
Figure 3
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WARNING
MAINTENANCE INSTRUCTIONS

OPERATOR’S MANUAL
Power Line Industries 14717 HERITAGECREST WAY  RIVERTON, UTAH 84065  PHONE: [phone]
PAGE 10
Adjustment of the unloader requires removal of
the locking nut. Turn adjusting nut to the
lowest spring tension (counterclockwise) and
start machine. Open trigger gun and begin
adjustment of pressure by turning adjusting
nut (clockwise) until machine is at normal
operating pressure. Open and close the
trigger gun to set unloader and check for high
spike pressures. Turn the adjusting nut
(counterclockwise), decreasing pressure
slightly. Replace lock nut, adjusting it down to
lock the adjusting nut to shaft. See figure 4.
OIL BURNER AIR BAND ADJUSTMENT
Power Line® sets oil burners at sea level. Air bands may need adjustment at higher ele-
vations to offer enhanced performance of the burner and extended life of the machine.
IF BLACK OR WHITE SMOKE VENTS FROM
EXHAUST PORT UPON STARTING EQUIPMENT,
DISCONTINUE USE AND ADJUST AIR BANDS
BEFORE RESTARTING.
UNLOADER ADJUSTMENT
Figure 4
Adjustment of burner is done with
pump motor and burner switches “ON”.
Loosen locking screw on air band, then
close band until black smoke vents up
exhaust vent. Take careful note of air
band position when black smoke is
first noticed. Slowly open air band until
white smoke vents, then turn air band
halfway back to where black smoke
was first noted. Tighten air band
locking screw. See figure 5.
Figure 5
Adjusting Nut
Locking Nut
Pulsar Unloader
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WARNING
MAINTENANCE INSTRUCTIONS