Easy-kleen EZO3204D, EZO4035G-H-GP-12, EZO3508D, EZO4035G-K-GP-120, EZO6004G User Manual

Owner's Manual

Commercial and Industrial Hot Water Gas

and Diesel Driven, Oil Fired

1-800-315-5533 • [e-mail] • 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 (Bull Moose and Grizzly) hot water, gas and diesel driven, oil fired 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.............................................................................................................................................	9
OPERATING INSTRUCTIONS ........................................................................................................................	10
CHEMICAL APPLICATION.............................................................................................................................	12
WINTER PUMP/ COIL PROTECTION ............................................................................................................	13
GENERAL MAINTENANCE............................................................................................................................	13
MAINTENANCE CHECKLIST..........................................................................................................................	15
GLOSSARY OF TERMS..................................................................................................................................	17
COMPONENT IDENTIFICATION ...................................................................................................................	18
QUICK DIAGNOSTICS AND SOLUTIONS GUIDE............................................................................................	25
WIRING DIAGRAMS.....................................................................................................................................	27
MANUFACTURER’S WARRANTY..................................................................................................................	31
SERVICEMANUAL...................... ..................................................................................................................	32

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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: Risk of explosion. Operate only where open flame

or torch is permitted.

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

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. 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.

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. 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.

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.

WARNING: Hot discharge fluid. Do not touch or direct discharge stream at persons.

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RISK OF INJURY

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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.

Protect from freezing.

to keep your machine from freezing in order to keep it in its condition. Failure to protect your machine from freezing may

the machine and personal injuries may occur as a result.

Risk of Injury

with a 12 V burner: Disconnect battery ground terminal

pressure hoses from sharp objects and vehicles. Inspect prior to use, or serious injury could occur.

cids or other caustic or abrasive fluids through the pump.

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14.Never run pump dry of water or oil or 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

Commercial Hot Water Gas - Oil Fired

MODEL	GPM	PSI	BURNER OIL	BTU	HP/ ENGINE	DRIVE	ELECTRIC	BURNER
			PRESSURE (PSI)				START
EZO2703G	3	2700	130	300,000	6.5 KOHLER	DIRECT	NO	120V
EZO4035G-K-GP-R	3.5	4000	130	350,000	14 KOHLER	DIRECT	NO	120V
EZO4035G-H-GP-R	3.5	4000	130	350,000	13 HONDA	DIRECT	NO	120V
EZO4035G-K-GP-120	3.5	4000	130	350,000	14 KOHLER	DIRECT	YES	120V
EZO4035G-H-GP-120	3.5	4000	130	350,000	13 HONDA	DIRECT	YES	120V
EZO4035G-L-GP-12	3.5	4000	130	350,000	15 LIFAN	DIRECT	YES	12V
EZO4035G-K-GP-12	3.5	4000	130	350,000	14 KOHLER	DIRECT	YES	12V
EZO4035G-H-GP-12	3.5	4000	130	350,000	13 HONDA	DIRECT	YES	12V
EZO3504G-K	4	3500	130	400,000	14 KOHLER	GEARBOX	YES	12V
EZO3504G-H	4	3000	130	400,000	13 HONDA	GEARBOX	YES	12V

Commercial Hot Water Diesel - Oil Fired

MODEL		GPM		PSI		BURNER OIL	BTU		HP/ ENGINE	DRIVE	ELECTRIC			BURNER
					PRESSURE (PSI)						START
EZO4035D-K-GP-12		3.5	4000		130		350,000		9.8 KOHLER	DIRECT	YES			12V
EZO3504D-K		4	3500		130		400,000		9.8 KOHLER	GEARBOX	YES			12V
		Industrial Hot Water Gasoline – Oil Fired (Grizzly Series)
	MODEL*	GPM		PSI		BURNER OIL			BTU	HP/ENGINE				DRIVE
						PRESSSURE (PSI)
	EZO3004G	4		3000		160			400,000	13 HONDA				BELT
	EZO3504BG	4		3500		160			400,000	14 KOHLER			GEARBOX
	EZO3504G	4		3500		160			400,000	14 KOHLER				BELT
	EZO3505G	5		3500		130			500,000	20 HONDA				BELT
	EZO3506G	6		3500		145			600,000	25 KOHLER				BELT
	EZO3008G	8		3000		155			800,000	25 KOHLER				BELT
	EZO3010G	10		3000		130			1,000,000	38 KOHLER				BELT
	EZO3708G	8		3700		130			800,000	38 KOHLER				BELT
	EZO5005G	5		5000		130			500,000	25 KOHLER				BELT
	EZO6004G	4		6000		160			400,000	25 KOHLER				BELT
	EZO6006G	6		6000		145			600,000	38 KOHLER				BELT
	EZO7004G	4		7000		160			400,000	25 KOHLER				BELT

*-GG – has a generator *-ST – steam kit

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Industrial Hot Water Diesel – Oil Fired (Bull Moose Series)

	MODEL	GPM	PSI	BURNER OIL	BTU	HP/ENGINE	DRIVE
				PRESSURE (PSI)
	EZO3204D	4	3200	160	400,000	9.8 KOHLER	BELT
	EZO3506D	6	3500	145	600,000	26 KOHLER	BELT
	EZO3508D	8	3500	130	800,000	26 KOHLER	BELT
	EZO3010D	10	3000	130	1,000,000	26 KOHLER	BELT
	EZO5005D	5	5000	130	500,000	26 KOHLER	BELT
	EZO5010D	10	5000	130	1,000,000	58 KUBOTA	GEARBOX
	EZO6004D	4	6000	160	400,000	26 KOHLER	BELT
	EZO7004D	4	7000	160	400,000	26 KOHLER	BELT
	EZO8008D	8	8000	130	1,000,000	58 KUBOTA	GEARBOX

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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 – Be sure to install in an area that has sufficient air ventilation to support combustion of oil in burner.

Controls – Make sure all controls turned to the off position.

Pump – Oil level - Level the pressure washer. Be sure oil level in the pump is correct on dip stick. If the level is low, add the correct oil to the proper level. USE ONLY SAE 30 W NON-

DETERGENT OIL OR HYDRAULIC 68. DO NOT OVER FILL.

Gas Engine - Gasoline level – The engine is a 4 cycle and uses regular octane, unleaded fuel. DO NOT USE MIXED FUEL. Refer to the engine operation manual included with your pressure-washing unit.

Gas Engine - Oil level – The engine is a 4 cycle and uses 10W30 detergent oil. Refer to Glossary or engine manual.

Diesel Engine – Refer to engine operation manual included with your pressure washing unit for oil and fuel recommendations.

Oil Fired Burner - Oil Tank Level – #2 Furnace oil is recommended for the burner oil tank, as it burns cleaner and the burner requires less maintenance. Diesel fuel may be used as an alternative. Do not overfill burner tank.

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 machines operating pressure and temperatures.

2. Attach high-pressure hose to hot 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 the nozzle].

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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 the female pump inlet fitting. Make sure that the inlet screen/filter is intact and fitted correctly.

Turn on water source. WATER MUST BE IN SUFFICIENT SUPPLY, AND PRESSURE MUST BE BETWEEN 20 –60 PSI TO ENSURE PROPER AND SAFE OPERATION. Specific attention should be given if using a well water supply. Ensure water is flowing from end nozzle with the trigger gun pulled. Deplete system of all air.

4.Start Gas/Diesel Engine

Refer to instructions in engine manual. MAKE SURE THAT THE ENGINE EXHAUST IS NOT FACING ANY FLAMMABLE MATERIALS. Adjust burner thermostat to desired temperature, then turn BURNER switch to ‘ON’.

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.

IF YOU EXPERIENCE IGNITION FAILURE, DO NOT ATTEMPT TO RESTART BURNER! EXCESS FUEL AND VAPORS MAY HAVE ACCUMULATED AND THE CHAMBER MAY BE HOT. THE UNIT MUST COOL DOWN BEFORE RESTART CAN BE ATTEMPTED.

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. A leaking coil or system will be evident if the pump keeps cycling with the trigger released. The pump head pressure should read ‘0’.

Electrically Operated Burners – These models generate 12V from the gasoline engine and provide the necessary power for the burner. IF YOU REQUIRE UPGRADES OR MODIFICATIONS TO YOUR EXISTING ELECTRICAL SYSTEM IN ORDER TO OPERATE YOUR PRESSURE WASHER, THEY MUST BE PERFORMED BY A LICENSED ELECTRICIAN AND BE COMPLETED IN ACCORDANCE TO ALL APPLICABLE CODES IN YOUR AREA OF OPERATION. 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.).

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 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 Pressure Regulator/Unloader counter clockwise. If continuing to turn the unloader clockwise does not increase the pressure, then this implies the maximum has been reached for

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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.

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, release the trigger. DO NOT LEAVE UNIT RUNNING WHEN NOT IN USE.

8.To stop Burner operation – Turn BURNER switch to ‘PUMP’ (or to ‘OFF’ for Auto start stop models) and run pump for two minutes with trigger gun pulled to allow coil to cool down. After cooling period is complete, turn off main power to motor by turning BURNER switch to

‘OFF’ (turn PUMP switch to ‘OFF’ if equipped with auto start stop). Squeeze and release the trigger for the second time in order to relieve the pump system of pressure.

9.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/coil instructions found in this manual. If possible, do not allow unit to remain outside in the elements.

10.Warning – If unit is left running while not in use, pump damage may occur. Do not leave unit running while not in use!

11.Battery Specifications for electric start systems only – Rating: 165CCA, 190 CA or better, dimensions: 8” x 5” x 6” (applies to commercial units).

CHEMICAL APPLICATION

Downstream Chemical Injection: Standard (Direct Drive Units) 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.

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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/ COIL 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 female inlet on the pump.

2.Place the open end of the hose into a wide mouthed container of full strength, winter rated, vehicle windshield washing fluid or Anti-Freeze, RATED FOR MINIMUM -40°C.

3.Connect the pressure wand assembly.

4.Start the engine and engage the 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

Burner Maintenance

NOTE: Repair of the burner is to be done by authorized and trained burner professionals only.

The oil filter cartridge should be replaced every year to prevent fuel contamination and plugging of fuel pump and nozzle of oi burner. The nozzle should also be replaced at least once every year or twice if used daily and if poor combustion begins to occur. See the included burner manual for more information on burner.

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Final adjustments to burner include fuel pressure adjustment for controlling water temperature (tighten fuel pressure adjustment screw slightly to increase desired output temperature) and air band adjustment for combustion efficiency. A combustion test kit should be used for these final adjustments. Check SPECIFICATIONS chart (page 7) for the burner oil pressure corresponding to your model and be sure not to exceed this pressure. See included burner manual for more information and a parts break down of the burner.

If the burner floods with oil: run machine with heat on until all excess oil is burned off (this can take up to a couple of hours). If excess oil is not properly dealt with, the ceramic casing can absorb excess oil, causing a fire hazard. DO NOT LEAVE MACHINE UNATTENDED WHILE MACHINE IS FLOODED.

General Maintenance and Care

If the water heater is likely to be exposed to freezing weather then it should be winterized according to the winter pump/coil protection procedure in the previous section. 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.

Descaling Heater Coil Procedure

NOTE: Descaling of the heater coil is to be done by authorized and trained burner professionals only.

The best way to acidize the coil is with a circulation pump capable of handling acids.

1.Fill a plastic container with a suitable acid diluted with water to desired strength.

2.Connect discharge from the circulating pump to the hot water outlet on the water heater with a suitable hose. Connect the inlet of the circulating pump to the acid container with suction hose from the pump module and use it as a return hose to the acid container. As acid dissolves the scale it becomes neutralized, so about every five minutes add more acid to the container until all the scale has been removed from the coil. Flush out coil thoroughly with water after descaling.

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MAINTENANCE CHECKLIST

Maintenance for Pump

Daily

1.Check oil for proper level and adjust accordingly.

2.Examine the quality of the oil.

3.Check pump for oil and/or water leaks.

4.Inspect and clean inlet filters.

Weekly

1. Examine all fittings, components, hoses, connections, and nozzles for damages, loose parts, or leaks. – Replace accordingly—

Recommendation for Oil Changes and Component Replacement

1.Change the oil in the pump after the first 50 hours and every 500 hours after the initial oil change. Use SAE 30 W Non-Detergent for GP Pumps and Hydraulic 68 for EK Pumps.

2.Change all other components on the pump as needed.

Maintenance for Gasoline Engine

Daily

1.Check oil for proper level and adjust accordingly.

2.Examine the quality of the oil

3.Examine the air cleaner element

Weekly

1. Examine engine components for damages, loose parts, or leaks.

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