Summary of Contents for Magnum 4000 Series
- Page 1 OWNER’S MANUAL Commercial Hot Water Gas & Diesel Driven, Oil Fired ULTRA GOLD PLUS 3600 ENGLISH World Wide Parts & Service Support: 1-877-441-4430 MAGNUM4000.COM...
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Page 2: Table Of Contents
1-877-441-4430 This manual contains operational information that is specific for commercial hot water, electric and gas 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. -
Page 3: Important Safety Information
IMPORTANT SAFETY INFORMATION Magnum 4000 Series’s first priority is the safe operation of our high pressure cleaning equipment. This can be achieved by following the operation and maintenance instructions as explained in this manual and all other enclosed information. This manual contains essential information regarding the safety hazards, operation, and maintenance associated with this machine. - Page 4 WARNING: WARNING: Protect your equipment This machine exceeds from freezing. 85 dB. Protect your It is important to protect your machine ears when using this from freezing in order to keep it in its best equipment. operating condition. Freezing can cause damage to your machine which may then cause injury.
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Page 5: Specifications
SPECIFICATIONS MAGNUM ULTRA - COMMERCIAL HOT WATER GAS - OIL FIRED ELECTRIC BURNER OIL MODEL HP/ ENGINE DRIVE BURNER PRESSURE (PSI) START ULTRA 4000 350,000 15 LIFAN DIRECT 120V MAGNUM PLUS - COMMERCIAL HOT WATER GAS - OIL FIRED ELECTRIC... -
Page 7: Introduction
Our goal is that you will be satisfied with the performance, quality, and service you receive from Magnum 4000 Series and that if you need to replace this machine in years to come, you will give us the opportunity to continue supplying your equipment. -
Page 8: Operating Instructions
OPERATING INSTRUCTIONS 1. Perform pre-start maintenance inspection on all applicable systems prior to operating the machine. This is essential for safe, effective, and efficient operation. You will get optimal performance from your system ONLY IF these instructions and inspections are followed. Any indication that the pressure washing system was not operated and maintained in accordance with these instructions may void the manufacturers’... - Page 9 4. Start gas engine/electric motor and switch on burner. PUMP and BURNER switches are located on electrical box. For Manual Stop/Start: Turn BURNER switch to ‘PUMP’ , adjust the burner thermostat to desired temperature, then turn BURNER switch to ‘BURNER’ . For Auto Stop/Start: Turn PUMP switch to ‘ON’...
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Page 10: Chemical Application
8. To stop burner operation – Turn BURNER switch to ‘PUMP’ (or to ‘OFF’ for Auto Stop/Start 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 Stop/Start). -
Page 11: Winter Pump Protection
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 female inlet on the pump. 2. -
Page 12: General Maintenance
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 the fuel pump and nozzle of oil burner. The nozzle should also be replaced at least once every year or twice if used daily and if poor combustion begins to occur. -
Page 13: Maintenance Check
MAINTENANCE CHECK 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. -
Page 14: Glossary Of Terms
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. -
Page 15: Component Identification
COMPONENT IDENTIFICATION COMMERCIAL ELECTRIC MODEL: Burner Switch & Thermostat Coil Skin Electric Motor 10 Gallon Poly Fuel Tank 13” Pnuematic Tires... - Page 16 COMMERCIAL GAS MODEL: Gasoline Engine Coil Skin Burner Switch & Thermostat 10 Gallon Poly Fuel Tank...
- Page 17 DIRECT DRIVEN PUMP ASSEMBLY: Safety Relief Valve Chemical Injector Unloader Burner Control Pressure Switch Temperature Probe Water Inlet Water Pump Hot Water Outlet Quick Connector...
- Page 18 PUMP ASSEMBLY: Unloader Pump Head Pressure Gauge Burner Control Pressure Switch Water Inlet Water Pump Water Filter...
- Page 19 HOT WATER TANK INTERIOR (TOP COVER REMOVED): Ceramic Casing Coil Inner Steel Layer Coil Skin (Outer Stainless Steel Layer)
- Page 20 PRESSURE WAND ASSEMBLY: Spray Gun Nozzle Quick Coupler Trigger High Pressure Hose Yellow 3.5 Orifice, Quick Black 40Orifice, Quick Connect, Nozzle Included Connect, Nozzle Included 15 Degree Spray Angle 15 Degree Spray Angle...
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Page 21: Quick Diagnostics & Solutions Guide
QUICK DIAGNOSTICS & SOLUTIONS GUIDE PUMP TYPE OF OIL Pump 30W SAE Non-Detergent Gas Engine 10W30 PROBLEM POSSIBLE CAUSES SOLUTIONS PRESSURE - Examine oil in pump to see if there is metal in oil. Metal in oil - If you find traces or pieces of metal, your pump has damaged components. - Page 22 PROBLEM POSSIBLE CAUSES SOLUTIONS BURNER - Make sure your battery is fully charged. Dead battery - If the battery’s charge is not full, please replace or re-charge your battery. - Make sure thermostat is connected properly. Damaged thermostat - If burner fan does not come on when you turn thermostat dial, replace thermostat.
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Page 23: Service Manual
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 and/or potential personal injury. -
Page 29: Diagnostics And Solutions Guides
DIAGNOSTICS AND SOLUTIONS GUIDES Power System Diagnostics - Gas Motor Not Starting PROBLEM POSSIBLE CAUSE SOLUTION Fuel Check to see if proper fuel levels are maintained. Check ignition by removing spark plug from cylinder. If electric start, No ignition try starting using the recoil starter. Gas motor not starting. - Page 30 Fluid System Diagnostics - Flow & Pressure PROBLEM POSSIBLE CAUSE SOLUTION Make sure pump is operating. Check drive belts and couplings, make necessary No power 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. No Flow Clogged spray nozzle Check spray nozzle, repair or replace.
- Page 31 PROBLEM POSSIBLE CAUSE SOLUTION Inspect places where air can enter the system. i.e. fittings, hose, Air in system connections, etc. If the chemical valve is on, ensure that the chemical line is fully submerged in Chemical line not submerged the chemical. All inlet connections should be snug and not kinked to reduce the chances of Inlet line restricted pump starvation.
- Page 32 PROBLEM POSSIBLE CAUSE SOLUTION Any variation in flow from what the orifice is sized can cause cycling. Improper flow System must produce the rated flow constantly. Nozzle too small A nozzle that is too small can cause the flow to be reduced. Nozzle clogged A distorted spray pattern indicates a clogged nozzle.
- Page 33 Fluid System Diagnostics - Leaking PROBLEM POSSIBLE CAUSE SOLUTION From inlet Garden hose washer Ensure the washer is present and in good condition. From low pressure (inlet) Loose clamps or connections Low pressure line should be properly sealed on barb and tightly clamped. line fittings If float is not floating above water, check the float to see if it has filled up with From float tank (option)
- Page 34 Fluid System Diagnostics - Trigger Gun/Spray Nozzle PROBLEM POSSIBLE CAUSE SOLUTION If water flows through discharge hose without gun, check trigger gun valve piston Broken piston rod in trigger gun rod and replace if necessary. No nozzle flow from nozzle when trigger Missing metal insert in trigger gun Inspect to assure insert is in place.
- Page 35 Boiler System Diagnostics - Oil Burner Will Not Fire PROBLEM POSSIBLE CAUSE SOLUTION Not reaching rated Not activating boiler controls Correct the fluid problem first - See fluid systems diagnostics. pressure flow Thermostat on low Thermostat set too low Set thermostat to an output temperature requiring heating. setting Burner not getting adequate fuel Check fuel and bring to proper levels.
- Page 36 PROBLEM POSSIBLE CAUSE SOLUTION Debris in internal fuel pump valve Check for clogging in the solenoid valve inside fuel pump. Fuel nozzle clogged Check fuel nozzle for clogging and clear if necessary. Solenoid valve energizing Restriction in fuel outlet line Check fuel line from pump to burner for any restriction.
- Page 37 Boiler System Diagnostics - Abnormal Flame Characteristics - Gas Fired PROBLEM POSSIBLE CAUSE SOLUTION Flame intermittently lifts If gas flow is not properly regulated, the regulator may need to be replaced. Gas line and returns to gas port Gas velocity exceeds flame speed may be too small.
- Page 38 Boiler System Diagnostics - Pressure Switch PROBLEM POSSIBLE CAUSE SOLUTION A multimeter can indicate whether or not a pressure, or flow switch, is working Power not flowing through switch Switch activates when properly. pressure is reached but Switch improperly wired Switch may be improperly wired for its function.
- Page 39 Boiler System Diagnostics - Thermostat PROBLEM POSSIBLE CAUSE SOLUTION Thermostat set Thermostat set too low Set thermostat properly and ensure connections are not loose or corroded. improperly Boiler fires when the thermostat jumped, Bad thermostat Replace thermostat. but will not fire with thermostat in circuit.