Amazing Machinery Performance Diesel Engine Operator`s manual

Operator’s Manual
TAG-A-LONG &
AUTO DETAILING PKG.
5.5hp, 11hp & 13hp
Gas Engine
READ
THIS
MANUAL
This manual contains important information for the use and safe operation of your
AMAZING MACHINERY™ 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.
AMAZING MACHINERY
3807 OLD TASSO RD. NE  CLEVELAND, TN 37312  Phone: 1-800-504-7435 Fax: 1-800-504-7436
Operator’s Manual
Page Table of Contents
Section 1
Operator’s Manual
 Unpacking....................................................................2
 Safety Instructions and Warnings.............................3
 Operating Instructions...............................................4
Section 2 Parts








and
Service Manual
Maintenance Instructions...........................................5
Parts Diagram.............................................................6
Plumbing Diagram........................................................7
Hose, Wand, & Gun.....................................................7
Pumps...........................................................................8
Wiring Diagram.............................................................9
Troubleshooting.........................................................10
Warranty....................................................................11
Unpacking Instructions
INSPECTION
Carefully unpack your new AMAZING MACHINERY equipment by
removing the banding and cardboard 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. Included Parts
• Pallet
• Packing Material
Outer Crate
• TAG-A-LONG or
AUTO DETAILING PKG.
Machine
• Operator’s
Manual
Figure 1
NOTICE
Information in this operator’s manual is subject to change without notice. AMAZING MACHINERY 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 AMAZING MACHINERY.
© AMAZING MACHINERY, 2005
All rights reserved. Printed in USA.
AMAZING MACHINERY
First Printing (August 2005)
3807 OLD TASSO RD. NE  CLEVELAND, TN 37312  Phone: 1-800-504-7435 Fax: 1-800-504-7436
Operator’s Manual
Page Safety Guidelines
�
WARNING
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.
 DO NOT operate this machine in areas where open flames are not permitted. DO NOT store or
use combustible materials on or near this machine. Use this equipment only in well ventilated
areas. Failure to follow this warning may cause carbon monoxide build up, fire or explosion, and
possible injury or death.
 DO NOT fill gasoline tank while engine is running. Allow engine to cool before refueling. Should
gasoline be spilled, move the machine away from the area of the spill. Do not attempt to restart
the machine until the gasoline has fully evaporated.
 DO NOT operate engine if air cleaner or cover directly over the carburetor air intake is removed.
 DO NOT touch hot mufflers, cylinders or fins, as contact may cause burns
 DO NOT operate this machine while under the influence of alcohol, drugs or while fatigued.
 DO NOT direct discharge stream at yourself or others. Risk of injection or injury may occur.
Never put your hand or fingers over the spray tip. Do not try to stop or deflect leaks with your hand or body. Always face nozzle and wand to the ground when testing.
 DO NOT operate this machine without wearing protective Eye Wear. Gloves, Hard Hat, Mask, Ear Plugs & Steel Toe Work Boots are also recommended, DO NOT wear loose clothing. Keep
your body and clothing clear of the engine and discharge stream when the machine is running.
 DO NOT tie back or block trigger gun in OPEN position. Never leave the pressure washer
unattended once you have started it. If you leave, shut down machine completely.
 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. This product should only be operated by
trained personnel.
 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 attempt to service this machine before reading the service manual.
 DO NOT use water with a temperature over 140 degrees Farenheit
 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 water to freeze inside this machine. Pump and plumbing damage may occur.
 Use only recommended AMAZING MACHINERY™ parts when servicing this machine.
 AMAZING MACHINERY™ will not be held liable for any unauthorized modifications made to this
machine. Any such action will void the warranty.
AMAZING MACHINERY
3807 OLD TASSO RD. NE  CLEVELAND, TN 37312  Phone: 1-800-504-7435 Fax: 1-800-504-7436
Operator’s Manual
Page Operating Instructions
LOCATION GUIDELINES
 Locate the machine on a solid and level surface so that engine and pump crankcase oil lubricate components properly.
Avoid areas where water can build up in the working area. Possible injury can occur caused by the surface becoming
slippery from water build up.
 Locate the machine in a well-ventilated area and away from flammable materials or fumes. Be sure ventilation warnings
are observed. Keep pressure washer at least 18” away from flamable materials.
 Locate the machine so the operator has easy access to the pressure washer and its controls. Locate the machine so that
it is protected from external damage.
 To prevent damage and excessive hose wear, locate the pressure washer so that the hose does not cross traffic areas
STARTING THE MACHINE
Following the steps below will insure successful operation:
 Read this manual completely before attempting to start the machine.
 Check the gasoline tank and fill with a good grade of gasoline.
 Check the engine oil level and fill with SAE 30 weight high-detergent oil
 Check the pump oil level and fill with SAE 30w non-detergent oil if needed.
 Check water tank to ensure adequate level of water required for the job.
 Attach high pressure hose to base of spray gun.
 Install water nozzle at the end of wand, making sure it is clear of any obstructions.
 Pull trigger on gun until a steady stream of water comes out the nozzle. This purges any air in the system.
 Slide fuel switch to the RIGHT and slide choke switch to the LEFT (closed position).
 Turn ON/OFF switch (on engine) to “ON”.
 Start gas engine and allow RPM to develop. Small Engines may kick back. Be careful not to hold cord too tightly.
 Let engine warm up for approximately 30 seconds and slide choke to “OPEN” position.
 Insert detergent siphoning tube into a DOT approved container and open the metering valve for detergent application.
 Check for leaks in the system and cycle trigger gun to insure bypass is adjusted correctly. Repair any leaks and correct unloader adjustment if needed. Turn off machine before attempting any repairs.
WASHING TECHNIQUES
 Washing from bottom up increases dwell time of soap and lessens vertical streaks.
 Turn soap metering valve “OFF” to purge system of soap
 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 engine to “OFF”.
 Pull gun trigger to release water pressure from system.
 Disconnect wand & gun assembly.
 Wind up pressure hose on hose reel.
AMAZING MACHINERY
3807 OLD TASSO RD. NE  CLEVELAND, TN 37312  Phone: 1-800-504-7435 Fax: 1-800-504-7436
Operator’s Manual
Page Maintenance Instructions
MOVING, STORAGE
 Place machine in covered area when not in use to protect from elements.Protect machine from
freezing in cold temperatures by storing in a heated location.
WINTERIZING
 Direct Drive Machines with Water Tank: To protect the machine from freezing temperatures while
storing or transporting, pour antifreeze into partially full (1/8 full or less) water tank. Remove water
nozzle from end of wand and carefully insert wand into opening of water tank. Start machine and run
until antifreeze water mixture has circulated throughout the machine returning back to the water tank.
ENGINE MAINTENANCE
 Every time (before start): Check oil level.
 First 8 hours: Change oil with SAE 30W High-Detergent 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 the specific oil created by the
pump manufacturer (i.e. General Pump Oil). Ensure the right oil for specific pump as it may vary.
 Change oil after 40 Hour Break-in Period.
 Change oil every Three Months or at 500 Hour Intervals thereafter.
UNLOADER ADJUSTMENT
 All Amazing Machinery machines have the
unloader correctly set at the the factory. Setting
an unloader is a difficult job without the proper
equipment and training. Should the need arise
to change the unloader settings, please contact
your local pressure washer dealer.
�
WARNING
AMAZING MACHINERY
Pulsar
Unloader
CHANGING THE UNLOADER SETTINGS WITHOUT THE PROPER
EQUIPMENT AND TRAINING MAY RESULT IN NON-WARRANTY
DAMAGE TO THE PUMP.
3807 OLD TASSO RD. NE  CLEVELAND, TN 37312  Phone: 1-800-504-7435 Fax: 1-800-504-7436
Operator’s Manual
Page Parts Diagram
8
5
7
6
4
1
2
See page #8
3
Ref.#
Part #
1
180-00390-01
(not shown) 620-00001-01
(not shown) 170-00011-01
2
180-00030-01
3
206-00048-01
3
206-00002-02
3
206-00004-03
4
5
6
7
8
180-00393-01
595-00001-03
595-00020-07
610-00005-03
180-00377-01
AMAZING MACHINERY
Description
Quantity
Plate,cold water skid
Big Wheel kit, 4’x54”
Wheel,for Big Wheel kit,#08813
Forklift Tine Engine,gas, 5.5hp Honda Engine,gas, 11hp Honda
Engine,gas, 13hp Honda
Stand,hose reel,cold water skid
Hose Reel,16”,RQ#4416 non-pivoting reel
Base Mount,Reel Quick#2001.037
Water Tank, 125 gallon
Tank Strap, 125 gallon, Stainless Steel
3807 OLD TASSO RD. NE  CLEVELAND, TN 37312  Phone: 1-800-504-7435 Fax: 1-800-504-7436
1
1
4
6
1
1
1
1
1
1
1
2
Operator’s Manual
Page Plumbing Diagram
1
7
4
3
5
2
6
10
8
9
Ref#
1
1
1
1
1
1
1
1
2.
3.
4.
5.
6.
7.
8.
9.
10.
AMAZING MACHINERY
Part#
Discription
Qty
270-00001-01
270-00001-02
270-00001-03
270-00001-04
270-00002-01
270-00002-02
270-00002-03
270-00002-04
554-00006-02
065-00002-01
275-00001-01
552-00004-03
284-00001-01
270-00038-01
552-00003-03
554-00007-03
020-00005-01
Nozzle,water,#3.5, 0° Quick Connect (5.5hp &13hp)
Nozzle,water,#3.5, 15° Quick Connect (5.5hp &13hp)
Nozzle,water,#3.5, 25° Quick Connect (5.5hp &13hp)
Nozzle,water,#3.5, 40° Quick Connect (5.5hp &13hp)
Nozzle,water,#4.0, 0° Quick Connect (11hp)
Nozzle,water,#4.0, 15° Quick Connect (11hp)
Nozzle,water,#4.0, 25° Quick Connect (11hp)
Nozzle,water,#4.0, 40° Quick Connect (11hp)
Quick Coupler Socket, 1/4” Male
Dual lance,8107-1101,Comet 15*,43”SS
Gun, ST1500-01 Quick Coupler Plug, 3/8” Hose Assembly, 50’, 3000PSI @ 250°F
Nozzle, Soap
Quick Coupler Plug, 3/8 nptm
Quick Coupler Socket, 3/8 nptf Downstream Injector Kit (hose not shown) 1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3807 OLD TASSO RD. NE  CLEVELAND, TN 37312  Phone: 1-800-504-7435 Fax: 1-800-504-7436
Operator’s Manual
Page Comet LWD Pumps
all 5.5hp & 6.5hp units
1
Ref.#
Part #
Description
1 220-00094-01 LWD 3020G Triplex Plunger Pump Complete (5.5hp) 1 221-00096-01 LWD 3025G Triplex Plunger Pump Complete (6.5hp)
Qty.
1
1
Pump Repair Kits
221-00310-01 Check Valve Kit, All LWD Series Pumps 1
221-00300-01 Piston Kit, All LWD Series Pumps
1
221-00302-01 Seal Kit, All LWD Series Pumps
1
Comet ZWD Pumps
Select 11hp & 13hp units
1
Ref.#
Part #
Description
1 220-00117-01 ZWD 3530G Triplex Plunger Pump Complete (11hp)
1 221-00114-01 ZWD 4040G Triplex Plunger Pump Complete (13hp)
Qty.
1
1
Pump Repair Kits
221-00310-02 Check Valve Kit, All ZWD Series Pumps 1
221-00300-01 Piston Kit, All ZWD Series Pumps
1
221-00302-07 Seal Kit, All ZWD Series Pumps
1
General EZ Pumps
Select 11hp & 13hp units
1
2
Ref.#
Part #
Description
1 220-00015-01 EZ4035G Triplex Plunger Pump Complete 2 221-00001-04 Manifold, Brass Head EZ4035G
Qty.
1
1
Pump Repair Kits
221-00021-01 Check Valve Assembly (Kit # 123), All EZ Series Pumps
1
221-00020-01 Oil Seal (Kit # 17), All EZ Series Pumps
1
221-00022-01 Oil Ring and Valve Cap ( Kit # 124), All EZ Series Pumps
1
221-00041-01 Head Packing Complete (One Cylinder) (Kit # 156)
3
221-00040-01 V-Packing ( Kit # 153)
1
AMAZING MACHINERY
3807 OLD TASSO RD. NE  CLEVELAND, TN 37312  Phone: 1-800-504-7435 Fax: 1-800-504-7436
Operator’s Manual
Page BURNER
MODULE
“Small” BLK
RED
WHT
BLK
BLOWER
“Big” RED
IGNITOR XFMR
yellow
- N.O.
+
yellow
White
BLK
Orange
FUEL SOLENOID
DROPOUT
TIMER
yellow
Photocell
“Small” RED
BLK
RED
WHT
BLK
CONTROL PANEL
RED
AC
+
BURNER SW
WHT
-
AC
RED
BLK
RED
BLK
WHT
TYPICAL
SCHEMATIC
BLK
87
WHT
86
85
1
30
P1
THERMOSTAT
RED
RED
BRN
RED
RED
GRN
WHT
BLK
FLOW SW or
PRESSURE SW
BATTERY
STARTER
SOLENOID
BLK
ALTERNATOR
12 VOLT
Electrical
Schematic
AMAZING MACHINERY
GAS ENGINE
3807 OLD TASSO RD. NE  CLEVELAND, TN 37312  Phone: 1-800-504-7435 Fax: 1-800-504-7436
1 4 2 75 NW FRE E WAY P H O N E : 71 3 . 9 8 3 . 6 0 0 0
H O U S T O N, TX 77 0 4 0 FA X: 71 3 . 9 8 3 . 6 4 05
Operator’s Manual
Page 10
troubleshooting
problem
cause
action
Low Water Pressure
Insufficient water source
Old or incorrect nozzle
Plumbing or hose leak
Obstruction in spray nozzle
Chemical valve open Unloader valve worn Pump valves dirty or worn
Check hose size/water source
Replace nozzle
Tighten, repair or replace leak
Clean or replace nozzle
Close valve or submerge hose
Replace unloader
Clean or replace packing/valves
No Chemical Flow
Detergent valve closed
Low detergent level Chemical screen dirty Open detergent valve
Fill detergent container
Clean detergent screen
Pressure Relief Valve Leaks
Nozzle is dirty
Defective relief valve Unloader adjusted incorrectly
Restriction on discharge hose
Scale restricting flow in coil
Clean or replace nozzle
Replace relief valve
Adjust unloader valve
Remove nozzle and flush line
Clean coil
Pump Motor Not Running Pump motor switch off
Turn on pump motor switch
GFCI tripped Reset and test GFCI
No voltage to machine Check power source
Clogged water nozzle Clean water nozzle
Insufficient voltage/amperage Use proper drop cord
Air in suction line
Pump valves dirty
Check valve springs worn
Low pump oil Pump bearings are worn
Incoming water too hot
High humidity environment
Oil seal worn Plunger packing worn Change oil frequently
Check and replace oil seal
Check and replace packing
Water Dripping/Pump
Plunger packing is worn
Plunger retainer oil ring worn Cracked ceramics
Install new packing kit
Replace oil ring
Replace ceramics
Oil Dripping
Oil seal worn Cracked manifold
Check and replace oil seals
Replace manifold
Unloader not adjusted Valves worn Dirt or blockage in valve
Pump sucking air
Worn plunger packing Adjust to specifications
Replace with valve kit
Clean or replace valve
Check water/detergent supply
Replace packing kit Extended period in bypass
Pull trigger gun for water flow
Pump Noisy
Water In Oil
Fluctuating Pressure
Pump Head Overheating AMAZING MACHINERY
Check inlet water fittings
Clean/replace pump valves
Replace check valves
Add SEA 30wt. non-detergent Replace/rebuild pump
Reduce temperature/ambient
3807 OLD TASSO RD. NE  CLEVELAND, TN 37312  Phone: 1-800-504-7435 Fax: 1-800-504-7436
Operator’s Manual
Page 11
WARRANTY
MANUFACTURER LIMITED WARRANTY
ENGINES
Honda GC Series Engines; ONE Year from date of purchase Honda will repair or replace any manufacturer
defect at their expense. To be handled directly by Honda Service Centers. See owners manual for details.
Honda GX Series Engines; TWO years from date of purchase Honda will repair or replace any manufacturer
defect at their expense. To be handled by Honda Service Centers. See owners Manual for details.
Vanguard Series Engines; TWO years from date of purchase Briggs and Stratton will repair or replace any
manufacturer defect at their expense. To be handled by Briggs and Stratton Service Centers. See owners
Manual for details.
Robin Series Engines; TWO years from date of purchase Robin/Subaru will repair or replace any manufacturer
defect at their expense. To be handled by Robin/Subaru Service Centers. See owners Manual for details.
Yanmar Diesel Engines; TWO years from date of purchase Yanmar will repair or replace any manufacturer defect
at their expense. To be handled by Yanmar Service Centers. See owners Manual for details.
ELECTRIC MOTORS
Marathon and Baldor brand electric motors have a manufacture limited warranty of one year from purchase date
to repair or replace the motor, at their options, any manufacturing defects.
The limited warranty does not include damage from low voltage or amperage use, high voltage or amperage
use, water, or any other operator incurred damage.
PUMPS
Pump manufacturers offer a "one and five" limited warranty on tri-plex ceramic plunger type pumps, from date
of purchase.
The body, head and power train of the pump is warranted for 5 years from date of purchase against
manufacturer defects. See owners manual for details.The valves, packings and "o"rings are warranted for one
year from date of purchase against manufacturer defects. See owners manual for details.Pump manufacturers
offer a one year limited warranty on Axial Type pumps from date of purchase. See owners manual for details.
NOTE - Over Heated Pumps void all warranties.
ACCESSORY PARTS
Including, but not limited to; unloader valve, thermal relief valve, reels, easy start valve, chemical injector,
rotating nozzles, spray tips, spray guns, wand extensions, telescoping wands, ball valves, sand injectors, quick
couplers, high pressure hose, ground fault interrupter; all burner electronics and wiring, flow switches, diesel
fuel injectors are warranted for repair or replacement by Equipment Manufacturer for a period of 90 days from
date of purchase. Including, but not limited to; Surface Cleaners, Becket or Wayne Burners, Burner Fans and
Heater Coils warranted against manufacture defects for repair or replacement by Equipment Manufacturer for
a period of one (1) year from date of purchase. Including, but not limited to; Cart or Frame warranted against
manufacture defects for repair or replacement by Equipment Manufacturer for a period of one (1) year from
date of purchase.
LIMITATION OF LIABILITY
Amazing Machinery and Equipment Manufacturer liability for special, incidental, or consequential damages is
expressly disclaimed. In no event shall any liability exceed the purchase price of the product in question.The
warranty contained herein is in lieu of all other warranties express or implied, including any implied warranty of
fitness for particular purpose.
NOTE - It is understood that a manufacturers limited warranty pertains to equipment used in it's prescribed
manner, without abuse, and does not include wear and tear.
NOTE - All freight charges incurred on warranty situations are the responsibility of the customer.
Specifications, Warranties and Pricing are subject to change without notice.
*Refund does not include shipping/handling fees. No refund will be given for installation kits. Customer is
responsible for lost or misdirected packages. It is recommended that the customer insure the package for its
full retail value. This warranty does not cover or include any damage as a result of acts of God, improper
installation, alteration, negligence or abuse.
AMAZING MACHINERY
3807 OLD TASSO RD. NE  CLEVELAND, TN 37312  Phone: 1-800-504-7435 Fax: 1-800-504-7436