OPERATOR INSTRUCTION MANUAL COMMANDO 4000

Transcription

1 HUGH CRANE Cleaning Equipment Limited FS0962 SOUTH WALSHAM ROAD, ACLE, NORWICH, NORFOLK, NR13 3ES TEL: FAX: OPERATOR INSTRUCTION MANUAL COMMANDO 4000 For Sales, Service and Spare Parts contact: HUGH CRANE (Cleaning Equipment) Ltd SOUTH WALSHAM ROAD, ACLE, NORWICH NR13 3ES TEL: FAX: sales@hughcrane.co.uk

2 HUGH CRANE (Cleaning Equipment) 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. Wearing 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 document may be reproduced or transmitted in any form or by any means, electronic or mechanical for any purpose other than to assist in the safe operation and maintenance of the Hugh Crane COMMANDO 4000 without the express permission of Hugh Crane (Cleaning Equipment ) Ltd. Hugh Crane (Cleaning Equipment ) Ltd.

3 HUGH CRANE (Cleaning Equipment) Ltd COMMANDO 4000 Page 3 INTRODUCTION The Hugh Crane (Cleaning Equipment) Ltd range of COMMANDO high pressure washing equipment is manufactured to rigorous quality standards. The basic concept is to use quality materials and components together with proven designs to attain the highest standards of reliability and safe operation. This instruction manual is provided to assist the operator to use the equipment safely whilst obtaining the best performance from it. The units are supplied with manual rewind hose reels as standard complete with highpressure hoses, guns and lances. The COMMANDO 4000 is mounted on a single axle road going trailer with a poly water tank. The COMMANDO 4000 is a versatile machine used in agriculture, hire, construction and civil engineering. SPECIFICATION COMMANDO 4000 ENGINE: Model: Nett Power Fuel: PUMP: Model Type Pump pressure Pump flow UNLOADER VALVE: Type Pressure setting Honda GX rev/min Petrol UDOR MC20/20S Triplex Ceramic Plunger 200 bar/2900psi 20 l/min / 4.40 gal/min ST bar/2900psi HIGHWAY TOW: Dimensions LxWxH 3475x1550x1350mm Weight (tank empty / full) 400 kg / 1500 kg Tank capacity 1100 l / 240 gallons Wheels & Tyres 2 off 185R14 8ply Coupling specification Knott KRV20

4 HUGH CRANE (Cleaning Equipment) Ltd COMMANDO 4000 Page 4 GENERAL HEALTH & SAFETY DATA RESPONSIBILITIES OF EMPLOYERS: 1. It is the responsibility of all employers and employees to work within the requirements of the Health and Safety at Work Act It is the duty of every employer to ensure, as far as is reasonably practical, the health and safety at work of all his employees by carrying out risk assessment and implementing any necessary control measures. 3. With regard to high pressure washing equipment, the maintenance of plant is of great importance and should any equipment be suspected of being damaged or defective IT SHOULD NOT BE USED UNTIL INSPECTED BY A COMPETENT PERSON. 4. Where chemical substances or abrasives are to be used, a COSHH risk assessment should be conducted and any necessary control measures implemented. 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 himself and persons working in conjunction with himself or passers-by. 2. All employees should co-operate with their employer to ensure that safe working practices are maintained in all respects.

5 HUGH CRANE (Cleaning Equipment) Ltd COMMANDO 4000 Page 5 BEFORE MOVING ONTO THE PUBLIC HIGHWAY: a) Ensure that towing vehicle is of suitable capacity to tow the COMMANDO 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. Handbrake Ball hitch Jockey wheel locking handle Breakaway cable Jockey wheel 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 empty. g) Ensure that all ancillary equipment is securely attached and stowed on the vehicle. h) Fit a registration plate to the COMMANDO 4000 to suit the towing vehicle. OPERATIONAL PROCEDURES:

6 HUGH CRANE (Cleaning Equipment) 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 equipment. Training courses are available from Hugh Crane (Cleaning Equipment) 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 animals and children are kept well out of the working area. The jet must not be directed at people, animals, the machine itself, non-waterproof, fragile items or electrical equipment. 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 steam cleaners. Eye protection to BS2092/2 must be worn when this equipment is used. d) All repairs to this equipment must be carried out only by suitably qualified personnel. No modifications or changes to the specification of this machine should be made without prior consultation with and approval of the manufacturer. e) The machine is supplied with guarding in compliance with current legislation. The machine must not be operated with any of the guards, covers or any other safety equipment removed or damaged. f) Components that are supplied by others, such as the engine, are covered by individual manufacturer s information, which is included for your use. g) Chemicals may be used in conjunction with this equipment using a chemical injector. Only chemicals supplied or recommended by the manufacturer should be used, as other products may affect the safe use of the equipment. Consideration should also be given to environmental 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.

7 HUGH CRANE (Cleaning Equipment) 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 remove key from 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 number plate compatible with towing vehicle.

8 HUGH CRANE (Cleaning Equipment) Ltd COMMANDO 4000 Page 8 BEFORE STARTING WORK: a) Ensure the unit is standing on level ground. b) Check the oil level in the pump by looking at the site glass set in the end of the crankcase of the pump and that the oil is up to the red dot when the pump 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 pump (use Hugh Crane Cleaning Equipment Ltd. pump oil) c) Fill fuel tank with clean petrol ENGINE STARTER KEY SWITCH CHOKE LEVER ENGINE SPEED CONTROL LEVER FUEL COCK LEVER d) Open the bleed valve on the pump 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 from cold first move the choke lever to the closed position. (Refer to the Honda Engine instruction manual for further information). f) Close the bleed valve on the pump. g) Release the gun from the securing position on the frame 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 from 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 volume and pressure.

9 HUGH CRANE (Cleaning Equipment) 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 abnormal symptoms occur during operation, this should be investigated immediately. Likely causes include:- i) A lack of water entering the unit causing air to be drawn into the pump. ii) A blockage of the main inlet filter causing water starvation at the pump. iii) The inlet water valve between tanks and pump not fully open. iv) Leaking seals or damaged 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 pump. d) Close the engine fuel valve on the pump.

10 HUGH CRANE (Cleaning Equipment) Ltd COMMANDO 4000 Page 10 REGULAR MAINTENANCE CHECK LIST ENGINE: GEARBOX: 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 sediment 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 Terminals * * 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 Check break off pressure First hours hours * *

11 HUGH CRANE (Cleaning Equipment) 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: PUMP: Refer to Engine Manufacturer s Handbook. Refer to Pump Manufacturer s Handbook GEARBOX: Check oil level monthly 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.

12 HUGH CRANE (Cleaning Equipment) 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 temperatures down to - 5 C. During winter months it is strongly recommended 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) Remove bowl from 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 mixture should be introduced into the pump, hose and gun. The antifreeze mixture can be reclaimed after use for recycling when next required. 4) Before starting work again the antifreeze must be emptied out of the system by running the pump and directing the using the solution back into the container. Always ensure that all anti-freeze solutions are flushed out of the system before using the unit for cleaning tasks, as anti-freeze solution can be highly detrimental to certain surfaces and materials.

13 HUGH CRANE (Cleaning Equipment) Ltd COMMANDO 4000 Page 13 REPLACEABLE ITEMS LIST See the following illustrations for reference numbers Ref. Description Qty Part Number 22 PUMP MC 20/20S 1 HC GEARBOX RM HC HONDA GX390 ENGINE 1 HC RAB MOUNTS 4 HCOB/ ADAPTER 3/8-3/8 BSP M-M 1 HYAD ADAPTER ½ - 1 BSP M-M 1 HYAD ADAPTER 3/8 3/8 BSP M-F 90 1 HYAD INSERT 1 x 1 FEMALE BSP 90 SHORT 1 HYIN1616NU90S 44 BRAIDED HOSE 3/8 0.8M ¾ BULKHEAD PLASTIC 1 DP9902BH34 48 ¾ x ¾ BSP HOSETAIL 90 ELBOW 1 DP9901HB ADAPTER 3/8-3/8 BSP M-M 3 HYAD /8 BSP BULKHEAD FITTING C/W NUT 1 HY UNLOADER VALVE ST280 1 GSST ADAPTER HEX TEE 3/8 BSP F-F-F 1 HYAD /8 BALL VALVE SS, 6000 PSI 1 HC ADAPTER 3/8 3/8 BSP M-F 90 1 HYAD P CLIP, RUBBER LINED 16mm 3 HC INSERT 3/8-3/8 BSP F 1 HYIN0606NU 58 ADAPTER ¼ ½ BSP M-M 1 HYAD ½ ST. ST. M-F 90 ELBOW 1 HC ¾ x ½ REDUCING BUSH 1 O2ST/NT COUPLING INLET ¾ FEMALE 1 HCQC ¾ HOSE TAIL INLET NIPPLE 1 HCQC BLACK NOVOLINE HOSE 1.5M ¼ FILTER, 50 MESH 1 DP ¼ 25mm FLYNUT HOSE TAIL, 90 2 DP ¼ FLYNUT 1 DP BRASS 1 x 1 HOSE TAIL, TAPER 1 HC BALL VALVE, ST. ST PSI 1 HC REDUCING NIPPLE HEX 2 1 M-M ST. ST. 1 HC TEE 1 HC HEX NIPPLE BSPT ST. ST. 2 HC HOSE REEL PAINTED 15m 1 GS GUN 1 GSST1500SQR 96 TWIN LANCE 1 GSST JET /MEG

14 HUGH CRANE (Cleaning Equipment) Ltd COMMANDO 4000 Page

15 HUGH CRANE (Cleaning Equipment) Ltd COMMANDO 4000 Page

16 HUGH CRANE (Cleaning Equipment) Ltd COMMANDO 4000 Page 16 TROUBLE SHOOTING FAULT CAUSE ACTION 1. Knocking noise from pump. Water starvation. Pump sucking in air. 2. Loss of pressure. Water starvation. Pump sucking in air. Lance nozzle too large or missing. High pressure water leak. Unloader not correctly set up. Pump speed too low. 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 might allow air to be drawn in. Ensure that there is sufficient water in the tanks. Check that the strainer is not blocked and that the pump inlet valve is open. Check the suction hose for leaks, which might allow air to be drawn in. Check that the correct nozzle is fitted and is in good condition. Examine the high pressure hose and fittings for leakage. Have unloader checked by a suitably equipped and trained engineer. Check that engine speed is correct. 3. Pressure too high. 4. Safety valve passing water. Pump speed to high. Lance nozzle too small or blocked. Unloader not correctly set up. Stop engine immediately. Restart at idle and reset engine speed. Check that the correct nozzle is fitted and is in good condition. Have unloader checked by a suitably equipped and trained engineer.

17 HUGH CRANE (Cleaning Equipment) Ltd COMMANDO 4000 Page 17 MANUFACTURERS LITERATURE UDOR MC20/20 PUMP

18 HUGH CRANE (Cleaning Equipment) Ltd COMMANDO 4000 Page 18

19 HUGH CRANE (Cleaning Equipment) Ltd COMMANDO 4000 Page 19 MANUFACTURERS LITERATURE UDOR RM122 GEARBOX

20 HUGH CRANE (Cleaning Equipment) Ltd COMMANDO 4000 Page 20

21 HUGH CRANE (Cleaning Equipment) Ltd COMMANDO 4000 Page 21 MANUFACTURERS LITERATURE HONDA GX390 ENGINE

22 HUGH CRANE (Cleaning Equipment) Ltd COMMANDO 4000 Page 22