2000-4V - Zep® Equipment · 2000-4V p/n 825701. This symbol is used to identify safety information...

Service Man

ual

Service Man

ual

For full warranty information, contact your delivering distribu-tor or contact the manufacturer at [email protected]

2000-4Vp/n 825701

This symbol is used to identify safety information about hazards that can result in personal injury.A signal word (DANGER, WARNING, or CAUTION) is used with the alert symbol to indicate the likelihood and the potential severity of injury. In addition, a hazard symbol may be used to represent the type of hazard.

Indicates a hazard which, if not avoided, will result in death or serious injury.

Indicates a hazard which, if not avoided, could result in death or serious injury.

Indicates a hazard which, if not avoided, might result in minor or moderate injury.

CAUTION, when used without the alert symbol, indicates a situation that could result in damage to the equipment.

DANGER

CAUTION

WARNING

CAUTION

SEM-00011F 20100415

______________________________________________________INSTALLATION DATE PART NUMBER

______________________________________________________MAKE/MODEL SERIAL NUMBER

______________________________________________________SELLER

______________________________________________________ADDRESS CITY/STATE/ZIP

�Specifications

Specifications

PERFORMANCEDischarge Volume 3.8 gal/m / 14.4 L/mPump Head Pressure 2000 psi / 138 barTemperature Rise 120˚F @ 2.0 gal/m / 49˚C @ 7.6 L/mTemperature Limit (optional)

210˚F / 99˚CCombustion Smoke/Bacharach Scale

#1 OR #2 SMOKECarbon Monoxide Allowed

0.01%Draft/Stack Installation

0.2” – 0.04” WC READINGHeat Input

392,000 Btu/Hr / 98,784 Kcal/Hr

GENERALMinimum Inlet Water Pressure over 65 psi may require water inlet regulator

10 psi / 0.68 barStack Size

8” OD / 203.2 mm ODFuel Tank Capacity

4.5 gal / 17 LPump to Coil Hose p/n Y01-00016Spray Tip (#5.0 - 15˚) p/n JA0-15050-2Discharge Hose Assembly 3/8” x 50’ 4000psi

P/N K02-03150E5Belt

p/n R02-00236Trigger Gun & Wand

p/n J06-00158-B - Trigger Gun p/n J06-00158 - Trigger Wand p/n J06-00104EZCoil Standard Coil & SS Wrapper 18”OD x ½”ID x 158’ Schedule 40 p/n 4202-05204Coil Back Pressure (New)

5 psi / 0.34 barCoil Back Pressure Requiring Descaling

50 psi / 3.40 bar

4 Specifications

ELECTRICALMachine Voltage 230v 60hz 1PHCurrent 24 ATemp Control, Adjustable Panel Mount p/n F04-00830Power Cord p/n W4182-00342Cam Switch

p/n F04-00743B

Pump MotorMotor P/N F02-00088-UMotor Horsepower 5.0HP / 3.7 KWMotor Speed 3450 RPMMotor Voltage 208v / 230v 60 Hz 1PH

Burner Part Number Without Solenoid V00-17367-2Burner Part Number With Solenoid V00-17365-2 Burner Type Pressure AtomizingFuel Type Kerosene, #1 or #2 DieselFuel Pressure 125 PSI / 9 BARFuel Pump Part Number V00-14283Motor Voltage 230V 60 Hz 1PHMotor Horsepower 1/7 HPMotor Speed 3450 RPM

Burner Nozzle p/n V2.50 80DB Fuel Consumption

2.80 Gal/Hr / 10.6 L/HrHeat Input

392,000 Btu/h / 98,784 kcal/h

2

OPERATION TABLE OF CONTENTSELECTRIC DRIVEN OIL FIRED CLEANER

SAFETY INSTRUCTIONS Page Number

• Safety Symbols 3• General 3• Mechanical 4• Electrical 4• Fuel 5

INSTALLATION• Location 5• Electrical 6• Extension Cord 6• Venting 5• Water Supply 5• Barrier 5• Water Conditions 5• Freezing 5• Cold weather 5• Chemicals 5

VENTING• Draft Diverters 6, 7• Venting Installation Information 7

OPERATION•Pre Start-Up 7•Start-Up 8•To Clean, Apply Chemical, To Rinse 9•Shut Down 9

COMBI OPERATION (OPTIONAL)

•Pre Start-Up 10•Start-Up 11•To Clean, Apply Chemical, To Rinse 11•Shut Down 11

MAINTENANCE Machine• Spray Tip Maintenance 12• Belt Tension 12• Coil Back Pressure 12• Schedule 14• Flushing, Storage 13 Burner• Fuel Pump Screen See Parts List Section

• Transformer Check See Parts List Section

• Burner Gun Remove/Replace See Parts List Section

• Blower Fan Remove/Replace See Parts List Section

Fuel Filter Page Number

• Maintenance See Parts List Section

TROUBLESHOOTING

•Machine 16, 17• Water Heater 15• Oil Burner See Parts List Section• Pump See Parts List Section• Fuel Filter See Parts List Section

SERVICE• Pump See Parts List Section• Fuel Filter See Parts List Section• Trigger Gun See Parts List Section• Unloader See Parts List Section• Machine Breakdown See Parts List Section

COMPONENT ADJUSTMENT Burner• Air Band Adjustment See Parts List Section• Buss Bar Alignment

See Parts List Section• Electrode Ass’y Adjustment

See Parts List Section

Chemical Metering ValveSee Parts List Section

Temperature Control (If So Equipped)See Parts List Section

Unloader ValveSee Parts List Section

WARRANTY Inside Back Cover

SPECIFICATIONS Inside Front Cover

SCHEMATIC Last Page

Supersedes 08-19-05 Z08-03940TC 07-05-06 Z08-03940TC

3

SAFETY, INSTALLATION, AND OPERATIONELECTRICAL DRIVEN OIL FIRED CLEANER

3

GENERAL SAEFTY

Supersedes 08-19-05 Z08-03940 07-05-06 Z08-03940

Read and understand this “OPERATOR’SMANUAL” and “LABELSON THE MACHINE” beforestarting.

WARNING: The discharge reaching over125° F can cause SERIOUS BODILY INJURY toyou and anyone coming in contact with it.

La décharge atteignant par-dessus 125° F peutcauser LA BLESSURE PHYSIQUE SERIEUSE à vouset n'importe qui entrant le contact avec cela.

La expulsión de que es más de125°F puedo hacerun lesión de grave a Usted o alguien quien usaresto equipo.

1. Before operating this machine, read and observe allsafety, unpacking, and operating instructions.Failure to comply with these instructions couldcreate a hazardous situation.

2. The operator of this equipment should not operate thisequipment when fatigued or under influence ofalcohol or drugs.

3. The operator of this equipment should bethoroughly familiar with its operation and trainedin the job to be accomplished.

4. The operator of this equipment should wearprotective face shields and other protectiveclothing as required for safe operation.

5. Keep all protective covers and shields in place.Operating this machine with moving parts couldallow operator or bystander serious injury or evendeath.

6. Do not operate the machine if any mechanicalfailure is noted or suspected. Keep all shields inplace.

7. Do not leave this machine unattended when it isoperating.

8. All installations must conform to all applicable Localcodes. Contact your electrician, plumber, utilitycompany or seller for details.

9. If a water leak is found, DO NOT OPERATE THEMACHINE. Shut off the motor and repair.

10. Follow instructions on how to stop the machine andbleed pressures quickly. Be thoroughly familiar withthe controls.

11. When starting a job, survey the area for possiblehazards and correct before proceeding.

12. If chemicals are used in conjunction with thisequipment, read and follow the product label directions.

13. During normal operation of this machine, HOTdischarges and surfaces may be produced.

MACHINE UNPACKINGALL CLEANERS ARE CAREFULLY INSPECTED ANDCARTONED TO PROTECT AGAINST SHIPPINGDAMAGE. IF THERE IS DAMAGE OR MISSING PARTS,THE TRANSPORTATION COMPANY AGENT SHOULDMAKE A NOTATION TO THAT EFFECT ON THE BILL.REFER TO THE PARTS LIST IN THIS MANUAL ANDADVISE WHAT PARTS ARE MISSING OR DAMAGED.IF AVAILABLE, GIVE THE INVOICE NUMBER ON ALLORDER BILLS. THIS PROCEDURE WILL ENABLENEEDED PARTS TO BE SHIPPED QUICKLY.

READ ALL Installation, Operation, and Maintenanceinstructions before operating the machine.

NOTE: Refer to CLEANER MODEL for SERIAL NUMBERlocation.

NOTE: Dimensions are in inches unless otherwise note.

The safety alert symbol. This symbol is used toidentify safety information about hazards that can resultin personal injury.A signal word (DANGER, WARNING, or CAUTION) is usedwith the alert symbol to indicate the likelihood and thepotential severity of injury. In addition, a hazard symbolmay be used to represent the type of hazard

DANGER indicates a hazard which, if not avoided,will result in death or serious injury.

WARNING indicates a hazard which, if not avoided,could result in death or serious injury.

CAUTION indicates a hazard which, if not avoided,might result in minor or moderate injury.

CAUTION, when used without the alert symbol,indicates a situation that could result in damage tothe equipment.

IMPORTANT SAFETYINSTRUCTIONS

4

18. Do not start the machine unless the gun assemblyis firmly gripped by the machine operator. Failure todo this could result in injury from flying hose andgun assembly.

1. All guards, shields, and covers must bereplaced after adjustments are made toprevent accidental contact withhazardous parts.

2. Drive belts must be inspected and tightened throughout to operate at optimum levels.

3. Inspect machine for damaged or worn componentsand repair or replace to avoid potential hazards. Donot operate the machine if any mechanical failure isnoted or suspected.

4. Always use the correct size spray tip specified inthe GENERAL section of the MODELSPECIFICATIONS or MODEL EXPLODED VIEW.

1. This machine must be electrically grounded. Failureto have the machine grounded may result in theoperator being electrically shocked and even death.

2. Do not plug-in or un-plug machine with wet hands.

3. Keep power cords and connections (connectors) outof water.

4. If an extension cord must be used to operate thismachine, it should be as short as possible. Theextension cord must be properly sized and fitted witha grounding type plug and receptacle.

5. All wiring and electrical connections should complywith the National Electrical Code (NEC) and withbarcodes and practices.

6. Fuses or circuit breakers should be compatible withmachine requirements. (See ELECTRICAL sectionof MODEL SPECIFICATIONS for poser requirements)

7. High voltage may be present within this machine.Servicing should only be performed by properlytrained personnel.

14 . Always shut down machine before refueling.

15 .Do not overfill the fuel tank. If any spillage occurs,clean up immediately and/or neutralize the spill beforeattempting to operate the machine.

16 .Always point the gun assembly in a safe directionand do not direct spray on the cleaner.

17. Do not start the burner unless a full flow of water iscoming from the wand. Air leaks or insufficient waterto the machine means less than full flow of waterthrough the coil. This could cause hose failure andburns to the operator.

4Supersedes 08-19-05 Z08-03940A 07-05-06 Z08-03940A

ELECTRICAL SAFETY

MECHANICAL SAFETY

WARNING: OPEN FLAME. Do not operatethis machine in an area with combustiblematerials. A suitable fire extinguisher shouldbe available in operating area.

FLAMME OUVERTE. Ne pas fonctionner cettemachine dans un secteur avec les matérielscombustibles. Un extincteur d'incendieconvenable doit être disponible dans l'opérationde secteur.

ADVERTENCIA: LLAMA ABIERTA. Nofuncione esta máquina en un área con losmateriales combustibles. Un extintorconveniente debe estar disponible en áreadefuncionamiento.

WARNING: ELECTRICAL SHOCK HAZARD

LE DANGER ELECTRIQUE DE CHOC

ADVERTENCIA: CHOQUE ELÉCTRICO

WARNING: RISK OF INJECTION ORSEVERE INJURY. KEEP CLEAR OFNOZZLE. DO NOT DIRECT DISCHARGESTREAM AT PERSONS. THISEQUIPMENT IS TO BE USED ONLY BYTRAINED OPERATORS.

AVERTISSEMENT:RISQUE D’INJECTION ETDE BLESSURES GRAVES. SE TENIR À L’ÉCARTDU JET. NE PAS DIRIGER LE JET DE SOTIE VERSD’AUTRES PERSONNES CONFIER L’UTILISATIONLE JET DE SOTIE VERS D’AUTRES PERSONNES.CONFIER L’UTILISATION DE CE MATÉRIEL À UN

OPÉRATEUR QUALIFIÉ.

ADVERTENCIA:RIESGO DE LA INYECCIÓNO SEVERO LESIÓN. CLARO DE LASUBSISTENCIA DEL INYECTOR. NO DIRIJA LACORRIENTE DE LA DESCARGA EN LAS PERSO-NAS. ESTO EL EQUIPO DEBE SER UTILIZADOSOLAMENTE LOS OPERADORESENTRENADOS.

5

1. Use only fuel #1 or #2 diesel. The use of incorrect fuelmay result in fire or explosion and severe injury to theoperator.

2. Do not refuel machine while it is running or hot. Allowit to cool sufficiently to prevent ignition of any spilledfuel.Clean up any spilled fuel before resumingoperation.

3. Fuel burning equipment must have proper ventilationfor cooling, combustion air, and exhausting ofcombustion products.

4. Stacking, where required, must be installed inaccordance with all local codes. A draft diverter mustbe installed on a machine connected to an exhauststack to prevent improper operation.

5. Where stacking is not required, provide adequateventilations to prevent any possible accumulation ofhazardous fumes.

6. Personnel trained in and familiar with the type ofequipment being serviced should only performadjustments to fuel burning equipment.

SAVE THESE SAFETY

INSTRUCTIONS

1. LOCATION: This machine should be installed byonly qualified technicians. The machine should beset upon a level surface where it will not be affectedby strong winds, rain, snow, extreme heat, andfreezing temperatures. Install the machineconsidering locations for chemical pick-up, fuelconnections, electrical connections, water hook-up,venting, and maintenance.

All wiring and electrical connections should complywith the National Electrical Code (NEC) and with localcodes and practices. Use the chart on the next pagefor your cord selection

5

2. WATER CONDITIONS: Local water conditions affectthe coil adversely more than any other element. Inareas where troublesome conditions may exist withlike equipment (such as water heaters), werecommend the use of a water softener.

3. VENTING: This machine emits carbon monoxide, adeadly gas, and must be vented if used in an enclosedarea. Improper venting can cause poor combustion,delayed ignition, down drafts, and the possibility offreezing the coil. Contact your distributor or localheating and air conditioning dealer for propermaterials.Local codes must be observed.

4. WATER SUPPLY: This machine must have a watersupply meeting or exceeding the maximum dischargevolume and a minimum water inlet pressure of 10PSI/ 0.68 BAR.

5. BARRIER: We recommend a barrier be installedbetween the machine and wash area to preventmoisture from coming in direct contact with electricalcontrols, motors and transformers. This will increasethe machine’s life and lessen electrical problems.

6. FREEZING: This machine must be protected fromfreezing according to STORAGE section of MACHINEMAINTENANCE.

7. COLD WEATHER: As the weather becomes colder,fuel becomes thicker and may become so viscousthat the fuel will not flow properly. As viscosityincreases, the thicker oil can cause delayed ignition,poor spray patterns, and rumbling fires. As moisturewill quickly destroy fuel pumps, make certain thattank openings are secure and moisture cannot enter.In cold weather areas, frost build up will occur in fueltanks. As the weather warms it turns to condensate,and the water will be in the tank. Keep the tank clearof water, as moisture reaching the fuel pump willcause rust, and the pump will bind. A full fuel tankwill lessen condensation build up.

8. CHEMICALS: Mix chemicals per the chemicalmanufacturers printed directions. Follow all mixing,handling, application, and disposal instructions.Wear gloves, boots, goggles, and protective clothingappropriate for the chemical being used.

INSTALLATION

Supersedes 08-19-05 Z08-03940B 07-05-06 Z08-03940B

WARNING: DO NOT USE GASOLINE,CRANKCASE DRAININGS, OR OIL CONTAININGGASOLINE OR SOLVENTS.

AVERTISSEMENT: NE PAS UTILISERD’ESSENCE DE PRODUITS DE VIDANGE NID’HUILE CONTENANT DE L’ESSENCE OU DESSOLVANTS

ADVERTENCIA: NO UTILICE LA GASOLINA, ELCÁRTER DEL MOTOR DRAININGS, O ELACEITEQUE CONTIENE LA GASOLINA O SOLVENTES.

FUEL SAFETY

WARNING: CARBON MONOXIDE HAZARD

AVERTISSEMENT: MONOXYDE DECARBONE

ADVERTENCIA:MONÓXIDO DE CARBONO

6

9. ELECTRICAL: Connect machine to an electricallygrounded circuit that is fused or circuit breakerprotected. The circuit must match that specified inthe ELECTRICAL section under MODELSPECIFICATION.

10. EXTENSION CORD: The use of an extension cordthat has undersize wire compared to the amp drawof your machine will adversely limit the starting loadcarrying abilities of the motor and machinesperformance. Use only 3-wire extension cords thathave 3-prong plugs and 3-pole cord connectors thataccept the plug from the product. Use only extensioncords that are intended for outdoor use. Theseextension cords are identified by a marking“Acceptable for use with outdoor appliances; storeindoors while not in use.” Use only extension cordshaving an electrical rating not less than the rating ofthe product. Do not use damaged extension cords.Use an extension cord in good repair free of frays orcracks in the outer covering. Do not abuse extensioncord and do not yank on any cord to disconnect.Keep cord away from heat and sharp edges. Alwaysdisconnect the extension cord from the receptaclebefore disconnecting the product from the extensioncord.

11. THREE PHASE INSTALLATION: Three phase power must be connected so that the motor has clockwise rotation as you look at the shaft end of the motor.

WATER INSTALLATION

1. WATER TEMPERATURE VARIATION: Onmachines not equipped with a temperature controldevice, the temperature of the discharged water isdependant on the incoming water temperature. Someminor adjustment to the fuel input may be required ifthe incoming water is significantlY different than 50degrees fahrenheit.

2. WATER CONDITIONS: Local water conditions affectthe coil and spray tip more adversely than any otherelement. In areas where troublesome conditions mayexist with like equipment (such as water heaters),we recommend the use of a water softener.

WARNING: This machine emits carbon monoxide,and deadly gas, and must be vented if used in anenclosed area. Improper venting can cause poorcombustion, delayed ignition, down drafts, and thepossibility of freezing the coil. Contact your distributoror local heating and air conditioning dealer for propermaterials. Local codes must be observed.

The information contained herein is offered forreference only. You must comply with local codesand investigate through your gas and other utilitycompanies when installing, as there may be somespecial local requirements you must comply with.Also see ANSI Z223.

1. DRAFT DIVERTERS: (STACKED CLEANERS)

Oil fired machines use a force air burner. The oil burnercan be influenced by “Natural Draft” even though theyhave their own fan. A Bell type draft diverter must beused here also.

A. A draft diverter must be used on all cleaners thatare stacked. This includes any chimney even ifnot expelled to the outside.

6Supersedes 08-19-05 Z08-03940C 07-05-06 Z08-03940C




CHART FIGURES ARE BASED ON NOT MORETHAN 100 FOOT.

(Based on Ambient Temperature of 86°F (30°C)).*Use Amp Draw indicated the same or higher than yourmachine outputEXAMPLE: Machine Amp Draw 51, use 55 (2 Conductor).The thermostat type of cord shall be C, PD, E, EO, EN,S, SO, SRD, SJ, SJO, SV, SVO, SP.The thermo set plastic types shall be ET, ETT, ETLB,ETP, ST, STO, SRDT, SJT, SJTO, SVT, SVTO, and SPTB.

COPPER WIRESIZE

MINIMUM AWG

16151412108642

MACHINE AMPDRAW*

3 CONDUCTORWIRES

10—15202535456080

MACHINE AMPDRAW*

2 CONDUCTORWIRES

13—18253040557095

VENTING

WARNING: CARBON MONOXIDE HAZARD

DANGERMONOXYDE DE CARBONE

MONÓXIDO DE CARBONOPELIGRO

7

1. The first time the machine is operated, after repairshave been made, or if the machine has set for a periodof time (30 days or more) follow the followingprocedures.

A. Check the tension of the belt (if so equipped) perinstructions in MACHINE MAINTENANCE.

B. Flush the machine per instructions in MACHINEMAINTENANCE.

C. Install float tank drain plug (if so equipped).D. Open float tank ball valve (if so equipped).

2. CAUTION: Always use the factory supplied washhose with your machine. Do not substitute otherhoses as a potential safety problem may develop.

CAUTION: If machine has been exposedto sub-freezing temperatures, it must be thoroughlywarmed to above freezing before operating. Failure towarm machine can cause damage to the pumppackings and other components.

Read and observe all items in “CLEANERINSTALLATION”.

♦ SPRAY TIP: Choose the correct spray tip for the jobto be performed.

♦ OIL LEVEL: Check the oil level in the water pump.

♦ BELT: Make sure belt tension and condition is asspecified in MACHINE MAINTENANCE.

♦ STACK COVER: Remove the stack cover (if soequipped).

♦ FUEL FILTER: Inspect fuel filter for evidence of watercontaminants.

♦ FUEL: Make sure the fuel lines are open (CAUTION:Closed valves will DAMAGE the fuel pump and voidwarranty). Use #1 or #2 diesel.

♦ FUEL QUANTITY: Make sure the fuel supply issufficient to complete the job. See the GENERALsection of MODEL SPECIFICATIONS for the fuel tankcapacity.

♦ Refer to the MAINTENANCE SCHEDULE for anymaintenance to be performed before operation of thismachine.

7Supersedes 08-19-05 Z08-03940D 07-05-06 Z08-03940D

B. Use a draft diverter of the inverted funnel or belltype that meets all codes for capacity andmaterials. Mount the draft diverter directly tothe stacking flange on the machine.

C. The draft diverter’s function is to insure that thebarometric pressures are as close to the sameas possible at the air inlet and outlet to the coiland will not be changed by either up drafts ordown drafts.

D. Installation of a draft diverter WILL NOTPREVENT THE COIL FROM FREEZING. Inareas where freezing temperatures arecommon, some type of down draft preventionmust be used. Check local codes for acceptablemethods for the prevention of down drafts.

2. VENTING INSTALLATION INFORMATION:

A. Never Reduce the Stack size. The diverter andstacking should be the same size as the stackopening on the machine.

B. Straight Stacking through the roof is preferred.Horizontal runs are not desirable, but if necessary,be sure to pitch the stack upward at a rate oftwo inches per foot. When horizontal stacksare used, vertical stacking must extend at leasttwo feet for every foot of horizontal stack.

C. Stack Extension above the roofline should besufficient to clear the peak of the roof. (Refer toANSI Z223.1 page 100 of SPECIFICS)

D. A Rain Cap U.L. approved should be installed onthe stack.

OIL OR GAS FIRED MACHINES ARE NOT TO BECONNECTED TO A TYPE B GAS VENT.

NE PAS RACCORDER CET APPAREIL À UN TUYAUD’ÉVACUATION DE GAZ DU TYPE B.

MÁQUINA DE ACIETE O GAS ES NO SER CONECTADOCON A MECANOGRAFÍE B RESPIRADERO DEL GAS.

PRE START-UP

Vent/Rain CapDiverter

OPERATINGINSTRUCTIONS

8

CAUTION: A good flow of water must be flowingfrom the end of a gun for 30 seconds, beforeproceeding. Lack of water can cause damage to thewater pump and like components.

CAUTION: On a machine equipped with a triggergun valve, if the trigger gun valve remains in the closedposition for more than 3 minutes, water pump damagemay occur.

3. Turn the switch to the “burner” position.

CAUTION: Do not run the machine with the burnerswitch in the on position when the fuel tank is emptyor with tank valves closed.This will cause damageto the fuel pump and void warranty.CAUTION: Do not operate with the trigger gun valveclosed for more than 3 minutes or water pumpdamage may occur.

8

START-UP

Supersedes 08-19-05 Z08-03940E 07-05-06 Z08-03940E

Quick-Connect spray tips have fixed spray patterns thatare more consistent than those produced by an adjustablenozzle. Each tip is color-coded for easy identification. White(40°): produces a wide-fan spray for general cleaning andrinsing. Green (25°): provides a narrower-fan spray for toughstains in general cleaning applications. Yellow (15°): main-tains a tight-fan spray with intense cleaning power for heavy-duty cleaning and paint preparation. Red (0°): creates aconcentrated pinpoint water jet for stubborn stains on con-crete, masonry, or steel, and for stripping paint.

♦ ELECTRICAL: Connect the machine to an electricallygrounded circuit that is fuse or circuit breaker protected.Do not use any type of adapter. If the correct type ofreceptacle is not available, have one installed by aqualified electrician.

♦ WATER SUPPLY: This machine must have a watersupply meeting or exceeding the maximum dischargevolume specified in the PERFORMANCE section, anda minimum water inlet pressure of 40 PSI / 0.68 BAR.

♦ LIME: Water containing large amounts of lime, calciumor other similar materials can produce a coating on theinside of the spray tip, impact nozzle and coil pipe.

♦ FLOAT TANK: Check the float tank (if so equipped) toassure it is full and the float valve shuts off securely.

♦ FLOAT TANK BALL VALVE: Check the position of theball valve on the outlet side of the float tank (if soequipped) that it is in the open position

♦ CHEMICAL: Use factory recommended chemicals forbest cleaning action and for extended pump life. Followinstructions on chemical container.

1. Select temperature (if so equipped).

2. With the gun assembly in hand (on trigger gun modelshold the trigger gun valve in open position) and with agood flow of water turn the switch to the “pump” position.




WARNING: RISK OF INJECTION ORSEVERE INJURY. KEEP CLEAR OF

NOZZLE. DO NOT DIRECT DISCHARGE STREAMAT PERSONS. THIS EQUIPMENT IS TO BE USEDONLY BY TRAINED OPERATORS.

AVERTISSEMENT:RISQUE D’INJECTION ETDE BLESSURES GRAVES. SE TENIR À

L’ÉCART DU JET. NE PAS DIRIGER LE JET DESOTIE VERS D’AUTRES PERSONNES CONFIERL’UTILISATION LE JET DE SOTIE VERS D’AUTRESPERSONNES. CONFIER L’UTILISATION DE CEMATÉRIEL À UN OPÉRATEUR QUALIFIÉ.

ADVERTENCIA:RIESGO DE LA INYECCIÓNO SEVERO LESIÓN. CLARO DE LA

SUBSISTENCIA DEL INYECTOR. NO DIRIJA LACORRIENTE DE LA DESCARGA EN LAS PERSO-NAS. ESTO EL EQUIPO DEBE SER UTILIZADOSOLAMENTE LOS OPERADORESENTRENADOS.

WARNING: Use of pressure washer can create puddlesand slippery surfaces.

High pressure spray could cause you to fall if you aretoo close to the cleaning surface.• Keep spray nozzle between 8 to 24 inches away fromcleaning surface.• Operate this unit on a stable surface.• The cleaning area should have adequate slopes anddrainage to reduce the possibility of a fall due to slipperysurfaces.• Be extremely careful if you must use the pressurewasher from a ladder, scaffolding or any other relatively

unstable location.• Firmly grasp spray gun with both hands when using high

pressure spray to avoid injury when gun kicks back.

99

Supersedes 08-19-05 Z08-03940F 07-05-06 Z08-03940F

TO RINSE:

A. Close the chemical metering valve buy turningclockwise. If the gun assembly is equipped with a duallance wand open the valve.

NOTE: It is advisable to dip the chemical screen in acontainer of clean water and open the valve 1 minuteto clean the valve of any remaining residue.

B. If the gun assembly is equipped with variable ormultiple nozzle assembly, open and close to cleannozzle of any remaining residue.

C. After a clear flow of water is noted from the end ofthe wand, Engage the trigger safety latch on the spraywand. Pull back the Quick-Connect collar on the endof the wand and remove the tip. Now insert highpressure tip into the fitting, and release the collar.startfrom the top, working downward using long,overlapping strokes.

NOTE: Machines with PRESSURE SWITCHES,because of lower pressures may lose heat duringsoaping.

1. Turn the switch to the “pump” position. (If not alreadydone so in the cold water rinse.)

2. After cool, clear water is coming from the end of thewand, turn switch to the “off” position .

3. Turn off the water supply.

4. If freezing conditions may exist, refer to STORAGEin MACHINE MAINTENANCE.

5. Replace stack cover (if so equipped).

CAUTION: You cannot draw an abrasive product suchas an aluminum brightner. It will cause annon-warrantable premature pump failure.

TO CLEAN:

A. Start on the lower portion of the area to be cleanedand work up using long, even, overlapping strokes.

B. Dirt is generally removed easily if grease and/oroil are not present. However if grease and/or oilare present, hot water and chemical willaccelerate in the cleaning process.

4. TO APPLY CHEMICAL:

Upstream Chemical InjectionWhen injecting chemicals “upstream” what you are do-ing is introducing chemicals to the water flow as it entersthe actual pump inlet and requires a float tank. The popu-larity of this type of chemical injection is due to the factthat this allows chemicals to be applied at full pressurea major advantage for productivity.

Downstream Chemical InjectionMounted to the outlet of the pump or the coil a down-stream injector introduces chemicals to the water flowAFTER it leaves the pump or the coil. This effectivelyeliminates the major risks of exposing the inner work-ings of a pump to harsh chemicals. When chemical isdesired, the system must be switched over to the lowpressure nozzle to draw chemical.

A. Engage the trigger safety latch on the spray wand.Pull back the Quick-Connect collar on the end of thewand and remove the tip. Now insert “black” tip into thefitting, and release the collar. You can draw chemicalonly with the “black” low pressure nozzle.Tug on spraytip to make sure the connection is secure. Rotate todesired spray angle. For most effective cleaning, keepspray tip from 8 to 24 inches away from the cleaningsurface.

B. Insert chemical screen into chemical container.C. Turn the burner switch to the “off” postion.

There will be air in the chemical line. Air heats veryquickly and needs to be eliminated before the burner canbe turned on.Open the metering valve counter clockwisewith the trigger gun open allowing the chemical to comeup the chemical line. Chemical should begin moving upthe chemical line. Once the chemical line is completelyfull, trigger the gun on and off numerous times to breakany possible air locks. Turn burner system switch to“on” position.

D. If the gun assembly is equipped with variable ormultiple nozzle assembly, adjust to low pressure.

E. If the gun assembly is equipped with a dual lancewand open the valve.

Do not allow the detergent to dry on the surface(prevents streaking).

SHUT-DOWN

10

NOTE: In process of making steam, the water flowthrough the coil has to be decreased. The amount ofwater is determined by the pressure and watertemperature of your location.

If the incoming water temperature is as high as 70°F,the amount of water going through the coil has todecrease very little.

If the incoming water temperature is as low as 40°F,the amount of water going through the coil has to bedecreased.

The water temperature is relative to the seasonvariation and should be taken in consideration whenoperating steam.

The 2 systems used to create steam they are the highvolume and low volume system. The high volumesystem uses a regulating valve and the low volumeuses a metering valve.

1. Set temperature control at 300°F / 150°CMAXIMUM.

2. Open the water bypass ball valve (if so equipped)on the coil inlet assembly.

TEMPERATURE REGULATING:

Regulate the temperature indicated on thethermometer to 300°F by adjusting the regulatingvalve.

3. Turn the tee on the regulating valve (if so equipped)clockwise to DECREASE the temperature andcounter clockwise to INCREASE the temperature.

1. Set temperature control at 300°F / 150°CMAXIMUM.

2. Completely open the water bypass metering valve(if so equipped) handle turning it counterclockwise found on the pump or unloaderassembly.

COMBI OPTIONOPERATING INSTRUCTIONS

ELECTRIC DRIVEN OIL/GAS FIRED

O P E N C L O S E D

B A L L V A L V E P O S I T I O N

PRESTART-UPHIGH VOLUME COMBI

PRESTART-UPLOW VOLUME COMBI

g g OPENCLOSED g g

05-26-06 Z08-05465

DECREASETEMPERATURECLOCKWISE g g

g g INCREASE TEMPERATURE COUNTER CLOCKWISE

PRESSUREREGULATINGVALVE

WARNING: The discharge reaching over 300°F can cause SERIOUS BODILY INJURY to youand anyone coming in contact with it.

La décharge atteignant par-dessus 300° F peutcauser LA BLESSURE PHYSIQUE SERIEUSE àvous et n'importe qui entrant le contact avec cela.

La expulsión de que es más de300°F puedohacer un lesión de grave a Usted o alguien quienusar esto equipo.

WARNING: RISK OF INJECTION ORSEVERE INJURY. KEEP CLEAR OF

NOZZLE. DO NOT DIRECT DISCHARGESTREAM AT PERSONS. THIS EQUIPMENT ISTO BE USED ONLY BY TRAINED OPERATORS.

AVERTISSEMENT:RISQUE D’INJECTIONET DE BLESSURES GRAVES. SE TENIR À

L’ÉCART DU JET. NE PAS DIRIGER LE JET DESOTIE VERS D’AUTRES PERSONNES CONFIERL’UTILISATION LE JET DE SOTIE VERSD’AUTRES PERSONNES. CONFIERL’UTILISATION DE CE MATÉRIEL À UNOPÉRATEUR QUALIFIÉ.

ADVERTENCIA:RIESGO DE LA INYECCIÓNO SEVERO LESIÓN. CLARO DE LA

SUBSISTENCIA DEL INYECTOR. NO DIRIJA LACORRIENTE DE LA DESCARGA EN LAS PER-SONAS. ESTO EL EQUIPO DEBE SERUTILIZADO SOLAMENTE LOSOPERADORESENTRENADOS.

11

OPEN CLOSED

BALL VALVE POSITION

3. With a small common screw driver turn the screwon the metering valve (if so equipped) counterclockwise to DECREASE thetemperature and clockwise toINCREASE the temperature.

1. Install the open gun assembly.

2. With the gun assembly in hand (on trigger gun modelshold the trigger gun valve in open position) and with agood flow of water, turn the switch to “pump” position.

CAUTION: A good flow of water must be flowing fromthe end of a gun for 30 seconds, before proceeding.Lack of water can cause damage to the water pumpand like components.CAUTION: On a machine equipped with a trigger gunvalve, if the trigger gun valve remains in the closedposition for more than 3 minutes, water pump damagemay occur.

3. Turn the switch to the “burner” positionCAUTION: Do not run the machine with the burnerswitch in the on position when the fuel tank is emptyor with tank valves closed. This will cause damage tothe fuel pump and void warranty.CAUTION: Do not operate with the trigger gun valveclosed for more than 3 minutes or water pump damagemay occur.

4. To CLEAN:

A. Start on the lower portion of the area to be cleanedand work up using long, even, overlapping strokes.

B. Dirt is generally removed easily if grease and/or oilis not present. However if grease and/or oil arepresent, hot water and chemical will accelerate in thecleaning process.

5. TO APPLY CHEMICAL:

CHEMICAL: Use factory recommended chemicals forbest cleaning action and for extended pump life.Contact your dealer for chemicals available. Followinstructions on chemical container.

Note : If the valve is open without the chemical linein a source the water pump will draw air causing thesystem not to pressure up.Mix chemicals per label instructions. Use necessarysafety percautions.

When chemical is desired, the system must beswitched over to the low pressure nozzle to drawchemical.

A. Insert chemical screen into chemical container.

B. If your system is hot water turn the burner switchto the off postion. There will be air in the soap line.Air heats very quickly and needs to be eliminatedbefore the burner can be turned on. Open, counterclockwise the soap metering valve to up the chemicalline. Once the chemical line is completely full triggercontrol gun. Soap should begin moving up thechemical line. Once the chemical line is completelyfulltrigger, the gun on and off numerous times to breakany possible air locks. Turn burner system switch to“on” position if equipped.

C. Adjust metering valve or injector. Install yourinjector tip.

D. If the gun assembly is equipped with variable ormultiple nozzle assembly, adjust to low pressure .

5. To Rinse: (For cold water rinse, turn the burner switch off.)

A. If the machine is equipped with a panel mountedmetering valve, close the chemical metering valve.NOTE: It is advisable to dip the chemical screen in acontainer of clean water and open the valve 1 minuteto clean the valve of any remaining residue.

B. If the gun and wand is equipped with variable ormultiple nozzle assembly, open and close to cleannozzle of any remaining residue.

C. After a clear flow of water is noted from the end ofthe wand, start from the top, working downward usinglong, overlapping strokes.

1. Turn the burner switch to the “off” position. (If notalready done so in the cold water rinse.)

2. After cool, clear water is coming from the end of thewand, turn the switch to “off” position.

HIGH VOLUME COMBI:

A. Close the water bypass ballvalve (if so equipped) on the coilinlet assembly.

LOW VOLUME COMBI:

A. Completely Close the water bypass metering valve(if so equipped) handle turning it clockwise found onthe pump assembly.

3. Turn off the water supply.4. If freezing conditions may exist,

refer to STORAGE in the sectionof MACHINE MAINTENANCE.

5. Replace stack cover (if soequipped)

05-26-06 Z08-05465A

SHUT-DOWN

OPEN g gCLOSED g g

START-UP

g DECREASETEMPERATURE

g

g INCREASETEMPERATURE

SCREW

CAUTION: You cannot draw an abrasive product suchas an aluminum brightner. It will cause annon-warrantable premature pump failure.

12

1. Deflection for each inch of span between pulleycenters with a 6-pound force applied in the middleof the span.

EXAMPLE: A 6-pound force applied at the middleof an 8 inch span should produce a deflection of8/64 inch or 1/8 inch.

2. Belts can be tightened or loosened by looseningthe nuts holding the pump assembly to the motormount. Then tighten or loosen the j-bolt on the motormount. Retighten the pump assembly after thedesired tension is reached.

1. Remove the spray tip from the gun assembly.

2. Blow out debris with compressed air from the outsidein. Any debris remaining in the inlet side of thenozzle should be cleaned out. If lime or chemicalscale is present in the inlet side, the nozzle maybe soaked in descaling solution or replaced. If thetip is worn, replace with one specified in theGENERAL section of MODEL SPECIFICATIONSor MODEL EXPLODED VIEW.

3. Before replacing spray tip flush the machine per“FLUSHING”.

4. Reinstall Spray tip to gun assembly.

A regular maintenance schedule for descaling yourheating coil is essential to insure its longevity.

The frequency of descaling depends upon the amountof use and the condition of the water.

06-21-06 Z08-02809

Above is a cross section view showing the progressiveliming of coils.

COIL BACK PRESSURE CHECK INSTRUCTIONS

1. Check the condition of your water pump unloadervalve. Remove the hose and gun assembly fromthe coil outlet.

2. Remove any flow restrictions, such as guns andhoses, from the coil outlet.

3. Install a pressure gauge between the water pumpand coil inlet.

4. Turn on the water supply. Check the float valve (ifso equipped) to assure float tank is full and thefloat valve shuts off securely.

5. Check the position of the ball valve (if so equipped)on the outlet line of the float tank assuring it is inthe open position.

6. Turn on the switch to the “PUMP” position. If the coilback pressure reading is above that found in thechart above then your machine needs to bedescaled.

A separate descaling pump is recommended so scaleand other chemicals will not come in contact with yourwater pump and causes premature wear.

NOTE: Contact your local dealer for descaling of yourmachine.

7. Disconnect the water supply.

8. Disconnect the electrical supply.

9. Reinstall the hose and gun assembly.

10. Remove the pressure gauge.

Descaling Instructions are available upon request, ask

for part number Z08-00493.

MACHINEMAINTENANCE

Electric Driven Oil Fired Machine

DEFLECTION

SPAN

x

SPRAY TIP MAINTENANCE

COIL BACK PRESSURE CHECK

BELT TENSION

50 PSI75 PSI

100 PSI150 PSI175 PSI

DISCHARGE VOLUMEGALLONS PER MINUTE/

LITERS PER MINUTE

2-3 GPM/ 7.6-11.4 LPM3-4 GPM/11.4-15.1 LPM4-5 GPM/15.1-18.9 LPM

6 GPM/ 22.7 LPM8-10 GPM/ 30.3-37.9 LPM

BACK PRESSUREREQUIRING DESCALING

USE A 1000 PSI PRESSURE GAUGE

Supersedes 08-15-03 Z08-02809

13

1. Rinse the chemical line by inserting the screen intoa container of clear water and open the meteringvalve 1 minute to clean it of any remaining residue.Be sure the chemical metering valve is closed whenfinished.

2. Check the position of the ball valve (if so equipped)on the outlet of the float tank assuring it is in theclosed position.

3. Attach an air chuck to the air valve stem on thepump assembly. With the trigger gun in the openposition, apply air until a mixture of air and verylittle water is coming from the gun wand Then turnswitch to the “BURNER” position and depress thevacuum switch. Run it for 45 seconds allowing anyremaining water to turn to steam. Allow air to blowfor 60 seconds. Turn switch to the “OFF” position.

4. Remove the air chuck.

5. Fill a 1-gallon container with Ethylene Glycol typeantifreeze. Minimum should be a mixture of ½antifreeze and ½ water strength before each use,as the antifreeze will dilute with use.

6. FLOAT TANK EQUIPPED: Pour the anti-freezesolution into the float tank.

7. WITHOUT FLOAT TANK: Install a 2-ft. Garden hoseto the water inlet. Insert the other end into acontainer of antifreeze solution.

8. Turn on the switch to the “PUMP” position.

9. Turn off the switch just prior to running out ofantifreeze mixture.

10. Disconnect electrical supply.

11 Fill the fuel tank with kerosene or #1 or #2 diesel.

12 It is recommended to install a coil cover to keepcoil free of debris

13 Drain the float tank.

14 Place machine in a dry place protected from weathercondition.

PART NO. DESCRIPTION

Y02-00001 …….....0-1000 PSI (69 BAR) Pressure Gauge

NOTE: All Gauges are Glycerin Filled ¼ NPT

Z01-00070-1…….3/8” x 100 Yards Thread Tape

1. Connect machine to an electrically groundedcircuit that is fuse or circuit breaker protected.

2. Connect machine to a pressurized water supplymeeting the requirements specified in the GENERALsection of the MODEL SPECIFICATIONS.

3. Turn on the water supply.

4. Check the float tank (if so equipped) to assure it isfull and the float valve shuts off securely.

5. Check the position of the ball valve (if so equipped)on outlet line of the float tank assuring it is in theopen position.

6. Remove spray tip from gun assembly.

7. With the gun assembly in hand (on trigger gunmodels hold the trigger gun valve in open position)and with a good flow of water turn switch to thePUMP position

CAUTION: A good flow of water must be flowingfrom the end of a gun within 30 seconds, beforeproceeding. Lack of water can cause water pumpdamage.

CAUTION: DO NOT RUN PUMP WITHOUT WATER,AS THIS WILL CAUSE DAMAGE TO THE PUMPAND VOID WARRANTY.

OPEN CLOSED

BALL VALVE POSITION

x 06-21-06 Z08-02810

ACCESSORIES

FLUSHING

STORAGE




CAUTION: On a machine equipped with a triggergun valve, if the trigger gun valve remains in theclosed position for more than 5 minutes, water pumpdamage may occur.

Supersedes 08-15-03 Z08-02810

14

MOTOR DRIVEN OIL FIRED CLEANERS

OIL BATH WATER PUMP:Oil Level - check and add as needed per PUMPSERVICE insert.Oil Change- drain and refill per PUMP SERVICEinsert.CAUTION: Used oil must be disposed into a nenviromental safe container and brought to an oilrecycling center.Oil contamination- Milky color indicates water.

HOSES:Blistering, Loose CoveringAbrasion of cover exposing reinforcement.Cuts exposing reinforcement.

BELTS:Cracks or frayingBelt Tension- For correct tension, see MACHINEMAINTENANCE insert.

FILTER-WATER:Check water inlet hose screen for debrisCheck float tank screen for debris.

LEAKS:Check for water and buildup of scale at pipeconnections.

FUEL:Adequate fuel supply.

FILTER-FUEL:If contaminats are present see FUEL FILTERinsert.Remove and Replace fuel filter per FUEL FILTERinsert.

SCREEN-FUELPUMP:Check fuel pump screen for debris see OILBURNER MAINTENANCE insert.

BURNER Nozzle:Replace nozzle as specified in BURNER section ofMODEL SPECIFICATIONS or BURNER ASSEMBLYinsert.

GUARDS AND SHIELDS:Check that all guards and sheilds are in place andsecure.

PUMP MOTOR WITH GREASE FITTINGS:Remove drain plug. Use 1 or 2 full strokes of shell“DOBLIUM RB”, Cheveron”SR1 No.2” or Texaco“PREMIUM RB”. Operate for 20 minutes and replacedrain plug.

FREEZING TEMPERATURES:Freezing temperatures break coils and waterpumps. See STORAGE in the MACHINEMAINTENANCE section for cold weatherinstructions.

MACHINE MAINTENANCE SCHEDULEElectric Driven Oil Fired Cleaners

EACH HR AFTER FIRST EVERY EVERY EVERY DAILY 8 HRS 50 HRS 50HRS 100 HRS 500 HRS YEARLY

05-26-06 Z08-02812

15Supersedes 07-15-03 Z08-02850 07-03-06 Z08-02850x

REMEDYPOSSIBLE CAUSETROUBLE

ELECTRIC MOTOR DRIVEN PRESSURE CLEANERS

1. Poor cleaningaction.

2. Machine willnot drawchemical.

3. Low operatingpressure.

4. Excessive,unusualnoise.

5. Belts slipping.

A. Hard water.B. Low pressure.C. Little or no chemical being drawn.D. Improper chemical.E. Improper chemical mixture.

F. Low discharge pressure.

A. No chemical solution.B. Metering valve not open.C. Chemical line strainer clogged.D. Air leak in Chemical line.E. Metering valve clogged.F. Restrictor orifice too large or missing.

A. Insufficient water supply.

B. Incoming water hose too small.C. Water supply hose too long.D. Belt slippage.

E. Worn belt.F. Spray tip worn or wrong size.

G. Dirty or worn check valves in water pump.H. Water supply hose kinked. I. Inlet filter screen clogged.J. Motor runs slowly.

K. Air leak in inlet plumbing.L. Defective water pump.M. Leaking discharge hose.

N. Chemical metering valve open and sucking air.O. Defective unloader.P. Inlet ball valve not fully open (if so equipped).Q. Restricted coil.

A. Pump.B. Defective motor.

C. Pulleys rubbing.D. Misalignment of pump &motor

A. Belts too lose.B. Excessive backpressure.C. Defective water pump.

A. Connect the machine to a water softener.B. See “Low operating pressure.”C. See “machine will not draw chemical.”D. Obtain proper chemical.E. Mix chemical per the label. Follow all the mixing,

handling, application, and disposal instructions.F. See “Low operating pressure.”

A. Replenish supply.B. Turn metering valve knob to open.C. Remove screen and cleaan.D. Tighten all fittings and hoses for the chemical line.E. Disassemble and clean.F. Install proper size orifice.

A. The water supply must meet or exceed themaximum discharge volume specified in thePERFORMANCE section, and minimum water inletpressure specified in the General section of theMODEL SPECIFICATIONS section.

B. Use larger water supply hose.C. Use shorter water supply hose.D. Tighten belt per instructions in MACHINE MAINTENANCE insert.E. Replace belt per CLEANER EXPLODED VIEW.F. Replace with spray tip specified in the GENERAL section of MODEL SPECIFICATIONS.G. See PUMP TROUBLE SHOOTING.

H. Straighten hose. I. Clean water filter screen or hose inlet screen.J. See “Pump engine starts slow or overheats and

stops.”K. Tighten all fittings.L . See PUMP TROUBLESHOOTING.M. If a water leak is found, DO NOT OPERATE THE

MACHINE. Disconnect the power and replacehose.

N. Refill chemical, place soap screen in water, or shut off metering valve.O. Repair or replace unloader valve.P. Open inlet ball valve completely. (Handle parallel w/

valve body).Q. See COIL BACK PRESSURE CHECK on MACHINE

MAINTENANCE.

A. See PUMP TROUBLESHOOTING.B. Call service technician or take engine to Reapir/

Warranty station.C. Adjust shields or pulley(s).D. Realign pump and engine.

A. Tighten per instruction on MACHINE MAINTENANCE.B. See “Excessive Back Pressure” BelowC. See PUMP SERVICE.

CLEANER TROUBLESHOOTING

16Supersedes 07-15-03 Z08-02850 07-03-06 Z08-02850A

A. Spray tip built up with lime.

B. Water pump turning too fast.C. Coil built up with lime.D. Relief valve defective.

A. Defective belt.

B. Defective Pump.C. Defective accumulator.

A. No power.

B. Defective motor starter or ONOFF switch.

C. Defective motor.

A. Pump frozenB. Defective Motor.

C. Defective water pumpD. Excessive backpressure.

A. Low voltage.B. Excessive backpressure.C. Defective motor.

A. Motor starter “kicked out” (if soequipped) or thermal overloadtripped.

B. Excessive backpressure.C. Defective motor.

A. Incoming voltage incorrect.

B. Not large enough extensioncord.

C. Too long extension cord.

A. Machine improperly grounded.

B. Outlet not grounded.

A. Remove and clean, or replace spray tip with tip specifiedin GENERAL section of MODEL SPECIFCATIONS.

B. See MODEL SPECIFICATIONS.C. Delime Coil.D. Remove and replace.

A. Remove and replace using belt specified inCLEANEREXPLODED VIEW or the GENERAL section ofMODEL SPECIFICATIONS.

B. See PUMP TROUBLESHOOTING.C. Recharge/replace.

A. Use a different outlet, check fuses in main disconnectswitch. Replace fuse if blown.

B. Call service technician.

C. Call service technician, or take motor to repair. Warrantystation.

A. Machine must be thoroughly warmed to above freezing.B. Call service technician or take motor to Repair/ Warranty

station.C. See PUMP STATION.D. See “Excessive Back Pressure.”

A. See “Low voltage.”B. See “Excessive Back Pressure.”C. Call service technician, or take motor to Repair/Warranty

station.

A. Turn motor starter off to reset, and then turn on, or pushthermal overload reset button on motor.

B. See “Excessive Back Pressure.”C. Call service technician, or take motor to Repair/ Warranty

station.

A. Have a qualified technician check motor terminal voltage.Correct voltage is in MODEL SPECIFICATIONS.

B. Use an extension cord with amperes or watts rating ashigh or higher than that of the MODEL SPECIFICATIONS.

C. Shorten extension cord.

A. STOP! Operating machine. Call Service technician.

B. Have properly wired outlet installed.

CLEANER TROUBLESHOOTING (CONT.)ELECTRIC MOTOR DRIVEN PRESSURE CLEANERS

TROUBLE POSSIBLE CAUSE REMEDY

6. Excessive backpressure.

7. Excessivevibration.

8. Pump motor willnot start (motordoes not hum).

9. Pump motor willnot start (motorhums).

10. Pump motorstarts slow oroverheats andstops.

11. Pump motorstops and will notstart.

12. Low voltage.

13. Machine shocksoperator.

17Supersedes 07-15-03 Z08-00133 07-03-06 Z08-00133

1. Machine will not rise tooperating temperature.

2. Machine overheats

3. Machine Smokes

4. Machine fumes(exhaust

burns eyes)

5. Excessive oil drippingfrom laydown coilcondensate.

6. Poor Combustion

7. Dry Steam (very littlemoisture, veryhotsteam)

A. Low fuel pressureB. Poor combustionC. Fuel filter clogged

D. Temperature controlinoperative

E. Improper fuel supply.F. Water in the piping.

A. Insufficient water

B. Temperature controlinoperative

C. Improper fuel supply.

A. Improper fuel supply.B. Clogged or improper burner

nozzles.

C. Loose burner nozzle.D. Insufficient combustion air.

A. Improper fuel pressureB. Too munch combustion air.

A. Incorrect burner nozzle.

B. Burner nozzle defective.

C. Loose nozzle.

D. Fuel pressure too high.

A. Low fuel pressureB. Improper fuel supplyC. Insufficient combustion air.

A. Insufficient water.

B. Improper fuel supply.C. Improper fuel pressure

A. Fuel pressure should be at 125 PSI/8.6 BAR.B. See “Poor Combustion”.C. Remove and replace filter element per

FUEL FILTER INSERT.D. See the TEMPERATURE CONTROL

section.E. Use #1 or #2 diesel.F. Drain fuel tank and remove, and replace

filter element per FUEL FILTER INSERT.

A. See Low Operating Pressure on MACHINETROUBLE SHOOTING INSERT.

B. See the TEMPERATURE CONTROLsection.

C. Use fuel specified in “BURNER” section ofthe MODEL SPECIFICATIONS.

A. Use #1 or #2 diesel.B. Remove and replace with appropriate

nozzle found on the MACHINESPECIFICATIONS.

C. See BURNER MAINTANCE INSERT.D. See AIR BAND ADJUSTMENT section

on OIL BURNER MAINTANCE.

A. Fuel Pressure should be 125 PSI/ 8.6 BAR.B. See BURNER TROUBLESHOOTING

INSERT.

A. Replace nozzle with one found inspecification page per burner. Nozzlereplacement on BURNER MAINTANCEpage.

B.Replace nozzle with one found inspecification page per burner. Nozzlereplacement on BURNER MAINTANCEpage.

C. Tighten per Burner Nozzle Replacement inBURNER MAINTANCE section.

D. See FUEL PRESSURE ADJUSTMENTsection on BURNER MAINTANCE INSERT.

A. Fuel Pressure should be 125 PSI/ 8.6 BAR.B. Fuel Pressure should be 125 PSI/ 8.6 BAR.C. See AIR BAND ADJUSTMENT section in

OIL BURNER MAINTANCE.

A. See Low Operating Pressure on MACHINETROUBLE SHOOTING INSERT.

B. Use #1 or #2 diesel.C. Fuel Pressure should be 125 PSI/ 8.6 BAR.

TROUBLE POSSIBLE CAUSE REMEDY

OIL WATER HEATER TROUBLESHOOTING

5Trigger Gun and Wand

6/2/2009p/n: J06-00158-B

ASSEMBLY, GUN & WAND - 42"

ITEMNO. PART NUMBER PART DESCRIPTION QTY.

1 J06-00104E ASSEMBLY, WAND - 42" 1

2 J06-00158 GUN, TRIGGER 1

3 W04-24225-A COUPLER, 1/4F X 1/4FNPT 1

2

1

3

Trigger Gun & Wand Assembly

2102-00710 PART LISTITEM PART NUMBER PART DESCRIPTION

1 W04-31231-B Coupler, 3/8M X 3/8FNPT2 K02-03150E5 Assembly, Hose – 3/8 X 50’

4120-00902P PART LISTITEM PART NUMBER PART DESCRIPTION

1 C04-00131 Screen, Chemical2 Z01-08413-2 Hose, Poly Braid – 84”

2

1

Trigger Gun and Wand

� Trigger Gun and Wand

1. Remove screws from handles and remove handle housings.2. With 18mm socket remove retainer being careful to catch the spring and ball as they fall out of the housing.3. Remove and replace parts with those found in the kit. 4. Assembly in reverse order.

PART LISTS

ITEM PART NUMBER PART DESCRIPTION QTY.

1 C07-01300-08 O-RING - 1/16CS X 5/16ID 12 C07-01425 FILTER, WATER 13 J06-00121-07 O-RING - 3/32 CS X 1/8 ID 14 J06-00121-15 BALL, SS 5/16 15 J06-00132-19 SCREW, SELF TAP - 3.5MM X 18MM 76 J06-00158-01 FITTING, DISCHARGE - 1/4 FNPT 17 J06-00158-02 PIN, TRIGGER - 5MM X 27.5MM 18 J06-00158-03 CAM 19 J06-00158-04 TRIGGER 110 J06-00158-05 LATCH, SAFETY 111 J06-00158-06 FITTING, INLET - 3/8 FNPT 112 J06-00158-08A SEAT, VALVE 113 J06-00158-09 WASHER, FLAT 114 J06-00158-10 WASHER, FLAT - BRASS 115 J06-00158-11 HOUSING, VALVE 116 J06-00158-12A RETAINER, VALVE 117 J06-00158-13 SPRING, COMPRESSION 118 J06-00158-14 PIN, VALVE - 4MM X 44MM 119 J06-99158A HOUSING, HANDLE 1

REPAIR INSTRUCTIONS

SPECIFICATIONS 2 3 4 6 71

BEVEL SIDE TOWARDS BALL

DISHED SIDE TOWARDS BALL

KIT, REPAIR PART - NUMBER J06-99158C

5

BREAKDOWN, GUN - TRIGGEREXPLODED VIEW - P/N J06-00158

16

17

2

4

1

12 18 13 314

15

6

19 5

9107

8

19

MAXIMUM VOLUME..............10.0 GPM / 37.9 LPMMAXIMUM PERSSURE.........5000 PSI / 344.7 BARRATED TEMPERATURE....................300 F / 150 CWEIGHT........................................1.8 LBS. / 0.8 KGINLET .........................................3/8" NPT FEMALEOUTLET......................................1/4" NPT FEMALE

YG3500

WARNING:DO NOT USE ACID CONCENTRATESTHROUGH THE GUN

WARNING:Never secure trigger gun in an openpostion (trigger pulled back) by means other than the operator's hand.Bodilay harm may occur if the operatorloses control of the trigger gun.

CAUTION:Always engage trigger safety latch when not in use.

7Pump Assembly

Pump Assembly

11

2

1621247

15

6

19

20

18

17

12

3

1

5

13

25

9

4

10

14

4

22

8

ASSEMBLY, PUMP9/11/2008

ITEM NO. PART NUMBER PART DESCRIPTION QTY.

1 C03-00810 VALVE, AIR 1

2 C07-0 VALVE, UNLOADER 1

3 E04-00001-58 BUSHING, PIPE 1

4 E04-00005-48 BUSHING, PIPE 2

5 E07-00001-4 CROSS, PIPE 1

6 E08-00006-48 ELBOW, PIPE 1

7 E08-00011-58 ELBOW, PIPE 1

8 E09-00003-2 PLUG, PIPE 1

9 E10-00005-4 TEE, PIPE 1

10 E13-00010-2 NIPPLE, PIPE 111 E14-00010-68 NIPPLE, 3/8MNPT-CLOSE PS PIPE SCH80 112 E15-00010-48 NIPPLE, BRASS 1/2" 1

13 E15-00025-48 NIPPLE, BRASS 1/2" 1

14 F04-00761 SWITCH, VACCUM 1

15 K21-02214-1/4 ASSEMBLY, HOSE-OIL, DRAIN 1

16 K33-01300 HOSE, WATER - 3/8 X 13" 1

17 N07-00180 PUMP, WATER - 4PGM @ 2500PSI 1

18 N07-20046-P MOUNT, PUMP 1

19 R03-006 PULLEY, V 1

20 R04-00001 BUSHING, PULLEY 1

21 W02-00032 CLAMP, HOSE 2

22 W02-10016-8 BARB, HOSE 1

23 W02-10030-8 BARB, HOSE 1

24 W02-10040-8 BARB, HOSE 1

25 W02-10057-8 BARB, HOSE 1

8 Pump Breakdown

Pump, Water

10-03-08 Z08-03934

PUMP, WATER DIMENSIONS - P/N N07-00180

PERFORMANCE DISCHARGE VOLUME.................................................. 4 GPM / 15.1 LPM

PUMP HEAD PRESSURE............................................ 2500 PSI / 172 BAR

GENERAL CRANKSHAFT ROTATION.CLOCKWISE AND COUNTERCLOCKWISE

MAXIMUM SPEED............................................................. 1450 / 1750 RPM

MAXIMUM PUMPED FLUID TEMPERATURE............................ 165°F / 74°C

INLET PRESSURE -9 IN HG@75°F TO 116 PSI / -0.3 BAR@24°C TO 8 BAR

WEIGHT .......................................................................... 19.0 LBS / 8.6 KG

LUBRICATION OIL CAHNGE INTERVA..........AFTER FIRST 50 HRS THEN AFTER 500 HRS

OIL TYPE .......................................SAE 20 OR SAE 30 (NON DETERGENT)

CRANKCASE CAPACITY .................................................4.0 FL OZ / 0.4LT

TORQUE VALVE PLUG ...................................................... 73.7 FT LBS / 10.7 KG M

MOUNT TO CRANKCASE ......................................14.7 FT LBS / 2.0 KG M

REAR CRANKCASE COVER TO CARNKCASE ....... 7.3 FT LBS / 1.0 KG M

*HEAD TO CRANKCASE .......................................14.7 FT LBS / 2.0 KG M *NOTE: When plunger nut is removed, it is important you install anew copper washer and flinger washer to ensure proper fit andseal of ceramic plunger. each time plunger screw is torqued, copperwashers conform to plunger. If same copper washers are used,plunger cracking or poor seal may result.

TX1813S17

ACCESSORIES Oil - Case - (6) One Pint Bottles................ p/n N07-0ILCA

Oil - Bottle - (1) One Pint Bottle.............. p/n N07-0ILCA-1

Oil - Case - (24) One Pint Bottles............ p/n N07-0ILCA-2

PART NO. DESCRIPTION ITEM QTY

N07-99123 VALVE ASSEMBLIESASS’Y, CHECK VALVE 36 60-RING 26A

N07-99124 VALVE PLUGSPLUG 38 60-RING 27 6

N07-99159 CROSSHEAD SEALSSEAL, CROSSHEAD 45 3

N07-99161 V-PACKINGSSEAL, WATER -18 MM 26 3PACKING, V-18MM 37 3

N07-99167 V-PACKINGS

SEAL, WATER - 18MM 26 1PACKING, V - 18MM 37 1REATINER, SEAL- 24 1

N07-99163 SEAL RETAINERRETAINER, SEAL 24 3

SPECIFICATIONS PARTS PACKAGES Parts ListItem p/n Description Item p/n Description

1 N07-20018 Screw, Cap 24 N07-98083 Retainer, Seal

2 N07-20019 Retainer, Bearing 25 N07-98016 O-Ring

3 N07-40029 Cover, Crankshaft 26 N07-98030 Seal, Water – 18mm

4 N07-20021 O-Ring 27 N07-99163 Adapter, Female – Front 18mm

5 N07-20022 Bearing, Roller 28 N07-98084 Packing, V – High Press 18mm

6 N07-20024 Dipstick, Oil 29 N07-20049 Plug, Pipe

7 N07-98023 Crankcase 30 N07-20050 Plug, Pipe

8 N07-98038 Crosshead 31 N07-20051 Washer, Flat

9 N07-98034 Rod, Connecting 32 N07-20011 Washer, Flat

10 N07-29026 O-Ring 33 N07-98001 Head, Pump – Brass

11 N07-98026 Cover, Rear 34 N07-20003 Washer, Flat

12 N07-20027 Screw, Cap 35 N07-98002 Screw, Cap – 8mm x 65mm

13 N07-98029 Indicator, Oil Level 36 N07-99123 Kit, Valve Assembly

14 N07-80009 O-Ring 37 N07-20004 O-Ring

15 N07-20030 Plug, Pipe 37A N07-20009 O-Ring

16 N07-20028 O-Ring 38 N07-47010 Plug, Pipe

17 N07-98032 Pin, Crosshead 39 N07-12056 Nut, Hex

18 N07-17931 Crankshaft 40 N07-98085 Adapter, Plunger

19 N07-98033 Key 41 N07-44040 Plunger – 18mm

20 N07-98045 Seal, Oil 42 N07-20039 Washer, Flinger – Copper

21 N07-20046 Mount, Pump 43 N07-98028 O-Ring

22 N07-20047 Washer, Lock 44 F04-76509 Ring, Anti-Extrusion

23 N07-20048 Screw, Cap 45 N07-99159 Kit, Crosshead

N07-00180

�Pump Breakdown

Parts ListItem p/n Description Item p/n Description

1 N07-20018 Screw, Cap 24 N07-98083 Retainer, Seal

2 N07-20019 Retainer, Bearing 25 N07-98016 O-Ring

3 N07-40029 Cover, Crankshaft 26 N07-98030 Seal, Water – 18mm

4 N07-20021 O-Ring 27 N07-99163 Adapter, Female – Front 18mm

5 N07-20022 Bearing, Roller 28 N07-98084 Packing, V – High Press 18mm

6 N07-20024 Dipstick, Oil 29 N07-20049 Plug, Pipe

7 N07-98023 Crankcase 30 N07-20050 Plug, Pipe

8 N07-98038 Crosshead 31 N07-20051 Washer, Flat

9 N07-98034 Rod, Connecting 32 N07-20011 Washer, Flat

10 N07-29026 O-Ring 33 N07-98001 Head, Pump – Brass

11 N07-98026 Cover, Rear 34 N07-20003 Washer, Flat

12 N07-20027 Screw, Cap 35 N07-98002 Screw, Cap – 8mm x 65mm

13 N07-98029 Indicator, Oil Level 36 N07-99123 Kit, Valve Assembly

14 N07-80009 O-Ring 37 N07-20004 O-Ring

15 N07-20030 Plug, Pipe 37A N07-20009 O-Ring

16 N07-20028 O-Ring 38 N07-47010 Plug, Pipe

17 N07-98032 Pin, Crosshead 39 N07-12056 Nut, Hex

18 N07-17931 Crankshaft 40 N07-98085 Adapter, Plunger

19 N07-98033 Key 41 N07-44040 Plunger – 18mm

20 N07-98045 Seal, Oil 42 N07-20039 Washer, Flinger – Copper

21 N07-20046 Mount, Pump 43 N07-98028 O-Ring

22 N07-20047 Washer, Lock 44 F04-76509 Ring, Anti-Extrusion

23 N07-20048 Screw, Cap 45 N07-99159 Kit, Crosshead

N07-00180

10 Pump Maintenance

6

72

6

31

GeneralPACKING EXTRACTION KIT P/N Z09-00028COMPLETE TOOL KIT P/N Z09-00021

Valve Service1. Remove the plugs holding the valve assemblies.2. Remove and discard o-rings from the plugs. Clean plugs with

solvent or soap and water. Allow to dry.3. Using needle nose pliers, fingers, or hook shaped tool,

remove the valve assemblies from the head. Remove and discard the o-rings from the valve assemblies and/or head. Examine each valve assembly and discard damaged parts. Refer to the PUMP BREAKDOWN for part numbers of any replacement items.

4. Clean any accumulated debris from the valve cavities and flush with water.

5. Wash the valve assemblies in clean water and rinse. While still wet, test each valve assembly by sucking on the valve seat. A properly sealing valve will allow a good vacuum to be developed and maintained, while a malfunctioning valve will not. Good valve assemblies should be set aside for installation in step 7.

6. Malfunctioning valve assemblies must be replaced.7. Lubricate a new o-ring with the pump crankcase oil and install

into valve cavity in the head. Install a good valve assembly into the cavity as illustrated.

8. Lubricate a new o-ring with pump crankcase oil and place on a plug cleaned in step 2 above.

9. Install a plug into the pump head. Tighten plug by hand.10. Torque the plug to the value indicated in the TORQUE section

of the pump specifications.11. Repeat steps 7 through 11 for remaining valve assemblies.

Head Removal1. Remove the cap screws holding the pump head to the

crankcase. A metric tool is required for this step. Be careful not to lose the washer on each cap screw.

2. Remove the head by rotating the crankshaft and tapping the head away from the crankcase with a soft mallet. Keep rear surface of the head parallel to the front surface of the crankcase to prevent binding on the plungers.

3. Once the head is removed, protect the plungers from damage.

Plunger Service1. Remove pump head per HEAD REMOVAL.2. Remove any packings and retainers left on the plungers by

pulling them straight off.

Pump Maintenance

11Pump Maintenance

3. Examine each plunger, looking for a smooth surface free of any scoring, cracks, or pitting. Any defective plungers should be removed per PLUNGER REMOVAL.

4. Discard and replace any defective plungers.5. Reinstall the plunger per PLUNGER INSTALLATION.6. Reinstall head per HEAD INSTALLATION.

Plunger RemovalNOTE: When the plunger screw is removed, it is important to install new o-ring, anti-extrusion, and copper washers.

1. When the plunger screw is removed, it is important to install a new o-ring, anti-extrusion, and copper washers.

2. Remove the plunger retaining screw by turning counterclockwise. Remove and replace copper washer.

3. Remove and discard o-ring and anti-extrusion ring from retainer screw.

4. Remove the plunger from the cross head and examine it for cracks, scoring, or pitting.

5. Remove and discard copper flinger washer, clean with solvent and allow to dry.

Plunger Installation1. Install the copper flinger washer onto the cross head.2. Slide the plunger onto the crosshead.3. Lubricate an o-ring with crankcase oil and install into the

groove on the plunger screw. Install the anti-extrusion ring

12 Pump Maintenance

into the groove next to the o-ring. NOTE: The o-ring should be nearest the screw head and the anti-extrusion ring nearest the threads.

4. Apply a drop of thread sealant to the threads of the retainer screw.

5. Thread the plunger retainer screw into the cross head making sure the copper flat washer is installed onto the screw.

6. Torque the plunger retainer screw to the value indicated in the torque section of the pump specifications.

Packing Service1. Remove the head per PUMP HEAD REMOVAL.2. Remove any packings and female adapters left on the

plungers by pulling them straight off. Insert proper packing extractor onto the extractor hammer. Insert packing extractor and tool through the packings and adapters remaining in the head. Tighten the hammer and remove the remaining items in the head. Remove packings and o-rings from adapters. Discard the o-rings and packings.

3. Clean the packing canities in the head and rinse with clean water.

4. Clean exposed plungers. Clean male and female adapters with soap and water and allow it to dry.

5. Examine male and female adapters, discard worn items. Trial fit the female adapters into the head checking for binding or damage. Discard and replace damaged items

6. Lubricate packing cavities in the head and all packings and adapters with pump crankcase oil.

7. Lay head on the bench with packing cavities up. Install one male adapter in each cavity with the flat side down.

8. Install one v-packing into each cavity with the lips pointing down. A packing insertion tool of the appropriate size is recommended for this operation.

9. Install the re-stop ring with the lips pointing down.10. Install a front female adapter into each cavity with the flat side

up. Make certain the adapter goes all the way down into the cavity.

11. Install the low pressure packing with the flat side down.12. Install the rear female adapter into each cavity with the lips

pointing down.13. Lubricate o-rings with pump crankcase oil and install one into

the groove of each adapter.14. Install one adapter and o-ring into each cavity with the flat

side up. Each adapter and o-ring assembly should push into the head to approximately 1/16 inch of being flush with the surface of the head. Only hand pressure should be required to perform this operation. This step is VERY IMPORTANT. If the rear female adapter does not fit is obtained, proceed to step 16. If a proper fit is not obtained, remove the female

1�Pump Maintenance

53

17

64

28

7

adapters from the offending cavity and reinstall items per steps 8 through 15.15. Install head per HEAD INSTALLATION.

Head Installation1. Prepare pump head per instructions in PACKING SERVICE.2. Rotate the plungers so the outer plungers are projecting the same distance from the crankcase.3. Lubricate the exposed plungers with crankcase oil.4. Start the head onto the plungers and, using a soft mallet, tap the head evenly until it comes in

contact with the crankcase.5. Start the cap screws through the head and into the crankcase. Do not forget the lock washer on

each screw.6. Tighten all cap screws by hand.7. Torque the cap screws to the value indicated in the TORQUE section of PUMP SPECIFICATIONS.

Torque the cap screws in the order listed below.

14 Pump Maintenance Records

Oil ChangeMonth/Day/Year Operating Hours Oil Brand & Type

Pump ServiceMonth/Day/Year Operating Hours Type of Service

Pump Maintenance Record

15Unloader Valve Breakdown

UNLOADER PRESET AT FACTORY – DO NOT READJUST Unloading Adjustment – Adjustment only after repair or replacemant

1. Install an appropriate pressure gauge in pump head outlet. The gauge should have a range twice the operating pressure.

2. Loosen nut (Item 28) and turn the knob (Item 30) counter clockwise until minimum spring tension.3. Open the trigger gun, start the pump, and observe pressure gauge reading. Slowly tighten the

knob.4. Close and open the trigger gun to check unloading pressure and bypass function of the unloader

valve. The unloading pressure should not exceed operating pressure more than 400 PSI.5. Lock the setting by tightening the nut (Item 28)

Note: Once the operating pressure is reached, turning the knob clockwise will increase the unloading pressure only.

Item Part Number Description Qty Kit1 C07-04500-01 Guide, Ball 12 C07-02300-08 O-Ring 2 *3 C07-04500-02 Spring, Compression 14 C07-04500-03 Ball, SS-13/32 1 *5 C07-04500-04 O-Ring - .437ID x .070CS 1 *6 C07-04500-05 Guide, Piston - SS 1 *7 C07-04500-06 Housing, Unloader - 3/8NPT 18 C07-04500-07 Plug - 3/8NPT 2

10 C07-04500-08 Ring, Anti-Extrusion 2 *11 C07-01900-19 O-Ring - .424ID x .103CS 1 *12 C07-04500-09 Piston - SS 113 C07-02000-11 O-Ring - .299ID x .103CS 1 *14 C07-04500-10 Ring, Anti-Extrusion 1 *15 C07-04500-11 Guide, Piston 116 C07-04500-12 Pin, Roll 117 C07-04500-13 Spring, Blue 120 C07-04500-14 O-Ring - .236ID x .118CS 1 *21 C07-04500-15 Orifice, Shutter 122 C07-04500-16 Spring, Compression 123 C07-19505 O-Ring - .739ID x .070CS 1 *24 C07-04500-17 Fitting, Outlet 127 C07-04500-18 Cover, Knob N/A28 C07-04500-19 Nut, Nylock - M8 129 C07-04500-20 Insert - M8 130 C07-04500-21 Knob, Adjustment N/A

31 C07-04500-22 Follower, Spring - 9mm x 24mm 1

32 C07-04500-23 Nut, Brass - M8 2

* C07-04500K Kit, Repair - Parts Package

Unloader Valve Breakdown


1� Unloader Valve Breakdown


INLET

INLET

BY-PASS

DISCHARGE

SpecificationsUnloader p/n C07-04500-AMaximum Flow 7.8 GPM / 30 LPMMax Unloading Press. 4000 PSI / 276 BARMaximum Temperature 194˚F / 90˚CWeight 1.6 LBS / 0.73 KGBypass 3/8 FNPTInlet & Discharge 3/8 FNPT

17Float Tank Assembly

Float Tank Assembly


1 C03-00631 FLOAT VALVE 1

2 C05-00274 ADAPTER, GARDEN HOSE 1

3 E09-00002-P5 RESTRICTOR, PLUG - 11/32 ORIFICE 1

4 EM28-20200-L TANK, FLOAT 15 H05-62500 WASHER, FLAT 26 W02-10025-P BARB, HOSE 1

ASSEMBLY, TANK - FLOATp/n W4182-01121

5

64

5

2

1

3

18 Float Tank Assembly

3

54

68

9

10

17

15

14

1

12

7

13

16

11

2

18

PARTS LIST

VALVE, FLOAT - P/N C03-00631

SPECIFICATIONS8/8/2008


1 C03-00625-10 SCREW, WING - 10-32UNF 1

2 C03-00628 FLOAT, PLASTIC 1

3 C03-00631-01 NUT,HEX - 3/8FNPT 1

4 C03-00631-02 WASHER, FLAT - RUBBER 1

5 C03-00631-03 NIPPLE, BRASS - 3/8NPT 1

6 C03-00631-04 SEAT, VALVE-NYLON 1

7 C03-00631-05 HOUSING, VALVE 1

8 C03-00631-06 PISTON 1

9 C03-00631-07 ROD, PISTON-5/16CS X 1 1/4 PLASTIC 1

10 C03-00631-08 GUIDE, PISTON 1

11 C03-00631-10 SCREW, CAP 1

12 C03-00631-11 ARM, FLOAT 1

13 C03-00631-14 NUT, HEX - BRASS 1

14 C03-00631-16 LEVER - BRASS 1

15 C03-00631-17 KEY, COTTER 1

16 C03-00631-18 NIPPLE, TOE 1

17 C03-0631-09 NUT, RETAINER 1

18 H05-18700 WASHER, FLAT 1

MAXIMUM VOLUME.............................7 GPM / 26 LPMMAXIMUM PRESSURE........................140 PSI / 10 BARMAXIMUM TEMPERATURE ......................140 F/60 CPORT SIZE - INLET..........................................3/8" NPTDIMENSIONS...11.4 X 4.1 X 2.8 IN / 290 X 104 X 71MMWEIGHT...................................................0.6 LB / 0.3 KGHOUSING MATERIAL .........................................BRASSO-RING MATERIAL............................................BUNA-N

1�Burner Assembly

Burner Assembly

5

3

6

1 2

4 7ASSEMBLY, BURNER

ITEM NO. Part Number PART DESCRIPTION QTY.

1 E08-00006-2 ELBOW, PIPE 1

2 E13-00010-2 NIPPLE, PIPE - 1/4" 1

3 V00-173 BURNER, OIL 1

4 V04-003 FILTER , FUEL 1

5 V 0D NOZZLE, BURNER 1

6 W02-10019-8 BARB, HOSE 1

7 W02-10031 BARB, HOSE 1

20 Buner Breakdown

Burner BreakdownBurner Breakdown

21Burner Specs

Burner SpecsPA

RTS LIST

ITEMPART NUMBER

PART DESCRIPTIONITEM

PART NUMBERPART DESCRIPTION

1F04-00517

J-Box17

V00-13494-1Elbow, Flare

2H04-19000

Screw, Thread Cutting18

V00-14283Pump, Fuel

3H04-16401

Screw, Machine*19

F04-00978Valve, Solenoid

4F04-00512

Cover, J-Box*19A

V13-00654Coil, Solenoid

5F04-00315

Nut, Hex20

V00-13279Coupling, Shaft

6H05-87500

Washer, Flat

21V00-02668

Band, Air – Outer7

V00-13360Screw, Thread Cutting

22V00-02669

Band, Air – Inner8

V00-13038Clip, Hold Down

23V00-04725

Housing, Fan9

V00-13121Strain Relief, Cord

24V00-30540-07

Assembly, Burner Gun10

V00-20358Transformer, Ignition

25V00-14160

Cone, Air11


26V00-12484

Gasket, Flange12

F04-00316Nipple, Chase

274120-00440

Weldment, Air Tube

13V00-13392

Cover, Slot28


14V00-14296

Nut, Hex29

H04-31302Screw, Set

15H04-31313

Screw, Cap30

V00-20289Fan w/ Item 29

16V00-14452-1

Assembly, Oil Line31

V00-21328Motor, Electric

*16V00-14451-1

Assembly, Oil Line – 6”*Specific to P/N V00-17365-2 w/ Solenoid

22 Burner Specs

2�Burner Maintenance

Oil Burner MaintenanceOil Fired Cleaners

Air Band AdjustmentNote: The air band adjustment on this burner has been preset at the factor

(elevation approximately 1400 feet). On equipment installed where elevation is substantially different, the air band(s) must be readjusted.

1. Loosen the cap screw retaining the air bands.2. Move the air bands as indicated below with the machine in

operation. Note: The air band should be set so the exhaust gives the smoke spot specified in the GENERAL section of the MACHINE SPECIFICATIONS on a Shell-Bacharach scale. If a smoke tester is not available, a smoky exhaust, oily odor, or sweet smell indicates insufficient air while eye-burning fumes indicate too much air.

3. Tighten the cap screw retaining the air bands.

Fuel Pump FilterSundstrand Pump

1. Shut off fuel supply.2. Loosen the 4 screws holding the cover to the fuel pump housing.3. Take cover and cover gasket off and pull strainer off of pump

housing.4. Clean out any dirt remaining in the bottom of strainer cover. If

there is evidence of rust inside of the unit, be sure to remove water in supply tank and fuel filter.

5. Turn on fuel supply. Failure to do so will result in fuel pump damage.

Fuel Pump Pressure Adjustment1. Install a 0-200 PSI Pressure Gauge.2. Remove Plug on top of the fuel pump.3. Insert a 1/8” Allen Wrench and turn clockwise to increase pressure

and counter clockwise to decrease.4. Remove Gauge and reinstall plug.

Blower Fan Replacement1. Shut off power to the burner and disconnect wires.2. Loosen the two screws securing blower motor and fan to the

PART NUMBERV00-14283-2

PART NUMBERV00-14283-5

24 Burner Maintenance

housing.3. Remove the blower.4. Install the blower onto the shaft and place .030 feller gauge on

the motor as shown, sliding blower until it contacts feeler the gauge. Rotate wheel until set screw is centered on the flat of the motor shaft. Tighten set screws onto motor shaft.

5. Reinstall motor and blower assembly.6. Reconnect wires and turn on power.

Transformer Test1. Remove burner junction box cover.2. Turn on burner and make sure ignition transformer is receiving

rated voltage.3. Turn off burner.4. Loosen screw and swing transformer away from burner gun

assembly.5. Turn on burner.6. Short the high voltage terminals. 7. Open gap by drawing screwdriver away from one electrode

while touching the other.8. The spark should jump between 5/8 inches and ¾ inches, if it

doesn’t jump, replace the transformer.9. Turn burner off.10. Partially close transformer. Check if buss bars align and

contact transformer electrodes. If buss bars do not contact, see Buss Bar Alignment.

11. Close transformer, reposition retainer clip and tighten screw.

Buss Bar Alignment1. With burner off, loosen screw and swing the transformer away

from burner gun assembly.2. Inspect the buss bars and transformer electrodes for pitting or

corrosion.3. Partially close the transformer. Check if the buss bars contact

and are in alignment with transformer electrodes.4. Proper adjustment is obtained by gently bending the buss

bars until they spring against, parallel, and are in full contact with the transformer electrodes.

5. With buss bars aligned, carefully close and fasten the transformer.

Burner Gun Removal & Installation1. Disconnect the fuel line from the burner gun assembly oil line

fitting. Loosen the other end of the line and swing line out of the way.

2. Remove the retaining nut.3. Loosen screw and swing transformer away from burner gun

assembly.4. Carefully remove the burner gun assembly.

WARNING

Use screwdriver with a well insulated

handle to avoid shock.

25Burner Maintenance

1) Check and replace electrode insulators if cracked.2) Clean burnt buss bars.3) Clean carbon off electrodes.4) Clean carbon off oil nozzle (use caution not to

scratch face of nozzle or orifice).5) Check for a loose oil nozzle. Note: Check with

dealer and/or replace nozzle with proper nozzle.5. Gently replace burner gun assembly in air tube. CAUTION:

Do not force. Forcing will cause electrode misalignment.6. Reinstall the retaining nut.7. Reinstall the oil line making sure both ends are tight.8. Partially close transformer. Check if buss bars align and

contact the transformer electrodes. If buss bars do not contact, see Buss bar Alignment.

9. Close transformer, reposition retainer and tighten screw.

Accessories p/n Y01-00041 Gauge-0- 200 PSI p/n Z09-00004 Bacharach Smoke Tester p/n Y01-00090 Allen Wrench 1/8” #8 p/n z01-00092 Fuel Nozzle Changing Wrench

Electrode Assembly Adjustment1. Loosen screws holding electrode assemblies.2. Raise electrode tips 5/32” above surface plane or end of oil

nozzle.3. Place each electrode tip 5/16” from center of spray nozzle

hole, maintaining previous measurement.4. Spread electrode tips to 1/8” gap maintaining previous

measurements.5. When the proper measurements are obtained, gently tighten

screws that hold electrode assembly in place. CAUTION: Do not over tighten, as this will cause the electrode insulator to fail.

2� Electical Schematic

Electrical SchematicPART NUMBER

DA

TE:

PAR

T NU

MB

ER

TITLE / DESC

RIPTIO

N

DR

AW

N B

Y:R

EDB

LAC

KW

HITE

BR

OW

N

YELLOW

BLU

E

GR

EENPIN

KO

RA

NG

E

ELECTRICAL

SCHEMATIC

ES-00873

ES-00873

07-21-04

LCL

GR

N(3X

)

RE

D(3X

)W

HT

WH

T

WH

T

BLK

BLK

BLK

TEM

PS

WITC

HV

AC

UU

MS

WITC

H

BU

RN

ER

MO

TOR

230 VA

C

IGN

ITION

TRA

NS

FOR

ME

R230 V

AC

PU

MP

MO

TOR

230 VA

C

CA

MS

WITC

H

EQUIPMENT

GROUND

LINE1

230V

AC

PILO

TLIG

HT

PILO

TLIG

HT

RE

D

FUE

LS

OLE

NO

ID230 V

AC

OR

GW

HT

BLK

(3X)

BLK

(2X)

5 678

1 234

LINE2

WH

TB

LK

BLK

(2X)

27Coil Assembly

Coil Assembly

3

2

1

4

6

5

WELDMENT, COIL - CRS WRAP, SCH803/31/2008

ITEM NO. PART NUMBER PART DESCRIPTION QTY.

1 4020-00206 WELDMENT, COIL - SCH80 1

2 AB36-00701-B BRACKET, LIFT 1

3 AS16- 5613PR WRAPPER, COIL 1

4 E08-00012-5 ELBOW, REDUCING PIPE 1

5 E08-00016-5 ELBOW, FORGED 1

6 E15-00035-2 NIPPLE, PIPE - GS 1

28 Trouble Shooting

Trouble ShootingPump

Trouble Possible Cause RemedyOil leaking in the area of water pump crankshaft

Worn crankshaft seal, bad bearing, grooved shaft, or failure of retainer o-ring.

Remove and replace.

Excessive play on crankshaft

Defective bearings. See “Worn bearing.”

Excess shims. Set up crankshaft.

Loud knocking in pump Loose connecting rod screws. Tighten connecting rod screws per PUMP SPECIFICATIONS

Worn connecting rod. Replace connecting rod per PUMP MAINTENANCE.Worn bearings. Replace bearings per PUMP MAINTENANCE.Loose plunger bushing screw. Tighten plunger screw per PUMP SPECIFICATIONS.

Oil leaking at the rear portion of the pump

Damaged or improperly installed oil gauge window gasket or rear cover.

Replace gasket or o-ring.

Oil gauge loosed. Tighten oil gauge.Rear cover screws loose. Tighten rear screws to torque values in PUMP

SPECIFICATIONS.Pump overfilled with oil, displaced through crankcase breather hole in oil cap/dipstick.

Drain oil. Refill to recommended oil level as stated in OIL LEVEL in PUMP MAINTENANCE.

Water in crankcase May be caused by humid air condensing into water inside.

Maintain or step up lubrication schedule.

Worn or damaged plunger screw o-ring.

Remove and replace. See PLUNGER SERVICE in PUMP MAINTENANCE.

Worn bearing Excessive belt tension. See BELT TENSION in MACHINE MAINTENANCE.Oil contamination. Check oil type and change intervals per PUMP

SPECIFICATIONS.

Short bearing life Excessive belt tension. See BELT TENSION in MACHINE MAINTENANCE.Misalignment between pump and motor.

Re-align pump and motor.

Oil has not been changed on regular basis.

Check oil type and change intervals per PUMP SPECIFICATIONS.

Short seal life Damaged plunger bushing. Replace plunger bushing.Worn connecting rod. Replace connecting rod.Excess pressure beyond the pump’s maximum rating.

Match pressure stated in PUMP SPECIFICATIONS.

High water temperature. Lower water temperature stated in PUMP SPECIFICATIONS.

2�Trouble Shooting

Dirty or worn check valves

Normal wear. Remove and replace.

Debris. Check for lack of water inlet screens.

Presence of metal particles during oil change

Failure of internal component. Remove and disassemble to find probable cause.

New pump. New pumps have machine fillings and debris and should be drained and refilled per PUMP SPECIFICATIONS.

Water leakage from under head

Worn packing. Install new packing.

Cracked/scored plunger. Remove and replace plunger.Failure of plunger retainer o-ring. Remove and replace plunger retainer o-ring.

Loud knocking noise in pump

Pulley loose on crankshaft. Check key and tighten set screw.

Defective bearing. Remove and replace bearing.Worn connecting rod, crankshaft, or crosshead.

Remove and replace.

Frequent or premature failure of the packing

Scored, damaged, or worn plunger. Remove and replace plungers.

Overpressure to inlet manifold. Reduce inlet pressure.Abrasive material in the fluid being pumped.

Install proper filtration on pump inlet pumping.

Excessive pressure and/or temperature of fluid being pumped.

Check pressures and fluid inlet temperature. Be sure they are within specified range.

Over pressure of pumps. Reduce pressure.Running pump dry. Do not run pump without water.

Low Pressure Dirty or worn check valves. Clean/replace check valves.Worn packing. Remove and replace packing.Belt slipping. See BELT TENSION in MACHINE MAINTENANCE.Improperly sized spray tip or nozzle.

See MACHINE SPECIFICATIOSN for specified spray tip or nozzle.

Inlet filter screen is clogged. Clean inlet filter screen.Pitted valves. See VALVE SERVICE in PUMP MAINTENANCE.

Erratic pressure; pump runs rough

Dirty or worn check valves. Clean/replace check valves.

Foreign particles in valve assemblies.High inlet water temperature. See temperature in PUMP SPECIFICATIONS.

�0 Trouble Shooting �0

Excessive vibration Dirty or worn check valves See “Dirty or worn check valves.”

Scored plungers Abrasive material in fluid being pumped.

Install proper filtration on pump inlet plumbing.

Fitted plungers Cavitation. Decrease inlet water temperature and/or increase inlet water pressure.

Cavitation High inlet fluid temperature, low inlet pressure.

Lower inlet fluid temperature and raise inlet fluid pressure.

Trouble Possible Cause RemedyBurner will not ignite Electrodes out of alignment. See “ADJUSTING ELECTRODE ASSEMBLY” in

BURNER MAINTENANCE SECTION.Electrode insulator failure. Remove and replace if there are breaks, cracks,

or spark trails.Water flow switch not closing. Adjust, repair, or replace switch.Vacuum switch not closing. Adjust, repair, or replace switch.Temperature control switch not closing. Adjust or replace the TEMPERATURE CONTROL.Fuel solenoid valve not opening. Clean, repair, or replace solenoid.Weak transformer. Clean and check transformer terminals. Check

transformer for spark pre “TRANSFORMER TEST” in BURNER MAINTENANCE SECTION.

Faulty cad cell (if equipped). Clean and test cad cell, replace if required.Faulty primary control (if equipped). Replace primary control.Burner motor thermal protector locked out.

See “Burner motor thermal protector locked out.”

Wiring. All wire contacts are to be clean and tight. Wire should not be cracked or frayed.

Burner switch. Test switch operation. Remove and replace as necessary.

Pump pressure. See “Low fuel pressure.”Venting. A downdraft will cause delayed ignition. Soot

deposits on the coil and burner can interrupt air flow, and cause shorting of the electrodes. Clean as required.

Sooting. Soot deposits on the coil and burner can interrupt air flow, and cause shorting of the electrodes. Clean as required.

No fuel. See “No fuel.”

Burner

�1Trouble Shooting

No fuel Clogged fuel filter. Remove and replace filter per FUEL FILTER SECTION.

Fuel leak. Repair as necessary.Kinked or collapsed fuel line. Remove and replace fuel line.Low fuel pressure. See “Low fuel pressure.”Faulty burner oil pump. Adjust pressure or replace.Air leak in intake lines. Tighten all fittings.Clogged burner nozzle. Remove and replace (do not clean).

Low fuel pressure Clogged fuel filter. See “No Fuel.”Clogged fuel pump filter screen. Remove pump cover and clean strainer using a

brush and clean fuel oil, diesel oil or kerosene.Fuel oil too viscous. Operate a lighter oil or in warmer area.Air leaks in intake lines. Tighten all fittings.Kinked or collapsed fuel line. Remove and replace.Burner shaft coupling slipping. Remove and replace.Fuel nozzle worn. Remove and replace with specified nozzle on

BURNER ASSEMBLY.Faulty oil pump. Remove and replace.

Pulsating pressure Partially clogged fuel pump strainer or filter.

Remove and replace strainer per FUEL PUMP FILTER in OIL BURNER MAINTENANCE section.

Air leaking around fuel pump cover. Check fuel pump cover screws for tightness and damaged gasket.

Unit smokes Improper fuel. Refuel with FUEL specified on MACHINE SPECIFICATIONS.

Air to burner insufficient. See AIR BAND ADJUSTMENT in OIL BURNER MAINTENANCE section.

Fuel nozzle interior loose. Replace nozzle.Water in fuel Inspect fuel filter for water presence.Gun out of alignment. Bend oil pipe to center burner nozzle.

Burner motor thermal protector kicked out

Low voltage. Voltage must match those specified in the BURNER section of MACHINE SPECIFICATIONS section.

Fuel too viscous. See “Low fuel pressure.”Fuel pump defective. Check that fuel pump turns freely.Motor defective. Call service technician or take motor to repair/

warranty station.

�2 Trouble Shooting

Delayed ignition (rumbling, noise starts)

Dirty or damaged electrodes. Clean or replace.

Air adjustment open too far. Readjust per AIR BAND ADJUSTMENT in OIL BURNER MAINTENANCE section.

Poor fuel spray pattern. Remove and replace with fuel nozzle specified in BURNER ASSEMBLY.

Incorrect electrode setting. Readjust per ADJUSTING ELECTRODE ASSEMBLY in OIL BURNER MAINTENANCE section.

Weak transformer. See TRANSFORMER CHECK on OIL BURNER MAINTENANCE section.

Water Heater

Trouble Possible Cause RemedyMachine will not rise to operating temperature

Low fuel pressure. See BURNER on MODEL SPECIFICATIOSN for specified pressure.

Water in fuel piping. Drain fuel tank and remove and replace filter per FUEL FILTER INSERT.

Fuel filter clogged. Remove and replace fuel filter element per FUEL FILTER INSERT.

Poor combustion. See “Poor combustion.”Improper fuel supply. Use fuel specified in BURNER section of

the MODEL SPECIFICATIONS.Temperature control inoperative (if equipped).

See TEMPERATURE CONTROL INSERT.

Machine overheats Insufficient water. See “Low operating pressure” on MACHINE TROUBLESHOOTING insert.

Temperature control inoperative. See TEMPERATURE CONTROL INSERT.Improper fuel supply. Use fuel specified in BURNER section of

the MODEL SPECIFICATIONS.

Dry steam (very little moisture, very hot steam)

Insufficient water. See “Low operating pressure” on MACHINE TROUBLESHOOTING insert.

Improper fuel supply. Use fuel specified in BURNER section of the MACHINE SPECIFICATIONS.

Improper fuel pressure. See BURNER on MODEL SPECIFICATIONS for specified pressure.

��Trouble Shooting

Machine smokes (sweet smelling exhaust)

Improper fuel supply. Use fuel specified in BURNER section of MODEL SPECIFICATIONS.

Insufficient combustion air. See AIR BAND ADJUSTMENT on OIL BURNER MAINTENANCE insert.

Leaking fuel system. Correct leakage problem.Clogged or improper burner nozzle. Remove (DO NOT CLEAN) and replace

nozzle per BURNER ASSEMBLY INSERT.Loose burner nozzle. See BURNER MAINTENANCE insert.

Machine fumes (exhaust burns eyes)

Too much combustion air. See BURNER TROUBLESHOOTING insert.

Improper fuel pressure. See FUEL on MODEL SPECIFICATIONS for specified pressure.

Excessive oil dripping from laydown coil condensate.

Loose nozzle. See BURNER TROUBLESHOOTING insert.

Fuel pressure too high. See FUEL PRESSURE ADJUSTMENT section on BURNER MAINTENANCE insert.

Burner nozzle defective. Remove and replace with appropriate nozzle found on the BURNER ASSEMBLY or BREAKDOWN insert.

Incorrect burner nozzle. Remove and replace with appropriate nozzle found on the BURNER ASSEMBLY or BREAKDOWN insert.

Poor combustion Low fuel pressure. See “Low fuel pressure” on BURNER TROUBLESHOOTING insert.

Improper fuel supply. See “Low fuel pressure” on BURNER TROUBLESHOOTING insert.

Insufficient combustion air. See AIR BAND ADJUSTMENT section on OIL BURNER MAINTENANCE.

WARRANTY POLICY

All machines and parts are guaranteed to be free from defects in material or workmanship under normal use and service for a period of 1 year after delivery from the factory. Any part (other than the vendor items) that is determined to be warranty will be repaired or replaced at NO CHARGE provided the warranty card is filled out in it’s entirety and the part is sent back freight prepaid. Any replacement parts accepted as warranty will be returned to you freight prepaid.

Our heating coil will carry a five year prorated warranty credit. The coil will be repaired or replaced without charge for 2 years after delivery date from the factory for any defect in the coil that was caused by workmanship or defective steel. After 2 years have expired, the credit will be prorated as follows:

2 years – 3 years 75% Credit Allowed3 years – 4 years 50% Credit Allowed4 years – 5 years 25% Credit AllowedAfter 5 years NO CREdIT ALLOWEd

Any parts supplied to us by other manufacturers will be subject to their guarantee and warranty. Generators, motors, and engines are required by vendors to be repaired or replaced by authorized warranty repair stations. We will assist you in locating warranty stations around the country in cases where that is necessary. Select items carry 6 (six) month warranty such as unloaders, trigger guns, etc.

This warranty covers the repair and replacement of defective parts only, and does not allow for field labor charges for removal, installation, analysis, travel expense, or special freight expenses incurred for replacement of parts.

Warranty does not apply to normal wear and tear including, but not limited to, freezing damage, freight damage, damage caused by misuse or misapplication, chemical related failures, contaminated filters and screens, moisture related fuel pump failures, stuck check valves, pump packing or seals, nozzles or orifices, paint, hoses, and gauges.

Record Model Number and Serial NumberAlways include them in Service Correspondence

�5 Warranty

Service Man

ual

Service Man

ual

For full warranty information, contact your delivering distribu-tor or contact the manufacturer at [email protected]

Date post:	07-Aug-2020
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