PDHW4500 HOT WATER PRESSURE WASHER Owner`s Manual

PDHW4500 HOT WATER PRESSURE WASHER Owner`s Manual
PDHW4500
HOT WATER PRESSURE WASHER
Owner’s Manual
This manual provides information regarding the operation and maintenance of these
products. We have made every effort to ensure the accuracy of the information in this manual.
We reserve the right to change this product at any time without prior notice.
Please keep this manual available to all users during the entire life of the HOT WATER
PRESSURE WASHER.
TABLE OF CONTENTS
SAFETY GUIDELINES/DEFINITIONS................ .... ......... ...... ...... .......... ...... ...... ............... 1
CONSUMER SAFETY INFORMATION. ..................................................... ............................ 1
IMPORTANT SAFETY INSTRUCTIONS................................ ............................................. 2-4
CARTON CONTENTS....................................................... ......... ......................................... 5
ASSEMBLY INSTRUCTIONS................... .................................. ............................................ 5
OPERATING INSTRUCTIONS. ......................................................................................... 7-14
MAINTENANCE .... .................................. ....................... .................................................15-17
STORAGE .................................................. ............................................................................18
TROUBLE SHOOTING GUIDE ........................................................... .............................19-30
EXPLODED VIEW OF PUMP .......................... .................................. .............................19-30
IMPORTANT
Please make certain that the person who is to use this equipment carefully
understands these instructions before operating.
reads and
PRESSURE PUMP TECHNICAL PARAMETER AND PERFORMANCE
Model
PDHW4500
Revolution
3600rpm
Max pressure
4500PSI
Capacity
Max. Water Temperature
Power require
4.0GPM(15L/min)
190̧(88ć)
16HP(11.7KW)
This manual contains information that will be specific for your pressure washer, as well as
similar models. The table of contents will allow you to identify the sections that apply to your
equipment. Carefully review any additional manuals that have been included with your
system and follow ALL ADDITIONAL OPERATING INSTRUCTIONS. They are specific for
the quality components that have been used to manufacture our machine and are an
integral part of the operating and maintenance procedures.
If you have any questions please do not hesitate to contact us.
CARTON CONTENTS
ASSEMBLY INSTRUCTIONS
1. Slide a wheel (with the inflation valve facing out) and a flat washer over the axle, then fix
the wheel tightly with nuts (M16).
2 . Attach high pressure hose to gun. Tighten securely.
3. Connect wand to gun. Tighten securely.
4. Place the nozzle holder the panel (located on the handle assembly) and push each no
holder into place.
5. Remove five colored quick connect nozzles from plastic bag and insert them into correct
grommet on the nozzle holder.
NOTE: Nozzles e color coded to match colored nozzles on panel.
NOTE: The high pressure pump was filled with oil at the factory. There is no need to add oil at
this time, Maintenance section of this manual for Maintenance information.
WARNING: The shipping plug must be removed and replaced with the dipstick/oil plug before
operating pressure washer.
6. Using a 7/8" wrench, remove shipping plug from pump by turning it
counterclockwise. Discard plug.
7 Remove dipstick/oil plug from plastic bag and install into pump, tighten
securely.
OPERATING INSTRUCTIONS
ALL MACHINES WITH BURNERS MUST BE INSTALLED ON A NON-COMBUSTIBLE
FLOOR, WITH ADEQUATE AIR CIRCULATION.
Perform pre-start check maintenance inspection on all applicable operation systems prior
to operating the machine. This is essential for the safe, effective and efficient operation. You
will get optimum performance from you system ONLY if these instructions and inspections are
followed. Any indication that the pressure washing system was not operated and maintained
according to these instructions may cancel the manufacturers warranty.
Carefully review any additional manuals that have been included with your system and
follow ALL ADDITIONAL OPERATING INSTRUCTIONS. They are specific for the quality
components that have been used to manufacture your machine and are an integral part of the
operating and maintenance procedures.
Compare the illustrations with your unit to familiarize yourself with the location of various
controls and adjustments. Save this manual for future reference.
BASIC ELEMENTS OF A PRESSURE WASHER
High Pressure Pump: Increases the pressure of the water supply. The pump moves the
water through the system and delivers it to the pressure wand assembly.
Engine: Drives the high-pressure pump.
High Pressure Hose: Carries the pressurized water from the pump to the gun and spray
wand.
Spray Gun: Connects with spray wand to control water flow rate, direction, and pressure.
Quick Connect Spray Wand: Allows the user to quickly change out high- pressure nozzles.
See How To Use Spray Wand instructions in this section.
Pressure Wand Assembly – This refers to the gun, wand, and nozzle.
Unloader Valve – Is a valve located at the head of the pump for unloading water back into
the bypass when the trigger gun is shut off. It releases water when the trigger on the gun
is pressed. The un-loader valve is preset at the factory and should not be adjusted.
Burner – The burner heats the water in hot water pressure washers. It is located in the coil
and may be powered by propane, gas, or oil.
Chemical Hose: Feed cleaning agents into the pump to mix with the water. See How To
Apply Chemicals/Cleaning Solvents instructions in this section.
Burner Boiler: High-pressure water is heated by heat energy from when burner is working.
Fuel Tank (Diesel): Supply fuel for burner, using only diesel.
BASIC ELEMENTS OF ENGINE
Refer to the engine manual for location and operation of engine controls.
Choke Control: Opens and closes carburetor choke valve.
Starter Grip: Pulling starter grip operates recoil starter to crank engine.
Fuel Valve Lever: Opens/close connection between fuel tank carburetor.
Engine Switch: Enables and disables ignition system.
PRESSURE WASHER TERMINOLOGY
PSI: Pounds per Square Inch. The unit of measure for water pressure. Also used for air
pressure, hydraulic pressure, etc.
GPM: Gallons Per Minute. The unit of measure for the flow rate of water.
CU: Cleaning Units. GPM multiplied by PSI.
GPM x PSI=CU
Bypass Mode: Allows water to re-circulate within pump when gun trigger is not pulled.
CAUTION: Allowing the unit to run for more than two minutes without the gun trigger
pulled could cause overheating and damage to the pump.
Chemical Injection System: Mixes cleaners or cleaning solvents with the water to improve
cleaning effectiveness.
Water Supply: All pressure washers must have a source of water. The minimum
requirements for a water supply are 20 PSI and 5 gallons per minute.
BURNER TERMINOLOGY
Oil Fired Burner-Oil Tank Levels- Diesel fuel is recommended fuel for Oil Fired Hot Water
Pressure Washers.
Electrical Burner systems –The burner get the power from engine charging coil via 12V
diode-automatic manostat.
IF YOU REQUIRE UPGRADES OR MODIFICATIONS TO YOUR EXISTING ELECTRICAL
SYSTEM IN ORDER TO OPERATE YOU PRESSURE WASHER, THEY MUST BE
PERFORMED BY A LICENSED ELECTRICIAN AND BE COMPLETED IN ACCORDANCE
TO ALL APPLICABLE CODES IN YOUR AREA OF OPERATION.
Visually inspect all electrical components to assure they are in good condition, showing no
signs of exposure, breakage or splicing.
Visually inspect all hoses, nozzles and guns to assure they are in good condition. If
replacements are necessary they must be rated to withstand the machines operating pressure
and temperatures.
Visually inspect the pressure gauge, the glass must be intact and the pressure at zero.
Turn the burner thermostat knob control to “OFF”.
All controls turned to the off position.
READ AND UNDERSTAND ALL WARNINGS BEFORE STARTING UNIT
DANGER: When using the high pressure setting. DO NOT allow the high pressure
spray to come in contact with unprotected skin, eyes, or with any pets or animals. Serious
injury can occur.
Your washer operates at fluid pressures and velocities high enough to penetrate human
and animal flesh, which could result in amputation or other serious injury. Leaks caused by
loose fittings or worn or damaged hoses can result in injection injuries. DO NOT TREAT
FLUID INJECTION AS A SIMPLE CUT! See a physician immediately!
WARNING: NEVER fill fuel tank when engine is running or hot. Do not smoke when filling
fuel tank.
NEVER fill fuel tank completely. Fill tank to 1/2" below bottom of filler neck to provide
space for fuel expansion. Wipe any fuel spillage from engine and equipment before
starting engine.
NEVER run engine indoors or in enclosed, poorly ventilated areas. Engine exhaust
contains carbon monoxide, an odorless and deadly gas.
DO NOT let hoses come in contact with very hot engine muffler during or immediately after
use of you pressure washer. Damage to hoses from contact with hot engine surfaces will
NOT be covered by warranty.
CAUTION: NEVER pull water supply hose to pressure washer. This could damage hose
and/or pump inlet.
DO NOT use hot water, use cold water only.
NEVER turn water supply off while pressure washer engine is running or damage to
pump will result.
DO NOT stop spraying water fore than two minutes at a time. Pump in bypass mode when
spray gun trigger is not pressed. If pump is left in bypass mode for me than two minutes
internal components of the pump can be damaged.
If you do not understand these precautions, please contact to a service
representative for further instructions.
STARTING USING
Prior to starting refer to your engine manual for proper starting procedure.
1. In a well ventilated outdoor area add fresh, high quality, unleaded gasoline with a pump
octane rating of 86 or higher. Do not overfill. Wipe up spilled fuel before starting the engine.
The engine is a 4 cycle and uses regular octane, unleaded fuel. DO NOT USE MIXED FUEL.
Refer to Engine Owners Manual for correct procedure.
2. Check engine oil level. See Engine Owners Manual for correct procedure.
3. Adding 0# diesel into fuel tank of burner (1# , 2#, or kerosene is optional), Do not overfill.
Wipe up spilled fuel before starting the engine.
5. Verify the filter screen is in water inlet of pump. NOTE: Cone side faces out.
6. Water source at 20 PSI. Attach the water source to the water inlet located on the pump.
Turn on the water source. The water source may be attached with a good quality standard
garden type hose, 3/ą is recommended.
Connect the male fitting into the female pump inlet swivel fitting making sure that the inlet
screen is intact and fitted correctly.
NOTE: Water must be in sufficient supply (must provide a minimum of 5 gallons per
minute) and pressure must be between 20-60 PSI to ensure proper and safe
operation. Do not attach a hose that is smaller in size than the inlet of the pump.
7. Attach the high-pressure hose to the outlet coupling on the boiler or pump. Ensure that
quick disconnect connections are tightly locked together.
8. If applying a chemical or cleaning solution, see How to Apply Chemicals/Cleaning
Solvents instructions in this section.
9. Turn water source on. NOTE: Failure to do so could cause damage to the pump.
10. Start engine. See Engine Owners Manual for correct procedure. MAKE SURE THAT THE
ENGINE EXHAUST IS NOT FACING ANY FLAMMABLE MATERIALS.
NOTE: When engine rope is pulled, pressure starts building in the gun. If the engine does not
start after two pulls, pull the gun trigger to relieve this pressure.
CAUTION: MAKE SURE THAT THE ENGINE EXHAUST IS NOT FACING ANY
FLAMMABLE MATERIALS.
11. Depress trigger on gun start water flow.
NOTE: Stand on a stable surface and grip gun/spray wand firmly with both hands. Expect the
gun to kick when triggered.
12. Release trigger to stop water flow.
13. Burner operation˖
Adjust the burner thermostat knob control to the desired temperature. The burner start
automatically, when trigger is pulled
NOTE: The machine must be operating with water source prior to turning on the burner. IF
YOU EXPERIENCE IGNITION FAILURE, DO NOT ATTEMPT TO RESTART BURNER!
EXCESS FUEL AND VAPORS MAY HAVE ACCUMULATED AND THE CHAMBER MAY BE
HOT. THE UNIT MUST COOL DOWN BEFORE RESTART CAN BE ATTEMPTED. If the
burner does not restart contact our service department or your local oil burner service
technician.
14. Pull trigger on the pressure wand assembly to start cleaning. To stop the pressurized water,
release the trigger. Do not leave unit running when not in use.
WARNING: If unit is left running while not in use, pump damage may occur. Do not
leave unit running while not in use!
WARNING: DON’T TOUCH THE BARE METAL OF PRESSURE WAND
ASSEMBLY AND HIGH PRESSURE HOSE WHEN USING
THE HOT WATER. OTHERWISE WILL BE SCALD.
15. Adjust spray for the task being performed by changing quick connect nozzle. See How
Use Spray Wand instructions in this section.
PRESSURE WASHER OPERATING FEATURES PRESSURE ADJUSTMENTS
The pressure setting is preset at the factory to achieve optimum pressure and cleaning. If
you need to lower the pressure, it can be accomplished by these methods.
1. Back away from the surface to be cleaned.
The further away you are, the less the pressure will be on the surface to be cleaned.
2. Change to the 40ώ nozzle. (White)
This nozzle delivers a less powerful stream of water and a wider spray pattern.
CAUTION: DO NOT attempt to increase pump pressure. A higher-pressure setting than the
factory set pressure may damage pump.
3. Adjust the pressure regulator on the pump. Turn the pressure regulator knob
counterclockwise to lower pressure. Refer to the illustrations to identify your pressure
regulator. Once you have finished using your pressure washer, return the pressure regulator
to its original position by turning it clockwise.
This machine has been adjusted to operate at a specifically rated PSI and Volume, as per the
machine specifications. Always monitor the pressure gauge when adjusting pressure.
CAUTION: DO NOT try to turn pressure regulator knob past the built-in stop or damage to
pump will result.
TO USE SPRAY WAND
The nozzles for the spray wand are stored in nozzle holder on the panel assembly. Colors on
the panel identify nozzle location and spray pattern. See chart to choose the correct nozzle for
the job to be performed.
CAUTION: The high pressure spray from your pressure is washer capable of causing damage
to surfaces such as wood, glass, automobile paint, auto striping and trim, and delicate objects
such as flowers and shrubs. Before spraying, check the item to be cleaned to assure yourself
that it is strong enough resist damage from the force of the spray.
CHANGING NOZZLES ON SPRAY WAND
WARNING: Risk of Flying Object could cause risk of serious in. DO NOT attempt to
change nozzles while pressure washer is running. Turn engine off before changing
nozzles.
1. Pull quick connect coupler back and insert nozzle.
2. Release quick connect couple and twist nozzle to make sure it is see in coupler.
WARNING: Risk of Flying Object could cause risk of serious in. Ensure nozzle is
completely inserted QC socket, and QC snap ring is fully engaged (forward) before
squeezing gun trigger.
WARNING: Risk of injection or injury to person. Do not direct discharge stream toward
persons, unprotected skin, eyes, or any pets or animals. Serious injury can occur.
SHUTTING DOWN
1. After each used if you have applied chemicals, place chemical hose into container of clean
water and draw clean water through chemical injection system to rinse system thoroughly.
NOTE: Failure to do so could cause damage to the pump.
2. To stop Burner operation:
Turn the thermostat knob control to “OFF”, allow burner unit to cool for 2 minutes. Release
trigger on the pressure wand assembly.
3. Turn engine off. See Engine Owner’s Manual. NOTE: NEVER turn the water off with the
engine running. Release the trigger for the second time in order to relieve the pump system of
pressure.
4. Turn water source off.
5. Pull trigger on spray gun to relieve any water pressure in hose or spray gun.
6. See Storage section in this manual for proper storage procedures.
HOW TO APPLY CHEMICAL AND CLEANING SOLVENTS
Applying chemicals or cleaning solvents is a low pressure operation.
NOTE: Use only soaps and chemicals designed for pressure washer use. Do not use bleach.
To Apply chemical:
1. Press chemical hose onto barbed fitting located near high pressure hose connection of
pump as shown.
2. Place other end of chemical hose with filter on it into container holding chemical/cleaning
solution. NOTE: For every 7 gallons of water pumped 1 gallons of chemical/cleaning solution
will be used.
3. Install low pressure (black) nozzle into quick connect fitting of spray wand, see How To Use
Spray Wand paragraph in this section.
4. After use of chemicals, place chemical hose into container of clean water and clean water
tough chemical injection system to rinse system thoroughly. If chemical remain in the pump it
could damaged. Pumps damaged due to chemicals will not be covered under warranty.
NOTE: Chemicals and soaps will not siphon when spray wand is in the high pressure setting.
MAINTENANCE
WARNING: When performing maintenance, you may be exposed to hot surfaces, water
pressure, or moving parts that can cause serious injury or death!
Before performing any maintenance or repair, disconnect spark plug wire, let engine cool
release all water pressure. The engine contains flammable fuel. DO NOT smoke or work near
open flames while performing maintenance. To ensue efficient operation a longer life of your
pressure washer, a routine maintenance schedule should be prepared and followed. If the
pressure washer is used in unusual conditions, such as high-temperatures or dusty conditions,
more frequent maintenance checks will be required.
ENGINE
Consult the Engine Owners Manual for the manufacturer's recommendations for any and all
maintenance. Consult the Engine Owners Manual for the manufacturer's recommendations for
any and all maintenance. NOTE: The frame is equipped with an oil drain hole to help make
changing the engine oil easier.
PUMP
NOTE: The pump was filled with oil at the factor.
1. Change pump oil after the first ten (10) hours of operation and every fifty (50) hours
thereafter.
To Check Oil:
1. The oil level should come to the dot in the middle of the sight glass.
How to Change Pump Oil
1. Loosen dipstick/oil plug.
2. Place a container under the oil drain plug.
3. Remove oil drain plug.
4. After oil is drained place oil drain plug. Tighten securely.
5. Remove dipstick/oil plug and fill with 19 oz(526ml) of EXA70 pump oil, if EXA70 is not
available use 30W non detergent oil.
6. Replace dipstick/oil plug and tighten securely.
NOZZLE CLEANING
If the nozzle becomes clogged with foreign materials, such as dirt, excessive pressure may
develop. If the nozzle becomes partially clogged or restricted, the pump pressure will pulsate.
Clean the nozzle immediately using the nozzle kit supplied and the following instructions:
1. Shut of the pressure washer and turn off the water supply.
2. Pull trigger on gun handle to relieve any water pressure.
3. Disconnect the spray wand from the gun.
4. Remove the high-pressure nozzle from the spray wand. Remove any obstructions with the
nozzle cleaning tool provided and back flush with clean water.
5. Direct water supply into spray wand to back flush loosened particles for 30 seconds.
6. Reassemble the nozzle to the wand.
7. Reconnect spray wand to gun and turn on water supply.
8. Start pressure washer and place spray wand into high pressure setting to test.
HOW TO CLEAN THE WATER INLET FITER
This screen filter should be checked periodically and cleaned if necessary.
1. Remove filter by grasping end and removing it from water inlet of pump as shown.
2. Clean filter by flushing it with water on both sides.
3. Re-insert filter into water inlet of pump. NOTE: Cone side faces out.
NOTE: Do not operate pressure washer without filter properly installed.
BURNER
If the machine is found to be thermal and firepower keep decreasing or the efficiency
decreases or the temperature is slow to reach the required level quickly after it has been in
use for 6 months, it may need the following maintenance:
1. Remove any sediment and clean the fuel tank.
2. Disassemble the filter, take out the central part of filter and remove any grease or dirt by
compressed air and wash it in fresh diesel then re-install it. (Do NOT use petrol, water or
banana oil)
3. Disassemble the central part of filter on the oil pump and clean it with compressed air and
diesel then re-install it. (Do NOT use petrol water and banana oil)
4. Take out the oil nozzle with the oil nozzle spanner and clean it by compressed air and
diesel then re-install it.
Remove any carbide deposits on the ignition electrode. There must be a gap of 4mm
distance between the two electrodes otherwise it will be difficult to ignite.
BURNER REPAIR AND MAINTENANCE
1. Check each connector and socket to see if there are any loose contacts and tighten them if
necessary..
2. Check if the engine is running or not, and to check to see if the temperature of the engine
exceeds 80 centigrade. If it exceeds 80 C then the machine will start the high temperature
protection condition, it will return to the normal state after engine cools. If there is no high
temperature then check the capacitance to see whether it is disconnected or not and if
water has entered the engine and caused the rotor to become rusty and engine burn out
3. Check if the electrode ignites or not. It will appear as an electric arc in normal conditions. If
there is no electric arc please switch off the main power and check whether the electrode
is carbonized or not. If everything is normal please check the high voltage bag to see if it
has a loose contact or not and tighten if necessary. If not then please change the high
voltage bag.
4. Check to see if the oil access is obstructed. Pull the plug of high voltage bag power supply
wire, connect to a power source to observe if the nozzle will spurt oil or not. If it does not
spurt oil then check whether the oil pump is running using the rubber stick.. Check if the
electromagnetic valve has voltage or not, if not it has it been burn out and should be
replaced with a new oil pump.
BURNER ELECTRIC CIRCUIT BLUEPRINT AND OIL ACCESS BLUEPRINT
STORAGE
ENGINE
Consult the Engine Owners Manual for the manufacturer's recommendations for storage.
PUMP
The manufacturer recommends using a pump protector/winterize, such as EXA80, when
storing the unit for more than 30 days and/or when freezing temperatures (below 0ć/32̧)
are expected. If a pump protector/winterize is not available, *RV antifreeze needs to be run
through the pump as outlined in the steps below.
NOTE: Using a pump protector/winterize or*RV antifreeze is to provide proper lubrication to
the internal seals of the pump regardless of temperature or environment.
1. Obtain a funnel, six ounces of *RV antifreeze, and 16-36 inches of garden hose with a male
hose connector attached to one end.
CAUTION: Use only RV antifreeze or vehicle windshield washing fluid (RATED FOR
MINIMUM -40ć). Any other antifreeze is corrosive and can damage pump.
2. Disconnect engine spark plug wire.
3. Connect length of garden hose to water inlet of pump.
4. Add *RV antifreeze (or vehicle windshield washing fluid) to hose as shown.
5. Pull engine starter rope slowly several times until antifreeze (or vehicle windshield washing
fluid) comes out of high pressure hose connection of pump.
6. Remove garden hose from water inlet of pump.
7. Reconnect engine spark plug wire.
8. Your machine is now prepared for storage.
*Windshield washer fluid may also be used.
HOT WATER PRESSURE WASHER
1. Drain all water from burner boiler high, pressure hose, coil it, and store it in cradle of the
pressure washer handle.
2. Drain all water from burner boiler high, and install the quick connector back ensure that
quick disconnect connections are tightly locked together.
3. Drain all water from spray gun and wand by holding spray gun in a vertical position with
nozzle end pointing down and squeezing trigger. Store in gun holder.
4. Store chemical hose so it is protected from damage.
TROUBLE SHOOTING GUIDE
POWER SYSTEM DIAGNOSTICS-Electric Motor Not Starting
PROBLEM
Electric
starting
POSSIBLE CAUSE
SOLUTION
No
power
to Inspect power supply and cords, correct any
machine
deficiencies
Reset breaker. If problem reoccurs revaluate
Breaker tripped
number of items drawing on the same system.
motor
Faulty
power
Test voltage to the meter box.
supply
GFCI
tripped Reset GFCI. If problem reoccurs, test for proper
(optional)
ground.
Loose connection
Check connections between switch and motor.
POWER SYSTEM DIAGNOSTICS-Gas Motor Not Starting
PROBLEM
POSSIBLE CAUSE
SOLUTION
Fuel
Check to see if proper fuel levels are maintained
Check ignition by removing spark plug from
Gas motor not No ignition
cylinder. If electric start, try starting using the recoil
starting
starter.
Electric
Recharge or replace battery.
Starter/Battery
Flooded
Wait 5 minutes before attempting to restart.
Check ignition by removing spark plug from
Spark
No ignition
cylinder. If electric start, try staring using the recoil
Plug-strong gas
starter.
smell
Check spark plug and replace if necessary. Carbon
Bad plug
deposits can indicate a fouled plug or too much
fuel.
Poor connection
Inspect the ignition connection.
Plug does not fire
Bad magneto
Check the source of spark plug for engine ignition.
Bad
ignition
Poor connection
Check the source of spark for the engine ignition.
system
Check fuel delivery from carburetor to cylinder.
No fuel to cylinder
Check carburetor float bowl for fuel.
Inspect fuel line to carburetor for restrictions or
Fuel line restricted
clogging. Flexible line may be kinked.
Spark
Plug-no
Stuck
carburetor
gas smell
Unstuck float.
float
Clogged carburetor
Unclog needle valve.
needle valve
Bad fuel pump
Replace fuel pump.
FLUID SYSTEM DIAGNOSTICS-Flow and Pressure
PROBLEM
No Flow
POSSIBLE
CAUSE
SOLUTION
Trigger gun valve
Make sure pump is operating. Check drive belts
and couplings, make necessary adjustments.
Check trigger gun, repair or replace.
No water source
Ensure water supply is not restricted and hoses
No power
are in good repair and not kinked.
Clogged
spray
Check spray nozzle, repair or replace.
nozzle
Clogged inlet filter Check inlet filter, repair or replace.
Float valves can become stuck in the “UP”
Float Valve stuck
position. Manually dislodge and inspect for
(optional)
problems.
Faulty
unloaded Remove and check for proper action, repair or
valve
replace.
Nozzle should be properly sized for the system.
Incorrect or on
Low pressure indicates that the nozzle in use is
spray nozzle
too large.
Replace nozzle when it shows signs of internal
Worn spray nozzle
erosion.
Clean valves and check o-rings for pits and
Debris in valves
cracks.
Low
pressure, Lance
on
low Adjust pressure so the water flows through
adequate flow
pressure
properly.
Unloaded is no
Adjust unloaded to proper level.
adjusted correctly
Use a new pressure gauge on a quick connect at
Pressure
gauge
outlet to check system pressure and replace if
inaccurate
gauge is faulty.
If low pressure persists, pump pickings may need
Pump pickings bad
replaced.
Volume improperly If unit has volume adjustment, it may need
adjusted
readjustment
Discharge leaks
Look for leaks on the discharge side of system.
Downstream
Remove the injector and retest system. If the flow
chemical injector
is restored, replace the injector.
(Demas)
If belts do not have proper deflection, replace
Loose drive belts
them.
Pump not running Check engine throttle and see that the motor is
Low
pressure,
at rated speed
rated for the same speed as the pump.
low flow
Stripped
pump
Inspect coupling and repair or replace.
drive coupling
Defective
easy
Check the start or throttle-back valve for proper
start valve
operation.
(optional)
Malfunctioning
Ensure that the motor or engine is working
motor or gear
properly
Unloaded stuck in
Piston assembly may be stuck or fouled
bypass
Build up can restrict flow. If water is not flowing
Outlet restriction
freely, flush with garden hose to isolate the clog
or restriction.
Distorted spray pattern can indicate a clogged
Low
pressure, Clogged nozzle
nozzle.
low flow- bogs
Nozzle to small
Ensure nozzle is proper size for the system.
Correct any kinks or restrictions. Replace crushed
Hose restriction
hoses.
Debris
in
the Debris can lodge in the discharge side of the
system
Small spray nozzle
Excessive
pressure
Faulty
gauge
pressure
Improperly
adjusted unloaded
Faulty unloaded
Air in system
Chemical line not
submerged
Inlet line restricted
Inadequate water
Pump
chatters, supply
cavitations,
vibration
Float
valve
stuck(optional)
Turbulence in float
tank (optional)
Inlet
or
inlet
strainer clogged
Water supply to
hot
Air in system
Debris
in
inlet
check valves
Inlet line vibrates
Outlet
line Air in system
vibrates
Debris
in
inlet
check valves
Pump packing bad
system(valves, fittings, injectors, filters) flushing
With water may correct it.
Nozzle must be properly sized for the rated flow
and pressure. Reset unloaded or pressure relief if
nozzle size is changed
Check the pressure gauge using a properly
calibrated pressure gauge on quick connects at
the equipment outlet.
Adjust to the proper pressure using pressure
gauge.
Check the unloaded action. If it is not working
properly, it may need repaired or replaced.
Inspect places where air can enter the system,
i.e.; fittings, hose, connections etc.
If the chemical valve is on, ensure that the
chemical line is fully submerged in the chemical
All inlet connections should be snug and not
kinked to reduce the chances of pump starvation.
Water supply to the system must meet or exceed
the rated flow(GPM) on the serial number plate.
Faucet must be completely opened or water
above the tank outlet in a gravity fed system.
If float valve is stuck in the up position, water can
not enter the float tank. Unstuck valve if possible
of replace if necessary.
Excessive turbulence allows the pump to draw air
into the system. Correct excessive turbulence.
Regularly clean the inlet and inlet strainer to keep
debris from entering the float tank
Inlet temperature should not exceed 140F-160F
range.
Inspect places where air can enter the system,
i.e.; fittings, hose, connections etc
If there is no float tank and the outlet line does no
vibrate, the inlet check valve may be clogged.
Remove debris. Check o-rings under valves.
Inspect places where air can enter the system,
i.e.; fittings, hose, connections etc.
If there is no float tank and the outlet line does no
vibrate, the inlet check valve may be clogged.
Remove debris.
If they show signs of ware or damage, replace
them.
Inlet and outlet
Inlet and outlet
Look for the source of debris in the inlet and
check
valves
lines vibrate
discharge check valves and remove.
fouled
FLUID SYSTEM DIAGNOSTICS-Unloaded
PROBLEM
POSSIBLE CAUSE
SOLUTION
Isolate the flow problem. If it occurs before the
Very low or no Unloaded stuck in
unloaded discharge point, check the piston
flow
bypass
assembly to see if it is fouled or stuck in bypass
mode.
Take bottom nut off unloaded, identify ball,
spring and seat. Clean out any debris and
Debris in unloaded
Unloaded will not
unload
Sever leak on the
Check for leads and repair.
outlet of unit
Any variation in flow form what the orifice is
Improper flow
sized can cause cycling system must produce
the rated flow constantly.
A nozzle that is too small can cause the flow to
Nozzle to small
be reduced.
A distorted spray pattern indicates a clogged
Nozzle clogged
nozzle.
Improper unloaded The systems rated output should indicate the
orifice
proper sized orifice for your system.
Unloaded(flow)
Unloaded
orifice Check the orifice for clogs and clear out any
cycles
with
clogged
debris.
system
under
Injector
orifice If the system has a venture injector downstream
pressure
clogged
of the unloaded, check the orifice for clogs.
Scale buildup can restrict flow. Check; controls,
Other downstream valves, switches, trigger gun, and lance.
restriction
Rescale as necessary and begin preventive
maintenance program for scale prevention.
Pump not delivering
See low pressure or low flow diagnostics.
the rated pressure
High water supply
Check inlet water supply for excessive pressure.
pressure
Check unloaded bypass port to see if a flow
No restrictions on
restrictor is properly installed. Install one if none
the unloaded
is present.
Weep
gun
in If a weep gun is installed, try replacing with a
Unloaded (flow)
system(option)
regular gun.
cycles
with
Causes the unloaded to since a continuing flow
system in bypass Downstream
and divert it to the closed gun. Repair or
leakage(excessive)
replace.
Accumulator
Remove the accumulator from the system.
downstream(option)
Unloaded adjusted Adjust the unloaded using the pressure gauge
too low
for the correct pressure.
Spray
nozzle A distorted spray pattern indicates a clogged
clogged
nozzle.
Unloaded(pressu
Spray nozzle too A small nozzle causes a reduced flow and
re)
produces
small
cycling may result.
smooth flow &
If the system has a ventures injector
low volume
Injector
orifice
downstream of the unloaded. Check the orifice
blocked
for clogs.
System
not
See flow diagnostics.
delivering rated flow
Unloaded adjusted Adjust unloaded and regulator until proper
pressure is achieved.
Unloaded (flow) too low
produces smooth Unloaded
valve If unloaded is sticking, repair or replace as
flow
&
low stuck in bypass
necessary.
volume
Restriction
in Downstream restrictions can cause a reduction
system
in flow. Check; controls, valves, switches, trigger
gun, and lance. Decaled as necessary and
begin preventive maintenance program for scale
preventions
Unloaded adjusted If the unloaded is diverting flow to bypass it may
too low
be adjusted too low, readjust as necessary.
Unloaded
Spray nozzle to
Ensure the proper nozzle is installed on system.
(pressure)
large
produces
low
The number of hours of usage can give you a
Internal
nozzle
flow and normal
clue to the extent of the ware. If in doubt,
erosion
pressure
change
Insufficient
pump Check pump seals and pickings and tighten
pressure
drive belts.
Unloaded(flow)pr Unloaded adjusted If unloaded is diverting flow to bypass, readjust
oduces low flow too low
using the pressure gauge.
&
normal
Nozzle too large
Ensure the proper sized nozzle is being used.
pressure
Unloaded
(pressure) leaks Shaft o-ring in valve Check o-rings for ware or damage and replace
Form main spring body warn
as necessary.
or adjusting bolt
Unloaded
piston Check unloaded shaft for proper action. Unstuck
piston and shaft or replace unloaded.
Unloaded (flow) stuck or frozen
pressure
Bypass port clogged Ensure that unloaded bypass port is not
increases when or restricted
clogged.
trigger released
Excessive tension If tension is incorrect, adjust or replace as
on main spring
necessary.
Unloaded (flow)
leaks
water
Check o-rings for ware or damage and replace
Sleeve o-ring worn
around adjusting
as necessary.
blot
ANY LEAKS SHOULD BE REPAIRED ASAP TO PREVENT DAMAGE TO THE SYSTEM.
PROBLEM
From inlet
POSSIBLE CAUSE
SOLUTION
Garden
hose Ensure the washer is present and in good
washer
condition.
From
low
Loose clamps
pressure(inlet)
connections
line fittings
or Low pressure line should be properly sealed on
barb and tightly clamped.
If float is not floating above water, check the
Float tank full of
float to see if it has filled up with water. If
water or stuck
necessary, drain and seal.
Fittings
not Usually metal to metal fittings should be taped
From
pressure
tightened or taped, with Teflon tape to provide a tight seal.(unless
fittings
or cracked
fittings are provided with an o-ring or seal)
From
quick
If quick connect o-ring shows wear or damage,
Bad o-rings
connects
replace it.
If the seal leak is detected under the pump
From pump
Bad pacing
manifold, packing may be worn and in need of
replacement.
If o-rings show wear or damage, they may need
Bad rod o-ring
replaced.
From trigger gun
Stripped connectors Physical damage may not be apparent, but
From float tank
unseen warping from freezing or extreme
pressure can still cause leakage.
If a weep gun has been installed, check the gun
Weep gun(optional)
valve seat to ensure it is functioning properly.
From nozzle
Inspect trigger gun valve assembly for damage
Damage gun valve
or ware to ball or seal. Lodged debris can stop
ball or seat
valve from closing. Repair with kit or replace.
If quick connect o-ring shows wear, damage or
From unloaded
Bad o-rings or seals
improper seating.
From
variable Bad
o-rings
at Inspect o-rings for ware or damage and replace
pressure lance
adjusting knob
as necessary.
Take bottom nut off unloaded, identify ball,
Debris in unloaded
spring and seat. Clean out any debris and
Unloaded will not
reassemble.
unload
Sever leak on he
Check for leaks and repair.
outlet of unit
System
over See pressure and flow diagnostics to find the
pressure
cause of the excessive pressure and correct it.
Spray pattern will be distorted if nozzle is
Clogged nozzle
clogged, clean out.
Trigger gun valve If trigger gun valve action is not correct, repair or
not working
replace.
From
pop-off
If water spurts from valve when trigger is
valve
Excessive pressure released, check unloaded adjustment. Pressure
spike
spike should be below the level where pressure
relief valve is activated.
Wear or damage to Inspect ball and seal for damage and adjust as
ball or seal
necessary.
Improper relief valve
Adjust valve properly.
adjustment
FLUID SYSTEM DIAGNOSTICS-Trigger Gun/Spray Nozzle
PROBLEM
No nozzle flow
from
nozzle
when
trigger
depressed.
Excess pressure
when trigger gun
is released
Flow
not
stopping
when
trigger
gun
released
Trigger
action
sticks
Trigger gun leaks
POSSIBLE CAUSE
SOLUTION
If water flows through discharge hose without
Broken piston rod in
gun, check trigger gun valve piston rod and
trigger gun
replace if necessary.
Missing metal insert
in
trigger
gun
Inspect to assure insert is in place.
(European
style
gun)
Blockage in system Check nozzle or spray accessory for blockage
past gun
and clear it.
After unloaded increases pressure to a
Excessive pressure
maximum, further adjustment will only increase
spikes
the pressure spikes. Re-adjust.
Broken return spring If trigger action is too loose, return spring may
on trigger gun
need replaced.
Debris in gun valve can stop piston return. Clear
Debris in gun valve
debris.
Keeper plug too It may be possible to loosen plug slightly without
tight
leakage but it will likely need replaced.
Worn or bad o-ring
Check trigger gun o-rings for ware or damage
and replace.
Physical damage may not be apparent but
Stripped or loose
unseen warping from freezing or sever
connections
overpressure may still cause leaking.
Open chemical valve. If it chatters with no
chemical delivery, air is being drawn from the
Chemical
valve
upstream side of the pump. Check fittings,
closed
connections and ensure the inlet line is fully
submerged into the chemical jug.
Chemical dried up in
Inspect and clean as necessary.
the injector
Chemical
foot May be a strainer or check valve. Ensure that
strainer clogged
the ball is not stuck or clogged.
Chemical
line Chemical line linking or binding prevents
kinked
chemical delivery.
No chemical
An overly long chemical line can prevent the
Chemical line too
pump from drawing chemical into the system. try
long
installing a shorter line.
Chemical too dilute
Verify chemical strength.
Downstream injectors only-low pressure is
No adjustment for required for most injectors to draw chemical. If
low pressure
no adjuster exists it may need low pressure
spray nozzle installed on the lance.
If not properly sized for the systems rated
Incorrect
injector
output, chemical delivery problems will result.
orifice
Check serial plate for specs.
Valve
improperly
To properly adjust, a chemical flow meter may
adjusted,
check
be used to precisely measure chemical flow.
Excessive
knob on injector
chemical
Chemical dilution to
Verify chemical strength.
strong
Spray
pattern
Spray pattern will be distorted if nozzle is
Clogged nozzle
irregular
clogged.
Ensure that the nozzle is sized properly sized for
Nozzle to large
the system.
Volume proper,
pressure low
A loss of pressure may result form gradual
Internal nozzle wear
nozzle wear. Replace a nozzle of correct size.
Spray pattern will be distorted if nozzle is
Pressure proper,
Clogged nozzle
clogged. Check nozzle for clogging if the unit
volume low
has a pressure unloaded.
BLILER SYSTEM DIAGNOSTICS-Oil Burner Will Not Fire
PROBLEM
Not
reaching
rated pressure
Thermostat
on
low setting
POSSIBLE CAUSE
Not activating boiler
controls
Thermostat set to
low
Burner no getting
No or low fuel in adequate fuel
tank
Low fuel shut-off
control activated.
No air movement
No
air
being
SOLUTION
Correct the fluid problem first-see fluid systems
diagnostics.
Set thermostat to an output temperature
requiring heating.
Check fuel and ring to proper levels. Inspect fuel
tank for water or debris.
Full featured equipment may have a shut off if
fuel is low.
Ensure that the blower is working and that the
supplied
through
Thermal
tripped
reset
Burner motor
capacitor is bad
or
Contaminated fuel
in the tank
Improper fuel in the
Fuel in the fuel
tank
tank
Low fuel shut-off
sensor stuck or
faulty
Water in the fuel
Water in fuel supply
filter bowl
Clogged strainer
Debris in the fuel
filter bowl
Clogged fuel nozzle
air band or damper is properly adjusted and in
good repair.
Press the thermal reset button on burner motor.
If the reset trios again an additional problem
must be sought.
If motor does not turn, first check
thermostat/press switch, the motor starting
capacitor and finally the burner motor itself.
Ensure that the proper clean fuel is being used.
If not, siphon any debris or water from the tank.
If the improper fuel is found in the tank, drain
and rinse the tank, then fill with proper fuel.
Check the sensor. The assembly may need to
be removed to un-stick the float or to replace it
completely.
Drain water from the tank promptly to prevent
rusting. If fuel delivery problems persist, check
the fuel pump for rust.
If the fuel strainer or in-line filter is clogged,
clean or replace.
Replace if there is any evidence of clogging or
debris.
Check lines for clogging and clear if necessary.
Check only if no fuel in the filter bowl-drain the
tank and check for rust. If problem persists, fuel
pump should be checked for rust.
Clogged fuel line
Water comes out
drain at bottom of Water in fuel supply
tank
Cannot smell or No
fuel
being
Check fuel delivery and correct any problems.
see fuel at stack
supplied
Ensure that air is not entering through the lines
Air leak to pump
or connections.
Ensure that the fuel line is connected and is not
Broken fuel line
broken/punctured.
Clogged fuel filter
Check any clogging that exists in the fuel filter
No fuel to bleed
Clogged fuel inlet Check any clogging that exists in the fuel inlet
valve
line
line
Frozen fuel pump
If the fuel pump is frozen it will need replaced.
Check pump coupling if direct or belt driven.
Broken fuel pump
Replace or tighten or replace the drive belts if
coupling
needed.
Remove the solenoid cover and place blade of
Steady fuel flow
an insulated screwdriver in the coil with the
Solenoid valve not
at bleed valve but
system operating in hot water mode. A good
energizing
none
in
working solenoid will hold the screwdriver in the
combustion
solenoid. If not it may need replaced.
chamber
Oil pump may have debris, replace as
necessary.
If boiler controls work properly, the pressure or
Boiler
controls Solenoid valve coli
vacuum on the fuel pump may be misadjusted.
activating
not energizing
Check solenoid coil again.
Solenoid
valve Debris in internal Check for clogging in the solenoid valve inside
energizing
fuel pump valve
fuel pump.
Check fuel nozzle for clogging and clear if
Fuel nozzle clogged
necessary.
Restriction in fuel
outlet line
Fuel pump piston
frozen closed
No power reaching
transformer
Ignition transformer
bad
Electrode
improperly set
Electrode
Air and fuel flow cracked
proper
gap
caps
Electrode
wires
loose or damaged
Electrodes arcing to
fuel lines
Transformer
bus
bars not lining up
Burner
or
electrode
assembly
fires
when
removed
from housing
Ignites with air
bands
closed
down
Ignites with air
bands opened up
check fuel line from pump to burner for any
restriction.
Check piston in fuel pump to see if it will travel.
Free piston or replace fuel pump.
Ensure the proper voltage is reaching the
ignition transformer with a volt meter.
Using a volt meter ensure that the transformer is
supplying the proper voltage.
Check the gap and readjust if necessary, taking
care that the proper distance is maintained from
the fuel nozzle.
Down fired, multi-pass boiler systems have a
cap on the top of each electrode. Examine caps
for cracks or carbon build-up and replace if there
problems are evident.
Applies to down fired, multi-pass boiler
systems-Check the wire to ensure there is a
good connection.
Electrodes should not be arcing to fuel lines or
nozzle. Check electrode for cracking or carbon
build-up
Applies to gun type burners-Bus bars on the
transformer should line up and connect properly
with the electrode terminals
Check air delivery to combustion chamber.
Improper air delivery Down fired; check air damper and air bag. Gun
type; check air bands
Excessive electrode
Ensure electrode gap is properly set.
gap
Choked down
Open air bands to proper setting.
BOILER SYSTEM DIAGNOSTICS-Gas Burner Will Not Fire
PROBLEM
POSSIBLE CAUSE
No arc at the Spark gap incorrect
ignition
pilot
assembly
Ignition module bad
SOLUTION
Check the spark gap and reset if necessary.
Check for air in the propane line.
Check the ignition module and replace if
necessary
Ignition operating Boiler
controls Check boiler controls for good operation and
properly
malfunctioning
correct problems
Boiler
controls Gas
valve If pilot and boiler controls operate properly, the
operating properly
malfunctioning
problem may exist with the gas valve. Replace if
necessary.
Abnormal Flame Characteristics-Gas Fired
PROBLEM
POSSIBLE CAUSE
SOLUTION
Flame intermittently Gas
velocity If gas flow is not properly regulated, the
lifts and returns to exceeds
flame regulator may need to be replaced. Gas line
gas port ”candles”
speed
Flame
height
changes suddenly
Flame floats around
the
combustion
chamber
Flame has yellow
tip
Flame comes out
from under burner
housing
Gas burns inside
the
burner
tube-roars
Burner pops when
gas is shut off
may be too small.
Check orifice for partial blockage. If no blockage
Uneven gas supply
found, ensure that the gas supply and regulator
pressure
are working properly.
Check stack for fuel restriction and correct. It
Insufficient air
may require new ventilation if the original
system is inadequate.
Flame
speed Check for proper gas pressure while burner is
improper
operating.
Insufficient air and Usually occurs at ignition. Check stack for fuel
ventilation
restriction.
Burner underrated
Inquire about a burner with the proper rated
capacity.
Flame travels back Flame travel when the gas is shut off does not
into burner
damage the unit.
BOILER SYSTEM DIAGNOSTICS
Water Output Temperature Too Low-Oil or Gas Fired
PROBLEM
POSSIBLE CAUSE
SLUTION
Burner
firing
normally but with Thermostat set too
Set the thermostat to proper output temperature.
outlet temp lower low
than rated
If inlet water is freezing to the touch, the boiler
may not be able to reach the desired
Inlet water too cold
temperature increase. Use a water supply with a
higher temperature.
Burner
firing
Soot build up on the coil can keep the water
constantly
Sooting
from reaching the desired temperature. Remove
all soot from the coil and check for smoking.
The outlet fitting to the hose can get scale
Scaling
build-up and reduce heat exchange. Descale
and prevent further build-up.
BOILER SYSTEM DIAGNOSTICS-BOILER Controls
PROBLEM
POSSIBLE CAUSE
SLUTION
A millimeter can be used to check continuity
through controls and pinpoint the problem areas;
Boiler control or
No voltage solenoid
Or first check the engine charging coil, then
electrical problem
check the 12V diode-automatic manostat, and
confirm if there is current.
Bad connection to Electrical connections to solenoid valve coil
solenoid coil
should be tight and not corroded
Check to see if fuel solenoid will energize when
Solenoid coil does
Coil
bad
the proper voltage is applied Solenoid may need
not energize
replacing
Boiler control
not If coil energizes when proper voltage is applied
activating
Solenoid
energizes
check boiler controls
If solenoid valve coil energizes when the cleaner
coil Problem occurring
is operating in hot water the problem is
elsewhere
elsewhere Check the air/fuel delivery
BOILER SYSTEM DIAGNOSTICS-Pressure Switch
PROBLEN
POSSIBLE CAUSE
SOLUTION
A millimeter can indicate if the proper voltage
Control not flowing
flows through the boiler side of the switch If not
Switch
activates through switch
the switch may not need replaced
when pressure is
Switch
improperly
reached but boiler
Switch may be improperly wired for it’s function
wired
not firing
If wiring is proper and still no current flow when
Switch bad
activated, switch may need replacement
Plunger fouled or Check pressure plunger to see if it will travel
stuck
freely .If not the passage may need cleared
Switch dose not
Check to see if the plunger is traveling far
activate
Plunger not moving
enough to depress the micro switch .Adjust if
through switch
necessary
If switch activates manually but boiler does not
Current not flowing
fire current may not be flowing through The
through switch
switch may need replacing
Micros witch not Micros witch may need readjustment so plunger
Switch
activated properly adjusted
can trip in
manually
Switch bad
Replace switch with another one
If switch works manually and current is flowing
Problem elsewhere
properly the problem is elsewhere .Try other
in the system
boiler diagnostics
BOILER SYSTEM DIAGNOSTICS-Vacuum Switch-Optional
PROBLEM
POSSIBLE CAUSE
SOLUTION
Improper diaphragm Replace switch
if improper diaphragm
movement
movement is detected
Correct problems related to inadequate water
Switch
activated Low water flow
flow
manually
Air leak in or
Replace vacuum switch if diaphragm shows an
punctured
air leak or hole
diaphragm
Switch
shows
Problem elsewhere If vacuum switch works properly continue with
continuity
when
in system
other boiler control diagnostics
activated
Switch does not
shows
continuity Switch contact bad
Replace switch with another one
when activated
BOILER SYSTEM DIAGNOSTICS-Flow Switch Optional
PROBLEM
POSSIBLE CAUSE
SOLUTION
Reed
switch
activates
when
tested with external
magnet
Reed switch does
not activate when
tested with external
magnet
Magnet fouled and If magnet does not move freely within its
will mot move
housing, remove debris to unstuck it
TO adjust it for the flow
the system is
Reed
switch
producing, loosen the reed switch and move it in
misadjusted
its
If reed switch activated the boiler when tested
Magnet is bad
with a hand held magnet, the internal magnet
may
If reed switch does not activated the boiler when
Reed switch is bad
tested with a hand held magnet , the reed switch
may need replacement
Problem else where
See diagnostics listed above
in system
BOILER SYSTEM DIAGNOSTICS-Thermostat
PROBLEM
POSSIBLE CAUSE
Thermostat set improperly
Thermostat
low
set
Boiler fires when thermostat
jumped ,but will not fire with Thermostat bad
thermostat in circuit
SOLUTION
too Set thermostat properly and ensure
connections are not loose or corroded
Replace Thermostat
Continue with boiler control diagnostics. If
Boiler will not fire when Problem else where
boiler still does not fire, the thermostat
thermostat jumped
in system
may need replaced
BOILER SYSTEM DIAGNOSTICS-High Temperature Limit
PROBLEM
POSSIBLE CAUSE
SOLUTION
Connections loose Check connections to high temperature limit switch
or corroded
to ensure that they are not loose or corroded
Electrical continuity
If there is continuity through switch but the boiler
through switch
Problem else where still does not fire, there is a problem elsewhere in
in system
the system. Continue with boiler control
diagnostics
Mo
continuity
Switch bad
Replace switch
through switch
BOILER SYSTEM DIAGNOSTICS-Low Fuel Shut-Off
PROBLEM
Fuel level low
Fuel level proper
POSSIBLE CAUSE
SOLUTION
Switch
may
be
Add fuel and retest
operating properly
Check level sensor for proper movement.
Level sensor stuck
Clear, or replace sensor assembly
Check
level
sensor
for
proper
Reed switch bad
action .Replace switch if needed
EXPLODED VIEW OF PUMP
PARTS LIST OF PUMP
Item
Description
Item
Description
1
Bolt, cover of crank case
46
Under washer, spring
2
Oil gauge
47
Water return valve
3
Gasket oil gauge
48
Gasket, valve rod
4
Gasket, oil drain plug
49
Inner gasket, valve jacket
5
Oil drain plug
50
Water return valve jacket
6
Crank case cover
51
Outer gasket valve jacket
7
Gasket, cover of crank case
52
Outer gasket valve jacket
8
Cover, oil inlet plug
53
Water return valve core
9
Oil inlet plug
54
Water return valve seat
10
Gasket, oil inlet plug
55
Gasket, valve seat
11
Crank case
56
Gasket, outlet tee connector
12
Bolt, Crank shaft case
57
Water outlet tee connector
13
Crank shaft case
58
Gasket, fix bolt
14
Gasket bearing cover
59
Fix bolt, outlet tee connector
15
Bearing clip
60
Fix bolt, inlet tee connector
16
Ball bearing
61
Gasket, inlet tee connector
17
Crank shaft
62
Water inlet tee connector
18
Needle rotter bearing
63
Gasket, the two tee connector
19
Gasket, bearing cover
64
Gasket, inlet tee connector
20
Flange
65
Gasket, water inlet connector
21
Oil seal, flange
66
Water inlet connector
22
Bolt, flange
67
Screw cap
23
Connecting rod
68
Water inlet swivel nut
24
Plunger pin
69
Clip
25
Plunger rod
70
Gasket, 3/8ąQD
26
Gasket, plunger rod
71
Compaction, 3/8ąQD
27
Water checking flake
72
Clip, QD
28
Ceramic plunger
73
Steel ball, QD
29
Washer, plunger fix nut
74
3/8ąQD body
30
Plunger fix nut
75
Detergent injector
31
Plunger oil seat
76
Spring, injector
32
Locating ring
77
Ball, injector
33
Gasket, locating ring
78
Gasket, injector nozzle
34
Locating ring water seal
79
Injection nozzle
35
36
37
38
39
40
41
42
43
44
Compaction ring, water seal
Compaction flake water seal
U-Packing
U-Packing seat
Pressure adjusting handle cover
Pressure adjusting screw
Fix nut, adjusting screw
Pressure adjusting handle
Pressure adjusting seat
Upper washer, spring
80
81
82
83
84
85
86
87
88
89
Water shooting tube
Water outlet joint
Gasket, water outlet joint
Spring water outlet cone valve
water outlet cone valve
Gasket, water outlet cone valve
Cylinder
Gasket, check valve
Washer check valve
Check valve
45
91
92
Pressure adjusting spring
Check valve box
Gasket compaction cap
90
93
94
Spring check valve
Check valve compaction cap
Bolt cylinder
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