Ser vic e M anual
Service Manual
6
.
______________________________________________________
INSTALLATION DATE
PART NUMBER
______________________________________________________
MAKE/MODEL
SERIAL NUMBER
______________________________________________________
SELLER
______________________________________________________
ADDRESS
CITY/STATE/ZIP
Specifications
PERFORMANCE
Discharge Volume
Pump Head Pressure
Temperature Limit
Combustion Smoke/Bacharach
Scale
Carbon Monoxide Allowed
Draft/Stack Installation
Heat Input
GENERAL
Minimum Inlet Water Pressure
Stack Size
Fuel Tank Capacity
3.6 GPM / 13.2LPM
3200 psi / 208 bar
210˚F / 99˚C
#1 OR #2 SMOKE
0.01%
0.2” – 0.04” WC READING
352,800 BTU/HR / 88,905 KCAL/HR
over 65 psi may require water inlet regulator
10 psi / 0.68 bar
8” OD / 203.0 mm OD
8 Gallon / 30.3 Liter
Specifications Weight
Specifications
Belt
730 Lbs / 331 Kg
p/n R02-00236
Spray Tip
Hose Assembly
Coil
Coil
Coil w/ wrapper Part Number
Coil Back Pressure (New)
Coil Back Pressure Requiring
Descaling
(#4.0 - 0˚) p/n JA0-00040-2
(#4.0 - 15˚) p/n JA0-15040-2
(#4.0 - 25˚) p/n JA0-25040-2
(#4.0 - 40˚) p/n JA0-40040-2
3/8” x 50’ P/N K02-03150E1
18”OD x ½”ID x 158’ Schedule 80
W425R-07204
5 PSI @ 3.0 GPM / 0.34 BAR @ 11.4 LPM
50 PSI @ 3.0 GPM / 3.40 @ 11.4 LPM
ELECTRICAL
Machine Voltage
Temp Control, Adjustable
PUMP MOTOR
Motor
Motor Horsepower
Motor Speed
Motor Voltage
Motor Amps
Burner Part Number Without
Solenoid
Burner Part Number With Solenoid
Burner Type
Fuel Type
Fuel Pressure
Fuel Pump Part Number
Motor Voltage
Motor Horsepower
Motor Speed
Burner Nozzle
Fuel Consumption
Specifications
115v 60hz 1PH
p/n F04-00818
P/N F02-00069
8 HP / 6 KW
3450 RPM
208v / 230v 60 Hz 1PH
208v (36 AMP) / 230v (33 AMPS)
V00-17367-2
V00-17365-2
Pressure Atomizing
Kerosene, #1 or #2 Diesel
125 PSI / 9 BAR
V00-14283
230V 60 Hz 1PH
1/7 HP
3450 RPM
2.25 Gallon per Hour 80 Degree B
p/n V2.25 80DB
2.52 Gal/Hr / 9.5 L/Hr
Final Assembly
3
2
1
ASS'Y, GUN - OPEN 1/4" X 42"
p/n: J06-00102B
4/28/2009
ITEM
NO.
PART NUMBER
PART DESCRIPTION
QTY.
1
J06-00101
GUN, OPEN
1
2
J06-00104E
ASSEMBLY, WAND - 42"
1
3
W04-24225-A
COUPLER, 1/4F X 1/4FNPT
1
1
ITEM
2102-00710 PART LIST
PART NUMBER
PART DESCRIPTION
1
W04-31231-B
Coupler, 3/8M X 3/8FNPT
2
K02-03150E5
Assembly, Hose – 3/8 X 50’
2
ASSEMBLY, CHEMICAL HOSE
p/n 4120-00902P
ITEM
NO.
1
PART
NUMBER
Z01-08413-2
2
C04-00131
PART DESCRIPTION QTY.
HOSE, POLYBRAID 1
1/4" X 84"
STRAINER, W/CHECK
1
Final Assembly Final Assembly
Float Tank Assembly
4
7
10
9
8
3
2
5
15
6
13
1
14
12
11
16
ASSEMBLY, TANK - FLOAT
4/1/2008
ITEM
NO.
PART NUMBER
PART DESCRIPTION
QTY.
1
4120-10540
ASSEMBLY, RESTRICTOR
1
2
5181-00120
FLOAT TANK WELDMENT
1
3
AR14-00300
ROD,THREAD 1/4-20UNC X 3
1
4
C03-00620-Q
VALVE, FLOAT
1
5
C03-00622-B
BALL,FLOAT-PLASTIC
1
6
C04-00120
FILTER, SOAP SCREEN
1
7
C05-00270-1
NUT, GARDEN HOSE
1
8
C05-00271
WASHER, GARDEN HOSE
1
9
C05-00272
ADAPTER, GARDEN HOSE
1
10
E06-00008-2
COUPLING, FULL
1
11
E08-00016-4T
ELBOW, 1/2" FNPT
1
12
E09-00002-P
PLUG, PIPE - NYLON
1
13
E13-00010-2
NIPPLE, PIPE
1
14
E15-00010-48
NIPPLE, BRASS 1/2"
1
15
F04-00761B
SWITCH, VACUUM
1
16
W02-10025-8
BARB, HOSE
1
Float Tank Assembly Burner Assembly
5
3
6
1
2
ASSEMBLY, BURNER
4
7
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
4
V04-003
5
V 0D%
6
W02-10019-8
BARB, HOSE
1
7
W02-10031
BARB, HOSE
1
Burner Assembly
BURNER, OIL
1
FILTER , FUEL
1
NOZZLE, BURNER
1
Maintenance Procedures
Priming the machine
Shut off the fuel tank valves. Spin off the clear bowl, fill with
clean fuel and coat the round gasket (3) with fuel. Reinstall the
clear bowl and tighten ¼ to 1/3 turns after the gasket contacts
the upper housing. Turn on the fuel tank valves. Start the
machine and check that there are no leaks.
1
Draining water
Check the collection bowl daily. Drain off water
contaminants by unscrewing the clear bowl turning counterclockwise. Start the machine and allow air to purge from the
fuel system prior to operating the equipment.
2
3
Element replacement frequency
Frequency of element replacement is determined by
contamination level in the fuel. Replace the element every 500
hours.
Note: Foul smelling diesel fuel is an indication of
microbiological contamination. A change in fuel source is
recommended. Always carry a spare filter element as one
tank full of contaminated fuel will plug the fuel filter element
prematurely.
4
FILTER, FUEL - 1/4F X 1/4F
p/n: V04-00314
2/26/2010
ITEM
NO.
PART NUMBER
1
V04-00314-1
2
V04-00314-2
3
V04-00314-3
4
V04-00314-4
PART DESCRIPTION
QTY.
HOUSING, UPPER-1/4F X 1/4F
ALUMINUM
O-RING,
1
SCREEN,FILTER-SS ELEMENT
BOWL, FILTER-CLEAR
PLASTIC
1
1
1
Element replacement procedure
1.
Shut off the fuel tank valves.
2.
Unscrew the clear bowl turning counter-clockwise.
3.
Remove and discard the filter element.
4.
Follow listed procedures under “PRIMING.”
Trouble
1. Fuel bowl leaking.
2. Air leaking into system
(indicated by air bubbles in
bowl during operation).
Possible Cause
Remedy
B. Loose Filter bowl.
D. Replace Gasket.
E. Tighten Fuel Bowl Onto Filter.
A. Inspect Filter Bowl, Filter Housing, and
Gasket.
B. Tighten Fuel Bowl Onto Fuel Filter.
A. Deteriorated gasket.
B. Housing Cracked.
C. Bowl rim cracked, nicked, or
scratched.
D. Gasket missing.
E. Loose Fuel Bowl.
A. Cracked Component.
A. Remove and Replace Gasket.
B. Remove and Replace Housing.
C. Remove and Replace Bowl.
Burner Assembly Burner Assembly
Burner Assembly Pump, Fuel
Valve, Solenoid
Coil, Solenoid
Coupling, Shaft
Band, Air – Outer
Band, Air – Inner
Housing, Fan
Assembly, Burner Gun
Cone, Air
Gasket, Flange
Weldment, Air Tube
Screw, Thread Cutting
Screw, Set
Fan w/ Item 29
Motor, Electric
V00-14283
F04-00978
V13-00654
V00-13279
V00-02668
V00-02669
V00-04725
V00-30540-07
V00-14160
V00-12484
4120-00440
V00-12699
H04-31302
V00-20289
V00-21328
18
*19
*19A
20
21
22
23
24
25
26
27
28
29
30
31
Screw, Machine
Cover, J-Box
Nut, Hex
Washer, Flat
Screw, Thread Cutting
Clip, Hold Down
Strain Relief, Cord
Transformer, Ignition
Screw, Thread Cutting
Nipple, Chase
Cover, Slot
Nut, Hex
Screw, Cap
Assembly, Oil Line
Assembly, Oil Line – 6”
H04-19000
H04-16401
F04-00512
F04-00315
H05-87500
V00-13360
V00-13038
V00-13121
V00-20358
V00-13045
F04-00316
V00-13392
V00-14296
H04-31313
V00-14452-1
V00-14451-1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
*16
*Specific to P/N V00-17365-2 w/ Solenoid
Elbow, Flare
V00-13494-1
17
PART DESCRIPTION
Screw, Thread Cutting
PART NUMBER
J-Box
ITEM
PARTS LIST
PART DESCRIPTION
F04-00517
PART NUMBER
1
ITEM
10
Burner Assembly
Oil Burner Maintenance
Oil Fired Cleaners
Air Band Adjustment
Note: 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.
PART NUMBER
V00-14283-5
PART NUMBER
V00-14283-2
Fuel Pump Filter
Sundstrand 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.
Danfoss pump
1. Shut off fuel supply.
2. Loosen the 2 screws with 7/64 allen wrench one turn.
3. Turn cover counter clockwise and pull strainer and cover 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. Reinstall reverse of removal.
PART NUMBER
6. Turn on fuel supply.
V00-99004
Burner Maintenance 11
Blower Fan Replacement
1. Shut off power to the burner and disconnect wires.
2. Loosen the two screws securing blower motor and fan to the 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.
WARNING
Use screwdriver
with a well insulated
handle to avoid
shock.
Transformer Test
1. 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 Alignment
1. 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 Maintenance 29
12
Burner Maintenance
Burner Gun Removal & Installation
1. 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.
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 Z01-00095
P/N Z01-00092
P/N Z01-00093
Fuel Nozzle Changing Wrench
Fuel Pump Wrench (Sundstrand)
Solenoid Wrench (ASCO)
Electrode Assembly Adjustment
1. 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.
30
Burner Maintenance
Burner Maintenance 13
Electrical Schematic
E
Q
G
U
R
I
O
P
U
M
N
E
D
N
T
GRN (3X)
WHITE
BLACK
RED
BROWN
BLUE
230
VAC
2
4
3
1
1
L
I
N
E
7
2
8
L
I
N
E
6
BLK
5
PUMP
MOTOR
230 VAC
YELLOW
GREEN
PINK
ORANGE
CAM
SWITCH
BLK
WHT / RED
DATE:
06-07-03
BWK
DRAWN BY:
VACUUM
SWITCH
BLK
WHT
BLK
WHT
BLK
BLK
`
BURNER
MOTOR
230 VAC
IGNITION
TRANSFORMER
230 VAC
TITLE / DESCRIPTION
ELECTRICAL
SCHEMATIC
ES-00024
PART NUMBER
Electical Schematic
14
WHT / RED
PART NUMBER
ES-00024
Pump Maintenance
General
PACKING EXTRACTION KIT
COMPLETE TOOL KIT
P/N Z09-00028
P/N Z09-00021
Valve Service
1.
2.
Remove the plugs holding the valve assemblies.
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 Removal
1.
2.
3.
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.
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.
Once the head is removed, protect the plungers from damage.
3
6
1
2
7
6
Pump Maintenance 15
Plunger Service
1.
2.
3.
4.
5.
6.
Remove pump head per HEAD REMOVAL.
Remove any packings and retainers left on the plungers by pulling them straight off.
Examine each plunger, looking for a smooth surface free of any scoring, cracks, or pitting. Any
defective plungers should be removed per PLUNGER REMOVAL.
Discard and replace any defective plungers.
Reinstall the plunger per PLUNGER INSTALLATION.
Reinstall head per HEAD INSTALLATION.
Plunger Removal
NOTE: 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 Installation
1.
2.
3.
4.
5.
6.
16
Install the copper flinger washer onto the cross head.
Slide the plunger onto the crosshead.
Lubricate an o-ring with crankcase oil and install into the groove on the plunger screw. Install the
anti-extrusion ring 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.
Apply a drop of thread sealant to the threads of the retainer screw.
Thread the plunger retainer screw into the cross head making sure the copper flat washer is
installed onto the screw.
Torque the plunger retainer screw to the value indicated in the torque section of the pump
specifications.
Pump Maintenance
Packing Service
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Remove the head per PUMP HEAD REMOVAL.
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.
Clean the packing canities in the head and rinse with clean water.
Clean exposed plungers. Clean male and female adapters with soap and water and allow it to
dry.
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
Lubricate packing cavities in the head and all packings and adapters with pump crankcase oil.
Lay head on the bench with packing cavities up. Install one male adapter in each cavity with the
flat side down.
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.
Install the re-stop ring with the lips pointing down.
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.
Install the low pressure packing with the flat side down.
Install the rear female adapter into each cavity with the lips pointing down.
Lubricate o-rings with pump crankcase oil and install one into the groove of each adapter.
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 adapters from the offending cavity and reinstall items per
steps 8 through 15.
Install head per HEAD INSTALLATION.
Head Installation
1.
2.
3.
4.
5.
6.
7.
Prepare pump head per instructions in PACKING SERVICE.
Rotate the plungers so the outer plungers are projecting the same distance from the crankcase.
Lubricate the exposed plungers with crankcase oil.
Start the head onto the plungers and, using a soft mallet, tap the head evenly until it comes in
contact with the crankcase.
Start the cap screws through the head and into the crankcase. Do not forget the lock washer on
each screw.
Tighten all cap screws by hand.
Torque the cap screws to the value indicated in the TORQUE section of PUMP
SPECIFICATIONS. Torque the cap screws in the order listed below.
5
8
3
2
1
4
7
6
Pump Maintenance 17
Pump Maintenance Record
18
Month/Day/Year
Oil Change
Operating Hours
Oil Brand & Type
Month/Day/Year
Pump Service
Operating Hours
Type of Service
Pump Maintenance
Trouble Shooting
Pump
Trouble
Possible Cause
Remedy
Excessive play on
crankshaft
Defective bearings.
See “Worn bearing.”
Excess shims.
Set up crankshaft.
Loud knocking in pump
Loose connecting rod screws.
Worn connecting rod.
Tighten connecting rod screws per PUMP
SPECIFICATIONS
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 in the area of Worn crankshaft seal, bad bearing, Remove and replace.
water pump crankshaft grooved shaft, or failure of retainer
o-ring.
Oil leaking at the rear
portion of the pump
Damaged or improperly installed oil Replace gasket or o-ring.
gauge window gasket or rear cover.
Oil gauge loosed.
Tighten oil gauge.
Rear cover screws loose.
Tighten rear screws to torque values in PUMP
SPECIFICATIONS.
Pump overfilled with oil, displaced Drain oil. Refill to recommended oil level as stated in
through crankcase breather hole in OIL LEVEL in PUMP MAINTENANCE.
oil cap/dipstick.
Water in crankcase
May be caused by humid air
condensing into water inside.
Worn or damaged plunger screw
o-ring.
Maintain or step up lubrication schedule.
Worn bearing
Excessive belt tension.
Oil contamination.
See BELT TENSION in MACHINE MAINTENANCE.
Check oil type and change intervals per PUMP
SPECIFICATIONS.
Short bearing life
Excessive belt tension.
Misalignment between pump and
motor.
Oil has not been changed on
regular basis.
See BELT TENSION in MACHINE MAINTENANCE.
Re-align pump and motor.
Damaged plunger bushing.
Worn connecting rod.
Replace plunger bushing.
Replace connecting rod.
Excess pressure beyond the
pump’s maximum rating.
Match pressure stated in PUMP SPECIFICATIONS.
Short seal life
Remove and replace. See PLUNGER SERVICE in
PUMP MAINTENANCE.
Check oil type and change intervals per PUMP
SPECIFICATIONS.
Trouble Shooting 19
High water temperature.
Lower water temperature stated in PUMP
SPECIFICATIONS.
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.
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.
Loud knocking noise in
pump
Frequent or premature
failure of the packing
Low Pressure
20
Scored, damaged, or worn plunger. Remove and replace plungers.
Overpressure to inlet manifold.
Reduce inlet pressure.
Abrasive material in the fluid being
pumped.
Excessive pressure and/or
temperature of fluid being pumped.
Over pressure of pumps.
Install proper filtration on pump inlet pumping.
Running pump dry.
Do not run pump without water.
Dirty or worn check valves.
Worn packing.
Clean/replace check valves.
Remove and replace packing.
Belt slipping.
See BELT TENSION in MACHINE MAINTENANCE.
Improperly sized spray tip or
nozzle.
Inlet filter screen is clogged.
See MACHINE SPECIFICATIOSN for specified spray
tip or nozzle.
Clean inlet filter screen.
Trouble Shooting
Check pressures and fluid inlet temperature. Be sure
they are within specified range.
Reduce pressure.
Pitted valves.
See VALVE SERVICE in PUMP MAINTENANCE.
Dirty or worn check valves.
Clean/replace check valves.
Foreign particles in valve
assemblies.
High inlet water temperature.
See temperature in PUMP SPECIFICATIONS.
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.
Erratic pressure; pump
runs rough
Trouble
Water Heater
Possible Cause
Remedy
Improper fuel supply
Use fuel specified in FUEL section of the MODEL
SPECIFICATIONS.
See the TEMPERATURE CONTROL
section.
Raise incoming water temperature.
Machine will not rise to Low fuel pressure
operating temperature.
Poor combustion
Temperature control inoperative
Incoming water temperature
too low
Machine overheats
Insufficient water
(Dry steam – very little
moisture, very hot
steam)
Temperature control inoperative
Improper fuel supply
Improper fuel pressure
Incoming water temperature
too high
Machine smokes
Improper fuel supply
Improper burner jets
Loose burner jets
Missing burner jets
See specified pressure in the FUEL section of
MODEL SPECIFICATIONS.
See “Poor combustion”.
Increase water flow and pressure. Check coil back
pressure.
See TEMPERATURE CONTROL section.
Use fuel specified in FUEL section of the MODEL
SPECIFICATIONS.
See FUEL section of the MODEL
SPECIFICATIONS for specified fuel pressure.
Lower incoming water temperature.
Use fuel specified in FUEL section of the MODEL
SPECIFICATIONS.
Remove and replace jets per BURNER
ASSEMBLY.
Tighten burner jets.
Install appropriate burner jets see BURNER
ASSEMBLY.
Trouble Shooting 21
Machine fumes
(exhaust burns eyes)
Improper fuel pressure
See specified pressure in the FUEL section of
MODEL SPECIFICATIONS.
Poor Combustion
Low fuel pressure
See specified pressure in FUEL section of
MODEL SPECIFICATIONS.
Use fuel specified in FUEL section of MODEL
SPECIFICATIONS.
See National Fuel Gas Code (ANSI Z223.1 and
NFPA No. 54)
See specified pressure in the FUEL section of
MODEL SPECIFICATIONS.
Improper fuel supply
Improper venting
Fuel pressure too high
Pilot will not stay lit
Check for drafts
Pilot flame not sharp blue
Install draft diverter.
Clean pilot orifice.
Defective thermocouple
Test and/or replace thermocouple.
Improper fuel pressure
See specified pressure in the FUEL section of
MODEL SPECIFICATIONS.
See pilot orifice specified in the FUEL section of
MODEL SPECIFICATIONS.
Incorrect pilot orifice
22
Trouble Shooting
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
3 years – 4 years
4 years – 5 years
After 5 years
75% Credit Allowed
50% Credit Allowed
25% Credit Allowed
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 Number
Always include them in Service Correspondence
For full warranty information, contact your delivering distributor or contact the manufacturer at [email protected]
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