ALKOTA 4355H User manual

40" 28"
42"
MODEL 4355H
SPECIFICATIONS
04-26-05 Z08-05016
MACHINE SPECIFICATIONS
PUMP......................................................................P/NN07-00016-LH
PUMP PULLEY....................................................................R03-00774
PUMP PULLEY BUSHING..................................................R04-00001
UNLOADER..................................................................P/N C07-03800
ENGINE HORSEPOWER............................................ 13 HP / 9.7 KW
ENGINE MAKE........................................................................ HONDA
ENGINE CHARGE RATE.........................................................18 AMP
ENGINE PART NUMBER............................................ P/N F05-00488
ENGINE PULLEY............................................................... R03-00732
ENGINE PULLEY BUSHING ............................................ R04-00006
ENGINE OIL FILTER...................................................................... N/A
ENGINEAIR FILTER.............................................P/N F05-004462-10
ENGINE AIR PRE-CLEANER........................................................ N/A
MACHINEVOLTAGE..........................................12 VDC CONTROLS
SWITCH,SOLENOID ...................................................P/N F05-00992
SWITCH, FLOW ...........................................................P/N F04-00805
BATTERY .......................................................................... GROUP 24
BATTERY CABLE - STARTER............................... P/N F05-00218-1
BATTERY CABLE - STARTER............................... P/N F05-00218-1
BURNER ..................................................................... P/N V00-17140
BURNER TYPE........................................... PRESSURE ATOMIZING
FUEL TYPE.......................................KEROSENE, #1 OR #2 DIESEL
FUEL PRESSURE......................................................120 PSI / 8 BAR
FUEL NOZZLE........................(1.50 90 DEGREE A) P/N V1.50 90DA
FUEL CONSUMPTION................................. 1.64 GPHR / 6.20 LPHR
FUEL PUMP......................................(DAN FOSS) P/N V-100714-001
FUEL SOLENOID - 115V ............................................ P/N F04-00974
MOTORHORSEPOWER............................................................1/4 HP
PERFORMANCE
ELECTRICAL
PUMP ENGINE
GENERAL
PUMP & UNLOADER
BURNER
DISCHARGE VOLUME........................................4.0 GPM / 15.1 LPM
PUMP HEAD PRESSURE....................................3500 PSI / 242 BAR
TEMPERATURE RISE............105°F @ 4.0 GPM / 41°C @ 15.1 LPM
COMBUSTION SMOKE/BACHARACH SCALE....#1 OR #2 SMOKE
CARBON MONOXIDE ALLOWED............................................ 0.01%
DRAFT/STACK INSTALLATION............. 0.2” - 0.04” WC READING
HEAT INPUT............................. 229,600 BTU/HR / 57,859 KCAL/HR
MINIMUM INLET WATER PRESSURE..................40 PSI / 0.68 BAR
WEIGHT (DRY) .......................................................340 LBS / 154 KG
HOSE, PUMP TO UNLOADER.............................. P/N K02-03117A1
HOSE, UNLOADER TO COIL................................ P/N K02-03124A1
SPRAY TIP.........................................(#4.0-15DEG) P/N J00-15040-2
HOSE, DISCHARGE..............................3/8” X 50’ P/N K02-03150E1
WAND & TRIGGER GUN......................................... P/N J06-00158-B
BELT - ENGINE TO PUMP......................................... P/N R02-00245
COIL SIZE................. 14” DIAMETER - 1/2”ID X 95’ SCHEDULE 80
REPLACEMENT COIL ........................................... P/N 4405F-00206
COIL BACK PRESSURE (NEW)
.....................5 PSI @ 4.0 GPM / 0.34 BAR @ 15.1 LPM
COIL BACK PRESSURE REQUIRING DESCALING
........................... 50 PSI @ 4.0 GPM / 3.40 @ 15.1 LPM

SERIAL NUMBER DATE OF
PURCHASE PLACE OF PURCHASE
MONTH / DAY / YEAR OPERATING
HOURS MAINTENANCE PERFORMED
MACHINE RECORD
Supersedes 01-08-04 Z08-04527 08-25-04 Z08-04527
NOTES

OPERATION TABLE OF CONTENTS
OIL FIRED ENGINE DRIVEN CLEANER
02-11-04 Z08-03976
Supersedes 11-13-02 z08-03976 2
OPERATION - TABLE OF CONTENTS
SAFETY INSTRUCTIONS
Page Number
•Safety Symbols 3
•General 3
•Mechanical 4
•Electrical 4
•Fuel 4
INSTALLATION
•Location 5
•Electrical 5
•Extension Cord 5
•Venting 5
•Water Supply 5
•Barrier 5
•Water Conditions 5
•Freezing 5
•Cold weather 5
•Chemicals 5
OPERATION
•Pre Start-Up 6
•Start-Up 6
•To Clean, Apply Chemical, To Rinse 7
•Shut Down 7
(OPTIONAL) Combination Instructions 8
MAINTENANCE
Machine
•Flushing, Storage 9
•Spray Tip Maintenance 9
•Belt Tension 10
•Coil Back Pressure 10
•Schedule 11
Burner
•Fuel Pump Filter 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 See Parts List Section
TROUBLESHOOTING
Page Number
•Machine 12, 13
•Water Heater 14
•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
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 Valve
See Parts List Section
Temperature Control (If So Equipped)
See Parts List Section
Unloader Valve
See Parts List Section
PUMP OIL CHANGE
RECORD See Parts List Section
WARRANTY Inside Back Cover
SPECIFICATIONS 1

SAFETY, INSTALLATION, AND OPERATION
ENGINE DRIVEN OIL FIRED CLEANER
11-07-03 Z08-00489
ECN-03022 Supersedes 02-12-01
MACHINE UNPACKING
ALL CLEANERS ARE CAREFULLY INSPECTED
AND CARTONED TO PROTECT AGAINST SHIPPING
DAMAGE. IF THERE IS DAMAGE OR MISSING
PARTS, THE TRANSPORTATION COMPANY
AGENT SHOULD MAKE A NOTATION TO THAT
EFFECT ON THE BILL. REFER TO THE PARTS
LIST IN THIS MANUAL AND ADVISE WHAT PARTS
ARE MISSING OR DAMAGED. IF AVAILABLE,
GIVE THE INVOICE NUMBER ON ALL ORDER
BILLS. THIS PROCEDURE WILL ENABLE
NEEDED PARTS TO BE SHIPPED QUICKLY.
READ ALL Installation, Operation, and
Maintenance instructions before operating the
machine
NOTE: Refer to CLEANER MODEL for SERIAL
NUMBER location
NOTE: Dimensions are in inches unless otherwise
noted
IMPORTANT SAFETY
INSTRUCTIONS
The safety alert symbol.
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
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 to the equipment.
GENERAL SAFETY
1. Before operating this machine, read and observe
all safety, unpacking, and operating
instructions. Failure to comply with these
instructions could create a hazardous
situation.
2. The operator of this equipment should not
operate this equipment when fatigued or under
influence of alcohol or drugs.
3. The operator of this equipment should be
thoroughly familiar with its operation and
trained in the job to be accomplished.
4. The operator of this equipment should wear
protective face shields and other protective
clothing as required for safe operation.
5. Keep all protective covers and shields in place.
Operating this machine with moving parts
could allow operator or bystander serious injury
or even death.
6. Do not operate the machine if any mechanical
failure is noted or suspected.Keep all shields
in place.
7. Do not leave this machine unattended when it
is operating.
8. All installations must conform to all applicable
local codes. Contact your electrician, plumber,
utility company or seller for details.
9. If a water leak is found, DO NOT OPERATE
THE MACHINE. Shut off the engine and repair.
10. Follow instructions on how to stop the machine
and bleed pressures quickly. Be thoroughly
familiar with the controls.
11. When starting a job, survey the area for
possible hazards and correct before proceeding.
12. If chemicals are used in conjunction with this
equipment, read and follow the product label
directions.
13. During normal operation of this machine, hot
discharges and surfaces may be produced.
Avoid burns by being aware of these areas and
staying clear of them during and immediatly
following equipment operation.
14. Do not start the burner unless a full flow of
water is coming from the gun. Air leaks or
insufficient water to the machine, or an open
chemical valve means less than full flow of
water through the coil. This could cause hose
failure and burns to the operator.
3

11-07-03 Z08-00489A
15. Do not start the machine unless the gun
assembly is firmly gripped by the machine
operator. Failure to do this could result in injury
from a flying hose and gun assembly.
16. Always point the gun assembly in a safe
direction and do not direct spray on the cleaner
or personnel in the area.
17. Always shut down machine before refueling.
18. Do not overfill the fuel tank. If any spillage
occurs, clean up immediately and/or neutralize
the spill before attempting to operate the
machine.
MECHANICAL SAFETY
1. All guards, shields, and covers must be replaced
after adjustments are made to prevent
accidental contact with hazardous parts.
2. Drive belts must be inspected and tightened
periodically to operate at optimum levels.
3. Inspect machine for damaged or worn
components and repair or replace to avoid
potential hazards. Do not operate the machine
if any mechanical failure is noted or suspected.
4. Always use the correct size spray tip found in
the GENERAL section of the MODEL
SPECIFICATIONS or MODEL EXPLODED
VIEW.
5. DO NOT start the engine until you have
observed all safety and operating instructions
found in the engine manual..
FUEL SAFETY
1. Use only #1 or #2 diesel fuel for the water heater
burner. The use of incorrect fuel may result in
fire or explosion and severe injury to the
operator.
2. Do not refuel machine while it is running or
hot. Allow it to cool sufficiently to prevent
ignition of any spilled fuel. Clean up any spilled
fuel before resuming operation.
3. Fuel burning equipment must have proper
ventilation for cooling, combustion air, and
exhausting of combustion products.
4. Stacking, where required, must be installed in
accordance with all local codes. A draft
diverter must be installed on a machine
connected to an exhaust stack to prevent
improper operation. (See GENERAL section of
MODEL SPECIFICATIONS for stack size).
5. Where stacking is not required, provide
adequate ventilations to prevent any possible
accumulation of hazardous fumes.
6. Personnel trained in and familiar with the type
of equipment being serviced should only
perform adjustments to fuel burning
equipment.
SAVE THESE SAFETY
INSTRUCTIONS
WARNING: DO NOT USE GASOLINE,
CRANKCASE DRAININGS, OR OIL
CONTAINING GASOLINE OR SOLVENTS.
AVERTISSEMENT: NE PAS UTILISER
D’ESSENCE DE PRODUITS DE VIDANGE
NI D’HUILE CONTENANT DE L’ESSENCE
OU DES SOLVANTS
WARNING: OPEN FLAME. Do not operate
this machine in an area with combustible
materials. A suitable fire extinguisher
should be available in operating area.
4
WARNING: RISK OF INJECTION OR
SEVERE INJURY. KEEP CLEAR OF
NOZZLE. DO NOT DIRECT DISCHARGE
STREAM AT PERSONS. THIS EQUIPMENT
IS TO BE USED ONLY BY TRAINED
OPERATORS.
AVERTISSEMENT:RISQUE
D’INJECTION ET DE BLESSURES
GRAVES. SE TENIR À L’ÉCART DU JET. NE
PAS DIRIGER LE JET DE SOTIE VERS
D’AUTRES PERSONNES CONFIER
L’UTILISATION LE JET DE SOTIE VERS
D’AUTRES PERSONNES. CONFIER
L’UTILISATION DE CE MATÉRIEL À UN
ECN-03022Supersedes 02-12-01 Z08-00489A

11-07-03 Z08-00489B
INSTALLATION
This machine emits CARBON MONOXIDE, a
DEADLY GAS, and must be vented if used in an
enclosed area. Improper venting can cause poor
combustion, delayed ignition, down drafts, and the
possibility of freezing the coil. Contact your
distributor or local heating and air conditioning
dealer for proper materials. Local codes must
be observed.
1. VENTILATION: Oil fired machines that must
be vented. See the VENTING section of this
manual. Where stacking is not required,
provide adequate ventilations to prevent any
possible accumulation of hazardous fumes.
2. FIRE HAZARD: Keep combustible materials
away from oil machines. DO NOT allow lint or
dust to collect in the burner area.
3. BARRIER: We recommend a barrier be installed
between the machine and wash area to prevent
moisture from coming in direct contact with
electrical controls and engine. This will increase
the machine’s life and lessen electrical
problems.
2. WATER SUPPLY: This machine must have a
water supply meeting or exceeding the
maximum discharge volume specified in the
machine specifications, and a minimum water
inlet pressure of 40PSI / 12.1KGM.
7. WATER CONDITIONS: Local water conditions
affect the coil adversely more than any other
element. In areas where troublesome conditions
may exist with like equipment (such as water
heaters), we recommend the use of a water
softener.
8. FREEZING: This machine must be protected
from freezing according to STORAGE section
of MACHINE MAINTENANCE.
9. COLD WEATHER: As the weather becomes
colder, fuel becomes thicker and may become
so viscous that the fuel will not flow properly.
As viscosity increases, the thicker oil can cause
delayed ignition, poor spray patterns, and
rumbling fires. As moisture will quickly destroy
fuel pumps, make certain that tank openings
are secure and moisture cannot enter. In cold
weather areas, frost build up will occur in fuel
tanks. As the weather warms it turns to
condensate, and the water will be in the tank.
Keep the tank clear of water, as moisture
reaching the fuel pump will cause rust, and
the pump will bind. A full fuel tank will lessen
condensation build up.
10. CHEMICALS: Mix chemicals per the chemical
manufacturers printed directions. Follow all
mixing, handling, application, and disposal
instructions. Wear gloves, boots, goggles, and
protective clothing appropriate for the chemical
being used
VENTING
DANGER: This machine emits carbon monoxide,
and deadly gas, and MUST NOT be used in an
enclosed or confined area.
DANGER: Engine exhaust gases contain
poisonous carbon monoxide. Carbon monoxide is
oderless, colorless, and can cause death if inhaled.
Avoid inhaling gas fumes. Engine MUST NOT be
used in an enclosed or confined area.
5
ECN-03022Supersedes 02-12-01 Z08-00489B
DANGER: CARBON
MONOXIDE HAZARD

OPERATING
INSTRUCTIONS
PRE START-UP
1. The first time the machine is operated, after
repairs have been made, or if the machine has
set for a period of time (30 days or more) follow
the following procedures.
A. Check the tension of the belt (if so
equipped) per instructions in MACHINE
MAINTENANCE.
B. Flush the machine per instructions in
MACHINE MAINTENANCE.
C. Install float tank drain plug (if so equipped).
D. Open float tank ball valve (if so equipped).
♦CAUTION: Always use the factory supplied
pressure wash hose with your machine.
♦DO NOT substitute any other hoses as a
potential safety problem may develop.
¨CAUTION: If machine has been exposed to
sub-freezing temperatures, it must be
thoroughly warmed to above freezing before
operating. Failure to warm machine can cause
damage to the pump packings and other
components.
2. Read and observe all items in “CLEANER
INSTALLATION”.
START-UP
♦Refer to the MAINTENANCE SCHEDULE for
any maintenance to be performed before
operation.
♦This machine emits carbon monoxide, a deadly
gas, and must be vented if used in an enclosed
area.
♦OIL LEVEL: Check the oil level in the water
pump, the gear case (if so equipped), and the
engine.
♦BELT (if so equipped): Make sure the belt
tension and condition is as specified in
MACHINE MAINTENANCE.
♦METERING VALVE (if so equipped): Make sure
the metering valve is closed before
operation. If air enters the system through this
valve, poor performance and machine damage
will occur. Refer to the metering valve insert
for proper operation.
♦FUEL FILTER: Inspect the fuel filter for any
evidence of water contaminants.
♦FUEL: Make sure the fuel lines are open
(CAUTION: Closed fuel valves will DAMAGE the
fuel pump and void warranty) and fuel is the
type specified in the BURNER section of
MODEL SPECIFICATIONS
♦FUEL QUANTITY: Make sure the fuel supply
is sufficient to complete the job. See the
GENERAL section of the MODEL
SPECIFICATIONS for the fuel tank capacity.
♦WATER SUPPLY: This machine must have a
water supply meeting or exceeding the
maximum discharge volume specified in the
machine specifications, and a minimum water
inlet pressure of 40PSI / 12.1KGM.
♦LIME: Water containing large amounts of lime,
calcium or other similar materials can produce
a coating on the inside of the impact nozzle or
spray tip and coil pipe.
♦FLOAT TANK: Check the float tank to assure
it is full and the float tank valve shuts off
securely.
♦BALL VALVE: Check the position of the ball
valve (if so equipped) on outlet line of the float
tank assuring that it is in the open position.
11-07-03 Z08-00489C
6
ECN-03022 Supersedes 06-06-01 Z08-
00489C
DANGER: CARBON
MONOXIDE HAZARD

1. Select temperature (if so equipped).
2. With the gun assembly in hand (on trigger gun
models hold the trigger gun valve in open
position) and with a good flow of water start
the engine per engine owner’s manual.
CAUTION: A good flow of water must be Flowing
from the end of a gun for 30 seconds, before
proceeding. Lack of water can cause damage to
the water pump and like components.
CAUTION: On a machine equipped with a
trigger gun valve, if the trigger gun valve
remains in the closed position
for more than 3 minutes, water pump damage
may occur.
4. Turn the burner switch on.
CAUTION: Do not run the machine with the
burner switch in the on position when the fuel
tank is empty or with tank valves closed. This
will cause damage to the fuel pump and
void warranty.
CAUTION: Do not operate with the trigger gun
valve closed for more than 3 minutes or water
pump damage may occur.
5. To CLEAN:
A. Start on the lower portion of the area to be
cleaned and work up using long, even,
overlapping strokes.
B. Dirt is generally removed easily if grease
and/or oil is not present. However if grease
and/or oil are present, hot water and
chemical will accelerate in the cleaning
process.
6. TO APPLY CHEMICAL:
CHEMICAL: Use factory recommended
chemicals for best cleaning action and for
extended pump life. Contact your dealer for
chemicals available. Follow instructions on
chemical container.
Mix chemicals per label instructions. Use
necessary safety precautions.
A. Insert chemical screen into chemical
container
B. Adjust metering valve (if so equipped).
C. If the gun assembly is equipped with
variable or multiple nozzle assembly,
adjust as desire.
7. TO RINSE:
A. If the machine is equipped with a panel
mounted metering valve, close the chemical
metering valve (if so equipped). NOTE: It is
advisable to dip the chemical screen in a
container of clean water and open the valve
1 minute to clean the valve of any remaining
residue.
B. If the gun assembly is equipped with variable
or multiple nozzle assembly, open and close to
clean nozzle of any remaining residue.
C.After a clear flow of water is noted from the
end of the wand, start from the top, working
downward using long, overlapping strokes.
SHUT-DOWN
1. Turn the burner switch to the off position. (If
not already done so in the cold water rinse.)
2. After cool, clear water is coming from the end
of the wand, turn off the engine.
3. Turn off the water supply.
4. If freezing conditions may exist, refer to
STORAGE in MACHINE MAINTENANCE.
5. Replace stack cover (if so equipped).
11-07-03 Z08-00489D
7
ECN-03022 Supersedes 06-06-01 Z08-00489
WARNING: RISK OF INJECTION OR SEVERE
INJURY. KEEP CLEAR OF NOZZLE. DO
NOT DIRECT DISCHARGE STREAM AT
PERSONS. THIS EQUIPMENT IS TO BE
USED ONLY BY TRAINED
OPERATORS.
AVERTISSEMENT:RISQUE
D’INJECTION ET DE BLESSURES GRAVES.
SE TENIR À L’ÉCART DU JET. NE PAS
DIRIGER LE JET DE SOTIE VERS D’AUTRES
PERSONNES CONFIER L’UTILISATION LE
JET DE SOTIE VERS D’AUTRES
PERSONNES. CONFIER L’UTILISATION DE
CE MATÉRIEL À UN OPÉRATEUR QUALIFIÉ.

11-07-03 Z08-00489E
8ECN-03022 Supersedes 02-12-01 Z08-00489E
COMBINATION OPTION
INSTRUCTION
NOTE: In process of making steam, the water
flow through the coil has to be decreased. The
amount of water is determined by the pressure
and water temperature of your location.
If the incoming water temperature is as high
as 70°F, the amount of water going through
the coil has to decrease very little.
If the incoming water temperature is as low as
40°F, the amount of water going through the
coil has to be decreased quite a bit.
The water temperature is relative to the
season variation and should be taken in
consideration when operating steam.
1. Install the open gun assembly.
2. Open the ball valve on coil inlet assembly.
3. Set the temperature control to 300°F
MAXIMUM.
4. For startup see “START UP” section of this
manual
5. Turn the burner switch on.
CAUTION: Do not run the machine with the burner
switch in the on position when the fuel tank is
empty. This will cause damage to the fuel pump
and void warranty.
CAUTION: Do not operate with the trigger gun
valve closed for more than 3 minutes or water
pump damage may occur.
WARNING: This machine should be
operated only by personnel instructed in and
familiar with its operation. The discharge
produced is 300°F / 150°C and can cause
SERIOUS BODILY INJURY to you and
anyone coming in contact with it.
TEMPERATURE
DECREASE
INCREASE
TEMPERATURE
PRESSURE
REGULATING
VALVE
6. To CLEAN:
A. Start on the lower portion of the area to be
cleaned and work up using long, even, overlapping
strokes.
B. Regulate the temperature indicated on the
thermometer to 300°F by turning the regulating
valve on the coil inlet assembly clockwise to
DECREASE the temperature and counter
clockwise to INCREASE the temperature.
C. To RINSE:
D. Turn off the burner.
E. After a clear flow of water is noted from the
end of the wand, start from the top, working
downward using long, overlapping strokes.
SHUT-DOWN
1. Turn the burner switch off. (If not already done
so in the cold water rinse.)
2. After cool, clear water is coming from the end of
the wand, turn off the engine.
3. Turn off the water supply
4. Close the ball valve on the coil inlet
assembly.
5. Replace the stack cover (if so equipped)
6. If freezing conditions may exist, refer to
STORAGE in MACHINE MAINTENANCE.
7. Replace stack cover (if so equipped).

9
MACHINE MAINTENANCE
FLUSHING
1. Connect machine to a pressurized water
supply meeting the requirements specified in
the GENERAL section of the MODEL
SPECIFICATIONS.
2. Turn on the water supply.
3. Check the float tank (if so equipped) to
assure it is full and the float valve shuts off
securely.
4. Check the position of the ball valve (if so
equipped) on outlet line of the float tank
assuring it is in the open position.
5. Remove spray tip from gun assembly.
6. With gun assembly in hand, start the engine.
On trigger gun models hold the trigger gun
valve in open position.
CAUTION: DO NOT RUN PUMP WITHOUT
WATER, AS THIS WILL CAUSE DAMAGE TO
THE PUMP AND VOID WARRANTY.
7. When clean water flows from gun, turn off
the switch.
8. Reinstall spray tip.
9. With gun assembly in hand, start the
engine. On trigger gun models hold the
trigger gun valve in open position.
10. When clean water flows from gun, turn off
the engine.
11. If freezing conditions may exist, refer to
“STORAGE” section.
12. Turn off and disconnect the water supply.
STORAGE
1. To prevent the fuel tank rusting from
condensation, drain and flush with clean
fuel. Do not use gasoline or water. Refill with
proper fuel.
2. Rinse the Soap Line by inserting the screen
into a container of clear water and open the
metering valve 1 minute to clean it of any re-
maining residue. Be sure chemical metering
valve is closed when finished.
3. Disconnect the water supply.
4. Remove the spray tip nozzle from gun assem-
bly and wire to machine.
GAS ENGINE DRIVEN OIL FIRED CLEANERS
5. Check the position of the ball valve (if so
equipped) on the outlet of the float tank
assuring it is in the closed position.
6. Attach an air chuck to the air valve stem on
the pump assembly. With the trigger gun in the
open position, apply air until a mixture of air
and very little water is coming from the gun
wand Then turn on the burner and depress the
vacuum switch. Run it for 45 seconds allowing
any remaining water to turn to steam. Do not
remove air until after the burner is off.
7. Fill a 1-gallon container with Ethylene Glycol
type antifreeze. Minimum should be a mixture
of ½ antifreeze and ½ water strength before
each use, as the antifreeze will dilute with each
use.
8. Install a 2-ft. Garden hose to the water inlet.
Insert the other end into a container of
antifreeze solution.
9. With the discharge gun assembly in hand,
start the engine. On trigger gun models hold
the trigger gun valve in open position.
10. Turn off the switch just prior to running out of
antifreeze mixture.
11. Disconnect electrical supply.
12. Disconnect gun and hose.
13. Place machine in a dry place protected from
weather conditions.
SPRAY TIP MAINTENANCE
1. Remove the spray tip from the gun assembly.
2. Blow out debris with compressed air from the
outside in. Any debris remaining in the inlet
side of the nozzle should be cleaned out. If
lime or chemical scale is present in the inlet
side, the nozzle may be soaked in descaling
solution or replaced. If the tip is worn, replace
with one specified in the GENERAL section of
MODEL SPECIFICATIONS or MODEL
EXPLODED VIEW.
3. Before replacing spray tip flush the machine
per “FLUSHING” section.
4. Reinstall Spray tip to gun assembly.
02-14-01 Z08-03089ECN-02248

10
MACHINE MAINTENANCE CONT’D
BELT TENSION
DEFLECTION
SPAN
1. Correct belt tension will allow a 1/64-inch
deflection for each inch of span between
pulley centers with a 6-pound force applied
in the middle of the span.
EXAMPLE: A 6-pound force applied at the
middle of an 8 inch span should produce a
deflection of 8/64 inch or 1/8 inch.
2. Belts can be tightened or loosened by
loosening the nuts holding the pump
assembly to the motor mount.
Then tighten or loosen the j-bolt on the
motor mount. Retighten the pump assembly
after the desired tension is reached.
COIL BACK PRESSURE CHECK
Above is a cross section view showing the
progressive liming of coils.
A regular maintenance schedule for descaling
your heating coil is essential to insure its
longevity.
The frequency of descaling depends upon the
amount of use and the condition of the water.
1. Check the condition of your water pump
and unloader valve.
2. Install a pressure gauge between the water
pump and coil inlet as specified below.
GAS ENGINE DRIVEN OIL FIRED CLEANERS
COIL BACK PRESSURE CHECK INSTRUCTIONS
DISCHARGE VOLUME BACK PRESSURE
GPM REQ
UIRING DESCALING
2-3 GPM 50 PSI
3-4 GPM 75 PSI
4-5 GPM 100 PSI
6 GPM 150 PSI
8-10 GPM 175 PSI
USE A 1000 PSI GAUGE
4. Remove the hose and gun assembly from the
coil outlet.
5. Turn on the water supply. Check the float
valve (if so equipped) to assure float tank is
full and the float valve shuts off securely.
6. Check the position of the ball valve (if so
equipped) on outlet line of the float tank
assuring it is in the open position.
7. Start the engine. If the coil back pressure
reading is above that found in the GENERAL
section of the MODEL SPECIFICATIONS then
your machine needs to be descaled.
A separate descaling pump is recommended so
scale and other chemicals will not come in contact
with your water pump and causes premature wear.
NOTE: Contact your local dealer for descaling of
your unit.
7. Disconnect the water supply.
8. Disconnect the electrical supply.
9. Reinstall the hose and gun assembly.
10. Remove the pressure gauge.
ACCESSORIES
PART NO. DESCRIPTION
Y02-00001 ……..… 0-
1000 PSI (69 BAR) Pressure Gauge
Z01-00070-1……… 3/8” x 100 Yards Thread Tape
NOTE: All Gauges are Glycerin Filled—¼ NPT
02-14-01 Z08-03089AECN-02248

ENGINE DRIVEN OIL FIRED
CLEANERS DAILY
EACH
HR
FIRST
8 HRS
AFTER
FIRST
50
HRS
EVERY
50
HRS
EVERY
100
HRS
EVERY
500
HRS
YEARLY
OIL BATH WATER PUMP:
Oil Level – check and add as needed per
PUMP SERVICE insert.
Oil Change – drain and refill per PUMP
SERVICE insert. CAUTION: Used oil must
be disposed into an environment safe
container and brought to an oil recycling
center.
Oil Contamination –Milky color indicates
water
HOSES:
Blistering, Loose Covering
Abrasion of cover exposing
reinforcement.
Cuts exposing reinforcement
BELTS:
Cracks or fraying
Belt Tension - For correct belt tension,
see MACHINE MAINTENANCE insert.
FILTER – WATER:
Check water inlet hose screen for debris
Check float tank screen for debris
SPRAY TIP:
Check Tip for debris.
FUEL:
Adequate fuel supply.
FILTER—FUEL:
If contaminants are present see FUEL
FILTER insert.
Remove and Replace fuel filter per FUEL
FILTER insert.
SCREEN—FUEL:
Check fuel pump screen for debris see OIL
BURNER MAINTENANCE insert.
BURNER NOZZLE:
Replace Nozzle as specified in BURNER
section of MODEL SPECIFICATIONS or
BURNER ASSEMBLY insert.
GUARDS AND SHIELDS:
Check that all guards and shields are in place
and secure.
ENGINE:
Check oil level per engine manual.
Fill fuel tank.
Check air cleaner for dirty, loose or damaged
parts.
Service pre-cleaner element
Service air cleaner
MACHINE MAINTENANCE
11-10-03 Z08-03090
ECN-03022 Supersedes 02-12-01 Z08-03090 11

CLEANER TROUBLESHOOTING
GAS ENGINE DRIVEN HOT WATER CLEANERS
TROUBLE POSSIBLE CAUSE REMEDY
1. Poor
Cleaning
Action.
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. Connect machine to water softener.
B. See “Low operating pressure”
C. See “Machine will not draw chemical”.
D. Obtain proper chemical.
E. Mix chemicals per the label. Follow all
mixing, handling, application, and
disposal instructions.
F. See “Low operating pressure”
2. Machine will
not draw
chemical.
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. Replenish supply.
B. Turn metering valve knob to open.
C. Remove screen and clean.
D. Tighten all fittings and hoses for the
chemical line.
E. Disassemble and clean.
F. Install proper size orifice.
3. Low operating
pressure
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. Engine runs slow.
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 valve
P.
Inlet ball valve not fully open
(if so equipped)
Q. Restricted coil
A. The water supply must meet or exceed the
maximum discharge volume specified in
the PERFORMANCE section, and
minimum water inlet pressure specified in
the GENERAL section of the MODEL
SPECIFCATIONS 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 TROUBLESHOOTING.
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 replace hose.
N. Resupply 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.
02-12-01 Z08-03085
12

09
-
18
-
02 Z08
-
03085A
TROUBLE POSSIBLE CAUSE REMEDY
4. Excessive,
unusual
noise.
A. Pump
B. Defective engine.
C. Pulleys rubbing.
D. Misalignment of pump &
engine
A. See PUMP TROUBLESHOOTING.
B. Call service technician or take engine to
Repair/Warranty station.
C. Adjust shields or pulley(s).
D. Realign pump and engine.
5. Belts slipping. A. Belts too loose.
B. Excessive Back Pressure.
C. Defective Water Pump.
A. Tighten belt per instructions on
MACHINE MAINTENANCE.
B. See “Excessive Back Pressure”
C. See PUMP SERVICE.
6. Excessive
Back Pressure
A. Spray tip built up with lime.
B. Water pump turning too fast.
C. Coil built up with lime.
D. Relief valve defective.
A. Remove and clean, or replace spray tip
with tip specified in the GENERAL section
of MODEL SPECIFICATIONS. Flush
machine per FLUSHING in MACHINE
MAINTENANCE.
B. See MODEL SPECIFICATIONS.
C. Delime coil.
D. Remove and replace.
7. Excessive
vibration.
A. Defective Belt.
B. Defective Pump.
C. Defective accumulator
A. Remove and replace using belt specified in
CLEANER EXPLODED VIEW or the
GENERAL section of MODEL
SPECIFICATIONS.
B. See PUMP TROUBLESHOOTING.
C. Recharge/Replace.
8. Engine will
not start
A. No Fuel
B. Plugged fuel filter.
C. Water in fuel
D. Defective or corroded battery
cable.
E. Defective engine
A. Replenish fuel per owners manual.
B. Change fuel filter.
C. Drain and replenish fuel.
D. Clean cables and cable ends.
E. Call service technician.
9. Engine will
not turn over.
A. Pump frozen
B. Defective engine.
C. Defective water pump
D. Excessive back pressure
A. Machine must be thoroughly warmed to
above freezing.
B. Call service technician or take engine to
Repair/Warranty station.
C. See PUMP SERVICE.
D. See “Excessive Back Pressure”
10. Engine starts
slow or
overheats and
stops.
A. Improper fuel.
B. Excessive back pressure.
C. Defective engine.
D. Dirt in fuel line or filters.
E. Incorrect oil level.
F. Dirty air cleaner.
G. Faulty spark plug.
H. Engine overloaded.
A. See “Low voltage”.
B. See “Excessive Back Pressure”.
C. Call service technician.
D. Clean and replace fuel filters.
E. Check oil level per engine owners manual.
F. Change air filters per engine owners
manual.
G. Change spark plug and set gap per engine
owners manual.
H. See “Excessive Back Pressure”.
11. Engine
operates
erratically
knocks or
pings.
A. Improper fuel.
B. Dirt in fuel line or filter.
C. Dirty air cleaner.
D. Faulty spark plug.
E. Engine overloaded.
A. Replenish fuel as specified in engine
owners manual.
B. Clean and replace fuel filters.
C. Change air filters per engine owners
manual.
D. Change spark plug and set gap per
engine owners manual.
E. See “Excessive Back Pressure”.
CLEANER TROUBLESHOOTING (CONT.)
ELECTRIC DRIVEN HOT WATER CLEANERS
13

OIL FIRED WATER HEATER TROUBLESHOOTING
07-15-03 Z08-00133
ECN-02981 Supersedes 04-10-02 Z08-00133
TROUBLE POSSIBLE CAUSE REMEDY
1. Machine will not rise to
operating temperature
A. Low fuel pressure.
B. Water in fuel piping.
C. Fuel filter clogged.
D. Poor combustion.
E. Improper fuel supply.
F. Temperature control
inoperative (if equipped).
A. See BURNER on MODEL
SPECIFICATIONS for specified pressure.
B. Drain fuel tank and remove and replace
filter per FUEL FILTER INSERT.
C. Remove and replace fuel filter element per
FUEL FILTER INSERT.
D. See "Poor combustion".
E. Use fuel specified in "BURNER" section of
the MODEL SPECIFICATIONS.
F. See TEMPERATURE CONTROL INSERT.
2. Machine overheats A. Insufficient water.
B. Temperature control
inoperative.
C. Improper fuel supply
A. See Low Operating Pressure on MACHINE
TROUBLESHOOTING INSERT.
B. See TEMPERATURE CONTROL INSERT.
C. Use fuel specified in "BURNER" section of
the MODEL SPECIFICATIONS.
3. Dry steam (very little
moisture, very hot
steam)
A. Insufficient water.
B. Improper fuel supply.
C. Improper fuel pressure.
A. See Low Operating Pressure on MACHINE
TROUBLESHOOTING INSERT.
B. Use fuel specified in BURNER section of
the MACHINE SPECIFICATIONS.
C. See BURNER on MODEL
SPECIFICATIONS for specified pressure.
4. Machine smokes (sweet
smelling exhaust)
A. Improper fuel supply.
B. Insufficient combustion
air.
C. Leaking fuel system.
D. Clogged or improper
burner nozzle.
E. Loose burner nozzle.
A. Use fuel specified in BURNER section of
MODEL SPECIFICATIONS.
B. See AIR BAND ADJUSTMENT on OIL
BURNER MAINTENANCE INSERT.
C. Correct leakage problem.
D. Remove (DO NOT CLEAN) and replace
nozzle per BURNER ASSEMBLY INSERT.
E. See BURNER MAINTENANCE INSERT.
5. Machine fumes
(exhaust burns eyes)
A. Too much combustion air.
B. Improper fuel pressure.
A. See BURNER TROUBLESHOOTING
INSERT.
B. See FUEL on MODEL SPECIFICATIONS
for specified pressure.
6. Excessive oil dripping
from laydown coil
condensate.
A. Loose nozzle.
B. Fuel pressure too high.
C. Burner nozzle defective.
D. Incorrect burner nozzle.
A. See BURNER TROUBLESHOOTING
INSERT.
B. See FUEL PRESSURE ADJUSTMENT
section on BURNER MAINTENANCE
INSERT.
C. Remove and replace with appropriate
nozzle found on the BURNER ASSEMBLY
OR BREAKDOWN INSERT.
D. Remove and replace with appropriate
nozzle found on the BURNER ASSEMBLY
OR BREAKDOWN INSERT.
7. Poor combustion. A. Low fuel pressure.
B. Improper fuel supply.
C. Insufficient combustion
air.
A. See Low Fuel Pressure on BURNER
TROUBLESHOOTING INSERT.
B. See Low Fuel Pressure on BURNER
TROUBLESHOOTING INSERT.
C. See AIR BAND ADJUSTMENT section on
OIL BURNER MAINTENANCE.
14

03-24-2005 Z08-04768
PART LISTS
ITEM PART NUMBER PART DESCRIPTION QTY.
1C03-00120 VALVE,BALL-1/4"MNPT x 1/4"FNPT 1
2C03-00310-2 VALVE, METERING 1
3C09-00006 VALVE, EASY START 1
4E04-00005-48 BUSHING, PIPE 1
5E08-00017-48 ELBOW, STREET 1
6E10-00005-4 TEE, PIPE 1
7E10-00018-4 TEE, STREET 1
8E10-00021-58 TEE, STREET 1
9E13-00010-48 NIPPLE, PIPE 1
10 E15-00010-48 NIPPLE, CLOSE - 1/2"NPT 1
11 K31-01100 (-1) HOSE, WATER 1
12 N07-00016-LH PUMP,WATER-TS1511 4GPM @3500PSI 1450RPM 1
13 N07-40046-P1 RAIL, PUMP - W/HOLES 1
14 R03-00774 PULLEY,DBL V-2AK74H 1
15 R04-00001 BUSHING, PULLEY 1
16 W02-00033 CLAMP, HOSE 2
17 W02-10019-8 BARB, HOSE 2
18 W02-10030-8 BARB, HOSE 1
19 W02-10057-8 BARB, HOSE 1
11
8
16
3
19
16
6
10
12 14 15
5
4
1
9
17
18
13
17
2
ASSEMBLY, PUMP - PRESSURE SWITCH
EXPLODED VIEW - P/N 4355H-00501

36
37
75
105
176
71
176 106
204
310
19
13
M10 X 1.5
15
30
42
103
145
13
98 126
224
105
12
159
11 8
27
24
12
35
3
*NOTE: When plunger screw is removed, install a new copper washer and flinger washer to ensure proper fit
and seal of ceramic plunger. Each time the plunger screw is torqued, copper washers form to plunger. If the
same copper washers are reused cracking or a poor seal may result.

OIL LEVEL
TOOL KITS
PACKING EXTRACTION KIT - P/N Z09-00028
COMPLETE TOOL KIT - P/N Z09-00021
PLUNGER INSTALLATION
1. 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 a 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 illus-
trated.
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. 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.
GENERAL PUMP MAINTENANCE
07-23-03 Z08-0063
ECN-02981 Supersedes 11-14-02 Z08-00063
1
3
6
27
6
20

PLUNGER SERVICE
1. Remove pump head per “HEAD REMOVAL”.
2. Remove any packings and retainers left on the
plungers by pulling them straight off.
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 REMOVAL
NOTE: When the plunger screw is removed, it is
important to install new o-ring, anti-extrusion,
and copper washers.
1. Remove the plunger screw is removed, it is
important to install 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. 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 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 SERVICE
1. 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 to dry.
5. Examine male and female adapters, discard worn
items. Trial fit the female adapters into the head
GENERAL PUMP MAINTENANCE
07-23-03 Z08-00063A
ECN-02981 Supersedes 11-14-02 Z08-00063A 21