ALKOTA 3182 User manual

P.O. Box 288 105 Broad Street Alcester, SD 57001
800.255.6823 www.alkota.com
OLD VALUES. NEW IDEAS.
3182

x
MAINTENANCE PERFORMED
SERIAL NUMBER DATE OF PURCHASE PLACE OF PURCHASE
MONTH/ DAY/YEAR OPERATING HOURS
NOTES
06-14-06 Z08-04527
Supersedes 8-25-04 Z08-04527
MACHINE RECORD

3182 - OPERATION TABLE OF CONTENTS
OIL FIRED ELECTRIC DRIVEN CLEANER
01-16-04 Z08-03937
Supersedes 09-17-03 z08-03937 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 6
•Water Supply 6
•Barrier 6
•Water Conditions 6
•Freezing 6
•Cold weather 6
•Chemicals 6
VENTING
•Draft Diverters 6
•Venting Installation Information 7
OPERATION
•Pre Start-Up 7
•Start-Up 7
•To Clean, Apply Chemical, To Rinse 8
•Shut Down 8
(OPTIONAL) Combination Instructions 9
MAINTENANCE
Machine
•Flushing, Storage 11
•Spray Tip Maintenance 11
•Belt Tension 12
•Coil Back Pressure 12
•Schedule 10
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 13, 14
•Water Heater 15
•Oil Burner See Parts List Section
•Pump See Parts List Section
•Fuel Filter See Parts List Section
SERVICE
•Pump See Parts List Section
•Fuel Filter See Parts List Section
•Trigger Gun See Parts List Section
• Unloader See Parts List Section
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
ELECTRIC DRIVEN OIL FIRED CLEANER
08-15-03 Z08-02830
ECN-02981Supersedes 09-00 Z08-02830
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 motor 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.
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

08-15-03 Z08-2830A
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.
ELECTRICAL SAFETY
1. This machine must be electrically grounded.
Failure to have the machine grounded may
result in the operator being electrically shocked
and even death.
2. Do not plug–in or un–plug machine with wet
hands.
3. Keep power cords and connections (connectors)
out of water.
4. If an extension cord must be used to operate
this machine, it should be as short as possible.
The extension cord must be properly sized and
fitted with a grounding type plug and
receptacle.
5. All wiring and electrical connections should
comply with the National Electrical Code (NEC)
and with local codes and practices.
6. Fuses or circuit breakers should be compatible
with machine requirements. (See ELECTRICAL
section of MODEL SPECIFICATIONS for power
requirements.)
7. High voltage may be present within this machine.
Servicing should only be performed by properly
trained personnel.
FUEL SAFETY
1. Use only fuel #1 or #2 diesel. 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.
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-02981Supersedes 09-00 Z08-02831

08-15-03 Z08-02830B
3. Fuel burning equipment must have proper ven-
tilation for cooling, combustion air, and ex-
hausting 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 opera-
tion.
5. Where stacking is not required, provide adequate
ventilations to prevent any possible accumula-
tion of hazardous fumes.
6. Personnel trained in and familiar with the type
of equipment being serviced should only per-
form adjustments to fuel burning equipment.
SAVE THESE SAFETY
INSTRUCTIONS
INSTALLATION
1. LOCATION: This machine should be
installed by only qualified technicians. The
machine should be set upon a level surface
where it will not be affected by strong winds,
rain, snow, extreme heat, and freezing
temperatures. Install the machine
considering locations for chemical pick-up, fuel
connections, electrical connections, water
hook-up, venting, and maintenance.
All wiring and electrical connections should
comply with the National Electrical Code (NEC)
and with local codes and practices. Use the
chart on the next page for your cord selection
2. ELECTRICAL: Connect machine to an
electrically grounded circuit that is fused or
circuit breaker protected. The circuit must
match that specified in the ELECTRICAL
section under MODEL SPECIFICATION
3. EXTENSION CORD: The use of an extension
cord that has undersize wire compared to the
amp draw of your machine will adversely limit
the starting load carrying abilities of the motor
and machines performance. Use only 3-wire
extension cords that have 3-prong plugs and
3-pole cord connectors that accept the plug
from the product. Use only extension cords
that are intended for outdoor use. These
extension cords are identified by a marking
“Acceptable for use with outdoor appliances;
store indoors while not in use.” Use only
extension cords having an electrical rating not
less than the rating of the product. Do not use
damaged extension cords. Use an extension
cord in good repair free of frays or cracks in
the outer covering. Do not abuse extension
cord and do not yank on any cord to disconnect.
Keep cord away from heat and sharp edges.
Always disconnect the extension cord from the
receptacle before disconnecting the product
from the extension cord.
WARNING: To reduce the risk of electrocution,
keep all connections dry and off the ground.
Do not touch plug with wet hands.
CHART FIGURES ARE BASED ON NOT
MORE THAN 100 FOOT
(Based on Ambient Temperature of 86°F (30°C)).
*Use Amp Draw indicated the same or higher than
your machine output
EXAMPLE: Machine Amp Draw 51, use 55 (2
Conductor). The thermostat type of cord shall be
C, PD, E, EO, EN, S, SO, SRD, SJ, SJO, SV, SVO,
SP.
The thermoset plastic types shall be ET, ETT, ETLB,
ETP, ST, STO, SRDT, SJT, SJTO, SVT, SVTO, and
SPT.
COPPER
WIRE SIZE
MINIMUM
AWG
MACHINE AMP
DRAW*
3 CONDUCTOR
WIRES
MACHINE AMP
DRAW*
2 CONDUCTOR
WIRES
16 10 13
15 -- --
14 15 18
12 20 25
10 25 30
835 40
645 55
460 70
280 95
WARNING: ELECTRICAL SHOCK
HAZARD
5
ECN-02981Supersedes 09-00 Z08-02832

WARNING: CARBON
MONOXIDE
HAZARD
4. VENTING: 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.
5. WATER SUPPLY: This machine must have a
water supply meeting or exceeding the
maximum discharge volume specified in the
PERFORMANCE section, and a minimum water
inlet pressure specified in the GENERAL section
of the MODEL SPECIFICATIONS.
6. BARRIER: We recommend a barrier be installed
between the machine and wash area to prevent
moisture from coming in direct contact with
electrical controls, motors and transformers.
This will increase the machine’s life and lessen
electrical problems.
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
WARNING: This machine emits carbon
monoxide, and 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.
The information contained herein is offered for
reference only. You must comply with local
codes and investigate through your gas and
other utility companies when installing, as
there may be some special local requirements
you must comply with. Also see ANSI Z223.
1. DRAFT DIVERTERS: (STACKED CLEANERS)
Oil fired machines use a force air burner. The
oil burner can be influenced by “Natural Draft”
even though they have their own fan. A Bell
type draft diverter must be used here also.
THIS MACHINE IS NOT TO BE CONNECTED
TO A TYPE B GAS VENT.
NE PAS RACCORDER CET APPAREIL À UN
TUYAU D’ÉVACUATION DE GAZ DU TYPE B.
A. A draft diverter must be used on all
cleaners that are stacked. This includes
any chimney even if not expelled to the
outside.
B. Use a draft diverter of the inverted funnel
or bell type that meets all codes for
capacity and materials. Mount the draft
diverter directly to the stacking flange on
the machine
C.The draft diverter’s function is to insure
that the barometric pressures are as close
to the same as possible at the air inlet and
outlet to the coil and will not be changed
by either up drafts or down drafts.
08-15-03 Z08-02830C
6
ECN-02981Supersedes 09-00 Z08-02833

D. Installation of a draft diverter WILL NOT
PREVENT THE COIL FROM FREEZING.
In areas where freezing temperatures are
common, some type of down draft
prevention must be used. Check local codes
for acceptable methods for the prevention
of down drafts.
2. VENTING INSTALLATION INFORMATION:
A. Never Reduce the Stack size. The diverter
and stacking should be the same size as
the stack opening on the machine.B.
B. Straight Stacking through the roof
is preferred. Horizontal runs are not
desirable, but if necessary, be sure to pitch
the stack upward at a rate of two inches
per foot. When horizontal stacks are used,
vertical stacking must extend at least two
feet for every foot of horizontal stack.
C. Stack Extension above the roofline should
be sufficient to clear the peak of the roof.
(Refer to ANSI Z223.1 page 100 of
SPECIFICS)
D. A Rain Cap U.L. approved should be
installed on the stack
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).
2. CAUTION: Always use pipe or hose suitable to
carry live steam. The pipe or hose should be
large enough ID as not to restrict the flow.
3. 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.
4. Read and observe all items in “CLEANER
INSTALLATION”.
START-UP
1. Refer to the MAINTENANCE SCHEDULE for
any maintenance to be performed before
operation
2. ELECTRICAL: Connect the machine to an
electrically grounded circuit that is fuse or
circuit breaker protected. Do not use any type
of adapter. If the correct type of receptacle is
not available, have one installed by a qualified
electrician.
3. OIL LEVEL: Check the oil level in the water
pump.
4. BELT: Make sure belt tension and condition
is as specified in MACHINE
MAINTENANCE.
5. STACK COVER: Remove the stack cover (if so
equipped).
6. FUEL FILTER: Inspect fuel filter for evidence
of water contaminants.
7. FUEL: Make sure the fuel lines are open
(CAUTION: Closed valves will DAMAGE the fuel
pump and void warranty). Use #1 or #2 diesel.
8. FUEL QUANTITY: Make sure the fuel supply
is sufficient to complete the job. See the
GENERAL section of MODEL
SPECIFICATIONS for the fuel tank capacity.
9. WATER SUPPLY: This machine must have a
water supply meeting or exceeding the
maximum discharge volume specified in the
PERFORMANCE section, and a minimum water
inlet pressure specified in the GENERAL
section of the MODEL SPECIFICATIONS.
10. LIME: Water containing large amounts of lime,
calcium or other similar materials can produce
a coating on the inside of the impact nozzle or
spry tip and coil pipe.
08-15-03 Z08-02830D
7
WARNING: ELECTRIC SHOCK HAZARD
ECN-02981Supersedes 09-00 Z08-02834

11. FLOAT TANK: Check the float tank to assure
it is full and the float valve shuts off securely.
12. 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.
13. Turn the switch to the burner position.
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.
14. Select temperature (if so equipped).
15. 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 turn
switch to the pump position.
CAUTION: A good flow of water must be flowing
from the end of a gun within 30 seconds, before
proceeding. Lack of water can cause water
pump damage.
CAUTION: DO NOT RUN PUMP WITHOUT
WATER, AS THIS WILL CAUSE DAMAGE TO
THE PUMP AND VOID WARRANTY.
CAUTION: On a machine equipped with a
trigger gun valve, if the trigger gun valve
remains in the closed position for more than 5
minutes, water pump damage may occur.
14. Turn the switch to the pump position.
15. Do not start the burner unless a full flow of
water is coming from the steam trap. Air leaks
or insufficient water to the machine means less
than full flow of water through the coil. This
could cause hose failure and burns to the
operator.
16. 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.
17. 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.
TO RINSE:
A. Close 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. Start from the top, working downward
using long, overlapping strokes
SHUT-DOWN
1. Turn the switch from the burner position to
the pump position.
2. After cool, clear water is coming from the end
of the wand, turn pump switch to the off
position.
3. Turn off the water supply.
4. Disconnect from electrical supply.
5. If freezing conditions may exist, refer to
STORAGE in MACHINE MAINTENANCE.
6. Replace stack cover (if so equipped).
08-15-03 Z08-02830E
8ECN-02981Supersedes 09-00 Z08-02835

TEMPERATURE
DECREASE
INCREASE
TEMPERATURE
PRESSURE
REGULATING
VALVE
COMBINATION OPTION
ELECTRIC DRIVEN OIL FIRED CLEANER
08-15-03 Z08-02830F
ECN-02981
COMBINATION OPTION
INSTRUCTIONS
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 on the
previous page.
5. 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.
6. For shut down follow “SHUT DOWN”
previously shown on this page.
7. Close the ball valve on the coil inlet
assembly.
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.
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.
OPEN CLOSED
9

MOTOR 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.
PUMP MOTOR WITH GREASE
FITTINGS:
Remove drain plug. Use 1 or 2 full strokes of
shell “DOLIUM RB”, Chevron “SR1 No. 2” or
Texaco “PREMIUM RB:. Operate for 20
minutes and replace drain plug.
MACHINE MAINTENANCE
09-17-03 Z08-02830G
ECN-02981 10

MACHINE
MAINTENANCE
FLUSHING
1. Connect machine to an electrically grounded
circuit that is fuse or circuit breaker
protected.
2. Connect machine to a pressurized water
supply meeting the requirements specified in
the GENERAL section of the MODEL
SPECIFICATIONS.
3. Turn on the water supply.
4. Check the float tank to assure it is full and
the float valve shuts off securely.
5. Check the position of the ball valve (if so
equipped) on outlet line of the float tank
assuring it is in the open position.
6. Remove spray tip from gun assembly.
7. 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 turn
switch to the PUMP position.
CAUTION: A good flow of water must be flowing
from the end of a gun within 30 seconds, before
proceeding. Lack of water can cause water
pump damage.
CAUTION: DO NOT RUN PUMP WITHOUT
WATER, AS THIS WILL CAUSE DAMAGE TO
THE PUMP AND VOID WARRANTY.
CAUTION: On a machine equipped with a
trigger gun valve, if the trigger gun valve
remains in the closed position for more than 5
minutes, water pump damage may occur.
8. When clean water flows from the gun, turn
switch to the OFF position.
9. Disconnect the water supply.
10. Dissconnect the electrical supply.
11. If freezing conditions may exist, refer to
“STORAGE” section.
STORAGE
1. Rinse the chemical line by inserting the screen
into a container of clear water and open the
metering valve 1 minute to clean it of any
remaining residue. Be sure the chemical
metering valve is closed when finished.
2. Check the position of the ball valve (if so
equipped) on the outlet of the float tank
assuring it is in the closed position.
3. 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 switch to the BURNER
position and depress the vacuum switch. Run
it for 45 seconds allowing any remaining water
to turn to steam. Allow air to blow for 60
seconds. Turn switch to the OFF position.
4. Remove the air chuck.
5. 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 use.
6. FLOAT TANK EQUIPPED: Pour the anti-freeze
solution into the float tank.
7. WITHOUT FLOAT TANK: Install a 2-ft.
Garden hose to the water inlet. Insert the other
end into a container of antifreeze solution.
8. Turn on the switch to the PUMP position.
9. Turn off the switch just prior to running out
of antifreeze mixture.
10. Disconnect electrical supply.
11. Fill the fuel tank with kerosene or #1 or #2
diesel.
12. It is recommended to install a coil cover to keep
coil free of debris
13. Drain the float tank.
14. 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.
08-15-03 Z08-02809
ECN-02981 Supersedes 09-00 Z08-02809 11
MACHINE MAINTENANCE
ELECTRIC DRIVEN OIL FIRED CLEANERS

3. Before replacing spray tip flush the machine
per “FLUSHING”.
4. Reinstall Spray tip to gun assembly.
BELT TENSION
1. 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.
COIL BACK PRESSURE CHECK
INSTRUCTIONS
1. Check the condition of your water pump
unloader valve. Remove the hose and gun
assembly from the coil outlet.
2. Remove any flow restrictions, such as guns
and hoses, from the coil outlet.
3. Install a pressure gauge between the water
pump and coil inlet.
DISCHARGE VOLUME BACK PRESSURE
GPM REQUIRING 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 PRESSURE GAUGE
4. 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.
5. Check the position of the ball valve (if so
equipped) on the outlet line of the float tank
assuring it is in the open position.
6. Turn on the switch to the PUMP positon. 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.
For Descaling Instructions request Z08-00493.
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
08-15-03 Z08-02810
ECN-02981 Supersedes 02-16-01 Z08-02910 12
SPAN
DEFLECTION
MACHINE MAINTENANCE CONT’D
ELECTRIC DRIVEN OIL FIRED 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.Air leak in chemical line.
D. Metering valve clogged.
E. 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. 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. Motor 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.
ELECTRIC MOTOR DRIVEN OIL FIRED CLEANERS
CLEANER TROUBLESHOOTING
ECN -02981 Supersedes 06-00 Z08-02850
07-15-03 Z08-02850
13

TROUBLE POSSIBLE CAUSE REMEDY
4. Excessive,
unusual noise.
A. Defective Pump.
B. Defective motor.
C. Pulleys rubbing.
D. Misalignment of pump & motor
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" below.
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. Pump motor
will not start
(motor does not
hum)
A. No Power.
B. Defective motor starter or
ON/OFF switch.
C. Defective motor.
A. Use a different outlet,check fuses in main
disconnect switch. Replace fuse if blown.
B. Call service technician.
C. Call service technician, or take motor to
Repair/Warranty station.
9. Pump motor
will not start
(motor hums)
A. Pump frozen.
B. Defective motor.
C. Defective water pump.
D. Excessive back pressure
A. Machine must be thoroughly warmed to
above freezing.
B. Call service technician or take motor to
Repair/Warranty station.
C. See PUMP SERVICE.
D. See "Excessive Back Pressure" above.
10. Pump motor
starts slow or
overheats and
stops.
A. Low voltage
B. Excessive back pressure
C. Defective motor
A. See "Low voltage" below.
B. See "Excessive Back Pressure" above.
C. Call service technician, or take motor to
Repair/Warranty station.
11. Pump motor
stops and will
not start.
A. Motor starter "kicked out" (if so
equipped) or thermal overload
tripped.
B. Excessive back pressure.
C. Defective motor.
A. Turn motor starter off to reset, then turn
on, or push thermal overload reset button
on motor.
B. See "Excessive Back Pressure". above.
C. Call service technician, or take motor to
Repair/Warranty station.
12. Low voltage A. Incoming voltage incorrect.
B. Not large enough extension cord.
C. Too long extension cord
A. Have a qualified technician check the
motor terminal voltage. Correct voltage is
in MODEL SPECIFICATIONS.
B. Use an extension cord with amperes or
watts rating as high or higher than that of
the MODEL SPECIFICATIONS.
C. Shorten extension cord.
13. Machine
shocks
operator
A. Machine improperly grounded.
B. Outlet not grounded
A. STOP! Operating machine. Call service
technician.
B. Have properly wired outlet installed.
07-15-03 Z08-02851ECN -02981 Supersedes 06-00 Z08-02851
ELECTRIC MOTOR DRIVEN OIL FIRED CLEANERS
CLEANER TROUBLESHOOTING (CONT.)
14

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.
15

7
FROM FLOAT
TANK ASSEMBLY
FROM CHEMICAL
METERING VALVE IN
CONTROL PANEL
CAM SWITCH
VACUUM SWITCH FROM
FROM

5