Alto Contractor Diesel Operating instructions

Repair Manual
CONTRACTOR DIESEL
125 03 47 (03.2003)
www.alto-online.com
2003-11-14

Copyright © 2003
ALTO Danmark A/S
ALTO Danmark A/S
Industrikvarteret
DK-9560 Hadsund
Tel.: [phone]
www.alto-online.com

A Technical data
B Structure
C Function
D Trouble-shooting
E Service / Repair
F Test / Adjustment
G El. diagrams
H Spare parts proposal
I (Info & spare parts)
INDEX
CONTRACTOR
Diesel
Petrol

4D_CON. 03GB.
CONTRACTOR Diesel Motor data A
Diesel motor RUGGERINI MD 151, S
Engine type 4 stroke two cylinder
Max. output at 3600 rpm 13 HP / continuous 12.3 HP
Max. torque st 2400 rpm 3.26 Kgm
Fuel consumption Approx. 3 l/h
Fuel tank capacity 4.1 l
Adjusted speed at max. pressure 3500±10 rpm
Cooling system Forced air 700 m3/h
Air requirement for combustion 62 m3/h
PTO shaft rotation clockwise
Max. vacuum intake 0.024 bar
Max. exhaust backpressure 0.039 bar
Engine oil capacity / type 1.8 l / SAE 15 - 50
Dry weight 50 kg

D_CON. 03GB. 5
125 03 47 - (03.2003)
CONTRACTOR Diesel Pump data A
Heavy Duty
Opening pressure 210 bar 225
Pump pressure 180 bar / 2550 psi 205
Nozzle pressure 170 bar / 2410 psi 195
By-pass pressure 8 bar 10
Water quantity at min./max. pressure 20/19 l/min. 17.5/16 l/min.
Water quantity at steam 9 l/min. 8 l/min.
Pump pressure at steam 40 bar 30 bar
High pressure nozzle 1506 = 1.35 mm 1505
Max. temperature of inlet water 35°C 35°C
Inlet pressure, max. 10 bar 10 bar
Chemical injector (external only) 03 injector / foam injector
Density (control box) IP45
Engine r.p.m. (pump pressure) 1750 ± 25 r.p.m.
Noise level according to ISO 3746 85 DB(A) from 7 m distance
Type of piston Stainless steel Ceramic
Wobble disc no. 7 3
Type of oil BP Bartran HV 100

6D_CON. 03GB.
CONTRACTOR Diesel Boiler data A
Heavy Duty
Boiler effect 115 kW 100
Water outlet temp. at max. water quantity (12°C) 95°C (205°F) =
Oil consumption at max. water quantity and temp. 12 l/h 10 l/h
CO210-12% =
CO 50-100 ppm =
Temp. flue gas at 20°C ambient temp. 160-200°C =
Smoke scale number Max. 1 =
Flue gas loss Max. 10% =
Oil nozzle type 9 kg/h - 60°S =
Oil pressure 12 bar 11 bar
Boiler tube / measurements Welded st. 35.8 / 20 x 3mm x 48m
Heating surface 3 m2
Quantity of inlet air Approx. 180 m3/h
Outlet flue gas 260 m3/h at 200°C
Tank capacity max./min. Jerry can 20 l / 3 l

D_CON. 03GB. 7
125 03 47 - (03.2003)
CONTRACTOR Diesel Electrical parts A
A1 KEW-steering 24V AC 642009A
A2 KEW-converter 12V DC / 24V AC 6420013
B1 Flow control After pump magnet oper. Reed-switch
B2 Flow control Before boiler magn. oper. Reed-switch
B4/B5 Temperature sensor PT500
B6 Flame sensor Light-sensitive transistor
B67 Motor oil switch Open at a normal oil pressure
F1 Fuse on print A2 1 AT
F2 Fuse on print A2 *) 6.3 AT
F3 Fuse for PC-board A1 (see page 5) 1.25 AT
F4 Fuse for start protection (see page 5) 1.25 AT
G1 Accumulator battery 12V min. 50 AH (300 Amp.)
G2 Generator internal/external 12V - 15V - 280 Watt / 300 Watt
G3 Regulator/Rectifier
H1 Motor oil alarm Lamp on front
H2 Starting relay Lamp on front
M1 Starting motor 1.1 kW
R1 Resistance (only where B5 is not used) 560 ohm
S1 Start switch Key on front
T1 Ignition transformer Prim: 2x12VAC/17 Amp. Sec. 11KV
Y1 Magnet valve for oil pump 24 VAC
F3 *) secure against fault polarization of battery

8D_CON. 03GB.
Electrics box
Manometer for HP-pump
Back of electrics box
Fuses
F3
F4
Pump oil Diesel tank for motor
Ignition key
Starter battery
Ignition transformer
Exhaust outlet from boiler
Motor suspension
The base plate for the motor/pump unit is mounted on 4 inclined vibration absorbers.
The boiler is mounted on a plate construction, which serves as air duct from blower to boiler.
Electrics box is suspended in the pipe frame and contains the controlling and safety system of the
machine
Exhaust from motor
Control lamps
H1 H2
Setup Structure B
The Contractor is constructed on a combined pipe and plate frame, surface coated with a strong poly-
ester. Each single item of the machine is placed in a way that an optimum weight distribution is obtained
taking service and operation into consideration.
Temperature indicator Front panel
Temperature regulation
Chemicals container rack

D_CON. 03GB. 9
125 03 47 - (03.2003)
Diesel oil for pump
Setup Structure B
Water quantity regulation
Pump front
Water inlet
Water outlet
Pressure outlet
Sludge glass
Manometer
Flow switch B1
Electromagnet Y2 Y3 (safety stop)
Oil pressure
switch B7
Starter relay Starting motor
Rectifier G3
Motor connection (- pinch)
Gearbox
Motor air filter
Fuel oil pump Flow switch B2
Air adjustment screw
Blower
Flexible coupling
Solenoid
valve Y1
Flow
switch B2

10 D_CON. 03GB.
A flame tube consisting of two rings has the purpose of securing that the hot exhaust gases are forced
round the labyrinth of tubes.
The boiler is mounted on the air duct with a gasket between and fastened with 3 bolts. In the air duct
an adjustable throttle is mounted.
Boiler Structure B
The boiler is the heat generating part of a hot water machine. It consists of a labyrinth-constructed
tube coil, which encloses the combustion chamber.
The tube coil is enclosed by a double container with boilerjacket, bottom, and top in a sandwich con-
struction, between which the combustion air is pressed into the combustion. An insulating material
placed in the bottom of the boiler makes sure that the inner bottom, among other things, is protected
from superheating.
Gasket
Exhaust gas Electrodes Flame sensor
Oil nozzle
Air distributor
Burner tube
Flame tube bottom part
Insulating mat
Water outletWater inlet Air inletGasket
Outer jacket
Flame tube top part
Inner jacket
Air duct