Hy-flo 4355h User manual

Service ManualService Manual

For full warranty information,contact your delivering distribu-

tor or contact the manufacturer at info@warrantysvc.com

20200506

Compact Skid GED Series

Model 4355H

(800) 421-4018

www.hy-oequipment.com

English to Metric Conversions

1 gal/m = 3.7843 L/m

1 hp = .7457 kw

100 psi = 6.8964 bar

1 ft = .3048 m

1 in = 2.54 cm

1 lb = .4536 kg

(˚F – 32)

1.8 =˚C

20180730

WARNING: This product can expose you to chemicals including lead, which is

known to the State of California to cause cancer and birth defects or other repro-

ductive harm. For more information, go to www.P65Warning.ca.gov

ADVERTENCIA: Este producto puede exponerle a productos químicos incluso

el plomo, que es conocido al Estado de California causar cáncer y defectos de

nacimiento u otro daño reproductivo.

AVERTISSEMENT : Ce produit peut vous exposer aux produits chimiques en in-

cluant l’avance, qui est connue à l’État de Californie provoquer le cancer et les

anomalies congénitales ou d’autre mal reproducteur.

WARNING:

ADVERTENCIA:

AVERTISSEMENT: California Prop 65 Warning

Register your machine at

warranty.alkota.com

_________________

INSTALLATION DATE

______________________________________________________

MAKE/MODEL SERIAL NUMBER

______________________________________________________

SELLER

______________________________________________________

ADDRESS CITY/STATE/ZIP

Contents

Table of Contents

Quick Machine Checklist ��4

Specications ��1

Maintenance Schedule��3

General Assembly ��4

Fuel Tank Assembly ��6

Fuel Filter ��7

Specications, Trouble Shooting��7

Maitennace Schedule ��8

Assembly, Control Panel ��9

Electrical Schematic��10

Float Tank Assembly��11

Water Pump��12

Injector, Chemical - Downstream ��13

Pump Maintenance��14

Plunger Service, Removal, Installation��15

Packing Service ��16

Head Installation - Torgue Sequence��17

Freezing conditions - Pump Oil Change��17

Pump��18

Specications ��18

Exploded View ��19

Pump Kits��20

Unloader Assembly ��22

Specications ��23

Parts List ��24

Maintenance - Exploded View ��25

Trouble Shooting��26

Pre-Cleaner Assembly ��27

Oil Burner��28

Burner Maintenance��29

Burner Breakdown ��32

Burner Parts List ��33

Coil Assembly��34

Troubleshooting ��35

Pump��35

Burner��37

Water Heater��39

Schematic, Engine��41

Warranty��43

(800) 421-4018

www.hy-oequipment.com

Machine Check List

Gasoline Powered Hot Water Equipment

Daily:

_

___

_

Check oil level in motor.

Daily:

_

___

_

Check fuel levels. Add diesel or kerosene to black tank marked diesel. Add

gasoline to red tank marked gas. DO NOT ADD GAS TO DIESEL TANK -

EXPLOSION CAN OCCUR!II

Monthly:

_

___

_

Check oil level in pump and inspect belts for wear.

To start machine:

_____ 1. Make sure burner switch is in off position.

_

___

_

2. Choke engine - start motor. (Starting the motor with the trigger pulled ensures

easy start.)

_

___

_

3. Turn on burner - set temperature gauge to desired temperature.

_

___

_

4. When finished cleaning - turn off burner and run machine until discharge water is

cool.

_

___

_

5. Pull trigger when machine is off to release pressure in system.

Winterization

To winterize system:

_

___

_

1. With machine off - close ball valve to water and open valve to antifreeze tank.

_____ 2. Start engine - do not turn on burner.

_

___

_

3. Run machine with antifreeze valve open until it flows out end of wand, then

release trigger and re-pull trigger briefly. System is now antifreezed.

_

___

_

4. Upon start-up: close antifreeze ball valve and open water valve. Remove nozzle

and place end of wand in antifreeze tank. Start machine and run machine until all

antifreeze has been recaptured into antifreeze tank.

IMPORTANT: CHECK ANTIFREEZE PROTECTION LEVEL AND MAKE SURE THAT

FREEZE LEVEL IS BELOW AMBIENT TEMPERATURES! Freezing will cause extensive

damage to equipment.



Quick Machine Checklist

1

Specications

PERFORMANCE

Discharge Volume

3.7 gal/m / 14.0 L/m

Pump Head Pressure

3500 psi / 242 bar

Combustion Smoke/Bacharach

Scale

#1 OR #2 SMOKE

Carbon Monoxide Allowed

0.01%

Draft/Stack Installation

0.2” – 0.04” WC READING

Heat Input

235,200 Btu/h / 59,270 kcal/h

Combustion Smoke/Bacharach

Scale

#1 OR #2 SMOKE

GENERAL

Minimum Inlet Water Pressure over 65 psi may require water inlet regulator

10 psi / 0.68 bar

Weight

705 lbs / 320 Kg

Burner Fuel Tank Capacity

11gal / 42 Ltr

Engine Fuel Tank Capacity

1.7 gal / 4.4 Ltr.

Dimensions

40”” Long x 42 High x 24” Wide

Pump

Triplex, Oil Bath Crankcase, Solid

Ceramic Plungers

Spray Tip

Red (#4 - 0˚) p/n JA0-00040-2

Yellow (#4 - 15˚) p/n JA0-15040-2

Green (#4 - 25˚) p/n JA0-25040-2

White (#4 - 40˚) p/n JA0-40040-2

Belt

p/n R02-00245

Coil

Standard 14” OD x 1/2” ID x 95’ Schedule 80

Coil Back Pressure (New) 5 psi / 0.34 bar

Coil Back Pressure Requiring Descaling 50 psi / 3.40 bar

2Specications

Pump Engine

p/n F05-00488

Make Honda GX390

Horsepower 13 hp / 9.7 kw

Fuel Gasoline

Engine Starting Electric

Engine Air Filter p/n F05-000462-10

Engine Air Pre-Cleaner None

Engine Oil Filter None

Fuel Tank Capacity 6.4 Qt / 6.5 L

Oil Capacity 1.16 Qtl / 6.5 L

Engine Oil Alert Yes

BURNER

Burner Part Number V00-173141

Burner Type Pressure Atomizing

Voltage 12VDC

Horsepower 1/8 HP

Fuel Type Kerosene, #1 or #2 Diesel

Fuel Pressure 125 PSI / 9 BAR

Fuel Pump P/N V0014283

ELECTRICAL

Machine Voltage

12v

Battery Cable Negative - Black

32” Clmp/Eye p/n F05-00232

Battery Cable Positive + Red

32” Clmp/Eye p/n F05-00232-R

Burner Nozzle 1.50 90 Degree A

p/n V1.50 90DA

Fuel Consumption 1.68 Gal/Hr / 6.3 L/Hr

Fuel Pressure 125 Psi

3

Final Assembly

Maintenance Schedule

ENGINE DRIVEN Maintenance Schedule

Pressure Washer Cleaners

daily

Each HR

1st 8 HRS

AFTER

1ST 50

EVERY 50

HRS

EVRERY

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 rell per PUMP

SERVICE insert

CAUTION: Used oil must be disposed into an

environmentally 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 oat tank screen for debris ●

Leaks:

Check for water and build up of scale at pipe

connections ●

Guards and Shields: ●

Check that all guards and shields are in place

and secure

Freezing Temperatures:

Freezing temperatures break water pumps

and like components. See STORAGE in the

MACHINE MAINTENANCE section for cold weather

instructions.

● ●

Fuel:

Adequate fuel supply ●

Filter-Fuel:

If contaminants are present see FUEL FILTER

insert ●

Remove and replace fuel lter. ●

Guards and Shields:

Check that all guards and shields are in place

and secure ●

4General Assembly

General Assembly

27 29/32"

11

3

29 20 19

8

5

7

13

30

12

15

6

21

1612410

18

28

2

22

17

27

14

4

37 29/32"

41 13/16"

5

General Assembly

ASSEMBLY, GENERAL

3/5/2008

ITEM NO.

PART NUMBER

PART DESCRIPTION

QTY.

1

4355H-00501

ASSEMBLY, PUMP

1

2

4355H-00515

ASSEMBLY, UNLOADER

1

3

4355H-00657

ASSEMBLY, PRE - CLEANER

1

4

4355H-01121

ASSEMBLY, TANK - FLOAT

1

5

4405F-00126

ASSEMBLY, TANK - FUEL

1

6

4405F-00302

ASSEMBLY, CONTROL PANEL

1

7

E05-10025

CAP, PIPE

1

8

E09-00002-2

PLUG, PIPE

1

9

F04-00342

CLIP, INSULATED - 1/2"

6

10

H03-31311

BOLT,J-5/16-18UNC x 3 1/2

1

11

H04-19011

SCREW, SELF TAP

4

12

H04-31301

SCREW, CAP - 5/16 X 3/4

4

13

H04-31326

CAP, SCREW

2

14

H06-25003

NUT, HEX

4

15

H06-31300

NUT, LOCK - 5/16"

7

16

H06-37500

NUT,LOCK-3/8-16UNC HEX

4

17

K02-03222A2

ASSEMBLY, HOSE - 3/8 x 22""

1

18

K02-03225A2

ASSEMBLY, HOSE - 3/8 x 25"

1

19

K23

HOSE, LOW PERMEATION, BLACK

1

20

K23

HOSE, LOW PERMEATION, BLACK

1

21

K33-00900

HOSE, WATER - 3/8 X 9"

1

22

K60-02300

HOSE, WATER - 5/8 X 23"

1

23

R03-00732

PULLEY,V2AK32H

1

24

R03-00774

PULLEY,DBL V-2AK74H

1

25

R04-00001

BUSHING, PULLEY

1

26

R04-0006

BUSHING, PULLEY

1

27

W02-00031

CLAMP, HOSE

2

28

W02-00032

CLAMP, HOSE

2

29

W02-00033-P

CLAMP, HOSE

4

30

W04-34155-A

COUPLER, QUICK

1

6Fuel Tank

6

2

7

1

5

4

3

ASSEMBLY, TANK - FUEL

p/n: 4405F-00126

10/22/2009 - 10 Gallon

ITEM

NO. PART NUMBER PART DESCRIPTION QTY.

1 4405F-00125 TANK, FUEL 1

2 E08-00005-2 ELBOW,1/4FNPT 1

3 E09-00002-2 PLUG, PIPE 1

4 E13-00025-48 NIPPLE, PIPE 1

5 V04-00308 FILTER, FUEL 1

6 W02-10019-8 BARB, HOSE 1

7 W02-10031 BARB, HOSE 1

Fuel Tank Assembly

7

Fuel Filter

Specications, Trouble Shooting

FILFIL

FILTER,TER,

TER,TER,

TER, FUELFUEL

FUELFUEL

FUEL

P/N V04-00308

REMEDY

1. Fuel bowl leaking.

2. Air leaking into system

(indicated by air bubbles in bowl

during operation).

A. Deteriorated gasket.

B. Housing Cracked.

C. Bowl rim cracked, nicked, or scratched.

D. Gasket missing.

E. Loose Fuel Bowl.

A.Loose Valve Assembly.

B. craked Component.

C. loose Filter bowl.

A. Remove and Replace Gasket.

B. Remove and Replace Housing.

C. Remove and Replace Bowl.

D. Replace Gasket.

E. Tighten Fuel Bowl Onto Filter.

A.Tighten Valve Assembly.

B. Inspect Filter Bowl, Filter Housing,

and Gasket.

C. Tighten Fuel Bowl Onto Fuel Filter.

TROUBLE POSSIBLE CAUSE

TRTR

TROUBLE SHOOOUBLE SHOO

OUBLE SHOOOUBLE SHOO

OUBLE SHOOTINGTING

TINGTING

TING

•MAXIMUM FLOW 15 GPH / 57 LPM

• MAXIMUM FILTRATION 2 MICRONS

• MAXIMUM TEMPERATURE 212°F / 100°C

• WEIGHT 1.0 LBS. / 340 GM

• INLET 1/4 NPT

• OUTLET 1/4 NPT

SPECIFICASPECIFICA

SPECIFICATIONSTIONS

TIONSTIONS

TIONS

3 1/4"

5 1/2" (6 1/2" Required For

Element Removal)

Inlet

Vent Plug

Drain Port

Outlet

ALL DIMENTIONS ARE

IN INCHES UNLESS OTHERWISE

NOTED. 25.4 MM = 1 INCH

Specications

Maximum Flow 15 GPM / 57 LPM

Maximum Filtration 2 Microns

Maximum Temperature 212˚F / 100˚C

Weight 1.0lbs / 340km

Inlet ¼ NPT

Outlet ¼ NPT

All dimensions are in inches unless otherwise noted.

25.4 mm = 1 inch

Maintenance Procedures

Priming the machine

Shut off the fuel tank valves. Spin off the clear bowl, ll 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.

Draining water

Check the collection bowl daily. Drain off water contaminants by unscrewing the clear bowl turning

counter-clockwise. Start the machine and allow air to purge from the fuel system prior to operating the

equipment.

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 lter element as one tank full of contaminated fuel will plug the

fuel lter element prematurely.

Element replacement procedure

1. Shut off the fuel tank valves.

2. Unscrew the clear bowl turning counter-clockwise.

3. Remove and discard the lter element.

4. Follow listed procedures under “PRIMING.”

Filter, Fuel

p/n V04-00308

8Fuel Filter

Maitennace Schedule

PRIMING THE MACHINE

Shut off the fuel tank valves. Spin off the element, fill with clean

fuel and coat the square gasket (3) with fuel. Reinstall the

element and tighten 1/4 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.

2. DRAINING WATER

Check the collection bowl daily. Drain off water contaminants

by opening the head vent and then the drain. If more than 1/8

cup of fluid is drained, follow the priming instructions,

otherwise, close the vent and drain. Start the machine and allow

air to purge from the fuel system prior to operating the

equipment.

3. ELEMENT REPLACEMENT FREQUENCY

Frequency of element replacement is determined by con-

tamination level in the fuel. Replace the element upon power

loss of the engine (if so equipped) or every 500 hours

whichever comes first.

NOTE: Foul smelling diesel fuel is an indication of microbio-

logical contamination. A change in fuel source is recommended.

Always carry a spare element as one tank full of contaminated

fuel will plug the fuel filter element prematurely.

4. ELEMENT REPLACEMENT PROCEDURE:

1. Shut off the fuel tank valves.

2. Unscrew the amber bowl from the fuel filter.

3. Unscrew and discard the filter from the upper housing.

4. Follow listed procedures under “PRIMING”.

MAINTENMAINTEN

MAINTENAA

AA

ACE PRCE PR

CE PRCE PR

CE PROCEDURESOCEDURES

OCEDURESOCEDURES

OCEDURES

EXPLEXPL

EXPLODEDODED

ODEDODED

ODED VIEWVIEW

VIEWVIEW

VIEW

GASKETS:

1. Inspect for deterioration or tearing.

2. Remove and Replace.

BOWLS:

Inspect rim of bowl to insure it is free

of nicks, cracks, or scratches.

FILTER ELEMENT:

1. Inspect for damage or deterioration.

2. Remove and Replace. (500 hours)

FUEL BOWL:

If contaminants are found, check more

frequently.

NOTE:

intervals stated are for normal operating conditions. the

intervals suggested may be shiortened or lengthened as

determined by existing conditions.

WEEKLY 100 HRS

**

*

MAINTENMAINTEN

MAINTENANCE SCHEDULEANCE SCHEDULE

ANCE SCHEDULEANCE SCHEDULE

ANCE SCHEDULE

FILFIL

FILTER,TER,

TER,TER,

TER, FUELFUEL

FUELFUEL

FUEL

BREAKDOWN - P/N V04-00308

7

6

1

8

4

5

3

2

10

9

PARTS LIST

ITEM PART NUMBER PART DESCRIPTION QTY.

1 V04-00308-02 HOUSING, UPPER 1

2 V04-00308-07 ASSEMBLY, DRAIN 1

3 V04-00308-06 BOWL, AMBER - 3" 1

4 V04-00308-01 ELEMENT, FILTER 1

5 V04-00308-05 O-RING - 3/32CS X 2 1/2ID 1

6 C07-01300-08 O-RING - 1/16CS X 5/16ID 1

7 V04-00308-08 PLUG, PIPE 1

8 V04-00308-03 RING, FLAT 1

9 V04-00308-K KIT, REPLACEMENT

BOWL 1

10 V04-00308-04 ASSEMBLY, VENT 1

PARTS LIST

ITEM PART NUMBER PART DESCRIPTION QTY.

1 V04-00308-02 HOUSING, UPPER 1

2 V04-00308-07 ASSEMBLY, DRAIN 1

3 V04-00308-06 BOWL, AMBER - 3" 1

4 V04-00308-01 ELEMENT, FILTER 1

5 V04-00308-05 O-RING - 3/32CS X 2 1/2ID 1

6 C07-01300-08 O-RING - 1/16CS X 5/16ID 1

7 V04-00308-08 PLUG, PIPE 1

8 V04-00308-03 RING, FLAT 1

9 V04-00308-K KIT, REPLACEMENT

BOWL 1

10 V04-00308-04 ASSEMBLY, VENT 1

Maintenance Schedule

Weekly

EVRERY

100 HRS

Gaskets

Inspect for deterioration or tearing. ●

Remove and replace. ●

Bowls

Inspect rim of bowl to insure it is free of nicks,

cracks, or scratches. ●

Filter Element

Inspect for damage or deterioration. ●

Remove and replace.

Fuel Bowl

If contaminants are found, check more

frequently. ●

PART LIST

ITEM PART NUMBER PART DESCRIPTION QTY

1 V04-00308-02 Housing, Upper 1

2 V04-00308-07 Assembly, Drain 1

3 V04-00308-K Bowl, Amber – 3” 1

4 V04-00308-01 Element, Filter 1

5 V04-00308-05 O-Ring – 3/32CS x 2 1/2ID 1

6 V04-01300-08 O-Ring – 1/16CS x 5/16ID 1

7 ------------------ Plug, Pipe 1

8 V04-00308-03 Ring, Flat 1

9 V04-00308-K Kit, Replacement Bowl 1

10 V04-00308-04 Vent Plug & O-ring 1

Filter, Fuel

p/n V04-00308

Troubleshooting

Trouble Possible Cause Remedy

Fuel bowl leaking Deteriorated gasket Remove and

Housing cracked Remove and replace housing

Bowl rim cracked, nicked, ors cracked Remove and replace bowl

Gasket missing Replace gasket

Loose fuel bowl Tighten fuel bowl onto lter

Air leaking into system

(indicated by air bubbles

in bowl during operation)

Cracked component Inspect lter bowl, lter housing,

and gasket

Loose lter bowl Tighten fuel bowl onto fuel lter

Loose valve assembly Tighten valve assembly

9

Control Panel

4 8 14

3

1

12

2

9

10

13

11

CONNECTS TO PUMP

ASSEMBLY, CONTROL PANEL

2/27/2011

ITEM

NO.

PART NUMBER

PART DESCRIPTION

QTY.

1

4355H-00301

WELDMENT,CONTROL PANEL

1

2

F04-00411

BUSHING, STRAIN RELIEF

1

3

F04-00411

BUSHING, STRAIN RELIEF

2

4

F04-00451

GROMMET, RUBBER

4

5

F04-00615

TERM, SPLICE

4

6

F04-00616

TERM, INSULATOR

4

7

F04-00618

INSULATED SPADE

7

8

F04-00693

SWITCH, ROCKER

1

9

F04-00790

SWITCH, PRESSURE

1

10

F05-00168A

MODULE, RECTIFIER

1

11

FA5-00063

RELAY, AUTOMOTIVE

1

12

H04-13808

SCREW, MACHINE

2

13

H04-25000

SCREW, CAP

1

14

H06-25003

NUT, HEX

1

Assembly, Control Panel

10 Electrical Schematic

Electrical Schematic

PART NUMBER

DATE:

PART NUMBER

DRAWN BY:

RED

BLACK

WHITE

BROWN

YELLOW

BLUE

GREEN

PINK

ORANGE

ELECTRICAL

SCHEMATIC

ES-01835B

09-28-15

LCL

BL K

RED

YEL

CAD

CELL

IGNITOR

TIMER

12 VDC

+

_

YEL

RED

BL K

WHT

RED

NOTES

:

1.) 20 AMP FUSE O N WAYNE BURNER ONLY.

2.) RED WIRE (SHOWN HERE OPPOSITE CAD CELL), IS NOT IN ANY WAYNE

B URNE R B UT , IS IN SOME BE CKETT BURNERS. THE Y ELL OW WI RE (SHOWN HERE

OPPOSITE CAD CELL) IS BLUE IN BECKETT BURNERS, AND THE OTHER RED WIRE

(FROM I GNITE R/ TIMER IS WHITE IN BECKETT BURNERS.

87

30

86

85 87A

** NOTE:

THE RELAY SPADE TERMINAL NUMBERS SHOWN IN THIS

DRAWING ARENOT VISIBLE ON THE RELAY. THEREFORE, TO

MAKE CORRECT WIRE CONNECTIONS, POSITION RELAY SO

SPADES CAN BE SEEN EXACTLY AS SHOWN HERE (3

VERTICAL, 2 HORIZONTAL), THEN MA KE WIRE

CONNECT IONS AS SHOWN.

RECTIFIER

RED

WHT

GRN BLK

ORG

BLK

WHT

RELAY

**

RED

BU RNE R

SWITCH

EN GI NE

REGULATOR

GREY

EN GI NE

STATO R

LE ADS

BLK

12 VDC

BATTE RY

P RE SS U RE

SWITCH

FUEL

SOLENOID

BU RNE R

MOTOR

ELECTRONIC

IGNITER

12 VDC

BRN

WHT

PURP

RED

BL K

RED

NC

NOCBLU

STARTER

SOLENOID

RED

11

Float Tank Assembly

5

8

9

12

11 4

10

1

7

2

6

ASSEMBLY, TANK - FLOAT

2/28/2008

ITEM

NO.

PART NUMBER

PART DESCRIPTION

QTY.

1

4120-10540P

ASSEMBLY, RESTRICTOR

1

2

5305A-04120

WELDMENT, TANK - FLOAT

1

3

AR14-00300

ROD,THREAD 1/4-20UNC X 3

1

4

C03-00216-4

VALVE, BALL - 3-WAY

1

5

C03-00620-Q

VALVE, FLOAT

1

6

C03-00622-B

BALL,FLOAT-PLASTIC

1

7

C04-00120

FILTER, SOAP SCREEN

1

8

C05-00273

ADAPTER, GARDEN HOSE

1

9

E04-00009-48

BUSHING, PIPE

1

10

E09-00002-P

PLUG, PIPE - NYLON

1

11

E15-R0006-4

NIPPLE, HEX

1

12

W02-10057-8

BARB, HOSE

1

21 6

3

5

1

7

Only Replaceable Part

Is The plunger With Seals

Float Ball and Stem Found

In The Assembly Where

Float Valve Used.

VALVE, FLOAT

p/n C03-00620-Q

ITEM

NO. PART NUMBER PART DESCRIPTION QTY.

1 -------------- HOUING-VALVE 1

2 -------------- ARM,PLUNGER 1

3 -------------- NUT,WING 1

4 -------------- ARM,BALL 1

5 C03-99620-Q PLUNGER 1

6 -------------- LINK,PLUNGER 1

7 --------------- ARM,PLUNGER 1

8 ---------------- WASHER, FIBER 1

9 ----------------- NUT, HEX 1

12 Water Pump

Water Pump

6

19

17

14

2

12

1

4

20

8

10

18

13

21

7

16

11

155

9

3

ASSEMBLY, PUMP

2/29/2008

ITEM

NO.

PART NUMBER

PART DESCRIPTION

QTY.

1

C03-00120

VALVE,BALL-1/4"MNPT x

1/4"FNPT

1

2

C03-00310-2

VALVE, METERING

1

3

C09-00008

VALVE, EASY START

1

4

E04-00005-48

BUSHING, PIPE

1

5

E04-00016-58

BUSHING, 3/8 - 1/4

1

6

E08-00006-48

ELBOW, PIPE

1

7

E08-00011-58

ELBOW, PIPE

1

8

E08-00017-48

ELBOW, STREET

1

9

E10-00005-4

TEE, PIPE

1

10

E10-00018-4

TEE, STREET

1

11

E10-00021-58

TEE, STREE - 3/8

2

12

E13-00010-48

NIPPLE, PIPE

1

13

E15-00010-48

NIPPLE, CLOSE - 1/2"NPT

1

14

K21-02214-1/4

ASSEMBLY, HOSE-OIL, DRAIN

1

15

K31-00900

HOSE, WATER

1

16

N07-00016-LH

PUMP,WATER-TS1511 4GPM

@3500PSI 1450RPM

1

17

N07-40046-P1

RAIL, PUMP - W/HOLES

1

18

W02-00033

CLAMP, HOSE

2

19

W02-10019-8

BARB, HOSE

2

20

W02-10030-8

BARB, HOSE

1

21

W02-10057-8

BARB, HOSE

1

NOTE:

Chemical Injector

Item # 2 adjusts

chemical intake

by turning

the valve knob

after opening

valve item #1

13

Water Pump

2 0

FLO W C O N TROLS

The Alkon Series J Flo w Control, Needle an d C heck V alv es offer substantially higher

flo w than an y oth er comp arable v alve in their size or pressure range. Alkon pioneered

th e t w o tap er needle and the in-line flo w p ath designs to provide the highest flo w

coupled w ith the most sensitive metering from full open to full closed.

In-LineFlow Controls, Needle& Check Valves

DESIG N FE A T U RES :

A. Aluminum controlknob permits adjustment of

flo w w ith v alve under pressure.

B. Locking set scre w on controlknob.

C. Brass retainer acts as a positive stop for needle

travel.

D. Buna-N sealstandard (V iton sealavailable) one-

piece back-up ring to prevent e xtrusion.

E. Heat treated, ground and polish ed 4 1 6 st ainless

steelneedle.

F. One-piece, high tensile brass forged body.

G. Four stage needle provides the most sensitive

flo w m etering from full closed to full open.

H. Large unobstructed orifices.

I.Stainless steelball acts against a lapped seat to

provide best sealing.

J. The stainless steelcage acts as a spring support

ball guide and ball stop. The spring is stainless

steelwire.

K. In-line check v alve has an orifice larger than the

nominalpipe siz e. Lo w pressure differential, no

chatter and lo w friction loss.

FEA TURES F ORDESIGN-IN Q U A LIT Y

•

Positive no-leak stem seal

•

Safe positive stop for needle travel

•

Precision calibrated dialto determine and allo w

a return to required flo w se ttings

•

Maximum O peratin g Pressure: 3, 0 0 0 PSI

•

2 PSI che ck cracking pressure

•

One piece forged housing

OPTIO N S

•

Nickelplating for service with corrosiv e media

•

Friction O-Ring for micrometer adjustment

•

Viton seals

•

British standard parallelpipe threads

•

Removable knob

N O T E:

Patents 3,421,547 and 3,441,2 49

Chemical Injector

16

Downstream Injector Operation

A downstream injector works by maintaining a certain psi

on the pump side of the injector by means of an orice

installed into the injector body. When the psi drops by at

least a 30% differential on the outlet side of the injector

it creates a vacuum draw that pulls your pre mixed

chemical solution into the injector body and mixes it with

the ow of water traveling through the injector and out

the hose and gun assembly of the pressure washer.

Operation:

1. Connect the chemical line & lter screen

onto the injector making sure the injector is

closed.

2. Place the suction lter into a container

chemical and attach the black low pressure

soap nozzle to the tip of the wand.

3. Start your pressure washer as normal

and turn the injector open. You are always

supposed to soap from the bottom up and

rinse from the top down.

4. When you are done applying cleaning

solution onto the surface, turn off the

chemical adjustable knob and replace the

soap nozzle with a 0º (red color) or 15º

(yellow color) nozzle to remove loosened

dirt.

You should never use anything but pressure washer

safe cleaning solutions. Use of other chemicals such

as bleach will damage seals and o-rings in the gun,

wand, hoses and pumps. What chemicals can be

used? Use only chemicals designed for pressure

washer use (pressure washer approved). They will

not damage your pressure washer, plus they are

biodegradable and environmentally friendly.

A. Control Knob

B. Locking set screw

C. Brass retainer

D. Buna-N o-ring seal

E. Needle valve

F. Housing

G. 4 stage needle

H. Orices

I. Stainless steel ball

J. Ball cage

K. Check valve

Down Stream Injector

Injector, Chemical - Downstream

p/n C03-00310-2

Injector, Chemical - Downstream

14 Pump Maintenance

22 Pump Maintenance

6

7

2

6

3

1

General

PACKING EXTRACTION KIT P/N Z09-00028

COMPLETE TOOL KIT P/N Z09-00021

Valve Service

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 needle nose pliers, ngers, 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

ush 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 specications.

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.

Pump Maintenance

15

Pump Maintenance

23

Pump Maintenance

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. 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 inger washer, clean with solvent and allow to dry.

Plunger Installation

1. Install the copper inger 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 at washer is

installed onto the screw.

6. Torque the plunger retainer screw to the value indicated in the torque section of the pump

specications.

Plunger Service, Removal, Installation

16 Pump Maintenance

24 Pump Maintenance

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 it to dry.

5. Examine male and female adapters, discard worn items. Trial t the female adapters into the head

checking for binding or damage. Discard and replace damaged items

6. Lubricate packing cavities in the head and all packings and adapters with pump crankcase oil.

7. Lay head on the bench with packing cavities up. Install one male adapter in each cavity with the

at side down.

8. 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.

9. Install the re-stop ring with the lips pointing down.

10. Install a front female adapter into each cavity with the at side up. Make certain the adapter goes

all the way down into the cavity.

11. Install the low pressure packing with the at side down.

12. Install the rear female adapter into each cavity with the lips pointing down.

13. Lubricate o-rings with pump crankcase oil and install one into the groove of each adapter.

14. Install one adapter and o-ring into each cavity with the at side up. Each adapter and o-ring

assembly should push into the head to approximately 1/16 inch of being ush 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 t is obtained, proceed to step 16. If a proper t

is not obtained, remove the female adapters from the offending cavity and reinstall items per steps

8 through 15.

15. Install head per HEAD INSTALLATION.

Packing Service

HY-FLO 4355H User manual

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