Ramteq XV LP Series User manual

READ THIS MANUAL
This manual contains important information for the use and safe operation of
your RAMTEQ®machine. FAILURE TO READ THIS MANUAL AND
FOLLOW ITS INSTRUCTIONS PRIOR TO OPERATING OR ATTEMPTING
ANY SERVICE OR MAINTENANCE PROCEDURE COULD RESULT IN
SERIOUS INJURY OR DEATH TO YOU OR OTHER PERSONS; ALSO
DAMAGE TO THE MACHINE OR TO OTHER PROPERTY.
RAMTEQ®14275 NORTHWEST FREEWAY HOUSTON, TX 77040 PHONE: [phone] FAX: [phone] 300-00010-03 8/05
Operator’s Manual
XV NG/LP Series
Natural Gas/Propane

OperatOr’sManual
RAMTEQ®14275 NORTHWEST FREEWAY HOUSTON, TX 77040 PHONE: [phone] FAX: [phone] 300-00010-03 8/05
page 2
Section 1 operator’SManual
Unpacking....................................................................2
Safety inStrUctionS and WarningS.............................3
operating inStrUctionS...............................................4
Maintenance inStrUctionS...........................................5
Section 2 partS and Service Manual
partS diagraM..............................................................7
pUMpS...........................................................................7
HoSe, Wand, & gUn......................................................8
control Box aSSeMBly.................................................8
plUMBing diagraMS.......................................................9
NG/LP plUMBing diagraMS.............................................10
Wiring diagraMS...........................................................11
troUBleSHooting...........................................................12
 W arranty .................................................................13
Table of Contents
NOTICE
Information in this operator’s manual is subject to change without notice.
RAMTEQ SHALL NOT BE LIABLE FOR TECHNICAL OR EDITORIAL ERRORS OR OMISSIONS CONTAINED HEREIN. This operator’s manual
contains information protected by copyright. No part of this operator’s manual may be photocopied or reproduced in any form without
prior written consent from RAMTEQ
®
.
© RAMTEQ
®
, 2005
All rights reserved. Printed in USA.
INCLUDED PARTS
• Pallet
• Packing Material
Outer Box
• XVNG or XVLP
Series Machine
• Operator’s Manual
• Wand / Trigger Gun
• Nozzle 0º, 15º, 25º, 40º
• Hose 3/8” X 50’
• QC Hose Fittings
INSPECTION
Carefully unpack your new RAMTEQ equipment by removing the banding
and cardboard box from pallet. Remove the pressure washer from the
pallet and check for any physical damages that may have occurred during
shipment. Check for all parts specified and shown below.
Unpacking Instructions

OperatOr’sManual
RAMTEQ®14275 NORTHWEST FREEWAY HOUSTON, TX 77040 PHONE: [phone] FAX: [phone] 300-00010-03 8/05
page 3
DO NOT operate this machine in areas where open flames are not permitted. DO NOT store or
use combustible materials on or near this machine. Use this equipment only in well ventilated
areas. Failure to follow this warning may cause carbon monoxide build up, fire or explosion, and
possible injury or death.
DO NOT operate this machinery unless the gas installation has been done by a competent
professional and the installation meets all federal, state, and local codes.
DO NOT operate this machine while under the influence of alcohol, drugs or while fatigued.
DO NOT direct discharge stream at yourself or others. Risk of injection or injury may occur.
Never put your hand or fingers over the spray tip. Do not try to stop or deflect leaks with your
hand or body. Always face nozzle and wand to the ground when testing.
DO NOT operate this machine WITHOUT wearing protective Eye Wear. Gloves, Hard Hat, Mask,
Ear Plugs & Steel Toe Work Boots are also recommended, DO NOT wear loose clothing. Keep
your body and clothing clear of the engine and discharge stream when the machine is running.
DO NOT tie back or block trigger gun in OPEN position. Never leave the pressure washer
unattended once you have started it. If you leave, shut down machine completely.
DO NOT overreach or stand on an unstable support while operating this machine. Maintain
good footing and balance.
DO NOT permit this machine to run while unattended or for extended periods of time with
trigger gun closed. Damage to pump may occur.
DO NOT operate this machine in an unsafe manner or around unsupervised children. Keep all
other personnel clear while operating this machine. This product should only be operated by
trained personnel.
DO NOT alter original factory settings prior to operating this machine. Risk of injury to yourself or
other persons may occur.
DO NOT remove hoses, guns, nozzles or any components while this machine is still hot or while
it is running.
DO NOT attempt to service this machine before reading the service manual.
DO NOT use water with a temperature over 140 degrees Fahrenheit
DO NOT use any electrical outlet that is not properly grounded or does not comply with all
federal, state, and local laws and/or electrical codes
DO NOT operate this machine without knowing how to stop and bleed water pressures. Know all
controls before using this machine.
DO NOT spray caustic, acids or abrasive fluids through this machine.
DO NOT permit water to freeze inside this machine. Pump and plumbing damage may occur.
Use only recommended RAMTEQ parts when servicing this machine.
RAMTEQ will not be held liable for any unauthorized modifications made to this
machine. Any such action will void the warranty.
Safety Guidelines
READ THIS FIRST! FAILURE TO READ AND OBSERVE ALL
WARNING STATEMENTS COULD RESULT IN SEVERE BODILY
INJURY OR DEATH, POSSIBLE INJURY TO OTHER PERSONS,
DAMAGE TO MACHINE OR OTHER PROPERTY.
�
WARNING

OperatOr’sManual
RAMTEQ®14275 NORTHWEST FREEWAY HOUSTON, TX 77040 PHONE: [phone] FAX: [phone] 300-00010-03 8/05
page 4
LOCATION & INSTALLATION GUIDELINES
Locate the machine on a solid and level surface so that engine and pump crankcase oil lubricate components properly.
Avoid areas where water can build up in the working area. Possible injury can occur caused by the surface becoming
slippery from water build up.
Locate the machine in a well-ventilated area and away from flammable materials or fumes. Be sure ventilation warnings
are observed. Keep pressure washer at least 18” away from flamable materials.
Locate the machine so the operator has easy access to the pressure washer and its controls. Locate the machine so that
it is protected from external damage.
 Confer with local gas company, and with proper municipal officials regarding any specific code or regulations governing
this installation. Installation must conform with all local codes prior to operation of machine.
 A draft diverter hood must be installed and vented to the outside.
 Check gas union located under burner ring prior to operation. Soap test gas pipe fittings for leaks once pressurized.
To prevent damage and excessive hose wear, locate the pressure washer so that the hose does not cross traffic areas
 The gas line should be a separate supply direct from the meter to the burner. New pipe is recommended to be
used and located so that a minimum amount of work will be required in future servicing. The piping should be
so installed as to be durable, substantial and gas tight. It should be clear and free from cutting burrs and defects
in structure of threading. Cast iron fittings or aluminum tubing should not be used for the main gas circuit. Joint
compounds (pipe dope) should be used sparingly on male threads only and be approved for all gases.
 The following pipe sizes should be used between the meter and the machine:
Natural Gas Distance from Meter Pipe Size
0 - 50’ 1-1/2” 1 PS
50’ - 100’ 2” 1 PS
100’ - 200’ 2-1/2” 1 PS
Liquid Propane Distance from Meter Pipe Size
0 - 50’ 1” 1 PS
50’ - 100’ 1-1/2” 1 PS
100’ - 200’ 1-3/4” 1 PS
 Venting: A vented draft diverter hood should be used with all indoor installations. Poor draft will cause the
machine to soot and not operate efficiently. Positioning of the machine should be in such a manner so that the
stack is as straight as possible and have suffecient height to eliminate downdraft.
Installation Instructions
Natural Gas & LP Installation Checklist Checked
 Has gas supply been inspected by an authorized
contractor and meets all local codes? _____
 Is machine protected from downdraft and excessive wind? _____
 Is machine shielded from moisture of water spray? _____
 Is voltage correct and circuit breaker adequate according
to specifications and serial plate notations? _____
 Is the machine electrically grounded? _____
 Have all flammable liquids or gases been removed
from location? _____
 Is there adequate gas supply for BTU rating of the burner? _____
 Is incoming gas supply pressure between 6” and 14” water column? _____
 Has the proper gas regulator been installed with proper
pressure and volume? _____
 Is machine properly vented allowing adequate air flow? _____
 Are the propane tanks large enough to prevent freezing? _____
 Have gas lines been checked for gas leaks? _____

OperatOr’sManual
RAMTEQ®14275 NORTHWEST FREEWAY HOUSTON, TX 77040 PHONE: [phone] FAX: [phone] 300-00010-03 8/05
page 5
STARTING THE MACHINE
Following the steps below will insure successful operation:
Read this manual completely before attempting to start the machine.
Check that the Motor/Burner switches are in the "OFF" position
Check the pump oil level and fill with SAE 30w non-detergent oil if needed.
Connect water hose to pump (or float tank if equipped). Turn on water source.
Connect the power cord to a properly grounded power source.
 Turn the manual gas valve to “ON” position. Adjust incoming gas to 12” wc minimum for LP unit, 5” wc minimum for NG
(maximum14”wc or 1/2psi). The correct operating manifold pressure for natural gas is 3.5” wc and 11” wc for propane.
Attach high pressure hose to base of spray gun.
Install water nozzle at the end of wand, making sure it is clear of any obstructions.
Turn pump switch to “ON”
Pull trigger on gun until a steady stream of water comes out the nozzle. This purges any air in the system.
Check for leaks in the system and cycle trigger gun to insure bypass is adjusted correctly. Repair any leaks and correct
unloader adjustment if needed. Turn off machine before attempting any repairs.
Turn burner switch to "ON". Check for buner ignition.
Adjust thermostat to desired temperature appropriate to the task. Maximum temperature setting may not be needed.
Insert detergent siphoning tube into a DOT approved container and open the metering valve for detergent application.
WASHING TECHNIQUES
Washing from bottom up increases dwell time of soap and lessens vertical streaks.
Turn soap metering valve “OFF” to purge system of soap
Rinsing with cold water from top down will retard detergent reaction which will enhance the rinsing performance.
Wash at 30 to 60 degree angles to prevent splashback.
STOPPING THE MACHINE
Turn burner switch to “OFF”. Allow water to discharge for a few minutes while cooling down.
Turn pump switch to "OFF".
Disconnect water source.
Pull gun trigger to release water pressure from system.
Disconnect wand & gun assembly.
Wind up pressure hose on hose reel.
MAINTENANCE PRECAUTIONS
 Do not permit acidic, caustic or abrasive fluids to be pumped through system.
Periodically clean detergent inlet screen. This will ensure proper flow of water to the pump.
High mineral content in water may adversely affect your machine and may require the use of a water softener
to ensure proper operation.
NEVER run the pump dry under any circumtances. Doing so will cause exteme damage to the pump.
Maintenance Instructions
Operating Instructions

OperatOr’sManual
RAMTEQ®14275 NORTHWEST FREEWAY HOUSTON, TX 77040 PHONE: [phone] FAX: [phone] 300-00010-03 8/05
page 6
MOVING, STORAGE
Place machine in covered area when not in use to protect from elements.Protect machine from
freezing in cold temperatures by storing in a heated location.
WINTERIZING
 Non-float Tank Machines: To protect the machine from freezing temperatures while
storing or transporting, connect short length of garden hose (approximately 3 ft.) to
water inlet connection on machine. Remove the pressure nozzle from the wand and
insert the short garden hose end into a container of antifreeze. Place the wand into the
antifreeze container and start engine running machine until antifreeze appears from the
end of the wand. Turn engine “OFF” and replace pressure nozzle. Coil up hose and
move machine to storage area.
 Float Tank Machines: Pour antifreeze into float tank and remove water nozzle from end
of wand and carefully insert into opening of float tank. Start machine and run until
antifreeze water mixture has circulated throughout the machine returning back to the
float tank.
PUMP MAINTENANCE
Fill crankcase to dot on oil gauge window per specifications with the specific oil created by the pump
manufacturer (i.e. General Pump Oil). Ensure the right oil for specific pump as it may vary.
Change oil after 40 Hour Break-in Period.
Change oil every Three Months or at 500 Hour Intervals thereafter.
EXCHANGER COIL MAINTENANCE
  Hard water conditions may eventually cause clogging in the heat exchanger coil if left unattended.
Scale deposits will compromise the heating efficiency and produce an unsafe condition over time.
It may be necessary to descale coil.
 Scale buildup from certain detergents may eventually clog up the heat exchanger coil causing an
unsafe condition. Use only recommended detergents for better cleaning efficiency.
 Black carbon deposits that collect on the outside wall of the heat exchanger coil may be a result of
using a poor grade of fuel or improper burner operation. Heating fuel should be void of water and
sediments to eliminate the possibility of sooting and compromising the efficiency of the coil.
FAILURE TO MAINTAIN HEAT EXCHANGER COIL
MAY RESULT IN A STEAM EXPLOSION WHICH
MAY CAUSE SERIOUS INJURY OR DEATH.
�
WARNING
 All RAMTEQ machines have the unloader
correctly set at the the factory. Setting an
unloader is a difficult job without the proper
equipment and training. Should the need arise
to change the unloader settings, please contact
your local distributor.
UNLOADER ADJUSTMENT
CHANGING THE UNLOADER SETTINGS WITHOUT THE PROPER
EQUIPMENT AND TRAINING MAY RESULT IN NON-WARRANTY
DAMAGE TO THE PUMP.
�
WARNING
Sutner
Unloader
Pulsar
Unloader

OperatOr’sManual
RAMTEQ®14275 NORTHWEST FREEWAY HOUSTON, TX 77040 PHONE: [phone] FAX: [phone] 300-00010-03 8/05
page 7
Chassis Components
Part # Description Qty.
180-00300-01 Chassis, XV Series 1
180-00308-01 Handle, XV series (round tubing) 1
180-00030-01 Forklift Tine 4
175-00001-04 (LP version -not shown) Axle, SS, 5/8"x28.5" 2
567-00016-01 (LP version -not shown) Spacer, nylon 4
516-00001-01 (LP version -not shown) Bushing, Wheel Collar 4
170-00007-01 (LP version -not shown) Wheel ,Pneumatic, 12" 4
180-00292-01 Power Plate, XVNG Series 1
180-00298-01 XVNG Belt Guard 1
180-00318-01 XVNG Closeout Panel 1
155-00002-01 XV Coil 1
180-00015-02 XV Coil Shell, Stationary 1
180-00016-02 XV Coil Shell, Removable 1
180-00071-01 XV Coil Cap 1
191-00003-01 XV Coil Cap Insulation 1
180-00382-01 (LP version -not shown) LP Tank Carrier 1
200-00009-01 Motor, 5.0HP, 230/60/1, Baldor L1410T 1
584-00002-40 Pulley, Maska# 2MBL49 1
516-00002-23 Bushing, SP, split taper, Maska# L-1 1/8" 1
220-00093-01 Pump, Comet Model# FW4030S 1
584-00002-43 Pulley, Maska# 2MBL57 1
200-00009-01 Bushing, SP, split taper, Maska# L-1 1/8" 1
XVNG Belt Drive Pumps
General Pump TC1509S17, TC1809S17, TC91811S17 Triplex Pump
Ref.# Part # Description Qty
1a 220-00105-01 TC1509S17 Triplex Plunger Pump Complete (XV150, XV200) 1
1b 220-00106-01 TC1809S17 Triflex Plunger Pump Complete (XV200, XV300) 1
1c 220-00107-01 TC1811S17 Triplex Plunger Pump Complete (XV500) 1
2a 221-0000XX-X Manifold, Brass Head (TC1509S17 & TC1811S17) 1
2b 221-0000XX-X Manifold, Brass Head (TC1809S17) 1
Pump Repair Kits
221-00021-01 Check Valve Assembly Kit #123 (All TC Pumps) 1 kit
221-00003-01 Oil Seal Kit #83 (All TC Pumps) 1 kit
221-0000X-XX Seals, HP, 15mm Kit #196 (TC1509S17 & TC1811S17) 1 kit
221-0000X-XX Seals, HP, 18mm Kit #197 (TC1809S17) 1 kit
221-0000X-XX Rings, 15mm Kit #198 (TC1509S17 & TC1811S17) 1 kit
221-0000X-XX Rings, 18mm Kit #199 (TC1809S17) 1 kit
221-0000X-XX Seals, LP, 15mm Kit #200 (TC1509S17 & TC1811S17) 1 kit
221-0000X-XX Seals, LP, 18mm Kit #225 (TC1809S17) 1 kit
221-0000X-XX Packing, 15mm Kit #226 (TC1509S17 & TC1811S17) 1 kit
221-0000X-XX Packing, 18mm Kit #227 (TC1809S17) 1 kit
1
2

OperatOr’sManual
RAMTEQ®14275 NORTHWEST FREEWAY HOUSTON, TX 77040 PHONE: [phone] FAX: [phone] 300-00010-03 8/05
page 8
Dual Lance Wand
Down Stream injection
6
7
8
1
3
4
5
2
Hose, Wand & Gun
Ref.# Part # Description Qty
1 270-00002-01 Nozzle 4.0 0° 1/4" (XV150) 1
270-00001-01 Nozzle 3.5 0° 1/4" (XV200) 1
270-00006-01 Nozzle 6.0 0° 1/4" (XV200) 1
270-00003-01 Nozzle 4.5 0° 1/4" (XV300) 1
270-00004-01 Nozzle 5.0 0° 1/4" (XV500) 1
270-00002-02 Nozzle 4.0 15° 1/4" (XV150) 1
270-00001-02 Nozzle 3.5 15° 1/4" (XV200) 1
270-00006-02 Nozzle 6.0 15° 1/4" (XV200) 1
270-00003-02 Nozzle 4.5 15° 1/4" (XV300) 1
270-00004-02 Nozzle 5.0 15° 1/4" (XV500) 1
270-00002-03 Nozzle 4.0 25° 1/4" (XV150) 1
270-00001-03 Nozzle 3.5 25° 1/4" (XV200) 1
270-00006-03 Nozzle 6.0 25° 1/4" (XV200) 1
270-00003-03 Nozzle 4.5 25° 1/4" (XV300) 1
270-00004-03 Nozzle 5.0 25° 1/4" (XV500) 1
270-00002-04 Nozzle 4.0 40° 1/4" (XV150) 1
270-00001-04 Nozzle 3.5 40° 1/4" (XV200) 1
270-00006-04 Nozzle 6.0 40° 1/4" (XV200) 1
270-00003-04 Nozzle 4.5 40° 1/4" (XV300) 1
270-00004-04 Nozzle 5.0 40° 1/4" (XV500) 1
2 265-00001-01 36" Wand, Insulated 1
3 275-00001-01 ST1500 Trigger Gun 1
4 552-00004-03 3/8" Quick Connect Plug 1
5 284-00001-01 Hose 3/8" X 50' 3000 PSI Swivel Ends 1
6 554-00006-02 1/4” nptm Quick Connect Socket 1
7 270-00038-01 Nozzle (Low Pressure Soap) #40, 15° 1
8 265-00002-01 Dual Lance Wand 1
Ref.# Part # Description Qty
1 450-00001-01 Rocker Switch 2
2 571-00002-01 Hourmeter (optional) 1
3 305-00040-01 Label, Controls 1
4 573-00001-01 Thermostat Assembly 1
5 180-00289-01 XV Control Box (Not Shown) 1
2
4
3
1
Control Box Area

OperatOr’sManual
RAMTEQ®14275 NORTHWEST FREEWAY HOUSTON, TX 77040 PHONE: [phone] FAX: [phone] 300-00010-03 8/05
page 9

OperatOr’sManual
RAMTEQ®14275 NORTHWEST FREEWAY HOUSTON, TX 77040 PHONE: [phone] FAX: [phone] 300-00010-03 8/05
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