for full warranty information, contact your delivering ...valve, unloader p/n c07-04506 - 11/22/2017...

Service Man

ual

Service Man

ual

For full warranty information, contact your delivering distribu-tor or contact the manufacturer at [email protected]

20200304

p/n 418AX-SEF035(800) 421-4018www.hy-floequipment.com

Model Cougar

English to Metric Conversions1 gal/m = 3.7843 L/m

1 hp = .7457 kw100 psi = 6.8964 bar

1 ft = .3048 m1 in = 2.54 cm1 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.govADVERTENCIA: 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 atwarranty.alkota.com

_________________INSTALLATION DATE

______________________________________________________MAKE/MODEL SERIAL NUMBER

______________________________________________________SELLER / PHONE NUMBER

______________________________________________________ADDRESS CITY/STATE/ZIP

______________________________________________________

Table of ContentsSpecifications �� 1General Assembly �� 4Pump Assembly �� 5Unloader �� 6

Trouble Shooting �� 7Maintenance - Exploded View �� 8Parts List �� 9

Pump �� 10Specifications �� 10Pump Mainteance Record ��11Exploded View �� 12

Pump Maintenance �� 14Plunger Service, Removal, Installation �� 15Packing Service �� 16Head Installation - Torgue Sequence �� 17

Float Tank Assembly �� 18Float Valve �� 19

Control Panel Assembly �� 20 Valve, Metering �� 21

Electrical Schematic�� 22Pre-Cleaner Assembly �� 23Burner Assembly �� 24

Fuel Filter �� 25Burner Breakdown �� 26

Burner Maintenance �� 28Fuel Filter, Adjustment Air Band , Fuel Pressure �� 28Blower Fan Replacement, Transformer Test, �� 29Bus Bar Alignment �� 29Burner Gun Removal & Replacement, Accessories, �� 30 Elctrode Adjustment �� 30

Trouble Shooting �� 31Pump �� 31Burner �� 33Water Heater �� 35

Axle Location �� 37Warranty �� 38

Month/Day/Year Operating Hours Maintenance PerformedMachine Record

1Specifications

SpecificationsPERFORMANCEDischarge Volume 4.0 gal/m / 15.1 L/mPump Head Pressure 1800 psi / 124 barHeat Input 140˚F @ 4.0 gal/m / 60˚C @ 15.1 L/mTemperature Limit

210˚F / 99˚CCombustion Smoke/Bacharach Scale

#1 OR #2 SMOKECarbon Monoxide Allowed

0.01%Draft/Stack Installation

0.2” – 0.04” WC READING

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

10 psi / 0.68 barStack Size

8” OD / 203.2 mm ODFuel Tank Capacity

8 gal / 30 LSpray Tip

Red (#5 - 0˚) p/n JA0-00050-2Yellow (#5 - 15˚) p/n JA0-15050-2Green (#5 - 25˚) p/n JA0-25050-2White (#5 - 40˚) p/n JA0-40050-2

Beltp/n R02-00228

Coil Coil 14” OD x 1/2”ID x 126’ Schedule 40

Coil Back Pressure (New)5 psi / 0.34 bar

Coil Back Pressure Requiring Descaling

50 psi / 3.40 bar

2 Specifications

ELECTRICALMachine Voltage 230v 60hz 1PHCurrent 22 ATemp Control – Hi-Limit

p/n F04-00867

Burner Part Number Without Solenoid V00-17367-2Burner Part Number With Solenoid V00-17365-2 Burner Type Pressure AtomizingFuel Type Kerosene, #1 or #2 DieselFuel Pressure 125 PSI / 9 BARFuel Pump Part Number V00-14283Motor Voltage 230V 60 Hz 1PHMotor Horsepower 1/7 HPMotor Speed 3450 RPM

Pump MotorMotor P/N F02-00262Motor Horsepower 5.0HP / 3.7 KWMotor Speed 3450 RPMMotor Voltage 208v / 230v 60 Hz 1PHAmp Draw 22 AmpsShaft Size 7/8”

Burner Nozzle 2.25 Gallon per Hour 80 Degree B p/n V2.25 90DB Fuel Pressure 125 PsiFuel Consumption 2.52 Gal/Hr / 9.5 L/HrHeat Input 352,800 Btu/Hr / 88,905 Kcl/Hr

4 General Assembly

General Assembly4 29

28

5

26

1

27

6

2

15

12

9

18

11

30

14

8

7

13

3

ASSEMBLY, GENERAL418AX-SEF035

03/04/2020

ITEM NO. PART NUMBER PART DESCRIPTION Complete/QTY.1 2122-00210 ASSEMBLY, COIL TOP 12 216AX-00125-P TANK, FUEL - PLASTIC 13 216AX-00150-P SHIELD, PULLEY - PLASTIC 14 216AX-00164F HANGER, GUN 15 418AX-00501I ASSEMBLY, PUMP 16 418AX-01121 ASSEMBLY, TANK - FLOAT 17 324AX-00302 ASSEMBLY, CONTROL PANEL 18 418AXX-0X657 ASSEMBLY, PRE-CLEANER 19 AS14-00616-NPB BRACKET, BRAKE 1

10 C03-00509-30 VALVE, RELIEF 111 D430M-10176R HANDLE, BRAKE 112 F04-00453 GROMMET, RUBBER 113 H04-19011 SCREW, SELF TAP 314 H04-25002 SCREW, CAP 815 H04-25006 SCREW, CAP 416 H04-31306 SCREW, CAP - 5/16 X 3/4 517 H06-25003 NUT, HEX 418 H06-25007 NUT, TINNERMAN - 1/4" 619 H06-31300 NUT, LOCK - 5/16" 820 H06-31309 NUT, LOCK 121 K23 HOSE, FUEL - 1/4 X 2.0' 222 K31-00900 HOSE, WATER 123 K60-01200 HOSE, WATER - 5/8 X 12" 124 R03-00830-1 PULLEY 125 W02-00031 CLAMP, HOSE 226 W02-00033 CLAMP, HOSE 727 W04-34155-A COUPLER, 3/8F X 1/2MNPT 128 Y01-00016 HOSE, PULSE 129 Z01-00014 CAP, VINYL 330 ZA1-00002 CAP, FILLER 1

5Pump Assembly

Pump Assembly

21

PANEL

11

3

16

13

24

8

7

19

20

18

17124

5

2

6

25

9

5

1014

FROM FLOAT TANK

FROM CONTROL

1

ASSEMBLY, PUMPPN: 420X-00501I

12/8/2017

ITEM NO. PART NUMBER PART DESCRIPTION QTY.

1 09-05325 SWIVEL, 3/8 -HYD 12 C03-00810 VALVE, AIR 1

3 C07-04506 VALVE UNLOADER 1

4 E04-00001-58 BUSHING, PIPE 15 E04-00005-48 BUSHING, PIPE 2

6 E07-00001-4 CROSS, PIPE 17 E08-00006-48 ELBOW, PIPE 1

8 E08-00010-5 ELBOW, PIPE 19 E10-00005-4 TEE, PIPE 1

10 E13-00010-2 NIPPLE, PIPE 111 E14-00010-68 NIPPLE, HEX - 3/8MNPT 112 E15-00010-48 NIPPLE, BRASS 1/2" 113 E15-00025-48 NIPPLE, BRASS 1/2" 1

14 F04-00761 SWITCH, VACCUM 115 K21-02214-1/4 ASSEMBLY, HOSE-OIL, DRAIN 116 K33-01300 HOSE, WATER - 3/8 X 13" 1

17 N07-00180 PUMP, WATER - 4PGM @ 2500PSI 118 N07-20046-P MOUNT, PUMP 1

19 R03-00674 PULLEY, V 120 R04-00001 BUSHING, PULLEY 1

21 W02-00032 CLAMP, HOSE 222 W02-10030-8 BARB, HOSE 1

23 W02-10031 BARB, HOSE 124 W02-10040-8 BARB, HOSE 125 W02-10057-8 BARB, HOSE 1

6 Unloader

Unloader

SpecificationsMaximum Flow 10.5 gal/m / 40L/m

Unloading Press

Rated 4050 psi / 280 bar

Max 4500 psi / 310 barMaximum Temperature 195˚F / 88˚C

Weight 1.54 lbs / 700 GBypass 3/8 FNPT

Inlet 3/8 FNPT

Discharge 3/8 MNPT

Valve, Unloader p/n C07-04506 - 11/22/2017

PULSAR4HPMGENERAL PUMP A member of the Interpump GroupTrapped Pressure Unloader Valve

DIMENSIONS

SELECTION This product is intended to be incorporated on a finished machine. This product is to be used with clean fresh water, for use involving different or corrosive liquids, contact the GP Customer Service Department. Appropriate filtration should be installed when using impure liquids. Choose the valveappropriate to the working data of the pump (permissible pressure, flow and rated temperature of the system). The pressure of the pump must notexceed the maximum pressure of the valve.

OPERATION The valve regulates the maximum pressure of the system by varying the flow discharged by the bypass. The adjustment is made by altering, by meansof a piston, the position of a sphere which partially closes the bypass opening. The valve is sensitive to water flow. At gun opening, the water flowsthrough the valve which maintains the system in pressure until the gun closes, the interruption of the flow provokes the complete aperture of thebypass which allows to discharge the flow at low pressure. At gun closure, the special mechanism of zero setting, which does not include a checkvalve, keeps in connection the delivery line and the bypass line, in that way permitting to lower the pressure all around the system and not only in thesource line of the valve.

SELECTION AND OPERATION

INSTALLATIONThis valve, on a system that produces hot water, must be fitted upstream from the source of heat. On a system that generates hot water, it is advisableto use accessories that limit the accidental increase of fluid temperature. Always install a safety valve. We recommend the use of a nozzle with flowrate which allows a regular discharge from the valve bypass of at least 5% of the flow supplied by the pump. In order to achieve a constant pressureand easy adjustment. If the nozzle wears out, the pressure decreases. To reset pressure back to working level, it is necessary to replace the worn nozzle. When a new nozzle is fitted, resetting of the system to its original working pressure is required.

DISCHARGE SYSTEM AND WATER ADDUCTIONThe bypass discharge can be sent back to the pump intake or returned into a tank; in such cases it is advisable that the tank be fitted with baffles toreduce eventual turbulence and air bubbles which could be harmful to the pump.

PRESSURE ADJUSTMENT/CALIBRATIONThe desired working pressure must be adjusted with the system running and the gun opened. Adjust the pressure by screwing or unscrewing theadjustment screw. The operation is easier if the correct nozzle has been chosen (see above). When screwing the adjustment screw a consequentpressure increase must be matched. If, before reaching the desired pressure, there is no pressure increase, DO NOT FORCE. Rather, check the correct ratio of nozzle/flow rate - pressure and, if necessary, replace with a smaller size nozzle.

ATTENTION: the nut in position 23 is a mechanical security device that limits the maximum pressure; it must absolutely NOT be removed.

Ref 300938 Rev. A11-13

7Unloader Vlalve

Trouble Shooting

16 Unloader

Trouble Shooting

Troubleshooting – C07-04506 – 11/22/2017Trouble Possible Cause Remedy

Frequent valve recycles Damaged check valve O-ring Remove and replace

Leaking connections Check or renew

Restricted bypass or too small diameter ofthe bypass hose

Clean or adapt passage diameter

Valve does not reachpressure Piston O-rings worn out Remove and replace

Debris between seat and shutter Clean the seat

Seat worn out Remove and replace

Nozzle worn out Remove and replace

Incorrect choice of nozzle Fit with smaller nozzle

High pressure peaks atgun closure

There is not a minimum of 5% of total flowdischarged in bypass

Reset Correctly

Excessive flow in bypass Change type of valve or adjust passages

Adjustment with spring totally compressed

Loosen adjustment screw and eventually fit with smaller nozzle

Valve does not dischargeat low pressure at gunclosure

Jammed check valve Clean or replace

Debris on check valve Clean

8 Unloader

Maintenance - Exploded ViewValve, Unloader p/n C07-04506 - 11/11/2017

Last updated 03/01/2013

60.0130.00 Pulsar 4 unload. 3/8F Bsp-15MPa60.0130.05 Pulsar 4 unload. 3/8F Npt-15MPa

60.0130.60 Pulsar 4 unload. 3/8F Bsp-31MPa60.0130.65 Pulsar 4 unload. 3/8F Npt -31MPa

Pos. P/N Description Q.ty K1K2K3K4 Pos. P/N Description Q.ty K1K2K3K41 60.0146.31 Piston holder, brass 1 52 10.3064.01 O-ring, 1,78x14 mm Ni 85 2 • 103 60.0145.51 Puls.4 piston, Sst. 1 54 10.4058.00 Back-up ring, opn. 14x16x2 mm 1 • 105 10.3058.01 O-ring, 1,78x10,82 mm 1 • 106 60.0141.35 Housing -Pulsar 4- 3/8 Bsp F brass (1,2) 1 16 60.0136.35 Housing -Pulsar 4- 3/8 Npt F brass (3,4) 1 17 60.0259.20 Seat, 8mm + O-ring, 1,78mm 1 • 109 14.7461.00 Ball, 13/32" Sst. 1 • 1010 60.0410.51 Spring, 1,6x11,5x20 mm Sst. 1 511 60.0142.31 Suction coupl., 3/8F Bsp brass (1,2) 1 1011 60.0137.31 Suction coupl., 3/8F Npt brass (3,4) 1 1012 14.4042.00 Washer, 16,7x22x1,5 mm alu. (1,2) 2 2513 60.0028.31 Plug,brass 3/8 Bsp,hex.19 (1,2) 2 2513 60.0025.31 Grub screw, brass 3/8M Npt (3,4) 2 10

14 10.4006.01 Back-up ring, opn. 6,2x9x1,2 mm 1 • 1015 10.3051.01 O-ring, 1,78x6,07 mm 1 • 1016 10.3213.00 O-ring, 3x6 mm 1 • 1017 60.0052.99 Shutter pin, brass+o-ring 3x6 mm 1 1018 60.0053.51 Spring, 0,7x9x20 mm Sst. 1 1019 10.3066.01 O-ring, 1,78x15,6 mm Ni 85 1 • 1020 60.1811.31 Shutter coupl., 3/8F Bsp brass (1,2) 1 320 60.1817.31 3/8Npt F nipple (3,4) 1 321 11.4574.00 Hex. nut, M8 2 1022 60.0011.31 Spring holder ring, brass 1 523 11.4576.31 Hex. nut, M8, brass 1 1024 60.0012.61 Spring, 5x25x50 mm white (1,3) 1 524 60.0033.61 Spring, 5,7x26x53 mm blue (2,4) 1 530 10.4409.00 Seal frame >Pulsar/zero ** 1 1

** On request

Kit P/N DescriptionK1 60.0131.24 Spares kit -Pulsar 4, 9(10)x1pcs. 1

(1) 60.0130.00 (2) 60.0130.60 (3) 60.0130.05 (4) 60.0130.65

UNLOADER PRESET AT FACTORY – DO NOT READJUSTUnloading Adjustment – Adjustment only after repair or replacement

1. Install an appropriate pressure gauge in pump head outlet. The gauge should have a range twice the operating pressure.

2. Install the spray nozzle in the end of the wand.3. Ensure the relief valve is set properly. 4. Loosen top lock nut (upper Item 21) and turn the nut (lower Item 21) counter

clockwise until minimum spring tension.5. With machine turned on, open the trigger gun, start the pump, and observe

pressure gauge reading. Slowly loosen the nut (lower Item 21) until pressure starts to drop on the gauge.

6. Tighten adjusting nut (lower Item 21) on the unloader. Pressure should start to increase. Tighten adjusting nut (lower Item 21) until pressure stops climbing.

7. Close and open the trigger gun to check unloading pressure and bypass function of the unloader valve. The unloading pressure should not exceed operating pressure more than 400 PSI.

8. Lock the setting by tightening the lock nut (upper Item 21).

9Unloader Vlalve

Parts ListValve, Unloader p/n C07-04506 - 11/22/2017

ATTENTION: the nut in position 21 is a mechanical security device that limits the maximum pressure; it must absolutely NOT be removed.

MAINTENANCE STANDARD: every 400 working hours, check and lubricate the seals with water resistant grease.

Item Part Number Description Qty Kit1 C07-04504-11 Guide, Piston 1 2 C07-04504-01 O-Ring 2 *3 C07-04504-09 Piston – SS 14 C07-04504-02 Ring, Back-Up 1 *5 N07-20028 O-Ring 1 *6 ------------------- Housing 17 C07-04500A-05 Kit Seat & O-Ring 1 *

7A C07-02300-08 O-Ring 1/16CS x 11/16OD 19 C07-04500-03 Ball, SS-13/32 1

10 C07-02700-06 Spring, 1.6x11x20MM 111 C07-04506-04 Coupling, Inlet 3/8 NPT SS 112 N16-28110084 Washer, Flat 213 C07-04504-05 Plug-3/8NPT 214 C07-04504-07 Ring, back-up 1 *15 P04-00215 O-Ring, 1.78 x 6.07mm 1 *16 C07-03200-20 O-Ring, 3 x 6mm 2 *17 C07-04500-15 Valve, Check 118 C07-01009A-18 Spring, Compression 119 C07-04504-16 O-Ring, 1/16cs x 5/8 1 *20 C07-04506-10 Fitting, Outlet – 3/8”M SS 121 C07-04504-14 Nut, Hex 222 C07-04504-13 Follower, Spring 123 C07-04504-15 Nut, Hex - Brass 124 C07-04500-13 Spring, Comp. Blue 1

C07-9904504 Kit, Repair - Parts Package *

10 Pump Breakdown

PumpSpecifications

TC Series “60”FEATURES

GENERAL PUMPA member of the Interpump GroupTR

IPLE

XTR

IPLE

X

• Compact design

• Oversized bearings for long life

• New generation seal system for longer life

• Forged brass manifold with an exclusive lifetime warranty*

Pump Model TC1509S17 TC1511S17 TC1809S17 TC1811S17 TC1507S34 TC1508S34Maximum Volume 1.75/2.1 GPM 2.1/2.6 GPM 2.5/3.1 GPM 3.25/3.9 GPM 3.0 GPM 3.3 GPMMaximum Discharge Pressure 2500 PSI 2500 PSI 2200 PSI 2200 PSI 2700 PSI 2500 PSIHorsepower 3.0/3.6 EBHP 3.6/4.4 EBHP 3.7/4.6 EBHP 4.9/5.8 EBHP 5.5 EBHP 5.65 EBHPMaximum Pump Speed 1450/1750 RPM 3400 RPMMaximum Inlet Pressure 125 PSIMinimum Inlet Pressure 3 Ft. Water / 2.6 in. Hg. FloodedPlunger Bore (in / mm) .591 in / 15 mm .709 in / 18 mm .591 in / 15 mmPlunger Stroke (in / mm) .370 in /9.4 mm .453 in /11.5 mm .370 in /9.4 mm .453 in / 11.5 mm .283 in / 7.2mm .315 in / 8 mmOil Capacity 11.8 ozMaximum Fluid Temperature 165ºFInlet Port Thread 1/2 - 14 BSP-FDischarge Port Thread 3/8 - 19 BSP-FShaft Diameter .945 in / 24 mmWeight 15.2 lbsDimensions 7.6 x 8.0 x 4.9 in

DIMENSIONAL DRAWING

SPECIFICATIONS

Triplex Plunger Pump, Solid Shaft

Pump Model N07-00180TX1813S17

Maximum Volume (GPM) 4.1 GPM / 15.2 LPM

Max. Discharge Pressure (PSI) 2500 PSI / 172 Bar

Maximum Pump Speed (RPM) 1750

Bore .591 in. / 15 mm

Maximum Inlet Pressure 125 PSI

Maximum Inlet Vacuum 3 ft. water (2.6 in. Hg)

Crankcase Oil Capacity 14 ounces. / 0.414 liter

Crankshaft Rotation Clockwise & Counterclockwise

Maximum Fluid Temperature 165˚F

Inlet Port Thread 1/2-14 BSPP-F

Discharge Port Thread 3/8-19 BSPP-F

Shaft Diameter .945 in. / 24 mm

Weight 19 lbs. / 8.6 grams

Dimensions 8.4 in. x 8.3 in. x 4.8 in.

Pump Specifications

p/n N07-00180

Oil Change

We recommend the first oil change after the first 50 hours, with the pump stopped and the oil still warm.This change is not recommended because the oil has lost its properties, but rather to eliminate the impurities that have gotten into the oil during the running-in phase. If these impurities are not removed, but are allowed to remain in the oil, they may cause premature wear to the moving parts and the oil seals. After this initial change, the oil can then be changed every three months or 300 hours of operation thereafter.Please note: If the pump works in conditions with high humidity and with sharp temperature changes, it is possible that condensation will appear inside the crankcase, which mixing with the oil can change its properties. This is easy to see because the oil changes to a white, milky color.If the pump does not have excessive water leaking from the packings, and the oil becomes milky, the oil has to be changed more frequently.The percentage of water in the oil must not exceed 20%.

Freezing Conditions / long Time Storage

1. Drain all of the water out of the pump.2. Run a 50% solution of a RV or non-toxic/biodegradable antifreeze through the pump.3. Flush the pump with fresh water before the next use.4. In freezing conditions failure to do this may cause internal pump damage.5. For long periods of storage in non-freezing areas the solution will keep the seals and O-rings lubricated.

Parts Packages – N07-00180Part No. Description Item QtyN07-99123 Valve Assemblies

Ass’y, check valve 36 6

O-Ring 36A 6

N07-99124 Valve Plugs

Plug 38 6

O-Ring 37 6

N07-99159 Crosshead Seals

Seal, Crosshead 45 3

N07-99161 Retainer & Seal

Seal, Water – 18mm 26 3

Packing, V – 18mm 28 3N07-99167 Packing, Adapter & Seal

Retainer, Seal–18mm 24 1O-Ring 25 1Seal, Water – 18mm 26 1Adapter – 18mm 27 1V-Packing – 18mm 28 1

N07-99165 Adapter, Female – 18 mm

Adapter, Front 27 3

N07-99163 Seal Retainer – 18 mm

Retainer, Seal 24 3

Pump Kits

11Pump Maintenance Records

Oil ChangeMonth/Day/Year Operating Hours Oil Brand & Type

Pump ServiceMonth/Day/Year Operating Hours Type of Service

Pump Mainteance Record

12 Pump Breakdown

Exploded ViewPu

mp

Expl

oded

Vie

w -

N07

-001

80

Part

s Lis

tIt

emp/

nD

escr

iptio

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emp/

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escr

iptio

n1

N07

-200

18Sc

rew,

Cap

24N

07-8

2083

Ret

aine

r, Se

al

2N

07-2

0019

Ret

aine

r, B

earin

g25

N07

-980

16O

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g

3N

07-4

0029

Cov

er, C

rank

shaf

t26

N07

-820

63Se

al, W

ater

– 1

5mm

4N

07-2

0021

O-R

ing

27N

07-9

9164

Ada

pter

, Fem

ale

– Fr

ont 1

5mm

5N

07-2

0022

Bea

ring,

Rol

ler

28N

07-8

2084

Pack

ing,

V –

Hig

h Pr

ess 1

5mm

6N

07-2

0024

Dip

stic

k, O

il29

N07

-200

49Pl

ug, P

ipe

7N

07-9

8023

Cra

nkca

se30

N07

-200

50Pl

ug, P

ipe

8N

07-9

8038

Cro

sshe

ad31

N07

-200

51W

ashe

r, Fl

at

9N

07-9

8034

Rod

, Con

nect

ing

32N

07-2

0011

Was

her,

Flat

10N

07-2

9026

O-R

ing

33N

07-9

4001

Hea

d, M

anif

old

15m

m

11N

07-9

8026

Cov

er, R

ear

34N

07-2

0003

Was

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Flat

12N

07-2

0027

Scre

w, C

ap35

N07

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02Sc

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, Cap

– 8

mm

x 6

5mm

13N

07-9

8029

Indi

cato

r, O

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vel

36N

07-9

9123

Kit,

Val

ve A

ssem

bly

14N

07-8

0009

O-R

ing

37N

07-2

0004

O-R

ing

15N

07-2

0030

Plug

, Pip

e37

AN

07-2

0009

O-R

ing

16N

07-2

0028

O-R

ing

38N

07-4

7010

Plug

, Pip

e

17N

07-9

8032

Pin,

Cro

sshe

ad39

N07

-120

56N

ut, H

ex

18N

07-1

7931

Cra

nksh

aft

40N

07-9

8085

Ada

pter

, Plu

nger

19N

07-9

8033

Key

41N

07-4

7040

Plun

ger –

15m

m

20N

07-9

8045

Seal

, Oil

42N

07-2

0039

Was

her,

Flin

ger –

Cop

per

21N

07-2

0046

Mou

nt, P

ump

43N

07-9

8028

O-R

ing

22N

07-2

0047

Was

her,

Lock

44F0

4-76

509

Rin

g, A

nti-E

xtru

sion

23N

07-2

0048

Scre

w, C

ap45

N07

-991

59K

it, C

ross

head

N07

-001

79

13Pump Breakdown

Item

Part

No.

Des

crip

tion

1N

07-2

0018

Scr

ew, C

ap

2N

07-2

0019

Ret

aine

r, B

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g

3N

07-4

0029

Cov

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rank

shaf

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4N

07-2

0021

O-R

ing

5N

07-2

0022

Bea

ring,

Rol

ler

6N

07-2

0024

Dip

stic

k, O

il

7N

07-9

8023

Cra

nkca

se

8N

07-9

8038

Cro

sshe

ad

9N

07-9

8034

Rod

, Con

nect

ing

10N

07-2

9026

O-R

ing

11N

07-9

8026

Cov

er, R

ear

12N

07-2

0027

Scr

ew, C

ap

13N

07-9

8029

Indi

cato

r, O

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vel

14N

07-8

0009

O-R

ing

15N

07-2

0030

Plu

g, P

ipe

16N

07-2

0028

O-R

ing

17N

07-9

8032

Pin

, Cro

sshe

ad

17N

07-1

7931

Cra

nksh

aft

18N

07-9

8033

Key

19N

07-9

8045

Sea

l, O

il

20N

07-9

8026

Cov

er, R

ear

21N

07-2

0046

Mou

nt, P

ump

22N

07-2

0047

Was

her,

Lock

Item

Part

No.

Des

crip

tion

23N

07-2

0048

Scr

ew, C

ap

24N

07-9

8083

Ret

aine

r, S

eal

- 18m

m

25N

07-9

8016

O-R

ing

26N

07-9

8030

Sea

l, Lo

w P

ress

N07

-001

80 1

8mm

27N

07-9

9163

Ada

pter

, Fem

ale

– Fr

ont 1

8mm

28N

07-9

8084

Pac

king

, V –

Hig

h P

ress

18m

m

29N

07-2

0049

Plu

g, P

ipe

30N

07-2

0050

Plu

g, P

ipe

31N

07-2

0051

Was

her,

Flat

32N

07-2

0011

Was

her,

Flat

33N

07-9

8001

Hea

d, P

ump

– N

07-0

0180

18

mm

34N

07-2

0003

Was

her,

Flat

35N

07-9

8002

Scr

ew, C

ap –

8m

m x

65m

m

36N

07-9

9123

Kit,

Val

ve A

ssem

bly

36A

N07

-200

04O

-Rin

g

37N

07-2

0009

O-R

ing

38N

07-4

7010

Plu

g, P

ipe

39N

07-1

2056

Nut

, Hex

40N

07-9

8085

Ada

pter

, Plu

nger

41N

07-4

4040

Plu

nger

– 1

8mm

42N

07-9

8028

O-R

ing

43F0

4-76

509

Rin

g, A

nti-E

xtru

sion

44N

07-2

0039

Was

her,

Flin

ger –

Cop

per

45N

07-9

9159

Kit,

Cro

sshe

ad S

eals

Torq

ueVa

lve

Plu

g (3

8)73

.7 ft

lbs

/ 100

kg

M

Mou

nt to

Cra

nkca

se (2

3)14

.7 ft

lbs

/ 2.0

kg

M

Rea

r Cra

nkca

se C

over

to C

rank

case

(12)

7.3

ft lb

s / 1

0 kg

M

Bea

ring

Ret

aine

rto

Cra

nkca

se (1

)7.

3 ft

lbs

/ 10

kg M

Rea

r Cra

nkca

se C

over

to P

lug

(15)

14.7

ft lb

s / 2

.0 k

g M

Nut

to C

ross

head

(39)

11.0

ft lb

s / 1

5.0

kg M

Plu

g to

Pum

p H

ead

(29,

30)

29.4

ft lb

s / 4

0 kg

M

*Hea

d to

Cra

nkca

se (3

5)14

.7 ft

lbs

/ 2.0

kg

M*N

ote:

Whe

n pl

unge

r nut

is re

mov

ed, i

nsta

ll a

new

cop

per w

ashe

r and

fl

inge

r was

her t

o en

sure

pro

per fi

t and

sea

l of c

eram

ic p

lung

er.

Eac

h tim

e th

e pl

unge

r scr

ew is

torq

ued,

cop

per w

ashe

rs fo

rm to

plu

nger

.If

sam

e co

pper

was

hers

are

reus

ed c

rack

ing

or a

poo

r sea

l may

resu

lt.

Pum

p Pa

rts L

ist

PAR

TS P

AC

KA

GES

Part

No.

D

escr

iptio

n Ite

m

QTY

N07

-990

01

Valv

e A

ssem

blie

s

A

ss’y

, che

ck v

alve

39

6

O

-Rin

g 39

A 6

N07

-990

02

Oil

Seal

s

O

il S

eals

47

3

N07

-990

03

Cra

nksh

aft S

eal

S

eal,

Cra

nksh

aft

12

2

N07

-990

04F

Kit,

Plu

gs &

O-R

ing

P

lug,

Pip

e 41

6

O

-ring

40

6

N07

-990

06

Kit,

Plu

nger

Scr

ew &

“O

-Rin

gs”

Scr

ew, P

lung

er

42

3

Was

her,

Flat

14

3

O-R

ing

43

3

Rin

g, A

nti-e

xtru

sion

44

3

Was

her,

Flat

46

3

N07

-990

07

Ada

pter

, Mal

e

Ada

pter

, Mal

e 44

6

N07

-990

10

Rea

r Ada

pter

s

A

dapt

er, F

emal

e 26

3

O

-Rin

g 25

3

N07

-990

28

Plun

ger P

acki

ng w

/ Ret

aine

r

NO

TE: O

rder

th

ree

for

com

plet

e pu

mp.

O-R

ing

25

1

Pac

king

, V-L

o P

ress

26

1

Ret

aine

r, P

acki

ng

27

1

Ada

pter

, Fem

ale

28

1

Rin

g, R

esto

p 29

1

Pac

king

, V-H

i Pre

ss

30

1

Ada

pter

, Mal

e 31

1

N07

-990

69

Ret

aine

r & O

-Rin

gs

P

acki

ng, V

-Hi P

ress

30

3

R

ing,

Res

top

29

3

P

acki

ng, V

-Lo

Pre

ss

27

3

N07

-990

71

Ada

pter

, Fro

nt

P

acki

ng, V

-Lo

Pre

ss

27

3

A

dapt

er, F

emal

e 26

3

AC

CES

SOR

IES

Oil

– C

ase

(6) O

ne P

int B

ottle

s p/

n N

07-O

ILC

A

Oil

– B

ottle

(1) O

ne P

int B

ottle

p/

n N

07-O

ILC

A-1

Kit N

07-O

IL C

A-1

Kit N

07-O

IL C

A

14 Pump Maintenance

22 Pump Maintenance

6

72

6

31

GeneralPACKING EXTRACTION KIT P/N Z09-00028COMPLETE TOOL KIT P/N Z09-00021

Valve Service1. 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, fingers, or hook shaped tool,

remove the valve assemblies from the head. Remove and discard the o-rings from the valve assemblies and/or head. Examine each valve assembly and discard damaged parts. Refer to the PUMP BREAKDOWN for part numbers of any replacement items.

4. Clean any accumulated debris from the valve cavities and flush with water.

5. Wash the valve assemblies in clean water and rinse. While still wet, test each valve assembly by sucking on the valve seat. A properly sealing valve will allow a good vacuum to be developed and maintained, while a malfunctioning valve will not. Good valve assemblies should be set aside for installation in step 7.

6. Malfunctioning valve assemblies must be replaced.7. Lubricate a new o-ring with the pump crankcase oil and install

into valve cavity in the head. Install a good valve assembly into the cavity as 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 specifications.11. Repeat steps 7 through 11 for remaining valve assemblies.

Head Removal1. 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 MaintenancePump Maintenance

15Pump Maintenance 2�Pump Maintenance

Plunger Service1. 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 RemovalNOTE: 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 flinger washer, clean with solvent and allow to dry.

Plunger Installation1. Install the copper flinger washer onto the cross head.2. Slide the plunger onto the crosshead.3. Lubricate an o-ring with crankcase oil and install into the groove on the plunger screw. Install the

anti-extrusion ring into the groove next to the o-ring. NOTE: The o-ring should be nearest the screw head and the anti-extrusion ring nearest the threads.

4. Apply a drop of thread sealant to the threads of the retainer screw.5. Thread the plunger retainer screw into the cross head making sure the copper flat washer is

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

specifications.

Plunger Service, Removal, Installation

16 Pump Maintenance24 Pump Maintenance

Packing Service1. 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 fit the female adapters into the head

checking for binding or damage. Discard and replace damaged items6. 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

flat 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 flat side up. Make certain the adapter goes

all the way down into the cavity.11. Install the low pressure packing with the flat 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 flat side up. Each adapter and o-ring

assembly should push into the head to approximately 1/16 inch of being flush 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 fit is obtained, proceed to step 16. If a proper fit 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

17Pump Maintenance

13Pump Maintenance

13

62

5

4

53

17

64

28

7

Head Installation1. Prepare pump head per instructions in PACKING SERVICE.2. Rotate the plungers so the outer plungers are projecting the same distance from the crankcase.3. Lubricate the exposed plungers with crankcase oil.4. Start the head onto the plungers and, using a soft mallet, tap the head evenly until it comes in

contact with the crankcase.5. Start the cap screws through the head and into the crankcase. Do not forget the lock washer on

each screw.6. Tighten all cap screws by hand.7. Torque the cap screws to the value indicated in the TORQUE section of PUMP SPECIFICATIONS.

Torque the cap screws in the order listed below.

Head Installation - Torgue Sequence

18 Float Tank Assembly

Float Tank Assembly


1 C03-00631 FLOAT VALVE 1

2 C05-00274 ADAPTER, GARDEN HOSE 1

3 E09-00002-P2 RESTRICTOR, PLUG - 9/32 ORIFICE 1

4 EM28-20200-L TANK, FLOAT 15 H05-62500 WASHER, FLAT 26 W02-10025-P BARB, HOSE 1

ASSEMBLY, TANK - FLOATp/n 418AX-01121

5

64

5

2

1

3

19Float Valve

Float Valve3

54

68

9

10

17

15

14

1

12

7

13

16

11

2

18

PARTS LIST

VALVE, FLOAT - P/N C03-00631

SPECIFICATIONS8/8/2008

ITEMNO. PART NUMBER PART DESCRIPTION QTY.

1 C03-00625-10 SCREW, WING - 10-32UNF 1

2 C03-00628 FLOAT, PLASTIC 1

3 C03-00631-01 NUT,HEX - 3/8FNPT 1

4 C03-00631-02 WASHER, FLAT - RUBBER 1

5 C03-00631-03 NIPPLE, BRASS - 3/8NPT 1

6 C03-00631-04 SEAT, VALVE-NYLON 1

7 C03-00631-05 HOUSING, VALVE 1

8 C03-00631-06 PISTON 1

9 C03-00631-07 ROD, PISTON-5/16CS X 1 1/4 PLASTIC 1

10 C03-00631-08 GUIDE, PISTON 1

11 C03-00631-10 SCREW, CAP 1

12 C03-00631-11 ARM, FLOAT 1

13 C03-00631-14 NUT, HEX - BRASS 1

14 C03-00631-16 LEVER - BRASS 1

15 C03-00631-17 KEY, COTTER 1

16 C03-00631-18 NIPPLE, TOE 1

17 C03-0631-09 NUT, RETAINER 1

18 H05-18700 WASHER, FLAT 1

MAXIMUM VOLUME.............................7 GPM / 26 LPMMAXIMUM PRESSURE........................140 PSI / 10 BARMAXIMUM TEMPERATURE ......................140 F/60 CPORT SIZE - INLET..........................................3/8" NPTDIMENSIONS...11.4 X 4.1 X 2.8 IN / 290 X 104 X 71MMWEIGHT...................................................0.6 LB / 0.3 KGHOUSING MATERIAL .........................................BRASSO-RING MATERIAL............................................BUNA-N

20 Control Panel Assembly

Control Panel Assembly

3

8

9

1

7

16

10

2

6 124

5

15

14

ASSEMBLY, CONTROL PANEL

ITEM NO. Part Number PART DESCRIPTION QTY.

1 216AX-00301-P PANEL, CONTROL - PLASTIC 12 216AX-00310-P BOX, CONTROL - PLASTIC 13 4120-00902P ASSEMBLY, CHEMICAL LINE 14 C03-00307 VALVE, METERING 15 D01-00060 DECAL, METERING VALVE 16 F04-00311 CONNECTOR, CONDUIT - 3/4" 0.68 - 0.80 27 F04-00411 BUSHING, STRAIN RELIEF 18 F04-00420 BUSHING, INSULATION 19 F04-00451 GROMMET, RUBBER 4

10 F04-00743A SWITCH, CAM - 32AMPS, 2 POLE 111 W02-00033 CLAMP, HOSE 212 W02-10019-8 BARB, HOSE 113 W02-10031 BARB, HOSE 114 Z01-00031 CAP, PLUG - 3/16" 215 Z01-00032 CAP, PLUG - 7/16" 116 Z01-00161 PLUG, DOMED 117 Z01-01713-2 HOSE, POLYBRAID 1

21Metering Valve

Valve, Metering

Electrical Schematic22

Electrical SchematicPART NUMBER

DA

TE:

PAR

T N

UM

BER

TITL

E / D

ESC

RIP

TIO

N

DR

AW

N B

Y:R

EDB

LAC

KW

HIT

E

BR

OW

N

YELL

OW

BLU

E

GR

EEN

PIN

KO

RA

NG

E

ELEC

TRIC

AL

SCH

EMA

TIC

ES-0

0026

ES-00026

CA

MS

WIT

CH

BW

K

E Q U I P M E N T

G R O U N D

L I N E 1

L I N E 2

VAC

UU

MS

WIT

CH

TEM

PC

ON

TRO

L

IGN

ITIO

NTR

AN

SFO

RM

ER

230

VA

C

BU

RN

ER

MO

TOR

230

VA

C

230

VA

C

06-0

7-03

GR

N

RE

DBL

K

BLK

WH

T / R

ED

WH

T/BL

KBL

KBL

KBL

K

BLK

BLK

BLK

WH

T

BLK

WH

T/R

ED

PUM

PM

OTO

R23

0 V

AC

567 8

123 4

23Pre-Cleaner Assembly

Pre-Cleaner Assembly

ASSEMBLY, PRE-CLEANERp/n 418AX-0X657

3/04/2020 S/N 271645 & UP

ITEM NO. PART NUMBER PART DESCRIPTION Default/QTY.1 216AX-00130AL SIDE, FRAME (LEFT) 22" X 33" 12 216AX00130ARZ SIDE, FRAME (RIGHT) 22" X 33" PODWER COAT 13 216AX-00134B MOUNT, PUMP & MOTOR 14 216AX-00164F HANGER, GUN 15 216AX-00179F HANDLE, FRAME 16 216AX-00193A WELDMENT, MOUNT - TANK 17 420XX-00401B ASSEMBLY, BURNER 18 3242-00206 COIL, PIPE 19 AR34-02600 AXLE, ROD-CRS 3/4" X 26 1/2" 2

10 E10-00021-58 TEE, STREE - 3/8 111 F02-00262 MOTOR, ELEC 5 HP 112 G02-10016C ASS'Y, TIRE & RIM - 13", 3/4" AXLE 413 H04-25002 SCREW, CAP 614 H04-31306 SCREW, CAP - 5/16 X 3/4 1015 H04-31331 SCREW, CAP 416 H05-31300 WASHER, FLAT - 5/16 817 H06-25006 NUT, TINNERMAN - 5/16 1018 H06-25007 NUT, TINNERMAN - 1/4" 619 H06-31300 NUT, LOCK - 5/16" 420 H06-37500 NUT,LOCK-3/8-16UNC HEX 321 H06-75002 COLLAR, SHAFT - 3/4" 422 Z01-00048 CAP, VINYL - ROUND 4


1 90-00119 INSULATION - 1 x 14DIA 1

5 E08-00012-1 ELBOW, REDUCING 1

6 E08-00016-5 ELBOW, FORGED 1

7 E15-00035-2 NIPPLE, PIPE - GS 1

8 E15-00045-2 NIPPLE, PIPE - GS 1

9 Z01-05043 INSULATION, CERAMIC FIBER 2

19

15

16

83

1104

1713

18 7

20

69

2122

1411

12

5

WELDMENT, COILp/n 3242-00206

7

DETAIL ACOIL OUTLET

6

6 A

2

4

9

1

7 9

B

DETAIL BCOIL INLET8

5

24 Burner Assembly

Burner Assembly

8

63

2

7

1

45

ASSEMBLY, BURNER

ITEM NO. Part Number PART DESCRIPTION

DefaultQTY.

1 AS16-01204-PB BRACKET, TRANSFORMER 1

2 E08-00006-2 ELBOW, PIPE 1

3 E13-00010-2 NIPPLE, PIPE - 1/4" 1

4 H04-19011 SCREW, SELF TAP 2

5 V00-17365-2 BURNER, OIL - 230V 1

6 V04-00311 FILTER , FUEL 1

7 W02-10019-8 BARB, HOSE 1

8 W02-10031 BARB, HOSE 1

21Burner Maintenance

Maintenance Procedures

Priming the machineShut off the fuel tank valves. Spin off the clear bowl, fill 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 waterCheck 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 frequencyFrequency 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 filter element as one tank full of contaminated fuel will plug the fuel filter element prematurely.

Element replacement procedure1. Shut off the fuel tank valves.2. Unscrew the clear bowl turning counter-clockwise.3. Remove and discard the filter element.4. Follow listed procedures under “PRIMING.”

2

3

1

4

FILTER, FUEL - 1/4F X 1/4Fp/n: V04-00314

2/26/2010ITEMNO. PART NUMBER PART DESCRIPTION QTY.

1 V04-00314-1 HOUSING, UPPER-1/4F X 1/4F ALUMINUM 1

2 V04-00314-2 O-RING, 1

3 V04-00314-3 SCREEN,FILTER-SS ELEMENT 1

4 V04-00314-4 BOWL, FILTER-CLEAR PLASTIC 1

Trouble Possible Cause Remedy1. Fuel bowl leaking. A. Deteriorated gasket.

B. Housing Cracked.C. Bowl rim cracked, nicked, or scratched.D. Gasket missing.E. Loose Fuel 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.

2. Air leaking into system (indicated by air bubbles in bowl during operation).

A. Cracked Component.

B. Loose Filter bowl.

A. Inspect Filter Bowl, Filter Housing, and Gasket.B. Tighten Fuel Bowl Onto Fuel Filter.

23Oil Burner Maintenance

Z01-00095

Burner Gun Removal & Installation1. Disconnect the fuel line from the burner gun assembly oil line fitting. Loosen the other end of the

line and swing line out of the way.2. Remove the retaining nut.3. Loosen screw and swing transformer away from burner gun assembly.4. Carefully remove the burner gun assembly.

1) Check and replace electrode insulators if cracked.2) Clean burnt buss bars.3) Clean carbon off electrodes.4) Clean carbon off oil nozzle (use caution not to scratch face of nozzle or orifice).5) Check for a loose oil nozzle. Note: Check with dealer and/or replace nozzle with proper

nozzle.5. Gently replace burner gun assembly in air tube. CAUTION: Do not force. Forcing will cause

electrode misalignment.6. Reinstall the retaining nut.7. Reinstall the oil line making sure both ends are tight.8. Partially close transformer. Check if buss bars align and contact the transformer electrodes. If

buss bars do not contact, see Buss bar Alignment.9. Close transformer, reposition retainer and tighten screw.

Accessories p/n Y01-00041 Gauge-0- 200 PSI p/n Z09-00004 Bacharach Smoke Tester p/n Y01-00090 Allen Wrench 1/8” #8 p/n z01-00092 Fuel Nozzle Changing Wrench

Electrode Assembly Adjustment1. Loosen screws holding electrode assemblies.2. Raise electrode tips 5/32” above surface plane or end of oil nozzle.3. Place each electrode tip 5/16” from center of spray nozzle hole, maintaining previous

measurement.4. Spread electrode tips to 1/8” gap maintaining previous measurements.5. When the proper measurements are obtained, gently tighten screws that hold electrode assembly

in place. CAUTION: Do not over tighten, as this will cause the electrode insulator to fail.

Fuel Filterp/n V0�-0031�

Trouble Shooting

25Fuel Filter

Fuel Filter

21Burner Maintenance

Maintenance Procedures

Priming the machineShut off the fuel tank valves. Spin off the clear bowl, fill 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 waterCheck 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 frequencyFrequency 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 filter element as one tank full of contaminated fuel will plug the fuel filter element prematurely.

Element replacement procedure1. Shut off the fuel tank valves.2. Unscrew the clear bowl turning counter-clockwise.3. Remove and discard the filter element.4. Follow listed procedures under “PRIMING.”

2

3

1

4

FILTER, FUEL - 1/4F X 1/4Fp/n: V04-00314

2/26/2010ITEMNO. PART NUMBER PART DESCRIPTION QTY.

1 V04-00314-1 HOUSING, UPPER-1/4F X 1/4F ALUMINUM 1

2 V04-00314-2 O-RING, 1

3 V04-00314-3 SCREEN,FILTER-SS ELEMENT 1

4 V04-00314-4 BOWL, FILTER-CLEAR PLASTIC 1

Trouble Possible Cause Remedy1. Fuel bowl leaking. A. Deteriorated gasket.

B. Housing Cracked.C. Bowl rim cracked, nicked, or scratched.D. Gasket missing.E. Loose Fuel 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.

2. Air leaking into system (indicated by air bubbles in bowl during operation).

A. Cracked Component.

B. Loose Filter bowl.

A. Inspect Filter Bowl, Filter Housing, and Gasket.B. Tighten Fuel Bowl Onto Fuel Filter.


Z01-00095











Fuel Filterp/n V0�-0031�

Trouble Shooting

26 Burner Breakdown

1�

Burner Breakdown

27Burner Specs

Item Part No. Description1 F04-00517 J-Box2 H04-19000 Screw, Thread Cutting3 H04-16401 Screw, Machine4 F04-00512 Cover, J-Box5 F04-00315 Nut, Hex6 H05-87500 Washer, Flat7 V00-13360 Screw, Thread Cutting8 V00-13038 Clip, Hold Down9 V00-13121 Strain Relief, Cord

10 V00-21153 Transformer, 230V11 V00-13045 Screw, Thread Cutting12 F04-00316 Nipple, Chase13 V00-13392 Cover, Slot14 V00-14296 Nut, Hex15 H04-31313 Screw, Cap16 V00-14452-1 Assembly, Oil Line

*16 V00-14451-1 Assembly, Oil Line17 V00-13494-1 Elbow, Flare18 V00-14283 Pump, Fuel

*19 F04-00978 Valve, Solenoid*19A V13-00653 Coil, Solenoid

20 V00-13279 Coupling, Shaft

21 V00-02668 Band, Air – Outer 1 ¾” x 6 ¾”22 V00-02669 Band, Air – Inner 13/4” x 6 ¾”23 V00-04725 Housing, Fan24 V-30540-07 Assembly, Burner Gun25 V00-14160 Cone, Air – #4A26 V00-12484 Gasket, Flange27 4120-00440 Weldment, Air Tube28 V00-12699 Screw, Thread Cutting29 H04-31302 Screw, Set30 V00-20289 Fan w/ Item 2931 V-24004-001 Motor, Electric

*Specific to p/n V00-173065-2 w/solenoid

Item Part No. Description1 V-100772-001 Assembly, Electrode – RH

*1A --- Stem, Electrode – RH1B V00-12574 Insulator, Electrode1C V00-100004-1 Bar, Buss – Straight1D V00-13110 Nut, Pal

2 V00-12408 Bushing, Insulator3 V00-12694 Screw, machine4 H04-19002 Screw, Set5 V00-12695 Screw, Machine6 V-21410-002 Assembly, Oil Pipe

Burner Breakdown Parts Listp/n V00-173��-2, V00-173�7-2

Burner Gun Breakdown Parts Listp/n V00-30��0-07

7 V-100773-001 Assembly, Electrode – LH*7A --- Stem, Electrode – LH7B V00-12574 Insulator, Electrode7C V00-100004-1 Bar, Buss – Straight7D V00-13110 Nut, Pal

8 V00-13409 Plate, Baffle – 2 ½”9 V00-14310 Support, Electrode

10 V00-14442 Spring, Electrode Support11 V00-13411 Screw, Thread Cutting12 V00-12362 Adapter, Nozzle13 V1.10 80DA Nozzle. Burner

1�

28 Burner Maintenance


PART NUMBERV00-14283-2

PART NUMBERV00-14283-5

Oil Burner MaintenanceOil Fired Cleaners

Air Band AdjustmentNote: The air band adjustment on this burner has been preset at the factor (elevation approximately 1400

feet). On equipment installed where elevation is substantially different, the air band(s) must be readjusted.1. Loosen the cap screw retaining the air bands.2. Move the air bands as indicated below with the machine in operation. Note: The air band should

be set so the exhaust gives the smoke spot specified in the GENERAL section of the MACHINE SPECIFICATIONS on a Shell-Bacharach scale. If a smoke tester is not available, a smoky exhaust, oily odor, or sweet smell indicates insufficient air while eye-burning fumes indicate too much air.

3. Tighten the cap screw retaining the air bands.

Fuel Pump FilterSuntec Pump

1. Shut off fuel supply.2. Loosen the 4 screws holding the cover to the fuel pump housing.3. Take cover and cover gasket off and pull strainer off of pump housing.4. Clean out any dirt remaining in the bottom of strainer cover. If there is evidence of rust inside of

the unit, be sure to remove water in supply tank and fuel filter.5. Turn on fuel supply. Failure to do so will result in fuel pump damage.

Fuel Pump Pressure Adjustment1. Install a 0-200 PSI Pressure Gauge.2. Remove Plug on top of the fuel pump.3. Insert a 1/8” Allen Wrench and turn clockwise to increase pressure and counter clockwise to

decrease.4. Remove Gauge and reinstall plug.

Fuel Filter, Adjustment Air Band , Fuel PressureBurner Maintenance

29Burner Maintenance22 Oil Burner Maintenance

Blower Fan Replacement1. Shut off power to the burner and disconnect wires.2. Loosen the two screws securing blower motor and fan to the housing.3. Remove the blower.4. Install the blower onto the shaft and place .030 feller gauge on the motor as shown, sliding blower

until it contacts feeler the gauge. Rotate wheel until set screw is centered on the flat of the motor shaft. Tighten set screws onto motor shaft.

5. Reinstall motor and blower assembly.6. Reconnect wires and turn on power.

Transformer Test1. Remove burner junction box cover.2. Turn on burner and make sure ignition transformer is receiving rated voltage.3. Turn off burner.4. Loosen screw and swing transformer away from burner gun assembly.5. Turn on burner.6. Short the high voltage terminals. 7. Open gap by drawing screwdriver away from one electrode while touching the other.8. The spark should jump between 5/8 inches and ¾ inches, if it doesn’t jump, replace the

transformer.9. Turn burner off.10. Partially close transformer. Check if buss bars align and contact transformer electrodes. If buss

bars do not contact, see Buss Bar Alignment.11. Close transformer, reposition retainer clip and tighten screw.

WARNING

Use screwdriver with a well insulated

handle to avoid shock.

Buss Bar Alignment1. With burner off, loosen screw and swing the transformer away from burner gun assembly.2. Inspect the buss bars and transformer electrodes for pitting or corrosion.3. Partially close the transformer. Check if the buss bars contact and are in alignment with

transformer electrodes.4. Proper adjustment is obtained by gently bending the buss bars until they spring against, parallel,

and are in full contact with the transformer electrodes.5. With buss bars aligned, carefully close and fasten the transformer.

Blower Fan Replacement, Transformer Test, Bus Bar Alignment

30 Burner Maintenance

2�Oil Burner Maintenance

Z01-000��











Burner Gun Removal & Replacement, Accessories, Elctrode Adjustment

31Trouble Shooting

Trouble Possible Cause RemedyOil leaking in the area of water pump crankshaft

Worn crankshaft seal, bad bearing, grooved shaft, or failure of retainer o-ring.

Remove and replace.

Excessive play on crankshaft

Defective bearings. See “Worn bearing.”

Excess shims. Set up crankshaft.

Loud knocking in pump Loose connecting rod screws. Tighten connecting rod screws per PUMP SPECIFICATIONS

Worn connecting rod. Replace connecting rod per PUMP MAINTENANCE.Worn bearings. Replace bearings per PUMP MAINTENANCE.Loose plunger bushing screw. Tighten plunger screw per PUMP SPECIFICATIONS.

Oil leaking at the rear portion of the pump

Damaged or improperly installed oil gauge window gasket or rear cover.

Replace gasket or o-ring.

Oil gauge loosed. Tighten oil gauge.Rear cover screws loose. Tighten rear screws to torque values in PUMP

SPECIFICATIONS.Pump overfilled with oil, displaced through crankcase breather hole in oil cap/dipstick.

Drain oil. Refill to recommended oil level as stated in OIL LEVEL in PUMP MAINTENANCE.

Water in crankcase May be caused by humid air condensing into water inside.

Maintain or step up lubrication schedule.

Worn or damaged plunger screw o-ring.

Remove and replace. See PLUNGER SERVICE in PUMP MAINTENANCE.

Worn bearing Excessive belt tension. See BELT TENSION in MACHINE MAINTENANCE.Oil contamination. Check oil type and change intervals per PUMP

SPECIFICATIONS.

Short bearing life Excessive belt tension. See BELT TENSION in MACHINE MAINTENANCE.Misalignment between pump and motor.

Re-align pump and motor.

Oil has not been changed on regular basis.

Check oil type and change intervals per PUMP SPECIFICATIONS.

Short seal life Damaged plunger bushing. Replace plunger bushing.Worn connecting rod. Replace connecting rod.Excess pressure beyond the pump’s maximum rating.

Match pressure stated in PUMP SPECIFICATIONS.

High water temperature. Lower water temperature stated in PUMP SPECIFICATIONS.

Trouble ShootingPump

32 Trouble Shooting

Dirty or worn check valves

Normal wear. Remove and replace.

Debris. Check for lack of water inlet screens.

Presence of metal particles during oil change

Failure of internal component. Remove and disassemble to find probable cause.

New pump. New pumps have machine fillings and debris and should be drained and refilled per PUMP SPECIFICATIONS.

Water leakage from under head

Worn packing. Install new packing.

Cracked/scored plunger. Remove and replace plunger.Failure of plunger retainer o-ring. Remove and replace plunger retainer o-ring.

Loud knocking noise in pump

Pulley loose on crankshaft. Check key and tighten set screw.

Defective bearing. Remove and replace bearing.Worn connecting rod, crankshaft, or crosshead.

Remove and replace.

Frequent or premature failure of the packing

Scored, damaged, or worn plunger. Remove and replace plungers.

Overpressure to inlet manifold. Reduce inlet pressure.Abrasive material in the fluid being pumped.

Install proper filtration on pump inlet pumping.

Excessive pressure and/or temperature of fluid being pumped.

Check pressures and fluid inlet temperature. Be sure they are within specified range.

Over pressure of pumps. Reduce pressure.Running pump dry. Do not run pump without water.

Low Pressure Dirty or worn check valves. Clean/replace check valves.Worn packing. Remove and replace packing.Belt slipping. See BELT TENSION in MACHINE MAINTENANCE.Improperly sized spray tip or nozzle.

See MACHINE SPECIFICATIOSN for specified spray tip or nozzle.

Inlet filter screen is clogged. Clean inlet filter screen.Pitted valves. See VALVE SERVICE in PUMP MAINTENANCE.

Erratic pressure; pump runs rough

Dirty or worn check valves. Clean/replace check valves.

Foreign particles in valve assemblies.High inlet water temperature. See temperature in PUMP SPECIFICATIONS.

Pump Trouble Shooting Continued

33Trouble Shooting

Excessive vibration Dirty or worn check valves See “Dirty or worn check valves.”

Scored plungers Abrasive material in fluid being pumped.

Install proper filtration on pump inlet plumbing.

Fitted plungers Cavitation. Decrease inlet water temperature and/or increase inlet water pressure.

Cavitation High inlet fluid temperature, low inlet pressure.

Lower inlet fluid temperature and raise inlet fluid pressure.

Trouble Possible Cause RemedyBurner will not ignite Electrodes out of alignment. See “ADJUSTING ELECTRODE ASSEMBLY” in

BURNER MAINTENANCE SECTION.Electrode insulator failure. Remove and replace if there are breaks, cracks,

or spark trails.Water flow switch not closing. Adjust, repair, or replace switch.Vacuum switch not closing. Adjust, repair, or replace switch.Temperature control switch not closing. Adjust or replace the TEMPERATURE CONTROL.Fuel solenoid valve not opening. Clean, repair, or replace solenoid.Weak transformer. Clean and check transformer terminals. Check

transformer for spark pre “TRANSFORMER TEST” in BURNER MAINTENANCE SECTION.

Faulty cad cell (if equipped). Clean and test cad cell, replace if required.Faulty primary control (if equipped). Replace primary control.Burner motor thermal protector locked out.

See “Burner motor thermal protector locked out.”

Wiring. All wire contacts are to be clean and tight. Wire should not be cracked or frayed.

Burner switch. Test switch operation. Remove and replace as necessary.

Pump pressure. See “Low fuel pressure.”Venting. A downdraft will cause delayed ignition. Soot

deposits on the coil and burner can interrupt air flow, and cause shorting of the electrodes. Clean as required.

Sooting. Soot deposits on the coil and burner can interrupt air flow, and cause shorting of the electrodes. Clean as required.

No fuel. See “No fuel.”

Burner

Pump Trouble Shooting Continued

34 Trouble Shooting

No fuel Clogged fuel filter. Remove and replace filter per FUEL FILTER SECTION.

Fuel leak. Repair as necessary.Kinked or collapsed fuel line. Remove and replace fuel line.Low fuel pressure. See “Low fuel pressure.”Faulty burner oil pump. Adjust pressure or replace.Air leak in intake lines. Tighten all fittings.Clogged burner nozzle. Remove and replace (do not clean).

Low fuel pressure Clogged fuel filter. See “No Fuel.”Clogged fuel pump filter screen. Remove pump cover and clean strainer using a

brush and clean fuel oil, diesel oil or kerosene.Fuel oil too viscous. Operate a lighter oil or in warmer area.Air leaks in intake lines. Tighten all fittings.Kinked or collapsed fuel line. Remove and replace.Burner shaft coupling slipping. Remove and replace.Fuel nozzle worn. Remove and replace with specified nozzle on

BURNER ASSEMBLY.Faulty oil pump. Remove and replace.

Pulsating pressure Partially clogged fuel pump strainer or filter.

Remove and replace strainer per FUEL PUMP FILTER in OIL BURNER MAINTENANCE section.

Air leaking around fuel pump cover. Check fuel pump cover screws for tightness and damaged gasket.

Unit smokes Improper fuel. Refuel with FUEL specified on MACHINE SPECIFICATIONS.

Air to burner insufficient. See AIR BAND ADJUSTMENT in OIL BURNER MAINTENANCE section.

Fuel nozzle interior loose. Replace nozzle.Water in fuel Inspect fuel filter for water presence.Gun out of alignment. Bend oil pipe to center burner nozzle.

Burner motor thermal protector kicked out

Low voltage. Voltage must match those specified in the BURNER section of MACHINE SPECIFICATIONS section.

Fuel too viscous. See “Low fuel pressure.”Fuel pump defective. Check that fuel pump turns freely.Motor defective. Call service technician or take motor to repair/

warranty station.

Burner Trouble Shooting Continued

35Trouble Shooting

Delayed ignition (rumbling, noise starts)

Dirty or damaged electrodes. Clean or replace.

Air adjustment open too far. Readjust per AIR BAND ADJUSTMENT in OIL BURNER MAINTENANCE section.

Poor fuel spray pattern. Remove and replace with fuel nozzle specified in BURNER ASSEMBLY.

Incorrect electrode setting. Readjust per ADJUSTING ELECTRODE ASSEMBLY in OIL BURNER MAINTENANCE section.

Weak transformer. See TRANSFORMER CHECK on OIL BURNER MAINTENANCE section.

Burner does not electrically come on

Burner motor reset button tripped. Reset if necessary. CAUTION: Do not keep hitting the “reset” button if you have oil pressure you are just filling the burner combustion chamber with oil and if ignited will cause an explosion.

High limit temp control reset tripped if so equipped.

Reset if necessary.

Trouble Possible Cause RemedyMachine will not rise to operating temperature

Low fuel pressure. See BURNER on MODEL SPECIFICATIOSN for specified pressure.

Water in fuel piping. Drain fuel tank and remove and replace filter per FUEL FILTER INSERT.

Fuel filter clogged. Remove and replace fuel filter element per FUEL FILTER INSERT.

Poor combustion. See “Poor combustion.”Improper fuel supply. Use fuel specified in BURNER section of

the MODEL SPECIFICATIONS.Temperature control inoperative (if equipped).

See TEMPERATURE CONTROL INSERT.

Machine overheats Insufficient water. See “Low operating pressure” on MACHINE TROUBLESHOOTING insert.

Temperature control inoperative. See TEMPERATURE CONTROL INSERT.Improper fuel supply. Use fuel specified in BURNER section of

the MODEL SPECIFICATIONS.

Dry steam (very little moisture, very hot steam)

Insufficient water. See “Low operating pressure” on MACHINE TROUBLESHOOTING insert.

Improper fuel supply. Use fuel specified in BURNER section of the MACHINE SPECIFICATIONS.

Improper fuel pressure. See BURNER on MODEL SPECIFICATIONS for specified pressure.

Water Heater

Burner Trouble Shooting Continued

36 Trouble Shooting

Machine smokes (sweet smelling exhaust)

Improper fuel supply. Use fuel specified in BURNER section of MODEL SPECIFICATIONS.

Insufficient combustion air. See AIR BAND ADJUSTMENT on OIL BURNER MAINTENANCE insert.

Leaking fuel system. Correct leakage problem.Clogged or improper burner nozzle. Remove (DO NOT CLEAN) and replace

nozzle per BURNER ASSEMBLY INSERT.Loose burner nozzle. See BURNER MAINTENANCE insert.

Machine fumes (exhaust burns eyes)

Too much combustion air. See BURNER TROUBLESHOOTING insert.

Improper fuel pressure. See FUEL on MODEL SPECIFICATIONS for specified pressure.

Excessive oil dripping from laydown coil condensate.

Loose nozzle. See BURNER TROUBLESHOOTING insert.

Fuel pressure too high. See FUEL PRESSURE ADJUSTMENT section on BURNER MAINTENANCE insert.

Burner nozzle defective. Remove and replace with appropriate nozzle found on the BURNER ASSEMBLY or BREAKDOWN insert.

Incorrect burner nozzle. Remove and replace with appropriate nozzle found on the BURNER ASSEMBLY or BREAKDOWN insert.

Poor combustion Low fuel pressure. See “Low fuel pressure” on BURNER TROUBLESHOOTING insert.

Improper fuel supply. See “Low fuel pressure” on BURNER TROUBLESHOOTING insert.

Insufficient combustion air. See AIR BAND ADJUSTMENT section on OIL BURNER MAINTENANCE.

Water Heater Trouble Shooting Continued

37Axle Location

Axle Location

38 Warranty

Warranty PolicyMachines are guaranteed to be free from defects in material or workmanship under normal use and service for period of one year after delivery from the factory. Any part (other than vendor items) that is determined to be warranty will be repaired or replaced at NO CHARGE provided the warranty registration form is filled out in its entirety and the part is sent back freight prepaid. Any replacement parts accepted as warranty will be returned to you freight prepaid.

Our heating coil will carry a seven-year prorated warranty credit. The manufacturer will repair or replace the coil without charge for five years after delivery date from the factory for any defect in the coil that was caused by workmanship or defective steel. After the five years have expired, the credit will be prorated as follows:

O – 5 years 100% Credit Allowed6 & 7 years 50% Credit AllowedAfter 7 years NO Credit Allowed

All parts supplied to us by other manufacturers will be subject to their guarantee and warranty. Generators, motors, and engines are required by vendors to be repaired or replaced by authorized warranty repair stations. The manufacturer will assist you in locating warranty stations around the country in cases where that is necessary. Select items carry a six-month warranty such as unloaders, triggers guns, etc.

The manufacturer, at its option, will repair or replace defective parts only, and does not allow for field labor charges for removal, installation, analysis, travel expense, or special freight expenses incurred for replacement parts.

Warranty does not apply to normal wear and tear including, but not limited to, freezing damage, freight damage, damage caused by misuse or misapplication, chemical related failures, contaminated filters and screens, moisture related fuel pump failures, stuck check valves, pump packings or seals, nozzles or orifices, paint, hoses, and gauges.

Warranty

Service Man

ual

Service Man

ual

For full warranty information, contact your delivering distribu-tor or contact the manufacturer at [email protected]

for full warranty information, contact your delivering ...valve, unloader p/n c07-04506 - 11/22/2017...

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