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ALKOTA 4142 Manual

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OLD VALUES. NEW IDEAS.
4142
P.O. Box 288 105 Broad Street
Alcester, SD 57001
800.255.6823 www.alkota.com

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  • Page 1 OLD VALUES. NEW IDEAS. 4142 P.O. Box 288 105 Broad Street Alcester, SD 57001 800.255.6823 www.alkota.com...
  • Page 3 MODEL 4142 PART NUMBER SPECIFICATIONS 4142-300000 4142-30020 PUMP & UNLOADER PERFORMANCE PUMP ................P/N N07-00016 DISCHARGE VOLUME........4.0 GPM / 15.1 LPM PUMP PULLEY..............R03-00774 PUMP HEAD PRESSURE........1400 PSI / 96.5 BAR PUMP PULLEY BUSHING..........R04-00001 TEMPERATURE RISE..150°F @ 4.0 GPM / 65°C @ 15.1 LPM PUMP TYPE....GENERAL CERMAIC PLUNGER, OIL BATH...
  • Page 4 MACHINE RECORD DATE OF PURCHASE PLACE OF PURCHASE SERIAL NUMBER MONTH/ DAY/ YEAR OPERATING HOURS MAINTENANCE PERFORMED NOTES Supersedes 8-25-04 Z08-04527 06-14-06 Z08-04527...
  • Page 5 OPERATION TABLE OF CONTENTS ELECTRIC DRIVEN OIL FIRED CLEANER SAFETY INSTRUCTIONS Page Number Fuel Filter Page Number • • Safety Symbols Maintenance See Parts List Section • General • Mechanical TROUBLESHOOTING • Electrical • • Machine 16, 17 Fuel • Water Heater INSTALLATION •...

  • Page 6: Machine Unpacking

    SAFETY, INSTALLATION, AND OPERATION ELECTRICAL DRIVEN OIL FIRED CLEANER GENERAL SAEFTY MACHINE UNPACKING 1. Before operating this machine, read and observe all ALL CLEANERS ARE CAREFULLY INSPECTED AND safety, unpacking, and operating instructions. CARTONED TO PROTECT AGAINST SHIPPING Failure to comply with these instructions could DAMAGE.

  • Page 7: Mechanical Safety

    14 . Always shut down machine before refueling. 18. Do not start the machine unless the gun assembly is firmly gripped by the machine operator. Failure to do this could result in injury from flying hose and WARNING: OPEN FLAME. Do not operate gun assembly.

  • Page 8: Fuel Safety

    2. WATER CONDITIONS: Local water conditions affect FUEL SAFETY the coil adversely more than any other element. In areas where troublesome conditions may exist with 1. Use only fuel #1 or #2 diesel. The use of incorrect fuel like equipment (such as water heaters), we may result in fire or explosion and severe injury to the recommend the use of a water softener.

  • Page 9: Specification

    11. THREE PHASE INSTALLATION: Three phase power 9. ELECTRICAL: Connect machine to an electrically must be connected so that the motor has clockwise grounded circuit that is fused or circuit breaker protected. The circuit must match that specified in rotation as you look at the shaft end of the motor. the ELECTRICAL section under MODEL SPECIFICATION.

  • Page 10: Pre-Start-Up

    B. Use a draft diverter of the inverted funnel or bell OPERATING type that meets all codes for capacity and INSTRUCTIONS materials. Mount the draft diverter directly to the stacking flange on the machine. PRE START-UP C. The draft diverter’s function is to insure that the barometric pressures are as close to the same as possible at the air inlet and outlet to the coil The first time the machine is operated, after repairs...
  • Page 11 CAUTION: A good flow of water must be flowing from the end of a gun for 30 seconds, before proceeding. Lack of water can cause damage to the water pump and like components. WARNING: RISK OF INJECTION OR Quick-Connect spray tips have fixed spray patterns that SEVERE INJURY.
  • Page 12 TO CLEAN: TO RINSE: A. Start on the lower portion of the area to be cleaned A. Close the chemical metering valve buy turning and work up using long, even, overlapping strokes. clockwise. If the gun assembly is equipped with a dual lance wand open the valve.
  • Page 13 COMBI OPTION PRESTART-UP OPERATING INSTRUCTIONS HIGH VOLUME COMBI ELECTRIC DRIVEN OIL/GAS FIRED 1. Set temperature control at 300°F / 150°C NOTE: In process of making steam, the water flow MAXIMUM. through the coil has to be decreased. The amount of water is determined by the pressure and water 2.
  • Page 14 A. Insert chemical screen into chemical container. 3. With a small common screw driver turn the screw on the metering valve (if so equipped) counter B. If your system is hot water turn the burner switch clockwise to DECREASE the INCREASE to the off postion.

  • Page 15: Machine Maintenance

    MACHINE MAINTENANCE Electric Driven Oil Fired Machine Above is a cross section view showing the progressive liming of coils. BELT TENSION COIL BACK PRESSURE CHECK INSTRUCTIONS 1. Check the condition of your water pump unloader DEFLECTION valve. Remove the hose and gun assembly from the coil outlet.
  • Page 16 ACCESSORIES CAUTION: On a machine equipped with a trigger gun valve, if the trigger gun valve remains in the closed position for more than 5 minutes, water pump PART NO. DESCRIPTION damage may occur. Y02-00001 ……..0-1000 PSI (69 BAR) Pressure Gauge STORAGE NOTE: All Gauges are Glycerin Filled ¼...

  • Page 17: Machine Maintenance Schedule

    MACHINE MAINTENANCE SCHEDULE Electric Driven Oil Fired Cleaners MOTOR DRIVEN OIL FIRED CLEANERS EACH HR AFTER FIRST EVERY EVERY EVERY DAILY 8 HRS 50 HRS 50HRS 100 HRS 500 HRS YEARLY OIL BATH WATER PUMP: Oil Level - check and add as needed per PUMP SERVICE insert.
  • Page 18 CLEANER TROUBLESHOOTING ELECTRIC MOTOR DRIVEN PRESSURE CLEANERS TROUBLE POSSIBLE CAUSE REMEDY A. Hard water. Poor cleaning A. Connect the machine to a water softener. B. Low pressure. action. B. See “Low operating pressure.” C. Little or no chemical being drawn. C.
  • Page 19 CLEANER TROUBLESHOOTING (CONT.) ELECTRIC MOTOR DRIVEN PRESSURE CLEANERS TROUBLE POSSIBLE CAUSE REMEDY A. Spray tip built up with lime. 6. Excessive back A. Remove and clean, or replace spray tip with tip specified pressure. in GENERAL section of MODEL SPECIFCATIONS. B.
  • Page 20 OIL WATER HEATER TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY 1. Machine will not rise to A. Low fuel pressure A. Fuel pressure should be at 125 PSI/8.6 BAR. operating temperature. B. Poor combustion B. See “Poor Combustion”. C. Fuel filter clogged C.

  • Page 29: Oil Level

    GENERAL PUMP MAINTENANCE OIL LEVEL 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.

  • Page 30: Plunger Installation

    GENERAL PUMP MAINTENANCE PLUNGER SERVICE PLUNGER INSTALLATION 1.Remove pump head per “HEAD REMOVAL”. 1. Install the copper flinger washer onto the cross head. 2.Remove any packings and retainers left on the plung- ers by pulling them straight off. 2. Slide the plunger onto the crosshead. 3.Examine each plunger, looking for a smooth surface 3.

  • Page 31: Head Installation

    GENERAL PUMP MAINTENANCE HEAD INSTALLATION 9. Install the restop 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 way 1. Prepare pump head per instructions in “PACKING down into the cavity.

  • Page 32: Pump Troubleshooting

    PUMP TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY A. Worn crankshaft seal Remove and replace 1. Oil leaking in the B. Bad bearing Remove and replace area of water pump crankshaft C. Grooved shaft C. Remove and replace D. Failure of retainer o-ring D.
  • Page 33 PUMP TROUBLESHOOTING CONT. TROUBLE POSSIBLE CAUSE REMEDY A. Dirty or worn check valves 11. Low Pressure Clean/Replace check valves B. Worn packing Remove and replace packing A. Dirty or worn check valves 12. Excessive vibration See “Dirty or worn check valves” A.
  • Page 34 PUMP MAINTENANCE RECORD OIL CHANGE MONTH / DAY / YEAR OPERATING HOURS OIL BRAND & TYPE NOTES MONTH / DAY / YEAR OPERATING HOURS TYPE OF SEVICE Supersedes 08-25-04 Z08-04527 06-13-06 Z08-03516...
  • Page 35 M10 X 1.5...
  • Page 38 BREAKDOWN, BURNER - OIL 115V 1PH 60HZ EXPLODED VIEW - P/N V00-17365-2 06-13-06 Z08-00061 Supersedes 04-92 Z08-00061...

  • Page 40: Fuel Pump Screen

    OIL BURNER MAITENANCE OIL FIRED CLEANERS DANFOSS PUMP AIR BAND AJUSTMENT Shut off fuel supply. Loosen the 2 screws with 7/64 allen wrench one NOTE: The air band adjustment on this burner has been turn. preset at the factory (elevation approximately 1400 feet). On equipment installed where elevation is substantially Turn cover counter clockwise and pull strainer and different, the air band(s) must be readjusted.

  • Page 41: Fuel Pressure Adjustment

    4. Spread electrode tips to 1/8-inch gap maintaining 3. Partially close the transformer. Check if the buss previous measurements. bars contact and are in alignment with transformer electrodes. 5. When the proper measurements are obtained, gently 4. Proper adjustment is obtained by gently bending tighten screws that hold electrode assembly in place.
  • Page 42 OIL FIRED BURNER TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY A. Electrodes out of alignment. A. See “ADJUSTING ELECTRODE ASSEMBLY” in BURNER MAINTENANCE 1. Burner will not ignite. SECTION. B. Electrodes insulator failure. B. Remove and replace if there are breaks, cracks, or spark trails. C.
  • Page 43 FILTER, TER, TER, TER, FUEL FUEL FUEL FUEL TER, FUEL P/N V04-00308 Vent Plug 3 1/4" Inlet Outlet 5 1/2" (6 1/2" Required For Element Removal) Drain Port ALL DIMENTIONS ARE IN INCHES UNLESS OTHERWISE SPECIFICA SPECIFICA SPECIFICA SPECIFICA SPECIFICATIONS TIONS TIONS TIONS...
  • Page 44 FILTER, TER, TER, TER, FUEL FUEL FUEL FUEL TER, FUEL BREAKDOWN - P/N V04-00308 MAINTEN MAINTEN MAINTENA A A A A CE PR CE PR CE PR CE PROCEDURES OCEDURES OCEDURES OCEDURES MAINTEN MAINTEN CE PR OCEDURES EXPL EXPL EXPL EXPL EXPLODED ODED...
  • Page 45 ES-00022 ES-00024 VACUUM SWITCH wht/blk SWITCH SWITCH BURNER BURNER MOTOR MOTOR 230 VAC 230 VAC wht/red wht/red IGNITION IGNITION TRANSFORMER TRANSFORMER 230 VAC 230 VAC wht/red wht/red PUMP PUMP MOTOR MOTOR 230 VAC 230 VAC ES-00025 VACUUM SWITCH wht/ SWITCH FUEL SOLENOID 230 VAC...

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