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ALKOTA 4405G Manual

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PERFORMANCE
DISCHARGE VOLUME........................................4.0 GPM / 15.1 LPM
PUMP HEAD PRESSURE....................................4000 PSI / 276 BAR
TEMPERATURE RISE............105°F @ 4.0 GPM / 41°C @ 15.1 LPM
COMBUSTION SMOKE/BACHARACH SCALE....#1 OR #2 SMOKE
CARBON MONOXIDE ALLOWED............................................ 0.01%
DRAFT/STACK INSTALLATION............. 0.2" - 0.04" WC READING
HEAT INPUT..............................345,800 BTU/HR / 87,141 KCAL/HR
GENERAL
MINIMUM INLET WATER PRESSURE..................40 PSI / 0.68 BAR
STACK SIZE.....................................................8" DIA / 203.2 MM DIA
WEIGHT (DRY) .......................................................340 LBS / 154 KG
HOSE, PUMP TO UNLOADER........................................K02-3228A2
HOSE, UNLOADER TO COIL..........................................K02-3238A2
SPRAY TIP...........................................(#5-15DEG) P/N J00-00040-2
HOSE, DISCHARGE..............................3/8" X 50' P/N K02-03150E1
WAND & TRIGGER GUN......................................... P/N J06-00158-B
BELT - ENGINE TO PUMP......................................... P/N R02-00246
COIL SIZE..............................................1/2"ID X 158' SCHEDULE 80
REPLACEMENT COIL ........................................... P/N 4305E-00206
COIL BACK PRESSURE (NEW)
.....................5 PSI @ 4.0 GPM / 0.34 BAR @ 15.1 LPM
COIL BACK PRESSURE REQUIRING DESCALING
........................... 50 PSI @ 4.0 GPM / 3.40 @ 15.1 LPM
PUMP & UNLOADER
PUMP............................................................................P/N N09-00053
PUMP PULLEY....................................................................R03-00794
PUMP PULLEY BUSHING..................................................R04-00001
UNLOADER..................................................................P/N C07-03800
ALKOTA MODEL 4405G
SPECIFICATIONS
PUMP ENGINE
ENGINE HORSEPOWER...........................................20 HP / 14.9 KW
ENGINE MAKE.........................................................................HONDA
ENGINE CHARGE RATE.........................................................20 AMP
ENGINE PART NUMBER....................................................F05-00402
ENGINE PULLEY................................................................R03-00744
ENGINE OIL FILTER.............................................. P/N F05-00467-01
ENGINE AIR FILTER...............................................P/N F05-00467-05
ENGINE AIR PRE-CLEANER.................................P/N F05-00467-04
ENGINE MUFFLER.................................................P/N F05-00465-01
ELECTRICAL
MACHINE VOLTAGE............12 VDC / 115V 60HZ 1PH CONTROLS
PRESSURE SWITCH ...................................................P/N F04-00790
BATTERY .......................................................................... GROUP 24
BATTERY CABLE - STARTER................................P/N F05-00248-1
BATTERY CABLE - GROUND.................................P/N F05-00238-1
BURNER
BURNER PART NUMBER............................................... V00-173140
BURNER TYPE........................................... PRESSURE ATOMIZING
FUEL TYPE.......................................KEROSENE, #1 OR #2 DIESEL
FUEL PRESSURE......................................................120 PSI / 8 BAR
FUEL NOZZLE........................(2.25 80 DEGREE B) P/N V2.25 80DB
FUEL CONSUMPTION..................................2.47 GPHR / 9.34 LPHR
FUEL PUMP......................................(DAN FOSS) P/N V-100714-001
MOTOR SPEED....................................................................3450 RPM
MOTOR VOLTAGE...................................................................12V DC
MOTOR PART NUMBER...............................................V-101126-002
2
07-02-04 Z08-04649

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Summary of Contents for ALKOTA 4405G

  • Page 1 ALKOTA MODEL 4405G SPECIFICATIONS PERFORMANCE PUMP ENGINE DISCHARGE VOLUME........4.0 GPM / 15.1 LPM ENGINE HORSEPOWER...........20 HP / 14.9 KW PUMP HEAD PRESSURE........4000 PSI / 276 BAR ENGINE MAKE.................HONDA TEMPERATURE RISE....105°F @ 4.0 GPM / 41°C @ 15.1 LPM ENGINE CHARGE RATE............20 AMP COMBUSTION SMOKE/BACHARACH SCALE..#1 OR #2 SMOKE...
  • Page 2 OPERATION TABLE OF CONTENTS OIL FIRED ENGINE DRIVEN CLEANER - 4405G-SLD036 TROUBLESHOOTING SAFETY INSTRUCTIONS Page Number Page Number Safety Symbols • Machine 12, 13 • General • Water Heater • Mechanical • Oil Burner See Parts List Section • Electrical •...

  • Page 3: Machine Unpacking

    SAFETY, INSTALLATION, AND OPERATION ENGINE DRIVEN OIL FIRED CLEANER MACHINE UNPACKING GENERAL SAFETY ALL CLEANERS ARE CAREFULLY INSPECTED 1. Before operating this machine, read and observe AND CARTONED TO PROTECT AGAINST SHIPPING all safety, unpacking, and operating DAMAGE. IF THERE IS DAMAGE OR MISSING instructions.

  • Page 4: Mechanical Safety

    15. Do not start the machine unless the gun 5. DO NOT start the engine until you have assembly is firmly gripped by the machine observed all safety and operating instructions operator. Failure to do this could result in injury found in the engine manual..

  • Page 5: Installation

    INSTALLATION 10. CHEMICALS: Mix chemicals per the chemical manufacturers printed directions. Follow all mixing, handling, application, and disposal This machine emits CARBON MONOXIDE, a instructions. Wear gloves, boots, goggles, and DEADLY GAS, and must be vented if used in an protective clothing appropriate for the chemical enclosed area.

  • Page 6: Pre-Start-Up

    ♦ METERING VALVE (if so equipped): Make sure OPERATING the metering valve closed before INSTRUCTIONS operation. If air enters the system through this valve, poor performance and machine damage will occur. Refer to the metering valve insert PRE START-UP for proper operation. 1.
  • Page 7 and/or oil are present, hot water and WARNING: RISK OF INJECTION OR SEVERE chemical will accelerate in the cleaning INJURY. KEEP CLEAR OF NOZZLE. DO process. NOT DIRECT DISCHARGE STREAM AT 6. TO APPLY CHEMICAL: PERSONS. THIS EQUIPMENT IS TO BE USED ONLY TRAINED...
  • Page 8 COMBINATION OPTION 6. To CLEAN: INSTRUCTION A. Start on the lower portion of the area to be cleaned and work up using long, even, overlapping strokes. WARNING: This machine should be B. Regulate the temperature indicated on the operated only by personnel instructed in and thermometer to 300°F by turning the regulating familiar with its operation.

  • Page 9: Machine Maintenance

    MACHINE MAINTENANCE GAS ENGINE DRIVEN OIL FIRED CLEANERS FLUSHING 5. Check the position of the ball valve (if so equipped) on the outlet of the float tank assuring it is in the closed position. 1. Connect machine to a pressurized water 6.
  • Page 10 MACHINE MAINTENANCE CONT’D GAS ENGINE DRIVEN OIL FIRED CLEANERS BELT TENSION COIL BACK PRESSURE CHECK INSTRUCTIONS DEFLECTION DISCHARGE VOLUME BACK PRESSURE REQUIRING DESCALING 2-3 GPM 50 PSI 3-4 GPM 75 PSI 4-5 GPM 100 PSI 6 GPM 150 PSI SPAN 1.
  • Page 11 MACHINE MAINTENANCE EACH AFTER EVERY EVERY EVERY ENGINE DRIVEN OIL FIRED FIRST DAIL Y YEARLY CLEANERS FIRST 8 HRS OIL BATH W A TER PUM P : Oil Level – check and add as needed per PUMP SERVICE insert. O i l Change – drain and refill per PUM P CAUTION: SERVICE insert...
  • Page 12 CLEANER TROUBLESHOOTING GAS ENGINE DRIVEN HOT WATER CLEANERS TROUBLE POSSIBLE CAUSE REMEDY Poor A. Hard water. A. Connect machine to water softener. Cleaning B. Low Pressure. B. See “Low operating pressure” Action. C. Little or no chemical being C. See “Machine will not draw chemical”. drawn.
  • Page 13 CLEANER TROUBLESHOOTING (CONT.) ELECTRIC DRIVEN HOT WATER CLEANERS TROUBLE POSSIBLE CAUSE REMEDY A. See PUMP TROUBLESHOOTING. 4. Excessive, A. Pump unusual B. Defective engine. B. Call service technician or take engine to noise. Repair/Warranty station. C. Pulleys rubbing. C. Adjust shields or pulley(s). D.
  • Page 14 OIL FIRED WATER HEATER TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY A. See BURNER on MODEL 1. Machine will not rise to A. Low fuel pressure. SPECIFICATIONS for specified pressure. operating temperature B. Water in fuel piping. B. Drain fuel tank and remove and replace filter per FUEL FILTER INSERT.
  • Page 17 2.25 3.74 3.12 4.38 NOTE: When plunger nut is removed, install a new copper washer and flinger washer to ensure proper fit and seal of ceramic plunger. If same copper washers are reused cracking or a poor seal may result.
  • Page 19 PUMP HEAD REMOVAL PUMP HEAD REINSTALLATION...

  • Page 22: Pump Troubleshooting

    PUMP TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY 1. Oil leaking in the A. Worn crankshaft seal. A. Remove and replace. area of water pump B. Bad bearing. B. Remove and replace. crankshaft. C. Grooved shaft. C. Remove and replace. D. Failure of retainer o-ring D.
  • Page 23 PUMP TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY 9. Dirty or worn check A. Normal wear. A. Remove and replace. valves. B. Debris B. Check for lack of water inlet screens. 10. Presence of metal A. Failure of internal component. A. Remove and disassemble to find particles during oil probable cause.
  • Page 27 MAXIMUM FLOW....................15 GPH / 57 LPM MAXIMUM FILTRATION....................2 MICRONS MAXIMUM TEMPERATURE..................212° / 100° WEIGHT.........................1 LB / 340 GM INLET AND OUTLET PORT SIZE..................1/4 NPT...

  • Page 28: Filter Element

    1. PRIMING THE MACHINE 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. Start the machine and check that there are no leaks.

  • Page 32: Transformer Test

    OIL BURNER MAINTENANCE OIL FIRED CLEANERS DANFOSS PUMP AIR BAND ADJUSTMENT Shut off fuel supply. NOTE: The air band adjustment on this burner Loosen the 2 screws with 7/64 allen wrench has been preset at the factory (elevation one turn. approximately 1400 feet).
  • Page 33 OIL BURNER MAINTENANCE OIL FIRED CLEANERS BUSS BAR ALIGNMENT 7. Partially close transformer. Check if buss bars align and contact the transformer electrodes. 1. With burner off, loosen screw and swing the If buss bars do not contact, see Buss Bar transformer away from burner gun assembly.
  • Page 34 OIL FIRED BURNER TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY 1. Burner will not A. Electrodes out of alignment. A. See "ADJUSTING ELECTRODE ASSEMBLY" in BURNER ignite. M A INTENANCE SECTION. B. Electrode insulator failure. B. Remove and replace if there are breaks, cracks, or spark trails.

  • Page 35: Oil Burner Troubleshooting

    OIL BURNER TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY 4. Pulsating pressure A. Partially clogged fuel pump A. Remove and replace strainer per FUEL PUMP FILTER in OIL BURNER strainer or filter. MAINTNANCE Section. B. Air leaking around fuel pump B. Check fuel pump cover screws for cover.
  • Page 37 Turning Chemical flow handle clockwise will shut off chemical flow. Turning the flow adjusting screw clockwise lowers the chemical CHEMICAL CONTROL flow. Turning the screw counterclockwise lowers the flow. Maximum Pressure....4000 PSI / 276 BAR Maximum Flow ......12 GPM / 45 LPM Minimum Flow ......1.0 GPM / 3.8 LPM MAXIMUM TEMPERATURE ....200F°...
  • Page 41 KIT, WHEEL - W/OUT HANDLE EXPLODED VIEW - P/N 4405F-99008A PART LISTS ITEM PART NUMBER PART DESCRIPTION QTY. AR58-03601 ROD,AXLE-5/8 X 36 1/4 CRS W/HOLES G02-00018A ASS'Y, TIRE & RIM - 10" H06-62500 NUT, PAL 4/18/2006 Z08-05406...

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