X-4 Series. Mid Frame

Transcription

1 X-4 Series Mid Frame Service Manual

2

3

4

5 INSTALLATION DATE PART NUMBER MAKE/MODEL SERIAL NUMBER SELLER ADDRESS CITY/STATE/ZIP NOTES:

6 This symbol is used to identify safety information about hazards that can result in personal injury. A signal word (DANGER, WARNING, or CAUTION) is used with the alert symbol to indicate the likelihood and the potential severity of injury. In addition, a hazard symbol may be used to represent the type of hazard. DANGER Indicates a hazard which, if not avoided, will result in death or serious injury. WARNING Indicates a hazard which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazard which, if not avoided, might result in minor or moderate injury. CAUTION CAUTION, when used without the alert symbol, indicates a situation that could result in damage to the equipment.

7 Table of Contents Specifications... 8 Pump Maintenance General Valve Service Head Removal Plunger Service Plunger Removal Plunger Installation Packing Service Head Installation Oil Burner Maintenance Air Band Adjustment Fuel Pump Filter Blower Fan Replacement Transformer Test Buss Bar Alignment Burner Gun Removal & Installation Electrode Assembly Adjustment Pump Maintenance Record General Assembly Control Panel Assembly Pump Assembly Pump Breakdown Pump Specifications Unloader Valve Breakdown Trigger Gun & Wand Float Tank Assembly Pre-Cleaner Assembly Pipe Coil - Short Burner Assembly Burner Specifications Electrical Schematics Standard Xtreme Troubleshooting Pump Burner Water Heater SEM Contents C

8 Specifications PERFORMANCE Heat Input 761B 1011B Temperature Rise 761B 1011B Temperature Limit Combustion Smoke/Bacharach Scale Carbon Monoxide Allowed Draft/Stack Installation 600,000 BTU/hr / 151,200 Kcal/hr 1,040,000 BTU/hr / 262,000 Kcal/hr gal/m / L/m gal/m / L/m Up to 200 F / 93 C #1 OR #2 SMOKE 0.01% WC READING GENERAL Minimum Inlet Water Pressure over 65 psi may require water inlet regulator 40 psi / 2.76 bar Stack Size 8 OD / mm OD Dimensions 761B 30 l x 24 w x 60 h /.76m x.61m x 1.5m 1011B Coil Coil 14 OD x 1/2 ID x 126 Schedule 40 (Schedule 80 on Xtreme series and 324X4 & 330X4) Coil Back Pressure (New) 5 psi / 0.34 bar Coil Back Pressure Requiring Descaling 50 psi / 3.40 bar 8 Specifications

9 ELECTRICAL Machine Voltage 216X4, 311X4 115v 60hz 1PH 320X4, 324X4, 330X4, 420X4 230v 60hz 1PH Current 216X4, 311X4 20 A 320X A 324X4, 330X4, 420X4 24 A Temp Control, Adjustable (optional) p/n F Temp Control (Xtreme) p/n F Power Cord 216X4, 311X4 p/n X4 p/n 320AX X4 p/n 324AX X4, 420X4 p/n F A English to Metric Conversions 1 gal/m = L/m 1 hp =.7457 kw 100 psi = bar 1 ft =.3048 m 1 in = 2.54 cm 1 lb =.4536 kg ( F 32) 1.8 = C Specifications 9

10 Pump Maintenance General PACKING EXTRACTION KIT P/N Z COMPLETE TOOL KIT P/N Z Valve Service 1. Remove the plugs holding the valve assemblies. 2. Remove and discard o-rings from the plugs. Clean plugs with solvent or soap and water. Allow to dry. 3. Using needle nose pliers, 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 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 Removal 1. Remove the cap screws holding the pump head to the crankcase. A metric tool is required for this step. Be careful not to lose the washer on each cap screw. 2. Remove the head by rotating the crankshaft and tapping the head away from the crankcase with a soft mallet. Keep rear surface of the head parallel to the front surface of the crankcase to prevent binding on the plungers. 3. Once the head is removed, protect the plungers from damage. 10 Pump Maintenance

11 Plunger Service 1. Remove pump head per HEAD REMOVAL. 2. Remove any packings and retainers left on the plungers by pulling them straight off. 3. Examine each plunger, looking for a smooth surface free of any scoring, cracks, or pitting. Any defective plungers should be removed per PLUNGER REMOVAL. 4. Discard and replace any defective plungers. 5. Reinstall the plunger per PLUNGER INSTALLATION. 6. Reinstall head per HEAD INSTALLATION. Plunger Removal NOTE: When the plunger screw is removed, it is important to install new o-ring, anti-extrusion, and copper washers. 1. When the plunger screw is removed, it is important to install a new o-ring, anti-extrusion, and copper washers. 2. Remove the plunger retaining screw by turning counterclockwise. Remove and replace copper washer. 3. Remove and discard o-ring and anti-extrusion ring from retainer screw. 4. Remove the plunger from the cross head and examine it for cracks, scoring, or pitting. 5. Remove and discard copper flinger washer, clean with solvent and allow to dry. Pump Maintenance 11

12 12 Pump Maintenance Plunger Installation 1. 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. Packing Service 1. Remove the head per PUMP HEAD REMOVAL. 2. Remove any packings and female adapters left on the plungers by pulling them straight off. Insert proper packing extractor onto the extractor hammer. Insert packing extractor and tool through the packings and adapters remaining in the head. Tighten the hammer and remove the remaining items in the head. Remove packings and o-rings from adapters. Discard the o-rings and packings. 3. Clean the packing canities in the head and rinse with clean water. 4. Clean exposed plungers. Clean male and female adapters with soap and water and allow it to dry. 5. Examine male and female adapters, discard worn items. Trial fit the female adapters into the head checking for binding or damage. Discard and replace damaged items 6. Lubricate packing cavities in the head and all packings and adapters with pump crankcase oil. 7. Lay head on the bench with packing cavities up. Install one male adapter in each cavity with the 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.

13 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 Install head per HEAD INSTALLATION. Head Installation 1. 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 Pump Maintenance 13

14 Oil Burner Maintenance Oil Fired Cleaners Air Band Adjustment Note: 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 eyeburning fumes indicate too much air. 3. Tighten the cap screw retaining the air bands. PART NUMBER V PART NUMBER V Fuel Pump Filter Sundstrand 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. Danfoss pump 1. Shut off fuel supply. 2. Loosen the 2 screws with 7/64 allen wrench one turn. 3. Turn cover counter clockwise and pull strainer and cover 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. Reinstall reverse of removal. 6. Turn on fuel supply. PART NUMBER V Oil Burner Maintenance

15 Blower Fan Replacement 1. 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 Test 1. 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 Alignment 1. 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. Oil Burner Maintenance 15

16 Burner Gun Removal & Installation 1. 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 Z P/N Z P/N Z Fuel Nozzle Changing Wrench Fuel Pump Wrench (Sundstrand) Solenoid Wrench (ASCO) Electrode Assembly Adjustment 1. 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. 16 Oil Burner Maintenance

17 Pump Maintenance Record Oil Change Month/Day/Year Operating Hours Oil Brand & Type Pump Service Month/Day/Year Operating Hours Type of Service Pump Maintenance Record 17

18 General Assembly Y PULSE HOSE x 24" K HOSE, 5/8ID x 18" ALL MODELS 216X PRE-CLEANER ASSEMBLY 216X4 216XX PRE-CLEANER ASSEMBLY 216X4X 311X PRE-CLEANER ASSEMBLY 311X4 311XX PRE-CLEANER ASSEMBLY 311X4X 320X PRE-CLEANER ASSEMBLY 320X4 320XX PRE-CLEANER ASSEMBLY 320X4X Y PULSE HOSE x 24" K HOSE, 5/8ID x 18" ALL MODELS 324X PRE-CLEANER ASSEMBLY 324X4 324XX PRE-CLEANER ASSEMBLY 324X4X 330X PRE-CLEANER ASSEMBLY 330X4 330XX PRE-CLEANER ASSEMBLY 330X4X 420X PRE-CLEANER ASSEMBLY 420X4 420XX PRE-CLEANER ASSEMBLY 420X4X R BELT, PULLEY 216X4(X) & (UL) 420X4(X) & (UL) R BELT, PULLEY 311X4(X) & (UL) 320X4(X) & (UL) 324X4(X) & (UL) R BELT, PULLEY 330X4(X) & (UL) PRESSURE FEED OUTLET HOW WATER 3 18 WATER INLET ASSEMBLY, CLEANER 216X CONTROL PANEL 216X4(X) 311X4(X) 320X CONTROL PANEL 320X4(X) 330X CONTROL PANEL 324X4(X) 330X4(X) 420X CONTROL PANEL 420X4(X) 47 11/32" 45 5/8" 30 1/8" 18 General Assembly

19 R MOTOR PULLEY 216X4(X) & (UL) R MOTOR PULLEY 311X4(X) & (UL) 320X4(X) & (UL) 330X4(X) & (UL) R MOTOR PULLEY 324X4(X) & (UL) R MOTOR PULLEY 420X4(X) & (UL) AX PUMP ASSEMBLY 216X4(X) & (UL) 311AX PUMP ASSEMBLY 311X4(X) & (UL) 320X4(X) & (UL) 324X4(X) & (UL) 330X PUMP ASSEMBLY 330X4(X) & (UL) 420X PUMP ASSEMBLY 420X4(X) (UL) X FLOAT TANK ASSEMBLY 216X4(X) & (UL) 320X FLOAT TANK ASSEMBLY 311X4(X) & (UL) 320X4(X) & (UL) 324X4(X) & (UL) 324X FLOAT TANK ASSEMBLY 330X4(X) & (UL) 420X FLOAT TANK ASSEMBLY 420X4(X) & (UL) ASSEMBLY, CLEANER ITEM NO. Part Number PART DESCRIPTION MID X4/QTY ASSEMBLY, COIL TOP AX-00164F HANGER, GUN X P SHIELD, PULLEY - PLASTIC 1 4 AS NPB BRACKET, BRAKE 1 5 C VALVE, RELIEF 1 6 D430M-10176R HANDLE, BRAKE 1 7 F LOOM, CORRUGATED 2 8 H Bolt, J 1 10 H SCREW, CAP H SCREW, SET - 1/4-20UNC 2 12 H SCREW, CAP - 5/16 X 3/ H NUT, HEX 6 14 H NUT, TINNERMAN - 5/ H NUT, TINNERMAN - 1/4" 6 16 H NUT, LOCK - 5/16" 9 18 i TANK, FUEL - PLASTIC, 8 GAL 1 20 W BARB, HOSE 1 21 W BARB, HOSE 1 22 W A COUPLER, 3/8F X 1/2MNPT 1 23 Y GAUGE, GAS - CAP 1 24 Z CAP, VINYL 3 General Assembly 19

20 Control Panel Assembly F A - CAM SWITCH 216X4(X) 311X4(X) F A - CAM SWITCH 320X4(X) 324X4(X) 330X4(X) 420X4(X) 5 *OPTIONAL* D DECAL, TEMP F TEMP CONTROL, ADJ 216X4(X) 311X4(X) 320X4(X) 324X4(X) 330X4(X) 420X4(X) ASSEMBLY, POWER CORD 216X4(X) 311X4(X) 320AX ASSEMBLY, POWER CORD 320X4(X) 324AX ASSEMBLY, POWER CORD 324X4(X) 330X4(X) 420X4(X) ASSEMBLY, CONTROL PANEL ITEM NO. Part Number PART DESCRIPTION QTY AX P BOX, CONTROL - PLASTIC P ASSEMBLY, CHEMICAL LINE X P PANEL, CONTROL - PLASTIC 1 4 C VALVE, METERING 1 5 D DECAL, METERING VALVE 1 6 F CONNECTOR, CONDUIT - 3/4" 2 7 F BUSHING, STRAIN RELIEF 1 8 F BUSHING, INSULATION 1 9 F GROMMET, RUBBER 4 11 W CLAMP, HOSE 2 12 W BARB, HOSE 1 13 W BARB, HOSE 1 14 Z PLUG, DOMED 1 15 Z HOSE, POLYBRAID 1 20 Control Assembly

21 Pump Assembly N TX1810S17 216X4(X) & (UL) 311X4(X) & (UL) X4(X) & (UL) 324X4(X) & (UL) 5 N EX3042S 330X4(X) & (UL) N TX1812S17 420X4(X) & (UL) R PUMP PULLEY 216X4(X) & (UL) R PUMP PULLEY 311X4(X) & (UL) 320X4(X) & (UL) 324X4(X) & (UL) R PUMP PULLEY 330X4(X) & (UL) ASSEMBLY, PUMP R PUMP PULLEY 420X4(X) & (UL) ITEM NO. Part Number PART DESCRIPTION QTY. 1 C VALVE, AIR 1 2 C B VALVE, UNLOADER PSI 1 3 E BUSHING, PIPE 1 4 E BUSHING, PIPE 2 5 E BUSHING, PIPE 1 6 E CROSS, PIPE 1 7 E ELBOW, PIPE 1 8 E TEE, PIPE 1 9 E NIPPLE, PIPE 1 10 E NIPPLE, BRASS 1/2" 1 11 E NIPPLE, BRASS 1/2" 1 12 F SWITCH, VACCUM 1 13 K HOSE, WATER - 3/8 X 13" 1 15 N P MOUNT, PUMP 1 17 R BUSHING, PULLEY 1 18 W CLAMP, HOSE 2 19 W BARB, HOSE 1 20 W BARB, HOSE 1 21 W BARB, HOSE 1 22 W BARB, HOSE 1 Pump 21

22 Pump Breakdown ACCESSORIES Oil Case (6) One Pint Bottles p/n N07-OILCA Oil Bottle (1) One Pint Bottle p/n N07-OILCA-1 Oil Case (24) One Pint Bottles p/n N07-OILCA-2 22 Pump

23 PARTS LIST Item P/N Part Description Item P/N Part Description 1 N Screw, Cap 24 N Retainer, Seal 2 N Retainer, Bearing 25 N O-Ring 3 N Cover, Crankshaft 26 N Seal, Water 18mm 4 N O-Ring 27 N Adapter, Female - Ront 18mm 5 N Bearing, Roller 28 N Packing, V-High Press 18mm 6 N Dipstick, Oil 29 N Plug, Pipe 7 N Crankcase 30 N Plug, Pipe 8 N Crosshead 31 N Washer, Flat 9 N Rod, Connecting 32 N Washer, Flat 10 N O-Ring 33 N Head, Pump Brass 11 N Cover, Rear 34 N Washer, Flat 12 N Screw, Cap 35 N Screw, Cap 8mm x 65mm 13 N Indicator, Oil Level 36 N Kit, Valve Assembly 14 N O-Ring 37 N O-Ting 15 N Plug, Pipe 37-A N O-Ring 16 N O-Ring 38 N Plug, Pipe 17 N Pin, Crosshead 39 N Nut, Hex 18 N Crankshaft 40 N Adapter, Plunger 19 N Key 41 N Plunger 18mm 20 N Seal, Oil 42 N O-Ring 21 N Mount, Pump 43 N Ring, Anti-Extrusion 22 N Washer, Lock 44 N N Screw, Cap 45 N Washer, Flinger- Copper Kit, Seals - Crosshead Pump 23

24 Discharge Volume Pump Head Pressure PERFORMANCE GENERAL 3.4 gal/m / 12.9 L/m 2500 psi / 172 bar Water Pump p/n N Crankshaft Rotation Clockwise & Counterclockwise Maximum Speed 1750 RPM Maximum Pumped Fluid Temp. 165 F / 74 C Inlet Pressure 9 in HG@ 75 F to 116 PSI to 8 BAR Weight 32.0 lbs / 8.6 kg Oil Change Interval Oil Type Crankcase Capacity Pump Specifications LUBRICATION TORQUE After 1 st 50 hrs and 500 hrs SAE 20, SAE 30 (non-detergent) 4.0 fl oz / 0.4LT Valve Plug 73.7 ft lbs / 10.7 kg M Mount to Crankcase 14.7 ft lbs / 2.0 kg M Rear Crankcase cover to 7.3 ft lbs / 1.0 kg M Crankcase *Head to Crankcase 14.7 ft lbs / 2.0 kg M *Note: When plunger nut is removed, it is important you install a new copper washer and flinger washer to ensure proper fit and seal of ceramic plunger. Each time plunger screw is torqued, copper washers conform to plunger. If same copper washers are used, plunger cracking or poor seal may result. 24 Pump PARTS PACKAGES Part No. Description Item QTY N Valve Assemblies Ass y, check valve 36 6 O-Ring 26A N Valve Plugs Plug 38 6 O-Ring 27 6 N Crosshead Seals Seal, Crosshead 45 3 N V-Packings Seal, Water 18mm 26 3 Packing, V 18mm 37 3 N V-Packings Seal, Water 18mm 26 1 Packing, V 18mm 37 1 Retainer, Seal N Seal Retainer Retainer, Seal- 24 3

25 25

26 Unloader Valve Breakdown Unloading Adjustment 1. Install an appropriate pressure gauge in pump head outlet. The gauge should have a range twice the operating pressure. 2. Loosen set screw (Item 10) using 5/64 Allen wrench and nut (Item 9) and turn the knob & retainer (Item 11&8) counter clockwise. 3. Open the trigger gun, start the pump, and observe pressure gauge reading. Slowly tighten the knob. 4. 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. 5. Lock the setting by tightening the locking set screw (Item 10) Note: Once the operating pressure is reached, turning the knob clockwise will increase the unloading pressure only INLET 1/4NPT BYPASS 3/8NPT Specifications Unloader Valve p/n C B Maximum Flow 6.5 GPM / 24.6 LPM Max Unloading Press 3600 PSI / BAR Maximum Temperature 195 F / 91 C Weight 1.6 LBS / 0.73 KG Bypass 3/8 FNPT Inlet ¼ NPT Outlet 3/8 FNPT 5 6 OUTLET 3/8NPT 26 Unloader Valve Breakdown

27 PART LISTS ITEM PART NUMBER PART DESCRIPTION QTY 1 C B-03 Housing, Unloader 1 2 C B-09 Housing, Ball 1 3 C B-10 Guide, Piston SS 1 4 C B-08 Adapter, Outlet 1 5 C B-04 Valve, Check 1 6 C B-02 Spring, Compression SS 1 7 C B-06 Spring, Compression 1.6 X.5CS 1 8 C B-05 Retainer, Spring 1 9 C B-07 Nut, Hex 1 10 C Screw, Set 1 11 C B-01 Knob, Adjustment 1 12 C O-Ring 1/16CS X 5/8 ID RS6-000SV01 O-Ring 1/16CS X 1/2ID 1 14 C Seat, Valve SS 1 15 C Piston 1 16 C Housing, Piston 1 17 C Ring, Back-up 8mm X 11mm 1 18 C Ring, Back-up 8mm X 6mm 1 19 C O-Ring 1/16CS X 5/16ID 1 20 P O-Ring 1/16CS X 1/4ID 1 21 J O-Ring 1/16CS X 7/32ID 1 22 C O-Ring -.16ID X.10CS 1 23 C Guide, Spring 1 Unloader Valve Breakdown 27

28 Trigger Gun & Wand J B J B PART LIST ITEM PART NUMBER PART DESCRIPTION 1 J Valve, Trigger Gun 2 J E Assembly, Wand 42 3 W A Coupling, Female Maximum Volume Maximum Pressure Rated Temperature Weight Inlet Specifications 10.0 GPM / 37.9 LPM 5000 PSI / BAR 300 F / 150 C 1.8lbs / 0.8kg 3/8 NPT Female Outlet ¼ NPT Female All dimensions are in inches unless otherwise noted mm = 1 inch 28 Trigger Gun & Wand

29 Float Tank Assembly RISTRICTOR - 1/4" 216X4(X) & (UL) RESTRICTOR - 9/32" 311X4(X) & (UL) 320X4(X) & (UL) 324X4(X) & (UL) RESTRICTOR - 5/16" 330X4(X) & (UL) RESTRICTOR - 11/32" 420X4(X) & (UL) ASSEMBLY, FLOAT TANK ITEM NO. Part Number PART DESCRIPTION QTY B TANK, FLOAT 1 2 C FLOAT VALVE 1 3 C ADAPTER, GARDEN HOSE 1 4 C WASHER, GARDEN HOSE 1 5 E P PLUG, PIPE - NYLON 1 6 W BARB, HOSE 1 8 C FILTER, SOAP SCREEN 1 Float Tank Assembly 29

30 Pre-Cleaner Assembly F U - 2.3HP ELECTRIC MOTOR 216X4(X) & (UL) 311X4(X) & (UL) F U - 4HP ELECTRIC MOTOR 320X4(X) & (UL) F U - 5HP ELECTRIC MOTOR 324X4(X) & (UL) 420X4(X) & (UL) F HP ELECTRIC MOTOR 330X4(X) & (UL) COIL ASSEMBLY 216X4 & (UL) 311X4 & (UL) 320X4 & (UL) 420X4 & (UL) COIL ASSEMBLY 324X4 & (UL) 330X4 & (UL) S COIL ASSEMBLY 216X4X & (UL) 311X4X & (UL) 320X4X & (UL) 324X4X & (UL) 330X4X & (UL) 420X4X & (UL) 216X BURNER ASSEMBLY 216X BURNER ASSEMBLY 216X4X ASSEMBLY, PRE-CLEANER X BURNER ASSEMBLY 311X BURNER ASSEMBLY 311X4X 320X BURNER ASSEMBLY 320X4 324X4 330X4 320XX BURNER ASSEMBLY 320X4X 324X4X 330X4X 420X BURNER ASSEMBLY 420X4 420XX BURNER ASSEMBLY 420X4X ITEM NO. Part Number PART DESCRIPTION Mid X4/QTY AX-00164F HANGER, GUN X-00130FL FRAME, LEFT (27 X 39) X-00130FR FRAME, RIGHT - (27 X 39) X MOUNT - PUMP & MOTOR MOUNT X BASE - COIL MOUNT WELDMENT X-00179F HANDLE, POWDER COAT INSULATION - 1 x 14DIA 1 10 AR ROD, CRS - 5/8" X 30 1/8" 2 11 AS NPB FUEL TANK MOUNT 1 12 E TEE, STREET 1 14 G A ASS'Y, TIRE & RIM - 10" 4 15 H SCREW, CAP 6 16 H SCREW, CAP - 5/16 X 3/ H SCREW, CAP 4 18 H WASHER, FLAT - 5/ H NUT, TINNERMAN - 5/ H NUT, TINNERMAN - 1/4" 6 21 H NUT, LOCK - 5/16" 4 22 H NUT,LOCK-3/8-16UNC HEX 3 23 H COLLAR, SHAFT - 5/8" 4 24 Z INSULATION, CERAMIC FIBER 2 30 Pre-Cleaner Assembly

31 Pipe Coil - Short A - COIL, SCH40-126' 216X4 & (UL) 311X4 & (UL) 320X4 & (UL) 420X4 & (UL) A - COIL, SCH80-126' 216X4X & (UL) 311X4X & (UL) 320X4X & (UL) 324X4(X) & (UL) 330X4(X) & (UL) 420X4X & (UL) AS PR - WRAPPER, PAINTED - 126' 216X4 & (UL) 311X4 & (UL) 320X4 & (UL) 324X4 & (UL) 330X4 & (UL) 420X4 & (UL) AS PR - WRAPPER, PSS - 126' 216X4X & (UL) 311X4X & (UL) 320X4X & (UL) 324X4X & (UL) 330X4X & (UL) 420X4X & (UL) 4 5 COIL, PIPE - TALL ITEM NO. Part Number PART DESCRIPTION QTY. 3 E NIPPLE, PIPE - GS 1 4 E NIPPLE, PIPE - GS 1 5 E ELBOW, REDUCING 1 6 E ELBOW, FORGED 1 7 AA ANGLE, BRACKET 1 Pipe Coil 31

32 Burner Assembly V DA - BURNER NOZZLE 216X4(X) & (UL) V DA - BURNER NOZZLE 311X4(X) & (UL) 320X4(X) & (UL) 324X4(X) & (UL) 330X4(X) & (UL) V DB - BURNER NOZZLE 420X4(X) & (UL) V BURNER, OIL 216X4 & (UL) V BURNER, OIL - W/SOL 216X4X & (UL) V BURNER, OIL 311X4X & (UL) V BURNER, OIL - W/SOL 311X4X & (UL) V BURNER, OIL 320X4 & (UL) 324X4 & (UL) 330X4 & (UL) V BURNER, OIL - W/SOL 320X4X & (UL) 324X4X & (UL) 330X4X & (UL) V BURNER, OIL 420X4 & (UL) V BURNER, OIL - W/SOL 420X4X & (UL) *OPTIONAL BIO-DIESEL* SAME BURNER AS CURRENT MODEL. REPLACED EXISTING FUEL PUMP WITH BIO-DIESEL RATED PUMP. P/N: V SER USE ON ALL MODELS ASSEMBLY, BURNER ITEM NO. Part Number PART DESCRIPTION QTY. 1 E ELBOW, PIPE 1 2 E NIPPLE, PIPE - 1/4" 1 4 V FILTER, FUEL 1 6 W BARB, HOSE 1 7 W BARB, HOSE 1 32 Burner

33 Burner Specifications BURNER Burner Part Number V , V Burner Type Pressure Atomizing Fuel Type Kerosene, #1 or #2 Diesel Fuel Pressure 125 PSI / 9 BAR Fuel Pump (Dan Foss) P/N V Motor Voltage 115v 1PH 60hz Motor Speed 3250 RPM Horsepower 1/5 HP Burner Part Number V , V Burner Type Pressure Atomizing Fuel Type Kerosene, #1 or #2 Diesel Fuel Pressure 125 psi / 9 bar Fuel Pump (Dan Foss) p/n V Motor Voltage 115v 1PH 60hz Motor HP 1/7 Motor Speed 3450 rpm Burner Part Number V , V Burner Type Pressure Atomizing Fuel Type Kerosene, #1 or #2 Diesel Fuel Pressure 125 PSI / 9 BAR Fuel Pump (Dan Foss) P/N V Motor Voltage 230v 1PH 60hz Motor Speed 3450 RPM Horsepower 1/7 HP Burner Part Number Burner Type Fuel Type Fuel Pressure Fuel Pump Motor Voltage Motor Horsepower Motor Speed V / V Pressure Atomizing Kerosene, #1 or #2 Diesel 125 PSI / 9 BAR (Dan Foss) P/N V V 60 Hz 1PH 1/7 HP 3450 RPM Burner 33

34 Electrical Schematics Standard 120AX4, 216AX4, 311AX4 E Q G U R I O P U M E N D N T WHITE BLACK RED BROWN BLUE GRN (3X) 115 VAC L I N E L I N E 1 2 WHT (3X) PUMP MOTOR 115 VAC YELLOW GREEN PINK ORANGE CAM SWITCH VACUUM SWITCH WHT / DATE: DRAWN BY: BWK WHT BURNER MOTOR 115 VAC IGNITION TRANSFORMER 115 VAC TITLE / DESCRIPTION ELECTRICAL SCHEMATIC PART NUMBER ES Electrical Schematics

35 320AX4, 324AX4 E Q G U R I O P U M N E D N T GRN (3X) WHITE BLACK RED BROWN BLUE GREEN PINK ORANGE YELLOW PUMP MOTOR 230 VAC WHT / RED L I N E 4 L I N E 230 VAC CAM SWITCH WHT / RED VACUUM SWITCH WHT DATE: DRAWN BY: BWK WHT ` BURNER MOTOR 230 VAC IGNITION TRANSFORMER 230 VAC TITLE / DESCRIPTION ELECTRICAL SCHEMATIC PART NUMBER ES Electrical Schematics 35

36 Xtreme 120AX4X, 216AX4X, 311AX4X E Q G U R I O P U M N E D N T L I N E VAC L I N E 1 VACUUM SWITCH TEMP CONTROL CAM SWITCH FUEL SOLENOID 115 VAC WHT (3X) WHT BURNER MOTOR 115 VAC IGNITION TRANSFORMER 115 VAC GRN (3X) WHITE BLACK RED BROWN BLUE PUMP MOTOR 115 VAC YELLOW GREEN PINK ORANGE DATE: DRAWN BY: LCL TITLE / DESCRIPTION PART NUMBER ELECTRICAL SCHEMATIC ES Electrical Schematics

37 320AX4X, 324AX4X E Q G U R I O P U M N E D N T L I N E VAC L I N E 1 RED RED GRN (3X) PUMP MOTOR 230 VAC WHITE BLACK RED BROWN BLUE YELLOW GREEN PINK ORANGE CAM SWITCH WHT / RED VACUUM SWITCH TEMP CONTROL WHT/ DATE: DRAWN BY: BWK WHT FUEL SOLENOID 230 VAC BURNER MOTOR 230 VAC IGNITION TRANSFORMER 230 VAC TITLE / DESCRIPTION ELECTRICAL SCHEMATIC PART NUMBER ES Electrical Schematics 37

38 Troubleshooting Pump Trouble Possible Cause Remedy Oil 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. Excess shims. See Worn bearing. 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. Oil gauge loosed. Rear cover screws loose. Pump overfilled with oil, displaced through crankcase breather hole in oil cap/ dipstick. Replace gasket or o-ring. Tighten oil gauge. Tighten rear screws to torque values in PUMP SPECIFICATIONS. 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. Worn or damaged plunger screw o-ring. Maintain or step up lubrication schedule. 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 Re-align pump and motor. and motor. Oil has not been changed on regular basis. Check oil type and change intervals per PUMP SPECIFICATIONS. 38 Troubleshooting

39 Short seal life Damaged plunger bushing. Replace plunger bushing. Worn connecting rod. Replace connecting rod. Excess pressure beyond the pump s maximum rating. High water temperature. Match pressure stated in PUMP SPECIFICATIONS. Lower water temperature stated in PUMP SPECIFICATIONS. Dirty or worn check valves Normal wear. Debris. Remove and replace. Check for lack of water inlet screens. Presence of metal particles during oil change Failure of internal component. New pump. Remove and disassemble to find probable cause. New pumps have machine fillings and debris and should be drained and refilled per PUMP SPECIFICATIONS. Water leakage from under head Worn packing. Cracked/scored plunger. Failure of plunger retainer o-ring. Install new packing. Remove and replace plunger. Remove and replace plunger retainer o-ring. Loud knocking noise in pump Pulley loose on crankshaft. Defective bearing. Worn connecting rod, crankshaft, or crosshead. Check key and tighten set screw. Remove and replace bearing. Remove and replace. Frequent or premature failure of the packing Scored, damaged, or worn plunger. Overpressure to inlet manifold. Abrasive material in the fluid being pumped. Excessive pressure and/or temperature of fluid being pumped. Over pressure of pumps. Running pump dry. Remove and replace plungers. Reduce inlet pressure. Install proper filtration on pump inlet pumping. Check pressures and fluid inlet temperature. Be sure they are within specified range. Reduce pressure. Do not run pump without water. Troubleshooting 39

40 Low Pressure Dirty or worn check valves. Clean/replace check valves. Worn packing. Remove and replace packing. Belt slipping. Improperly sized spray tip or nozzle. Inlet filter screen is clogged. Pitted valves. See BELT TENSION in MACHINE MAINTENANCE. See MACHINE SPECIFICATIOSN for specified spray tip or nozzle. Clean inlet filter screen. See VALVE SERVICE in PUMP MAINTENANCE. Erratic pressure; pump runs rough Dirty or worn check valves. Foreign particles in valve assemblies. High inlet water temperature. Clean/replace check valves. See temperature in PUMP SPECIFICATIONS. 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. 40 Troubleshooting

41 Burner Trouble Possible Cause Remedy Burner will not ignite Electrodes out of alignment. Electrode insulator failure. Water flow switch not closing. Vacuum switch not closing. See ADJUSTING ELECTRODE ASSEMBLY in BURNER MAINTENANCE SECTION. Remove and replace if there are breaks, cracks, or spark trails. Adjust, repair, or replace switch. Adjust, repair, or replace switch. Temperature control switch not closing. Fuel solenoid valve not opening. Weak transformer. Faulty cad cell (if equipped). Faulty primary control (if equipped). Burner motor thermal protector locked out. Wiring. Burner switch. Pump pressure. Venting. Sooting. No fuel. Adjust or replace the TEMPERATURE CONTROL. Clean, repair, or replace solenoid. Clean and check transformer terminals. Check transformer for spark pre TRANSFORMER TEST in BURNER MAINTENANCE SECTION. Clean and test cad cell, replace if required. Replace primary control. See Burner motor thermal protector locked out. All wire contacts are to be clean and tight. Wire should not be cracked or frayed. Test switch operation. Remove and replace as necessary. See Low fuel pressure. 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. Soot deposits on the coil and burner can interrupt air flow, and cause shorting of the electrodes. Clean as required. See No fuel. Troubleshooting 41

42 No fuel Clogged fuel filter. Remove and replace filter per FUEL FILTER SECTION. Fuel leak. Repair as necessary. Kinked or collapsed fuel line. Low fuel pressure. Faulty burner oil pump. Air leak in intake lines. Clogged burner nozzle. Remove and replace fuel line. See Low fuel pressure. Adjust pressure or replace. Tighten all fittings. 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. Burner shaft coupling slipping. Fuel nozzle worn. Faulty oil pump. Remove and replace. Remove and replace. Remove and replace with specified nozzle on BURNER ASSEMBLY. Remove and replace. Pulsating pressure Partially clogged fuel pump strainer or filter. Air leaking around fuel pump cover. Remove and replace strainer per FUEL PUMP FILTER in OIL BURNER MAINTENANCE section. 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 Gun out of alignment. Inspect fuel filter for water presence. Bend oil pipe to center burner nozzle. 42 Troubleshooting

43 Burner motor thermal protector kicked out Low voltage. Fuel too viscous. Fuel pump defective. Motor defective. Voltage must match those specified in the BURNER section of MACHINE SPECIFICATIONS section. See Low fuel pressure. Check that fuel pump turns freely. Call service technician or take motor to repair/warranty station. Delayed ignition (rumbling, noise starts) Dirty or damaged electrodes. Air adjustment open too far. Poor fuel spray pattern. Incorrect electrode setting. Weak transformer. Clean or replace. Readjust per AIR BAND ADJUSTMENT in OIL BURNER MAINTENANCE section. Remove and replace with fuel nozzle specified in BURNER ASSEMBLY. Readjust per ADJUSTING ELECTRODE ASSEMBLY in OIL BURNER MAINTENANCE section. See TRANSFORMER CHECK on OIL BURNER MAINTENANCE section. Burner does not electrically come on Burner motor reset button tripped. High limit temp control reset tripped if so equipped. 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. Reset if necessary. Troubleshooting 43

44 Water Heater Trouble Possible Cause Remedy Machine will not rise to operating temperature Low fuel pressure. Water in fuel piping. Fuel filter clogged. Poor combustion. See BURNER on MODEL SPECIFICATIOSN for specified pressure. Drain fuel tank and remove and replace filter per FUEL FILTER INSERT. Remove and replace fuel filter element per FUEL FILTER INSERT. See Poor combustion. Improper fuel supply. Temperature control inoperative (if equipped). Use fuel specified in BURNER section of the MODEL SPECIFICATIONS. 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. Improper fuel supply. Improper fuel pressure. See Low operating pressure on MACHINE TROUBLESHOOTING insert. Use fuel specified in BURNER section of the MACHINE SPECIFICATIONS. See BURNER on MODEL SPECIFICATIONS for specified pressure. Machine smokes (sweet smelling exhaust) Improper fuel supply. Insufficient combustion air. Leaking fuel system. Clogged or improper burner nozzle. Loose burner nozzle. Use fuel specified in BURNER section of MODEL SPECIFICATIONS. See AIR BAND ADJUSTMENT on OIL BURNER MAINTENANCE insert. Correct leakage problem. Remove (DO NOT CLEAN) and replace nozzle per BURNER ASSEMBLY INSERT. See BURNER MAINTENANCE insert. 44 Troubleshooting

45 Machine fumes (exhaust burns eyes) Too much combustion air. Improper fuel pressure. See BURNER TROUBLESHOOTING insert. See FUEL on MODEL SPECIFICATIONS for specified pressure. Excessive oil dripping from laydown coil condensate. Loose nozzle. Fuel pressure too high. Burner nozzle defective. Incorrect burner nozzle. See BURNER TROUBLESHOOTING insert. See FUEL PRESSURE ADJUSTMENT section on BURNER MAINTENANCE insert. Remove and replace with appropriate nozzle found on the BURNER ASSEMBLY or BREAKDOWN insert. 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. Troubleshooting 45

46

47

48