ALKOTA 3102 Series, Safety, Installation, And Operation Manual

Page 1: ...P O Box 288 105 Broad Street Alcester SD 57001 800 255 6823 www alkota com OLD VALUES NEW IDEAS 3102 ...

Page 2: ...AP 18 O D X 1 2 ID X 158 SCHEDULE 40 P N 2102 00200 COIL BACK PRESSURE NEW 5 PSI 3 0 GPM 0 34 BAR 11 4 LPM COIL BACK PRESSURE REQUIRING DESCALING 50 PSI 3 0 GPM 3 40 11 4 LPM PUMP P N N07 00002 PUMP PULLEY R03 00646 1 PUMP PULLEY BUSHING R04 00001 PUMP TYPE GENERAL CERMAIC PLUNGER OIL BATH UNLOADER P N C07 02000 MOTOR HORSEPOWER 2 0 HP 1 5 KW MOTOR SPEED 1750 RPM MOTOR VOLTAGE 115V 230V 60HZ 1PH M...

Page 3: ...E R D A T E O F P U R C H A S E P L A C E O F P U R C H A S E M O N T H D A Y YE A R O P E R A T I N G H O U R S M A I N T E N A N C E P E R F O R M E D MACHINE RECORD Supersedes 01 08 04 Z08 04527 08 25 04 Z08 04527 NOTES ...

Page 4: ...rner Fuel Pump Screen See Parts List Section Transformer Check See Parts List Section Burner Gun Remove Replace See Parts List Section Blower Fan Remove Replace See Parts List Section Fuel Filter Maintenance See Parts List Section TROUBLESHOOTING Page Number Machine 13 14 Water Heater 15 Oil Burner See Parts List Section Pump See Parts List Section Fuel Filter See Parts List Section SERVICE Pump S...

Page 5: ... of this equipment should not operate this equipment when fatigued or under influence of alcohol or drugs 3 The operator of this equipment should be thoroughly familiar with its operation and trained in the job to be accomplished 4 The operator of this equipment should wear protective face shields and other protective clothing as required for safe operation 5 Keep all protective covers and shields...

Page 6: ...ctices 6 Fuses or circuit breakers should be compatible with machine requirements See ELECTRICAL section of MODEL SPECIFICATIONS for power requirements 7 High voltage may be present within this machine Servicing should only be performed by properly trained personnel 1 Use only fuel 1 or 2 diesel The use of incor rect fuel may result in fire or explosion and severe injury to the operator 2 Do not r...

Page 7: ...rical rating not less than the rating of the product Do not use damaged extension cords Use an extension cord in good repair free of frays or cracks in the outer covering Do not abuse extension cord and do not yank on any cord to disconnect Keep cord away from heat and sharp edges Always disconnect the extension cord from the receptacle before disconnecting the product from the extension cord COP ...

Page 8: ...rers printed directions Follow all mixing handling application and disposal instructions Wear gloves boots goggles and protective clothing appropriate for the chemical being used WARNING This machine emits carbon monoxide and deadly gas and must be vented if used in an enclosed area Improper venting can cause poor combustion delayed ignition down drafts and the possibility of freezing the coil Con...

Page 9: ...osed to sub freezing temperatures it must be thoroughly warmed to above freezing before operating Failure to warm machine can cause damage to the pump packings and other components Read and observe all items in CLEANER INSTALLATION Refer to the MAINTENANCE SCHEDULE for any maintenance to be performed before operation ELECTRICAL Connect the machine to an electrically grounded circuit that is fuse o...

Page 10: ...ilable Follow instructions on chemical container Mix chemicals per label instructions Use necessary safety precautions A Insert chemical screen into chemical container B Adjust metering valve if so equipped C If the gun assembly is equipped with variable or multiple nozzle assembly adjust as desired TO RINSE A If the machine is equipped with a panel mounted metering valve close the chemical meteri...

Page 11: ...ering valve if so equipped handle turning it counter clockwise found on the pump assembly 3 With a small common screw driver turn the screw on the metering valve if so equipped counter clockwise to DECREASE the temperature and clockwise to INCREASE the temperature 08 19 04 Z08 02830F 9 WARNING This machine should be operated only by personnel instructed in and familiar with its operation The disch...

Page 12: ... when the fuel tank is empty or with tank valves closed This will cause damage to the fuel pump and void warranty CAUTION Do not operate with the trigger gun valve closed for more than 3 minutes or water pump damage may occur TO CLEAN A Start on the lower portion of the area to be cleaned and work up using long even overlapping strokes B Regulate the temperature indicated on the thermometer to 300...

Page 13: ...mended so scale and other chemicals will not come in contact with your water pump and causes premature wear NOTE Contact your local dealer for descaling of your unit 7 Disconnect the water supply 8 Disconnect the electrical supply 9 Reinstall the hose and gun assembly 10 Remove the pressure gauge Descaling Instructions are available upon requestask for part number Z08 00493 MACHINE MAINTENANCE DEF...

Page 14: ... prior to running out of antifreeze mixture 10 Disconnect electrical supply 11 Fill the fuel tank with kerosene or 1 or 2 diesel 12 It is recommended to install a coil cover to keep coil free of debris 13 Drain the float tank 14 Place machine in a dry place protected from weather condition 08 19 04 Z08 02830H STORAGE 12 PART NO DESCRIPTION Y02 00001 0 1000 PSI 69 BAR Pressure Gauge NOTE All Gauges...

Page 15: ...ert FILTER WATER Check water inlet hose screen for debris Check float tank screen for debris LEAKS Check for water and build up of scale at pipe connections FUEL Adequate fuel supply FILTER FUEL If contaminants are present see FUEL FILTER insert Remove and Replace fuel filter per FUEL FILTER insert SCREEN FUEL PUMP Check fuel pump screen for debris see OIL BURNER MAINTENANCE insert BURNER NOZZLE R...

Page 16: ...nlet filter screen clogged J Motor runs slow K Air leak in inlet plumbing L Defective water pump M Leaking discharge hose N Chemical metering valve open and sucking air O Defective unloader valve P Inlet ball valve not fully open if so equipped A The water supply must meet or exceed the maximum discharge volume specified in the PERFORMANCE section and minimum water inlet pressure specified in the ...

Page 17: ...utlet check fuses in main disconnect switch Replace fuse if blown B Call service technician C Call service technician or take motor to Repair Warranty station 9 Pump motor will not start motor hums A Pump frozen B Defective motor C Defective water pump D Excessive back pressure A Machine must be thoroughly warmed to above freezing B Call service technician or take motor to Repair Warranty station ...

Page 18: ... See BURNER on MODEL SPECIFICATIONS for specified pressure 4 Machine smokes sweet smelling exhaust A Improper fuel supply B Insufficient combustion air C Leaking fuel system D Clogged or improper burner nozzle E Loose burner nozzle A Use fuel specified in BURNER section of MODEL SPECIFICATIONS B See AIR BAND ADJUSTMENT on OIL BURNER MAINTENANCE INSERT C Correct leakage problem D Remove DO NOT CLEA...

Page 19: ...102 10040 3102 10050 3102 10060 EXPLODED VIEW 2 3 4 5 6 7 8 910 11 12 12 13 N tr 14 Q 15 I 16 48 I I 17 18 13 19 20 21 19 22 46 23 12 24 43 27 16 17 _ 28 I I t 2 9 1P I 39 15 37 15 38 15 37 36353433 32 30 NOT ALL ITEMS SHOWN AAE ON IOUA MACHINE 03 85 Z8 00036 ...

Page 20: ...IRE 21 H6 25006 NUT TINNERMAN 48 2102 00130 WELDMENT FRAME 22 H6 31302 NUT LOCK 47 Z1 88 1 CAP FILLER NECK 23 Z1 123 1 EDGING BULK 18 1 4 48 3102 00119 INSULATION 1 x 18 DIA 24 3102 00302 ASSEMBLY CONTROL PANEL 49 H4 16400 SCREW THREAD CUTTING 25 C4 120 SCREEN FILTRATION 50 W2 67B COUPLER FEMALE 26 3702 00539 ASSEMBLY RESTRICTOR 51 E4 006 2 BUS HING PIPE 27 2102 00121 ASSEMBLY TANK FLOAT OPEN 52 F...

Page 21: ...12 12 02 Z08 00064S ECN 02897 Supersedes 09 00 Z08 00064 7 ...

Page 22: ...09 00 Z08 00064 ECN 02311 7 ...

Page 23: ...S LIST ITEM PART NO DESCRIPTION ITEM PART NO DESCRIPTION 1 C3 622 BALL FLOAT _ r 2 O2OO B R OAT Q __ 1 Q 1 _ __ m PIPL 3 C3 620 T V FLOAT _ _ 2 p _ 1 I HOS __1 _ Q 5 CS 270 1 NUT HOSE 1 _ E OOS 2 6 C5 OO2ff_ Q _ I 1 cs 2i1 WAS tER HOSE i F4 761 SWITCH VACUUM t 8 2102 00120 TANK FLOAT WHITE 01 85 28 00105 i I f ...

Page 24: ... x 44 __e 00604 TERMINAL SPADE e 3 F2 23 TIE CABLE F4 00j51 _e CORDSET MALE 4 F4 616 INSULATOR TERMINAL 13 C3 00300 VALVE METERING _e___e_e_ e 5 F4 615 TERMINAL SPL CE _1 __ e CLAMP HOSE e 6 F4 610 TERMINAL SPADE _ _ _3 ee BULK 1 _ 7 Z1 00141 6 TUBING SHRINK _ 4 61 e D BULK l_e 0 8 F4 00745 SWITCH CAM e _e_ e e F4 00603 TERMINAL RING e 9 AS16 02100 NPB PANEL CONTROL SPECIFY COLOR SEE TABl E OF CON...

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Page 27: ...13 W2 10030 BARB HOSE 3 E13 065 2 NIPPLE PIPE E14 010 2 NIPPLE PIPE 4 ES 006 2 ELBOW STREET 15 _N7 00002 PUMP WATER 5 R3 646 1 PUllEY SINGLE V E4 002 2 BUSHING PIPE 6 R4 01 BUSHING PUllEY 17 E15 030 2 NIPPLE PIPE 7 ES 00S 2 ELBOW PIPE 1S C3 S10 VALVE AIR a C7 1300 VALVE UNlOAD ER g W2 25 BARB HOSE g W2 23 BARB HOSE 20 es 0 ELBOW SIDE OUTler PiiE W2 30 CLAMP HOSE__ 2_ BARBL OSE 11 K 33 HOSE BULK 3 ...

Page 28: ...ep 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 indica...

Page 29: ...read 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 1 Remove the head per PUMP HEAD REMOVAL 2 Remove any packings and female adapters left on the plungers by pulling them stra...

Page 30: ...TANT If the rear female adapter does not fit almost flush something is not properly positioned If a proper 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 1 Prepare pump head per instructions in PACKING SERVICE 2 Rotate the plungers so the outer p...

Page 31: ...PUMP SERVICE MONTH DAY YEAR OPERATING HOURS OIL BRAND TYPE Supersedes 03 27 02 Z08 03516 08 24 04 Z08 03516 MONTH DAY YEAR OPERATING HOURS TYPE OF SEVICE PUMP MAINTENANCE RECORD OIL CHANGE P4 ...

Page 32: ...ole in oil cap dipstick A Replace gasket or o ring B Replace gasket or o ring C Tighten oil gauge D Tighten rear screws to torque values in PUMP SPECIFCATIONS S E Drain oil refill to recommended oil level as stated in OIL LEVEL in PUMP MAINTENANCE 5 Water in crankcase A May be caused by humid air condensing into water inside the crankcase B Worn or damaged plunger screw o ring A Maintain or step u...

Page 33: ... being pumped E Over pressure of pumps F Running pump dry A Remove and replace plungers B Reduce inlet pressure C Install proper filtration on pump inlet pumping D Check pressures and fluid inlet temperature be sure they are within specified range E Reduce pressure F Do not run pump without water 14 Low Pressure A Dirty or worn check valves B Worn packing C Belt slipping D Improperly sized spray t...

Page 34: ...ssure gauge reading while slowly turning 3 Open trigger gun start pump and observe 2 Turn knob item 2 counterclockwise until spring is loose of twice the operating pressure head outlet The gauge should have a pressure range 4 Close and open trigger gun to check unloading pressure and bypass operation with pressure not exceeding 400 psi than the operating pressure NOTE If the gauge does not reach w...

Page 35: ... OIL CHANGE INTERVAL AFTER FIRST 50 HOURS THEN AFTER EACH 500 HOURS OIL TYPE SAE 20 OR SAE 30 NON DETERGENT CRANKCASECAPACITY 0 3 LT 10 FL OZ TORQUE VALVE PLUG 10 0 KG M 72 FT LB MOUNTTO CRANKCASE 2 2 KG M 16 FT LB CONNECTINGROD CAP TO CONNECTING ROD 1 6 KG M 12 FTLB PLUNGERSCREW TO CROSSHEAD 2 0 KG M 15 FT LB REAR CRANKCASE COVERTO CRANKCASE 10 KG M 7 FT LB HEAD TO CRANKCASE 2 0 KG M 15 FT LB REP...

Page 36: ...ASHER FLAT 10 07 20034 RO CONNECTING 33 N07 20001 HEAD PUMP lOA N07 20035 WASHER FLAT 34 N07 20002 SCREW CAP lOB N07 20036 WASHER FLAT Serrated B Sldes 35 N07 20003 WASHER FLAT 10C N07 20037 SCREW CAP 36 N07 20054 ASSEMBLY VALVE 11 N07 20025 GASKET COVER 36A N07 20004 O RING 12 N07 20026 COVER CRANKCASE 368 N07 20005 SEAT VALVE 13 N07 20027 SCREW CAP 36C N07 20006 POPPET VALVE 14 N07 20029 INDICAT...

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Page 38: ... 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 s...

Page 39: ...Use caution not to scratch face of nozzle or orifice E 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 Reinstall the oil line making sure both ends are tight 7 Partially close transformer Check if buss bars align ...

Page 40: ...or frayed L Test switch operation Remove and replace as necessary M See Low fuel pressure N 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 O Soot deposits on the coil and burner can interrupt air flow and cause shorting of the electrodes Clean as required P See No fuel 2 No fuel A Clogged fu...

Page 41: ...ecified in the BURNER section of MACHINE SPECIFICATIONS section B Operate in warmer conditions or with fuel adapted to cold weather conditions C Check that fuel pump turns freely D Call service technician or take motor to repair warranty station 7 Delayed ignition rumbling noisy starts A Dirty or damaged electrodes B Air adjustment open too far C Poor fuel spray pattern D Incorrect electrode setti...

Page 42: ...06 13 06 Z08 00061 BREAKDOWN BURNER OIL 115V 1PH 60HZ EXPLODED VIEW P N V00 17365 2 Supersedes 04 92 Z08 00061 ...

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Page 45: ...ads stripped A Deteriorated gasket B Housing cracked C Bowl rim cracked nicked or scratched D Star nut loose E Star nut s threads stripped out F Gasket missing A Loose valve assembly B Cracked component C Loose filter bowl C Tighten star nut on fuel bowl retainer WEIGHT 12 OZ 340 GM MAXIMUM FILTRATION 25 MICRONS and gasket B Inspect filter bowl filter housing C Remove and replace bowl F Replace ga...

Page 46: ...omponents GASKETS A Inspect for deterioration or tearing B Remove and replace BOWL Inspect rim and bowl to insure it is free of nicks cracks or scratches FILTER ELEMENT A Inspect for damage or deterioration B Remove and replace FUEL BOWL A If contaminants are found check more frequently B If no contaminates are found check less frequently 3 Remove element ITEM 6 and clean by using a soft brush and...

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Page 49: ... MOTOR PUMP SWITCH VACUUM U O R N D U N A L R T 1 E VAC 115 G N E I L SWITCH 115 VAC BURNER 115 VAC IGNITION 115 VAC TRANSFORMER MOTOR FUEL SOLENOID BURNER MOTOR IGNITION 115 VAC TRANSFORMER 115 VAC BURNER MOTOR 115 VAC IGNITION 115 VAC TRANSFORMER 115 VAC MOTOR PUMP I N E T P M E U Q N O R U D U N A L R T 1 E VAC 115 G N E I L TRANSFORMER 115 VAC 115 VAC IGNITION MOTOR BURNER SWITCH VACUUM SWITCH...

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