Alto Contractor Diesel Betriebsanleitung

Repair Manual

CONTRACTOR DIESEL

125 03 47 (03.2003)

www.alto-online.com

2003-11-14

ALTO Danmark A/S

Industrikvarteret

DK-9560 Hadsund

Tel.: +45 7218 2100

www.alto-online.com

A Technical data

B Structure

C Function

D Trouble-shooting

E Service / Repair

F Test / Adjustment

G El. diagrams

H Spare parts proposal

I (Info & spare parts)

INDEX

CONTRACTOR

Diesel

Petrol

4D_CON. 03GB.

CONTRACTOR Diesel Motor data A

Diesel motor RUGGERINI MD 151, S

Engine type 4 stroke two cylinder

Max. output at 3600 rpm 13 HP / continuous 12.3 HP

Max. torque st 2400 rpm 3.26 Kgm

Fuel consumption Approx. 3 l/h

Fuel tank capacity 4.1 l

Adjusted speed at max. pressure 3500±10 rpm

Cooling system Forced air 700 m3/h

Air requirement for combustion 62 m3/h

PTO shaft rotation clockwise

Max. vacuum intake 0.024 bar

Max. exhaust backpressure 0.039 bar

Engine oil capacity / type 1.8 l / SAE 15 - 50

Dry weight 50 kg

D_CON. 03GB. 5

125 03 47 - (03.2003)

CONTRACTOR Diesel Pump data A

Heavy Duty

Opening pressure 210 bar 225

Pump pressure 180 bar / 2550 psi 205

Nozzle pressure 170 bar / 2410 psi 195

By-pass pressure 8 bar 10

Water quantity at min./max. pressure 20/19 l/min. 17.5/16 l/min.

Water quantity at steam 9 l/min. 8 l/min.

Pump pressure at steam 40 bar 30 bar

High pressure nozzle 1506 = 1.35 mm 1505

Max. temperature of inlet water 35°C 35°C

Inlet pressure, max. 10 bar 10 bar

Chemical injector (external only) 03 injector / foam injector

Density (control box) IP45

Engine r.p.m. (pump pressure) 1750 ± 25 r.p.m.

Noise level according to ISO 3746 85 DB(A) from 7 m distance

Type of piston Stainless steel Ceramic

Wobble disc no. 7 3

Type of oil BP Bartran HV 100

6D_CON. 03GB.

CONTRACTOR Diesel Boiler data A

Heavy Duty

Boiler effect 115 kW 100

Water outlet temp. at max. water quantity (12°C) 95°C (205°F) =

Oil consumption at max. water quantity and temp. 12 l/h 10 l/h

CO210-12% =

CO 50-100 ppm =

Temp. ﬂue gas at 20°C ambient temp. 160-200°C =

Smoke scale number Max. 1 =

Flue gas loss Max. 10% =

Oil nozzle type 9 kg/h - 60°S =

Oil pressure 12 bar 11 bar

Boiler tube / measurements Welded st. 35.8 / 20 x 3mm x 48m

Heating surface 3 m2

Quantity of inlet air Approx. 180 m3/h

Outlet ﬂue gas 260 m3/h at 200°C

Tank capacity max./min. Jerry can 20 l / 3 l

D_CON. 03GB. 7

125 03 47 - (03.2003)

CONTRACTOR Diesel Electrical parts A

A1 KEW-steering 24V AC 642009A

A2 KEW-converter 12V DC / 24V AC 6420013

B1 Flow control After pump magnet oper. Reed-switch

B2 Flow control Before boiler magn. oper. Reed-switch

B4/B5 Temperature sensor PT500

B6 Flame sensor Light-sensitive transistor

B67 Motor oil switch Open at a normal oil pressure

F1 Fuse on print A2 1 AT

F2 Fuse on print A2 *) 6.3 AT

F3 Fuse for PC-board A1 (see page 5) 1.25 AT

F4 Fuse for start protection (see page 5) 1.25 AT

G1 Accumulator battery 12V min. 50 AH (300 Amp.)

G2 Generator internal/external 12V - 15V - 280 Watt / 300 Watt

G3 Regulator/Rectiﬁer

H1 Motor oil alarm Lamp on front

H2 Starting relay Lamp on front

M1 Starting motor 1.1 kW

R1 Resistance (only where B5 is not used) 560 ohm

S1 Start switch Key on front

T1 Ignition transformer Prim: 2x12VAC/17 Amp. Sec. 11KV

Y1 Magnet valve for oil pump 24 VAC

F3 *) secure against fault polarization of battery

8D_CON. 03GB.

Electrics box

Manometer for HP-pump

Back of electrics box

Fuses

Pump oil Diesel tank for motor

Ignition key

Starter battery

Ignition transformer

Exhaust outlet from boiler

Motor suspension

The base plate for the motor/pump unit is mounted on 4 inclined vibration absorbers.

The boiler is mounted on a plate construction, which serves as air duct from blower to boiler.

Electrics box is suspended in the pipe frame and contains the controlling and safety system of the

machine

Exhaust from motor

Control lamps

H1 H2

Setup Structure B

The Contractor is constructed on a combined pipe and plate frame, surface coated with a strong poly-

ester. Each single item of the machine is placed in a way that an optimum weight distribution is obtained

taking service and operation into consideration.

Temperature indicator Front panel

Temperature regulation

Chemicals container rack

D_CON. 03GB. 9

125 03 47 - (03.2003)

Diesel oil for pump

Setup Structure B

Water quantity regulation

Pump front

Water inlet

Water outlet

Pressure outlet

Sludge glass

Manometer

Flow switch B1

Electromagnet Y2 Y3 (safety stop)

Oil pressure

switch B7

Starter relay Starting motor

Rectiﬁer G3

Motor connection (- pinch)

Gearbox

Motor air ﬁlter

Fuel oil pump Flow switch B2

Air adjustment screw

Blower

Flexible coupling

Solenoid

valve Y1

Flow

switch B2

10 D_CON. 03GB.

A ﬂame tube consisting of two rings has the purpose of securing that the hot exhaust gases are forced

round the labyrinth of tubes.

The boiler is mounted on the air duct with a gasket between and fastened with 3 bolts. In the air duct

an adjustable throttle is mounted.

Boiler Structure B

The boiler is the heat generating part of a hot water machine. It consists of a labyrinth-constructed

tube coil, which encloses the combustion chamber.

The tube coil is enclosed by a double container with boilerjacket, bottom, and top in a sandwich con-

struction, between which the combustion air is pressed into the combustion. An insulating material

placed in the bottom of the boiler makes sure that the inner bottom, among other things, is protected

from superheating.

Gasket

Exhaust gas Electrodes Flame sensor

Oil nozzle

Air distributor

Burner tube

Flame tube bottom part

Insulating mat

Water outletWater inlet Air inletGasket

Outer jacket

Flame tube top part

Inner jacket

Air duct

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