1. Manuals
  2. Brands
  3. ZEP Manuals
  4. Pressure Washer
  5. Pressure Washers
  6. Service manual

ZEP Pressure Washers Service Manual

Pressure washer zep
Hide thumbs
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Pressure Washers and is the answer not in the manual?

Questions and answers

Related Manuals for ZEP Pressure Washers

Summary of Contents for ZEP Pressure Washers

  • Page 2 ______________________________________________________ INSTALLATION DATE PART NUMBER ______________________________________________________ MAKE/MODEL SERIAL NUMBER ______________________________________________________ SELLER ______________________________________________________ ADDRESS CITY/STATE/ZIP 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.

  • Page 3: Specifications

    Specifications PERFORMANCE Discharge Volume 3.0 gal/m / 11.4 L/m Pump Head Pressure 2000 psi / 138 bar Temperature Rise 120˚F @ 2.0 gal/m / 49˚C @ 7.6 L/m Temperature Limit (optional) 210˚F / 99˚C Combustion Smoke/Bacharach Scale #1 OR #2 SMOKE Carbon Monoxide Allowed 0.01% Draft/Stack Installation...

  • Page 4: Pump Motor

    ELECTRICAL Machine Voltage 230v 60hz 1PH Current 24 A Temp Control, Adjustable (optional) Panel Mount p/n F04-00830 Temp Control, Adjustable (optional) Outlet Mount p/n F04-00818 Temp Control (optional) p/n F04-00845 Power Cord p/n 320AX-00344 Cam Switch p/n F04-00743B Pump Motor Motor P/N F02-00087-U Motor Horsepower...

  • Page 5: Part List

    Trigger Gun and Wand Trigger Gun & Wand Assembly ASSEMBLY, GUN & WAND - 42" p/n: J06-00158-B 6/2/2009 ITEM PART NUMBER PART DESCRIPTION QTY. J06-00104E ASSEMBLY, WAND - 42" J06-00158 GUN, TRIGGER W04-24225-A COUPLER, 1/4F X 1/4FNPT 2102-00710 PART LIST ITEM PART NUMBER PART DESCRIPTION...
  • Page 6 BREAKDOWN, GUN - TRIGGER EXPLODED VIEW - P/N J06-00158 SPECIFICATIONS MAXIMUM VOLUME....10.0 GPM / 37.9 LPM MAXIMUM PERSSURE..5000 PSI / 344.7 BAR RATED TEMPERATURE....300 F / 150 C WEIGHT........1.8 LBS. / 0.8 KG INLET .........3/8" NPT FEMALE OUTLET........1/4" NPT FEMALE BEVEL SIDE DISHED SIDE YG3500...

  • Page 7: Pump Assembly

    Pump Assembly ASSEMBLY, PUMP 9/11/2008 ITEM NO. PART NUMBER PART DESCRIPTION QTY. C03-00810 VALVE, AIR C07-03700X VALVE, UNLOADER (SILVER) E04-00001-58 BUSHING, PIPE E04-00005-48 BUSHING, PIPE E07-00001-4 CROSS, PIPE E08-00006-48 ELBOW, PIPE E08-00011-58 ELBOW, PIPE E09-00003-2 PLUG, PIPE E10-00005-4 TEE, PIPE E13-00010-2 NIPPLE, PIPE E14-00010-68...
  • Page 8 Pump, Water N0-0001 PUMP, WATER DIMENSIONS - P/N N07-00180 TX1813S17 SPECIFICATIONS PARTS PACKAGES PERFORMANCE PART NO. DESCRIPTION ITEM QTY DISCHARGE VOLUME..........4 GPM / 15.1 LPM N07-99123 VALVE ASSEMBLIES PUMP HEAD PRESSURE..........2500 PSI / 172 BAR ASS’Y, CHECK VALVE GENERAL 0-RING N07-99124...
  • Page 9 N07-00180 Parts List Item Description Item Description N07-20018 Screw, Cap N07-98083 Retainer, Seal N07-20019 Retainer, Bearing N07-98016 O-Ring N07-40029 Cover, Crankshaft N07-98030 Seal, Water – 18mm N07-20021 O-Ring N07-99163 Adapter, Female – Front 18mm N07-20022 Bearing, Roller N07-98084 Packing, V – High Press 18mm N07-20024 Dipstick, Oil N07-20049...

  • Page 10: Pump Maintenance

    Pump Maintenance General PACKING EXTRACTION KIT P/N Z09-00028 COMPLETE TOOL KIT P/N Z09-00021 Valve Service Remove the plugs holding the valve assemblies. Remove and discard o-rings from the plugs. Clean plugs with solvent or soap and water. Allow to dry. Using needle nose pliers, fingers, or hook shaped tool, remove the valve assemblies from the head.

  • Page 11: Plunger Installation

    Examine each plunger, looking for a smooth surface free of any scoring, cracks, or pitting. Any defective plungers should be removed per PLUNGER REMOVAL. Discard and replace any defective plungers. Reinstall the plunger per PLUNGER INSTALLATION. 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.

  • Page 12: Packing Service

    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. Apply a drop of thread sealant to the threads of the retainer screw. Thread the plunger retainer screw into the cross head making sure the copper flat washer is installed onto the screw.

  • Page 13: Head Installation

    adapters from the offending cavity and reinstall items per steps 8 through 15. 15. Install head per HEAD INSTALLATION. Head Installation Prepare pump head per instructions in PACKING SERVICE. Rotate the plungers so the outer plungers are projecting the same distance from the crankcase. Lubricate the exposed plungers with crankcase oil.

  • Page 14: Pump Maintenance Record

    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 Records...
  • Page 15 Unloader Valve Breakdown Unloader Valve C07-03700X, C07-03800X, C07-05700X Unloading Adjustment 1. Install an appropriate pressure gauge in pump head outlet. The gauge should have a range twice the operating pressure. 2. Loosen nut (Item 23) and turn the knob (Item 26) counter clockwise until minimum spring tension.

  • Page 16: Float Tank Assembly

    Float Tank Assembly ASSEMBLY, TANK - FLOAT ITEM Part Number PART DESCRIPTION QTY. 2120-04120B TANK, FLOAT 4120-10540 ASSEMBLY, RESTRICTOR C03-00631 FLOAT VALVE C04-00120 FILTER, SOAP SCREEN C05-00271 WASHER, GARDEN HOSE C05-00274 ADAPTER, GARDEN HOSE E09-00002-P PLUG, PIPE - NYLON W02-10057-8 BARB, HOSE Float Tank Assembly...

  • Page 17: Parts List

    VALVE, FLOAT - P/N C03-00631 8/8/2008 PARTS LIST SPECIFICATIONS MAXIMUM VOLUME......7 GPM / 26 LPM ITEM PART NUMBER PART DESCRIPTION QTY. MAXIMUM PRESSURE......140 PSI / 10 BAR MAXIMUM TEMPERATURE ......140 F/60 C C03-00625-10 SCREW, WING - 10-32UNF PORT SIZE - INLET..........3/8" NPT DIMENSIONS...11.4 X 4.1 X 2.8 IN / 290 X 104 X 71MM C03-00628 FLOAT, PLASTIC...

  • Page 18: Burner Assembly

    Burner Assembly ASSEMBLY, BURNER ITEM Defaul Part Number PART DESCRIPTION t/QTY. AS16-01204-PB BRACKET, TRANSFORMER E08-00006-2 ELBOW, PIPE E13-00010-2 NIPPLE, PIPE - 1/4" H04-19011 SCREW, SELF TAP V00-17318 BURNER, OIL - 230V V04-0031 FILTER , FUEL W02-10019-8 BARB, HOSE W02-10031 BARB, HOSE Burner Assembly...

  • Page 19: Maintenance Procedures

    Maintenance Procedures Priming the machine Shut off the fuel tank valves. Spin off the clear bowl, fill with clean fuel and coat the round gasket (3) with fuel. Reinstall the clear bowl and tighten ¼ to 1/3 turns after the gasket contacts the upper housing.
  • Page 20 Burner Breakdown Buner Breakdown...
  • Page 21 Burner Specs Burner Specs...
  • Page 22 Burner Specs...

  • Page 23: Oil Burner Maintenance

    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. Loosen the cap screw retaining the air bands.
  • Page 24 housing. Remove the blower. 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. Reinstall motor and blower assembly.
  • Page 25 Check and replace electrode insulators if cracked. Clean burnt buss bars. Clean carbon off electrodes. Clean carbon off oil nozzle (use caution not to scratch face of nozzle or orifice). Check for a loose oil nozzle. Note: Check with dealer and/or replace nozzle with proper nozzle. Gently replace burner gun assembly in air tube.

  • Page 26: Electrical Schematic

    Electrical Schematic WHT / RED Electical Schematic...

  • Page 27: Coil Assembly

    Coil Assembly COIL, PIPE - TALL ITEM Part Number PART DESCRIPTION QTY. 350-00205A COIL, REMOVABLE AA18-00101 ANGLE, BRACKET AS16-04425-PR WRAPPER, COIL E08-00012-1 ELBOW, REDUCING E08-00016-5 ELBOW, FORGED E15-00035-2 NIPPLE, PIPE - GS E15-00045-2 NIPPLE, PIPE - GS Coil Assembly...

  • Page 28: Troubleshooting

    Trouble Shooting Pump Trouble Possible Cause Remedy Oil leaking in the area of Worn crankshaft seal, bad bearing, Remove and replace. water pump crankshaft grooved shaft, or failure of retainer o-ring. Excessive play on Defective bearings. See “Worn bearing.” crankshaft Excess shims.
  • Page 29 Dirty or worn check Normal wear. Remove and replace. valves Debris. Check for lack of water inlet screens. Presence of metal Failure of internal component. Remove and disassemble to find probable cause. particles during oil change New pump. New pumps have machine fillings and debris and should be drained and refilled per PUMP SPECIFICATIONS.
  • Page 30 Erratic pressure; pump Dirty or worn check valves. Clean/replace check valves. runs rough Foreign particles in valve assemblies. High inlet water temperature. 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 Install proper filtration on pump inlet plumbing.
  • Page 31 No fuel Clogged fuel filter. Remove and replace filter per FUEL FILTER SECTION. Fuel leak. Repair as necessary. Kinked or collapsed fuel line. Remove and replace fuel line. Low fuel pressure. See “Low fuel pressure.” Faulty burner oil pump. Adjust pressure or replace. Air leak in intake lines.
  • Page 32 Delayed ignition (rumbling, Dirty or damaged electrodes. Clean or replace. noise starts) Air adjustment open too far. Readjust per AIR BAND ADJUSTMENT in OIL BURNER MAINTENANCE section. Poor fuel spray pattern. Remove and replace with fuel nozzle specified in BURNER ASSEMBLY. Incorrect electrode setting.
  • Page 33 Water Heater Trouble Possible Cause Remedy Machine will not rise to Low fuel pressure. See BURNER on MODEL operating temperature SPECIFICATIOSN for specified pressure. Water in fuel piping. Drain fuel tank and remove and replace filter per FUEL FILTER INSERT. Fuel filter clogged.
  • Page 34 Excessive oil dripping from Loose nozzle. See BURNER TROUBLESHOOTING insert. laydown coil condensate. Fuel pressure too high. See FUEL PRESSURE ADJUSTMENT section on BURNER MAINTENANCE insert. Burner nozzle defective. Remove and replace with appropriate nozzle found on the BURNER ASSEMBLY or BREAKDOWN insert.
  • Page 35 WARRANTY POLICY All machines and parts are guaranteed to be free from defects in material or workmanship under normal use and service for a period of 1 year after delivery from the factory. Any part (other than the vendor items) that is determined to be warranty will be repaired or replaced at NO CHARGE provided the warranty card is filled out in it’s entirety and the part is sent back freight prepaid.
  • Page 36 For full warranty information, contact your delivering distribu- tor or contact the manufacturer at info@warrantysvc.com...

Table of Contents