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Related Manuals for ZEP 1600-2V
Summary of Contents for ZEP 1600-2V
- Page 1 1600-2V N83901...
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Page 2: Specifications
______________________________________________________ INSTALLATION DATE PART NUMBER ______________________________________________________ MAKE/MODEL SERIAL NUMBER ______________________________________________________ SELLER ______________________________________________________ ADDRESS CITY/STATE/ZIP Specifications PERFORMANCE Discharge Volume 2.0 gal/m / 7.6 L/m Pump Head Pressure 1600 psi / 111 bar Temperature Rise 120˚F @ 2.0 gal/m / 49˚C @ 7.6 L/m Temperature Limit 210˚F / 99˚C Combustion Smoke/Bacharach... - Page 3 GENERAL Minimum Inlet Water Pressure over 65 psi may require water inlet regulator 10 psi / 0.68 bar Stack Size 8” OD / 203.2 mm OD Fuel Tank Capacity 4.5 gal / 17 L Spray Tip (#3.5 - 0˚) p/n JA0-00035-2 (#3.5 - 15˚) p/n JA0-15035-2 (#3.5 - 25˚) p/n JA0-25035-2 (#3.5 - 40˚) p/n JA0-40035-2...
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Page 4: 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 5 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...
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Page 6: Pump Assembly
Pump Assembly ASSEMBLY, PUMP P/N 216AX-00501E 08-19-2008 ITEM 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 NIPPLE, 3/8MNPT-CLOSE PS... -
Page 7: 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 8: Plunger Installation
Plunger Service Remove pump head per HEAD REMOVAL. Remove any packings and retainers left on the plungers by pulling them straight off. 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. -
Page 9: Packing Service
Packing Service Remove the head per PUMP HEAD REMOVAL. 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. -
Page 10: 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. Start the head onto the plungers and, using a soft mallet, tap the head evenly until it comes in contact with the crankcase. -
Page 11: 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 Record... -
Page 12: Unloader Valve
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 13: Float Tank Assembly
Float Tank Assembly ASSEMBLY, TANK - FLOAT 216AX-01121 ITEM PART NUMBER PART DESCRIPTION QTY. C03-00631 FLOAT VALVE C05-00274 ADAPTER, GARDEN HOSE RESTRICTOR, PLUG - 1/4 E09-00002-P1 ORIFICE EM28-20200-L TANK, FLOAT W02-10025-P BARB, HOSE Float Tank Assembly... -
Page 14: 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 15: Burner Assembly
Burner Assembly ASSEMBLY, BURNER ITEM Part Number PART DESCRIPTION QTY. E08-00006-2 ELBOW, PIPE E13-00010-2 NIPPLE, PIPE - 1/4" V00-173173 BURNER, OIL V04-00314 FILTER , FUEL V1.10 80DA NOZZLE, BURNER W02-10019-8 BARB, HOSE W02-10031 BARB, HOSE Burner Assembly... -
Page 16: 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 17: 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 18 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 19 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 20 Burner Breakdown Burner Breakdown...
- Page 21 Burner Specs Burner Specs...
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Page 22: Control Panel Assembly
Control Panel Assembly ... - Page 23 Control Panel Assembly...
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Page 24: Electrical Schematic
Electrical Schematic Electrical Schematic... -
Page 25: 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 26 Troubleshooting 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 27 Scored plungers Abrasive material in fluid being Install proper filtration on pump inlet plumbing. pumped. Fitted plungers Cavitation. Decrease inlet water temperature and/or increase inlet water pressure. Cavitation High inlet fluid temperature, low Lower inlet fluid temperature and raise inlet fluid inlet pressure.
- Page 28 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.
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Page 29: Water Heater
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 30 Machine smokes (sweet Improper fuel supply. Use fuel specified in BURNER section of smelling exhaust) MODEL SPECIFICATIONS. Insufficient combustion air. See AIR BAND ADJUSTMENT on OIL BURNER MAINTENANCE insert. Leaking fuel system. Correct leakage problem. Clogged or improper burner nozzle. Remove (DO NOT CLEAN) and replace nozzle per BURNER ASSEMBLY INSERT.
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Page 31: Warranty Policy
Warranty Policy Machines are guaranteed to be free from defects in material or workmanship under normal use and service for period of one year after delivery from the factory. Any part (other than vendor items) that is determined to be warranty will be repaired or replaced at NO CHARGE provided the warranty registration form is filled out in its entirety and the part is sent back freight prepaid. - Page 32 For full warranty information, contact your delivering distribu- tor or contact the manufacturer at info@warrantysvc.com...
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