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ZEP 1600-2V, Service Manual

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ZEP 1600-2V Service Manual Download Page 1

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For full warranty information, contact your delivering distribu-
tor or contact the manufacturer at [email protected]

 

1600-2V

 

N83901

Summary of Contents for 1600-2V

Page 1: ...Servic e Manua l Servic e Manua l g distribu c com 1600 2V N83901...

Page 2: ...____________________________ SELLER ______________________________________________________ ADDRESS CITY STATE ZIP Specifications PERFORMANCE Discharge Volume 2 0 gal m 7 6 L m Pump Head Pressure 1600...

Page 3: ...e Hose Assembly 3 8 x 50 P N K02 03150E1 Trigger Gun Wand p n J06 00158 B Trigger Gun p n J06 00158 Trigger Wand p n J06 00104EZ Coil x 95 sch 40 p n W216RS 05207 Coil Back Pressure New 5 psi 0 34 bar...

Page 4: ...ND 42 1 2 J06 00158 GUN TRIGGER 1 3 W04 24225 A COUPLER 1 4F X 1 4FNPT 1 2 1 3 Trigger Gun Wand Assembly 2102 00710 PART LIST ITEM PART NUMBER PART DESCRIPTION 1 W04 31231 B Coupler 3 8M X 3 8FNPT 2 K...

Page 5: ...13 J06 00158 09 WASHER FLAT 1 14 J06 00158 10 WASHER FLAT BRASS 1 15 J06 00158 11 HOUSING VALVE 1 16 J06 00158 12A RETAINER VALVE 1 17 J06 00158 13 SPRING COMPRESSION 1 18 J06 00158 14 PIN VALVE 4MM...

Page 6: ...0 E13 00010 2 NIPPLE PIPE 1 11 E14 00010 68 NIPPLE 3 8MNPT CLOSE PS PIPE SCH80 1 12 E15 00010 48 NIPPLE BRASS 1 2 1 13 E15 00025 48 NIPPLE BRASS 1 2 1 14 F04 00761 SWITCH VACCUM 1 15 K21 02214 1 4 ASS...

Page 7: ...e a malfunctioning valve will not Good valve assemblies should be set aside for installation in step 7 6 Malfunctioning valve assemblies must be replaced 7 Lubricate a new o ring with the pump crankca...

Page 8: ...se 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 Remo...

Page 9: ...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...

Page 10: ...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...

Page 11: ...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...

Page 12: ...tem Part Number Description Qty Kit C07 03700X C07 03800X C07 05700X 1 C07 03700X 01 Piston 1 2 C07 03700 15 Pin Roll 1 3 C07 03700 28 Ring Anti Extrusion 2 4 C07 03700 29 O Ring 3 32 x 7 16ID x 3043...

Page 13: ...4 2 5 3 1 ITEM NO PART NUMBER PART DESCRIPTION QTY 1 C03 00631 FLOAT VALVE 1 2 C05 00274 ADAPTER GARDEN HOSE 1 3 E09 00002 P1 RESTRICTOR PLUG 1 4 ORIFICE 1 4 EM28 20200 L TANK FLOAT 1 5 W02 10025 P B...

Page 14: ...05 HOUSING VALVE 1 8 C03 00631 06 PISTON 1 9 C03 00631 07 ROD PISTON 5 16CS X 1 1 4 PLASTIC 1 10 C03 00631 08 GUIDE PISTON 1 11 C03 00631 10 SCREW CAP 1 12 C03 00631 11 ARM FLOAT 1 13 C03 00631 14 NUT...

Page 15: ...ASSEMBLY BURNER ITEM NO Part Number PART DESCRIPTION QTY 1 E08 00006 2 ELBOW PIPE 1 2 E13 00010 2 NIPPLE PIPE 1 4 1 3 V00 173173 BURNER OIL 1 4 V04 00314 FILTER FUEL 1 5 V1 10 80DA NOZZLE BURNER 1 6...

Page 16: ...ry a spare filter element as one tank full of contaminated fuel will plug the fuel filter element prematurely Element replacement procedure 1 Shut off the fuel tank valves 2 Unscrew the clear bowl tur...

Page 17: ...much air 3 Tighten the cap screw retaining the air bands 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...

Page 18: ...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 Buss Bar Alignment 1 Wit...

Page 19: ...transformer electrodes If buss bars do not contact see Buss bar Alignment 9 Close transformer reposition retainer and tighten screw Accessories p n Y01 00041 Gauge 0 200 PSI p n Z09 00004 Bacharach Sm...

Page 20: ...20 Burner Breakdown Burner Breakdown...

Page 21: ...Fan w Item 27 8 V00 12699 Screw Machine 22 V00 14451 1 Assembly Oil Line 9 V 101121 001 Ignitor 22 V00 14451 Assembly Oil Line 10 V 30537 003 Assembly Burner Gun 23 F04 00310 Connector Conduit 11 V00...

Page 22: ...22 Control Panel Assembly Control Panel Assembly...

Page 23: ...23 Control Panel Assembly...

Page 24: ...K WHITE BROWN YELLOW BLUE GREEN PINK ORANGE ELECTRICAL SCHEMATIC ES 00015 ES 00015 06 03 03 BWK E Q U I P M E N T G R O U N D L I N E 1 L I N E 2 VACUUM SWITCH BURNER MOTOR 115 VAC IGNITION TRANSFORME...

Page 25: ...NS Pump overfilled with oil displaced through crankcase breather hole in oil cap dipstick Drain oil Refill to recommended oil level as stated in OIL LEVEL in PUMP MAINTENANCE Water in crankcase May be...

Page 26: ...ers Overpressure to inlet manifold Reduce inlet pressure Abrasive material in the fluid being pumped Install proper filtration on pump inlet pumping Excessive pressure and or temperature of fluid bein...

Page 27: ...ce the TEMPERATURE CONTROL Fuel solenoid valve not opening Clean repair or replace solenoid Weak transformer Clean and check transformer terminals Check transformer for spark pre TRANSFORMER TEST in B...

Page 28: ...emove and replace with specified nozzle on BURNER ASSEMBLY Faulty oil pump Remove and replace Pulsating pressure Partially clogged fuel pump strainer or filter Remove and replace strainer per FUEL PUM...

Page 29: ...dy Machine will not rise to operating temperature Low fuel pressure See BURNER on MODEL SPECIFICATIOSN for specified pressure Water in fuel piping Drain fuel tank and remove and replace filter per FUE...

Page 30: ...re See FUEL on MODEL SPECIFICATIONS for specified pressure Excessive oil dripping from laydown coil condensate Loose nozzle See BURNER TROUBLESHOOTING insert Fuel pressure too high See FUEL PRESSURE A...

Page 31: ...100 Credit Years 6 7 50 Credit After 7 Years No Credit Allowed All parts supplied to us by other manufacturers will be subject to their guarantee and warranty Generators motors and engines are requir...

Page 32: ...For full warranty information contact your delivering distribu tor or contact the manufacturer at info warrantysvc com...

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