ZEP Pressure Washers Service Manual Download Page 7

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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

NIPPLE, 3/8MNPT-CLOSE PS PIPE SCH80

E15-00010-48

NIPPLE, BRASS 1/2"

E15-00025-48

NIPPLE, BRASS 1/2"

F04-00761

SWITCH, VACCUM

K21-02214-1/4

ASSEMBLY, HOSE-OIL, DRAIN

K33-01300

HOSE, WATER - 3/8 X 13"

N07-00180

PUMP, WATER - 4PGM @ 2500PSI

N07-20046-P

MOUNT, PUMP

R03-00674

PULLEY, V

R04-00001

BUSHING, PULLEY

W02-00032

CLAMP, HOSE

W02-10016-8

BARB, HOSE

W02-10030-8

BARB, HOSE

W02-10040-8

BARB, HOSE

W02-10057-8

BARB, HOSE

Summary of Contents for Pressure Washers

Page 1: ...Servic e Manua l Servic e Manua l g distribu c com 6 ...

Page 2: ...a hazard which if not avoided could result in death or serious injury Indicates a hazard which if not avoided might result in minor or moderate injury CAUTION when used without the alert symbol indicates a situation that could result in damage to the equipment DANGER CAUTION WARNING CAUTION ______________________________________________________ INSTALLATION DATE PART NUMBER _______________________...

Page 3: ...r 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 Weight 420 Lbs 191 Kg Fuel Tank Capacity 4 5 gal 17 L Pump to Coil Hose p n Y01 00016 Spray Tip 4 0 15 p n JA0 15040 2 Discharge Hose Assembly 3 8 x 50 4000psi P N K02 03150E5 Belt p n R02 00229 Trigger Gun Wand p n J06 00158 B Trigger Gun p n J06 00158 Trigger Wand p n ...

Page 4: ...wer 4 0 HP 3 0 KW Motor Speed 3450 RPM Motor Voltage 208v 230v 60hz 1PH BURNER Burner Part Number V00 173189 V00 173191 Burner Type Pressure Atomizing Fuel Type Kerosene 1 or 2 Diesel Fuel Pressure 125 PSI 9 BAR Fuel Nozzle 1 10 80 Degree A P N V1 10 80DA Fuel Consumption 1 23 GPhr 4 7LPhr Fuel Pump Dan Foss P N V 100714 001 Voltage 230V 60 Hz 1PH Motor Horsepower 1 7 HP Motor Speed 3450 RPM Fuel ...

Page 5: ...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 K02 03150E5 Assembly Hose 3 8 X 50 4120 00902P PART LIST ITEM PART NUMBER PART DESCRIPTION 1 C04 00131 Screen Chemical 2 Z01 08413 2 Hose Poly Braid 84 2 1 Trigger Gun and Wand ...

Page 6: ...1 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 X 44MM 1 19 J06 99158A HOUSING HANDLE 1 REPAIR INSTRUCTIONS SPECIFICATIONS 2 3 4 6 7 1 BEVEL SIDE TOWARDS BALL DISHED SIDE TOWARDS BALL KIT REPAIR PART NUMBER J06 99158C 5 BREAKDOWN GUN TRIGGER EXPLO...

Page 7: ...8 E09 00003 2 PLUG PIPE 1 9 E10 00005 4 TEE PIPE 1 10 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 ASSEMBLY HOSE OIL DRAIN 1 16 K33 01300 HOSE WATER 3 8 X 13 1 17 N07 00180 PUMP WATER 4PGM 2500PSI 1 18 N07 20046 P MOUNT PUMP 1 19 R03 00674 PULLEY V 1...

Page 8: ... CRANKCASE 14 7 FT LBS 2 0 KG M NOTE When plunger nut is removed it is important you install a new copper washer and flinger washer to ensure proper fit and seal of ceramic plunger each time plunger screw is torqued copper washers conform to plunger If same copper washers are used plunger cracking or poor seal may result TX1813S17 ACCESSORIES Oil Case 6 One Pint Bottles p n N07 0ILCA Oil Bottle 1 ...

Page 9: ...0011 Washer Flat 10 N07 29026 O Ring 33 N07 98001 Head Pump Brass 11 N07 98026 Cover Rear 34 N07 20003 Washer Flat 12 N07 20027 Screw Cap 35 N07 98002 Screw Cap 8mm x 65mm 13 N07 98029 Indicator Oil Level 36 N07 99123 Kit Valve Assembly 14 N07 80009 O Ring 37 N07 20004 O Ring 15 N07 20030 Plug Pipe 37A N07 20009 O Ring 16 N07 20028 O Ring 38 N07 47010 Plug Pipe 17 N07 98032 Pin Crosshead 39 N07 12...

Page 10: ...allation in step 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 th...

Page 11: ...is removed it is important to install a new o ring anti extrusion and copper washers 2 Remove the plunger retaining screw by turning counterclockwise 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 Remove and discard copper flinger washer clean with solve...

Page 12: ...al fit the female adapters into the head checking for binding or damage Discard and replace damaged items 6 Lubricate packing cavities in the head and all packings and adapters with pump crankcase oil 7 Lay head on the bench with packing cavities up Install one male adapter in each cavity with the flat side down 8 Install one v packing into each cavity with the lips pointing down A packing inserti...

Page 13: ...e same distance from the crankcase 3 Lubricate the exposed 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 the crankcase Do not forget the lock washer on each screw 6 Tighten all cap screws by hand 7 Torque the cap screws to the value indicated in...

Page 14: ...14 Pump Maintenance Records Oil Change Month Day Year Operating Hours Oil Brand Type Pump Service Month Day Year Operating Hours Type of Service Pump Maintenance Record ...

Page 15: ...ion 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 1 5 C07 03700X 02 Housing Unloader 3 8 1 6 C07 0370019B Gasket Washer 14 x 8 3 x 1 5 1 7 C07 0370019A Plug 3 8 1 8 C07 03700 6B Gasket Washer 11 4 x 6 5 x 1 5 1 9 C07 03700 6A Plug 1 4 1 10 C07 03700 2 O Ring 11 16ID 3 11 C0...

Page 16: ...M NO Part Number PART DESCRIPTION QTY 1 2120 04120B TANK FLOAT 1 2 4120 10540 ASSEMBLY RESTRICTOR 1 3 C03 00631 FLOAT VALVE 1 4 C04 00120 FILTER SOAP SCREEN 1 5 C05 00271 WASHER GARDEN HOSE 1 6 C05 00274 ADAPTER GARDEN HOSE 1 7 E09 00002 P PLUG PIPE NYLON 1 8 W02 10057 8 BARB HOSE 1 ...

Page 17: ... 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 HEX BRASS 1 14 C03 00631 16 LEVER BRASS 1 15 C03 00631 17 KEY COTTER 1 16 C03 00631 18 NIPPLE TOE 1 17 C03 0631 09 NUT RETAINER 1 18 H05 18700 WASHER FLAT 1 MAXIMUM VOLUME 7 GPM 26 LPM MAXIMUM PRESS...

Page 18: ... Part Number PART DESCRIPTION Defaul t QTY 1 AS16 01204 PB BRACKET TRANSFORMER 1 2 E08 00006 2 ELBOW PIPE 1 3 E13 00010 2 NIPPLE PIPE 1 4 1 4 H04 19011 SCREW SELF TAP 2 5 V00 17318 BURNER OIL 230V 1 6 V04 0031 FILTER FUEL 1 7 W02 10019 8 BARB HOSE 1 8 W02 10031 BARB HOSE 1 ...

Page 19: ...rry 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 turning counter clockwise 3 Remove and discard the filter element 4 Follow listed procedures under PRIMING 2 3 1 4 FILTER FUEL 1 4F X 1 4F p n V04 00314 2 26 2010 ITEM NO PART NUMBER PART DESCRIPTION QT...

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

Page 21: ...V 20602 002 Band Air Outer 1 x 5 6 V00 13073 Cover Junction Box 20 V 20601 002 Band Air Inner 1 x 5 7 V00 21319 J Box 21 V 31910 002 Housing Fan w Tube 8 V 100991 002 Transformer 230V 60HZ 21A V 22080 001 Tube Air w Flange 9 V 21723 012 Cover Housing w Gasket 21B V00 14157 Cone Air 1A 10 H04 13801 Screw Machine 21C V00 14116 Screw Thread Cutting 11 V 30537 019 Assembly Burner Gun 21D V 21866 002 H...

Page 22: ...22 Burner Specs ...

Page 23: ...uch 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 gasket off and pull strainer 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 sure to remove water in supply tank a...

Page 24: ...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 With burner off loosen screw and swing the transformer away from burner gun assembly 2 Inspect the buss bars and transformer electrodes for pitting or corrosion 3 Partially close the transformer Check if ...

Page 25: ...ransformer 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 Smoke Tester p n Y01 00090 Allen Wrench 1 8 8 p n z01 00092 Fuel Nozzle Changing Wrench Electrode Assembly Adjustment 1 Loosen screws holding electrode assemblies 2 Raise electrode tips 5 32 above surfac...

Page 26: ...ITE BROWN YELLOW BLUE GREEN PINK ORANGE ELECTRICAL SCHEMATIC ES 00024 ES 00024 06 07 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 GRN 3X WHT RED BLK WHT RED BLK WHT BLK WHT BLK BLK BURNER MOTOR 230 VAC IGNITION TRANSFORMER 230 VAC VACUUM SWITCH PUMP MOTOR 230 VAC CAM SWITCH BLK 230 VAC 5 6 7 8 1 2 3 4 ...

Page 27: ...ALL ITEM NO Part Number PART DESCRIPTION QTY 1 350 00205A COIL REMOVABLE 1 2 AA18 00101 ANGLE BRACKET 1 3 AS16 04425 PR WRAPPER COIL 1 4 E08 00012 1 ELBOW REDUCING 1 5 E08 00016 5 ELBOW FORGED 1 6 E15 00035 2 NIPPLE PIPE GS 1 7 E15 00045 2 NIPPLE PIPE GS 1 ...

Page 28: ...ONS 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 caused by humid air condensing into water inside Maintain or step up lubrication schedule Worn or damaged plunger screw o ring Remove and replace See PLUNGER SERVICE in PUMP MAINTENANCE Worn bearing...

Page 29: ...g rod crankshaft or crosshead Remove and replace Frequent or premature failure of the packing Scored damaged or worn plunger Remove and replace plungers 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 being pumped Check pressures and fluid inlet temperatur...

Page 30: ... repair or replace switch Vacuum switch not closing Adjust repair or replace switch Temperature control switch not closing Adjust or replace 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 BURNER MAINTENANCE SECTION Faulty cad cell if equipped Clean an...

Page 31: ...Remove 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 PUMP FILTER in OIL BURNER MAINTENANCE section Air leaking around fuel pump cover Check fuel pump cover screws for tightness and damaged gasket Unit smokes Improper fuel Refuel with FUEL specified on MAC...

Page 32: ... electrode setting Readjust per ADJUSTING ELECTRODE ASSEMBLY in OIL BURNER MAINTENANCE section Weak transformer See TRANSFORMER CHECK on OIL BURNER MAINTENANCE section Burner does not electrically come on Burner motor reset button tripped Reset if necessary CAUTION Do not keep hitting the reset button if you have oil pressure you are just filling the burner combustion chamber with oil and if ignit...

Page 33: ...pply Use fuel specified in BURNER section of the MODEL SPECIFICATIONS Dry steam very little moisture very hot steam Insufficient water See Low operating pressure on MACHINE TROUBLESHOOTING insert Improper fuel supply Use fuel specified in BURNER section of the MACHINE SPECIFICATIONS Improper fuel pressure See BURNER on MODEL SPECIFICATIONS for specified pressure Machine smokes sweet smelling exhau...

Page 34: ...eplace with appropriate nozzle found on the BURNER ASSEMBLY or BREAKDOWN insert Incorrect burner nozzle Remove and replace with appropriate nozzle found on the BURNER ASSEMBLY or BREAKDOWN insert Poor combustion Low fuel pressure See Low fuel pressure on BURNER TROUBLESHOOTING insert Improper fuel supply See Low fuel pressure on BURNER TROUBLESHOOTING insert Insufficient combustion air See AIR BAN...

Page 35: ...s 5 years 25 Credit Allowed After 5 years NO CREdIT ALLOWEd Any parts supplied to us by other manufacturers will be subject to their guarantee and warranty Generators motors and engines are required by vendors to be repaired or replaced by authorized warranty repair stations We will assist you in locating warranty stations around the country in cases where that is necessary Select items carry 6 si...

Page 36: ...For full warranty information contact your delivering distribu tor or contact the manufacturer at info warrantysvc com ...

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