ZEP 1600-2V Manual de usuario
Service ManualService Manual
For full warranty information, contact your delivering distribu-
tor or contact the manufacturer at info@warrantysvc.com
1600-2V
N83901
2Specifications
______________________________________________________
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
Scale
#1 OR #2 SMOKE
Carbon Monoxide Allowed
0.01%
Draft/Stack Installation
0.2” – 0.04” WC READING
3
Specifications
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
Belt
p/n R02-00228
Discharge 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 ½ x 95’ sch 40
p/n W216RS-05207
Coil Back Pressure (New)
5 psi / 0.34 bar
Coil Back Pressure Requiring
Descaling
50 psi / 3.40 bar
ELECTRICAL
Machine Voltage
115v 60hz 1PH
Current
20 A
Temp Control, Adjustable
p/n F04-00830
Power Cord
p/n 2142-00344
English to Metric Conversions
1 gal/m = 3.7843 L/m
1 hp = .7457 kw
100 psi = 6.8964 bar
1 ft = .3048 m
1 in = 2.54 cm
1 lb = .4536 kg
(˚F – 32)
1.8 =˚C
4Trigger Gun and Wand
Trigger Gun and Wand
6/2/2009
p/n: J06-00158-B
ASSEMBLY, GUN & WAND - 42"
ITEM
NO. PART NUMBER PART DESCRIPTION QTY.
1 J06-00104E ASSEMBLY, WAND - 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 K02-03150E5 Assembly, Hose – 3/8 X 50’
4120-00902P PART LIST
ITEM PART NUMBER PART DESCRIPTION
1 C04-00131 Screen, Chemical
2Z01-08413-2 Hose, Poly Braid – 84”
2
1
5
Trigger Gun and Wand
1. Remove screws from handles and remove handle
housings.
2. With 18mm socket remove retainer being careful
to catch the spring and ball as they fall out of the
housing.
3. Remove and replace parts with those found in the
kit.
4. Assembly in reverse order.
PART LISTS
ITEM PART NUMBER PART DESCRIPTION QTY.
1 C07-01300-08 O-RING - 1/16CS X 5/16ID 1
2 C07-01425 FILTER, WATER 1
3 J06-00121-07 O-RING - 3/32 CS X 1/8 ID 1
4 J06-00121-15 BALL, SS 5/16 1
5 J06-00132-19 SCREW, SELF TAP - 3.5MM X 18MM 7
6 J06-00158-01 FITTING, DISCHARGE - 1/4 FNPT 1
7 J06-00158-02 PIN, TRIGGER - 5MM X 27.5MM 1
8 J06-00158-03 CAM 1
9 J06-00158-04 TRIGGER 1
10 J06-00158-05 LATCH, SAFETY 1
11 J06-00158-06 FITTING, INLET - 3/8 FNPT 1
12 J06-00158-08A SEAT, VALVE 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 23467
1
BEVEL SIDE
TOWARDS BALL DISHED SIDE
TOWARDS BALL
KIT, REPAIR PART - NUMBER J06-99158C
5
BREAKDOWN, GUN - TRIGGER
EXPLODED VIEW - P/N J06-00158
16
17
2
4
1
12 18 13 3
14
15
6
19 5
9
10
7
8
19
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
YG3500
WARNING:
DO NOT USE ACID CONCENTRATES
THROUGH THE GUN
WARNING:
Never secure trigger gun in an open
postion (trigger pulled back) by
means other than the operator's hand.
Bodilay harm may occur if the operator
loses control of the trigger gun.
CAUTION:
Always engage trigger safety latch
when not in use.
6Pump Assembly
Pump Assembly
ASSEMBLY, PUMP
P/N 216AX-00501E
08-19-2008
ITEM
NO. PART NUMBER PART DESCRIPTION QTY.
1 C03-00810 VALVE, AIR 1
2 C07-03700X VALVE, UNLOADER (SILVER) 1
3 E04-00001-58 BUSHING, PIPE 1
4 E04-00005-48 BUSHING, PIPE 2
5 E07-00001-4 CROSS, PIPE 1
6 E08-00006-48 ELBOW, PIPE 1
7 E08-00011-58 ELBOW, PIPE 1
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 N07-00115 PUMP, WATER 1
18 N07-20046-P MOUNT, PUMP 1
19 R03-00669 PULLEY, V 1
20 R04-00001 BUSHING, PULLEY 1
21 W02-00032 CLAMP, HOSE 2
22 W02-10016-8 BARB, HOSE 1
23 W02-10030-8 BARB, HOSE 1
24 W02-10040-8 BARB, HOSE 1
25 W02-10057-8 BARB, HOSE 1
23
1314 10 4 9 25
24
5
13
18 19 20
22
4
7
8
11
12
21
16
2
17
15 6
7
Pump Maintenance
6
7
2
6
3
1
Pump Maintenance
General
PACKING EXTRACTION KIT P/N Z09-00028
COMPLETE TOOL KIT P/N Z09-00021
Valve Service
1. Remove the plugs holding the valve assemblies.
2. Remove and discard o-rings from the plugs. Clean plugs with
solvent or soap and water. Allow to dry.
3. Using needle nose pliers, ngers, or hook shaped tool,
remove the valve assemblies from the head. Remove and
discard the o-rings from the valve assemblies and/or head.
Examine each valve assembly and discard damaged parts.
Refer to the PUMP BREAKDOWN for part numbers of any
replacement items.
4. Clean any accumulated debris from the valve cavities and
ush with water.
5. Wash the valve assemblies in clean water and rinse. While
still wet, test each valve assembly by sucking on the valve
seat. A properly sealing valve will allow a good vacuum to
be developed and maintained, while 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 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 the value indicated in the TORQUE section
of the pump specications.
11. Repeat steps 7 through 11 for remaining valve assemblies.
Head Removal
1. Remove the cap screws holding the pump head to the
crankcase. A metric tool is required for this step. Be careful
not to lose the washer on each cap screw.
2. Remove the head by rotating the crankshaft and tapping
the head away from the crankcase with a soft mallet. Keep
rear surface of the head parallel to the front surface of the
crankcase to prevent binding on the plungers.
3. Once the head is removed, protect the plungers from damage.
8Pump Maintenance
Plunger Service
1. Remove pump head per HEAD REMOVAL.
2. Remove any packings and retainers left on the plungers by pulling them straight off.
3. Examine each plunger, looking for a smooth surface free of any scoring, cracks, or pitting. Any
defective plungers should be removed per PLUNGER REMOVAL.
4. Discard and replace any defective plungers.
5. Reinstall the plunger per PLUNGER INSTALLATION.
6. 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.
1. When the plunger screw 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 inger washer, clean with solvent and allow to dry.
Plunger Installation
1. Install the copper inger washer onto the cross head.
2. Slide the plunger onto the crosshead.
3. Lubricate an o-ring with crankcase oil and install into the groove on the plunger screw. Install the
anti-extrusion ring 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.
4. Apply a drop of thread sealant to the threads of the retainer screw.
5. Thread the plunger retainer screw into the cross head making sure the copper at washer is
installed onto the screw.
6. Torque the plunger retainer screw to the value indicated in the torque section of the pump
specications.
9
Pump Maintenance
Packing Service
1. Remove the head per PUMP HEAD REMOVAL.
2. 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. Remove packings and o-rings from adapters. Discard the o-rings and packings.
3. Clean the packing canities in the head and rinse with clean water.
4. Clean exposed plungers. Clean male and female adapters with soap and water and allow it to dry.
5. Examine male and female adapters, discard worn items. Trial t 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
at 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 the re-stop ring with the lips pointing down.
10. Install a front female adapter into each cavity with the at side up. Make certain the adapter goes
all the way down into the cavity.
11. Install the low pressure packing with the at side down.
12. Install the rear female adapter into each cavity with the lips pointing down.
13. Lubricate o-rings with pump crankcase oil and install one into the groove of each adapter.
14. Install one adapter and o-ring into each cavity with the at side up. Each adapter and o-ring
assembly should push into the head to approximately 1/16 inch of being ush with the surface of
the head. Only hand pressure should be required to perform this operation. This step is VERY
IMPORTANT. If the rear female adapter does not t is obtained, proceed to step 16. If a proper t
is not obtained, remove the female adapters from the offending cavity and reinstall items per steps
8 through 15.
15. Install head per HEAD INSTALLATION.
10 Pump Maintenance
5
3
1
7
6
4
2
8
7
Head Installation
1. Prepare pump head per instructions in PACKING
SERVICE.
2. Rotate the plungers so the outer plungers are
projecting the 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 the
TORQUE section of PUMP SPECIFICATIONS. Torque
the cap screws in the order listed below.
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