Service Manual 440C-G p/n N84001
______________________________________________________ INSTALLATION DATE PART NUMBER ______________________________________________________ MAKE/MODEL SERIAL NUMBER ______________________________________________________ SELLER ______________________________________________________ ADDRESS CITY/STATE/ZIP NOTES: Phone: 1-877-7ZEPPRO (1-877793-7776) Email: zepprofessional@zep. com Zep Inc. 1310 Seaboard Ind. Blvd.
Specifications PERFORMANCE Discharge Volume Pump Head Pressure GENERAL Minimum Inlet Water Pressure Spray Tip Weight Hose Assembly Hose Assembly Hose Coupler Belt Trigger Gun & Wand - Trigger Gun - Trigger Wand PUMP ENGINE Engine Engine Horsepower Engine Fuel Engine Make Engine Regulator Engine Charge Rate Engine Start Engine Oil Filter Engine Air Filter Engine Air Pre-Cleaner 4.0 gal/m / 15.1 L/m 4000 psi / 275 bar over 65 psi may require water inlet regulator 10 psi / 0.68 bar (#4.
OPERATION TABLE OF CONTENTS GAS ENGINE DRIVEN COLD WATER CLEANER SAFETY INSTRUCTIONS • Safety Symbols • General SERVICE Pg. # • Pump • Fuel Filter • Trigger Gun • Unloader • Machine Breakdown • Chemical Metering Valve 3 3 OPERATION •Pre Start-Up •Start-Up •Shut Down 4 4 5 Pg.
SAFETY AND OPERATION GAS ENGINE DRIVEN COLD WATER CLEANER GENERAL SAEFTY MACHINE UNPACKING ALL CLEANERS ARE CAREFULLY INSPECTED AND CARTONED TO PROTECT AGAINST SHIPPING DAMAGE. IF THERE IS DAMAGE OR MISSING PARTS, THE TRANSPORTATION COMPANY AGENT SHOULD MAKE A NOTATION TO THAT EFFECT ON THE BILL. REFER TO THE PARTS LIST IN THIS MANUAL AND ADVISE WHAT PARTS ARE MISSING OR DAMAGED. IF AVAILABLE, GIVE THE INVOICE NUMBER ON ALL ORDER BILLS. THIS PROCEDURE WILL ENABLE NEEDED PARTS TO BE SHIPPED QUICKLY. 1.
OPERATION WARNING: Never put hands or fingers in wash spray. DO NOT point the gun assembly toward your body or at anyone else. Failure to do this could result in serious injury. PRE START-UP WARNING: Avoid the exhaust areas as they are dangerously hot during and a short time after operation. 1. The first time the machine is operated, after repairs have been made, or if the machine has set for a period of time (30 days or more) follow the following procedures. A.
CAUTION: On a machine equipped with a trigger gun valve, if the trigger gun valve remains in the closed position for more than 3 minutes, water pump damage may occur. 4. TO APPLY CHEMICAL: A. Mix chemicals per label instructions. Use necessary safety precautions. B. Insert chemical screen into chemical container C. Adjust metering valve (if so equipped). D. If the gun assembly is equipped with variable or multiple nozzle assembly, adjust as desired. TO RINSE: A.
CAUTION: DO NOT RUN PUMP WITHOUT WATER, AS THIS WILL CAUSE DAMAGE TO THE PUMP AND VOID WARRANTY. MACHINE MAINTENANCE Gas Engine Driven Cold Water Cleaners DEFLECTION 2. When clean water flows from the gun, turn switch to the “OFF” position. 6. Reinstall spray tip. 7. With the gun assembly in hand, turn on the switch. On trigger gun models hold the trigger gun valve in open position. SPAN 1. 5.
MACHINE MAINTENANCE SCHEDULE ENGINE DRIVEN OIL FIRED COLD WATER CLEANERS DAILY EACH HR AFTER FIRST 8 HRS 50 HRS EVERY 50HRS EVERY 100 HRS EVERY 500 HRS YEARLY OIL BATH WATER PUMP: Oil Level - check and add as needed per PUMP SERVICE insert. Oil Change- drain and refill per PUMP SERVICE insert. CAUTION: Used oil must be disposed into an enviromental safe container and brought to an oil recycling center. Oil contamination- Milky color indicates water.
CLEANER TROUBLESHOOTING ENGINE DRIVEN COLD WATER CLEANERS TROUBLE 1. Poor cleaning action. 2. Machine will not draw chemical. 3. Low operating pressure. POSSIBLE CAUSE REMEDY F. Low discharge pressure. A. Connect the machine to a water softner. B. See “Low operating pressure.” C. See “machine will not draw chemical.” D. Obtain proper chemical. E. Mix chemical per the label. Follow all the mixing, handling, application,and disposal instructions. F. See “Low operating pressure.” A.
CLEANER TROUBLESHOOTING (CONT.) ENGINE DRIVEN COLD WATER CLEANERS TROUBLE POSSIBLE CAUSE REMEDY 6. Excessive back pressure. A. Spray tip built up with lime. B. Water pump turning too fast. . A. Remove and clean, or replace spray tip with tip specified in GENERAL section of MODEL SPECIFCATIONS. B. See MODEL SPECIFICATIONS. 7. Excessive vibration. A. Defective belt. B. Defective Pump. C. Defective accumalator. A.
Final Assembly 13 DECAL, SERIAL NUMBER 14 DECAL, CAUTION DO NOT OPERATE UNATTENDED PUMP MAINTENANCE 6 4 9 17 DECAL, PROUD TO BE AN AMERICAN 5 DECAL, WARNING ENGINE EXHAUST ITEM NO.
Trigger Gun & Wand J06-00158-B PART LIST ITEM PART NUMBER PART DESCRIPTION 1 J06-00158 Valve, Trigger Gun 2 J06-00104EZ Assembly, Wand – 42” 3 W04-24225-A Coupling, Female 9/3/2008 J06-00158 2 1 BEVEL SIDE TOWARDS BALL 12 3 7 6 4 5 DISHED SIDE TOWARDS BALL 18 3 13 19 5 14 6 15 16 17 2 8 4 1 19 7 10 9 Final Assembly
Repair Instructions 1. Specifications Remove screws from handles and remove handle housings. With 18mm socket remove retainer being careful to catch the spring and ball as they fall out of the housing. Remove and replace parts with those found in the kit. Assemble in reverse order. 2. 3. 4. Maximum Volume 10.0 GPM / 37.9 LPM Maximum Pressure 5000 PSI / 344.7 BAR Rated Temperature 300˚ F / 150˚ C Weight 1.8lbs / 0.
General Assembly 12 27 10 31 9 28 24 26 15 20 9 17 9 16 P/N R02-00243 BELT, SINGLE V 23 18 14 25 6 11 13 7 1 2 3 4 8 5 29 30 21 22 19 445SE-00603 03-31-2009 ITEM NO. 1 2 3 4 5 6 PART NUMBER 535S-00130 AR58-02800 G02-10016B H06-62503 Z01-00029 H10-50000 7 H05-50001 8 9 H06-25003 H06-31300 10 H06-37500 11 12 13 14 H06-50001 445S-00515 H04-31326 445S-00134 15 F05-00439 16 R04-00006 ITEM NO.
Unloader Assembly 2 4 5 1 3 ASSEMBLY, UNLOADER p/n: 445S-00515 4/3/2009 ITEM NO. General Assembly PART NUMBER PART DESCRIPTION QTY.
Unloader Valve Breakdown C07-03700X,C07-03800X Unloading Adjustment 1. 2. 3. 4. 5. Install an appropriate pressure gauge in pump head outlet. The gauge should have a range twice the operating pressure. Loosen nut (Item 19) and turn the knob (Item 20) counter clockwise until minimum spring tension. Open the trigger gun, start the pump, and observe pressure gauge reading. Slowly tighten the knob. Close and open the trigger gun to check unloading pressure and bypass function of the unloader valve.
PART LISTS ITEM PART DESCRIPTION PART NUMBER 19 QTY 20 21 * 1 8RS6-000SV01 O-Ring – 1/16CS x 1/2ID 1 2 C07-02000-18 Ball, SS 11/32 1 3 C07-02000-20 O-Ring 1 4 C07-02300-08 O-Ring – 11/16ID 3 5 C07-03700-1 Fitting, Outlet – 3/8 1 6 C07-03700-11 Guide Piston 1 7 C07-03700-12 Ring, Anti-Extrusion 2 8 C07-03700-15 Pin, Roll 1 9 C07-03700-21 Guide, Piston – SS 1 10 C07-03700-23 Spring, Compression 1 12 C07-03700-26 Piston 1 13 C07-03700-28 Ring, Anti-Extrusion
Pump Assembly 10 9 11 3 5 1 12 6 4 7 2 8 445SE-00501 03-31-2009 ITEM NO. PART NUMBER PART DESCRIPTION QTY.
MAXIMUM FLOW ....................8.0 GPM / 30.3 LPM MINIMUM INLET PRESSURE.......15 PSI / 1.02 BAR MAXIMUM INELT PRESSURE....150 PSI / 10.3 BAR MAXIMUM TEMPERATURE ....................180°/ 82°C WEIGHT.....................................0.5 LBS. / 0.23 KG BYPASS..............1/4 FNPT (C04-00146, C04-00147) INLET/OUTLET....3/8 NPT (C04-00145, C04-00147) INLET/OUTLET....1/2 NPT (C04-00144, C04-00146) DIMENSIONS.....................................1.125" X 3.75" 10 Pump Assembly 1.
Water Pump N09-00053 Water Pump 11
12 Water Pump
Pump Maintenance Record Month/Day/Year Oil Change Operating Hours Oil Brand & Type Month/Day/Year Pump Service Operating Hours Type of Service Pump Maintenance Record 13
XW Series Pumps Operating Instructions and Parts Manual Plunger Pumps Service Pumps (continued) with your fingers (do not use any tools you may damage the seal). Make sure the seal is totally seated against the head ring. (See Figure 16 & 17) Figure 17 3. Place the brass intermediate ring squarely over the high-pressure seal. 4.
XW Series Pumps Operating Instructions and Parts Manual Plunger Pumps 3. Assembly: 1. Install the slinger washer. 2. Install the plunger rod O-ring and split back-up ring. Place a light film of oil on the O-ring and back-up ring. NOTE: The O-ring is closest to the threaded end of the rod. 3. Install the plunger by pushing straight down and twisting slightly in either direction. Make sure you fully seat the plunger. (See Figure Figure 23 23) 4.
Pump Maintenance XW Series Pumps Operating Instructions and Parts Manual Plunger Pumps 3. Use the needle nose pliers to remove the valve. (See Figure 7) 4. Use a small probe to move the poppet Figure 7 up and down to assure that the valve is functioning properly and that no debris is stuck in the valve. 5. Using the mechanics pick remove the valve seat O-ring and inspect for any damage, replace if necessary. Valve Assembly: Service Pumps 1.
XW Series Pumps Operating Instructions and Parts Manual Plunger Pumps Service Pumps (continued) 5. With your finger pull out the brass intermediate guide ring. (See Figure 13) 6. With your fingers pull the high-pressure seal and head ring out of the head. (See Figure 14) 7. The low-pressure seal is located in the brass seal retainer. Using the mechanics pick, go in Figure 14 between the seal and retainer and pull the seal straight out. NOTE: Models have a split support O-ring.
Troubleshooting Pump Trouble Possible Cause Remedy Excessive play on crankshaft Defective bearings. See “Worn bearing.” Excess shims. Set up crankshaft. Loud knocking in pump Loose connecting rod screws. Tighten connecting rod screws per PUMP SPECIFICATIONS Replace connecting rod per PUMP MAINTENANCE. Replace bearings per PUMP MAINTENANCE. Tighten plunger screw per PUMP SPECIFICATIONS. Oil leaking in the area of Worn crankshaft seal, bad bearing, Remove and replace.
Presence of metal particles during oil change Failure of internal component. Remove and disassemble to find probable cause. New pump. New pumps have machine fillings and debris and should be drained and refilled per PUMP SPECIFICATIONS. Water leakage from under head Worn packing. Install new packing. Cracked/scored plunger. Failure of plunger retainer o-ring. Remove and replace plunger. Remove and replace plunger retainer o-ring. Loud knocking noise in pump Pulley loose on crankshaft.
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. Any replacement parts accepted as warranty will be returned to you freight prepaid.
For full warranty information, contact your delivering distributor or contact the manufacturer at info@warrantysvc.
