ZEP 1600-2V User manual

Service ManualService Manual
For full warranty information, contact your delivering distribu-
tor or contact the manufacturer at [e-mail]
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 specications.
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
specications.

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.

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

12 Unloader Valve Breakdown
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.
3. Open the trigger gun, start the pump,
and observe pressure gauge reading.
Slowly tighten the knob.
4. Close and open the trigger gun to check
unloading pressure and bypass function
of the unloader valve. The unloading
pressure should not exceed operating
pressure more than 400 PSI.
5. Lock the setting by tightening the nut
(Item 23)
Note: Once the operating pressure is reached,
turning the knob clockwise will increase the
unloading pressure only.
Specications
Maximum Flow 7.8 gal/m / 30 L/m
Max Unloading Press
C07-05700X 2900 psi / 200 bar
C07-03700X 3650 psi / 252 bar
C07-03800X 4350 psi / 300 bar
Maximum Temperature 190˚F / 88˚C
Weight 2.1 lbs / 0.91 kg
Bypass 1/4 FNPT
Inlet & Discharge 3/8 FNPT
Item Part Number Description Qty Kit
C07-03700X
C07-03800X
C07-05700X
1C07-03700X-01 Piston 1 *
2C07-03700-15 Pin, Roll 1 *
3C07-03700-28 Ring, Anti-Extrusion 2 *
4C07-03700-29 O-Ring – 3/32 x 7/16ID x 3043 1 *
5C07-03700X-02 Housing, Unloader – 3/8” 1
6C07-0370019B Gasket, Washer – 14 x 8.3 x 1.5 1
7C07-0370019A Plug – 3/8” 1
8C07-03700-6B Gasket, Washer – 11.4 x 6.5 x 1.5 1
9C07-03700-6A Plug – 1/4” 1
10 C07-03700-2 O-Ring – 11/16ID 3 *
11 C07-02000-20 O-Ring 1 *
12 C07-03700-4 Orice, Shutter 1 *
13 C07-03700-3 Spring, Compression 1 *
14 C07-03700X-03 Fitting, Outlet 1
15 N07-20028 O-Ring – 1/16CS x 7/16ID 1 *
16 C07-03700X-04 Guide, Piston – SS 1 *
17 C07-03700X-05 Ball, SS – 11/32 1
18 C07-03700-23 Spring, Compression 1
19 C07-03700X-06 Guide, Ball 1
20 C07-03700-12 Ring, Anti-Extrusion 2 *
21 8RS6-000SV01 O-Ring – 1/16CS x 1/2ID 1 *
22 C07-03700X-07 Guide, Piston 1
23 C07-03700-7 Nut, Lock – M8 2
24
C07-05700X-08 Spring – yellow 2900 psi 1
C07-03700X-08 Spring – grey 3650 psi 1
C07-03800X-08 Spring – black 4350 psi 1
25 C07-03700X-09 Follower, Spring 1
26 C07-03700X-10 Knob, Adjustment 1
27
C07-05700X-11 Cover, Knob – orange 2900 psi 1
C07-03700X-11 Cover, Knob – blue 3650 psi 1
C07-03800X-11 Cover, Knob – grey 4350 psi 1
C07-03700XK Kit, Repair - Parts Package
1/17/2008

13
Float Tank Assembly
Float Tank Assembly
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 BARB, HOSE 1
ASSEMBLY, TANK - FLOAT
216AX-01121

14 Float Tank Assembly
3
5
4
6
8
9
10
17
15
14
1
12
7
13
16
11
2
18
PARTS LIST
VALVE, FLOAT - P/N C03-00631
SPECIFICATIONS
8/8/2008
ITEM
NO. PART NUMBER PART DESCRIPTION QTY.
1 C03-00625-10 SCREW, WING - 10-32UNF 1
2 C03-00628 FLOAT, PLASTIC 1
3 C03-00631-01 NUT,HEX - 3/8FNPT 1
4 C03-00631-02 WASHER, FLAT - RUBBER 1
5 C03-00631-03 NIPPLE, BRASS - 3/8NPT 1
6 C03-00631-04 SEAT, VALVE-NYLON 1
7 C03-00631-05 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 PRESSURE........................140 PSI / 10 BAR
MAXIMUM TEMPERATURE ......................140 F/60 C
PORT SIZE - INLET..........................................3/8" NPT
DIMENSIONS...11.4 X 4.1 X 2.8 IN / 290 X 104 X 71MM
WEIGHT...................................................0.6 LB / 0.3 KG
HOUSING MATERIAL .........................................BRASS
O-RING MATERIAL............................................BUNA-N

15
Burner Assembly
Burner Assembly
5
3
6
12
47
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
W02-10019-8 BARB, HOSE 1
7
W02-10031 BARB, HOSE 1

16 Burner Assembly
Maintenance Procedures
Priming the machine
Shut off the fuel tank valves. Spin off the clear bowl, ll 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. Turn on the fuel tank valves. Start the
machine and check that there are no leaks.
Draining water
Check the collection bowl daily. Drain off water
contaminants by unscrewing the clear bowl turning counter-
clockwise. Start the machine and allow air to purge from the
fuel system prior to operating the equipment.
Element replacement frequency
Frequency of element replacement is determined by
contamination level in the fuel. Replace the element every 500
hours.
Note: Foul smelling diesel fuel is an indication of
microbiological contamination. A change in fuel source is
recommended. Always carry a spare lter element as one
tank full of contaminated fuel will plug the fuel lter 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 lter 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 QTY.
1 V04-00314-1 HOUSING, UPPER-1/4F X 1/4F
ALUMINUM 1
2 V04-00314-2 O-RING, 1
3 V04-00314-3 SCREEN,FILTER-SS ELEMENT 1
4 V04-00314-4 BOWL, FILTER-CLEAR
PLASTIC 1
Trouble Possible Cause Remedy
1. Fuel bowl leaking. A. Deteriorated gasket.
B. Housing Cracked.
C. Bowl rim cracked, nicked, or
scratched.
D. Gasket missing.
E. Loose Fuel Bowl.
A. Remove and Replace Gasket.
B. Remove and Replace Housing.
C. Remove and Replace Bowl.
D. Replace Gasket.
E. Tighten Fuel Bowl Onto Filter.
2. Air leaking into system
(indicated by air bubbles in
bowl during operation).
A. Cracked Component.
B. Loose Filter bowl.
A. Inspect Filter Bowl, Filter Housing, and
Gasket.
B. Tighten Fuel Bowl Onto Fuel Filter.

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.
1. Loosen the cap screw retaining the air bands.
2. Move the air bands as indicated below with the machine in
operation. Note: The air band should be set so the exhaust
gives the smoke spot specied in the GENERAL section of the
MACHINE SPECIFICATIONS on a Shell-Bacharach scale. If
a smoke tester is not available, a smoky exhaust, oily odor, or
sweet smell indicates insufcient air while eye-burning fumes
indicate too 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 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 and fuel lter.
5. Turn on fuel supply. Failure to do so will result in fuel pump
damage.
Fuel Pump Pressure Adjustment
1. Install a 0-200 PSI Pressure Gauge.
2. Remove Plug on top of the fuel pump.
3. Insert a 1/8” Allen Wrench and turn clockwise to increase
pressure and counter clockwise to decrease.
4. Remove Gauge and reinstall plug.
Blower Fan Replacement
1. Shut off power to the burner and disconnect wires.
2. Loosen the two screws securing blower motor and fan to the
PART NUMBER
V00-14283-2
PART NUMBER
V00-14283-5

18 Oil Burner Maintenance
housing.
3. Remove the blower.
4. 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 at of
the motor shaft. Tighten set screws onto motor shaft.
5. Reinstall motor and blower assembly.
6. Reconnect wires and turn on power.
Transformer Test
1. Remove burner junction box cover.
2. Turn on burner and make sure ignition transformer is receiving
rated voltage.
3. Turn off burner.
4. Loosen screw and swing transformer away from burner gun
assembly.
5. Turn on burner.
6. Short the high voltage terminals.
7. Open gap by drawing screwdriver away from one electrode
while touching the other.
8. The spark should jump between 5/8 inches and ¾ inches, if it
doesn’t jump, replace the transformer.
9. Turn burner off.
10. Partially close transformer. 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 the buss bars contact
and are in alignment with transformer electrodes.
4. Proper adjustment is obtained by gently bending the buss
bars until they spring against, parallel, and are in full contact
with the transformer electrodes.
5. With buss bars aligned, carefully close and fasten the
transformer.
Burner Gun Removal & Installation
1. Disconnect the fuel line from the burner gun assembly oil line
tting. Loosen the other end of the line and swing line out of
the way.
2. Remove the retaining nut.
3. Loosen screw and swing transformer away from burner gun
assembly.
4. Carefully remove the burner gun assembly.
WARNING
Use screwdriver
with a well insulated
handle to avoid
shock.

19
Oil Burner Maintenance
1) Check and replace electrode insulators if cracked.
2) Clean burnt buss bars.
3) Clean carbon off electrodes.
4) Clean carbon off oil nozzle (use caution not to
scratch face of nozzle or orice).
5) Check for a loose oil nozzle. Note: Check with
dealer and/or replace nozzle with proper nozzle.
5. Gently replace burner gun assembly in air tube. CAUTION:
Do not force. Forcing will cause electrode misalignment.
6. Reinstall the retaining nut.
7. Reinstall the oil line making sure both ends are tight.
8. Partially close transformer. Check if buss bars align and
contact the 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 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 surface plane or end of oil
nozzle.
3. Place each electrode tip 5/16” from center of spray nozzle
hole, maintaining previous measurement.
4. Spread electrode tips to 1/8” gap maintaining previous
measurements.
5. When the proper measurements are obtained, gently tighten
screws that hold electrode assembly in place. CAUTION: Do
not over tighten, as this will cause the electrode insulator to
fail.

20 Burner Breakdown
Burner Breakdown