ZEP 440C-G User manual

Service ManualService Manual
For full warranty information, contact your delivering distribu-
tor or contact the manufacturer at [e-mail]
440C-G
p/n N84001

______________________________________________________
INSTALLATION DATE PART NUMBER
______________________________________________________
MAKE/MODEL SERIAL NUMBER
______________________________________________________
SELLER
______________________________________________________
ADDRESS CITY/STATE/ZIP
NOTES:
Phone: 1-877-7ZEPPRO (1-877-
793-7776)
Email: zepprofessional@zep.
com
Zep Inc.
1310 Seaboard Ind. Blvd.
Atlanta GA 30318

1
Specifications
Specifications
PERFORMANCE
Discharge Volume
4.0 gal/m / 15.1 L/m
Pump Head Pressure
4000 psi / 275 bar
GENERAL
Minimum Inlet Water Pressure over 65 psi may require water inlet regulator
10 psi / 0.68 bar
Spray Tip
(#4.0 - 15˚) p/n JA0-15040-2
Weight
435 lbs / 170 Kg
Hose Assembly 3/8” x 50’ 4000psi
Hose Assembly p/n 3401-00701A
Hose 3/8” x 50’ p/n K02-03150E5
Coupler p/n W04-34155-A
Belt
p/n R02-00246
Trigger Gun & Wand
p/n J06-00158-B
- Trigger Gun p/n J06-00158
- Trigger Wand p/n J06-00104EZ
PUMP ENGINE
Engine F05-00439B
Engine Horsepower 16 HP / 12 KW
Engine Fuel Gasoline
Engine Make Vanguard
Engine Regulator P/N F05-00440-02
Engine Charge Rate 20 AMP
Engine Start Electric
Engine Oil Filter p/n F05-00441-02
Engine Air Filter p/n F05-00422-3
Engine Air Pre-Cleaner p/n F05-00442-4

SERVICE
•Pump See Parts List Section
•Fuel Filter See Parts List Section
•Trigger Gun See Parts List Section
• Unloader See Parts List Section
• Machine Breakdown See Parts List Section
• Chemical Metering Valve See Parts List Section
Chemical Metering
•Flow Adjustment See Parts List Section
Unloader
•Pressure Adjustment See Parts List Section
WARRANTY Inside Back Cover
SPECIFICATIONS Inside Front Cover
SCHEMATIC Last Page
Supersedes 05-12-06 Z08-00485TC 05-17-06 Z08-00485TC
2
OPERATION TABLE OF CONTENTS
GAS ENGINE DRIVEN COLD WATER CLEANER
SAFETY INSTRUCTIONS
•Safety Symbols 3
•General 3
OPERATION
•Pre Start-Up 4
•Start-Up 4
•Shut Down 5
MAINTENANCE
Machine
•Belt Tension 6
•Spray Tip Maintenance 6
•Flushing 6
•Storage 6
•Schedule 7
TROUBLESHOOTING
Pg. # Pg. #
Machine 8
•Pump See Parts List Section
COMPONENT ADJUSTMENT

SAFETY AND OPERATION
GAS ENGINE DRIVEN COLD WATER CLEANER
05-17-06 Z08-00485
1. Before operating this machine, read and observe all
safety, unpacking, and operating instructions. Failure
to comply with these instructions could create a
hazardous situation.
2. The operator of this equipment should not operate this
equipment when fatigued or under influence of alcohol
or drugs.
3. The operator of this equipment should be thoroughly
familiar with its operation and trained in the job to
be accomplished.
4. The operator of this equipment should wear protective
face shields and other protective clothing as required
for safe operation.
5. Always point the gun assembly in a safe direction and
do not direct spray on the cleaner.
6. Do not operate the machine if any mechanical failure
is noted or suspected.
8. Do not leave this machine unattended when it is
operating.
9. All installations must conform to all applicable
Local codes. Contact your electrician, plumber,
utility company or seller for details.
3
GENERAL SAEFTY
Supersedes 05-12-05 Z08-00485
Read and understand this “OPERATOR’S
MANUAL” and “LABELS
ON THE MACHINE” before
starting.
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.
READ ALL Installation, Operation, and Maintenance
instructions before operating the machine.
NOTE: Refer to CLEANER MODEL for SERIAL NUMBER
location.
NOTE: Dimensions are in inches unless otherwise noted.
The safety alert symbol. This symbol is used
to identify safety information about hazards that can
result in personal injury.
A signal word (DANGER, WARNING, or CAUTION) is used
with the alert symbol to indicate the likelihood and the
potential severity of injury. In addition, a hazard symbol
may be used to represent the type of hazard
DANGER indicates a hazard which, if not avoided,
will result in death or serious injury.
WARNING indicates a hazard which, if not avoided,
could result in death or serious injury.
CAUTION 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.
IMPORTANT SAFETY
INSTRUCTIONS
WARNING: RISK OF INJECTION OR
SEVERE INJURY. KEEP CLEAR OF
NOZZLE. DO NOT DIRECT DISCHARGE
STREAM AT PERSONS. THIS EQUIPMENT
IS TO BE USED ONLY BY TRAINED
OPERATORS.
AVERTISSEMENT:RISQUE D’INJECTION ET
DE BLESSURES GRAVES. SE TENIR À
L’ÉCART DU JET. NE PAS DIRIGER LE JET
DE SOTIE VERS D’AUTRES PERSONNES
CONFIER L’UTILISATION LE JET DE SOTIE
VERS D’AUTRES PERSONNES. CONFIER
L’UTILISATION DE CE MATÉRIEL À UN
OPÉRATEUR QUALIFIÉ.
ADVERTENCIA:RIESGO DE LA INYECCIÓN
O SEVERO LESIÓN. CLARO DE LA
SUBSISTENCIA DEL INYECTOR. NO DIRIJA
LA CORRIENTE DE LA DESCARGA EN LAS
PERSONAS. ESTO EL EQUIPO DEBE SER
UTILIZADO SOLAMENTE POR LOS
OPERADORESENTRENADOS.

05-12-06 Z08-02830A
10. If a water leak is found, DO NOT OPERATE THE
MACHINE. Shut off the motor and repair.
11. Do not start the machine unless the gun assembly is
firmly gripped by the machine operator. Failure to do
this could result in injury from a flying hose and gun
assembly.
12. All guards, shields, and covers must be replace after
adjustment are made to prevent accidental contact
with hazardous parts.
13. If chemicals are used in conjunction with this
equipment, read and follow the product label
directions.
14. Do not refuel the machine while it is running or hot.
Allow it to cool sufficiently to prevent ignition of any
spilled fuel. .
15. Drive belts must be inspected and tightened
periodically to operate at optimum levels.
16. Inspect machine for damaged or worn components
and repair or replace to avoid potential hazards.
Do not operate the machine if any mechanical
failure is noted or suspected.
17. Always use the correct size spray tip specified in
the GENERAL section of the MODEL
SPECIFICATIONS or MODEL EXPLODED VIEW.
18. Do not start the engine until you have observed all
safety instructions and operating found in the
operating manual.
SAVE THESE SAFETY
INSTRUCTIONS
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. Check the tension of the belt (if so equipped)
per instructions in MACHINE MAINTENANCE.
B. Flush the machine per instructions in MACHINE
MAINTENANCE.
2. CAUTION: Always use the factory supplied wash
hose with your machine. Do not substitute other
hoses as a potential safety problem may develop.
CAUTION: If machine has been exposed
tosub-freezing temperatures, it must be thoroughly
warmed to above freezing before operating. Failure
to warm machine can cause damage to the pump
packings and other components.
♦ Refer to the MAINTENANCE SCHEDULE for any
maintenance to be performed before
operation
♦OIL LEVEL: Check the oil level in the water pump.
♦BELT: Make sure belt tension and condition is as
specified in MACHINE MAINTENANCE.
♦ METERING VALVE ( if so equipped): Make sure the
metering valve is closed before operation. If air enters
the system through this valve, poor performance and
machine damage will occur. Refer to the metering
valve insert for proper operation.
♦WATER SUPPLY: This machine must have a water
supply meeting or exceeding the maximum discharge
volume specified in the PERFORMANCE section, and
a minimum water inlet pressure of 40 PSI /12.1KGM.
1. Turn water supply.
2. With the gun assembly in hand (on trigger gun models
hold the trigger gun valve in open position) and with
a good flow of water turn the switch to the “pump”
position.
CAUTION: A good flow of water must be flowing
from the end of a gun for 30 seconds, before
proceeding. Lack of water can cause damage to
the water pump and like components.
4
Supersedes 08-19-04 Z08-02830A
WARNING: Avoid the exhaust areas as they are
dangerously hot during and a short time after
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.
WARNING: DO NOT run engine in an enclosed
area. Exhaust gases contain carbon monoxide,
an odorless and deadly poison.
PRE START-UP
OPERATION
START-UP

05-12-06 Z08-02830B
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. Close the chemical metering valve (if so
equipped). NOTE: It is advisable to dip the
chemical screen in a container of clean water
and open the valve 1 minute to clean the valve of
any remaining residue.
B. If the gun assembly is equipped with variable or
multiple nozzle assembly, open and close to clean
nozzle of any remaining residue.
C. Start from the top, working downward using
long, overlapping strokes.
1. Shut down per engine owners manual.
2. Turn off the water supply.
3. If freezing conditions may exist, refer to STORAGE
in MACHINE MAINTENANCE.
4. Refer to engine owners manual for proper engine
storage.
5
Supersedes 08-19-04 Z08-02830B
SHUT-DOWN

CAUTION: DO NOT RUN PUMP WITHOUT
WATER, AS THIS WILL CAUSE DAMAGE TO
THE PUMP AND VOID WARRANTY.
5. 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.
8. When clean water flows from the gun, turn switch
to the “OFF” position.
9. If freezing conditions may exist, refer to
“STORAGE” section.
10. Turn off and disconnect the water supply.
Disconnect elctrical supply.
1. Correct belt tension will allow a 1/64- inch
deflection for each inch of span between pulley
centers with a 6-pound force applied in the middle
of the span.
EXAMPLE: A 6-pound force applied at the middle
of an 8 inch span should produce a deflection of
8/64 inch or 1/8 inch.
2. Belts can be tightened or loosened by loosening
the nuts holding the pump assembly to the motor
mount. Then tighten or loosen
the j-bolt on the motor mount. Retighten the pump
assembly after the desired tension is reached.
1. Remove the spray tip from the gun assembly.
2. Blow out debris with compressed air from the
outside in. Any debris remaining in the inlet side
of the nozzle should be cleaned out. If lime or
chemical scale is present in the inlet side, the
nozzle may be soaked in descaling solution or
replaced. If the tip is worn, replace with one
specified in the GENERAL section of MODEL
SPECIFICATIONS or MODEL EXPLODED
VIEW.
3. Before replacing spray tip flush the machine per
“FLUSHING”.
4. Reinstall Spray tip to gun assembly.
1. Connect machine to a pressurized water supply
meeting the requirements specified in the
GENERAL section of the MODEL
SPECIFICATIONS.
2. Turn on the water supply.
3. Remove the spray tip from gun assembly.
4. With gun assembly in hand, start engine. On
trigger gun models hold the trigger gun valve in
open position.
05-17-06 Z08-027666
1
Supersedes02-16-01Z08-027666
MACHINE
MAINTENANCE
Gas Engine Driven Cold Water Cleaners
DEFLECTION
SPAN
SPRAYTIPMAINTENANCE
1. Rinse the chemical line by inserting the screen
into a container of clear water and open the
metering valve 1 minute to clean it of any
remaining residue. Be sure the chemical metering
valve is closed when finished.
2. Disconnect the water supply.
3. Remove the spray tip nozzle from gun assembly
and wire to machine.
4. Attach an air chuck to the air valve stem on the
pump assembly. With the trigger gun in the open
position, apply air until a mixture of air and very
little water is coming from the gun wand .
5. Fill a 1-gallon container with Ethylene Glycol type
antifreeze. Minimum should be a mixture of ½
antifreeze and ½ water strength before each use,
as the antifreeze will dilute with use.
6. Install a 2-ft garden hose to the water inlet. Insert
the other end into a container of antifreeze solution.
7. With the gun assembly in hand, turn on the switch.
On trigger gun models hold the trigger gun valve
in open position.
8. Turn off the switch just prior to running out of
antifreeze mixture.
9. Disconnect gun and hose.
10. Place machine and battery in a dry place protected
from weather conditions.
STORAGE
FLUSHING

x
MACHINE MAINTENANCE SCHEDULE
EACH HR AFTER FIRST EVERY EVERY EVERY
DAILY 8 HRS 50 HRS 50HRS 100 HRS 500 HRS YEARLY
ENGINE DRIVEN OIL FIRED COLD WATER
CLEANERS
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.
HOSES:
Blistering, Loose Covering
Abrasion of cover exposing reinforcement.
Cuts exposing reinforcement.
BELTS:
Cracks or fraying
Belt Tension- For correct tension, see MACHINE
MAINTENANCE insert.
LEAKS:
Check for water and buildup of scale at pipe
connections.
SCREEN-WATER:
Check Inlet Hose Screenfor debris.
Check float Tank Hose Screen ( if so equipped)
for debris.
Check Water Filter (if so equipped) for debris see
breakdown elsewhere in this manual.
SPRAYTIP:
Check tip for debris.
GUARDS AND SHIELDS:
Check that all guards and sheilds are in place and
secure.
PUMP MOTOR WITH GREASE FITTINGS:
Remove drain plug. Use 1 or 2 full strokes of shell
“DOBLIUM RB”, Cheveron”SR1 No.2” or Texaco
“PREMIUM RB”. Operate for 20 minutes and replace
drain plug.
FREEZING TEMPERATURES:
Freezing temperatures break coils and water
pumps. See STORAGE in the MACHINE MAINTE-
NANCE section for cold weather instructions.
Supersedes 11-23-03 Z08-02767 05-12-06 Z08-02767

ENGINE DRIVEN COLD WATER CLEANERS
1. Poor cleaning
action.
2. Machine will not
draw chemical.
3. Low operating
pressure.
4. Excessive,
unusual noise.
5. Belts slipping.
A. Hard water.
B. Low pressure.
C. Little or no chemical being drawn.
D. Improper chemical.
E. Improper chemical mixture.
F. Low discharge pressure.
A. No chemical solution.
B. Metering valve not open.
C. Chemical line strainer clogged.
D. Air leak in Chemical line.
E. Metering valve clogged.
A. Insufficeint water supply.
B. Incoming water hose too small.
C. Water supply hose too long.
D. Belt slippage.
E. Worn belt.
F. Spray tip worn or wrong size.
G. Dirty or worn check valves in water
pump.
H. Water supply hose kinked.
I. Inlet filter screen clogged.
J. Motor runs slow.
K. Air leak in inlet plumbing.
L. Defective water pump.
M. Leaking discharge hose.
N. Chemical metering valve open and
sucking air.
O. Defective unloader.
A. Pump.
B. Defective motor.
C. Pulleys rubbing.
D. Misalignment of pump &motor
A. Belts too losse.
B. Excessive back pressure.
C. Defective water pump.
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. Replenish supply.
B. Turn metering valve knob to open.
C. Remove screen and cleaan.
D. Tighten all fittings and hoses for the chemical line.
E. Disassemble and clean.
A. The water supply must meet or exceed the maximum
discharge volume specified in the PERFORMANCE
section, and minimum water inlet pressure specified
in the General section of theMODEL SPECIFICATIONS
section.
B. Use larger water supply hose.
C. Use shorter water supply hose.
D. Tighten belt per instructions inMACHINE
MAINTENANCE insert.
E. Replace bely per CLEANER EXPLODED VIEW.
F. Replace with spray tip specified in the GENERAL
section of MODEL SPECIFICATIONS.
G. SeePUMP TROUBLE SHOOTING.
H. Straighten hose.
I. Clean water filter screen or hose inlet screen.
J. See “Pump engine starts slow or overheats and
stops.”
K. Tighten all fittings.
L . SeePUMPTROUBLESHOOTING.
M. If a water leak is found, DO NOT OPERATE THE
MACHINE. Disconnect the power andreplace hose.
N. Resupply chemical, place soap screen in water, or
shut off metering valve.
O. Repair or replace unloader valve.
A. SeePUMPTROUBLESHOOTING.
B. Call service technician or take engine to Reapir/
Warranty station.
C. Adjust shields or pulley(s).
D. Realign pump and engine.
A. Tighten per instruction onMACHINEMAINTENANCE.
B. See “Excessive Back Pressure.”
C. SeePUMP SERVICE.
REMEDY
CLEANER TROUBLESHOOTING
POSSIBLE CAUSE
TROUBLE
Supersedes 01-16-04 Z08-02768 05-09-06 Z08- 02768
x

A. Spray tip built up with lime.
B. Water pump turning too
fast.
.
A. Defective belt.
B. Defective Pump.
C. Defective accumalator.
A. Clogged spra tip.
B. Worn or incorrect spray tip.
A. No fuel
B. Plugged fuel filter.
C. Defective or corroded
battery cable
D. Defective engine.
A. Improper fuel.
B. Excessive back pressure.
C. Defective engine
D. Dirt in fuel line or filters.
E. Incorrect oil level
F. Engine overloaded.
G. Dirty air cleaner.
H. Faulty spark plug.
A. Remove and clean, or replace spray tip with tip
specified in GENERAL section of MODEL
SPECIFCATIONS.
B. See MODEL SPECIFICATIONS.
A. Remove and replace using belt specified in
CLEANER EXPLODED VIEW or the GENERAL
section of MODEL SPECIFICATIONS.
B. See PUMP TROUBLESHOOTING.
C. Recharge/replace.
A. Remove and clean spray tip per SPRAY TIP
MAINTENANCE in MACHINE
MAINTENANCE.
B. Remove and replace with tip specified in the
GENERAL section of MODEL
SPECIFICATIONS or MODEL EXPLODED.
A. Replenish fuel as specified in engine owners
manual.
B. Change engine fuel filter.
C. Drain and replenish fuel.
D. Clean cables and cable ends.
E. Call service technician.
A. Replenish fuel as specified in engine owners
manual.
B. See “Excessive Back Pressure.”
C. Call service technichian, or take engine to
Repair/Warranty station.
D. Clean line or replace filter.
E. Check oil level per engine owners manual.
F. See “Excessive Back Pressure”
G. Change air cleaner filters per engine owners
manual.
H. Change plug and set gap per engine owners
manual.
CLEANER TROUBLESHOOTING (CONT.)
ENGINE DRIVEN COLD WATER CLEANERS
TROUBLE POSSIBLE CAUSE REMEDY
6. Excessive back
pressure.
7. Excessive
vibration.
8. Spray pattern is
broken or
irregular.
9. Engine will not
start.
10. Engine starts
slow or overheats
and stops.
x
Supersedes 01-16-04 Z08-02769 05-09-06 Z08- 02769

2Final Assembly
Final Assembly
ITEM
NO. PART NUMBER PART DESCRIPTION QTY.
1 3401-00710 ASS'Y, HOSE - 3/8 X 50 2
WIRE 5000PSI 1
2 435S-00183 WELDMENT, LIFT
BRACKET 1
3 445SE-00603 ASSEMBLY, CLEANER -
16HP 1
4 535S-05150
WELDMENT, SHIELD-
PULLEY SS 3 3/4 X 15 1/2
X 25
1
5 AS11-00906-PB BRACKET, BATTERY 3/4 X
9 3/8 1
6 D02-00001E DECAL, SERIAL NO 1
7 F04-00451 GROMMET, RUBBER 4
8 H04-13803 SCREW, MACHINE 6
9 H04-19000
SCREW, THREAD
CUTTING - #10 - 24 UNC X
1/2
3
10 H04-25007 SCREW, CAP 2
11 H04-25024 SCREW, CAP 2
12 H04-31326 CAP, SCREW 4
13 H06-31300 NUT, LOCK - 5/16" 4
14 H09-12500 RIVET, POP 2
15 J00-15040-2 TIP, SPRAY - #1504 1
16 J06-00158-B ASSEMBLY, GUN & WAND
- 42" 1
17 Z01-00014 CAP, VINYL 2
18 Z01-00017 PLUG, TUBING 2
19 Z01-00084 CAP, FUEL 1
Macine Assembly
p/n 445SE-000000
ENGINE EXHAUST
DECAL, CAUTION
PUMP MAINTENANCE
UNATTENDED -
6
NUMBER
DECAL, WARNING
14
DECAL, SERIAL
AN AMERICAN
DECAL,
TURN WATER ON
DECAL,
PROUD TO BE
5
RISK OF EYE INJURY
DECAL, CAUTION
DO NOT OPERATE
11 7
19
18
1
17
DECAL,
FUEL TANK
3
2
4
12
8
9
16
DECAL,
MODEL
445S
13
DECAL, MODEL
15

3
Final Assembly
ITEM
NO. PART NUMBER PART DESCRIPTION QTY.
1 3401-00710 ASS'Y, HOSE - 3/8 X 50 2
WIRE 5000PSI 1
2 435S-00183 WELDMENT, LIFT
BRACKET 1
3 445SE-00603 ASSEMBLY, CLEANER -
16HP 1
4 535S-05150
WELDMENT, SHIELD-
PULLEY SS 3 3/4 X 15 1/2
X 25
1
5 AS11-00906-PB BRACKET, BATTERY 3/4 X
9 3/8 1
6 D02-00001E DECAL, SERIAL NO 1
7 F04-00451 GROMMET, RUBBER 4
8 H04-13803 SCREW, MACHINE 6
9 H04-19000
SCREW, THREAD
CUTTING - #10 - 24 UNC X
1/2
3
10 H04-25007 SCREW, CAP 2
11 H04-25024 SCREW, CAP 2
12 H04-31326 CAP, SCREW 4
13 H06-31300 NUT, LOCK - 5/16" 4
14 H09-12500 RIVET, POP 2
15 J00-15040-2 TIP, SPRAY - #1504 1
16 J06-00158-B ASSEMBLY, GUN & WAND
- 42" 1
17 Z01-00014 CAP, VINYL 2
18 Z01-00017 PLUG, TUBING 2
19 Z01-00084 CAP, FUEL 1
Macine Assembly
p/n 445SE-000000
ENGINE EXHAUST
DECAL, CAUTION
PUMP MAINTENANCE
UNATTENDED -
6
NUMBER
DECAL, WARNING
14
DECAL, SERIAL
AN AMERICAN
DECAL,
TURN WATER ON
DECAL,
PROUD TO BE
5
RISK OF EYE INJURY
DECAL, CAUTION
DO NOT OPERATE
11 7
19
18
1
17
DECAL,
FUEL TANK
3
2
4
12
8
9
16
DECAL,
MODEL
445S
13
DECAL, MODEL
15
23467
1
BEVEL SIDE
TOWARDS BALL DISHED SIDE
TOWARDS BALL
5
16
17
2
4
1
12 18 13 3
14
15
6
19 5
9
10
7
8
19
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
Trigger Gun & Wand

4Final Assembly
Specications
Maximum Volume 10.0 GPM / 37.9 LPM
Maximum Pressure 5000 PSI / 344.7 BAR
Rated Temperature 300˚ F / 150˚ C
Weight 1.8lbs / 0.8kg
Inlet 3/8” NPT Female
Outlet ¼” NPT Female
All dimensions are in inches unless otherwise noted.
25.4 mm = 1 inch
Repair Instructions
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. Assemble in reverse order.
Kit, Repair Part – Number J06-99158C
Warning: Do not use acid concentrates through the gun. Never secure trigger gun in an open
position (trigger pulled back) by means other than the operator’s hand. Bodily harm may occur if
the operator loses control of the trigger gun.
Caution: Always engage trigger safety latch when not in use.
J06-00158 PART LIST
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 – 3/32CS x 1/8ID 1
4 J06-00121-15 Ball, SS 5/16 1
5 J06-00132-19 Screw, Self Tap – 3.5mm x 18mm 1
6 J06-00158-01 Fitting, Discharge – ¼ 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
1 535S-00130 WELDMENT, FRAME 1
2 AR58-02800 ROD, CRS - 5/8" X 28" 1
3 G02-10016B ASS'Y, TIRE & RIM - 13" 2
4 H06-62503 COLLAR, SHAFT - 5/8" 2
5 Z01-00029 CAP, VINYL - ROUND 2
6 H10-50000 MOUNT, SHOCK 4
7 H05-50001 WASHER, HELICAL
LOCK - 1/2" 8
8 H06-25003 NUT, HEX 2
9 H06-31300 NUT, LOCK - 5/16" 7
10 H06-37500 NUT,LOCK-3/8-16UNC
HEX 4
11 H06-50001 NUT, 1/2 - 20UNF 8
12 445S-00515 ASSEMBLY, UNLOADER 1
13 H04-31326 CAP, SCREW 2
14 445S-00134 WELDMENT, MOUNT 1
15 F05-00439 ENGINE, GAS - 16HP,
VANGUARD 1
16 R04-00006 BUSHING, PULLEY 1
NUMBER
PART QTY.PART DESCRIPTION ITEM
NO.
ITEM
NO.
PART
NUMBER PART DESCRIPTION QTY.
17 R03-00744 BUSHING, PULLEY 1
18 F05-00436-2 KIT, MUFFLER 1
19 535S-10125 TANK, FUEL - 3 13/16 X
15 5/8 X 17 5/8 4.5 GAL 1
20 445SE-00501 ASSEMBLY, PUMP 1
21 W02-10031 BARB, HOSE 1
22 E09-00002-2 PLUG, PIPE 1
23 H03-31311 BOLT,J-5/16-18UNC x 3
1/2 1
24 F04-00455 GROMMET, RUBBER 1
25 F05-00220 CABLE, BATTERY - 20"
EYE/EYE BLACK 2
26 F05-00220-R CABLE, BATTERY - 20"
EYE/EYE RED 2
27 K02-03216A2 ASSEMBLY, HOSE 1
28 K20-00900 HOSE, GAS 1
29 K33-01500 HOSE, WATER - 3/8 X
15" 1
30 W02-00033 CLAMP, HOSE 2
31 W02-00036 CLAMP, HOSE 2
30
25
8
3
12 9
19
22
4
13
6
14
18
27
1
16
5
9
24
20 P/N R02-0024310
26
17 9
7
15
11
2
29
28
BELT, SINGLE V
31
23
21
445SE-00603
03-31-2009

5
General Assembly
General Assembly
1 535S-00130 WELDMENT, FRAME 1
2 AR58-02800 ROD, CRS - 5/8" X 28" 1
3 G02-10016B ASS'Y, TIRE & RIM - 13" 2
4 H06-62503 COLLAR, SHAFT - 5/8" 2
5 Z01-00029 CAP, VINYL - ROUND 2
6 H10-50000 MOUNT, SHOCK 4
7 H05-50001 WASHER, HELICAL
LOCK - 1/2" 8
8 H06-25003 NUT, HEX 2
9 H06-31300 NUT, LOCK - 5/16" 7
10 H06-37500 NUT,LOCK-3/8-16UNC
HEX 4
11 H06-50001 NUT, 1/2 - 20UNF 8
12 445S-00515 ASSEMBLY, UNLOADER 1
13 H04-31326 CAP, SCREW 2
14 445S-00134 WELDMENT, MOUNT 1
15 F05-00439 ENGINE, GAS - 16HP,
VANGUARD 1
16 R04-00006 BUSHING, PULLEY 1
NUMBER
PART QTY.PART DESCRIPTION ITEM
NO.
ITEM
NO.
PART
NUMBER PART DESCRIPTION QTY.
17 R03-00744 BUSHING, PULLEY 1
18 F05-00436-2 KIT, MUFFLER 1
19 535S-10125 TANK, FUEL - 3 13/16 X
15 5/8 X 17 5/8 4.5 GAL 1
20 445SE-00501 ASSEMBLY, PUMP 1
21 W02-10031 BARB, HOSE 1
22 E09-00002-2 PLUG, PIPE 1
23 H03-31311 BOLT,J-5/16-18UNC x 3
1/2 1
24 F04-00455 GROMMET, RUBBER 1
25 F05-00220 CABLE, BATTERY - 20"
EYE/EYE BLACK 2
26 F05-00220-R CABLE, BATTERY - 20"
EYE/EYE RED 2
27 K02-03216A2 ASSEMBLY, HOSE 1
28 K20-00900 HOSE, GAS 1
29 K33-01500 HOSE, WATER - 3/8 X
15" 1
30 W02-00033 CLAMP, HOSE 2
31 W02-00036 CLAMP, HOSE 2
30
25
8
3
12 9
19
22
4
13
6
14
18
27
1
16
5
9
24
20 P/N R02-0024310
26
17 9
7
15
11
2
29
28
BELT, SINGLE V
31
23
21
445SE-00603
03-31-2009

6General Assembly
Unloader Assembly
3
2
4
1
5
ASSEMBLY, UNLOADER
p/n: 445S-00515
4/3/2009
ITEM
NO. PART NUMBER PART DESCRIPTION QTY.
1 835S-00514 BRACKET, UNLOADER 1
2 C07-03800X VALVE, UNLOADER (GREY) 1
3 E08-00010-5 ELBOW, PIPE 1
4 W02-10040-8 BARB, HOSE 1
5 W04-34155-A COUPLER, 3/8F X 1/2MNPT 1

7
Unloader Valve
Unloader Valve Breakdown
20
21
22
6
4
12
13
14
13
23
18
17
9
27
2
10
4
26
3
15
16
4
5
8
19
7
1
7
25
24
*
*
*
*
*
*
*
*
*
*
*
*
*
*
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 19) and turn the knob (Item 20) 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 19)
Note: Once the operating pressure is reached, turning the knob clockwise will increase the unloading pressure
only.
Specifications
Maximum Flow 7.8 GPM / 30 LPM
*Max Unloading Press. 3650 PSI / 251 BAR
**Max Unloading Press. 4200 PSI / 290 BAR
Maximum Temperature 190˚F / 88˚C
Weight 2.1 LBS / 0.91 KG
Bypass ¼ FNPT
Inlet & Discharge 3/8 FNPT
*P/N C07-03700 **P/N C07-03800
Repair Parts Package
*C07-03700K – Includes 1 of item #1, 1 of item #2, 1 of item #3, 3 of item
#4, 2 of item #7, 2 of item #13, 1 of item #14, 1 of item #27
C07-03700X,C07-03800X

8Unloader Valve
PART LISTS
ITEM PART NUMBER PART
DESCRIPTION QTY
18RS6-000SV01 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 2
14 C07-03700-29 O-Ring – 3/32 x 7/16ID
x 3043 1
15 C07-03700-3 Spring, Compression 1
16 C07-03700-4 Orice, Shutter 1
17 C07-03700-6A Plug, 3/8NPT 2
18 C07-03700-6B Gasket, Washer – 1/16CS x
5/16 x 7/16OD 2
19 C07-03700-7 Nut, Ny-Lock 1
20 C07-03700-8 Knob, Adjustment 1
21 C07-03700-9 Follower, Spring 1
*22 C07-0370010C Spring, Blue 1
**22 C07-0370010D Spring, Black 1
23 C07-0370018B Housing, Unloader – 3/8
FNPT 1
24 C07-0370019A Plug 1
25 C07-0370019B Gasket, Washer – 1/16CS x
5/16ID x 9/16OD 1
26 C07-03800-24 Guide, Ball 1
27 N07-20028 O-Ring – 1/16CS x 7/16ID 1
*P/N C07-03700 **P/N C07-03800
20
21
22
6
4
12
13
14
13
23
18
17
9
27
2
10
4
26
3
15
16
4
5
8
19
7
1
7
25
24
*
*
*
*
*
*
*
*
*
*
*
*
*
*

9
Pump Assembly
Pump Assembly
6
4
11
9
10
7
8
12
2
3
1
5
445SE-00501
03-31-2009
ITEM NO. PART NUMBER PART DESCRIPTION QTY.
1 4355EB-00513 MOUNT, PUMP 1
2 C04-00144 FILTER, WATER 1
3 E08-00011-58 ELBOW, PIPE 1
4 E10-00005-4 TEE, PIPE 1
5 E15-00010-48 NIPPLE, BRASS 1/2" 1
6 H05-31300 WASHER, FLAT - 5/16 4
7 H05-31304 WASHER 4
8 N07-20048 SCREW, CAP 4
9 N09-00053 PUMP, WATER -
RK1528HN 1
10 R03-00794 PULLEY, DBL 1
11 R04-00001 BUSHING, PULLEY 1
12 W02-10030-8 BARB, HOSE 1