Premium Series Professional Pressure Washers Service/Operation Manual Form No.
For Technical Assistance: Tel: 805-523-0211 Option 3 Email: techsupport@airlessco.com For Customer Service/Order Desk: Tel: 805-523-0211 Option 2 Email: customerservice@airlessco.com Manufactured by: AIRLESSCO BY DUROTECH CO. P.O. Box 8006, Moorpark, CA 93020-8006 Ship to: 5397 Commerce Ave., Moorpark, CA 93021 Tel: 805-523-0211 Fax: 805-523-1063 SUBJECT TO CHANGE WITHOUT NOTICE. Copyright © 2005, Airlessco by Durotech. All rights reserved.
TABLE OF CONTENTS Introduction Pressure Washer Specifications Safety Warnings 1 2 Getting Started Parts Users Guide Get The Most From Your Machine 4 5 6 Repairs/Maintenance Instructions Tips and Nozzles 7 Cleaning Nozzle Rating Chart 8 Troubleshooting 9 Pump Servicing Procedure 10 Application & Installation of the Unloader Valve 21 Troubleshooting - Unloader Valve 21 Downstream Chemical Injectors 31 Sandblast Kit 32 Sandblasting Application 33 Troubleshooting - Sandblast Kit 33 Limited Warranty 34 Acces
PRESSURE TO SUCCEED Direct Drive - No Belts • More compact design • No belt adjustment required • No slippage of belts • No bulky belt guard Honda Engine with oil alert Engine Protector Hose Rack and Gun Hook 50’ x 3/8” High Pressure Hose with Quick Couplers General Pump - Ceramic Plunger-3 Plex • Best Warranty • All easily accessible pump components Modular Unloader Valve Chemical Injector Color Coded Cleaning Nozzles Convenient Tip Holder on the Frame Durable Chrome Steel Tubular Frame Thermal Protecto
WARNINGS HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY. NEVER PUT YOUR HAND OR FINGERS IN FRONT OF GUN. NEVER POINT THE GUN AT YOUR BODY OR AT ANYONE ELSE. • Always shut off the pump and relieve fluid pressure in system by opening control handle if unit is left unattended or before removing or installing accessories. NOTE: Shutting off power by itself may not relieve fluid pressure. • When control handle is not in use, engage trigger safety to prevent accidental spraying.
WARNINGS ALWAYS: • Always remember that liquid released at pressure can penetrate skin, causing SERIOUS injury. If injury occurs, seek immediate medical attention. • • • • • Always follow all instructions and recommendations when operating equipment. Always protect high pressure hose from damage such as from vehicle traffic and sharp edges. Always wear protective clothing, gloves and goggles when using any potentially harmful chemicals. Always lock gun jet off when removing or changing nozzle.
PARTS INLET WATER FILTER • The inlet water screen is intended to prevent debris from entering the pump and causing damage. DO NOT OPERATE the machine without the Inlet Water Screen in place. • The Inlet Water Screen is stainless steel and should be removed and cleaned every 25 hours of operation. If your water conditions are poorer than normal, it should be cleaned more often.
USERS GUIDE Prior to Starting: • Read and understand all warnings before operating euipment. • Connect standard garden hose to water inlet. Hose must have minimum 5/8 inch diameter. Maximum 50 Ft. length is recommended. Water source must deliver 3.5 gallons per minute either through pressurized system of public utility or similar system or through gravity feed from unpressurized holding tank. Never allow pump to run dry or semi-dry.
USERS GUIDE To Operate Unit: Chemical Injector: 1. Select desired nozzle. Lock control handle (gun or wand) off and install nozzle in quick coupler at end of wand. Insure that coupler sleeve is properly locked by pulling on nozzle. 2. Start engine according to engine manual. 3. Unlock control handle (gun or wand), point wand at ground and operate to test. 4. Adjust pressure of spray to desired level.To Use TO REMOVE PEELING PAINT: 1. Push end of chemical pick-up tube onto injector inlet. 2.
TIPS AND NOZZLES TIPS OR NOZZLES THE 15 DEGREE NOZZLE – 3/4" The Quick Couplet Tips or Nozzles are inserted into the end of the wand by means of a Quick Coupler. Tips are supplied in the four most popular sizes & can do many jobs for you. You MUST seat the tip into the quick coupler firmly and make sure the quick coupler is closed. If you have a leak at the tip around the quick coupler, you have lost the O-Ring inside the quick coupler. If lost, the O-Ring MUST BE REPLACED! This is a chiseling nozzle.
CLEANING NOZZLE RATING CHART The chart below provides gallons per minute for a 0˚ cleaning nozzle used on different PSI (pounds per square inch) pressure washers. For example, a 2000 PSI pressure washer with a 0˚ No. 4.5 cleaning nozzle will produce 3.1 gallons per minute. This chart can also assist in determining the proper nozzle size for a particular pressure washer if the operating pressure and gallons per minute rating are known. For example: a pressure washer rated at 3000 PSI @ 3.
TROUBLE SHOOTING PROBLEM CAUSE • Worn nozzle • Air leak in inlet plumbing • Relief valve stuck, partially plugged or improperly adjusted valve seat worn • Inlet suction strainer clogged or improperly sized Low Pressure • Worn packing; Abrasives in pumped fluid or severe cavitation; Inadequate water • Fouled or dirty inlet or discharge valves. Leaky discharge hose • Install proper filter, suction at manifold must be limited to lifting less than 20 feet of water or -8.5 PSI vacuum.
PUMP SERVICING PROCEDURE Replacing Plungers Valve Assemblies 1. All inlet and discharge valves can be serviced without 1. Remove stainless steel piston screw and plunger from piston. disrupting the inlet discharge plumbing. The inlet and discharge valves are the identical in all models. 2. If slinger washer comes off with plunger, be certain this is replaced before new plunger is installed. 2. To service any valve, remove valve cap and extract valve assembly. 3. Separate piston screw from plunger. 3.
SPECIFICATIONS - MODEL 1500-3 PART NUMBER 163-060 Specifications Pump Model Maximum Volume Maximum Discharge Pressure Maximum Pump Speed Maximum Inlet Pressure Maximum Inlet Vacuum Bore Stroke (in./mm) Crankcase Oil Capacity Maximum Fluid Temperature Inlet Port Thread Discharge Port Thread Shaft Diameter Weight Dimensions 1500-3 2.8 GPM 1500 PSI 3400 RPM 125 PSI 3 ft. water (2.6 in. Hg) .591 in./ 15mm .260/ 6.6 11.2 oz. 165˚F 3/8 -19 BSPP-F 1/4 - 19 BSPP-F 3/4 in. / 19 mm 11.4 lbs. 7.2 x 7.2 x 5.5 in.
PARTS BREAKDOWN - MODEL 1500-3 PART NUMBER 163-060 ITEM PART # DESCRIPTION QTY. ITEM PART # DESCRIPTION 1 51.0106.22 Crankcase KIT 1 26 92.2216.00 Nut, M8 3 2 98.2100.00 Plug, 3/8-BSPP 2 27 96.7008.00 Washer, M8 3 3 90.3833.00 O-Ring, .549 x .103 1 28 51.0400.09 Plunger (15mm) 3 4 51.2091.02 Protector 1 29 90.3572.00 O-Ring, .208 x .070 3 5 90.1565.00 Oil Seal 3 30 90.5022.00 Back-up Ring 3 6 98.2041.00 Plug 1 31 96.7070.00 Washer, Flinger 3 7 51.
SPECIFICATIONS - MODEL 2500-3 PART NUMBER 163-061 Specifications Pump Model Maximum Volume Maximum Discharge Pressure Maximum Pump Speed Maximum Inlet Pressure Maximum Inlet Vacuum Bore Stroke (in./mm) Crankcase Oil Capacity Maximum Fluid Temperature Inlet Port Thread Discharge Port Thread Shaft Diameter Weight Dimensions Position 2 6 9 16 2500-3 3.2 GPM 2500 PSI 3400 RPM 125 PSI 3 ft. water (2.6 in. Hg) .709 in./ 18 mm .370 in./ 9.4 mm 11.2 oz. 165˚F 3/8 -19 BSPP-F 1/4 - 19 BSPP-F .945 in./ 24 mm 11.
PARTS BREAKDOWN - MODEL 2500-3 PART NUMBER 163-061 ITEM ITEM NO. PART # PART NO. QTY. OTY. ITEM PART # DESCRIPTION KIT # 1 51.0106.22 Crankcase 1 20 51.0800.70 Packing Retainer 86,96 2 98.2100.00 Plug 2 51.0803.70 18mm 139,140 3 90.3833.00 O-Ring 1 90.3604.00 O-Ring 86,96,97 4 51.2091.02 Protector 1 18mm 139,140,141 5 90.1565.00 Oil Seal 6 98.2041.00 Plug 1 7 51.12200.41 Manifold, Brass 1 23 97.5968.00 Slight Gauge 1 8 96.6938.00 Washer 8 24 91.8015.
SPECIFICATIONS - MODEL 2500-5 PART NUMBER 163-062 Specifications Pump Model Maximum Volume MaximumDischarge Pressure Maximum Pump Speed Maximum Inlet Pressure Maximum Inlet Vacuum Bore Stroke (in./mm) Crankcase Oil Capacity Maximum Fluid Temperature Inlet Port Thread Discharge Port Thread Shaft Diameter Weight Dimensions 2500-5 4.6 GPM 3000 PSI 3400 RPM 125 PSI 3 ft. water (2.6 in. Hg) .591 in./ 15 mm .433/ 11 14.0 oz. 165˚F 1/2-14 BSPP-F 3/8-19 BSPP-F 1.0 in./ 25.4 mm 19.1 lbs. 8.8 x 9.7 x 6.5 in.
PARTS BREAKDOWN - MODEL 2500-5 PART NUMBER 163-062 ITEM ITEM PART NO. PART # DESCRIPTION QTY. ITEM PART # DESCRIPTION 1 44.1200.41 Manifold (15mm) 1 30 96.7350.00 Washer 3 2 99.3175.00 Screw 8 31 90.5022.00 Anti-Extrusion Ring 3 3 96.7014.00 Washer 8 32 90.3572.00 O-Ring 3 4 90.3841.00 O-Ring 123 6 33 52.0400.09 Plunger, 15mm 3 5 36.2003.66 Valve Seat 123 6 34 96.7008.00 Washer 3 6 36.2001.76 Valve 123 6 35 92.2216.00 Nut 7 94.7376.
SPECIFICATIONS - MODEL 3000-4 PART NUMBER 163-063 Specifications Pump Model Maximum Volume MaximumDischarge Pressure Horsepower Maximum Pump Speed Maximum Inlet Pressure Maximum Inlet Vacuum Bore Stroke (in./mm) Crankcase Oil Capacity Maximum Fluid Temperature Inlet Port Thread Discharge Port Thread Shaft Diameter Weight Dimensions 3000-4 4.0 GPM 3000 PSI 12.3 GBHP 3400 RPM 125 PSI Flooded .591 in./15 mm .394 in./10mm 14.0 oz. 165˚F 1/2-14 BSPP-F 3/8-19 BSPP-F 1.0 in./ 25.4 mm 18 lbs. 8.4 x 8.4 x 6.5 in.
PARTS BREAKDOWN - MODEL 3000-4 PART NUMBER 163-063 ITEM ITEM PART # DESCRIPTION 1 63120041 Manifold, 15 mm 1 31 660024 Anti-extrusion Ring 3 2 99319200 Screw, M8 x 65 8 32 701009 O-ring 3 3 96701400 Lockwasher, M8.
SPECIFICATIONS - MODEL 4000-3.5 PART NUMBER 163-064 Specifications Pump Model Maximum Volume MaximumDischarge Pressure Maximum Pump Speed Maximum Inlet Pressure Maximum Inlet Vacuum Bore Stroke (in./mm) Crankcase Oil Capacity Maximum Fluid Temperature Inlet Port Thread Discharge Port Thread Shaft Diameter Weight Dimensions 4000-3.5 3.5 GPM 4000 PSI 3400 RPM 125 PSI Flooded .512 in./13 mm .433 in./11 mm 14.0 oz. 165˚F 1/2-14 BSPP-F 3/8-19 BSPP-F 1.0 in./ 25.4 mm 20 lbs. 8.8 x 9.7 x 6.5 in.
PARTS BREAKDOWN - MODEL 4000-3.5 PART NUMBER 163-064 ITEM PART # DESCRIPTION QTY.
APPLICATION & INSTALLATION OF THE UNLOADER VALVE APPLICATION This product is to be used with clean, fresh water. For different or corrosive liquids, contact the Technical Support Department. With not-clean liquids, appropriate filtration should be installed. Select the valve based on the nominal operating rating: system rated pressure, maximum flow and maximum temperature. Under no circumstances should the pressure of the system exceed the maximum rated pressure of any component.
UNLOADER VALVE FOR MODELS: 1500-3 & 2500-3 Specifications Part Number YVB135KDM Maximum Volume 6.5 GPM Rated Discharge Pressure 2300 PSI Maximum Discharge Pressure 3400 RPM Maximum Temperature 195° F Port Size Inlet 3/8" BSPP-F Port Size Outlet 3/8" BSPP-M Dimensions 5.75 x 3.0 x 1.75 in. Weight 1.4 lb. Material Brass, Stainless Steel Plastic, Buna-N PARTS BREAKDOWN FOR YVB135KDM Item Part # 1 Y60.0385.31 Banjo Bolt 1/4” BSPP, Brass Description 1 2 Y14.4100.
UNLOADER VALVE FOR MODELS: 2500-5 & 3000-4 Specifications Part Number YVB75KDMN Maximum Volume 8.0 GPM Rated Discharge Pressure 3200 PSI Maximum Discharge Pressure 3650 RPM Maximum Temperature 195° F Port Size Inlet 1/2" BSPP-F Port Size Outlet 3/8" BSPP-M Dimensions 6.25 x 4.5 x 1.0 in. Weight 2.0 lb. Material Brass, Stainless Steel Plastic, Buna-N PARTS BREAKDOWN FOR YVB75KDMN 23 Item Part # 1 Y60005831 Outlet Fitting, 3/8 BSP Description Qty. 1 2 Y10307002 O-Ring, .739 x .
FRAME ASSEMBLY PART NO. 163-055 PART # # PART 100-317 DESCRIPTION DESCRIPTION Nut, 5/16-18” Centerlock 113-031 Spacer, 5/8 ID x 1.0” 188-367 Axel 5/8 x 21.81" Long 143-029 Set Collar 5/8” ID 163-008A Rubber Foot 163-011A Washer, 1.25 x .312” 169-050 Screw, 5/16-18 x 1.00 HX HD 171-020 Grommet 9307K25 McMaster 188-042 Nut, 1/4”-20 NY-LOCK 188-185 Spacer, .25 x .088W x .
PUMP ASSEMBLY - PRESSURE WASHER MODEL 1500-3 NOTES: 1 r 2 r 3 r 4 r 5 r 6. TORQUE TO 24 FT-LB TORQUE TO 27 FT-LB ITEM 2 (PTP ASSEMBLY) OUTLET TO FACE DOWN AT ASSEMBLY APPLY ITEM 8 (TEFLON TAPE) TO THREADS SET ITEM 4 (SAFETY RELIEF VALVE) TO OPEN AT 2200 _+ 50 PSI TEST SPECIFICATIONS: (TEST WITH #4.5 NOZZLE) FLOW RATE 2.
PUMP ASSEMBLY - PRESSURE WASHER MODEL 2500-3 NOTES: 1 r 2 r 3 r 4 r 5 r 6. 7 r TORQUE TO 24 FT-LB TORQUE TO 27 FT-LB ITEM 2 (PTP ASSEMBLY) OUTLET TO FACE DOWN AT ASSEMBLY APPLY ITEM 8 (TEFLON TAPE) TO THREADS _ 50 PSI SET ITEM 4 (SAFETY RELIEF VALVE) TO OPEN AT 2600 + TEST SPECIFICATIONS: (TEST WITH #4.0 NOZZLE) FLOW RATE 3.
PUMP ASSEMBLY - PRESSURE WASHER MODEL 2500-5 NOTES: 1 r 2 r 3 r 4 r 5 r 6. 7 r TORQUE TO 30 FT-LB TORQUE TO 44 FT-LB ITEM 2 (PTP ASSEMBLY) OUTLET TO FACE DOWN AT ASSEMBLY APPLY ITEM 9 (TEFLON TAPE) TO ITEM 2 (PTP), ITEM 4 (SAFETY RELIEF VALVE), ITEM 5 (FILTER) AND ITEM 6 (NIPPLE). _ 50 PSI SET ITEM 4 (SAFETY RELIEF VALVE) TO OPEN AT 4700 + TEST SPECIFICATIONS: (TEST WITH #5.5 NOZZLE) FLOW RATE: 4.
PUMP ASSEMBLY - PRESSURE WASHER MODEL 3000-4 NOTES: 1 TORQUE TO 30 FT-LB r 2 r TORQUE TO 44 FT-LB 3 ITEM 2 (PTP ASSEMBLY) OUTLET TO FACE DOWN r 4 AT ASSEMBLY APPLY ITEM 9 (TEFLON TAPE) TO ITEM 2 (PTP), r r 5 6. ITEM 4 (SAFETY RELIEF VALVE), ITEM 5 (FILTER) AND ITEM 6 (NIPPLE). _ 50 PSI SET ITEM 4 (SAFETY RELIEF VALVE) TO OPEN AT 3700 + TEST SPECIFICATIONS: (TEST WITH #4.5 NOZZLE) FLOW RATE: 3.85 MIN.
PUMP ASSEMBLY - PRESSURE WASHER MODEL 4000-3.5 NOTES: 1 r 2 r 3 r 4 r 5 r 6. 7 r TORQUE TO 30 FT-LB TORQUE TO 44 FT-LB ITEM 2 (PTP ASSEMBLY) OUTLET TO FACE DOWN AT ASSEMBLY APPLY ITEM 9 (TEFLON TAPE) TO ITEM 2 (PTP), ITEM 4 (SAFETY RELIEF VALVE), ITEM 5 (FILTER) AND ITEM 6 (NIPPLE). _ 50 PSI SET ITEM 4 (SAFETY RELIEF VALVE) TO OPEN AT 4700 + TEST SPECIFICATIONS: (TEST WITH #3.5 NOZZLE) FLOW RATE: 3.
DOWNSTREAM CHEMICAL INJECTORS OPTIONAL ITEM FEATURES 1. 2. 3. 4. Streamline your combination injector/quick disconnect assembly with this latest one piece style design. Brass construction with stainless steel ball. Inconel Spring Built in 3/8” socket and 3/8” plug available with inlet or discharge on plug side of assembly. Item # Part # Description & Number Req’d 1 2 3 4 5* 6 7 8 9 10* 11* 12* 13 14* Ref.
SANDBLAST KIT - OPTIONAL ITEM PART NUMBER 176-040 For suction fed injection of sand into the water stream for abrasive cleaning. (High pressure spray tip not included.) SPECIFICATIONS Maximum Pressure Maximum Temperature Weight Material PARTS LIST 3500 PSI (241 bar) 200 F (93 C) 13 lbs. (5.9 kg) Plated Carbon Steel, Aluminum, Carbide, Rubber.
SANDBLASTING APPLICATION APPLICATION SAND USAGE: with 2500 PSI – 5 GPM, 9 lb. per min.
33 WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.
LIMITED WARRANTY Durotech Co. warrants the Airlessco spray unit to be free of defects in material and workmanship under normal use and service in accordance with Durotech Co.’s recommendations. This warranty extends to the original purchaser for a period of twelve (12) months from date of purchase. The warranty registration card must be signed by the distributor and the original purchaser and then returned to Durotech Co. within ten (10) days from date of purchase, or otherwise warranty is void.
* Note: Keep this top portion in the manual for future reference on the Limited Warranty. # cut along this line *Note: Cut and send this portion of the page to register your warranty to: Airlessco by Durotech Co. P.O. Box 8006 Moorpark, CA 93020-8006 35 WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.
PRESSURE WASHER ACCESSORIES PRESSURE WASHER GUN PN 176-070 Gun complete with fittings and wand PRESSURE WASHER CLEANING NOZZLES Pressure washer nozzles come in several sizes and spray angles. They are sized by the volume of water they will allow through the orifice, so you can change the width of the spray but not the volume. For more power use a narrow nozzle and move close to the work. For a large area use a wider nozzle. The most effective cleaning range is within 12 inches of the surface.
PRESSURE WASHER ACCESSORIES PRESSURE WASHER HOSE Pressure washer hose comes with 3/8" male fittings, with one end having a swivel to connect to the gun. The hose has a wire braid for strength and rubber outer cover to resist abrasion. For convenience you can use quick disconnects at each end of the hose, gun and pump.
