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AIRLESSCO Premium Series Service & Operation Manual

Premium series professional pressure washers
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Premium Series
Professional
Pressure Washers
Service/Operation
Manual
Form No. 001-612 APR2605

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Summary of Contents for AIRLESSCO Premium Series

  • Page 1 Premium Series Professional Pressure Washers Service/Operation Manual Form No. 001-612 APR2605...
  • Page 2 Email: techsupport@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.

  • Page 3: Table Of Contents

    HANDLE THIS UNIT AS YOU WOULD A LOADED FIREARM!! High pressure spray can cause extremely serious injury. OBSERVE ALL WARNINGS! Before operating this unit, read and follow all safety warnings and instructions related to the usage of this equipment. WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 4: Pressure Washer Specifications

    Durable Chrome Steel Tubular Frame Thermal Protector and Safety 13” Turf Saver Pneumatic Tires Pressure Relief Valve • Easier to roll • Shock absorbing capability Premium Series - Cold Water High Performance Pressure Washers Specifications P.N. Model 1500-3 163-060 2.80...

  • Page 5: Safety Warnings

    12 volt starting system. from accumulating. • Exhaust fumes are poisonous. Do not operate except in open and well ventilated areas. WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...
  • Page 6 • Gearbox Oil - Check through sight window on side of gearbox. Replenish with 90 wt. gear oil. • Pump Oil - Check through sight window on side of pump. Replenish with SAE 20/ 30 oil. WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 7: Parts

    HIGH PRESSURE HOSE • The hose provided by AIRLESSCO is selected from the finest hoses available and is intended to be used on your machine only. •...

  • Page 8: Users Guide

    PREPARATION INSTRUCTIONS BEFORE WASHING OR REPAINTING YOUR HOSE 1. Please read all safety warnings. 2. If walls are badly stained, mildewed or soiled, detergents and the Airlessco Chemical Injector are recommended. A strong cleanser or tri-sodium phosphate works well to remove stains. Bleaches help to kill mildew.

  • Page 9: Get The Most From Your Machine

    25° For Power Cleaning & Flushing - The perfect wider spray angle for effectively washing away dirt, mud and grime. 40º For Moderate Washing & Rinsing - Its wide spray pattern “sweeps” surfaces clean. WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 10: Tips And Nozzles

    Learning what each tip can do for you will make your 40° AIRLESSCO machine more valuable and will allow you to do your cleaning jobs faster and more effectively. By experimenting, you will find that different tips do the job...

  • Page 11: Cleaning Nozzle Rating Chart

    NOTE: The proper nozzle size for each pressure washer can be found on the machine specification plate (located on the frame). Nozzle Orifice Size 1000 1500 2000 2500 3000 3500 4000 5000 3.35 10.1 WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 12: Troubleshooting

    • Check pressure and fluid inlet temperature; temperature of fluid being pumped be sure they are with in specified range. • Over pressure of pumps • Reduce pressure • Running pump dry • Do not run pump without water WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 13: Pump Servicing Procedure

    4. Reinstall manifold head and torque to specifications per sequence described below. Torque Sequence For Tightening Head Install all head bolts finger tight. Torque to 10 foot pounds in sequence as shown below, then retorque to specifications again in sequence. WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 14: Specifications - Model

    Position Ft. - lbs. Position Ft. - lbs. 29.4 13.2 14.7 11.0 33.1 *Decrease torque by 20% if threads are lubricated. *For Position Number Reference Parts Breakdown Page 12. MODEL 1500-3 DIMENSIONAL DRAWING WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 15: Parts Breakdown - Model

    10, 11, 12 15, 16 20, 21, 18, 19, 18, 19, INCLUDED 6, 7, 8 20, 21, 21, 22 IN KIT (17) NUMBER OF ASSEMBLIES IN KIT NUMBER OF CYLINDERS KIT WILL SERVICE WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 16: Specifications - Model

    Position Ft. - lbs. Position Ft. - lbs. 29.4 13.2 14.7 11.0 33.1 *Decrease torque by 20% if threads are lubricated. *For Position Number Reference Parts Breakdown Page 14. MODEL 2500-3 DIMENSIONAL DRAWING WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 17: Parts Breakdown - Model

    (15mm) (15mm) (15mm) (18mm) (18mm) (18mm) ITEM NO.S 20,21 18,19 18,19 6,7,8 20,21 18,19 18,19 INCLUDED 20,21, 21,22 10,11,12 20,21 21,22 IN KIT (17) NUMBER OF ASSEMBLIES IN KIT NUMBER OF CYLINDERS KIT WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 18: Specifications

    Ft. - lbs. N-M Position Ft. - lbs 14.7 14.7 73.7 11.0 14.7 29.4 29.4 *Decrease torque by 20% if threads are lubricated. *For Position Number Reference Parts Breakdown Page 16. MODEL 2500-5 DIMENSIONAL DRAWING WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...
  • Page 19 Washer, 010 mm 10.0518.22 Gas Flange 97.7340.00 REPAIR KITS KIT NUMBER ITEM NO.S 43,44, 4,5,6 9,10 40,41 40,41,42 INCLUDED 7,8, 43,44,45, IN KIT (11) NUMBER OF ASSEMBLIES IN KIT NUMBER OF CYLINDERS KIT WILL SERVICE WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...
  • Page 20 Ft. - lbs. N-M Position Ft. - lbs 14.7 14.7 14.7 73.7 11.0 29.4 29.4 *Decrease torque by 20% if threads are lubricated. *For Position Number Reference Parts Breakdown Page 18. MODEL 3000-4 DIMENSIONAL DRAWING WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...
  • Page 21 Flinger Washer 99191200 Screw, M6 x 30 REPAIR KITS KIT NUMBER ITEM NO.S 4,5, 9,10 42,44 40,41,42 INCLUDED 6,7,8 43,44 IN KIT (11) NUMBER OF ASSEMBLIES IN KIT NUMBER OF CYLINDERS KIT WILL SERVICE WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...
  • Page 22 Ft. - lbs. N-M Position Ft. - lbs 14.7 14.7 73.7 14.7 29.4 29.4 *Decrease torque by 20% if threads are lubricated. *For Position Number Reference Parts Breakdown Page 20. MODEL 4000-3.5 DIMENSIONAL DRAWING WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...
  • Page 23 Cap Screw 99191200 Screw 97734000 REPAIR KITS KIT NUMBER ITEM NO.S 4,5, 9,10 40,41 43,44, 40,41,42, INCLUDED 6,7,8, 43,44,45, IN KIT (11) NUMBER OF ASSEMBLIES IN KIT NUMBER OF CYLINDERS KIT WILL SERVICE WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 24: Application & Installation Of The Unloader Valve

    Chemical Injector does •Foreign matter in chemical hose •Clean not draw solution •Foreign matter in check valve •Clean •Insufficient pressure drop •Put system in low pressure mode across injector •Shorten discharge hose •Check spray tip WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...
  • Page 25 O-Ring, 70 Duro, Buna-N, .394” ID x .039” CS Y60.0382.31 Bypass Fitting Y10.3109.96 O-Ring, 70 Duro, Viton, .406” ID x .094” CS Y60.0821.35 Manifold, Brass Y60.0803.31 Banjo Bolt 3/8” BSPP, Brass Y60.0305.31 Outlet Fitting, 3/8” BSPP-M Y60.0398.24 Repair Kit WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...
  • Page 26 O-Ring, .237 x .104 Y10402300 Backup Ring, .433 x .251 Y10321300 O-Ring, .237 x .119 Y10402400 Backup Ring, .451 x .276 Y60031061 Spring Seat, Zinc Plated Y60031361 White Spring Y60030431 Brass Cap Y60031584 Plastic Knob WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 27: Frame Assembly Part No. 163-055

    Spacer, .25 x .088W x .55” 301-165 Wheel, 13 x 500-6 Tubeless 301-510 Frame Weldment, LB/PW 305-088 Screw, 1/4”-20 x 2” SC HD *Note: For smaller frame part numbers Please call Airlessco's Technical Service at 805-523-0211 ext. 1751. WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 28: Frame Assembly Part No. 163-024

    ELBOW, 90°, 3/8 NPT-FX 3/8 NPT-M 800013 PTFE THREAD SEALING TAPE 1/2" 800001 ANAEROBIC THREAD SEALANT- BLUE 600035 PARTITION 10 3/8 x 40 5/8 600036 PARTITION 10 3/8 x 35 7/16 600037 PAD 35 1/4 x 40 9/16 WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 29: Pump Assembly - Model 2500-5

    ELBOW, 90°, 3/8 NPT-FX 3/8 NPT-M 800013 PTFE THREAD SEALING TAPE 1/2" 800001 ANAEROBIC THREAD SEALANT- BLUE 600035 PARTITION 10 3/8 x 40 5/8 600036 PARTITION 10 3/8 x 35 7/16 600037 PAD 35 1/4 x 40 9/16 WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...
  • Page 30 INJ. ASSEMBLY, ADJUSTABLE .083 800013 PTFE THREAD SEALING TAPE 1/2" 800001 ANAEROBIC THREAD SEALANT- BLUE 600035 PARTITION 10 3/8 x 40 5/8 600036 PARTITION 10 3/8 x 35 7/16 600037 PAD 35 1/4 x 40 9/16 WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 31: Pump Assembly - Model 3000-4

    INJ. ASSEMBLY, ADJUSTABLE .083 800013 PTFE THREAD SEALING TAPE 1/2" 800001 ANAEROBIC THREAD SEALANT- BLUE 600035 PARTITION 10 3/8 x 40 5/8 600036 PARTITION 10 3/8 x 35 7/16 600037 PAD 35 1/4 x 40 9/16 WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 32: Pump Assembly - Model 4000-3.5

    INJ. ASSEMBLY, ADJUSTABLE .083 800013 PTFE THREAD SEALING TAPE 1/2" 800001 ANAEROBIC THREAD SEALANT- BLUE 600035 PARTITION 10 3/8 x 40 5/8 600036 PARTITION 10 3/8 x 35 7/16 600037 PAD 35 1/4 x 40 9/16 WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...
  • Page 33 O-Ring (1) Ref. B Apply Loctite #242; Torque to 100 in./lb. *INDICATES ITEMS IN REPAIR KIT 7525K AIRLESSCO PART NUMBER USED ON MODEL NUMBER * For older pressure washer models only. New models come equipped with injector. 176-030B Adjust Chemical Injector PWD 3000-3.5...

  • Page 34: Downstream Chemical Injectors

    Remove the hose from the mixing head and rinse with water to remove all the sand, before storage. Before using the gun for other applications be sure to reinstall the tip guard, nozzle and male quick coupler. WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 35: Sandblast Kit

    Problem Solution Incorrect Water Nozzle Change to 15° nozzle Collapsed Hose Replace hose/remove restriction Partial Obstruction to Probe Clear rocks/paper from probe inlet Low Sand Level Change probe to new bag of sand WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 36: Sandblasting Application

    WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

  • Page 37: Limited Warranty

    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.
  • Page 38 * 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 WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...
  • Page 39 Turbo nozzle for 5 to 6 GPM machines PN 176-025 Repair Kit for 176-051 - Old Model PN 176-055 Repair Kit for 176-052 - Old Model PN 176-063 Repair Kit for 176-061 PN 176-064 Repair Kit for 176-062 WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...
  • Page 40 High pressure liquid fi lled gauges are used to test the working pressure of a pressure washer. They are designed to work to a maximum pressure of 4000 to 5000 psi. PN 100-039 Test gauge assembly for pressure washers complete with quick disconnects. WWW.AIRLESSCO.COM TEL: 805-523-0211 FAX: 805-523-1063 Email: technicalsupport@airlessco.com...

This manual is also suitable for:

Premium 1500-3Premium 3000-4Premium 2500-5Premium 2500-3Premium 4000-3.5

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