Dustless DuctlessVac D1603 User manual

OWNERS MANUAL
D16 Series
dustlesstools.com
PATENT NO. 5954863 & 5704956
This appliance
is intended for
commercial and
household use.

2Customer Service Helpline 1.800.568.3949 dustlesstools.com
IMPORTANT SAFETY INSTRUCTIONS
IMPORTANTES MESURES DE SECURITE
IMPORTANTE PARA SU SEGURIDAD
SAVE THESE INSTRUCTIONS
CONSERVER CES INSTRUCTIONS
GUARDAR ESTAS INSTRUCCIONES
WARNING
• WARNING: To reduce the risk of fire,
electric shock, or injury, do not expose to
rain. Store indoors.
• WARNING: Commercial users must be
trained, qualified and certified in the in
collection of hazardous materials such
as lead, asbestos, mold, silica or other
hazardous material prior to collecting it
in the vacuum.
• WARNING: For Household use, collection of
hazardous materials such as lead, asbestos,
mold, silica or other hazardous materials must
be done only after you have been trained
by a certifying body, or by a licensed and
trained commercial professional in the area
of hazardous material. Use only as described
in this manual. Use only manufacturer’s
recommended attachments.
• Do not put any object into openings. Do not
use with any opening blocked; keep free of
dust, lint, hair, and anything that may reduce
air flow.
WORK AREA SAFETY
• Do not operate vacuum in explosive
atmospheres. Sparks from static electricity or
the motors may ignite dust or fumes.
ELECTRICAL SAFETY
• Connect to a properly grounded outlet. See
grounding instructions.
• Do not leave appliance when plugged in.
Unplug from outlet when not in use and
before servicing.
ELECTRICAL SAFETY cont
• Electrical components are not user
serviceable. Refer all service to a qualified
repair technician.
• Do not handle plug or operate vacuum with
wet hands.
PERSONAL SAFETY
• Do not allow to be used as a toy. Close
attention is necessary when used by or near
children.
• Do not change filters, clean the unit, or
empty the barrel until the plug has been
disconnected from the electrical outlet.
• Use special care when emptying heavily
loaded barrels.
• Keep hair, loose clothing, fingers and all parts
of body away from openings and moving
parts. There is a risk of injury through getting
stuck or being drawn into moving machinery.
• Use extra care when working on stairs.
• Injury to the eyes and/or body can occur
if protective clothing and/or equipment
is not worn. Always wear safety goggles,
protective clothing, hearing protection, and
a dust mask. Exposure to high noise levels
can cause hearing loss or impairment. Wear
OSHA-approved hearing protection when
using this vacuum.
NOTE: The reading and understanding of the Owner’s Manual is imperative
prior to operating this machine. If you or your operator(s) cannot read English,
have this manual explained fully before attempting to operate this machine. Si
Ud. o sus operadores no pueden leer el inglés, el contenido completo de este
manual debe ser explicado antes de intentar operacion de esta máquina.
When using an electrical appliance, basic precautions should always be
followed, including the following:

3
Customer Service Helpline 1.800.568.3949 dustlesstools.com
GROUNDING INSTRUCTIONS:
This appliance must be grounded. If it should malfunction or
break down, grounding provides a path of least resistance
for electric current to reduce the risk of electric shock. This
appliance is equipped with a cord having an equipment-
grounding conductor and grounding plug. The plug must be inserted into an appropriate outlet
that is properly installed and grounded in accordance with all local codes and ordinances.
WARNING - Improper connection of the equipment-grounding conductor can result in a
risk of electric shock. Check with a qualified electrician or service person if you are in doubt as to
whether the outlet is properly grounded. Do not modify the plug provided with the appliance – if
it will not fit the outlet, have a proper outlet installed by a qualified electrician.
This appliance is for use on a nominal 120-V circuit, and has a grounded plug that looks like the
plug illustrated in sketch A. A temporary adapter that looks like the adapter illustrated in sketches
B and C may be used to connect this plug to a 2-pole receptacle as shown in sketch B if a properly
grounded outlet is not available. The temporary adapter should be used only until a properly
grounded outlet (sketch A) can be installed by a qualified electrician. The green colored rigid
ear, lug, or the like extending from the adapter must be connected to a permanent ground such
as a properly grounded outlet box cover. Whenever the adapter is used, it must be held in place
by a metal screw. Exception: In Canada, the use of a temporary adapter is not permitted by the
Canadian Electrical Code, C22.1.
B C
Adapter
A
Grounded Plug
TOOL USE AND CARE
• Always check the filters before each use. Do
not use without a dust collection bag and
filters in place.
• Do not use with damaged cord or plug.
• If appliance is not working as it should, has
been dropped, damaged, left outdoors, or
dropped into water, return it to a service
center.
• Do not pull or carry by the cord, use cord as
a handle, close a door on cord, or pull cord
around sharp edges or corners. Do not run
vacuum over cord. Keep cord away from
heated surfaces.
• Do not unplug by pulling on cord. To unplug,
grasp the plug, not the cord
• Turn off all controls before unplugging.
• Take notice of all safety and hazard notices
on the vacuum.
• All safety and hazard notices on the vacuum
must be kept complete and legible.
• Changes, add-ons, or conversions of the
vacuum which might have an influence to the
safety of the vacuum must not be undertaken
without the permission of the manufacturer.
This applies in particular to the fitting and
adjustment of safety devices and to welding
on major and load-bearing parts.
TOOL USE AND CARE cont
• In the event of operational malfunction the
vacuum must be shut down immediately. The
malfunction must be rectified before starting
the vacuum again.
• The dust bin of the dust collector has to be
emptied before transportation.
• Should dust begin to blow out of the
vacuum, it must be shut down, cleaned
(including the motor housing) and the
problem fixed before returning to service.
Failure to do so could put dangerous dust in
the air and will void the warranty.
SPECIFIC SAFETY RULES
• Do not use to pick up flammable or
combustible liquids, such as gasoline or use
in an area where they may be present.
• Do not pick up any objects that are burning
or smoking, such as cigarettes, matches, or
hot ashes.
• Dispose of the dust so that you meet the
requirements of local regulations.

4Customer Service Helpline 1.800.568.3949 dustlesstools.com
IN THE BOX
Extension Wands
D1603 16 GAL WET+DRY DUSTLESSVAC WITH 12 FT. HOSE:
D1605 16 GAL WET+DRY VAC-FOREIGN:
D1606 HEPA 16 GAL WET+DRY VAC:
Crevice
Tool Floor Tool
Lid
Barrel
Hose
WunderBag
10” Clamp 7” Clamp
Inner
Filter
Outer Filter
WunderBag
Filter Cover
HEPA Filter
10” Clamp
WunderBag
10” Clamp 7” Clamp
Inner
Filter
Outer Filter
Shaker Basket
Shaker Basket
Extension Wands
Crevice
Tool
Floor Tool
Lid
Barrel
Hose
Extension Wands
Crevice
Tool Floor Tool
Lid
Barrel
Hose
HEPA Filter
Support
Filter-Cleaning
Weight

5
Customer Service Helpline 1.800.568.3949 dustlesstools.com
16250 SHERWIN WILLIAMS HEPA RRP KIT:
16500 DUSTLESS EPA LEAD SAFE COMPLIANCE:
D1607 HEPA - 240V 16 GAL WET+DRY VAC:
Dustie HEPA Floor Tool
Adapter
ChipBuddie 6’ Hose
#32 Clamp Zip Tie
D1608 RENOVATE RIGHT EPA HEPA KIT:
+
ChipBuddie DustBuddie
18” Hose
HEPA Floor Tool
Adapter
HEPA Floor Tool
Adapter
WunderBag
Filter Cover
HEPA Filter
10” Clamp
Extension Wands
Crevice Tool Floor
Tool
Lid
Barrel
Hose
HEPA Filter
Support
Filter-Cleaning
Weight
IN THE BOX cont
+
+

6Customer Service Helpline 1.800.568.3949 dustlesstools.com
SETUP
1. Remove entire contents of box.
2. Slide legs into slots with the legs with the
hooks in the back. Screw in screws.
3. Attach tool tray.
4. Place intermediate on barrel. Use clips to
secure in place.
5. Slide one end of the hose into the port.
Slide desired attachments on to the other
end of the hose.
WUNDERBAG INSTALLATION
1. Place the cardboard collar with the rubber
gasket securely over the intake port on the
inside of the barrel.
2. Reach inside the port and with your fingers
press cardboard tight and secure around
port.
WET PICKUP
1. Vacuum should be emptied of any dry
waste. Filters can remain in place. Note:
Should filters become wet, dry both filters
thoroughly before continued use.
2. Connect hose and desired attachment.
3. After use or when barrel is full turn off
vacuum and disconnect from outlet.
Note: When barrel is full the automatic shut-
off mechanism will shut off vacuum pickup.
When this happens, the motor will become
noticeably higher pitch.
4. Empty barrel by unscrewing drain cap. Drain
is regulated so liquid can go from a drip to a
full flow. Note: Hose can be put in the drain
cap to drain up to 12 feet away.

7
Customer Service Helpline 1.800.568.3949 dustlesstools.com
USAGE
CLEAN FILTERS (REGULAR WET+DRY)
1. Always turn off the vacuum before cleaning
the filters.
2. Keep the lid closed on the barrel, do not
remove the lid.
3. Remove the black agitator rod cover from
the lid.
4. Lift the agitator rod slightly and rapidly
shake it from side to side five times so the
basket hits the sides of the outer filter to
knock off the layer of dust. Note: Pushing
down may push the filter off.
5. Replace the black agitator rod cover to the
top of the lid.
DRY PICKUP
1. Barrel should be emptied of any wet waste.
Filters can remain in place.
2. Connect hose and desired attachment.
3. As suction is reduced stop to clean or
replace filters. (Refer to Clean Filters or Filter
Installation)
4. After use or when barrel is full turn off
vacuum and disconnect from outlet.
5. Remove intermediate from barrel.
6. Empty barrel and/or remove WunderBag.
Note: To avoid back strain, do not lift a full
barrel/bag.
CLEAN FILTERS (HEPA WET+DRY)
1. Turn the vacuum off and wait 5 seconds
after motor comes to a stop. Repeat 5
times. This allows weight to expand filter
cover and release dust.
2. For increased effectiveness, move the
vacuum vigorously side to side and back
and forth while shut down. Plugging and
unplugging the hose while running may also
restore some suction.
3. THOROUGH FILTER COVER CLEANING
Hand or machine wash the filter cover. Let it
line dry. DO NOT PUT IN THE DRYER.
4. Filter covers may also be vacuumed off to
restore suction.
5. HEPA filter should be discarded, DO
NOT attempt to clean HEPA filter. Proper
installation and use of the Wunderbag
and filter cover will maximize the life of the
HEPA filter.

8Customer Service Helpline 1.800.568.3949 dustlesstools.com
USAGE cont
CHANGING WUNDERBAGS
1. Disconnect the vacuum from outlet.
2. Remove intermediate.
3. Seal and remove full WunderBag. Note: To
avoid back strain, do not lift a full bag.
4. Install new WunderBag. (Refer to
WunderBag Installation)
STORAGE
1. Disconnect from outlet
2. Empty barrel.
3. Rinse barrel thoroughly and wipe out.
4. Store hose and attachments.
EXTENSION CORDS
When using the appliance at a distance where
an extension cord becomes necessary, a
3-conductor grounding cord of adequate
size must be used for safety, and to prevent
loss of power and overheating. Use the table
that follows to determine A.W.G. wire size
required. To determine ampere rating of your
vacuum, refer to nameplate located on rear of
motor cover. Before using appliance, inspect
power cord for loose or exposed wires and
damaged insulation. Make any needed repairs
or replacements before using your appliance.
Use only three-wire outdoor extension cords
which have three-prong grounding-type plugs
and three-pole receptacles which accept the
extension cords plug. When vacuuming liquids,
be sure the extension cord connection does
not come in contact with the liquid.
VOLTS TOTAL LENGTH OF EXTENSION
CORD IN FEET
120V 25 50 100 150
Ampere Rating
More Not More
Than Than
AWG
0 - 6 18 16 16 14
6 - 10 18 16 14 12
10 - 12 16 16 14 12
12 - 16 14 12 Not
Recommended
NOTE: STATIC SHOCKS ARE COMMON
IN DRY AREAS OR WHEN THE RELATIVE
HUMIDITY OF THE AIR IS LOW. THIS IS ONLY
TEMPORARY AND DOES NOT AFFECT
THE USE OF THE APPLIANCE. TO REDUCE
THE FREQUENCY OF STATIC SHOCKS IN
YOUR HOME, THE BEST REMEDY IS TO ADD
MOISTURE TO THE AIR WITH CONSOLE OR
INSTALLED HUMIDIFIER.

9
Customer Service Helpline 1.800.568.3949 dustlesstools.com
MAINTENANCE
1. Place the inner filter (small white filter) over
the filter support cage and attach with the
7” hose clamp. Tighten the clamp with a
screw driver.
2.
Place the shaker basket rod in the brass hole.
The basket should rest on top of the filter.
3. Place the outer filter over the shaker basket
and around the raised lip on the lid (lip is 1”
from edge of the lid) attach with the 10” hose
clamp. Tighten the clamp with a screw driver.
FILTER INSTALLATION (REGULAR WET+DRY)
1. Place the HEPA filter over the crosspiece stud
and slide on the washer. Screw on the wing
nut to compress the washer and filter seal.
2. Place the HEPA filter cover support on the
HEPA filter.
3. Place the weighted filter cleaning plate on
HEPA filter support.
FILTER INSTALLATION (HEPA WET+DRY)

10 Customer Service Helpline 1.800.568.3949 dustlesstools.com
4. Place the filter-cleaning weight on the filter
cover support, then place the HEPA filter
cover over the HEPA filter cover support
and HEPA filter. Place the 10” hose clamp
over the HEPA filter cover so it rests on the
metal ring of the filter. Tighten the clamp
with a screw drive.
RECOMMENDED REPLACEMENT
INTERVALS
Every 6 months: Replace HEPA Filters
As needed: Replace WunderBag
Note: In order to prevent unnecessary
downtime, it is recommended that you keep
the following items in stock:
• 1X HEPA Filters
• 2X WunderBags
• Motor Brushes
MAINTENANCE cont
FILTER INSTALLATION (HEPA
WET+DRY) cont.
• Adjustments, servicing, and inspection
work and inspection intervals specified in
these Operating Instructions, as well as any
information on the replacement of parts and
systems of the vacuum must be undertaken
and complied with.
• These activities can only be undertaken by
qualified personnel.
• Make sure that electrical components used
for replacement comply with the original
parts and are correctly adjusted if necessary.
• Before performing any maintenance, place
the vacuum in the safety off position which
is the position of the vacuum when it cannot
generate any hazard. To do this, switch off
the dust collector, pull out plug, and secure
the vacuum against unintended start up.
• Inspection intervals and times for recurring
checks specified in these Operating
Instructions must be complied with.
SERVICE

11
Customer Service Helpline 1.800.568.3949 dustlesstools.com
THREE-YEAR LIMITED WARRANTY
At Dustless Technologies, we stand behind what we build. We warrant
this product to the original retail purchaser against defects in materials or
workmanship for a period of three years after date of purchase.
This limited warranty does not cover claims resulting from: (I) misuse (II) neglect
(III) modification (IV) failure to follow instructions.
WARRANTY CARD
Please register your product online at dustlesstools.com within 90 days of
purchase.
WARRANTY CLAIMS
For warranty or returns with any of our products, please contact your
place of purchase. Technical support is available at [phone] or
[e-mail].
QUESTION ANSWER
Why is the vacuum
blowing dust?
• Check filter(s) for holes and that they are securely in
place.
• WunderBag may not be securely in place.
Why have I lost suction? • The drain cap may be open.
• Check and clear any obstruction in the hose or
attachments.
• Filters may need to be cleaned/replaced.
• Agitator rod cover/brass plug may need tightening.
• WunderBag may be full and need to be replaced.
• Hose may have a split and needs to be replaced.
Why are my filters
getting wet?
• Barrel should be empty before use.
• Make sure the drain cap is clean, has an o-ring and is
screwed on tight.
Will the filter(s) meet
current EPA & OSHA
guidelines for asbestos
and mold removal?
• The outer and inner filters do not.
• The HEPA filter does.
Why does the
WunderBag say “do not
use for toxic materials
including lead”?
• The WunderBag must be used in line with a Dustless
HEPA vacuum to guarantee proper filtration.
FAQ
WARRANTY

12 Customer Service Helpline 1.800.568.3949 dustlesstools.com
OTHER PRODUCTS AVAILABLE (not to scale)
5” Dustie
Model #D1854
5” DustBuddie
Model #D1835
DustBuddie for 7-1/4” Worm Drive &
Hypoid Circular Saws
Model #D4000
1-3/8” BitBuddie
Model #D1900
7” CutBuddie
Model #D1750
HEPA Back Pack
Model #15505
OM007_0117
7” DustBuddie
Model #D5850
7” ChipBuddie
Model #D1750
SawBuddie
Model #D2415
Drywall Sander
Model #50001