Sealey Pcm2500sp.v2 User manual

Thank you for purchasing a Sealey product. Manufactured to a high standard this product will, if used according to these instructions and properly

maintained, give you years of trouble free performance.

1. SAFETY INSTRUCTIONS

INSTRUCTIONS FOR:

PETROL PRESSURE WASHER

MODEL No:PCM2500SP.V2

IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS & CAUTIONS.

USE THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE

DAMAGE AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.

GENERAL SAFETY

 WARNING! RISK OF FLUID INJECTION. This washer operates at fluid pressures and velocities high enough to penetrate human

and animal flesh. If there is an occurrence of fluid injection seek medical help immediately.

 WARNING! Stop the engine and disconnect the mains water supply before changing accessories or performing any maintenance.

WARNING! DO NOT operate the washer if damaged. Replace or repair using recommended parts only. Unauthorised parts may

be dangerous and will invalidate your warranty. Use authorised Service agent only.

Keep the washer in good condition. Regular maintenance will give the best and safest performance.

Ensure you comply with the water supply company regulations before connecting to the mains. If you are connecting to the mains drinking

water supply ensure you have a back flow preventer valve installed.

The water supply hose must be reinforced and have an internal diameter of 13mm (1/2”). The minimum water supply rate must be at least

equal to the cleaner capacity. The water temperers must not exceed 60oC, and the pressure must not exceed 10bar.

 WARNING! DO NOT operate the washer without the water supply connected. To do so will damage the machine.

Position the washer as near as possible to the water supply.

Only use recommended washing detergents. Failure to do so may cause corrosion to equipment and hoses.

WARNING! Use the washer on a flat, level surface, in a horizontal position. Failure to do so will invalidate your warranty.

 Wear safety goggles and adequate protective clothing, and anti-slip rubber soled footwear.

 WARNING! The high pressure jet must be used with caution. Ensure you aim the lance correctly at the work surface. Failure to do so may

scatter loose particles at the same force as the water pressure, resulting in possible damage or personal injury.

Keep all persons and animals at a safe distance from the hose working area. It is difficult to give an exact safe distance as it will depend upon your

circumstances. We recommend at least 15 metres. Also ensure other persons are aware before you start to depress the washer trigger.

Hold the gun firmly with both hands as it will tend to “kick” backwards when you first pull the trigger.

DO NOT allow children or untrained persons to operate the washer.

 DO NOT connect other appliances to the washer inlet or outlet. Only use the supplied or recommended outlet nozzle.

DO NOT use the washer if the water supply hose is damaged. Also check that the hose is laid out straight and safely.

DO NOT jam the operating trigger in the operating position and DO NOT pull the trigger without holding and aiming the gun correctly.

 WARNING! DO NOT attempt to alter the pressure regulating valve as this may cause serious damage.

DO NOT move the washer by pulling on the high pressure hose or the mains water supply hose. Use the machine handle.

DO NOT direct jet against yourself, other persons or animals, electrical equipment or the machine itself.

 WARNING! DO NOT leave the engine running for more than 2 minutes without operating the trigger, as temperature/pressure increase

may damage the sealing system.

DO NOT use the washer if you are tired or under the influence of alcohol, drugs or intoxicating medication.

Ensure that the hose pressure is discharged before disconnecting the mains water hose.

When not in use, disconnect from the water supply. Clean and dry the washer and store in a safe, dry, childproof area.

DO NOT allow the machine to become frozen.

ENGINE SAFETY

WARNING! Check the engine oil level before each startup. Only use a specified oil and never operate the engine with insufficient oil.

DO NOT operate the washer in an enclosed area as the motor exhaust fumes are a health hazard.

DO NOT use the washer with flammable, toxic or corrosive liquids.

DO NOT leave the washer unattended whilst operating and DO NOT remove the fuel cap whilst the engine is running.

DO NOT refuel the engine whilst it is running. Stop the engine and allow it to cool for two minutes before attempting to refuel.

DO NOT refuel in a closed or poorly ventilated environment as there is a danger of explosion or fire. Refuel out doors.

DO NOT smoke or place the washer near any naked flames whilst re-fuelling.

DO NOT operate washer if there is a fuel leak. Move the unit and avoid any combustion until the leak has been fixed and the machine is dry.

DO NOT start the engine if there are any flammable materials near the exhaust system or in the path of the exhaust gases.

DO NOT block the engine ventilation grilles.

Ensure engine fuel is stored in an approved container.

For long term storage ensure the fuel is drained and that the washer is adequately protected against frost.

DO NOT operate the engine with either the silencer or air filter removed.

DO NOT touch the engine during or after use. To avoid burns allow it to cool before handling.

WARNING: The warnings, cautions and instructions discussed in this manual cannot cover all possible conditions and situations that may

occur. It must be understood that common sense and caution are factors which cannot be built into this product, but must be applied by

the operator

2. SPECIFICATION & INTRODUCTION

Output Pressure/Flow:....................... 2500psi/600ltr/hr

Hose Length: .......................................5.0mtr

Nozzles:....Low Pressure, Wide Angle, High Pressure, 0°, 15°, 40°

Maximum Inlet Temperature:............................60°C

Engine Type: ...................4 Stroke, single cylinder, Petrol

Engine Capacity: ....................................196cc

Engine Power ......................4.8kW(6.5hp) @ 3600rpm

Starting: ...........................................Recoil

Weight: ............................................46kg

FuelTank:......................................... .3.6ltr

Fuel:. . . ....................Unleaded Petrol 85 RON minimum

Fuel Consumption: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 - 2.6ltr/hr

EngineOil: ...................................SAE10W-30

Spark Plug: .........................NGK BP6ES or BPR6ES

SparkPlugGap: ...............................0.7-0.8mm

Idle Speed:. .................................1700 +/- 15rpm

Valve Clearance (cold engine): Inlet .............0.15 +/- 0.02mm

................................................: Exhaust ..........0.20 +/- 0.02mm

Original Language Version PCM2500SP.V2 Issue: 1 - 27/01/12

fig.2

Petrol powered pressure washer with recoil starting. Ideal for commercial applications: with 5mtr pressure hose, 1mtr gun and lance and

adjustable nozzle. Self priming pump makes this unit fully portable and can be used where no mains pressure is available. Can draw clean

water from water butts and tanks etc. Low-pressure liquid detergent injection system with provision for detergent bottle stowage. Safety latch on

trigger and automatic low-oil engine shutdown reduce risks of misuse and equipment damage. Unit stands on four legs, two with sucker feet to

prevent creep, and tilts back onto two pneumatic tyred wheels for moving. Supplied with tools and full Instructions.

fig.1

Nozzle Holder

Fuel Tank

Air Filter

High Pressure Hose & Lance

Siphon Hose & Filter

Detergent Holder

Legs Recoil Starter

Original Language Version PCM2500SP.V2 Issue: 1 - 27/01/12

4.1 THERMAL RELIEF VALVE.

4.1.1 A thermal relief valve is fitted to protect the machine from

overheating if the gun remains closed for an extended

period of time or if the nozzle becomes blocked. To prolong the

life of the washer every effort should be made to avoid

overheating. It is recommended that if the unit is not going to

be used for two minutes or more it should be switched off.

4.2 TRIGGER LOCK.

4.2.1 To prevent accidental starting of the pressure washer the

trigger can be locked as shown in fig.4 by hinging out the

lever built into the back of the trigger and pressing it until it

locks into position. To release the locking lever flex the trigger

handle forwards and flip the lever out and fold it back into the

trigger. The trigger should be locked whenever the washer is

not in use.

4.3 LOW OIL SHUTDOWN.

4.3.1 The engine on this washer is equipped with a low oil shutdown

feature which stops the engine if the oil drops below a

specified level. Should the engine cut out, first check that it is

standing on a level surface. If the oil level is still low top it up

as described in Section 7.2.

Regulator Valve

Detergent Siphon

High Pressure Pipe

Mains / Siphon Pipe Water Inlet Connection

3. ASSEMBLY / PRE-OPERATION

Unpack contents and check to ensure all parts are in good

condition. If you experience any problems contact your

dealer immediately.

3.1 ASSEMBLY. (See fig.1.)

3.1.1 Screw together the two halves of the lance as shown in fig.2.

3.1.2 Select an appropriate nozzle from the nozzle stowage area. Pull

back the spring loaded sleeve at the end of the lance and insert the

nozzle. Let go of the sleeve and check that the nozzle is firmly

gripped in the fitting. The nozzle selection is colour coded and offers

the following options.

BLACK Low pressure wide angle spray for use with detergent.

RED High pressure, 0° degree spray, Very Aggressive. Use

with extreme caution to prevent damage to the surface

being cleaned or injury to persons or animals.

YELLOW High pressure, 15° Spray angle, normal cleaning,

provides a wide coverage and powerful water stream.

WHITE High pressure, 40° Spray angle, normal cleaning and

rinsing, provides a less powerful stream of water and is

suitable for most general cleaning jobs.

3.1.3 To attach the high pressure hose to the water inlet on the gun,

push it into the inlet on the gun until it is fully seated and tighten

as shown in figs.4 & 5.

3.1.4 Attach the other end of the high pressure hose to the pump

outlet as shown in fig.6. Push the end of the hose into the

pump outlet until it is fully seated and then tighten to secure.

3.1.5 Connect either a mains water supply hose or the siphon hose

to the pump inlet as shown in fig.6. USE COLD WATER ONLY.

Note: The water supply hose must be reinforced and have an internal

diameter of 13mm (1/2”). The minimum water supply rate must

be at least equal to the washer flow rate.

The siphon pipe may require priming if drawing water from a

level lower than the pump.

3.2 DETERGENT DELIVERY.

3.2.1 Attach the BLACK low pressure nozzle to the end of the lance.

Remove the cap from a bottle of detergent and place the bottle

in the detergent holder.

3.2.2 On the top of the pump outlet is a brass siphon injection fitting.

Push the detergent input pipe onto the fitting (fig.6) and place the

filter on the other end into the container of detergent ensuring

that it goes all the way to the bottom. When used with the low

pressure black nozzle detergent will be drawn from the

container by siphonic action and will mix automatically with the

water from the pump. Use Sealey General Purpose Detergent,

AK130 (25ltr) or AK131 (5ltr). Traffic Film Remover is also

available, AK132 (25ltr) or AK133 (5ltr).

3.3 ENGINE LUBRICATION.

3.3.1 THE PRESSURE WASHER ENGINE IS SHIPPED FROM THE

FACTORY WITHOUT OIL. DO NOT ATTEMPT TO START THE

ENGINE BEFORE THE SUMP HAS BEEN FILLED WITH THE

CORRECT AMOUNT OF OIL. Refer to the section 7.2.

3.4 FUEL.

3.4.1 Fill the tank with fresh unleaded petrol fuel. Keep fuel level

below the fuel filter which sits in the neck of the tank.

3.5 PUMP.

3.5.1 The pump is supplied already filled with oil. Re-check the oil

level before using the unit. The combined oil filler cap and

dipstick is on top of the pump. The oil level can also be seen in

the sight glass on the end of the pump.

3.6 SITING OF UNIT.

3.6.1 Ideally the unit should be used on level ground. Where this is

not possible the unit should not be inclined more than 20° in

any one direction.

3.7 RUNNING IN THE ENGINE.

3.7.1 For the first 20 hours of operation the unit should not be placed

under heavy load. After the first 20 hours change the oil.

fig.3

fig.4

fig.6

fig.5

4. SAFETY FEATURES

BLACK RED YELLOW WHITE

5. OPERATION

 WARNING! THE PRESSURE WASHER ENGINE IS SHIPPED

FROM THE FACTORY WITHOUT OIL.

 WARNING! RISK OF FLUID INJECTION. This washer

operates at fluid pressures and velocities high enough to

penetrate human and animal flesh. If there is an occurrence

of fluid injection seek medical help immediately.

 WARNING! Ensure you read, understand and apply

Section 1 safety instructions.

 WARNING! Dry running can seriously damage the unit.

 WARNING! DO NOT leave motor running for more than

2 minutes without operating the trigger, as

temperature/pressure increase may damage sealing system.

Original Language Version PCM2500SP.V2 Issue: 1 - 27/01/12

6. MAINTENANCE (WASHER)

6.2 Check and clean the water inlet filter every 50 operating

hours. The filter is moulded into a rubber washer. Unscrew

the brass connector from the black fitting on the water inlet on

the pump. Push the black fitting backwards which will eject

the filter/washer and then clean the filter washer. If the filter is

damaged in any way it should be replaced.

6.3 Check and clean the detergent filter at the end of the

detergent input tube on a regular basis.

6.4 WINTER STORAGE: Fill the pump with an antifreeze

mixture before storing in a frost free, safe, dry area for the

winter. Introduce the antifreeze by the following method.

6.4.1 Shut off the water supply and disconnect the supply hose.

Relieve pressure within the pump by squeezing the gun

trigger. Remove the high pressure hose and let all water drain

from it. Hold gun/lance with nozzle downwards and pull

trigger until all water has drained out.

6.4.2 Connect a short length of garden hose to the water inlet and

using a funnel pour an antifreeze mixture into it.

6.4.3 Pull the recoil starter several times to circulate the antifreeze

through the pump. Continue to add antifreeze and pull the

recoil until antifreeze is expelled from the pump.

5.1. MANUAL STARTING PROCEDURE.

5.1.1 Check engine oil level before each use.

5.1.2 Check that the mains water feed hose is laid straight, and

then fully open the water tap. Check to ensure there are no

leaks from hoses or connections.

5.1.3 Release gun trigger safety catch and depress trigger to allow

any air left in the system to escape, hold until there is a steady

flow of water coming out and release the trigger.

5.1.4 Rotate the engine switch clockwise to the ON position. See fig.8.

5.1.5 Fig.7 shows the fuel tap in the OFF position. Push the

fuel tap up to the right to the open position.

5.1.6 If the engine is cold move the choke lever to the left to close

the choke.

5.1.7 Move the throttle lever slightly to the left, fig.7 shows the

throttle in the full throttle position.

5.1.8 Turn the engine switch to the ON position.

5.1.9 Take hold of the recoil starter handle (see fig.1) and pull it

slowly until you feel resistance, then let it return slowly.

5.1.10 Now pull the starting handle hard and fast all the way out. Use

two hands if necessary.

5.1.11 If the engine doesn’t start repeat the process from 5.1.9.

5.1.12 Once started adjust throttle valve to the required setting and

return the choke to the open position when the engine is warm.

5.2. CLEANING

5.2.1. Only apply detergent using the BLACK low pressure nozzle.

5.2.2. Depress the trigger to apply the detergent to the dry surface

which is to be cleaned.

Vertical surfaces should be cleaned from the bottom upwards.

5.2.3 When detergent application is complete remove the syphon

tube from the detergent container and place it in a container

of clean water. Run the washer at low pressure to purge the

gun of detergent.

5.2.4. Leave the detergent to act for 1-2 minutes, but DO NOT

allow the surface to dry.

fig.7

fig.8

fig.9

5.2.5. The detergent should be rinsed off using either the YELLOW

or WHITE high pressure nozzles depending on the

spray angle required. Do not use the RED nozzle as the

aggressive spray action may erode the surface being

cleaned. Always lock the gun trigger before changing nozzles.

5.2.6. Hold the gun firmly with both hands and commence washing

with high pressure clean water. When rinsing work from the

top to the bottom to avoid streaks.

Note: Care should be taken when selecting the nozzle for the job in

hand. The distance from the nozzle to the surface being

cleaned will depend on the condition of that surface. Always

start further away and slowly move closer until the level of

cleaning required is achieved.

5.3. SHUT DOWN PROCEDURE.

5.3.1 When cleaning has finished and the unit is no longer

required allow the engine to run unloaded for 2 minutes

before shutting down.

5.3.2 Stop the engine by pushing the throttle lever fully to the right.

(See fig.7) and turn the engine switch to the OFF position.

5.3.3 Turn off the fuel tap. (See fig.7)

5.3.4 Turn off the mains water supply.

5.3.5 Discharge residual pressure from the washer by pressing the

trigger until no more water comes out of the nozzle.

5.3.6 Engage the gun trigger safety catch.

5.3.7 In an emergency turn the engine switch to the OFF position.

CAUTION!

a) Avoid sudden bursts of water as this will cause the

water pressure to drop and put extreme pressure on the

hoses and connections.

b) If another person is using water from the same supply as

the washer, the water pressure will drop and the washer

will not operate correctly. Switch the engine off

immediately and wait until the pressure is restored.

Maintenance should only be performed with the engine turned

off and the unit disconnected from the mains water supply.

6.1 CLEANING THE NOZZLES: Pull back the brass sleeve on

the end of the lance and pull out the nozzle. Clean the nozzle

with wire provided (fig 9). If this does not improve the flow

from the nozzle it should be replaced.

Throttle Lever

Fuel Tap

Choke

Carburettor Drain plug

Recoil Starter

Engine ON / OFF Switch

Original Language Version PCM2500SP.V2 Issue: 1 - 27/01/12

7. MAINTENANCE (ENGINE)

7.1 Change engine oil after the first 20 hours of operation.

Thereafter, change oil every six months or every 100 hours of

operation. Change oil more often if engine is operated under

heavy load, or in high ambient air temperatures. During

normal operation, partially burned fuel, small particles of

metal from the cylinder walls, pistons, bearings and

combustion deposits will gradually contaminate the oil. If the

oil is not changed regularly, these foreign particles can cause

increased friction and a grinding action which shortens the life

of the engine. Fresh oil also assists in cooling. Old oil

gradually becomes thick and loses its cooling ability as well

as its lubricating qualities.

fig.10

fig.11

7.2 CHECKING THE OIL LEVEL. Ensure the unit is on a level

surface.

7.2.1 Unscrew the dipstick/oil filler cap (see fig.10) and wipe it

clean of oil. Note that the maximum oil level should be just

below the opening of the filler neck.

7.2.2 Check the oil level by seating the dipstick into the hole

without screwing it in. See fig.11 above. On removal the oil

level should be between the two marks on the dipstick. If it is

at the lowest level or below, top-up immediately with an

SAE10W30 oil.

7.2.3 Screw dipstick fully home to seal oil fill hole.

Note: The engine is fitted with a low oil sensor which will

automatically shut the engine down in a low oil situation. The

sensor may also operate if the unit is not on a level surface.

7.3 CHANGING THE OIL.

7.3.1 Change the oil. Operate the engine for 3 minutes to warm the

oil then stop the engine using the shut down procedure

described in section 5.3. There is a hole in the chassis below

the oil drain plug. See fig.10. Place a suitable container below

the hole, remove the plug and allow the oil to drain. Replace

the drain plug and refill with fresh oil. Check the oil level using

the dipstick. Dispose of the old oil according to local authority

guidelines.

7.4 FUEL FILTER: The fuel filter is in the neck of the fuel tank.

7.4.1 Clean it every 300 hours.

7.6 AIR FILTER. To access the air filter element unscrew and

remove the wing nut and seal washer on the top of the cover.

Lift the air filter off its threaded mounting rod

7.6.1 Remove the metal retainer and the foam filter from the inside of

the outer air filter casing.

7.6.2 Wash the foam element with a household detergent or a high

flash-point solvent and squeeze dry. When the element is

thoroughly dry soak it in clean engine oil. Squeeze out any

excess oil, fit back into the outer casing and replace the metal

retainer.

7.6.3 Place the air filter back over the threaded rod and secure with

the seal and wing nut.

7.6.4 The foam element should be replaced after every 300 hours of

service.

fig.12

fig.13

7.5 ENGINE STORAGE. If the unit is not to be used for more

than one month the following procedure should be followed.

7.5.1 Drain the fuel from the fuel tank, fuel line and fuel tap.

7.5.2 Ensure that the engine switch is in the off position and pull the

recoil starter handle slowly until an increase in pressure is felt

indicating that the piston has commenced its compression

stroke and leave it in this position. This closes both the intake

and exhaust valves and prevents the inside of the cylinder from

rusting.

7.5.3 Cover the unit and store it in a clean dry place that is well

ventilated and away from open flame or sparks.

Oil Drain Plug

Dipstick

and Oil Filler

7.7 CARBURETTOR. To adjust the idling speed, turn the throttle

 adjustingscrew(g.14)clockwisetoincreaseand

anti-clockwise to decrease engine speed.

Standard idling speed:1700 +/- 15rpm

7.7.1 Tocleanthedepositcup(g.14),setthefueltaptoOFF,undo

the central bolt and lower the deposit cup, take care not to spill

any fuel, dispose of old fuel in accordance with local authority

 guidelines.Washcomponentsinanon-ammableorhigh

 ashpointcleaningsolvents,drycomponentsandret

components in reverse order. Turn fuel tap back ON and check

for leaks.

7.8 SPARK PLUG. To remove the spark plug, pull off the spark

 pluglead(g.15)andremovethesparkplug(g.16)usingthe

 sparkplugwrenchsupplied(g.18).

Note: Care must be taken if the engine is hot due to the close proximity

of the exhaust silencer to the spark plug.

7.8.1 Clean spark plug using a wire brush and check the insulator for

damage, replace if damaged or at service schedule.

7.8.2 Checktheelectrodeclearance(g.17)withafeelergauge,

adjust if required using a plug gap tool.

7.8.3 Replacesparkplugandretpluglead.

Original Language Version PCM2500SP.V2 Issue: 1 - 27/01/12

8. ENGINE MAINTENANCE SCHEDULE

Spark Plug Lead

Spark Plug

fig.14 fig.15 fig.16

fig.18fig.17

0.7 - 0.8mm

Operation Hours Daily

First Month

or 20hrs

Every 3 months

or 50hrs

Every 6 months

or 100 hrs

Every 12 months

or 300hrs

Task

Check and tighten nuts and bolts Check 

Engine oil

Oil Level Check 

Replace  

Replace air cleaner element

Check 

Clean  

Replace 

Spark Plug

Clean / Adjust 

Replace 

Fuel Tank & Fuel Filter Clean 

Fuel Supply Line Check Every 2 years (replace if required)

Carburettor Deposit Cup Clean 

Idling Check / Adjust 

Intake and exhaust valve clearances Check / Adjust 

Original Language Version PCM2500SP.V2 Issue: 1 - 27/01/12

9. GENERAL TROUBLESHOOTING

PROBLEM POSSIBLE CAUSES REMEDY

Engine will not start Low oil sensor has shut down engine Top up oil level

Engine Switch not in the ON position Turn switch ON

Pressure build up in pump Operate trigger

Engine is overloaded Nozzle partially blocked Clean nozzle

Excessive pressure build up ReturntoSealeydealertohavereuxvalveadjusted

Engine running, but pump not

building maximum pressure or

has irregular pressure

Mainswaterturnedofforinsufcientsupply Turn on mains water or increase supply

Unit has been stored in freezing temperatures Thaw out completely including hose, gun and wand

Waterinletlterclogged Cleanoutlter

Kink in water supply hose Straighten out hose

Lance nozzle worn or damaged Replace nozzle

Air in pump Refer to section 5.1 - 5.1.3 and bleed air out of system

No intake of detergent Injection tube not properly attached to unit Pushtubermlyontosiphonnozzle

Tube cracked or split Replace tubing

Highpressurenozzletted Fit low pressure nozzle (BLACK)

Siphon nozzle blocked Clean nozzle

Trigger will not move Trigger lock engaged Release trigger lock

Noisy operation Worn bearings Return to Sealey dealer for bearing replacement

Tappet clearances excessive Return to Sealey dealer for servicing.

Cavitation in pump Check inlet hose for correct size or leaks

Rough / pulsating operation

with pressure drop

Inlet restriction Check inlet hose for correct size, blockages or leaks

Cavitation in pump Check inlet hose for correct size or leaks

Engine running hot Wrong grade of oil Use recommended oil

Oil too high / low Adjust oil level to recommended level

NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.