TUFFCAT 2X1000 User manual

High Pressure Cleaning System
Standard and Pulsating
Owner’s Manual
Standard Models
2X1000, 2X1500, 3X1000, 3X1250
Pulsating Models
2X1000P, 3X1000P
SAVE THESE INSTRUCTIONS
®

▲CAUTION ▲
READ AND FOLLOW ALL SAFETY RULES AND
INSTRUCTIONS BEFORE OPERATING THIS UNIT.
INSTRUCTIONS GIVEN THIS SYMBOL
ARE FOR PERSONAL SAFETY.
BE SURE TO FOLLOW THEM.
▲
!
2
For one year from date of purchase, when the
High Pressure Cleaning System is maintained
and operated according to the instructions in the
owner’s manual, we will repair, free of charge,
any defects in material or workmanship.
This warranty does not cover repairs necessary
asaresultofoperatorneglectorabuseornormal
wear. This cleaning system may be returned to
anyCatPumpdistributorordirectly tothefactory.
SEND PREPAID to Cat Pumps,1681-94thLane
N.E.,Minneapolis,MN55449orcall 612-780-5440
for assistance.
Replacement of parts or accessories with non-
original items or servicing of unit other than that
specifically outlined in owner’s manual will VOID
THE WARRANTY.
High Pressure Cleaning System
ONE YEAR LIMITED WARRANTY
TABLE OF CONTENTS
Features............................................................................................................................................................................3
Specifications..............................................................................................................................................................3
Important Safeguards
Rules for Safe Operation .................................................................................................................................................4
Grounding Instructions ...................................................................................................................................................4
Ground-Fault Circuit-Interrupter .....................................................................................................................................5
Extension Cords ...............................................................................................................................................................5
Motor Reset .......................................................................................................................................................................5
Accidental Submersion ...................................................................................................................................................5
Assembly and Start-up.......................................................................................................................................6-7
Operation
Pressure Adjustment and Gauge Reading ....................................................................................................................8
Vari-Nozzle Adjustmen t ...................................................................................................................................................8
Chemical Injection ............................................................................................................................................................9
Unit Shut-Down and Storage Instructions .....................................................................................................................9
Freeze Protection .............................................................................................................................................................10
Lubrication ........................................................................................................................................................................10
Draining and Adding Oil .................................................................................................................................................. 10
Maintenance of the Pump
Disassembly of the Discharge Valve Assembly ............................................................................................................11
Disassembly of the Seal Assembly ................................................................................................................................12
Reassembly of the Seal Assembly .................................................................................................................................13
Reassembly of the Discharge Valve Assembly .............................................................................................................14
Maintenance of the Crankcase, Unloader, Chemical Injector, Pulsator..................15
Cleaning System Parts List.............................................................................................................................16
Cleaning System Exploded View...............................................................................................................17
SF Pump Exploded View and Parts List..............................................................................................18
Unloader Exploded View and Parts List..............................................................................................19
Chemical Injector Exploded View and Parts List........................................................................19
Troubleshooting........................................................................................................................................................20-21
Standard and Optional Accessories.......................................................................................................22-23
!!

3
FEATURES
1. The proven dependability of the SF
ceramic plunger pump offering unequaled
performance life in its horsepower range.
2. A custom designed, industrial electric
motor featuring Thermal Overload
Protection with reset button and low amp
draw performance.
3. 35 foot electrical cord with Ground-Fault
Circuit-Interrupter (GFCI) protection for
maximum safety during operation.
4. A convenient pop-up cord wrap making
carrying and storing easy and neat.
5. Impact resistant, lightweight molded plas-
tic case free of excess weight and bulk.
6. Easy to read, flat-mount, glycerine-filled
pressure gauge to monitor system opera-
tion and meet exact cleaning needs.
7. Adjustable pressure regulating unloader
to set and maintain system pressure for
various cleaning applications.
8. Adjustable downstream chemical injector
with inlet hose and chemical strainer.
9. Shut-off spray gun with molded extension
and quick coupling allows easy assembly
and quick changes to many optional
accessories.
10.Vari-Nozzle with extension, featuring
adjustable spray angle and high/low pres-
sure settings for chemical application and
pressure cleaning flexibility.
11.30 foot, 3/8 inch, wire braid, nonmarking
high pressure hose with swivel and quick
disconnect for convenience in assembly
and operation.
12.Safety By-Pass hose with Thermo Valve
to minimize excessive fluid heat build-up.
Note: 100V, 50HZ, 60HZ available upon request.
SPECIFICATIONS
MODEL 2X1000 and 2X1000P
Listed LR 91309
80U8
Flow......................................2.0 GPM (7.6 LM)
Pressure ..............................1000 PSI (70 Bar)
Horsepower...................................1.5 (1.5)
Voltage................110 to 115V, 60 HZ (110 to 115V, 60 HZ)
Maximum Amperage ......................15 (15)
Weight......................................60 lbs. (27.1 Kg)
PUMP MODEL...................2LIDX20E
MODEL 2X1500
Flow......................................2.0 GPM (7.6 LM)
Pressure ..............................1500 PSI (105 Bar)
Horsepower...................................2.0 (2.0)
Voltage................110 to 115V, 60 HZ (110 to 115V, 60 HZ)
Maximum Amperage ......................20 (20)
Weight......................................73 lbs. (33.2 Kg)
PUMP MODEL...................2LIDX20E
MODEL 3X1000 and 3X1000P
Flow......................................3.0 GPM (11.3 LM)
Pressure ..............................1000 PSI (70 Bar)
Horsepower...................................2.0 (2.0)
Voltage................110 to 115V, 60 HZ (110 to 115V, 60 HZ)
Maximum Amperage ......................20 (20)
Weight......................................73 lbs. (33.2 Kg)
PUMP MODEL...................2LIDX30E
MODEL 3X1250
Flow......................................2.4 GPM (9.0 LM)
Pressure ..............................1000 PSI (70 Bar)
Horsepower...................................2.0 (2.0)
Voltage...........................220V, 50 HZ (220 V, 50 HZ)
Maximum Amperage ...................10.2 (10.2)
Weight......................................73 lbs. (33.2 Kg)
PUMP MODEL...................2LIDX30E
COMMON SPECIFICATIONS
Inlet *Pressure.......Flooded to 40 PSI (Fld to 3 BAR)
Max. **Fluid Temperature.........140°F (60°C)
Pump Oil Capacity....................11 oz. (0.35 L)
Hose Length...............................30 ft. (9.1M)
Cord Length (w/GFCI)............... 35 ft. (10.7M)
Wand Length .............................36 in. (91 cm)
Dimensions...........21.75x17.0x9.62" (553x432x244mm)
*Contact factory for information on optional inlet suction kit
**or high temperature version.
®

WARNING - When using this product basic
precautions should always be followed,
including the following:
IMPORTANT: This manual should be read
and understood thoroughly before assembly
and operation of this High Pressure Cleaning
System. Keep this manual available for
future reference in servicing or ordering parts
or accessories.
Failure to follow basic safety rules and pre-
cautions could result in serious injury, shock
or fire.
RULES FOR SAFE OPERATION
●Connect only to
properly grounded
outlet.
●Do not remove
ground pin or use
cheater.
●Know how to stop the product and bleed pressures
quickly. Be thoroughly familiar with the controls.
●Do not overreach or stand on unstable support.
●Keep good footing and balance at all times.
●Do not use extension cords unless plugged into a
GFCI protected outlet and cord meets specifications
shown under “Extension Cords” in this manual.
●Keep all connections dry and off ground.
●Inspect electric cord before using and do not use if
damaged.
●Do not spray at electrical areas.
●Do not touch plug with wet hands.
●This product is provided with a Ground-Fault
Circuit-Interrupter built into the power cord plug. If
replacement of the plug or cord is needed, use only
identical replacement parts.
●Do not modify electric outlet. Have a qualified
electrician install the properly grounded outlet.
●Unplug cord from receptacle before disconnecting
cleaning system from extension cord.
●Keep operating area clear of all persons.
●Never leave unit unattended while running.
●To reduce the risk of injury, close supervision is
necessary when a product is used near children.
●Stay alert - watch
what you are doing.
●Engage safety lock on gun
trigger when not spraying.
●Do not place hand over end of
nozzle, injury will result.
●Do not remove nozzle guard.
●Do not lift or pull unit by
pop-up cord wrap.
●Do not operate the product when fatigued or
under the influence of alcohol or drugs.
●Do not spray at people or animals.
●WARNING
Risk of injection or
injury - Do not direct
discharge stream at
persons.
●Follow the maintenance
instructions specified in
the manual.
In case of accidental injection with water,
contact physician immediately or call:
EMERGENCY MEDICAL HOTLINE
1-800-228-5635.
4
GROUNDING INSTRUCTIONS
This product must be grounded. If it should
malfunction or break down, grounding pro-
vides a path of least resistance for electrical
current to reduce the risk of electric shock.
This product is equipped with a cord having
an equipment-grounding conductor and a
grounding plug. The plug must be plugged
into an appropriate outlet that is properly
installed and grounded in accordance with all
local codes and ordinances.
DANGER: Improper connection of the equip-
ment-grounding conductor can result in a
risk of electrocution. Check with a qualified
▲WARNING ▲
Risk of shock or electrocution.
IMPORTANT SAFEGUARDS
LOCK
!!
SAVE THESE
INSTRUCTIONS

5
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 product—if it will not fit the outlet,
have a proper outlet installed by a qualified
electrician. Do not use any type of adapter
with this product.
GROUND-FAULT
CIRCUIT-INTERRUPTER
PROTECTION
This pressure washer is provided with a
GROUND-FAULT CIRCUIT-INTERRUPTER
(GFCI) built into the plug of the power supply
cord. This device provides additional protec-
tion from the risk of electric shock. Should
replacement of the plug or cord become nec-
essary, use only identical replacement parts
that include GFCI protection.
If the GFCI is not the AUTOMATIC RESET
TYPE, it must be manually TESTED and
RESET each time the cleaning system is
plugged in. Press firmly to assure internal
spring activates switch. Push “test” then push
“reset”. Motor will not start if GFCI does not
reset. Check circuit
breakers or outlet.
If circuit breaker is
not tripped and
unit will not reset,
contact local
service center.
EXTENSION CORDS
Use only 3-wire extension cords that have
3-prong grounding-type plugs and 3-pole cord
connectors that accept the plug from the prod-
uct. Use only extension cords that are intend-
ed for outdoor use. The extension cords are
identified by a marking “Acceptable for use
with outdoor appliances; store indoors while
not in use". Use only extension cords having
an electrical rating not less than the rating of
the product. Do not use damaged extension
cords. Examine extension cord before using
and replace if damaged. Do not abuse exten-
sion cord and do not yank on any cord to dis-
connect. Keep cord away from heat and sharp
edges. Always disconnect the extension cord
from the receptacle before disconnecting the
product from the extension cord.
Extension cords are not recommended unless
they are plugged into a ground-fault circuit-
interrupter found in circuit boxes or protected
outlet receptacles.
MOTOR RESET
This cleaning system has a motor reset button
in the event the motor overheats or overloads.
If the motor stalls turn the power switch to
OFF and unplug. Follow the guidelines under
“TROUBLESHOOTING” to determine the
cause of the motor shutdown. A plastic exten-
sion inserted into the reset hole on the side of
the case will initiate motor operation. TEST
AND RESET THE GFCI BEFORE TURNING
THE UNIT “ON”.
ACCIDENTAL SUBMERSION
The molded case of this cleaning system is not
watertight. In case of accidental submersion,
case must be opened and all internal compo-
nents thoroughly dried. Pump crankcase
should be drained and fresh oil added. See
“LUBRICATION” for additional information.
▲WARNING ▲
To reduce the risk of electrocution, keep all
connections dry and off the ground. Do not
touch plug with wet hands.
Extension Cord Length
Model up to 50 feet 50 to 100 feet
2X1000 14 AWG 12 AWG
2X1500 12 AWG 10 AWG
3X1000 12 AWG 10 AWG
3X1250 14 AWG 12 AWG
RESET
RESET
!!

6
Remove the cleaning system from the carton
and inspect for damage or missing compo-
nents. Keep box for storage or shipping unit
if service is required.
Place unit on a hard level surface and
visually verify that the oil level is at the dot in
center of gauge. The unit is shipped slightly
overfilled. Tip case to see air bubble before
operation.
Be sure the power switch is in the “OFF”
position.
Set unit on a hard level surface. Do not oper-
ate unit in tall grass or on other soft surface
that would restrict air flow to and from the
bottom of the case.
Attach the high pressure hose quick-discon-
nect to the discharge nipple on the top of the
case by pulling back the collar and pressing
over the nipple. Push down until it snaps into
position.
ASSEMBLY AND START-UP
CAUTION
Lack of proper lubrication will result in
severe damage to pump. Visually check oil
before each use.
NOTE
When attaching accessories to the inlet
connection or chemical injector, some
movement may be noticeable. Each con-
nection is o-ring sealed and the movement
is normal.
AIR FLOW

7
Attach a garden hose to the inlet fitting on
the side of the case. Check for the gasket
and screen in the fitting. The gasket assures
a good seal and the screen keeps debris
from entering the pump. CLEAN THIS
SCREEN periodically to avoid restricting fluid
to the pump. Inlet line must be a minimum of
1/2". Be certain the inlet water supply is suffi-
cient before operating unit.
Uncoil the power cord and connect to a prop-
erly grounded receptacle. Voltage should be
between 110 and 115 to avoid stalling or
overloading motor. (15 amp for 1.5 H.P.,
20 amp for 2.0 H.P.)
Attach Vari-Nozzle with extension to gun with
extension. Snap Vari-Nozzle fitting into
extended hex collar on gun extension and
thread on hand tight.
Remove the
BACK FLOW
PREVENTER
from the owner’s
manual plastic
bag. Thread
female end of
preventer onto
water supply
faucet. Then
thread garden
hose onto
preventer.
Turn inlet
water supply to
the unit to full
open. Inlet water
temperature
should not
exceed the
maximum listed
in specifications.
Bleed air from system by triggering gun. With
adequate water pressure, unit should prime
within one minute. Trigger the gun with the
Vari-Nozzle in the (forward) low pressure
position to speed the priming.
Flip power switch from “OFF” to “ON”.
Then trigger gun to assure all air is bled from
system.
CAUTION
2 H.P. Model must be plugged into an
outlet that is rated for 20 amps or greater
or the circuit breaker will trip.
CAUTION
Be certain to install the BACK FLOW
PREVENTER to prevent chemicals or soap
from flowing back into the supply line.
CAUTION
NEVER leave unit unattended in by-pass
(with trigger gun shut off) for prolonged
periods.
CAUTION
If the unit is run with an inadequate inlet
water supply the unit will cavitate.
Cavitation causes the pump to operate
loudly, vibrate and cause damage to
the pump.
15 amp
2X1000
20 amp
2X1500
3X1000
3X1250
FAUCET
OPEN
BACK FLOW
PREVENTER
GARDEN
HOSE

PRESSURE ADJUSTMENT AND
GAUGE READING
Before using the cleaning system, the oper-
ating pressure must be set. The cleaning
system is equipped with a pressure gauge
for setting and monitoring system pressure.
To set or adjust
pressure, rotate the
unloader adjustment
knob, marked “PSI”
on the top of the
case clockwise to
increase pressure
and counterclock-
wise to decrease
pressure. Make all
adjustments with the gun off (trigger
released). Adjust unloader 1/2 turn, squeeze
trigger and read pressure. If operating pres-
sure has not been reached, repeat until
desired pressure is reached. Do not exceed
the maximum operating pressure listed in
specifications. Be certain to use only the
Vari-Nozzle provided with cleaning system or
replacement nozzle sized for the flow and
pressure of unit.
Check your gauge while setting pressure
and periodically during operation. Changes
in pressure will warn you of wear or improper
operating conditions. If maximum pressure
cannot be reached or pressure drops after
prolonged use, it is most likely due to a worn
nozzle or lack of sufficient inlet water to the
unit. Consult “TROUBLESHOOTING” or call
your local service center.
When unit is running but in by-pass (gun off,
trigger released) pressure should drop to
approximately 100 PSI. If the pressure read-
ing on the gauge does not drop, trigger gun
several times and check reading. If pressure
still has not dropped shut the unit off and con-
sult “TROUBLESHOOTING”. For safety and
optimum life, operation in by-pass should not
exceed 6 minutes.The cleaning system is
equipped with an internal by-pass hose and
Thermo Valve. The Thermo Valve will sense
the rise in fluid temperature as a result of run-
ning the unit in by-pass and bleed a small
amount of heated water from the bottom of
the case. Cool inlet water will fill the line and
protect the pump from overheating.
Prolonged operation in by-pass at high
pressure may result in damage to the pump
or the unloader. Turn system “OFF” during
prolonged periods of nonuse.
VARI-NOZZLE ADJUSTMENT
This unit is equipped with a multi-function
nozzle. The Vari-Nozzle changes from high
pressure (back position) to low pressure
(forward position) with an easy push-pull
motion. Changing from high to low pressure
permits the the low pressure adjustable chemi-
cal injector to begin drawing chemical into the
system. When chemical is no longer needed,
return to high pressure (back position). The
Vari-Nozzle will also rotate right to left to adjust
from a 0° to 60° spray angle for desired clean-
ing needs. Make high to low pressure adjust-
ments with gun off or trigger released.
▲ WARNING ▲
Do not place hand
over end of nozzle
while spraying or
adjusting nozzle.
8
OPERATION
CAUTION
The maximum operating pressure of your
cleaning system has been secured at the
factory with a Locking Collar. Tampering or
removal of the Locking Collar on the
unloader valve will VOID THE WARRANTY.
!!
HIGH
PRESSURE LOW
PRESSURE WIDE
SPRAY NARROW SPRAY

9
CHEMICAL INJECTION
To use the
injector, insert
the injector
hose into the
bottom of the
chemical bottle
and connect
the other end to
the exposed
barb on the
unit. Open the
injector by turning the adjustment collar
counterclockwise. The Chemical Injector will
only draw chemical when pressure is below
150 PSI. Push the Vari-Nozzle (forward) to
the low pressure position and chemical will
begin to flow. When chemical appears at the
nozzle, adjust injector to desired rate.
Reduce chemical flow by rotating injector
collar clockwise to desired amount. Stop
chemical flow by pulling Vari-Nozzle (back)
to the high pressure position. Periodically
clean the filter at the end of the chemical
hose to assure smooth flow.
UNIT SHUT-DOWN AND
STORAGE INSTRUCTIONS
Follow these safety steps when you are done
using your Cleaning System:
1. Flush chemical injector with clean water.
With injector knob fully open draw clean
water through injector for one minute.
2. Switch cleaning system to “OFF”.
3. Shut off inlet water supply and disconnect
garden hose.
4. Remove BACK FLOW PREVENTER
from supply faucet by inserting nail or
small pin in
the side hole on
preventer. Press
in to unlock the
preventer and
unthread pre-
venter from
faucet. Attach
preventer to
garden hose
while storing unit.
5. Trigger the gun to relieve pressure locked
in high pressure hose.
6. Turn unloader to low pressure setting.
7. Disconnect the high pressure hose and
completely drain water. Squeeze trigger
and hold Vari-Nozzle up in the air. Lift
hose and follow length until all water
drains from hose. This procedure is
acceptable for short term storage or
warm climates. For prolonged storage or
unheated storage in cold weather see
“FREEZE PROTECTION”. Straighten
hose and coil up for storage.
8. Unplug the electric power cord. Wind up
on pop-up cord wrap. Attach GFCI to
cord wrap with velcro strap.
9. Cleaning system
may be stored in
original carton, on
the special cleaning
system cart or on
the wall mount.
WARNING
Do not store unit in unheated areas
during cold weather. Severe damage
can occur if water freezes in unit. If
near or below freezing conditions can-
not be avoided, unit must be protected
from freezing.

10
FREEZE PROTECTION
Follow all the steps for normal shut-down
and storage. Flush the cleaning system with
a 50% antifreeze and 50% water solution
using one of two methods:
Method One
Tip the unit on end exposing inlet garden
hose fitting. Remove screen filter from fitting
and pour in approximately 1/2 cup of
antifreeze and water mixture. Turn on unit
while pouring the
mixture in to allow
circulation of
antifreeze. Turn
unit off as soon
as all solution has
been poured into
the system.
Method Two
Attach a short garden hose (not to exceed
four feet) to inlet fitting on pump and put
other end into the antifreeze and water mix-
ture. Turn the unit on until mixture flows out
of the discharge fitting. Then shut unit off.
LUBRICATION
Keep crankcase filled to proper level (11 oz.
capacity) with Cat Pumps special formula
Premium ISO 68 Grade Non-Detergent
Hydraulic oil. Cat Pumps oil contains anti-
wear and anti-rust inhibiting additives for
maximum protection and cool running. Do
not use motor oil. Annual oil changes are
recommended in heavy use applications.
With normal use change oil when service to
pump seals or valves becomes necessary.
(See Cleaning System Parts List.)
DRAINING AND ADDING OIL
1. Remove chemical injector knob and suc-
tion tube by pulling upward.
2. Unscrew unloader knob counterclockwise
and remove spring.
3. Remove the eleven case screws, lift off
top half of case and remove pump motor
assembly.
4. Place pump and motor on work table with
pump extended
over edge.
Secure pump to
work surface.
5. Remove oil drain
plug and drain oil
from crankcase.
Replace drain
plug when empty.
6. Ensure motor shims and air seal gasket
are in place.
7. Position the pump and motor into
lower case.
8. Fill pump with new oil to dot on oil gauge.
Oil can be added to the pump through the
oil filler cap on the top of the pump.
9. Place switch box and wires into proper
slots. Use tape to retain wires if they will
not lie flat in grooves.
10.Ensure that the foam seals on the
unloader, injector and discharge ports
are in place.
11.Replace upper case half.
12.Replace all cover screws, using the two
shortest in the handle area.
13.Push on injector knob and suction tube.
14.Place spring in unloader with metal insert
down. Screw on unloader knob.
CAUTION
The top half of the case must be removed
to add oil and the pump must be completely
removed from case to drain oil.
FILL
EMPTY
NOTE
WIRE REPLACEMENT

11
MAINTENANCE OF THE PUMP
DISASSEMBLY OF THE DISCHARGE VALVE ASSEMBLY
1. Remove pump and motor assembly from
case and drain oil from crankcase of pump.
2. Disconnect by-pass hose from the bottom
unloader by-pass fitting. (Figure A)
3. With a standard M6 allen wrench remove
the six (6) socket head screws from the
manifold. (Figure A)
4. Remove discharge manifold by tapping
backside of manifold on opposite sides
with a soft mallet. Support manifold and
unloader assembly from underside and
pull away from crankcase. (Figure B)
5. The discharge adapter-seats may stay
with either the discharge or inlet manifold.
By inserting two opposing screwdrivers
between adapter-seats and manifold you
can easily pry them out of the discharge
manifold. (Figure C)
If the discharge adapter-seats stay in the
inlet manifold, gently work them up and
down as you pull away from crankcase.
(Figure D)
6. The valve assemblies are in the dis-
charge manifold ports and will fall out
when manifold is turned over. A complete
valve assembly includes: (★) retainer,
spring, valve, and o-ring. (Figure E)
Figure A
Figure B
Figure C
Figure D
Figure E

12
1. Next remove the inlet valve assembly
from the exposed plunger rod ends,
including nut, washer, spring, spacer and
inlet valve. (Figure A)
2. Grasp the inlet manifold from the front and
underside and with a gentle up and down
motion, pull away from crankcase.
(Figure B)
3. Carefully examine back side of low pres-
sure seal before removing from manifold
as it will be damaged during removal. If
worn, insert screwdriver into inside diam-
eter (I.D.) of seal and pry out. Exercise
caution to avoid damage to the inlet man-
ifold. (Figure C)
4. Next remove ceramic plunger with thumb
or soft tool from backside of inlet manifold.
(Figure D)
5. The high pressure seal may stay with the
plunger or remain in inlet manifold. If on
the plungers, rotate and pull off by hand.
If in the manifold, use a reverse pliers to
remove. (Figure E)
6. Remove seal retainers from crankcase by
grasping tab with pliers and pulling out.
Examine crankcase oil seal to determine
if crankcase servicing is needed. Consult
local distributor or factory if drive end ser-
vicing is needed. Also see “MAINTE-
NANCE OF THE CRANKCASE” section.
(Figure F)
DISASSEMBLY OF THE SEAL ASSEMBLY
Figure A
Figure D
Figure F
Figure B
Figure C
Figure E

13
REASSEMBY OF THE SEAL ASSEMBLY
1. Examine seal retainers and replace if worn
or damaged. Install on plunger rod and press
into crankcase with tabs out. (Figure A)
2. Place inlet manifold on work surface with
small I.D. ports up. (Figure B)
3. Lubricate new low
pressure seal and
press into position
in the manifold
chambers with
garter spring
down. (Figure B)
4. Carefully examine plungers for scoring or
cracks and replace if worn. Next lubricate ce-
ramic plungers and new high pressure seals.
Place the
deeper
recessed
hole of the
plunger into
the metal back side of the seal and slide
seal to the middle of the plunger. (Figure C)
5. Place inlet manifold on work surface with
larger I.D. ports up. Install plungers with
seals into ports
with metal seal
side into mani-
fold.
Press into posi-
tion using the larger I.D. end of discharge
adapter-seat. (Fig. D)
6. Carefully install manifold over plunger rod
ends and slowly press into crankcase.
(Figure E)
7. Examine inlet valve and replace if worn.
Inlet valve cannot be lapped or reversed
if worn. Install
new inlet
valve with
ridged side
facing away
from the
crankcase,
toward the
discharge.
(Figure F)
8. Examine spacers for wear and replace as
needed. Install spacer on each plunger
with smaller outside diameter (O.D.)
into inlet valve.
9. Examine
springs for
damage or
fatigue and
replace as
needed.
Place on
plunger
rods. (Figure G)
10.Install washers next with concave side
toward manifold.
11.Next install nuts and torque to specifica-
tions in TORQUE CHART. (Figure H)
Figure A
Figure E
Figure F
Figure G
Figure H
Figure B
Figure C
Figure D
Note: Position with
garter spring down.

14
REASSEMBY OF THE DISCHARGE VALVE ASSEMBLY
1. Examine discharge adapter-
seat o-rings and replace if
worn. Lubricate and install
o-rings on both front and
rear of adapter-seat.
(Figure A)
2. Place discharge
manifold on work
surface and install
valve retainers in
each port with top
tab down and
completely seat
into the chamber.
(Figure B)
3. Replace worn or damaged springs and
place into retainers.
4. Examine valves and seats for pitting,
grooves or wear and replace as needed.
5. Place valves
over springs
with concave
side down.
(Figure C)
6. Lubricate O.D.
of discharge
adapter-seat and
insert smaller I.D.
into discharge
manifold ports.
Snap into position.
Exercise caution
not to cut or pinch
o-rings. (Figure D)
7. Carefully guide manifold with adapters
over plunger rod ends and press into inlet
manifold. (Figure E)
8. Replace six (6) socket head screws and
torque to specifications. See TORQUE
CHART below. Torque diagonally in order
shown. The outer four (4) screws, then
center two (2), hand tight. Then repeat
series to specifications. (Figure F)
9. Reattach by-pass hose to bottom of
unloader fitting.
10.Remember to fill
crankcase with
oil before replac-
ing top
cover to unit.
See “LUBRICATION”
for more information.
(Figure G)
Torque Sequence
153
462
↕
Torque Chart
Tool Torque
Pump Item Thread Size in.lbs. ft.lbs. Nm
Outer Bearing Case M6x16 M10 50 4.0 6.0
Inner Bearing Case M6x16 Phillips 50 4.0 6.0
Manifold Socket M8x75 M6 115 9.4 13
Head Screws
Plunger Rod Nuts M6 M10 55 4.4 6.2
Oil Gauge M28 Oil Gauge 45 3.6 5
Tool
Figure A
Figure B
Figure C
Figure E
Figure F
Figure G
Figure D

15
CRANKCASE
1) While inlet manifold, plungers and seal
retainers are removed, examine crank-
case seals for wear.
2) Check oil level and for evidence of water
in oil.
3) Rotate crankshaft by hand to feel for
smooth bearing movements.
4) Examine crankshaft oil seal externally for
drying, cracking or leaking.
5) Consult factory or your local distributor if
crankcase service is needed.
UNLOADER
Unloader o-rings should be examined for
wear and replaced at the same frequency as
servicing the valves and seals of the pump.
If after reasonable use your system cycles
(repeatedly goes on and off by-pass) or will
not come up to pressure you should examine
the unloader for worn o-rings, flow balancer
or ball and valve assembly. Refer to the
“TROUBLESHOOTING” guide for
more information.
To install a new unloader remove discharge
fitting, with check valve and spring, from the
unloader. Reinstall spring, then check valve
into injector. Remount o-ring into injector fit-
ting and thread into unloader discharge.
Discard unloader discharge fitting.
CHEMICAL INJECTOR
The chemical injector should be inspected
when chemical draw will not occur or at the
same frequency as servicing the valves and
seals of the pump. After prolonged use, the
chemical injector orifice may wear or a build
up of soap or other chemical on the ball may
cause the ball to stick in the seat. Flushing
with clear water after chemical application
will generally prevent this. However, after
prolonged use, ball and o-rings may fatigue
and need replacement.
PULSATOR
Special “P” models use a modified Discharge
Valve Adapter in the pump to work with the
Jetter Hose and Tri-Jet Nozzle to create a
pulsating action for added agitation while
cleaning.
Maintenance
of the
Crankcase,
Unloader
and Chemical Injector

16
CLEANING SYSTEM PARTS LIST
ITEM PART NO. DESCRIPTION QTY.
2X1000 2X1500 3X1000 3X1250
1 34691 34690 34690 34693 Kit, Motor 1
2 34520 34521 34521 34522 Cord, GFCI, Power Assembly 1
3 34666 34666 34666 34666 Gasket, Set 1
4 34669 34669 34669 34669 Hose, Injector Inlet Kit 1
5 34670 34670 34670 34670 Mount, Hardware Kit 1
6 34524 34524 34524 34524 Switch, Assembly 1
7 34183 34183 34183 34183 By-Pass Hose Assembly 1
8 23170 23170 23170 23170 O-Ring, Drain Plug 1
9 34560 34560 34560 34560 Pad, Foot 4
10 34726 34726 34726 34726 Case, Bottom Half 1
11 34251 34251 34251 34251 Wrap, Power Cord 1
★12 7140 7140 7140 7140 Valve, Thermo - 145° 1
13 34455 34455 34455 34455 Pulsator, Assembly 1
18 7500S 7500S 7500S 7500S Unloader (See pg 19) 1
19 34402 34402 34402 34402 Gasket w/Screen 1
20 34401 34401 34401 34401 Adapter Fitting 1
21 46488 46488 46488 46488 Nut, Swivel 1
22 34400 34400 34400 34400 Nipple (3/8" NPTMx3") 1
23 2LIDX20E 2LIDX20E 2LIDX30E 2LIDX30E Pump with Unloader (See pg 18) 1
24 30517 30517 30517 30517 Mount, Bolt Assy 1
31 34667 34667 34667 34667 Quick Disconnect Assembly (Hose-to-Unit) 1
32 34326 34326 34326 34326 Elbow - 90° (3/8"NPTF) 1
★33 7193 7193 7194 7194 Adjustable Chemical Injector (See pg 19) 1
34 34450 34450 34450 34450 Elbow - 90° (1/8"NPTF) Street Elbow 1
35 34501 34501 34501 34501 Adapter, Hex (1/8"NPTFx1/8"NPTM) 1
36 6094 ●6096 6094 6094 Gauge, Pressure, 1500 PSI/●3000 PSI 1
40 34335 34335 34335 34335 Kit, Lance O-Ring 1
42 34725 34725 34725 34725 Case, Top 1
43 32088 32088 32088 32088 Handle, Black, Unloader Adjustment 1
44 34839 34839 34839 34839 Valve, Back Flow 1
45 34374 34374 34374 34374 Hose, Assembly (30 ft.-3/8") 1
★46 34124.220 34124.220 34124.220 34124.220 Custom I Gun w/Extension 1
★47 7940.521 7930.521 7960.521 7950.521 Vari-Nozzle w/Extension 1
48 34836 34873 34874 34876 Label, Set 1
50 32415 32415 32415 32415 Trigger, Assembly 1
51 32414 32414 32414 32414 Handle, Assembly 1
52 6107 6107 6107 6107 Crankcase Oil (21 oz.) ISO 68 Prem. Gr. Hyd. 1
★53 34643 34643 34643 34643 Jetter Hose with Tri-Jet Nozzle (30 ft.) 1
★34644 34644 34644 34644 Jetter Hose with Tri-Jet Nozzle (50 ft.) 1
54 36634 36634 36634 36634 Nozzle, Tri-Jet - S.S. 1
★See individual data sheets for additional information on Accessories

17
CLEANING SYSTEM EXPLODED VIEW
MODEL 2X1000, 2X1500, 3X1000, 3X1250

Item P/N MATL Description Model Used Qty.
135 44871 S Spacer All Models 3
136 44872 S Spring, Inlet Valve All Models 3
137 88575 S Washer, Conical (M6) All Models 3
138 81240 SS Nut, Hex (M6) All Models 3
152 26089 NBR O-Ring, Adapter, Inner All Models 3
157 45859 BB Discharge Adapter-Seat Standard 3
45923 BB Discharge Adapter-Seat Pulsator Models 2
45923T BB Discharge Adapter-Seat Pulsator Models 1
159 26089 NBR O-Ring, Adapter, Outer All Models 3
166 43723 S Valve All Models 3
167 541062 S Spring All Models 3
168 44565 PVDF Retainer, Spring All Models 3
185 45724 BB Manifold, Discharge All Models 1
188 87859 STZP Screw, HSH (M8x75) All Models 6
255 30517 STZP Mount, Bolt Assy All Models 1
30980 STZP Washer, Flat (3/8") 4
30921 STZP Lockwasher, Split (3/8") 4
34100 STZP Screw, HH (3/8"-16x1-3/8") 4
6106 Lubricant, Antiseize 1
30050 STL Key (3/16x3/16x1-1/4") 1
306 34053 NBR Kit, Seal (Inclds: 106,125,152,159) All Models 1
310 34056 S Kit, Valve All Models 1
(Inclds: 152,157,159,166,167,168)
311 34668 Kit, Inlet Valve All Models 1
(Inclds: 134,135,136,137,152,159)
400 7500S BB Unloader All Models 1
Item P/N MATL Description Model Used Qty.
5 89551 STZP Screw, HHC (M6x16) All Models 3
6 150810 NBR Washer, Seal (M6) All Models 3
8 44857 AL Cover, Bearing, Inner All Models 1
10 14044 NBR O-Ring, Bearing Cover All Models 1
11 44859 NBR Seal, Oil All Models 1
15 14488 STL Bearing, Ball, Inner All Models 1
20 44863 ZZ Rod, Connecting All Models 3
25 45092 FCM Crankshaft - 3450 RPM 2LIDX20E 1
44931 FCM Crankshaft - 3450 RPM, 2LIDX30E 1
Tapped End (M8x1.25mm)
26 12385 STL Retainer, Ring All Models 1
27 15710 STL Bearing, Ball, Outer All Models 1
37 43987 Gauge, Bubble Oil All Models 1
38 44428 NBR Gasket, Flat Flex., Oil Gauge All Models 1
48 44842 NY Plug, Drain (1/2" NPT) All Models 2
49 14179 NBR O-Ring, Drain Plug All Models 2
●53 45702 AL Crankcase All Models 1●
64 16948 S Pin, Rist All Models 3
65 ••540073 SZZ Rod, Piston All Models 3
69 20017 STZP Washer, Oil Seal All Models 3
70 25461 NBR Seal, Oil All Models 3
90 45847 CC Plunger All Models 3
100 44869 PVDF Retainer, Seal All Models 3
106 44876 NBR Seal, LPS w/S-Spg All Models 3
110 44874 BB Manifold, Inlet All Models 1
125 43245 NBR Seal, HPS w/S All Models 3
134 45854 S Valve, Inlet All Models 3
SF PUMP PARTS LIST
●Industrial discount.
Italics are optional items.
Material Codes (Not Part of Part Number): AL=Aluminum BB=Brass CC=Ceramic FCM=Forged Chrome-moly
NBR=Medium Nitrile (Buna-N) NY=Nylon PVDF=Fluoroplastic (High Strength) S=304SS STL=Steel STZP=Steel/Zinc Plated ZZ=Zamack
••Effective with 6/92 mfg. date Cotterpin was eliminated.
18
EXPLODED VIEW
Models 2LIDX20E, 2LIDX30E

19
PRESSURE REGULATING
UNLOADER ADJUSTABLE
CHEMICAL INJECTOR
PARTS LIST
Item P/N MATL Description Qty.
402 540081 BB Cap, Hex Adjusting 1
404 31047 BB Nut, Locking (M18x1) 1
408 32094 STZP Spring, Coil 1
410 107672 BB Retainer, Spring 1
412 45694 BB Stem, Piston (M5) 1
415 20184 PTFE Back-up-Ring, Piston Stem 1
416 14190 NBR O-Ring, Piston Stem 1
425 107673 BB Retainer, Piston 1
428 13969 NBR O-Ring, Piston Retainer - 70 3
429 14759 NBR O-Ring, Body 1
430 107675 PTFE Back-up-Ring, Body 1
435 45696 BB Valve and Ball Assembly (M5) 1
436 107680 S Seat 1
440 — BB Body 1
441 13963 NBR O-Ring, Valve 1
443 541060 BB Valve, Check w/O-Ring 1
444 45924 S Spring - 85 G 1
455 45695 BB Fitting, By-Pass (3/8" NPTF) 1
468 32097 NBR Kit, O-Ring (Inclds: 414,415,416,428,429,430,441) 1
470 7193/7194 BB Chemical, Injector 1
Italics are optional items.
Material Codes (Not Part of Part Number): BB=Brass
NBR=Medium Nitrile (Buna-N) PTFE=Polytetrafluoroethylene (Teflon®)
S=304SS STZP=Steel/Zinc Plated
SPECIFICATIONS
Model 7500S U.S. Measure Metric Measure
Flow.................................................. .5-6.0 GPM (2-23 L/M)
PSI .................................................100-2000 PSI (7-140 BAR)
Inlet Port - Rear .....................................3/8" NPT (3/8" NPT)
Outlet Port - Rront................................M18 x 1.0 (M18 x 1.0)
By-Pass Port - Bottom.........................3/8" NPTF (3/8" NPTF)
Weight........................................................14 oz. (0.43L)
Dimensions..............................3.0" x 1.0" x 4.25" (76 x 25 x 108mm)
PARTS LIST
Item P/N MATL Description Model Used Qty.
471 33949 BBNY Cap, Adjustment All Models 1
472 32941 BB Hose Barb, Adjustment All Models 1
473 33503 NBR O-Ring, Hose Barb All Models 1
474 33500 S Spring All Models 1
475 33946 BB Retainer, Ball Seat All Models 1
476 33504 FPM O-Ring, Retainer All Models 1
477 34620 SS Ball All Models 1
478 33501 SS Spring, Tapered All Models 1
479 32373 S Orifice, Injector (2.1mm) 7193 1
32374 S Orifice, Injector (2.3mm) 7194 1
480 — BB Body All Models 1
481 33481 BB Barb, Assy Adjustable 7193, 7194 1
(Includes: 471-478)
482 13969 NBR O-Ring, Body - 70 All Models 1
Italics are optional items.
Material Codes (Not Part of Part Number):
BB=Brass FPM=Fluorocarbon (Viton®) NBR=Medium Nitrile (Buna-N)
NY=Nylon S=304SS SS=316SS SSS=440SS
SPECIFICATIONS
Models 7193 7194
Flow......................................................2 GPM 3 GPM
Nozzle Orifice.......................................2.1mm 2.3mm
Hose Barb.................................................1/4" 1/4"
Inlet port...........................................M18 x 1.0 M18 x 1.0
Outlet port .....................................3/8" NPTM 3/8" NPTM
Dimensions.......................................2 x 1 x 3" 2 x 1 x 3"
Weight ..................................................6.3 oz. 6.3 oz.
CHEMICAL INJECTOR PERFORMANCE CHART
Optional Special Ported Chemical Injector for Unloader Mounting
Lo-Pressure Hi-Pressure
Nozzle Nozzle
Injector (Max. Injecting Max. Chemical “Deduction”
Orifice SF Press. Less Hose Draw (0 PSI) (Pressure drop
Model Size Injector Friction Loss) (Downstream) across injector)
2X1000 2.1 mm std. 7193 100 PSI 50 oz. / min 75 PSI
2X1500 2.1 mm std. 7193 100 PSI 50 oz. / min 75 PSI
3X1000 2.1 mm opt. 7193 225 PSI 50 oz. / min 150 PSI
3X1250 2.3 mm std. 7194 150 PSI 50 oz. / min 125 PSI

20
TROUBLESHOOTING
Condition Probable Cause Solution
• Pump runs but pressure • Air leak in inlet plumbing or pump • Check that hoses and fittings are air tight.
does not achieve rated sucking air.
values. • Pressure gauge inoperative. • Check and replace gauge.
• Valves worn or dirty. • Clean or replace-See “MAINT. OF THE PUMP”
• Unloader valve seat faulty or worn. • Clean or replace-See “MAINT. OF THE PUMP”
• Nozzle setting incorrect or worn. • Check nozzle adjustment or replace orifice
in Vari-Nozzle, see parts list for correct size.
• Worn seals in pump. • Replace-See “MAINT. OF THE PUMP”
• Unloader not at maximum setting. • Turn adjustment knob to maximum setting.
• Insufficient time to fill supply line. • Allow time to fill supply line:
2.0 gpm = 30.8 seconds,
3.0 gpm = 20.3 seconds.
• Fluctuating or pulsing • Valves worn, dirty or stuck. • Clean or replace-
pressure. See “MAINT. OF THE PUMP”-VALVES
• Pump sucking air. • Check that hoses and fittings are air tight.
• Worn seals. • Replace-See “MAINT. OF THE PUMP”-SEALS
• Pressure drops after period • Nozzle worn. • Replace.
of normal use. • Valves worn, dirty or stuck. • Clean or replace-
See “MAINT. OF THE PUMP”-VALVES
• Unloader valve seat worn or dirty. • Clean or replace-See “MAINT. OF THE
PUMP”-UNLOADER
• Worn seals. • Replace-See “MAINT. OF THE PUMP”-SEALS
• Pump noise. • Pump sucking air. • Check that hoses and fittings are air tight.
• Valves worn or dirty. • Clean or replace-
See “MAINT. OF THE PUMP”-SEALS
• Worn bearings. • Consult factory.
• Water too hot. • Reduce temperature-check seals
and o-rings.
• Presence of water in oil. • High humidity in air. • Change oil as needed.
• Seals and oil seals worn. • Replace-See “MAINT. OF THE PUMP”-SEALS
• Water dripping from under • Seals worn. • Replace-See “MAINT. OF THE PUMP”-SEALS
pump or case. • O-rings worn. • Replace-See “MAINT. OF THE PUMP”-SEALS
• Loose connection. • Check all connections.
• Thermo-Valve discharging. • Excessive fluid temperature from
prolonged by-pass. Operate with cool fluid
and if continued discharge, check pump
seals and o-rings.
• Oil dripping. • Oil seal worn. • Consult factory.
• Motor does not start when • Plug not well connected or lack of • Check plug, cable and switch for snug
switched on. power supply. connection.
• GFCI tripped. • Reset GFCI-See “GROUND-FAULT
CIRCUIT-INTERRUPTER”
• Circuit breaker or fuse in house • Disconnect other appliances on same
tripped. circuit and reset circuit breaker.
• Motor stopped while spraying. • Totally release trigger for 5 seconds and
squeeze again.
• When switching on the • The main voltage is insufficient, lower • Check that the main power supply is
unit, the motor hums than the minimum required. adequate: 15AMP (2X1000), 20 AMP
but does not run. (2X1500, 3X1000).
• The pump is stuck or frozen. • Consult factory.
• Incorrect extension cord. • See “EXTENSION CORDS”