TUFFCAT 2X1000 Manuale utente

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.

▲

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 ..................................................................................................................................................

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

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.

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

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

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

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.

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

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.

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

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