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FULLER O’BRIEN PRO 3515, Owner'S Manual, Page: 2 / 28

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FULLER O’BRIEN PRO 3515 Owner'S Manual Download Page 2

308–526

INDEX

Warnings

3

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

Installation

5

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Startup

6

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Shutdown, Flushing and Storage

8

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Maintenance

8

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Troubleshooting Chart

9

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Pro 3515

10

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Pro 4020

12

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Pro 4030

14

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Gear Reducer (3515)

16

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Gear Reducer (4020)

18

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Pump (3515)

20

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Pump (4020)

22

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

Pump (4030)

24

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Pump Service

26

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Accessories

27

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Technical Data

27

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Warranty

Back Cover

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TERMS

WARNING:

  Alerts user to avoid or correct conditions

that could cause bodily injury.

CAUTION:

  Alerts user to avoid or correct conditions

that could cause damage to the equipment.

NOTE:

Identifies helpful procedures and information.

Summary of Contents for PRO 3515

Page 1: ...OPERATING PRESSURE 1900 psi 131 bar MAXIMUM WORKING PRESSURE PRO 4020 8 HP ENGINE P N 800 585 Series A 2000 psi 138 bar OPERATING PRESSURE 2400 psi 165 bar MAXIMUM WORKING PRESSURE PRO 4030 11 HP ENGINE P N 800 586 Series A 3000 psi 207 bar OPERATING PRESSURE 3400 psi 234 bar MAXIMUM WORKING PRESSURE FULLER O BRIEN CORPORATION 450 EAST GRAND AVENUE SAN FRANCISCO CA 94080 COPYRIGHT 1990 GRACO INC T...

Page 2: ...r 3515 16 Gear Reducer 4020 18 Pump 3515 20 Pump 4020 22 Pump 4030 24 Pump Service 26 Accessories 27 Technical Data 27 Warranty Back Cover TERMS WARNING Alerts user to avoid or correct conditions that could cause bodily injury CAUTION Alerts user to avoid or correct conditions that could cause damage to the equipment NOTE Identifies helpful procedures and information ...

Page 3: ...uid injection and splashing in the eyes or on the skin always follow this procedure whenever you stop spraying for more than 10 minutes when shutting down and before checking or repairing any part of the system 1 Engage the trigger safety latch 2 Turn the sprayer off 3 Remove the ignition cable from the spark plug 4 Shut off the water supply 5 Disengage the trigger safety latch and trigger the gun...

Page 4: ...y or other serious bodily injury or property damage ALL FLUID HOSES MUST HA VE STRAIN RELIEFS ON BOTH ENDS The strain reliefs help protect the hose from kinks or bends at or close to the coupling which can result in hose rupture TIGHTEN all fluid connections securely before each use High pressure fluid can dislodge a loose coupling or allow high pressure spray to be emitted from the coupling NEVER...

Page 5: ...af fect sprayer performance and chemical injector performance if used Install the appropriate spray tip on the wand See Installing and Changing Spray Tips If you are using a sandblaster kit see its separate manual for installation instructions Connect to Water Supply CAUTION Before attaching to the water supply check your local plumbing code regarding cross connection to the water supply A backflo...

Page 6: ...irmly Continue holding the rope as it returns Pull and return the rope until the engine starts In cool weather the choke may have to be kept closed for 10 to 30 seconds before opening it to keep the engine running Otherwise open the choke as soon as the engine starts If the engine is warm leave the choke open or just partly close it Start the engine as described in the preceding paragraph When it ...

Page 7: ...ging Spray Tips WARNING To reduce the risk of serious bodily injury including fluid injection or splashing in the eyes or onto the skin use extreme caution when changing spray tips ALWAYS follow the procedure below 1 Follow the Pressure Relief Procedure 2 Point the gun and wand away from yourself and anyone else 3 Without holding your hand over the spray tip A pull back the quick coupler ring B Re...

Page 8: ... the appropriate maintenance See maintenance chart MAINTENANCE Observing regular maintenance intervals helps ensure that you get maximum performance and life from the pressure washer There is a break in period for the engine pump and gear reducer if used After changing the oil in these components following their respective break in periods the interval between required changes is longer If the uni...

Page 9: ... in fuel tank or carburetor Low oil Start Stop switch in Stop position Water in gasoline or old fuel Choked improperly Flooded engine Dirty air cleaner filter Spark plug dirty wrong gap or wrong type Spray gun closed Water leakage from under pump manifold Install new packings See PUMP SERVICE Worn packings Water in pump Humid air condensing inside crankcase Worn packings Oil seals leaking Change o...

Page 10: ... 3515 Pressure Washer 4 56 57 55 20 17 11 11 18 14 10 46 6 60 63 29 31 61 16 27 30 9 16 18 19 7 13 54 3 2 53 33 44 46 6 6 45 41 32 40 39 36 35 34 38 37 36 67 36 50 51 36 35 40 52 42 43 47 64 48 49 66 6 46 6 8 1 12 27 30 22 23 24 25 26 21 ...

Page 11: ...801 569 QUICK COUPLER Female 3 8 incl 27 2 31 800 392 GUN WAND ASSEMBLY incl 11 59 60 61 62 63 1 32 800 662 CHASSIS 1 33 803 925 HANDLE 1 34 800 561 FRONT LEG ASSEMBLY incl 35 36 50 51 67 1 REF PART NO NO DESCRIPTION QTY 35 801 546 SCREW Cap hex hd 3 8 16 x 1 1 4 5 36 100 023 WASHER Flat 3 8 10 37 100 133 WASHER Lock 3 8 4 38 100 307 NUT Hex 3 8 16 4 39 802 139 AXLE 1 40 801 235 WASHER Flat 5 8 4 ...

Page 12: ... 4020 Pressure Washer 4 6 1 57 33 44 46 6 6 45 41 32 40 43 39 36 35 58 34 38 37 36 67 36 50 51 36 35 20 12 17 11 11 18 16 18 14 10 46 6 7 8 40 52 42 53 2 3 13 54 60 63 29 31 61 16 9 19 59 47 64 48 49 66 6 46 55 27 30 19 22 23 24 25 26 21 ...

Page 13: ...801 569 QUICK COUPLER Female 3 8 incl 27 2 31 800 392 GUN WAND ASSEMBLY incl 11 59 60 61 62 63 1 32 800 662 CHASSIS 1 33 803 925 HANDLE 1 34 800 561 FRONT LEG ASSEMBLY incl 35 36 50 51 67 1 REF PART NO NO DESCRIPTION QTY 35 801 546 SCREW Cap hex hd 3 8 16 x 1 1 4 1 36 100 023 WASHER Flat 3 8 10 37 100 133 WASHER Lock 3 8 4 38 100 307 NUT Hex 3 8 16 4 39 802 139 AXLE 1 40 801 235 WASHER Flat 5 8 4 ...

Page 14: ...6 PRO 4030 Pressure Washer 36 2 39 38 45 44 46 62 60 61 63 64 59 2 18 19 4 8 9 2 2 3 10 2 9 22 7 14 11 12 13 2 51 66 67 68 69 53 56 21 16 20 1 28 65 29 30 31 32 9 2 25 2 9 15 43 54 37 27 26 17 40 41 9 8 33 47 42 9 2 6 2 3 5 49 48 23 ...

Page 15: ... ASSEMBLY 00045 incl 65 66 1 30 800 315 TIP ASSEMBLY 15045 incl 65 67 1 31 800 316 TIP ASSEMBLY 25045 incl 65 68 1 32 800 317 TIP ASSEMBLY 40045 incl 65 69 1 REF PART NO NO DESCRIPTION QTY 33 PUMP ASSEMBLY see page 20 1 34 156 082 O RING Quick Coupler 3 8 2 35 154 594 O RING Quick Coupler 1 4 1 36 801 022 SCREW Cap hex hd 5 16 18 x 3 4 4 37 802 363 LABEL Caution 1 38 181 867 LABEL Warning 1 39 803...

Page 16: ...ounting 1 3 802 334 SCREW Set 1 4 802 352 GEAR Pump 1 5 802 353 O RING 1 6 801 659 DIPSTICK 1 7 802 354 CASE Mounting 1 8 100 527 WASHER Lock 8 9 802 342 SCREW 4 10 802 355 SEAL Oil 1 11 802 356 RING Snap 1 12 802 357 RING Snap 1 13 802 358 BEARING 1 14 802 359 GEAR Engine 1 15 801 484 CAP G 3 8 BSP 1 16 802 344 O RING 1 17 802 345 GAUGE Sight 1 18 802 331 BOLT 5 16 24 x 1 4 19 802 360 SCREW 4 20 ...

Page 17: ... Seal 10 NOTE The oil seal MUST be replaced if removed 1 Follow steps 1 and 2 under Replacing the O Ring 2 Pry the oil seal out of the gear case Be careful not to damage the gear case 3 Wipe the inner surface of the gear case clean then lightly coat it with grease Place the oil seal into the gear case Use a socket placed against the surface of the seal to push the seal into the case until its top ...

Page 18: ... 802 334 SCREW Set 1 4 802 335 GEAR Pump 1 5 802 336 GEAR Engine 1 6 802 337 RING Snap 1 7 802 338 BEARING 1 8 802 339 RING Snap 1 9 802 340 GASKET 1 10 801 475 DIPSTICK 1 11 802 341 CASE Mounting 1 12 100 527 WASHER Lock 13 13 802 342 SCREW 9 14 802 343 SEAL Oil 1 15 802 344 O RING 1 16 801 484 CAP G 3 8 BSP 1 17 802 345 GAUGE Sight 1 18 100 214 WASHER Flat 4 19 802 331 BOLT 5 16 24 x 1 4 20 802 ...

Page 19: ...ice required Replacing the Oil Seal 14 NOTE The oil seal MUST be replaced if removed 1 Follow steps 1 and 3 under Replacing the Gasket 2 Remove the snap ring 6 from the gear case using a snap ring pliers Pull the gear and bearing 3 Push the seal from the inside to the outside of the gear case by placing screwdriver against the seal and lightly tapping it with hammer 4 Wipe the inner surface of the...

Page 20: ...RTS DRAWING 802 265 Pump Assembly 1500 psi 14 13 12 14 1 3 2 31 33 32 34 35 36 38 39 40 41 28 42 43 15 16 17 12 18 19 20 21 22 23 24 22 45 21 44 19 18 47 48 10 9 11 52 49 51 50 37 25 26 29 27 28 30 10 9 8 7 6 5 4 11 ...

Page 21: ...il Drain 1 31 803 328 CRANKSHAFT 1 32 803 275 PIN Wrist 3 33 802 794 KEY 1 34 803 276 ROD Connecting 3 35 803 277 WASHER Flat 6 36 803 278 WASHER Lock 6 37 803 279 SCREW Cap socket hd 6 38 803 330 GUIDE Piston 3 39 801 489 WASHER Flinger 3 40 801 661 PLUNGER Ceramic 3 41 KIT 6 RING Backup 42 KIT 6 WASHER 43 KIT 6 SCREW Piston 44 803 281 SPACER 1 45 803 282 SEAL Crankshaft 1 47 802 317 WASHER Lock ...

Page 22: ...TS DRAWING 803 405 Pump Assembly 2000 psi 46 47 44 45 10 9 8 7 6 5 4 1 3 2 10 9 11 52 51 54 53 40 15 41 14 39 12 21 23 22 24 26 33 32 28 29 30 31 27 25 34 35 36 31 37 38 11 43 42 16 17 44 45 13 14 18 19 20 12 50 49 ...

Page 23: ...IT 6 O RING 32 803 294 SCREW Cap socket hd 6 33 801 652 WASHER Lock 6 34 801 489 WASHER Flinger 3 35 801 490 PLUNGER Ceramic 3 36 KIT 6 RING Backup 37 KIT 6 WASHER 38 KIT 6 SCREW Piston 39 803 295 COVER Crankcase 1 40 803 296 SHIM 2 41 KIT 3 SEAL Oil 42 KIT 28 O RING 43 KIT 28 RETAINER Packing 44 KIT 28 8 PACKING 45 KIT 28 RING Head 46 KIT 28 RETAINER Packing 47 KIT 28 RING Long Life 49 802 305 SC...

Page 24: ...ump Assembly 3000 psi 65 67 66 64 63 55 50 49 48 57 58 59 60 61 62 46 47 44 45 10 9 8 7 6 5 4 1 3 2 10 9 11 52 51 54 53 13 14 18 19 56 20 12 43 42 16 17 40 15 41 14 39 12 21 23 22 24 26 33 32 28 29 30 31 27 25 34 35 36 31 37 38 11 44 45 ...

Page 25: ...IM 2 41 KIT 3 SEAL Oil 42 KIT 28 O RING 43 KIT 28 RETAINER Packing 44 KIT 28 8 PACKING 45 KIT 28 RING Head 46 KIT 28 RETAINER Packing 47 KIT 28 RING Long Life 48 801 526 BRACKET Pump 2 49 802 305 SCREW Cap socket hd 2 50 802 304 WASHER Lock 2 51 801 482 PLUG Hex 1 52 801 483 WASHER Flat 1 53 801 484 PLUG Hex 1 54 801 485 WASHER Flat 1 55 801 737 PUMP 1 56 803 083 LABEL Keep From Freezing 1 57 802 ...

Page 26: ... plunger or seals 3 Carefully examine each plunger for any scoring or cracking and replace as necessary Servicing the Plungers NOTE Plunger repair kit P N 801 474 is available to replace retainers o rings washers and backup rings for three cylinders 1 Loosen the plunger retaining screw five to six turns using an M10 wrench Push the plunger towards the crankcase to separate the plunger and retainin...

Page 27: ...t back up of contaminated water into fresh supply Install upstream of pump ANTI FREEZE FLUSH KIT 802 327 For flushing system with 50 anti freeze solution prior to transporting or storing pressure washer in below freezing temperatures INLET PRESSURE REGULATOR 800 258 Regulates inlet water pressure to 60 psi 4 bar maximum TECHNICAL DATA Model 800 586 Model 800 585 Model 800 584 Engine air cooled 4 c...

Page 28: ...made at a reasonable charge which charges may include the costs of parts labor and transportation DISCLAIMERS AND LIMITATIONS THE TERMS OF THIS W ARRANTY CONSTITUTE THE PURCHASER S SOLE AND EXCLUSIVE REMEDY AND ARE IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND OF ANY NON CONTRACTUAL LIABILITIES INCLUDING...

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