Operators Manual ICRRFTSMRN°I 7.8 Horsepower 3000 PSI 2.5 GPM HIGH PRESSURE WASHER CLEANING SYSTEM Model No. 580.768050 HOURS: Mon.- Fr|. 8 a.m. to 5 p.m. (CT) • • • • • CAUTION: Before using this product, read this manual and follow all its Safety Rules and Operating Instructions. Sears, Roebuck and Co., Hoffman Estates, Visit our Craftsman webslte: www.sears.com/craftsman ! Part No. B3604 Draft2 (4/5/1999) Printe<:i in the U.S.A. IL 60179 Safety Assembly Operation Maintenance Parts Warranty ................................ 2 Safety Rules ........................... Assembly ............................... Operation ............................. Maintenance 2-3 4 5-9 ......................... 10-15 Storage ................................ 16 Troubleshooting ......................... 17 Replacements parts .................... Emission Control Warranty Statement .................... How to order parts and request service .................... 19-27 28-29 Back page LIMITED ONE YEAR WARRANTY ON CRAFTSMAN CLEANING SYSTEM For one year from the date of purchase, when this Craftsman Cleaning System is maintained and operated according to the instructions in the owner's manual, Sears will repair, free of charge, any defect in material and workmanship. If this washer is used for commercial purposes, this warranty applies for only 90 days from the date of purchase. If this cleaning system is used for rental purposes, this warranty applies for only 30 days after date of purchase. LIMITED TWO YEAR WARRANTY ON CRAFTSMAN ENGINE For two years from the date ol purchase, when this Craftsman engine is maintained and operated according to the instructions on the owner's manual, Sears will repair, free of charge, any defect in matedal and workmanship. If the Craftsman engine is used for commercial or rental purposes, this warranty applies for only one year from the date of purchase. ThJs warranty does not cover: • Expendable items such as spark plugs or air filters, which become worn during normal use. • Repairs necessary because of operator abuse or negligence, including damage resulting from no water being supplied to pump or failure to maintain the equipment according to the instructions contained in the owner's manual. WARRANTY SERVICE IS AVAILABLE BY RETURNING THE HIGH CLEANING SYSTEM TO THE NEAREST SEARS SERVICE CENTER OR DEALER IN TH E UNITED STATES. This warranty gives you specific legal dghts and you may dlso have other dghts, which vary from state to state. Sears, Roebuck and Co., Dept. 817WA, Hoffman Estates, IL 60179 Engine exhaust gases contain DEADLY carbon monoxide gas. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. Operate this equipment only in the open air where adequate ventilation is available. ,_ CAUTION: using this Rules product, manual andBefore follow all Safety andread this Operating Instructions. ,_ adjusting orWhen DANGER: making transporting, repairs to your setting cleaning up, system, always disconnect the spark plug wire and place it where it cannot contact the spark plug to prevent accidental starting. • Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE. Do not permit smoking, open flames, sparks or heat in the vicinity while handling gasoline. Avoid spilling gasoline on a hot engine. Allow unit to cool for 2 minutes before refueling. Comply with all laws regulating storage and handling of gasoline. • Locate this cleaning system in areas away from combustible materials, combustible fumes or dust. The high pressure equipment is designed to be used with Sears authorized parts only. If you use this equipment with parts that do not comply with minimum specifications, the user assumes all dsks and liabilities. • Never move the machine by pulling on the high pressure hose. Use the handle provided on the top of the unit. • Always be certain the spray gun, nozzles and accessories are correctly attached. • Some chemicals or detergents may be harmful if inhaled or ingested, causing severe nausea, fainting or poisoning. The harmful elements may cause property damage or severe injury. • Never use a spray gun which does not have a trigger lock or tdgger guard in place and in working order. • Do not allow CHILDREN to operate the cleaning system at any time. • • Operate engine only at governed speed. Running the engine at excessive speeds increases the hazard of personal injury. Do not tamper with parts which may increase or decrease the governed speed. Use a respirator or mask whenever there is a chance that vapors may be inhaled. Read all instructions with the mask so you are certain the mask will provide the necessary protection against inhaling harmful vapors. • High pressure spray may damage fragile items including glass. Do not point spray gun at glass when in the jet spray mode. • Keep the hose connected to machine or the spray gun while the system is pressurized. Disconnecting the hose while the unit is pressurized is dangerous. • • Do not wear loose clothing, jewelry or anything that may be caught in the starter or other rotating parts. • Before starting the cleaning system in cold weather, check all parts of the equipment and be sure ice has not formed there. • Units with broken or missing parts, or without protective housing or covers should NEVER be operated. The muffler and air cleaner must be installed and in good condition before operating the cleaning system. These components act as spark arrestors if the engine backfires. Hold the spray gun firmly in your hand before you start the unit. Failure to do so could result in an injury from a whipping spray gun. Do not leave the spray gun unattended while the machine is running. • The cleaning area should have adequate slopes and drainage to reduce the possibility of a fall due to slippery surfaces. • Keep water spray away from electric wiring or fatal electric shock may result. • Do not secure tdgger gun in the pull-back (open) position. • Do not by-pass any safety device on this machine. • • • Check the fuel system for leaks or signs of deterioration such as chafed or spongy hose, loose or missing clamps or damaged tank or cap. Correct all defects before operating the cleaning system. • Do not spray flammable liquids. • • Never allow any part of the body to come in contact with the fluid stream. DO NOT come in contact with a fluid stream created by a leak in the high pressure hose. The muffler and engine heat up dudng operation and remain hot immediately after shutting it down. Avoid contact with a hot muffler or engine or you could be severely burned. • Operate and store this unit on a stable surface. • Always store cleaning system with the Dial-a-Cleaner TM knob in the OFF position. • High pressure hose can develop leaks from wear, kinking, abuse, etc. Water spraying from a leak is capable of injecting material into skin. Inspect hose each time before using it. Check all hoses for cuts, leaks, abrasions or bulging of cover, or damage or movement of couplings. If any of these conditions exist, replace hose immediately. Never repair high pressure hose. Replace it with another hose that meets minimum pressure rating of your cleaning system. • High pressure streams of fluid this equipment produces can pieme skin and its underlying tissues, leading to serious injury and possible amputation. • Never aim the gun at people, animals or plants. • High pressure spray can cause paint chips or other particles to become airborne and fly at high speeds. • Always wear eye protection when you use this equipment or when you are in the vicinity where the equipment is in use. • Operate the pressure at no more than the PSI fluid pressure rated for your cleaning system. I_ MEANS "ATTENTION!!! BECOME ALERTIII YOUR SAFETY IS INVOLVED." OOK FOR THIS SYMBOL TO POINT OUT IMPORTANT SAFETY PRECAUTIONS. 3 IT CARTON CONTENTS The following parts are shipped loose with your cleaning system: • Main Unit -- cleaning system with wheels, chemical tanks, guide handle. • High Pressure Hose (already attached to pump) • Parts Box (which includes items listed below) • Spray Gun • Dual Lance with quick connect nozzle fitting • Engine Oil • Three-pack of chemical concentrates • Four multi-colored nozzles • Tank Labels • • Raise guide handle, secure in place. • Roll the cleaning system out the open end of the canon. • Check carton for additional loose parts. HOW TO SET UP YOUR CLEANING SYSTEM For the most part, your Craftsman High Pressure Cleaning System has been assembled at the factory. You must, however, assemble the spray gun, and attach the high pressure hose to the spray gun. • Cut the tie wraps on the high pressure hose and connect high pressure hose to gun. Tighten by hand. • Attach dual lance to spray gun. Manual Bag (which includes the items listed below) • Owner's Manual • Nozzle Cleaner Kit • _O"-Ring Kit Become familiar with each piece before assembling the cleaning system. Check all contents against the illustration on page 5. It any parts are missing or damaged, call the Pressure Washer Helpline at 1-800-222-3136. TO REMOVE CARTON CLEANING SYSTEM FROM Remove loose parts and parts box included with your cleaning system. Slice two corners at guide handle end of carton from top to bottom so the panel can be folded down flat. Place assembled spray gun on holder. Lift the handle to upright position and slide the locking caps into place 4 KNOW YOUR HIGH CLEANING SYSTEM Read this owner's manual and safety rules before operating your cleaning system. Compare the illustrations with your cleaning system to familiarize yourself with the locations of various controls and adjustments. System Rinse, Detergent and Chemical Rseervolre with Internal Filter and Baffle Spray Gun Gas Tank Dual Lance with QuickConnect Fitting Air Filter High Pressure Hose Primer Bulb Water Inlet Oil Fill Cap Dial-A-CleanerTM Selector Knob Pressure CommandTM Pump Air Filter - Dry type filter element limits the amount of dirt and dust that gets in the engine. Oil Fill Cap - Fill engine with oil here. See page 8 for oil recommendations. Dial-A-Cleaner TM Selector Knob - Selects any one of three chemicals or the clean water system rinse, Pressure Command Dual Lance with Quick-Connect Fitting- The dual lance attaches to the spray gun and aUows you to switch from low pressure mode, for applying chemicals, to high pressure mode, for cleaning. The quick connect fitting lets you quickly exchange the four provided nozzles to adjust the spray pattern of the high pressure spray. Pump - Develops high water pressure. Gas Tank - Fill gas tank with regular unleaded gasoline here. High Pressure Hose - Connect one end to the spray gun. TM - Sets output water pressure. Primer Bulb - Used to start a cold engine. Spray Gun - Controls the application of water onto cleaning surface with trigger device, includes safety latch. System Rinse, Detergent and Chemical Reservoirs with Internal Filter and Baffle - Used to provide detergent or other chemicals to the low pressure water stream. Water Inlet - Connection for garden hose. HOW TO USE YOUR CLEANING SYSTEM • Pull back the collar on the quick connect and pull the current nozzle off. Store the nozzle in the space provided on the control panel. Read these instructions and learn how to use your cleaning system before you attempt to start your cleaning system. If you have any problems operating your cleaning system, p_eace cell the pressure washer helpline at 1-800-222-3136. How To Use the Nozzles A DANGER: Never latch exchange locking the safety on thenozzles trigger.without The quick-connect on the dual lance allows you switch between four different nozzles. The nozzles vary the spray pattern of the high pressure stream as shown below. White Note: For a more gentle dnse, select the 40 ° or 25 ° degree nozzle. To scour the surface, select the 15° or 0 ° nozzle. • Green Pull back the collar, insert the new nozzle and release the collar, making sure it becomes flush with the end of the quick connect. Pull on the nozzle to make sure it is securely in place. Note: The chemical nozzle is permanently affixed to your dual lance and has a spray pattem of 25 degrees. It must be used when applying chemical. Yellow Red 0o • For most effective cleaning, keep spray nozzle between 8 to 24 inches away from cleaning surface. • Damage to the surface may occur if you get the spray nozzle too close to it. Cleaning With The Nozzles and Applying Chemical ,_ tumed ON will damage the pump. In order to change the nozzle being used, follow these instructions: • you start the engine. WARNING: You must Starting attachthe all engine hoses before without all the hoses connected and without the water II_IPORTANT: Use soaps designed specifically for pressure washer cleaning systems. Household detergents could damage the pump. Engage the safety latch on the spray gun. Up to three (3) different solutions can be carried on the cleaning system at one time. To apply detergent follow these steps: Dilution is necessary when using the supplied chemical packets. Simply snip one corner of the plastic pouch, pour the chemical into the tank, then fill the tank with clean water. Label tanks with the provided tank labels. Safety Latch Pour chemical into one of the tanks labeled A B, C. 6 BEFORE EACH USE • Check water inlet screen for damage. • Check high pressure hose for leaks. • Check chemical tanks and filters for damage. • Check gun and wand assembly for leaks. • Purge pump of air and contaminants. • Check engine oil level. CLEANING SYSTEM 4. Place the o-ring into the recess. Push the o-ring snugly against the in-line filter screen. MAINTENANCE 5. Assemble the lance to the spray gun, as described earlier in this manual. Check and Clean Inlet Screen Examine garden hose inlet screen. Clean if it is clogged or replace if it is torn, Purge Pump of Air and Contaminants To remove the air from the pump, follow these steps: Check High Pressure Hose High pressure hoses can develop leaks from wear, kinking, or abuse, inspect hose before each use. Check for cuts, leaks, abrasions, bulging of cover, or damage or movement of couplings. If any of these conditions exist, replace hose immediately. A If the screen is damaged, the o-ring kit contains a replacement in-line filter screen and an o-ring. If undamaged, reuse screen. 3. Place the in-line filter screen into the threaded end of the lance. Direction does not matter. Push the screen in with the eraser end of a pencil until it rests flat at the bottom of the opening. Take care to not bend the screen. . ANGER:with Never a highthe pressure hose. Replace hoserepair that meets minimum pressure rating of your cleaning system • Set up the cleaning system as described in the ASSEMBLY section and connect the water supply. • Remove the wand extension from the gun. • Pull the trigger on the gun and hold until a steady stream of water appears. To remove the contaminants from the pump, follow these steps: • Set up the cieaning system as described in the ASSEMBLY section, and connect the water supply. Check Chemical Reservoirs • Remove the nozzle attachment from the gun. Tank covers should snap cleanly onto tank. Ensure chemical labels correctly identify tank contents. Ensure that the System Rinse tank is filled with clean water. Ensure that Dial-A-Cleaner TM selector knob rotates freely between each position. Examine the tanks and replace if the filter is clogged • Start the engine according to instructions in OPERATION section. • Pull the trigger on the gun and hold. • When the water supply is steady and constant, engage the safety latch and refasten the nozzle attachment. Check Gun and Wand Nozzle Maintenance Examine hose connection to gun and make sure it is secure. Test trigger by pressing it and making sure it springs back into place when you release it. Put safety latch in UP position and test trigger. You should not be able to press trigger. Replace gun immediately if it fails any of these tests. Check In-Une Filter Refer to the illustration below and service the in-line filter if it becomes clogged, as follows: If the nozzle becomes restricted or clogged with for'eign materials, such as dirt, excessive pump pressure may develop. A partially clogged nozzle can cause a pulsing condition during use. This generally is not a pump related problem, but rather a clogged or partially restricted nozzle. If the nozzle becomes clogged or partially restricted, immediately clean the nozzle with the kit included with your cleaning system by following these instructions: Filter Screen • Shut off the engine and turn off the water supply. • Press trigger to relive water pressure. • Separate the dual lance from the gun. insert wire into nozzle and turn back and forth to clear obstruction. O-ring 1. Detach gun and lance from high pressure hose. Detach lance from gun and remove o-ring and screen from lance. Flush the screen, gun, and lance with clean water to clear debris. 11 Use the wire included in the kit or a small paper clip to free the foreign materials clogging or restricting the nozzle. • 1 rubber washer (p/n B2385) for the inside of the garden hose connector. • 1 water inlet screen (p/n B2384) for the garden hose connector. Remove additional debris by back flushing water supply through dual lance. Back flush between 30 to 60 seconds. Back flush both lances by turning chemical valve handle. • Ensure the in-line filter is in place, then reconnect the dual lance to the spray gun. • Reconnect the water supply, turn on the water, and start the engine. • Test the cleaning system by operating with the unit in high and the low pressure. To remove a worn or damaged o-ring: • ENGINE MAINTENANCE O-Ring Maintenance Maintenance, replacement or repair of the emission control devices and svstemg may be performed by any non-roed engine repair establishment or individual. Through the normal operation of your cleaning system, the o-rings keep the connections of the hoses and gun tight and leak-free. They may become worn or damaged with use. Provided with your cleaning system is an o-ring Maintenance Kit containing replacement o-rings, a rubber washer and a garden hose inlet screen. Checldng Oil Level Oil level should be checked prior to each use or at least every eight (8) hours of operation. Keep oil level maintained. Parts in the O-Ring Kit Include: • Use a small flathead screwdriver to get underneath the c-dng and pry it off. 1 O-Ring, red, (p/n B2726) for the end of the spray gun connection between gun and high/low spray wand. Changing Engine Oil and Oil Rlter Change oil after first eight (8) hours of operation. Change oil & oil filter every fifty (50) hours thereafter. If you are using your cleaning system under extremely dirty or dusty conditions, or in extremely hot weather, change oil more often. Change oii while engine is still warm from running, as follows: • • Clean area around oil drain plug. • Remove oil drain plug and oil fill plug and drain oil completely into a suitable container. 2 O-Rings, yellow, (p/n B2264) for the ends of the high pressure hose. Oil Fill Cap Note: The above two o-rings are close in size. Please match carefully to assure proper o-ring usage. Oil Drain Plug 12 When oil has completely drained, Install oil drain plug and tighten securely. Place a suitable container beneath the oil filter and turn filter counterclockwise to remove. Discard according to local regulations. To clean or replace foam pre-filter: • Coat gasket of new filter with engine oil. turn filter clockwise until gasket contacts tightly with filter adapter. Then tighten an additional 3/4 tum. Note: If you need to order a new air filter, please call 1-800-366-PART. • Fill oil sump with recommended oil. (See "Before Starting the Engine" on page 8 for oil recommendations) • Install the oil fill plug and tighten securely. • Wipe up any spilled oil. • • Service Air Cleaner Your engine will not run properly and may be damaged if you run it using a dirty air cleaner. Clean or replace the air cleaner paper filter once every 50 hours of operation or once a year, whichever comes first. Clean or replace more often if operating under dusty or dirty conditions. Clean foam pre--filter every 25 hours of operation or sooner under dusty conditions. To clean or replace the air cleaner components: • Loosen the two screws on the air cleaner cover. Remove the air cleaner cover. Foam Pro-Filter May Stick to Cover 1. Wash pre-filter in soapy water. 2. Squeeze pre-filter dry in clean cloth. Do not twist. If the pre-filter is still dirty after washing and drying it, replace it with a new one. 3. Apply enough engine oil to saturate the pre-filter. 4. Wrap the pre-filter in a clean dry cloth and squeeze out the excess oil. Do not twist. Set the pre-filter aside. To clean or replace paper air filter: 1. Clean paper filter by tapping it gently on a solid surface. If the filter is too dirty, replace it with a new one. Dispose of the old filter properly. 2. Clean air cleaner cover. 3. Insert pre-filter into the cover, then the paper air filter. 4. Reinstall the air cleaner cover and tighten the two (2) screws. Clean Spark Arrestor Screen The engine exhaust muffler has a spark arrestor screen. Inspect and clean the screen every 100 hours of operation or once each year, whichever comes first. Note: If you use your cleaning system on any forestcovered, brush-covered or grass-covered unimproved land, it must have a spark arrestor. The spark arrestor must be maintained in good condition by the owner/operator. Clean and inspect the spark arrestor as follows: Inspect the screen and replace it if it is tom, perforated or otherwise damaged. Do not use a defective screen. If the screen is not damaged, clean it with a chemical solvent. If the spark arrestor is damaged, replace it as follows: • Remove the paper air filter and the foam pre-filter from the air cleaner cover. Foam Pre-FIIter Paper Filter 13 Remove the four (4) screws that connect the heat shield to the muffler. Carburetor If you think your carburetor needs adjusting, see your nearest Sears Service Center. Engine performance may be affected at altitudes above 5000 feet. For operation at higher elevations, contact your nearest Sears Service Center. Spirk ArrHtor Scrlen S30413 Adjusting Valve Clearance After the first fifty (50) hours of operation, you should adjust the valve clearance in the engine. ® @ Important" If you feel uncomfortable about doing this procedure or you don't have the proper tools, please take your cleaning system in to the nearest service center to have the valve clearance adjusted. This is a ve_ impo_ant step to insure the longest life for your engine. To adjust valve clearance: Remove four (4) screws that attach the spark arrestor screen. Replace damaged screen with new screen (pin 83083). Reattach the spark arrestor screen and the heat shield. Clean / Replace Spark • Make sure the engine is at room temperature. • Make sure that the spark plug wire is removed from the spark plug and out of the way. Remove the breather tube from the valve cover. • • Remove the'four screws attaching the valve cover with a #2 or 3 phillips screwdriver. O Plug Replace the spark plug yearly or every 100 hours of operation, whichever comes first. A CAUTION: Disconnect spark wire fromplug. spark plug and keep wire awayplug from spark Clean area around spark plug. Remove spark plug form the cylinder head. Replace spark plug if the electrodes are pitted, burned or porcelain is cracked. For replacement use Champion RC12YC or equivalent. Check electrode gap with wire feeler gauge and set gap to 0.76mm (.030 inches), if necessary. Valve Cover Breather Tube Make sure the piston is at Top Dead Center (TDC) of its compression stroke (both valves closed). To get the piston at top dead center, pull on the recoil handle slowly watching the piston trough the spark plug hole. As you pull on the recoil handle the piston should move up and down. The piston is put Top Dead Center when it is up as high as it can go. Install a correctly gapped spark plug into the cylinder head, tighten securely. 14 Feeler Gusge Jam Nut to In-lb= Allen Wren©ll Important: If you feel uncomfortable about doing this procedure or you don't have the proper tools, please take your cleaning system in to the nearest service center to have the valve clearance adjusted. This is a very important step to insure the longest life for your engine. Note: Only perform this adjustment after first 50 hours of operation. The head bolts will need no further adjustment. Loosen Jam Nut • Using a 10mm wrench, loosen the rocker arm jam nut. Use an 8ram allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge. Correct clearance is 0.002-0.004 inch (0.050.1mm). Note: You must hold the rocker arm jam nut in place as you tum the pivot ball stud. • When valve clearance is correct, hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut. Tighten the jam nut to 65-85 inch-pounds torque. After tightening the jam nut, recheck valve clearance to make sure it did not change. • • Reattach the valve cover making sure the gasket between the valve cover and cylinder head is in place.. Start all four screws before tightening or you will not be able to get all the screws in place. Reattach the breather tube. • Reattach the spark plug wire to the spark plug. Retorque Head • Remove the four (4) screws from the valve cover. • Remove the valve cover and gasket. • Torque the bolts to 4.0 kg-m (22 ft-lb). • Torque sequence is as follows: A, B, C, D, E (star pattern). D B A Bolts After the first 50 hours of operation, you must retorque the head bolts to 4.0 kg.-m. (22 ft.-Ibs.) 15 E AFTER EACH USE • Flush the chemical system by selecting a tank and run the cleaning system with nozzle in low pressure mode. Flush until each tank is empty, then switch the selector knob to the next tank. The last tank to be emptied must be the System Rinse tank. • Connect a 3-foot section of garden hose to the inlet adapter. Pour RV-Antifreeze (antifreeze without alcohol) into the hose. Pull the recoil handle twice. Water should not remain in the unit for long periods of time. Sediments of minerals can deposit on pump parts and "freeze" pump action. Follow these procedures after every use: • Flush the chemical system by selecting the System Rinse tank and run the cleaning system with nozzle in low pressure mode. Flush for one minute or until the chemical is cleared from the system. • Shut off the engine and let it cool, then remove all hoses. ,_ • • • CAUTION: Be sure the engine switch is in the "Stop" position before Run/Stop you continue. Empty the pump of all pumped liquids by pulling recoil handle about 6 times with the Run/Stop switch in the "Stop" position. This should remove most of the liquid in the pump. Rotate the Dial-A-Cleaner TM selector knob to the OFF position. LONG TERM STORAGE If you do not plan to use the cleaning system for more than 30 days, you must prepare the engine for long term storage. It is important to prevent gum deposits from forming in essential fuel system parts such as the carburetor, fuel filter, fuel hose or tank during storage. Also, experience indicates that alcohol-blended fuels (called gasohol, ethanol or methanol) can attract moisture which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. Coil the high pressure hose and inspect it for damage. Cuts in the hose or fraying could result in leaks and loss of pressure. Should any damage be found, replace the hose. DO NOT attempt to repair a damaged hose. Replace the hose with the genuine Craftsman part. • Drain water from hose and properly hang it on the wire support provided. • Store system in a clean, dry area. A Protect Fuel System ,_ DANGER: Drainfrom fuel open into approved outdoors, away flame. Becontainer sure engine is cool. Do not smoke. • Remove all gasoline from the fuel tank to prevent gum deposits from forming on these parts and causing possible malfunction of engine. • Run engine until engine stops from lack of fuel. Make sure you have water supply to pump inlet connected and turned ON. DANGER: Never store the engine with fuel in the gas tank indoors or in enclosed, poorly ventilated areas where fumes may reach an open flame, a spark, or pilot light. Change Oil WINTER STORAGE While engine is still warm, drain oil from crankcase. Refill with recommended grade. (See Changing Oil) A Oil Cylinder CAUTION: You must protect your unit from freezing temperatures. Failure to do so will permanently damage your pump and render your unit inoperable. • To protect the unit from freezing temperatures: • ,_ Empty all chemical reservoirs as follows: a. b. Disconnect hose connected to chemical inject fitting on the pump. Place end of hose into suitable container. • Move the selector knob to Tank A and open that tank's cover. Gravity should shortly empty the tank contents into the container. ° • c. When the tankis tanks B and C. d. Reconnect the hose to the chemical inject fitting on the pump. Add 0.5 liter of clean fresh water to each tank and close tank's covers. Bore Remove spark plug. Squirt about 1 ounce (30 ml) of engine oil into the cylinder, Cover spark plug hole with rag. Crank engine slowly to distribute oil. CAUTION: Avoid spray from spark plug hole when cranking engine. Install spark plug. Do not connect spark plug wire. OTHER empty, repeatstep (b)for Do not store gasoline from one season to another. If possible, store your unit indoors and cover it to give protection from dust and dirt. BE SURE TO EMPTY THE FUEL TANK. IMPORTANT: NEVER cover your cleaning system while engine and exhaust area are warm. 16 CORRECTION CAUSE PROBLEM Pump has following problems: failureto producepressure,or erraticpressure,chattering,loss of I* Nozzle in low pressuremode. 1. Twist chemical valve handle 2. Water inlet is blocked. 2. to place in low pressure mode. Clear inlet pressure,low water volume. 3. inadequate water supply 3. Provide adequate water flow at least 3 gpm. 4. Inlet hose is kinked or leaking 4. Straighten inlet hose, patch leak. 5. Clogged water inlet screen. 5. Replace / clean water inlet 7. Water supply is over 140°F. Outlet hose is biooked. 6. 7. Provide cooler water supply. Clear blocks in outlet hose, 8. Outlet hose leaks. 8. Replace outlet hose if leaking. 9. Gun leaks. 9. Replace O-ring or gun if screen. 6, 10. Nozzle is obstructed. necessary. 10. Clear nozzle. 11. Pump is faulty. 11. Contact Sears Service Department. Detergentfailsto mix. Engine runs good when not spraying 1. Detergentline is collapsedor kinked 2. Chemicaltank filteris clogged. 1. Repair or replace detergent line. 3. Nozzle is in high pressuremode. 2. Replacetank 3. Twist chemicalvalve handle 4. to place in low pressuremode. 4. Rotate knobfor desiredchemical. Dial-a-Cleaner knob is in off positior Engine speed is too slow. Contact Sears Service Department. but dies when you begin to spray. Enginewill not start;or starts and runsrough 1. Dirty air cleaner 1. 2. 3. Out of gasoline. 2. Stale gasoline. 3. 4. Spark plug wire not connected 4. Clean or replace air cleaner. Fill fuel tank. Drain gas tank; fill with fresh fuel. Connect wire to spark plug. to spark plug. 5. Bad spark plug. 6. Water in gasoline. 7. Ovemhoking or flooded 8. Excessively rich fuel mixture. 5. Replace spark plug. 6. Drain gastank; fillwith freshfuel. 7. Set enginethrottlecontrolleverto fast position, choke in run position. 8. ContactSears Service Intake valve stuck open or closed, Department. 9. ContactSears Service 9. 10. Engine has lost compression. Department. 10. ContactSears Service Department. Engine shuts down during 1. Out of gasoline. 1. Fill fuel tank. Air filter dirty 2. Replace Air filter. operation 2. Enginelackspower. Dirty air filter. Replace air filter. 17 18 Generac Power Systems GN 220, 7.8HP, Model # EHC 04048-0 GREEN 14 15 8 16 15 9 25 14 10 25 51 8 / 12 _LACKG_E_N 21 17 2O 22 I&.__ Pa_# _ty 7 8 9 78653 85272 84195 1 1 1 10 11 12 85620 00285271 84329 1 1 1 13 14 15 16 17 18 00185271 22097 82981 81675 84274 87221A 1 2 2 1 1 1 19 20 21 22 45756 72347 86962 85953 1 1 1 1 it__q_m_ Part# Run/Stop Switch L.E.D. Assembly Low Oil Shutdown Decal Black Sleeving Black Wire Assembly 3-pin Male Connector Housing White Wire Assembly M6 Lock Washer M6 x 30mm Screw Ignition Coil Tinnerman Clamp Low Oil Shutdown Module M6 x 10mm Screw Spark Plug Govemor Lever Wear Washer 19 23 24 A9311 83512 1 Adjust Screw 1 25 26 78604 89230 1 1 27 29 30 31 32 33 34 83503 86384 86037 36701 22152 23897 A9567 1 1 1 1 1 1 1 35 A9568 1 36 37 38 36919 22264 A9943 1 1 M8 x 15mm Taptite Screw 60 Hz. Governor Spring M8-1.25 x 35ram Capscrew M5 Lock Nut Governor Rod Anti-lash Spring PHMS 10-32 x 1/2" Lockwasher, #10 Flatwasher, #10 Bracket, Pivot / Adjustment Bracket, Govemor Weldment PHMS 8-32 x 5/8" Lockwasher #8 1 Clamp, Bowden Generac Power Systems GN 220, 7.8HP, Model # EHC 04048-0 36 20 6 28 1! 12 47 33 13 18 Item Part# Qtv Desorlotion 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25" 78621 76389 88411 A8897A 77168 88057 76390 83337A 78658 78659 89213J A7637 81695 A8929 78645 A7811 72683 98752 89096 88156 A8822 78691 A5772 A5776 74908 1 1 1 1 5 1 2 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 Control Rod Assembly Piston Pin Piston Ring Set Gear Cover Assembly M8 x 52mm Head Bolt Piston Pin Retainer Ring Tapered Crankshaft Assm. Governor "R" Pin Governor Arm Thrust Washer Crankcase Assm. Governor Arm Oil Seal Governor Gear Assembly Govemor Gear C-Ring Governor Spool 1/8" NPT Pipe Plug Camshaft Assembly Crankcase Gasket Valve Stem Seal Cylinder Head Gasket Oil Pressure Relief Cover Oil Pressure Spring 11/32" Ball M5 Form Screw 20 Item 26 27 Part# 78606 76361 28 29 30 31 32 33 34 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 89230 99922 A1720 88401 84186 83192 86254 21705B 90082 90081 88396A 83235 80336 96362 77161 77160 76307 88403 72657 88412 76329 21944E 4 1 6 1 2 2 2 1 1 1 1 1 2 2 1 1 2 2 2 1 2 1 1 Descriotlon M6-1.0 x 12mm Screw Governor Gear Thrust Washer M8-1.25 x 35mm Screw Spring Washer Valve Spring Retainer Valve Spring Valve Spring Wear Washer Geroter Set "O" Ring Cylinder Head Assembly Exhaust Valve Intake Valve Push Rod Tappet Oil Pick-up Assembly Rocker Cover Gasket Pivot Ball Stud GN-190/220 Rocker Arm Rocker Arm Jam Nut Push Rod Guide Plate 1/4" NPT Pipe Plug Rocker Cover Assembly Plastic Oil Fill Plug Complete Long Block Generac Power Systems GN 220, 7.8HP, Model # EHC 04048-0 31------ 43 44 34 46 35 47 48 _ 36 / / _39 37 40 38 I...te_m _ _Q_ 31 32 33 34 35 36 37 38 39 90947 90051 57058 80318 80316 20136 22097 49813 21202 1 1 1 1 2 1 2 2 1 40 41 42 36935 80303 21201 2 1 1 43 44 45 46 47 48 21203 21200 66476 59635 78601 78602 1 1 1 1 1 1 2! 41 Description Breather Hose Manifold Head Gasket M6 x 55mm Capscrew M6 x 25ram Capscrew M6 x 30mm Screw Intake Manifold M6 Lock Washer M6 Hex Nut Carburetor/Air Box Gasket #10-32 x 3/4" Screw Canal Cover Carburetor/Manifold Gasket Carburetor Air Cleaner Base M6 x 12mm Capscrew #8 x 3/8" Plastite Screw Air Filter Precleaner Generac Power Systems GN 220, 7.8HP, Model # EHC 04048-0 6 81 4 Item 1 2 3 4 5 6 Part # 94820 91848 84982 92978 99236 70185 Q_tY 1 1 1 2 1 1 DescriPtion Expansion Plug Oil Filter Gasket Oil Filter Adapter M6 x 20mm Screw Oil Pressure Switch Oil Filter Item 78 79 80 81 90 Pa_# 82774 SRV77182E 83312 81810 A2842 Item 82 83 84 85 86 87 88 89 90 91 Part # 92984 45756 78609 78608A 90695A 89739 66476 A2799 A2842 78651C Qtv 1 1 1 1 1 DescriPtion Woodruff Key Flywheel (220cc) Conical Washer M16 Hex Nut Recoil Cup 91 83 84 85 86 \ 88 22 Q_tY 1 4 2 1 1 1 9 1 1 1 Deacriotlon Top Wrapper M6 x 10mm Screw Cover Bolt Air Box Cover Blower Housing Lower Wrapper M6 x 12ram Capscrew Recoil Assembly Recoil Cup Backplate Generac Power Systems GN 220, 7.8HP, Model # EHC 04048-0 59 61 Item 55 57 58 59 60 61 _ 83512 95213 77395 95214 30340 48031C Q_ty 2 1 2 1 12" 1 23 Description M6 x 15 Taptite ,Tank Bracket M6 Flange Nut Tank Cradle 1/4" ID Hose Hose Clamp Craftsman 3000 PSI Cleaning System 580.768050 Pump 32 31 29 33 26 9 lO 27 3 25 14 16 17 18 41 19 2o L 37 44 40 9 36 22 24 Craftsman 3000 PSI Cleaning System 580.768050 Pump Ram P_a[ Ow 1 2 3 B2218 B2260 94738 1 1 1 4 5 6 7 93887 96400 99735 93652 1 3 1 1 8 93876 1 9 Order B2480 3 10 11 12 13 Order B2480 Order B4123 Order B4123 97027 3 3 3 3 14 15 16 17 18 19 20 96137 95138 B2665 93874 B3769 46580 95320 1 1 6 6 1 3 1 21 93644 1 22 B2668 1 Item O-RING, 1.625 x .103 ADAPTER, Engine WASHER, Belleville 16 x 2.7 NUT, Jam M16 x 1.5 SPRING, Piston Return ASSY., Oil Breather/Fill SPRING, Thermal ByPass O-RING, 2,9 x 6.5 x 1.78 SEAL, High Pressure PTFE RING, Bearing Seal RING, Hytrile Back-Up O-RING, 2.6 x 26.6 ID TOWER, High Pressure Port PLUG, 1!8 x 28 NPT HEAD, (Brass with Tap) WASHER, Steel Special SHCS, M8 x 1.25 x 75 ASSY., Unloader SHCS, M6 x 1 x 45 CONNECTOR, Garden Hose ACTUATOR, Thermal By-Pass GASKET, Head Otv 23 95416 1 24 25 40945 93790 6 1 26 95165 1 27 28 29 30 S2261B 132217 SRV97672V ...... 4 4 0 1 31 ...... 1 32 33 34 ...... B2480 ...... 1 0 3 35 36 ...... ...... 1 3 37 38 39 40 41 42 43 44 ...... B3508 ...... ...... B4123 ...... B4124 ...... 3 0 3 1 0 6 0 1 25 PISTON, Thermal ByPass SHCS, M6 x 1 x 20 O-RING, 114 x 119 x 2.6 ADAPTER, Tapered Engine Shaft SCREW, 5/16 x 314 O-RING, .239 x .070 KIT, AXIAL CAM ASSY., Bearing Roller Thrust 15.5 CAM, Axial 2.5G/5.5 Race BEARING, Roller Thrust KIT, PISTON REPAIR ASSY., Ceramic Piston & Cap SHOE, Piston Pivot SEAL, Oil Piston 15 TC4 SEAL, Piston =U" Cup KIT, CRANKCASE SPACER, Pilot ASSY., CRANKCASE KIT, CHECK VALVE ASSY., Check Valve KiT, SPACER PLATE ASSY., Spacer Plate Craftsman 3000 PSI Cleaning System 580.768050 Main Unit 27 23 25 24_ 38 21 28 _ 5O 51 26 22 26 29 Craftsman Main Unit Item 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 3000 PSI Cleaning _ B3608A 30809 B3576 B3599 B3695 B3222A B3222B B3222C B3222D B3376B 96307 86292 B3311 B3721 B3377 EB3115 91526 49226 51716 B3306 B3840A B3840B B3840C B3840D B3601C 48031G EB3620 B2071 B1779 B2347 31669 46476 B2759 B1460 30340(3 96193 4803tC 95549 94994 96002 96001 21545 B1288 B4140 88521 75402 52858 27007 50190 _ 1 4 1 4 8 t 1 1 1 1 1 4 1 1 3 1 2 2 2 1 1 1 1 1 1 4 1 2 2 2 1 2 1 1 1 1 5 1 1 4 4 1 1 1 2 2 2 2 2 System 580.768050 Description LINK, Throttle Control GROMMET, Rubber DECAL, Control Panel 1210 ASSY., Chemical Tank I Gal. BOLT, 1/4" - 20 with Washer CAP, Chem Container "A" CAP, them Container "B" CAP, Chem Container "C" CAP, Chem Container "Water" TAG, System Flush Water DECAL, 1-800 Number SELF DRILL, 10 - 16 x 3/4" SCREW, Plastita HANDLE, 4-Way Valve SCREW, Plastite #8 x .75" PANEL, Control Powder Green PPHMS, M5-0.8x 12 LOCK WASHER, M5 NUT, HexM5- 0.8 ASSY., Sub 4-Way Valve HOSE, Chemical "A" - 10" HOSE, Chemical "B" - 14" HOSE, Chemical "C" - 14" HOSE, Chemical "D" - 10" HOSE, Chemical Pump 7.5" CLAMP, Hose 3/16" HANDLE, Powder Green NUT, 1/4" - 20 Flange Locking COVER, Hinge END CAP, Tube BOLT, 1/4"-20 x 1-3/4" Carriage CAPLUG, Tubing HOOK, Square Neck Gun CAP, Vinyl Black HOSE, .25" ID VALVE, Fuel Shut-Off HOSE, Clamp Band 1/2" CAP, Fuel TANK, 1 Gal Fuel BUSHING, Tank BOLT, M6 - 1.0 x 21 Shoulder SHIELD, Heat TAG, Breather Cap AXLE ROD, 1/2" x 24.65" WHEEL PUSHNUT, 112" NUT, M8- 1.25 Locking MOUNT, Vibration Donut Type FLAT WASHER, M8 Item 51 52 53 54 55 56 57 58 59 60 61 62 63 64 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 9_0 Pa_# 42909 40976 89476 83071 83208 39414 66476 B1436A B4341 B3589 B3454 B3604 B1748 EB3618 B3636 B2508 AB3061 132730 B3735 B4270 96207A 70453 67989 Qtv 2 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 21216 21217 B3680A 52857 A1701 B3706 38750 97098 21424 NSP 1 1 1 2 1 1 2 1 1 1 Descriotlon HHCS, M8 x 1.25 x 30 SHCS, M8- 1.26 x 20 GASKET, Exhaust MUFFLER BRACKET, Muffler HHCS, M8- 1.25 x 35 HHCS/LW, M6 - 1.0 x 12 GUN, Molded Grip KIT, Nozzles KIT, 3 Pak Concentrate KIT, Chemical Tags MANUAL ASSY., Dual Lance Ext. CRADLE, Powder Ct Green HOSE, 3/8" x 50' KIT, Cleaning Nozzle OIL BOTTLE KIT, Maintenance NUT,Water Inlet DECAL, Start Instruction DECAL, Recoil TAG, Warning Oil NUT, Hex Locking Flange M8 1.25 MOUNT, Rubber Shock MOUNT, Rubber Shock ASSY., Pump NUT, M6 - 1.0 Locking BRACKET, Pump Support HOSE, Water Inlet HHCS, M6 1.0 x 30 CAP, Garden Hose Inlet CONNECTOR, Garden Hose ENGINE Optional Accessories Not Illustrated: House Wash Concentrate 71-74300 71-74301 Deck Wash Concentrate 71-74302 Vehicle Wash Concentrate 71-74303 Degreaser Concentrate 71-74400 Heavy Duty Turbo Nozzle 71-74401 25' 3/8" Replacement Extension Hose 71-75116 O Ring Repair Kit Garden Hose Quick Connect 71-75187 71-75197 Accessory Quick Connect Kit 71-75199 Rotating Brush 71-76430 Floor/Siding Brush 71-76431 Utility Brush 27 CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT Your Warranty Rights and Obligations The California Air Resources Board (CARB), United States Environmental Protection Agency (EPA), and Sears Roebuck and Co. USA (Sears) are pleased to explain the emissions control system warranty on your 1997 and later utility and lawn and garden equipment engine. New Utility and Lawn and Garden Equipment (ULGE) engines must be designed, built, and equipped to meet both the State of Califomia and Federal stringent anti-smog standards. Sears must warrant the emission control system on your ULGE engine for the periods of time listed below provided there has been no abuse, neglect, or improper maintenance of your ULGE engine. As the ULGE engine owner, you should be aware that Sears may deny any and/or all warranty coverage or responsibility if your ULGE engine or a part/component of it has failed due to abuse, neglect, improper maintenance, unapproved modifications, or the use of counterfeit and/or 'grey-market' parts not made, supplied or approved by the original equipment manufacturer. You are responsible for presenting your ULGE engine to a Sears authorized service center as soon as a problem occurs. Warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have any questions regarding your warranty rights and responsibilities, you should contact your nearest authorized service center or call Sears at 1800-473-7247. The emissions control system may include parts such as the carburetor, ignition and exhaust systems. When a warrantable condition occurs, Sears will repair your lawn and garden equipment engine at no cost to you. Expenses covered under warranty include diagnosis, replacement parts and labor. Warranty Commencement Date The warranty pedod begins on the date the ULGE engine is delivered to the original, end-use purchaser. Length of Coverage Sears warrants to the initial owner and each subsequent purchaser that the engine is free from defects in materials and workmanship which cause the failure of a warranted part for a period of two years. Manufacturer's Warranty Coverage The 1997 and later ULGE engines are warranted for two years. If any emission related component or system on your engine (as listed below) is found to be defective, repairs or replacement will be performed by an authorized Sears service center. What is Covered Owner's Warranty Responsibilities Repair or Replacement of Parts As the ULGE engine owner, you are responsible for the completion of all required maintenance as listed in your factory supplied Owner's Manual. For warranty purposes Sears recommends that you retain all receipts covering maintenance on your ULGE engine. However, Sears cannot deny warranty solely because of the lack of receipts or for your failure to ensure the completion of all scheduled maintenance. Repair or replacement of any warranted part will be p_rformed at no charge to the owner at an approved Sears service center. If you have any questions regarding your warranty rights and responsibilities, you should contact your nearest authorized service center or call Sears at 1-800-473-7247. 28 WarrantyPeriod How to File a Claim Any warranted part which is not scheduled for replacement as required maintenance shall be warranted for 2 years. Any warranted part which is scheduled only for regular inspection and/or has instructions to the effect of "repair or replace as necessary" shall also be warranted for 2 years. Any warranted part which is scheduled for replacement as required maintenance shall be warranted either for the period of time up to its first scheduled replacement, or for 2 years, whichever comes sooner. If you have any questions regarding your warranty rights and responsibilities, you should contact your nearest authorized service center or call Sears at 1800-473-7247. Where to get Warranty Service Warranty services or repairs shall be provided at all Sears authorized service centers. Maintenance, Replacement and Repair of Emission Related Parts Diagnosis When the ULGE engine is inspected by an authorized Sears service center, the owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable. Any Sears approved replacement part used in the performance of any warranty maintenance or repair on emission related parts will be provided without charge to the owner if the part is under warranty. Consequential Damages Emission Control Warranty Parts List 1. Fuel Metering System: Sears may be liable for damages to ether engine components caused by the failure of a warranted part if the failed part was still under warranty. a. Carburetor assembly b. Fuel filter What is not covered 2. Air Induction System: a. Intake manifold Owner Responsibilities b. Air cleaner Any failures caused by abuse, neglect, or improper maintenance will not be covered. 3. Catalytic Muffler Assembly (if so equipped), including: Add-On or Modified Parts a. Muffler gasket b. Exhaust manifold The use of add-on, unauthorized or modified parts constitutes sufficient reason for denial of submitted warranty repairs. Sears will not be held liable for repairs of this type. 4. Ignition System a. Spark plug b. ignition module 5. Crankcase Breather Tube 29 For in-home major brand repair service: Call 24 hours a day, 7 days a week 1-800-4-MY-HOME" (1-800-469-4663) Para pedir servicio de reparaci(Sn a domicilio - 1-800-676-5811 In Canada for all your service and parts needs call - 1-800-665-4455 Au Canada pour tout le service ou les pieces For the repair or replacement parts you need: Call 7 am - 7 pm, 7 days a week 1-800-366-PART (1-800-366-7278) Para ordenar piezas con entrega a domicilio - 1-800-659-7084 For the location of a Sears Parts and Repair Center in your area: Call 24 hours a day, 7 days a week 1-800-488-1222 For information on purchasing a Sears Maintenance Agreement or to inquire about an existing Agreement: Call 9 am - 5 pm, Monday - Saturday 1-800-827-6655 SEARS HomeCentral = TheService SideofSears"