6.5 HP pressure washer Model 67596 Set up, Operating, and Servicing Instructions Using an engine indoors CAN KILL YOU IN MINUTES. Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell. NEVER use inside a home or garage, EVEN IF doors and windows are open. Only use OUTSIDE and far away from windows, doors, and vents. Visit our website at: http://www.harborfreight.com Read this material before using this product. Failure to do so can result in serious injury. Save this manual. Copyright© 2009 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing improvements, actual product may differ slightly from the product described herein. Tools required for assembly and service may not be included. For technical questions or replacement parts, please call 1-800-444-3353. Contents Important SAFETY Information���������������������������� 3 Set up precautions�������������������� 3 OPERATING PRECAUTIONS������������ 4 Service precautions����������������� 6 Basic Specifications������������� 8 Unpacking���������������������������������� 8 Set Up Instructions��������������� 8 Assembly���������������������������������������� 9 Parts List & Diagram E Crankshaft/Piston���������������� 32 Parts List & Diagram F - Gas Distribution Adjustment System�����������������������������������������33 Parts List & Diagram G Starter Subassembly���������� 34 Parts List & Diagram H Diversion Assembly��������������� 35 Parts List & Diagram J Carburetor������������������������������ 36 Parts List & Diagram K Flywheel/Coil Assembly������ 37 Engine diagram���������������������� 11 Parts List & Diagram M Control System���������������������� 38 Operating Instructions���� 12 Parts List & Diagram N - Air Cleaner�������������������������������������� 39 Starting the Engine����������������� 12 Equipment Operation��������������� 15 Parts List & Diagram P Muffler��������������������������������������40 Technical Specifications�� 17 Parts List & Diagram R Fuel Tank����������������������������������� 41 Servicing���������������������������������� 17 Maintenance Procedures����� 17 Cleaning, Maintenance, and Lubrication Schedule���������� 19 Storage����������������������������������������20 Troubleshooting���������������������� 21 Parts List & Diagram S Carbon Canister�������������������� 42 Limited 1 year / 90 Day warranty������������������������������ 43 Emission Control System Warranty����������������������������������� 43 Parts Lists and Diagrams� 25 General Parts List������������������� 25 General Assembly Diagram�� 26 Parts List A - Pump��������������������� 27 Assembly Diagram A - Pump��� 28 Parts List & Diagram B Cylinder Head�������������������������� 29 Parts List & Diagram C Crankcase�������������������������������� 30 Parts List & Diagram D Crankcase Cover������������������� 31 Page 2 For technical questions, please call 1-800-444-3353. SKU 67596 Save This Manual Notice NOTICE is used to address practices not related to personal injury. Keep this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the back of the manual near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and the receipt in a safe and dry place for future reference. Caution CAUTION, without the safety alert symbol, is used to address practices not related to personal injury. WARNING! Read all instructions. Failure to follow all instructions listed below may result in fire, serious injury and/or DEATH. The warnings and precautions discussed in this manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator. Important SAFETY Information In this manual, on the labeling, and all other information provided with this product: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. SAVE THESE INSTRUCTIONS Set up precautions 1. Gasoline fuel and fumes are flammable, and potentially explosive. Use proper fuel storage and handling procedures. Do not store fuel or other flammable materials nearby. 2. Have multiple ABC class fire extinguishers nearby. 3. This equipment has a spark arresting muffler included. A spark arresting muffler is required by law in California, on some US Forest Service land, and possibly in other areas or situations. 4. Set up and use only on a flat, level, well-ventilated surface. Danger WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. WARNING CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Caution SKU 67596 For technical questions, please call 1-800-444-3353. Page 3 5. The work area should have adequate drainage to reduce the possibility of a fall due to slippery surfaces. 6. Wear ANSI-approved safety goggles, heavy-duty work gloves, and dust mask/respirator during set up and use. 7. Use only oil and fuel recommended in the “Specifications” section of this manual. 8. Only use cold Water or pressure washer detergent in this tool. Do not use caustic materials, solvents, flammable materials, or detergents not designed for pressure washers. Use of any such material can cause injury, or damage this tool or personal property. NEVER use inside a home or garage, EVEN IF doors and windows are open. Only use OUTSIDE and far away from windows, doors, and vents. 2. Keep children away from the equipment, especially while it is operating. Do not dry run this product. Dry running will cause serious damage to the seals. Make sure the water supply used for the Pressure Washer is not dirty or sandy. 3. Do not leave the equipment unattended when it is running. Turn off the equipment (and remove safety keys, if available) before leaving the work area. 10. Prior to starting the Pressure Washer in cold weather, check all of the parts of the unit to make sure ice has not formed. Do not store the unit anywhere that the temperature will fall below 32° F (0° C). 4. Wear ANSI-approved safety goggles and hearing protection during use. 5. People with pacemakers should consult their physician(s) before use. Electromagnetic fields in close proximity to a heart pacemaker could cause pacemaker interference or pacemaker failure. Caution is necessary when near the engine’s magneto or recoil starter. 6. Use only accessories that are recommended by Harbor Freight Tools for your model. Accessories that may be suitable for one piece of equipment may become hazardous when used on another piece of equipment. 9. OPERATING PRECAUTIONS 1. Carbon Monoxide Hazard Using an engine indoors CAN KILL YOU IN MINUTES. Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell. Page 4 For technical questions, please call 1-800-444-3353. SKU 67596 7. Do not operate in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Gasoline-powered engines may ignite the dust or fumes. 8. Stay alert, watch what you are doing and use common sense when operating a piece of equipment. Do not use a piece of equipment while tired or under the influence of drugs, alcohol or medication. 9. Do not overreach. Keep proper footing and balance at all times. This enables better control of the equipment in unexpected situations. 10. Do not carry the spray handle with your finger on the trigger, whether engine is operating or not. 11. Use this equipment with both hands only. Using equipment with only one hand can easily result in loss of control. particular type of equipment, taking into account the working conditions and the work to be performed. Use of the equipment for operations different from those intended could result in a hazardous situation. 17. Do not operate the equipment with known leaks in the engine’s fuel system. 18. This product contains or, when used, produces a chemical known to the State of California to cause cancer and birth defects or other reproductive harm. (California Health & Safety Code § 25249.5, et seq.) 19. WARNING: The brass components of this product contain lead, a chemical known to the State of California to cause birth defects (or other reproductive harm). (California Health & Safety code § 25249.5, et seq.) 12. Dress properly. Do not wear loose clothing or jewelry. Keep hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts. 20. When spills of fuel or oil occur, they must be cleaned up immediately. Dispose of fluids and cleaning materials as per any local, state, or federal codes and regulations. Store oil rags in a bottom-ventilated, covered, metal container. 13. Parts of the Pressure Washer, especially exhaust system components, get very hot during use. Stay clear of hot parts. 21. Keep hands and feet away from moving parts. Do not reach over or across equipment while operating. 14. Do not cover the engine or equipment during operation. 15. Keep the equipment, engine, and surrounding area clean at all times. 16. Use the equipment, accessories, etc., in accordance with these instructions and in the manner intended for the SKU 67596 22. Before use, check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the equipment’s operation. If damaged, have the equipment serviced before use. Many accidents are caused by poorly maintained equipment. For technical questions, please call 1-800-444-3353. Page 5 23. Use the correct equipment for the application. Do not modify the equipment and do not use the equipment for a purpose for which it is not intended. 1. Anyone using vibrating tools regularly or for an extended period should first be examined by a doctor and then have regular medical checkups to ensure medical problems are not being caused or worsened from use. Pregnant women or people who have impaired blood circulation to the hand, past hand injuries, nervous system disorders, diabetes, or Raynaud’s Disease should not use this tool. If you feel any medical or physical symptoms related to vibration (such as tingling, numbness, and white or blue fingers), seek medical advice as soon as possible. 2. Do not smoke during use. Nicotine reduces the blood supply to the hands and fingers, increasing the risk of vibration-related injury. 3. Wear suitable gloves to reduce the vibration effects on the user. 4. Use tools with the lowest vibration when there is a choice between different processes. 5. Include vibration-free periods each day of work. 6. Grip tool as lightly as possible (while still keeping safe control of it). Let the tool do the work. 7. To reduce vibration, maintain the tool as explained in this manual. If any abnormal vibration occurs, stop use immediately. 24. The high pressure water flow can damage the work surface if not used properly. Always test the spray in an open area first. 25. When dispensing detergent, apply the detergent to the cleaning area at low pressure only. Detergent dispensing only works when the spray wand is in the low-pressure position. 26. Injection Hazard. The high pressure water jet produced by this tool can cut skin or cause injury to hands or eyes. Do not allow spray to strike you and do not spray toward people or animals. Do not spray the tool itself or any electrical source. 27. This Pressure Washer is intended for outdoor residential use only. 28. In case of an emergency during use, immediately release the trigger on the spray handle, turn the engine off and then shut off gas supply to the engine. Do not set the spray handle down without turning off the engine. Vibration Hazard: This tool vibrates during use. Repeated or long-term exposure to vibration may cause temporary or permanent physical injury, particularly to the hands, arms and shoulders. To reduce the risk of vibration-related injury: Page 6 Service precautions 1. Before service, maintenance, or cleaning: a.Turn the engine switch to its “OFF” position. For technical questions, please call 1-800-444-3353. SKU 67596 b.Allow the engine to completely cool. c. Then, remove the spark plug wire(s) from the spark plug(s). 2. Keep all safety guards in place and in proper working order. Safety guards include muffler, air cleaner, mechanical guards, and heat shields, among other guards. 3. Do not alter or adjust any part of the equipment or its engine that is sealed by the manufacturer or distributor. Only a qualified service technician may adjust parts that may increase or decrease governed engine speed. 4. Wear ANSI-approved safety goggles, heavy-duty work gloves, and dust mask/respirator during use and service. 5. 6. 7. 8. Keep the high pressure hose connected to the pressure washer and spray Gun while the system is pressurized. Disconnecting the pressure hose while the unit is pressurized is dangerous, and may cause injury. Do not allow the high pressure hose to come in contact with any hot part of the unit. The hose might be damaged, possibly causing it to burst or leak under high pressure. Maintain labels and nameplates on the equipment. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement. If water is leaking out of the Pressure Washer immediately turn off the unit. Unplug the Pressure Washer, SKU 67596 and discharge all pressure before tightening fittings or having repair work done by a qualified technician. 9. When the engine is running, do not allow the Pressure Washer to remain idle for more than two minutes. If allowed to remain idle, the water in the unit will heat up, possibly causing damage to the Pressure Washer. 10. Have the equipment serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the equipment is maintained. Do not attempt any service or maintenance procedures not explained in this manual or any procedures that you are uncertain about your ability to perform safely or correctly. 11. Store equipment out of the reach of children. 12. Follow scheduled engine and equipment maintenance. Refueling: 1. Do not smoke, or allow sparks, flames, or other sources of ignition around the equipment, especially when refuelling. 2. Do not refill the fuel tank while the engine is running or hot. 3. Do not fill fuel tank to the top. Leave a little room for the fuel to expand as needed. 4. Refuel in a well-ventilated area only. Save these instructions. For technical questions, please call 1-800-444-3353. Page 7 Basic Specifications Fuel Engine Oil Type 89+ octane unleaded gasoline Capacity 0.95 Gallons Type (SAE) 10W-30 above 32° F 5W-30 at 32° F or below Capacity 0.63 Quarts Pump Oil 3.75 fl-oz SAE 10W-30 Non-detergent Engine Speed 3,600 RPM Water Flow 3 GPM Maximum Maximum Pressure 2,500 PSI Note: Additional specifications found in the Technical Engine Specifications chart in this manual. The emission control system for this Generator’s Engine is warranted for standards set by the U.S. Environmental Protection Agency and by the California Air Resources Board (also known as CARB). For warranty information, refer to the last pages of this manual. Set Up Instructions Read the entire Important Safety Information section at the beginning of this manual including all text under subheadings therein before set up or use of this product. Risk of accidental starting; resulting in serious personal injury. Turn the Power Switch of the equipment to its “OFF” position, wait for the engine to cool, and unplug the spark plug wire(s) before assembling or making any adjustments to the equipment. WARNING Note: For additional information regarding the parts listed in the following pages, refer to the Assembly Diagram near the end of this manual. At high altitudes, the engine’s carburetor, governor (if so equipped), and any other parts that control the fuel-air ratio will need to be adjusted by a qualified mechanic to allow efficient high-altitude use and to prevent damage to the engine and any other devices used with this product. Unpacking When unpacking, make sure that the item is intact and undamaged. If any parts are missing or broken, please call Harbor Freight Tools at 1-800-444-3353 as soon as possible. Page 8 For technical questions, please call 1-800-444-3353. SKU 67596 Assembly 1. Detergent Inlet Pressure Regulator Knob (44A) Connection (26A) This equipment has a spark arresting muffler included. A spark arresting muffler is required by law in California, on some US Forest Service land, and possibly in other areas or situations. Dipstick (60A) Aluminum Pump Breather Plug (59A) Brass Pump Plug (14A) Figure 1 2. 3. Replace the Brass Pump Plug (14A) with the aluminum Pump Breather Plug (59A) and Dipstick (60A) before first use. The Pump Breather Plug must be used whenever the pressure washer is used. The Brass Pump Plug (without the breather hole) should be used for transporting only. Attach the Handle (14) onto the Frame (17) with the Handle Bolts (15) and Nuts (16). Hose Connection Figure 2 Water Inlet Connection 4. Attach the Hose (18) to the Hose Connection on the unit. (See Figure 2.) 5. Pull the Collar at the end of the hose back and attach the Gun (19) to the hose. 6. Screw the Wand (20) onto the Gun and secure with the grommet. 7. Choose the right Nozzle (5) for the job. Pull back the quick connect collar and push the Nozzle onto the end of the Wand. Make sure the quick connect collar locks the Nozzle in place. • Black Nozzle Low Pressure This Nozzle is used with pressure washer detergent. • White Nozzle Wide Spray This Nozzle can be used to clean very large areas. • Green Nozzle Medium Spray This Nozzle can be used to clean larger areas. SKU 67596 For technical questions, please call 1-800-444-3353. Page 9 • Yellow Nozzle Narrow Spray This Nozzle is used to clean small areas. • Red Nozzle Pencil Spray This Nozzle should only be used on hard surfaces such as concrete or metal. This Nozzle can damage wood. 8. Connect the water supply to the Water Inlet Connection. The water source must be able to provide a minimum of five gallons of clean, cold water per minute at 20 PSI. Only use a 5/8” inner diameter (or larger) hose that is rated to meet this capacity. If using detergent: 9. Read detergent directions. Connect one end of the Detergent Inlet Hose (8) to the Detergent Inlet Connection, and the other end into the container holding the detergent. Only use detergents specified for use with Pressure Washers. The Pressure Washer will draw one gallon of detergent for every seven gallons of water. Only use the Black (low pressure) Nozzle when spraying detergents. Page 10 For technical questions, please call 1-800-444-3353. SKU 67596 Engine diagram SKU 67596 For technical questions, please call 1-800-444-3353. Page 11 the upper limit (H) mark on the dipstick (bottom edge of the oil fill hole). Low oil level can trigger the low oil sensor to shutdown the engine and prevent restart (See Figure 3 for correct oil level). Operating Instructions Read the entire Important Safety Information section at the beginning of this manual including all text under subheadings therein before set up or use of this product. 4. If the oil level is low, add the appropriate type of oil until the oil level is at the bottom lip of the oil fill hole. Oil type: 32° F or above = SAE 10W-30 Below 32° F = SAE 5W-30. 5. Replace the Oil Filler Cap. Starting the Engine Inspect engine and equipment looking for damaged, loose, and missing parts before set up and starting. If any problems are found, do not use equipment until fixed properly. Checking Engine Oil Level CAUTION! Your Warranty is VOID if the engine’s crankcase is not properly filled with oil before each use. Before each use, check the oil level. Do not run the engine with low or no engine oil. Running the engine with no or low engine oil WILL permanently damage the engine. 1. Turn off engine and allow it to cool. 2. Clean the Oil Filler Cap and the area around it. Remove the Oil Filler Cap. CAUTION! Do not run the engine with too little or too much oil. The engine will be permanently damaged. Checking Pump Oil Level 1. The Oil pump is filled with 3.75 fl-oz of SAE 10W-30 NON DETERGENT oil at the factory. Under normal conditions there is no reason to add any oil or change the oil. 2. Turn off engine, allow it to cool and disconnect the spark plug wire. 3. Twist the Dipstick on the Pump Breather Plug until the arrow on it lines up with the arrow on the Plug and remove the Dipstick. 4. Remove the Pump Breather Plug from the Pump. Figure 3 3. Remove dipstick and wipe away the oil with dry cloth. Reinsert the dipstick into the oil filler neck, but do not screw in, then remove it to check the oil level. The oil level should reach Page 12 For technical questions, please call 1-800-444-3353. SKU 67596 Clear oil fill hole 8. Align the arrow on the Dipstick with the arrow on the Plug, insert it, and twist it to secure. 9. Reconnect the spark plug wire. Checking Fuel Level Warning! To prevent fire, shut the engine off and wait for it to cool before adding fuel. Do not smoke. Figure 4 5. Look into the hole in the pump housing. If a metal wheel can be seen extending into the hole, SLOWLY pull the starter rope until the hole appears clear, as shown above. Fill with oil to here 1. Clean the Fuel Filler Cap and the area around it. 2. To check the fuel level, unscrew and remove the Fuel Filler Cap. 3. Mix fuel stabilizer (not included) with 89 octane (or better) unleaded gasoline according to fuel stabilizer directions. 4. Fill the Fuel Tank to about 1 inch under the lip of the gasoline tank with the stabilized unleaded gasoline mixture. 5. Then replace the Fuel Filler Cap. TOO HIGH TOO LOW Figure 5 6. Wipe the Dipstick off with a clean, dry cloth. Insert the Dipstick into the pump housing and remove it. The oil level should be at least to the lower (L) notch on the dipstick, but not above the upper (H) notch. Add SAE 10W-30 NON-DETERGENT oil as needed. 7. Thread the Pump Breather Plug back into the pump. SKU 67596 For technical questions, please call 1-800-444-3353. Page 13 Start Procedure Before starting the engine: a.Follow the Set Up Instructions to prepare the equipment. b.Inspect the equipment and engine. Make sure the pump has the Pump Breather Plug installed. c. Replace the non-vented brass oil plug with the aluminum Pump Breather Plug. d.Fill the engine with the proper amount and type of both fuel and oil. e.Read the Equipment Operation section that follows. 1. Point Nozzle in safe direction and squeeze trigger to release all pressure from the pump. 2. Turn the fuel valve lever to its “OPEN” position. 3. Turn the ignition switch to its ON or RUN position. 4. Then, turn the engine choke lever to its “CHOKE” position for cold start. Set the choke lever in the “1/2 CHOKE” position when starting a warm engine. 5. Close the throttle. 6. Grasp the starter handle, and pull slowly until resistance is felt. While holding the handle, allow the starter rope to rewind slowly. Then, pull the starter handle with a rapid, full arm stroke. Once again while holding the handle, allow the rope to rewind slowly. Repeat as necessary, until the engine starts. Page 14 7. After the engine starts and warms up, slowly move the choke lever to its “RUN” position. 8. IMPORTANT: Allow the engine to run at no load (low pressure) for five minutes after each start-up so that the engine can stabilize. 9. Move the throttle up to operating speed. Operating speed is maximum speed (fast or rabbit), except during operational break-in period. Break-in Period 1. Breaking-in the engine will help to ensure proper equipment and engine operation. 2. The operational break-in period will last about 3 hours of use. During this period: • Do not apply a heavy load to the equipment. • Do not operate the engine at its maximum speed. 3. The maintenance break-in period will last about 20 hours of use. After this period: • Change the engine oil. Under normal operating conditions subsequent maintenance follows the schedule in the Maintenance and Servicing section. For technical questions, please call 1-800-444-3353. SKU 67596 Equipment Operation Do not direct spray from the pressure washer at a person or an animal. The water stream could cause serious injury. 3. Pull back the quick connect collar and push the Nozzle onto the end of the Wand. Make sure the quick connect collar locks the Nozzle in place. 4. Turn the water supply on and hold down the Trigger to start the stream. Be aware that when it is first started, the gun will kick. 5. It is best to start at a low pressure setting, and adjust the pressure upwards. Test spray the edge of the surface to be cleaned first to make sure that the stream is not too strong for the surface. If the stream damages the surface turn the Pressure Regulator Knob counterclockwise to reduce the pressure. Moving further away from the surface being cleaned will also reduce the pressure being applied to the surface. If the stream is still too strong. Turn the engine off, turn the water supply off, discharge the excess pressure from the gun by squeezing the Trigger, and change to a lower pressure Nozzle. 6. To increase the pressure, turn the Pressure Regulator Knob clockwise. WARNING Caution Use the pressure washer only on surfaces able to withstand the force of the spray. 1. Replace the non-vented brass oil plug with the aluminum Pump Breather Plug before first use. The Pump Breather Plug must be used whenever the pressure washer is used. The brass oil plug (without the breather hole) should be used for transporting only. 2. Choose the Nozzle that best meets the needs of the job. Only use the Nozzles on surfaces capable of withstanding the force of the spray. Only use the Black Nozzle when using pressure washer detergent. The power of the other Nozzles will propel mist back at the operator and can imbed detergent into the surface. SKU 67596 For technical questions, please call 1-800-444-3353. Page 15 7. Hold the Wand at about a 45° angle when cleaning; spraying the surface directly could embed dirt into the surface (especially with the high pressure Nozzles). Spray at a distance of about three to five feet. • Clean vertical and sloped surfaces from the top down. • When cleaning horizontal surfaces, occasionally use the stream to clear the area of excess water. CAUTION Do not allow the Pressure Washer to idle, without the Trigger held down, for more than two minutes. The water will heat up and damage the Pressure Washer. RISK OF BURNS! The pump will also expel very hot water if allowed to idle too long. 8. Hold the Trigger down and move the Wand back and forth slowly and steadily to pressure wash the surface. Take special care when spraying surfaces made of two different materials (brick and mortar, for example), to not damage the softer of the two materials during pressure washing. Page 16 9. If the surface is streaked or uneven at the end of a job, switch to a Nozzle that has a wider spray pattern to blend the affected area. 10. When finished; release the Trigger on the spray handle, turn the engine power switch “OFF”, turn the water supply off and then shut off gas supply to the engine. 11. Squeeze the Trigger to release excess pressure. 12. If Pressure Washer detergent has been used for the job, run clean water through the system to eliminate detergent residue. 13. To prevent accidents, turn off the engine and after the engine has cooled, disconnect its spark plug wire after use. Drain all water out of the unit. Clean external parts with clean cloth, then store the equipment out of children’s reach according to the Storage instructions in this manual. For technical questions, please call 1-800-444-3353. SKU 67596 Damaged equipment can fail, causing serious personal injury. Do not use damaged equipment. If abnormal noise, vibration, or excess smoking occurs, have the problem corrected before further use. Technical Specifications Engine Type Bore x Stroke Displacement Compression Ratio Rotation viewed from PTO (power takeoff - the output shaft) Type Fuel Capacity Type SAE Engine Oil Capacity Type Spark Plug Gap Intake Exhaust Idle Maximum Valve Clearance Speed Single Cylinder 4 stroke OHV 68mm x 54mm 196cc 8.5:1 Maintenance Procedures Counterclockwise 89+ octane unleaded gasoline 0.95 Gallons 10W30 above 32° F 5W30 at 32° F or below 0.63 Quarts F7RTC or NGK F7TC 0.028 - 0.031” 0.15 ± 0.02 mm 0.20 ± 0.02 mm 1,400 ± 150 RPM 3,600 RPM Many maintenance procedures, including any not detailed in this manual, will need to be performed by a qualified technician for safety. If you have any doubts about your ability to safely service the equipment or engine, have a qualified technician service the equipment instead. Engine Oil Change Servicing Risk of serious 1. personal injury from accidental starting. Turn the Power Switch of the 2. equipment to its “OFF” position, wait for the engine to cool, and unplug the spark plug wire(s) before performing any inspection, maintenance, 3. or cleaning procedures. 4. WARNING SKU 67596 CAUTION! Oil is very hot during operation and can cause burns. Wait for engine to cool before changing oil. Place a drain pan (not included) underneath the crankcase’s Drain Plug (61A). Remove the Drain Plug and, if possible, tilt the crankcase slightly to help drain the oil out. Recycle used oil. Replace the Drain Plug and tighten it. Refill the oil to the proper level following the instructions under the Starting the Engine section. For technical questions, please call 1-800-444-3353. Page 17 Air Filter Element Maintenance Spark Plug Maintenance 1. The air cleaner cover is held in place by a wing nut or clamps. Remove it. 1. 2. Remove the air filter element. Disconnect spark plug wire from end of plug. Clean out debris from around spark plug. 3. Cleaning: 2. Using a spark plug wrench, remove the spark plug. 3. Inspect the spark plug: If the electrode is oily, clean it using a clean, dry rag. If the electrode has deposits on it, polish it using emery paper. If the white insulator is cracked or chipped, the spark plug needs to be replaced. 4. When installing a new spark plug, adjust the plug’s gap to the specification on the Technical specification chart. Do not pry against the electrode, the spark plug can be damaged. 5. Install the new spark plug or the cleaned spark plug into the engine. Gasket-style: Finger-tighten until the gasket contacts the cylinder head, then about 1/2-2/3 turn more. Non-gasket-style: Finger-tighten until the plug contacts the head, then about 1/16 turn more. 6. Apply dielectric spark plug boot protector (not included) to the end of the spark plug and reattach the wire securely. a.For “paper” filter elements: To prevent injury from dust and debris, wear ANSI-approved safety goggles, NIOSH-approved dust mask/respirator, and heavy-duty work gloves. In a well-ventilated area away from bystanders, use pressurized air to blow dust out of the air filter. If this does not get the filter reasonably clean, replace it. b.For foam filter elements: Wash the element in warm water and mild detergent several times. Rinse. Squeeze out excess water and allow it to dry completely. Soak the filter in lightweight oil briefly, then squeeze out the excess oil. 4. Install the new filter or the cleaned filter. Secure the Air Cleaner Cover before use. Page 18 For technical questions, please call 1-800-444-3353. SKU 67596 Fuel Filter Replacement (if equipped) WARNING! Risk of fire or explosion. Replace the fuel filter in a well-ventilated area away from ignition sources. Do not smoke. 1. Wait for engine to cool completely before proceeding. 2. Wear protective gear including, ANSIapproved safety goggles, NIOSHapproved dust mask/respirator, and nitrile gloves. 3. Close fuel valve leading from gas tank completely. 4. Take note of the fuel filter’s orientation. 5. Place a suitable container under the fuel filter. 6. Disconnect the fuel lines leading to and from the fuel filter and allow fuel to drain onto the container. 7. 8. 9. Install new fuel filter in the same orientation. Make sure to properly secure both fuel lines. Clean up and properly dispose of all fuel. Wait for at least one hour before use to allow all residual fuel vapors to dissipate. To prevent fire, do not start the engine while the smell of fuel hangs in the air. Remember to open the fuel valve before restarting the engine. It may take a little longer than usual to start the engine because the fuel needs to refill the fuel line and new filter. SKU 67596 Cleaning, Maintenance, and Lubrication Schedule Note: This maintenance schedule is intended solely as a general guide. If performance decreases or if equipment operates unusually, check systems immediately. The maintenance needs of each piece of equipment will differ depending on factors such as duty cycle, temperature, air quality, fuel quality, and other factors. Note: These procedures are in addition to the regular checks and maintenance explained as part of the regular operation of the engine and equipment. After 20 Operation Hour Break-in Period: a.Change engine oil. After Every 25 Operation Hours: a.Clean/replace air filter element. b.Inspect/clean spark plug. c. Blow out water filters. After Every 50 Operation Hours: a.Change engine oil. b.Replace fuel filter (if equipped). After Every 100 Operation Hours: a.Replace spark plug. b.Replace air filter element. c. Change pump oil. Note: All maintenance procedures scheduled for 25, 50, and 100 operation hours should be performed at least yearly. For technical questions, please call 1-800-444-3353. Page 19 After Every 300 Operation Hours: 3. Apply a thin coat of rust preventive oil to all metal parts. 4. Cover and store in a dry, wellventilated area out of reach of children. 5. Before starting the engine after storage, keep in mind that untreated gasoline will deteriorate quickly. Drain the fuel tank and change to fresh fuel if untreated gasoline has been sitting for a month, if treated gasoline has been sitting beyond the fuel stabilizer’s recommended time period, or if the engine does not start properly. a.Clean fuel tank and carburetor. b.Clean carbon build-up from combustion chamber. Storage 1. Wait for engine to cool, then clean engine with clean cloth. 2. When the equipment is to remain idle for longer than 20 days, prepare the engine for storage as follows: a.Change engine oil and empty fuel tank. b.Either leave fuel tank empty or refill fuel tank with fresh unleaded gasoline mixed with a fuel stabilizer intended for long term engine storage (not included). After filling, run engine for about 5-10 minutes to circulate the treated gasoline through the carburetor. Wait for engine to cool before proceeding. c. Clean out area around spark plug. Remove spark plug and pour one tablespoon of engine oil into cylinder through spark plug hole. d.Replace spark plug, but leave spark plug wire disconnected. e.Pull recoil starter to distribute oil in cylinder. Stop after one or two revolutions when you feel the piston start the compression stroke (when you start to feel resistance). f. Disconnect battery (if equipped). Page 20 For technical questions, please call 1-800-444-3353. SKU 67596 Troubleshooting Problem Possible Causes Engine will not start Probable Solutions Starting instructions not followed completely. Fuel Related: 1. No fuel in tank or fuel valve closed. 2. Choke not in start position, especially with cold engine. 3. Low quality or deteriorated, old gasoline. 4. Dirty fuel passageways blocking fuel flow. Refer to starting instructions and follow them step-by-step. Fuel Related: 1. Fill fuel tank and open fuel valve. 2. Move choke to start position if engine is cold. 3. Use only fresh 89+ octane unleaded gasoline. 4. Clean out passageways using fuel additive. Heavy deposits may require further cleaning. 5. Carburetor needle stuck. Fuel can 5. Gently tap side of carburetor float be smelled in the air. chamber with screwdriver handle. 6. Too much fuel in chamber. This can 6. Turn choke to run position. Remove be caused by the carburetor needle spark plug and pull the start sticking. handle several times to air out the chamber. Reinstall spark plug and set choke to start position. Ignition (spark) Related: Ignition (spark) Related: 1. Connect spark plug wire properly. 1. Spark plug wire not connected securely. 2. Clean spark plug. 2. Spark plug electrode wet or dirty. 3. Correct spark plug gap. 3. Incorrect spark plug gap. 4. Spark plug wire broken. 4. Replace spark plug wire. 5. Incorrect spark timing or faulty 5. Have qualified technician diagnose/ ignition system. repair ignition system. Compression Related: Compression Related: 1. Cylinder not lubricated. Problem 1. Pour tablespoon of oil into spark after long storage periods. plug hole. Crank engine a few times and try to start again. 2. Loose or broken spark plug. 2. Tighten spark plug. If that does (Hissing noise will occur when trying not work, replace spark plug. If to start.) problem persists, may have head gasket problem, see #3. 3. Loose cylinder head or damaged 3. Tighten head. If that does not head gasket. (Hissing noise will remedy problem, replace head occur when trying to start.) gasket. 4. Engine valves or tappets 4. Adjust valve clearance. If that does misadjusted or stuck. not work, clean or replace valves/ tappets. Follow all safety precautions whenever diagnosing or servicing the equipment or engine. SKU 67596 For technical questions, please call 1-800-444-3353. Page 21 Troubleshooting Problem Engine misfires Possible Causes 1. Spark plug wire loose. 2. Incorrect spark plug gap or damaged spark plug. 3. Defective spark plug wire. 4. Old or low quality gasoline. 5. Incorrect compression. Engine stops suddenly 1. Low oil shutdown. 2. Fuel tank empty or full of impure or low quality gasoline. 3. Defective fuel tank cap creating vacuum, preventing proper fuel flow. 4. Faulty magneto. Engine knocks 1. Old or low quality gasoline. 2. Engine overloaded. Engine backfires 3. Incorrect spark timing, deposit buildup, worn engine, or other mechanical problems. 1. Impure or low quality gasoline. 2. Engine too cold. 3. Intake valve stuck or overheated engine. Does not produce high 1. Diameter of water supply hose too pressure small 2. Water supply is restricted. 3. Not enough water supply. Probable Solutions 1. Check wire connections. 2. Re-gap or replace spark plug. 3. Replace spark plug wire. 4. Use only fresh 89+ octane unleaded gasoline. 5. Diagnose and repair compression. (Use Engine will not start: Compression Related section.) 1. Fill engine oil to proper level. Check engine oil before EVERY use. 2. Fill fuel tank with fresh 89+ octane unleaded gasoline. 3. Test/replace fuel tank cap. 4. Have qualified technician service magneto. 1. Fill fuel tank with fresh 89+ octane unleaded gasoline. 2. Do not exceed equipment’s load rating. 3. Have qualified technician diagnose and service engine. 1. Fill fuel tank with fresh 89+ octane unleaded gasoline. 2. Use cold weather fuel and oil additives to prevent backfiring. 3. Have qualified technician diagnose and service engine. 1. Replace hose with a ¾ inch hose. 2. Check water supply hose for kinks, leaks, or blockage. 3. Open water faucet all the way. Follow all safety precautions whenever diagnosing or servicing the equipment or engine. Page 22 For technical questions, please call 1-800-444-3353. SKU 67596 Troubleshooting Problem Possible Causes Probable Solutions Output pressure varies 1. Not enough water supply. No intake of chemicals. 1. Check water supply hose for kinks, leaks, or blockage. Open faucet all the way. 2. Water inlet screen is clogged. 2. Remove inlet screen and rinse out. 3. Nozzle is clogged. 3. Remove Nozzle and clean. 4. Nozzle has mineral build up. 4. Remove Nozzle and clean with vinegar. 1. Chemical hose not properly inserted 1. Push firmly into injector. Replace into unit. tube. 2. Tube cracked or split. 2. Switch to black Nozzle. 3. Wrong Nozzle. 3. Turn collar counterclockwise. 4. Injector turned off. 4. Clean strainer. 5. Injection tube strainer clogged. 5. Clean Nozzle. 6. Nozzle blocked. 6. Dissolve by running warm water through the injection tube. 7. Dried chemicals in injector. 7. Run clean water through injector until clear. Follow all safety precautions whenever diagnosing or servicing the equipment or engine. SKU 67596 For technical questions, please call 1-800-444-3353. Page 23 PLEASE READ THE FOLLOWING CAREFULLY The manufacturer and/or distributor has provided the parts list and assembly diagram in this manual as a reference tool only. Neither the manufacturer or distributor makes any representation or warranty of any kind to the buyer that he or she is qualified to make any repairs to the product, or that he or she is qualified to replace any parts of the product. In fact, the manufacturer and/or distributor expressly states that all repairs and parts replacements should be undertaken by certified and licensed technicians, and not by the buyer. The buyer assumes all risk and liability arising out of his or her repairs to the original product or replacement parts thereto, or arising out of his or her installation of replacement parts thereto. Record Product’s Serial Number Here: Note: If product has no serial number, record month and year of purchase instead. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. Page 24 For technical questions, please call 1-800-444-3353. SKU 67596 Parts Lists and Diagrams General Parts List Part 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Description Gun & Hose Holder Washer Nut Grommet Nozzle Safety Warnings Filter Detergent Inlet Hose Bolt Lock Washer Pump Assembly Engine Key Handle Handle Bolt Nut Frame Hose Gun Wand SKU 67596 Qty 1 1 1 5 5 1 1 1 4 4 1 1 1 1 2 2 1 1 1 1 Part 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Description Pad Washer Nut Engine Bolt Lock Washer Washer Nut Lock Washer Axle Nut Lock Washer Washer Axle Clip Wheel Washer Wheel Nut Dipstick Pump Fill Plug O-ring Shock Pad For technical questions, please call 1-800-444-3353. Qty 2 2 2 4 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 4 Page 25 Page 26 14 15 16 17 18 19 20 7 8 4 5 6 3 2 1 9 10 37 38 39 11 12 13 23 21 22 24 25 26 40 27 28 29 30 31 32 33 34 35 36 General Assembly Diagram For technical questions, please call 1-800-444-3353. SKU 67596 Parts List A - Pump Part 1A 2A 3A 4A 5A 6A 7A 8A 9A 10A 11A 12A 13A 14A 15A 16A 17A 18A 19A 20A 21A Description Screw M8x16 Flange O-Ring 80x2,4 Radial Shaft Seal Real Bearing Sheath Wobble Plate Front bearing Spring Disk 15mm Plunger Plunger Spring Crankcase O-Ring 14.2x1.9 Brass Pump Plug Oil Seal O-ring 15x2.2 Spacer O-ring 22x2 Pressure Ring Water seal Inlet valve plug Part 22A 23A 24A 26A 27A 28A 29A 30A 31A 32A 33A 34A 36A 37A 38A 39A 40A 41A 42A 43A Description Backup ring O-ring Check Valve Detergent Inlet Connector O-ring 4.47x1.78 Ball Cone spring O-ring Outlet Valve Valve spring O-ring Siphon Body Outlet Connector Backup Ring O-ring Valve Core Pump Manifold Seal Gasket Water Inlet Body Thermal Relief Valve Part 44A 45A 46A 47A 48A 49A 50A 51A 53A 52A 54A 55A 56A 57A 58A 59A 60A 61A 62A Description Pressure Regulator Knob Screw Plug Backup Ring O-ring Spring Holder Large Pressure Spring Small Pressure Spring Ball Holder Ball Valve Port O-ring Manifold Bolt Inlet Swivel Nut Clip Ring Water Filter Pump Breather Plug Dipstick Drain Plug O-ring When ordering replacement parts from this list, the “A” suffix must be included in order to get the correct part. SKU 67596 For technical questions, please call 1-800-444-3353. Page 27 9A 10A Page 28 11A 1A 12A 2A 61A 13A 3A 15A 4A 16A 17A 18A 5A 19A 20A 6A 29A 28A 27A 26A 21A 7A 33A 23A 34A 24A 33A 23A 36A 22A 8A 32A For technical questions, please call 1-800-444-3353. 30A 33A 39A 38A 31A 37A 61A 13A 59A 60A 54A 52A 53A 51A 50A 49A 48A 47A 46A 62A 45A 44A 14A 40A 41A 42A 23A 24A 33A 61A 43A 56A 57A 55A 58A Assembly Diagram A - Pump SKU 67596 1B 2B 3B 4B 5B 6B 7B 8B 9B 10B 11B 12B 13B 14B 15B 16B 17B 18B Part # Parts List & Diagram B - Cylinder Head Description Cylinder Head Assembly Intake Valve Guide Exhaust Valve Guide Valve Guide Clip Cover Packing Breathing Tube Spark Plug Cylinder Gasket Muffler Gasket Pin Bolt 6x14 Bolt 8x55 Intake Bolt Exhaust Bolt Intake Valve Seat Exhaust Valve Seat Cylinder Head 1 1 1 1 1 1 1 1 1 1 2 4 4 2 2 1 1 1 Qty Note: When ordering parts for this component use the suffix “B”. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 67596 For technical questions, please call 1-800-444-3353. Page 29 Parts List & Diagram C - Crankcase Part # 1C 2C 3C 4C 5C 6C 7C 8C 9C 10C 11C Description Crank Case Assembly Oil Level Switch Gear Assembly Weight Gear Weight Pin Slider Shaft Arm Drain Plug Bolt Washer Washer 1 1 1 2 1 2 1 1 2 2 2 Qty Part # 12C 13C 14C 15C 16C 17C 18C 19C 20C 21C 22C Description Clip Ball Bearing Oil Seal O-ring Nut Washer R-pin Bolt 6x12 Shaft Assembly Oil Alarm 1 1 1 1 1 1 1 3 1 1 1 Qty Note: When ordering parts for this component use the suffix “C”. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. Page 30 For technical questions, please call 1-800-444-3353. SKU 67596 Parts List & Diagram D - Crankcase Cover 1D 2D 3D 4D 5D 6D 7D 8D 9D 10D 11D Part # Description Bolt Oil Stick Packing Cover Oil Seal Bearing Pin Oil Filler Cap Packing Case Cover Oil Fill Assembly Cap Assembly 6 1 2 1 1 1 2 1 1 1 1 Qty Note: When ordering parts for this component use the suffix “D”. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 67596 For technical questions, please call 1-800-444-3353. Page 31 Parts List & Diagram E - Crankshaft/Piston 1E 2E 3E 4E 5E 6E 7E 8E 9E 10E 11E 12E 13E 14E 15E 16E 17E Part # Description Ring Set Piston Pin Rod Assembly Crankshaft Assembly Bolt Clip Timing Gear Gear Crankshaft First Ring Second Ring Oil Ring Bushing Ring Connecting Rod Connecting Rod Cover Key 1 1 1 1 1 2 2 1 1 1 1 1 2 1 1 1 1 Qty Note: When ordering parts for this component use the suffix “E”. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. Page 32 For technical questions, please call 1-800-444-3353. SKU 67596 Parts List & Diagram F - Gas Distribution Adjustment System Part # 1F 2F 3F 4F 5F 6F 7F 8F 9F 10F 11F 12F 13F Description Nut Rocker Arm Valve Rocker Pivot Bolt Plate Assembly Block Guide Push Rod Guide Push Rod Valve Lifter Rotator Valve Valve Spring Retainer Valve Spring Guide Seal 2 2 2 2 1 2 1 2 2 2 2 2 1 Qty Part # 14F 15F 16F 17F 18F 19F 20F 21F 22F 23F 24F 25F Description Camshaft Assembly Reducer Pin Reducer Matching Block Pin Matching Block Flying Block Pin Spring Pin Flying Block Spring Flying Block Camshaft Exhaust Valve Intake Valve 1 1 1 2 1 1 1 1 1 1 1 1 Qty Note: When ordering parts for this component use the suffix “F”. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 67596 For technical questions, please call 1-800-444-3353. Page 33 Parts List & Diagram G - Starter Subassembly 1G 2G 3G 4G 5G 6G 7G 8G 9G 10G 11G 12G 13G 14G 15G 16G 17G 18G Part # Description Starter Assembly Set Screw Ratchet Guide Friction Spring Starter Ratchet Return Spring Recoil Starter Reel Recoil Starter Spring Recoil Starter Knob Fan Cover Rope Bolt 6x8 Bolt 6x10 Fan Cover Switch Assembly Recoil Starter Fan Cover Stop Switch Assembly 1 1 1 1 2 2 1 1 1 1 1 3 4 1 1 1 1 1 Qty Note: When ordering parts for this component use the suffix “G”. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. Page 34 For technical questions, please call 1-800-444-3353. SKU 67596 Parts List & Diagram H - Diversion Assembly 1H 2H 3H 4H 5H 6H Part # Description Bolt 6x20 Side Plate Bolt 6x8 Shroud Side Plate Grommet 1 1 2 1 1 1 Qty Note: When ordering parts for this component use the suffix “H”. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 67596 For technical questions, please call 1-800-444-3353. Page 35 Parts List & Diagram J - Carburetor Part # 1J 2J 3J 4J 5J 6J 7J 8J 9J 10J 11J 12J 13J 14J 15J 16J 17J 18J Description Carburetor Assembly Carburetor Main Nozzle Main Jet Float Valve Valve Set Spring Float Float Pin Oil Cup Gasket Oil Cup Gasket Bolt Bolt Drain Bolt Drain Bolt Gasket Fuel Strainer Cup Fuel Strainer Cup Packing Fuel Packing Lever 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Qty Part # 19J 20J 21J 22J 23J 24J 25J 26J 27J 28J 29J 30J 31J 32J 33J 34J 35J Description Lever Spring Setting Plate Screw 3x8 Jet Set Pilot Jet Set Choke Lever Assembly Choke Lever Choke Lever Pin Choke Set Screw Screw Spring Throttle Stop Screw Air Cleaner Carburetor Packing Carburetor Insulation Packing Throttle Valve 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Qty Note: When ordering parts for this component use the suffix “J”. Page 36 For technical questions, please call 1-800-444-3353. SKU 67596 Parts List & Diagram K - Flywheel/Coil Assembly Part 1K 2K 3K 4K 5K 6K 7K 8K 9K 10K 11K 12K 13K 14K 15K Description Ignition Assembly Ignition Coil Noise Suppression Cap Assembly Stop Switch Cord Bolt 6x30 Flywheel Cover Charge Coil Assembly Cooling Fan Starter Pulley Nut Flywheel Charge Coil Bolt 6x35 Cord Clamp Bolt 6x8 1 2 1 1 2 1 1 1 1 1 1 1 2 1 1 Qty Note: When ordering parts for this component use the suffix “K”. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 67596 For technical questions, please call 1-800-444-3353. Page 37 Parts List & Diagram M - Control System Part # 1M 2M 3M 4M 5M 6M 7M 8M 9M 10M 11M Description Bolt Spring Bolt Arm Nut Throttle Return Spring Rod Control Assembly Nut Fixing Plate Washer 2 1 1 1 1 1 1 1 1 1 1 Qty Part # 12M 13M 14M 15M 16M 17M 18M 19M 20M 21M 22M Description Washer Retainer Assembly Spring Screw 5x35 Cable Return Spring Control Handle Screw 5x25 Back Plate Screw 4x6 Locking Ring Clip 1 1 1 Qty 1 1 1 1 1 1 1 Note: When ordering parts for this component use the suffix “M”. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. Page 38 For technical questions, please call 1-800-444-3353. SKU 67596 Part 1N 2N 3N 4N 5N 6N 7N 8N 9N Parts List & Diagram N - Air Cleaner Description Air Cleaner Assembly Elbow Short Collar Long Collar Elbow Packing Bolt 6x20 Nut 6mm Nut Air Cleaner Cover Qty 1 1 2 2 1 1 2 2 1 Part 10N 11N 12N 13N 14N 15N 16N 17N Description Qty Air Cleaner Element Assembly Grommet Outer Filter Element Noise Silencer Air Cleaner Assembly Cover Screw 1 1 1 1 1 1 1 2 Note: When ordering parts for this component use the suffix “N”. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 67596 For technical questions, please call 1-800-444-3353. Page 39 Parts List & Diagram P - Muffler Part 1P 2P 3P 4P Description Muffler Assembly Gasket Air Valve Bolt Qty. 1 1 1 2 4P 1P 2P 3P Note: When ordering parts for this component use the suffix “P”. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. Page 40 For technical questions, please call 1-800-444-3353. SKU 67596 Parts List & Diagram R - Fuel Tank Part 1R 2R 3R 4R 5R 6R Description Fuel Tank Gasket Gas Valve Cover Cap Filter Qty. 1 1 1 1 1 1 5R 4R 3R 6R 2R 1R Note: When ordering parts for this component use the suffix “R”. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 67596 For technical questions, please call 1-800-444-3353. Page 41 Parts List & Diagram S - Carbon Canister Part 1S 2S 3S 4S 5S Description Shroud Mounting Grommet Carbon Canister Canister Vent Canister Vent Qty. 1 2 1 1 1 4S 1S 2S 5S 3S Note: When ordering parts for this component use the suffix “R”. Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. Page 42 For technical questions, please call 1-800-444-3353. SKU 67596 quickly provide you with a replacement. We will return repaired products at our expense, but if we determine there is no defect, or that Harbor Freight Tools Co. makes every the defect resulted from causes not within effort to assure that its products meet high the scope of our warranty, then you must quality and durability standards, and warrants bear the cost of returning the product. to the original purchaser that for a period of This warranty gives you specific legal ninety days from date of purchase that the rights and you may also have other rights engine/motor, the belts (if so equipped), which vary from state to state. and the blades (if so equipped) are free 3491 Mission Oaks Blvd. of defects in materials and workmanship. PO Box 6009 • Camarillo, CA 93011 Harbor Freight Tools also warrants to the (800) 444-3353 original purchaser, for a period of one year from date of purchase, that all other parts and components of the product are free from Emission Control System defects in materials and workmanship (90 Warranty days if used by a professional contractor or if used as rental equipment). This warranty California and United States Emission Control Defects Warranty Statement does not apply to damage due directly or The California Air Resources Board (herein CARB), the United indirectly, to misuse, abuse, negligence States Environmental Protection Agency (herein EPA), and Harbor or accidents, repairs or alterations outside Freight Tools (herein HFT) are pleased to explain the emission control system warranty on your 1995 and later Small Off-Road Engine our facilities, normal wear and tear, or to (herein engine). In California, the engine must be designed, built lack of maintenance. We shall in no event and equipped to meet the State’s stringent anti-smog standards. Elsewhere within the United States, new off-road, spark-ignition be liable for death, injuries to persons engines certified for model year 1997 and later, must meet similar or property, or for incidental, contingent, standards set forth by the EPA. HFT must warrant the emission control system on your engine for the periods of time described special or consequential damages arising below, provided there has been no abuse, neglect or improper from the use of our product. Some states maintenance of your engine. Your emission control system may include parts such as the do not allow the exclusion or limitation of carburetor or fuel-injection system, and the ignition system. Also incidental or consequential damages, so the included may be hoses, belts, connectors and other emissionabove limitation of exclusion may not apply related assemblies. Where a warrantable condition exists, HFT will repair your to you. This warranty is expressly engine at no cost to you including diagnosis, parts and labor. in lieu of all other warranties, Manufacturer’s Warranty Coverage express or implied, including the The 1995 and later engines are warranted for two (2) years. warranties of merchantability If any emission-related part on your engine is defective, the part and fitness. will be repaired or replaced by HFT. Limited 1 year / 90 Day warranty To take advantage of this warranty, the product or part must be returned to us with transportation charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise. If our inspection verifies the defect, we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and SKU 67596 Harbor Freight Tools Emission Control Defects Warranty Coverage Engines are warranted for a period of two (2) years relative to emission control parts defects, subject to the provisions set forth below. If any emission related part on your engine is defective, the part will be repaired or replaced by HFT. Owner’s Warranty Responsibilities • As the engine owner, you are responsible for the performance of the required maintenance listed in your Owner’s Manual. HFT recommends that you retain all receipts covering maintenance on your engine, but HFT cannot deny warranty For technical questions, please call 1-800-444-3353. Page 43 solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. • As the engine owner, you should, however, be aware that HFT may deny you warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications. • You are responsible for shipping your engine to a HFT warranty station as soon as a problem exists. Contact the HFT Customer Service department at the number below to make shipping arrangements. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. are warranted for the warranty period. Any warranted part which is scheduled for replacement as required maintenance is warranted for the period of time up to the first scheduled replacement point for that part. Any replacement part, provided it is equivalent in durability and performance, may be used in performance of maintenance or repairs. The owner is responsible for commissioning a qualified technician/mechanic to perform all required maintenance, as outlined in the Inspection, Cleaning, and Maintenance section in this manual. 6. Warranted Parts 1) If you have any questions regarding your warranty rights and responsibilities, you should contact the Harbor Freight Tools Customer Service Department at 1-800-444-3353. Harbor Freight Tools Emission Control Defects Warranty Provisions 1. Length of Coverage HFT warrants to a first retail purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship that cause the failure of warranted parts for a period of two (2) years after the date of delivery to the first retail purchaser. 2) 3) 4) 2. No Charge Repair or Replacement Repair or replacement of any warranted part will be performed at no charge to the owner if the work is performed through a warranty station authorized by HFT. For emissions warranty service, contact the HFT Customer Service Department at 1-800-444-3353. 3. Consequential Damages Coverage 5) Fuel Metering System i) Carburetor and its internal parts. ii) Fuel pump (if so equipped). iii) Cold start enrichment system. Air Induction System i) Intake pipe/manifold. ii) Air cleaner. Ignition System i) Spark plug. ii) Magneto ignition system. Catalyst System (if so equipped) i) Exhaust pipe stud. ii) Muffler. iii) Catalytic converter (if so equipped). Miscellaneous Items Used in Above Systems i) Vacuum, temperature and time sensitive valves and switches. ii) Hoses, belts, connectors, and assemblies. Coverage under this warranty shall also extend to the failure of any engine components caused by the failure of any warranted part while it is still covered under this warranty. 4. Coverage Exclusions Warranty claims shall be filed in accordance with the provisions of the HFT warranty policy explained in the box at the top of the previous page. HFT shall not be liable for any loss of use of the engine, for any alternative usage, for any damage to goods, loss of time, or inconvenience. Warranty coverage shall also be excluded for any part which fails, malfunctions, or is damaged due to failure to follow the maintenance and operating instructions set forth in the Owner’s Manual including, but not limited to: a) Use of parts which are not authorized by HFT b) Improper installation, adjustment or repair of the engine or of any warranted part unless performed by an authorized warranty center c) Failure to follow recommendations on fuel use contained in the Owner’s Manual d) Improper or inadequate maintenance of any warranted parts e) Repairs performed outside of the authorized warranty service dealers f) Alterations by changing, adding to or removing parts from the engine. 5. Service and Maintenance Component parts which are not scheduled for replacement as required maintenance or are scheduled only for regular inspection to the effect of “repair or replace as necessary” Page 44 For technical questions, please call 1-800-444-3353. SKU 67596 Model 67596 PRESSURE WASHER Easy Start-up guide 1. Remove Pump Oil Cap, check Pump’s oil level and add SAE 30W oil if low. Replace with Pump Breather Plug. (Figure 1) Running without the pump breather plug can cause pump damage. (See oil fill instructions in manual or on product label.) 2. Check Dipstick for Engine oil level (Figure 2 A). Fill Engine with proper amount of oil if dipstick indicates low oil (Figure 2 B). Use SAE 10W-30 oil for air temperature of 32° F or above, SAE 5W-30 below 32° F. Fill Fuel Tank with 89 or higher octane unleaded gas mixed with fuel stabilizer (not included). 3. Connect and turn on water supply. Turn the pressure regulator counterclockwise to lower the output pressure. Point Spray Nozzle in safe direction and squeeze trigger to release all pressure from the pump. 4. Turn the red ignition switch to ON position (Figure 4). 5. Turn the Fuel Valve Lever (Gas pump symbol) to its OPEN position (Figure 5). 6. Set Throttle to slow (turtle symbol) and turn the engine choke lever to its CHOKE position for cold start. Set the choke lever in the 1/2 CHOKE position when starting a warm engine (Figure 5). 7. Grasp the starter handle, and pull slowly until resistance is felt (Figure 6). While holding the handle, allow the starter rope to rewind slowly. Then, pull the starter handle with a rapid, full arm stroke. Once again while holding the handle, allow the rope to rewind slowly. Repeat as needed until the engine starts. 8. After the Engine starts and warms up, slowly move the Choke Lever to its RUN position (Figure 5). IMPORTANT: Allow the Engine to run at no load, low pressure for five minutes after each start-up so Engine can stabilize. 9. Move the throttle up to operating speed (Fast) except during OPERATIONAL break-in period (Figure 5). Turn the pressure regulator clockwise to raise the output pressure as needed. Remove Oil Cap Check Engine Oil Check/Fill Pump Oil Replace with Vented Oil Cap Fill Engine Oil Dipstick Figure 2 A Figure 1 Opposite Side of Figure 2A Figure 2 B Choke Lever Choke Closed Spray Nozzle Run Open Fast Slow Fuel Valve Lever Trigger Figure 4 Figure 3 Throttle Figure 5 OPERATIONAL Break-in Period Starter Handle Figure 6 Breaking-in the engine will help to ensure proper equipment and engine operation. The operational break-in period shall last about 3 hours of use. During this period: Do not apply a heavy load to the equipment. Do not operate the engine at its maximum speed.